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Related Manuals for Gardner Denver AUTO SENTRY EAU99G
Summary of Contents for Gardner Denver AUTO SENTRY EAU99G
- Page 1 13-10-614 GARDNER DENVER ® Version: 04 October 29, 2003 ELECTRA-SAVER STATIONARY BASE-MOUNTED COMPRESSOR ® AUTO SENTRY -- ES+ CONTROLS DOMESTIC MODELS EAU99G & M – 200, 250 & 300 HP INTERNATIONAL MODEL EAU99H – 150, 186 & 225 KW OPERATING AND...
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Page 2: Instructions For Ordering Repair Parts
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. Your local authorized distributor maintains a large inventory of genuine parts and he is backed up for emergency parts by direct access to the Master Distribution Center (MDC) in Memphis, Tennessee. -
Page 3: Foreword
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 maintenance. 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
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ..............i Instructions For Ordering Repair Parts ....................i Foreword............................ii Section 1, General Information......................1 Section 2, Installation..........................9 Section 3, Starting & Operating Procedures ..................20 Section 4, Controls &... - Page 5 INDEX Addition Of Oil Between Changes ....44 Lubrication, Cooling And Sealing .....2 Air Filter Element Life........58 Lubrication, Section 5........37 Air Filter, Section 6........57 Air Flow In The Compressor System ....1 Maintenance Schedule, Section 8....62 Air-Cooled Units, Location ......10 Moisture In The Oil System ......
- Page 6 Every 8 Hours Operation......62 Every 8000 Hours Operation ...... 62 Thermal Control (Thermostatic Mixing) Valve.. 50 Every Year ..........63 Troubleshooting, Section 9......64 Motor Lubrication........62 Turn Valve............2 Oil Separator..........62 Service Check List Water Flow Control Valve For Heat Exchanger Air Filter ............
- Page 7 LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle......................1 Figure 1-2 – Starter Box ........................3 Figure 1-3 – Package – Controller & Starters ..................3 Figure 1-4 – Package – Drive Motor & Air Filter..................4 Figure 1-5 – Package – Oil Filter, Oil Level Gauge, Mixing Valve ............5 Figure 1-6 –...
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Page 8: 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 9 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.
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Page 10: Figure 1-2 - Starter Box
Figure 1-2 – STARTER BOX 201EAU797 (Ref. Drawing) Figure 1-3 – PACKAGE – CONTROLLER & STARTERS 13-10-614 Page 3... -
Page 11: Figure 1-4 - Package - Drive Motor & Air Filter
201EAU797 (Ref. Drawing) Figure 1-4 – PACKAGE – DRIVE MOTOR & AIR FILTER 13-10-614 Page 4... -
Page 12: Figure 1-5 - Package - Oil Filter, Oil Level Gauge, Mixing Valve
Figure 1-5 – PACKAGE – OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE MINIMUM PRESSURE VALVE & CHECK VALVE 201EAU797 (Ref. Drawing) Figure 1-6 – PACKAGE – AIR/OIL FLOW DIAGRAM 13-10-614 Page 5... - Page 13 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: DANGER Failure to observe these notices could result in injury to or death of personnel.
- Page 14 DECALS 212EAQ077 206EAQ077 218EAQ077 211EAQ077 207EAQ077 13-10-614 Page 7...
- Page 15 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13-10-614 Page 8...
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Page 16: 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. CAUTION Do not electric weld on the compressor or base; bearings can be damaged by passage of current. -
Page 17: Figure 2-1 - Typical Compressor Room
Figure 2-1 – TYPICAL COMPRESSOR ROOM Minimum Air Flow * for Compression and Cooling DOMESTIC (CFM) Air-Cooled Air-Cooled Water-Cooled Package Module Package 28,500 20,500 8,000 35,900 26,000 9,900 37,900 26,000 11,900 INTERNATIONAL (M /MIN) Air-Cooled Air-Cooled Water-Cooled Package Module Package 1,016 1,072 * 80°... - Page 18 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 19: 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 20: 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 21 INLET LINE - Where an inlet line is used between the air filter and the compressor, it must be thoroughly cleaned on the inside to prevent dirt or scale from entering the compressor. If welded construction is used, the line must be shot blasted and cleaned to remove welding scale. In either case, the inlet line must be coated internally by galvanizing or painting with a moisture and oil-proof sealing lacquer.
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Page 22: Figure 2-5 - Heat Exchanger (Oil Cooler) Approximate Water Flow
HEAT EXCHANGER (INTERNATIONAL) Water Temperature to Heat Exchanger Maximum Approximate Water Water Flow Pressure Drop @ 32° C (ls) (ls) * Water Temperature Bar Model 16° C 21° C 27° C 32° C EAU99H Less than .15 bar for any flow rate shown in the EAU99H table... - Page 23 BLOWDOWN VALVE PIPING - The blowdown valve is fitted with a muffler for operation indoors. If the installation requires, the muffler may be removed and the blowdown valve piped to the outside with a pipe size the same as the blowdown valve outlet connection. 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.
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Page 24: Figure 2-7 - Series Piping
305EAQ797-A (Ref. Drawing) Figure 2-7 – SERIES PIPING 306EAQ797-A (Ref. Drawing) Figure 2-8 – PARALLEL PIPING * (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY 13-10-614 Page 17... - Page 25 SERIES PIPING (Figure 2-7, page 17) - Water flow must be through aftercooler first for effective cooling of discharge air and is so piped on the standard water-cooled unit. PARALLEL PIPING (Figure 2-8, page 17) - A separate water control valve is required to control the discharge air temperature.
- Page 26 MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The following charts show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions.
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Page 27: 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 28 WARNING Failure to properly ground the compressor package could result in controller malfunction. Rotation - Check for correct motor rotation using “JOG MODE.” Compressor drive shaft rotation must be counterclockwise standing facing the compressor coupling. Check the rotation on the fan motors.
- Page 29 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. Start the unit by pushing either the “CONSTANT RUN” button or one of the “AUTO” buttons. Since the unit is equipped with a minimum (65 psig, 4.5 bar) pressure discharge valve, no special procedure to maintain unit reservoir pressure is required.
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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 - Schematic Tubing Diagram
WARNING When the relief valve opens, a stream of high velocity air is released, resulting in a high noise level and possible discharge of accumulated dirt or other debris. Always wear eye and ear protection and stand clear of the discharge port when testing the relief valve to prevent injury. -
Page 32: Figure 4-2 - Minimum Discharge Pressure/Check Valve
The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor. Figure 4-2 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE... -
Page 33: Figure 4-3 - Inlet Valve
203EAU797-A (Ref. Drawing) Figure 4-3 – INLET VALVE Solenoid Valves IVC and IVO - These valves control position of the inlet valve in response to signals from the “AutoSentry”. With both valves de-energized, the normally open IVC valve allows control pressure to the inlet piston to close the valve. -
Page 34: Figure 4-5 - Blowdown Valve
Purge Air Valve - The purge valve is a normally closed two-way air actuated valve that admits purge air from the final discharge manifold to the compressor to counteract the oil knock that occurs in oil-flooded rotary screw compressors when they are completely unloaded with pressure in the oil reservoir. This valve is controlled by the same control pressure which controls the inlet valve. -
Page 35: Figure 4-6 - Turn Valve Actuator (Sectioned)
COMPRESSOR CAPACITY CONTROL The capacity of the compressor is controlled by the action of the Turn Valve and the Compressor Inlet Valve. The turn valve controls compressor delivery to match demands of 40% to 100% of the compressor’s maximum capacity. The inlet valve throttles to control compressor delivery to match demands of 0% to 40% of the compressors maximum capacity. - Page 36 Solenoid Valves TVC and TVO - These valves control position of the turn valve in response to signals from the “AutoSentry” controller. With both valves de-energized, equal pressure is supplied to both sides of the actuator to hold it in its current position. If TVC only is energized, the right side of the turn valve actuator is exhausted to the compressor inlet cavity, causing the turn valve to move towards the full load position.
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Page 37: Figure 4-7 - Control Schematic - Compressor At Full Load
206EAU797-A (Ref. Drawing) Figure 4-7 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD... -
Page 38: Figure 4-8 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch Off
207EAU797-A (Ref. Drawing) Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF... -
Page 39: Figure 4-9 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch On
208EAU797-A (Ref. Drawing) Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH ON... -
Page 40: Figure 4-10 - Wiring Diagram - (Wye Delta, Es+ Controller, Air-Cooled)
202EAU546-D (Ref. Drawing) Page 1 of 2 Figure 4-10 – WIRING DIAGRAM – (WYE DELTA, ES+ CONTROLLER, AIR-COOLED) - Page 41 202EAU546-D (Ref. Drawing) Page 2 of 2...
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Page 42: Figure 4-11 - Wiring Diagram - Wye Delta Es+ Controller - Water Cooled
205EAU546-D (Ref. Drawing) Page 1 of 2 Figure 4-11 – WIRING DIAGRAM – WYE DELTA ES+ CONTROLLER – WATER COOLED... - Page 43 205EAU546-D (Ref. Drawing) Page 2 of 2...
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Page 44: 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 45 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 46.
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Page 46: 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 47: Figure 5-3 - Flow Diagram
210EAU797-A (Ref. Drawing) Figure 5-3 – FLOW DIAGRAM... -
Page 48: Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted
202EAU797 (Ref. Drawing) 205EDM797 (Ref. Drawing) Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED 13-10-614 Page 41... -
Page 49: 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 50 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 42, 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 51 The shipped loose kit includes the oil stop valve, check valve and flanges and must be installed on all remote elevated coolers per Figure 5-4, page 41, 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 52 DANGER Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. CAUTION Excessive oil carry-over can damage equipment. Never fill oil reservoir above the "FULL" marker. LUBRICANT CHANGE PROCEDURE - Upgrading to a longer life lubricant is essentially a very worthwhile practice.
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Page 53: Figure 5-6 - Oil Level Gauge
Figure 5-6 – OIL LEVEL GAUGE OIL LEVEL GAUGE (Figure 1-2, page 3 and Figure 5-6) indicates the amount of oil in the oil reservoir. Read oil level only when unit is on. In operation the oil level will fluctuate as the compressor loads and unloads. - Page 54 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 the AEON lubricants. The first sample from a new unit should be sent in after 100 hours.
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Page 55: Figure 5-8 - Approximate Oil System Capacities
FILLING OIL RESERVOIR DANGER 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. - Page 56 COMPRESSOR OIL FILTER ( , page 40) - This patented design screw on oil filter is a vital part Figure 5-3 in maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valves are located in the top manifold of the filterstat. To replace, unbolt the manifolds and remove valves.
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Page 57: Figure 5-9 - Thermostatic Mixing Valve Element
To install a new oil filter, rotate the threaded portion of the filter head to align the channel. Align the tabs on the filter element with the channels in the filter head and snap the element into the filter head. Press the filter assembly into the filterstat assembly. - Page 58 DANGER 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. DANGER 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 59: Figure 5-10 - Water Control Valve
Figure 5-10 – WATER CONTROL VALVE WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) (Figure 5-10) - The water flow control valve is adjustable to compensate for varying water inlet temperatures and pressures and is to be mounted in the water outlet line after the oil cooler ( , page 40). -
Page 60: Figure 5-11 - Oil Separator
DANGER Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. OIL RESERVOIR - The oil reservoir-separator combines multiple functions into one vessel. The lower half is the oil reservoir, providing oil storage capacity for the system and the top portion, a primary oil separation means. - Page 61 Pressure Differential Gauging - The “CHANGE SEPARATOR” advisory will flash when the pressure differential across the oil separator reaches approximately 8 psid (.55 bar). Replace the oil separator element at this time. If ignored, the unit will shut down and the advisory will illuminate steadily when the pressure differential reaches 15 psid (1 bar).
- Page 62 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 63 Oil Cooler Water Pressure Differential (Water-Cooled Heat Exchanger) - The water pressure differential through the heat exchanger will depend on the supply pressure, flow rate, cooler tube cleanliness and outlet pressure. The inlet and outlet water pressure may be checked at the pipe fittings supplied by the customer.
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Page 64: 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 65 WARNING 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. Never use elements that are damaged, ruptured or wet. Never use gaskets that won't seal. Keep spare elements and gaskets on hand to reduce downtime.
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Page 66: Section 7, Coupling
SECTION 7 COUPLING Figure 7-1 – INSTALLATION OF COUPLING CUSHIONS DANGER 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 67 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 68 3. Apply a 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 69: 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 70 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 AutoSentry Every 8 1000 8000 * Year Controller Hours Hours Hours Hours •...
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Page 71: 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 72 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 73 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. 13-10-614...
- Page 74 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 75 For additional information contact your local representative or Gardner Denver Compressor and Pump Division, 1800 Gardner Expressway, Quincy, Illinois 62301 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 224-7814 Sales and Service in all major cities. Specifications subject to change without notice.