Related Manuals for Gardner Denver AirSmart EAU99T
Summary of Contents for Gardner Denver AirSmart EAU99T
- Page 1 13-10-618 Version: 00 March 22, 2013 ELECTRA-SAVER STATIONARY BASE-MOUNTED COMPRESSOR AirSmart™ CONTROLLER DOMESTIC and INTERNATIONAL MODELS EAU99T – 200, 250, 300 HP – 60HZ EAU99T – 200, 250, 300 HP – 50HZ (150,186,225 kW) OPERATING AND SERVICE MANUAL...
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Page 2: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services
Reliability in materials and quality assurance is incorporated in our genuine replacement parts. Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. A worldwide network of authorized distributors provides the finest product support in the air compressor industry. -
Page 3: Warning - Prohibition - Mandatory Label Information
WARNING – PROHIBITION – MANDATORY LABEL INFORMATION 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 maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. - Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.
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Page 5: Safety Precautions
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 6: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ............1 Instructions For Ordering Repair Parts ......................1 Warning – Prohibition – Mandatory Label Information .................. 2 Safety Precautions ............................4 Index ................................6 List Of Illustrations ............................ -
Page 7: Index
INDEX Addition Of Oil Between Changes ....52 Lifting Unit ............13 Air Filter Element Life ........66 Location ............13 Air Filter Vacuum Switch ........35 Air-Cooled Units ........... 14 Air Filter, Section 6 ........... 65 Water-Cooled Units ........14 Air Flow In The Compressor System .... - Page 8 Power Supply ........... 36 Service Check List Pressure Differential Gauging ......62 Air Filter ............70 Pressure Regulator .......... 34 Shuttle Valve ............ 34 Prestart-Up Instructions ........24 Solenoid Valves Ivc And Ivo ......34 Purge Valve ............34 Solenoid Valves Tvc And Tvo ......35 Starting &...
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Page 9: List Of Illustrations
LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ........................9 Figure 1-2 - Starter Box ..........................10 Figure 1-3 – Package – Controller & Starters ..................... 10 Figure 1-4 – Package – Drive Motor & Air Filter ..................11 Figure 1-5 – Package – Oil Filter, Oil Level Gauge, Mixing Valve .............. 11 Figure 1-6 –... -
Page 10: Section 1, General Information
GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR - The Gardner Denver Rotary Screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads. -
Page 11: Figure 1-2 - Starter Box
LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through the oil cooler, thermostatic mixing valve, and oil filter and discharges into the compressor main oil gallery. A portion of the oil is directed through internal passages to the bearings, gears and shaft oil seal. The balance of the oil is injected directly into the compression chamber to remove heat of compression, seal internal clearances and lubricate the rotors. -
Page 12: Figure 1-4 - Package - Drive Motor & Air Filter
201EAU797 (Ref. Drawing) Figure 1-4 – PACKAGE – DRIVE MOTOR & AIR FILTER 201EAU797 (Ref. Drawing) Figure 1-5 – PACKAGE – OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE MINIMUM PRESSURE VALVE & CHECK VALVE 13-10-618 Page 11... -
Page 13: Figure 1-6 - Package - Air/Oil Flow Diagram
202EDM797 (Ref. Drawing) Figure 1-6 – PACKAGE – AIR/OIL FLOW DIAGRAM 13-10-618 Page 12... -
Page 14: Section 2, Installation
SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passage of current. -
Page 15: Figure 2-1 - Typical Compressor Room
Figure 2-1 – TYPICAL COMPRESSOR ROOM Minimum Air Flow * for Compression and Cooling – CFM /MIN) Air-Cooled Air-Cooled Water-Cooled (Kw) Package Module Package 200 (150) 28,500 (808) 20,500 (580) 8,000 (226) 250 (186) 35,900 (1016) 26,000 (736) 9,900 (280) 300 (225) 37,900 (1073) 26,000 (736) - Page 16 Use of improper solution may result in damage to the cooler. FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be made at a maximum 10°...
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Page 17: Figure 2-3 - Cold Weather Installation
Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000SP lubricant. Monitor the unit carefully during start-up and operation to be sure it is functioning normally. -
Page 18: Figure 2-4 - Inlet Line Lengths
Refer to Engineering Data Sheet 13-9-411, available from an authorized Gardner Denver distributor, for the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit. - Page 19 When connecting two or more GD rotary screw units on a common manifold, each unit is isolated by the check valve in the unit discharge line. If a Gardner Denver rotary screw unit is connected to another compressor on a common manifold, be sure the other compressor has a check valve in the line between the machine and the manifold.
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Page 20: Figure 2-5 - Heat Exchanger Approximate Water Flow
HEAT EXCHANGER (INTERNATIONAL) Water Temperature to Heat Exchanger (ls) Approximate Water Maximum Pressure Drop @ 32° C Water Flow Water Temperature Model 16° C 21° C 27° C 32° C (ls) * (bar) EAU99T Less than .15 bar for any EAU99T flow rate shown in the table... -
Page 21: Figure 2-7 - Series Piping
BLOWDOWN VALVE PIPING - The blowdown valve is piped back into the airend between the inlet valve and air filter. WATER PIPING (Water-Cooled Heat Exchanger Models Only) - On machines equipped with water- cooled heat exchangers, the water inlet and outlet connections are located in the unit base flange. It is mandatory that any water cooled unit be installed in a shelter heated to temperatures above freezing (32°... -
Page 22: Figure 2-8 - Parallel Piping
SERIES PIPING (Figure 2-7, page 20) - Water flow must be through aftercooler first for effective cooling of discharge air and is so piped on the standard water-cooled unit. 306EAQ797-A (Ref. Drawing) Figure 2-8 – PARALLEL PIPING * (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY 13-10-618 Page 21... - Page 23 PARALLEL PIPING (Figure 2-8, page 21) - A separate water control valve is required to control the discharge air temperature. If a remote (externally mounted) water-cooled aftercooler is piped in parallel with the heat exchanger, provide a separate water control valve for the aftercooler and pipe separate inlet water lines to both the aftercooler and heat exchanger.
- Page 24 Wipe lubrication fitting clean and add grease with a hand-operated grease gun. Only enough grease should be added to replace the grease used by the bearing. Too much grease can be as harmful as insufficient grease. The grease capacity should be about ½ full. Leave the relief plug temporarily off.
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Page 25: Section 3, Starting & Operating Procedures
Compressor Oil - Check the oil level in the reservoir. Add oil only if the oil level gauge reads in the red “ADD OIL” range. Do not mix different type oils. The unit is shipped filled with Gardner Denver AEON™ 9000SP Lubricating Coolant which is suitable for the first 8000 hours under normal operating conditions. - Page 26 Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See Figure 4-11 thru Figure 4-12, page 40 thru page 43, for general wiring diagrams and Section 2, for installation instructions. Grounding - Equipment must be properly grounded according to Table 250-95 of the National Electrical Code.
- Page 27 The compressor starts and stops automatically. Automatic restarting can cause injury or death. Open, lockout and tagout main disconnect and any other circuits before servicing the unit. STARTING THE UNIT - Observe the following starting procedures. Unit Cold - If the unit is a water-cooled heat exchanger model, open any manual water inlet valves wide open.
- Page 28 Quick Start Guide Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run button to start the compressor, no other settings are required. The Target Pressure comes preset to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure setting is desired, the following steps can be used as a guide.
- Page 29 To change the Target Pressure, press the Enter button to edit the value. OPERATION ADJUSTMENT TARGET PRESSURE 100 PSI (EDIT PARAMETER) A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the Plus and Minus buttons to change its value.
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Page 30: Section 4, Controls & Instrumentation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver Rotary Screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop air line (and to the appropriate water supply if water-cooled). -
Page 31: Figure 4-1 - Key Pad
Figure 4-1 – KEY PAD Relief Valve A pressure relief valve(s) is (are) installed in the final discharge line and set to approximately 120-125% of the unit’s full load operating pressure for protection against over pressure. Periodic checks should be made to ensure its (their) operation. The relief valve should be tested for proper operation at least once every year. -
Page 32: Figure 4-2 - Schematic Tubing Diagram
Operation of the unit with improper relief valve setting can result in severe personal injury or machine damage. Ensure properly set valves are installed and maintained. 205EAU797-A (Ref. Drawing) Figure 4-2 – SCHEMATIC TUBING DIAGRAM 13-10-618 Page 31... -
Page 33: Figure 4-3 - Blowdown Valve
Figure 4-3 – BLOWDOWN VALVE Blowdown Valve (Figure 4-3) - This valve normally is used for control functions, but also serves to relieve reservoir pressure following a shutdown. The blowdown valve is a two-way solenoid valve which is piped into the oil reservoir outlet ahead of the minimum pressure valve. When the solenoid is de- energized, the valve opens and the coolant system is blown down. -
Page 34: Figure 4-5 - Inlet Valve
To service the valve, make sure all pressure is relieved, disconnect the unit from the power supply, lockout and tagout, then unscrew the valve cap from the body. The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor. 203EAU797-A (Ref. -
Page 35: Figure 4-6 - Shuttle Valve
Solenoid Valves IVC and IVO - These valves control position of the inlet valve in response to signals from the “AirSmart” Controller. With both valves de-energized, the normally open IVC valve allows control pressure to the inlet piston to close the valve. If IVC only is energized, the inlet valve is held in its current position. -
Page 36: Figure 4-7 - Turn Valve Actuator (Sectioned)
209EAU797 (Ref. Drawing) Figure 4-7 – TURN VALVE ACTUATOR (SECTIONED) Turn Valve (Electra-Saver only) (Figure 4-7) - The turn valve is a helical valve which, when rotated, opens and closes a series of ports cast into the compressor cylinder. When these ports are open, they direct some of the air which would otherwise be compressed back to the inlet, reducing both capacity and power consumption. - Page 37 Discharge Thermistor - This sensor is located directly in the compressor discharge. Its signal is used to monitor compressor temperature and shut down the compressor if a coolant problem is detected. Reservoir Thermistor - This sensor is located near the separator and is used to monitor temperature and shut down the compressor if high temperatures are detected.
- Page 38 Overload protection is provided for each motor on full voltage and Wye Delta applications. The overloads are adjustable and are factory set based on the motor nameplate amps and the instructions located inside the control box door. Less starter applications utilize a control relay for control of a remote mounted motor starter (not provided with compressor package).
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Page 39: Figure 4-8 - Control Schematic - Compressor At Full Load
206EAU797-B (Ref. Drawing) Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD... -
Page 40: Figure 4-9 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch Off
207EAU797-B (Ref. Drawing) Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF... -
Page 41: Figure 4-10 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch On
208EAU797-B (Ref. Drawing) Figure 4-10 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH ON... -
Page 42: Figure 4-11 - Wiring Diagram - Wye Delta
329EAU546-A (Ref. Drawing) Page 1 of 2 Figure 4-11 – WIRING DIAGRAM – WYE DELTA... - Page 43 329EAU546-A (Ref. Drawing) Page 2 of 2...
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Page 44: Figure 4-12 - Wiring Diagram - Wye Delta
330EAU546-A (Ref. Drawing) Page 1 of 2 Figure 4-12 – WIRING DIAGRAM – WYE DELTA... - Page 45 330EAU546-A (Ref. Drawing) Page 2 of 2...
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Page 46: Section 5, Lubrication - Oil Cooler, Oil Filter & Separator
OIL SPECIFICATIONS: EAU (Domestic and International) - The factory fill compressor lubricant is Gardner Denver AEON 9000SP lubricating coolant which can be used for year-round operation. AEON 9000SP is a synthetic, extended life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based lubricant. - Page 47 HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000SP lubricating coolant will operate at a sustained discharge temperature up to 210° F (99° C). When unusually high ambient air temperature is encountered, lubricant life will be shortened, see Figure 5-7, page 54.
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Page 48: Figure 5-1 - Dew Point Chart °F
Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 100 psig 125 psig 150 psig 175 psig Ambient Temp. F Figure 5-1 – DEW POINT CHART °F Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 6.9 bar 8.6 bar 10.4 bar 12.1 bar Ambient Temp. -
Page 49: Figure 5-3 - Flow Diagram
210EAU797-B (Ref. Drawing) Figure 5-3 – FLOW DIAGRAM... -
Page 50: Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted
202EAU797 (Ref. Drawing) 205EDM797 (Ref. Drawing) Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED 13-10-618 Page 49... -
Page 51: Figure 5-5 - Cooler Drain Detail
REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be disconnected after test and the vent fan motor connected in its place. The vent fan will be mounted in the enclosure. - Page 52 AFTERCOOLER PIPING - At shutdown of the system, all units should be drained completely of condensate if there is any possibility of freezing or corrosion damage. To help remove the condensate, the cooler may be tapped per Figure 5-5, page 50, and a drain cock installed. After opening the drain cock, blow air into the cooler from a connection on the opposite side of the cooler.
- Page 53 Kit number 205EAU4013 including the oil stop valve, check valve and flanges must be installed on all remote elevated coolers per Figure 5-4, page 49, and the following instructions: Mount the check valve (90J113) as shown. Mount the drain valves in the lowest section of the pipe on each side of the cooler connections. Mount the oil stop valve (90AR243) in the line after the thermal mixing valve as shown.
- Page 54 Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. ...
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Page 55: Figure 5-6 - Oil Level Gauge
Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis program with AEON lubricants. The first sample from a new unit should be sent in after 100 hours. - Page 56 DRAINING AND CLEANING OIL SYSTEM Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. ...
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Page 57: Figure 5-8 - Approximate Oil System Capacities
FILLING OIL RESERVOIR Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, tag and lockout the power supply to the starter. - Page 58 COMPRESSOR OIL FILTER ( , page 48) - This patented design screw-i oil filter is a vital part in Figure 5-3 maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is integrated into the replaceable oil filter element. Air/oil under pressure will cause severe personal injury or death.
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Page 59: Figure 5-9 - Thermostatic Mixing Valve Element
To remove the oil filter, using a 1” socket unthread the oil filter from the housing. Rotate the filter head (aluminum assembly) to align the channel in the head with the tabs on the oil filter element.. Lift the threaded part of the filter head until it is seated against the top of the filter head. With the channel aligned and the threaded portion of the filter head against the top of the filter head, disassemble the filter element from the filter head. - Page 60 THERMAL CONTROL (THERMOSTATIC MIXING) VALVE is installed in system as shown in Figure 5-3 page 48. This valve is used to control temperature of the oil in both air-cooled radiator and water-cooled heat exchanger type oil cooler systems. On start-up with unit cold, element is open to bypass, allowing oil to pass directly from the reservoir to compressor during warm-up.
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Page 61: Figure 5-10 - Water Control Valve
In many instances, the cooling water supply for the heat exchanger will contain impurities in solution and/or suspension. These substances can cause scale formation, corrosion and plugging of any water- cooled heat exchanger equipment. Disregarding the possibility that one or more of these conditions exist may result in increased maintenance and operation expense, reduced equipment life and emergency shutdown. -
Page 62: Figure 5-11 - Oil Separator
If the leak develops through the packing, tighten the packing gland nut firmly with a wrench to reseat the packing around the valve stem, then back off the nut until loose, and finally retighten the nut finger tight. Tightening the packing nut too tight may cause erratic operation. An occasional drop of oil on the valve stem at the packing nut will prolong packing life. - Page 63 COMPRESSOR (GD ELIMINATOR) OIL SEPARATOR located in a separate housing, consists of a renewable cartridge-type separator element and provides the final removal of oil from the air stream (Figure 5-11). Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity. Oil collected outside the element is returned through tubing to the compressor cylinder.
- Page 64 Removal of Oil Separator For Inspection Or Replacement: Be certain unit is completely off and that no air pressure is in the oil reservoir. Disconnect, tag and lockout power supply to the starter. Remove screws holding the top plate to the separator housing. Lift the top plate from the separator housing.
- Page 65 Oil Cooler Temperature Differential (Water-Cooled Heat Exchanger) - The oil temperature differential depends on the inlet water temperature and the water flow rate permitted by the water flow control valve setting. The oil inlet temperature is approximately the same as the air discharge temperature - see the gauge on the instrument panel.
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Page 66: Section 6, Air Filter
Filter Element - Service the air filter element when the “CHANGE AIR FILTER” LED is illuminated. Clean every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. - Page 67 Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water. Improper cleaning may damage the element. NOTICE Never operate the unit without the element.
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Page 68: Section 7, Coupling
SECTION 7 COUPLING Figure 7-1 – INSTALLATION OF COUPLING CUSHIONS Rotating machinery can cause personal injury or death. Turn the unit completely off, open the main disconnect, lockout and tagout before servicing the coupling. COUPLING - The motor and compressor are direct connected by a resilient type flexible coupling with a single element cushion. - Page 69 ASSEMBLY OF COUPLING ONTO THE AIREND AND MOTOR (see Figure 7-1). NOTICE Elements with non-uniform cross sections must be mounted with the rotation arrow on the coupling the same direction as the rotation arrow on the airend. Incorrect rotation will greatly decrease the torque carrying capacity of the coupling.
- Page 70 3. Apply light oil or grease film to both sides of the hardened steel washer. This is very important, since it will significantly reduce the rubber stresses around the metal bushings when torquing down the cap screws. Place the supplied hardened washers under the cap screw heads and torque the screws down to the torque rating in the assembly instructions supplied with the coupling.
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Page 71: Section 8, Maintenance Schedule
SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter - Operating conditions determine frequency of service. If the “CHANGE AIR FILTER” message is displayed, air filter requires servicing or changing. See “Air Filter", Section 6. Oil Separator - Operating conditions determine frequency of service. If the “CHANGE SEPARATOR” message is displayed, the oil separator element requires changing. - Page 72 Every Year Check the relief valve for proper operation. See Section 4. Check shutdowns for proper operation. MAINTENANCE SCHEDULE Maintenance Action As Indicated by Every Every Every Every AirSmart Every 8 1000 8000 * Year Controller Hours Hours Hours Hours •...
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Page 73: Section 9, Troubleshooting
SECTION 9 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate heaters tripped . cause of overload. Pressure in reservoir. Inspect blowdown valve and muffler. - Page 74 SYMPTOM POSSIBLE CAUSE REMEDY Compressor starts too Wye Delta switch time set Contact your Gardner slowly too long. Denver distributor. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Compressor is low on Restricted air filter.
- Page 75 NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13-10-618 Page 74...
- Page 76 GENERAL PROVISIONS AND LIMITATIONS Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty is made with respect to: Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.
- Page 77 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2013 Gardner Denver, Inc. Printed in U.S.A.