Gardner Denver ELECTRA-SAVER EAY Operating And Service Manual
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Gardner Denver ELECTRA-SAVER EAY Operating And Service Manual

Gardner Denver ELECTRA-SAVER EAY Operating And Service Manual

Stationary base–mounted compressors
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GARDNER DENVER
STATIONARY BASE–MOUNTED
AUTO SENTRY –ES+ CONTROLS
AUTO SENTRY –ES CONTROLS
ELECTRA–SAVER
COMPRESSORS
MODEL
EAY
OPERATING AND
SERVICE MANUAL
13–10–613
3rd Edition
January, 1998
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Summary of Contents for Gardner Denver ELECTRA-SAVER EAY

  • Page 1 13–10–613 GARDNER DENVER 3rd Edition January, 1998 ELECTRA–SAVER STATIONARY BASE–MOUNTED COMPRESSORS AUTO SENTRY –ES+ CONTROLS AUTO SENTRY –ES CONTROLS MODEL OPERATING AND SERVICE MANUAL...
  • Page 2 They are ready to respond and assist you by pro- Your authorized distributor can support your Gardner viding fast, expert maintenance and repair services. For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact: Distribution Center: Factory: Gardner Denver Machinery Inc.
  • Page 3 FOREWORD Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine the owner must exercise care in its operation and main- tenance. This book is written to give the operator and maintenance department essential information for day–to–day operation, maintenance and adjustment.
  • Page 4 TABLE OF CONTENTS Maintain Compressor Reliability and Performance With Genuine Gardner Denver Compressor Parts and Support Services ................
  • Page 5 INDEX Actuator, Turn Valve ..... . . Alignment ......Addition of Oil Between Changes .
  • Page 6 INDEX Oil Cooler Oil Pressure Differential ..Line, Inlet ....... . Oil Cooler Temperature Differential .
  • Page 7 INDEX System ....... Every 8 Hours Operation ....Every Year .
  • Page 8 LIST OF ILLUSTRATIONS Figure # Description Page Figure 1–1 Compression Cycle ............. Figure 1–2 View of Water Cooled Unit with Aftercooler (less enclosure) –...
  • Page 9 SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSION CYCLE COMPRESSOR – The Gardner Denver Electra–Sav- mixture trapped in the interlobe cavity by the rotors compressor is a single stage, positive displace- passes the discharge port and is released to the oil res- ment rotary machine using meshing helical rotors to ef- ervoir (C).
  • Page 10 FIGURE 1–2 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – MOTOR SIDE FIGURE 1–3 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) – MOTOR END 13–10–613 Page 2...
  • Page 11 FIGURE 1–4 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – RESERVOIR END FIGURE 1–5 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) RESERVOIR SIDE 13–10–613 Page 3...
  • Page 12 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
  • Page 13 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
  • Page 14 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–10–613 Page 6...
  • Page 15 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–10–613 Page 7...
  • Page 16 SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- cases it may be necessary to install the air filter at some age that may have been incurred during transit. Report distance from the compressor to obtain proper air sup- any damage or missing parts as soon as possible.
  • Page 17 PIPING SCHEMATIC OF COOLER PIPING SCHEMATIC OF COOLER WITH SCREWED CONNECTIONS. WITH FLANGED CONNECTIONS. FIGURE 2–3 – PIPING SCHEMATIC VENTILATION – The unit, whether air– or water– ACOUSTIC ENCLOSURE – The Electra–Saver unit cooled, requires sufficient air flow, FIGURE 2–2, for is furnished with an acoustic enclosure over the com- electric motor cooling.
  • Page 18 FIGURE 2–4 – PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER ers, and valves to be used in the pipe run. A dimensional sketch of the proposed piping sys- tem showing location of the compressor unit, oil The machine cannot be run blown cooler, pipe, and fittings illustrating design in- down with remote overhead oil cool- formation included in numbers 3 through 6 above.
  • Page 19 The moisture separator is furnished by Set the unit level on a firm, solid foundation. The Gardner Denver but must be mounted by the customer larger oil cooler models have lifting holes to facili- between the aftercooler and the auxiliary air receiver tate unit hoisting.
  • Page 20 Use only Gardner Denver AEON 9000 SP lu- A means of draining condensate will need to be pro- bricant.
  • Page 21 HEAT EXCHANGER Water Temperature to Heat Exchanger Approximate Rated Gallons/minute Maximum Water Pressure Pressure Water Flow Drop @ Maximum Size PSIG 60 F. 70 F. 80 F. 90 F. Flow (PSI) 350 HP 21.0 400 HP 21.0 500 HP 17.0 The maximum water flow shown is allowable through the heat exchanger.
  • Page 22 nections are located in the unit base flange on the left side of the unit. When an aftercooler is piped in series with the oil cooler, the maximum allowable flow rate through the It is mandatory that any water cooled oil/aftercooler system is the max- unit be installed in a shelter heated to imum allowed by the aftercooler.
  • Page 23 GROUNDING – Equipment must be grounded in ac- Remove the relief plug and free hole of hardened cordance with Section 250–95 of the National Electrical grease. Code. Wipe lubrication fitting clean and add grease with a hand–operated grease gun. The amount and type of grease added is very im- portant.
  • Page 24 Refer to Section 6, “Air Fil- red “ADD OIL” range. Do not mix different type ter,” page 39, for complete servicing instructions. oils. The unit is shipped filled with Gardner Denver Be sure the inlet line, if used, is tight and clean. AEON...
  • Page 25 System Pressure – Set the controls to the de- Check all screws and latches for tightness. Be sired load pressure. DO NOT EXCEED THE sure doors are closed and latched. MAXIMUM OPERATING PRESSURE ON THE STARTING THE UNIT – OBSERVE UNIT COLD OR COMPRESSOR NAMEPLATE.
  • Page 26 SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION – The Gardner Denver ical and easily operated control of the compressor and rotary screw compressor is prewired with all controls indication of its condition. The controller is factory ad- for the voltage and horsepower at the time of ordering.
  • Page 27 202EAY797–B (Ref Drawing) FIGURE 4–1 – SCHEMATIC TUBING DIAGRAM Blowdown Valve (FIGURE 4–2) – This valve normal- ly is used for control functions, but also serves to relieve reservoir pressure following a shutdown. The blow- down valve is a two–way solenoid valve which is piped into the oil reservoir outlet ahead of the minimum pres- sure valve.
  • Page 28 The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver Machinery distributor. Inlet Valve (FIGURE 1–4, page 3, and FIGURE 4–4, page 20) – The Inlet valve restricts the inlet to control FIGURE 4–3 –...
  • Page 29 to the inlet, reducing both capacity and power con- sumption. Turn Valve Actuator (Electra–Saver only) (FIGURE 4–7) – The turn valve actuator is a rotary rack and pinion device which positions the turn valve ac- cording to system demand. Filtered oil from the com- pressor sump is directed to the outboard end of the two actuating cylinders to move the rack and rotate the valve.
  • Page 30 present position. If TVC only is energized, the right side only – use the keypad [STOP/RESET] for normal con- of the turn valve actuator is exhausted to the compres- trolled stopping. sor inlet cavity, causing the turn valve to move towards the full load position.
  • Page 31 Terminal Strip – This provides connections for all tion of the Turn Valve and the Compressor Inlet Valve. 110–120 volt devices not contained within the enclo- The turn valve controls compressor delivery to match sure. demands of 40% to 100% of the compressor’s maxi- mum capacity.
  • Page 32 204EAY797–B (Ref. Drawing) FIGURE 4–8 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD...
  • Page 33 205EAY797–B (Ref. Drawing) FIGURE 4–9 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – CONSTANT SPEED MODE...
  • Page 34 206EAY797–B (Ref. Drawing) FIGURE 4–10 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE...
  • Page 35 202EAY546 (Ref. Drawing) FIGURE 4–11 – WIRING DIAGRAM...
  • Page 36 The separated oil is re- AEON 4000 Lubricating Coolant is a superior petro- turned to the compressor and the air passes to the final leum base lubricant formulated and containing addi- discharge line. tives for use in Gardner Denver compressors. 13–10–613 Page 28...
  • Page 37 Drain oil from air end and cooler while hot. – Break low point connections and drain oil from pipe runs. All materials used in Gardner Denver – Dump oil from the filter and reinstall used fil- compressor units are compatible with ter.
  • Page 38 Material Safety Data Sheets (MSDS) are available for Approximate Qty. – Top all AEON lubricants from your authorized Gardner System Reservoir of ADD to Denver distributor or by calling 217–222–5400. Capacity Capacity** Centerline Size (Initial Fill) (Refill) of RUN COLD AMBIENT OPERATION – See “Installation for Cold Weather Operation,”...
  • Page 39 drain the moisture and correct the condition causing the accumulation. See “Compressor Oil System Check,” page 38 and “Thermal Control (Thermostatic Mixing) Valve,” page 34. Compressor, air/oil reservoir, separa- tion chamber and all piping and tub- OIL CHANGE INTERVAL – Recommended oil change ing may be at high temperature during intervals based...
  • Page 40 FILLING OIL RESERVOIR Element must be replaced every 1000 hours or sooner, or when top of the Air/oil under pressure will cause indicator on the filter is in the red severe personal injury or death. Shut CHANGE FILTER half of the window. down compressor, relieve system of Unit must be running and warmed up all pressure, disconnect, tag and...
  • Page 41 (3) and rotate tee handle (9) clockwise until hand tight; do not exceed 20 foot–pound torque if tools are used. Reconnect starter to power source. If leakage appears around tee handle (9) remove snap ring (11) and remove tee handle (9) from head assembly (1).
  • Page 42 cal connection to the main compressor unit. Connect- ing piping and wiring are furnished by the user. See “Installation”, Section 2, page 8. Do not obstruct the air flow to and from the oil cooler. Allow two (2) feet clearance on all sides of the oil cooler. See FIGURE 2–2, Section 2, page 8, for cooling air flow requirements.
  • Page 43 FIGURE 5–7 – WATER CONTROL VALVE FIGURE 5–8 – DEW POINT TEMPERATURE VS. AMBIENT TEMPERATURE (100% RELATIVE HUMIDITY) the oil from the cooler to mix with oil from the bypass. Oil cooler malfunction may be traced by checking pres- After the unit is warmed up, the mixing valve maintains sure at oil inlet and outlet.
  • Page 44 ter side) of the heat exchanger to remove deposits which enhance fouling and corrosion. Hex head zinc anodes are used in the return bonnet (opposite end to the water pipe connections) of heat ex- changers to provide internal water system corrosion protection.
  • Page 45 is not foaming excessively, the oil return line from the Removal Of Oil Separator For Inspection Or Re- separator housing to the compressor cylinder is not placement: clogged or pinched off, the check valve in the oil return line is functioning properly, and there is not water or an oil/water emulsion in the oil.
  • Page 46 13. Install original oil return by slipping tube through ture level of FIGURE 5–10. Small variations in specific the fitting at the discharge manifold flange until water flows or temperatures will not be noted in the dis- ferrule bottoms in the fitting. If a new fitting and charge temperature since the water control valve will return tube are used, slip the tube through the tend to hold a constant oil temperature.
  • Page 47 Filter Element – Service the air filter element when the “CHANGE AIR FILTER” LED is illuminated. Clean ev- ery 50 to 150 operating hours depending on dust con- ditions. Use only genuine Gardner Denver air filter elements on Gardner Denver To service: compressor units. Genuine parts are...
  • Page 48 – wipe clean with a clean dry cloth. Do not bend the edge of the cup by striking on a hard surface. When Use only genuine Gardner Denver air installing the dust cup, make sure the clamp is securely tightened to prevent leakage.
  • Page 49 SECTION 7 COUPLING B76633X FIGURE 7–1 – INSTALLATION OF COUPLING – STYLE “A” FIGURE 7–2 – INSTALLATION OF COUPLING – STYLE “B” COUPLING – The motor and compressor are direct cushions and secure with cap screws. Rein- connected by a flexible coupling. Style “A” coupling has stall the cover plate.
  • Page 50 SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. If the “CHANGE AIR FILTER” message is Check for dirt accumulation on oil/aftercooler core displayed, air filter requires servicing or changing. See faces and the cooling fan.
  • Page 51 SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
  • Page 52 SYMPTOM POSSIBLE CAUSE REMEDY Compressor is low on 1. Restricted air filter. 1. Clean or replace filter. delivery and pressure. 2. Sticking inlet valve. 2. Inspect and clean inlet valve. 3. Unload pressure adjusted 3. Adjust the unload pressure. too low. See Section 4, page 21.
  • Page 53 9. Check oil reservoir tempera– ture and if low, change thermal mixing valve element to higher temperature. Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13–10–613...
  • Page 54 Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.