Gardner Denver AirSmart EAU99T, Operating And Service Manual

Page 1: ...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 A...

Page 2: ...it 3 A full line of factory tested AEON compressor lubricants specifically formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the necessary parts to simplify...

Page 3: ...mical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriate...

Page 4: ...low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Li...

Page 5: ...r oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any...

Page 6: ...8 Section 1 General Information 9 Section 2 Installation 13 Section 3 Starting Operating Procedures 24 Section 4 Controls Instrumentation 29 Section 5 Lubrication Oil Cooler Oil Filter Separator 45 S...

Page 7: ...8 Inlet Tube 66 Inlet Valve 33 Installation For Cold Cold Weather Operation 16 Installation Section 2 13 Lifting Unit 13 Location 13 Air Cooled Units 14 Water Cooled Units 14 Lubricant Recommended 45...

Page 8: ...0 Hours Operation 70 Every Year 71 Motor Lubrication 70 Oil Separator 70 Service Check List Air Filter 70 Shuttle Valve 34 Solenoid Valves Ivc And Ivo 34 Solenoid Valves Tvc And Tvo 35 Starting Operat...

Page 9: ...lve 32 Figure 4 5 Inlet Valve 33 Figure 4 6 Shuttle Valve 34 Figure 4 7 Turn Valve Actuator Sectioned 35 Figure 4 8 Control Schematic Compressor At Full Load 38 Figure 4 9 Control Schematic Compressor...

Page 10: ...air is drawn into the cavity between the main rotor lobes and secondary rotor grooves A When the rotors pass the inlet port cutoff air is trapped in the interlobe cavity and flows axially with the mes...

Page 11: ...l is injected directly into the compression chamber to remove heat of compression seal internal clearances and lubricate the rotors TURN VALVE The turn valve is a rotary helical valve located on the d...

Page 12: ...13 10 618 Page 11 Figure 1 4 PACKAGE DRIVE MOTOR AIR FILTER Figure 1 5 PACKAGE OIL FILTER OIL LEVEL GAUGE MIXING VALVE MINIMUM PRESSURE VALVE CHECK VALVE 201EAU797 Ref Drawing 201EAU797 Ref Drawing...

Page 13: ...13 10 618 Page 12 Figure 1 6 PACKAGE AIR OIL FLOW DIAGRAM 202EDM797 Ref Drawing...

Page 14: ...ightened When lifting the motor the lifting angle must not exceed 15 degrees Failure to observe this warning may result in damage to equipment or personal injury Compressor air oil reservoir separator...

Page 15: ...the air flow to and from the unit Allow three and one half 3 1 2 feet 1 1 m to the nearest obstruction on the starter end and control box end of the unit Allow three 3 feet 9 m to the nearest obstruct...

Page 16: ...ot sufficient to conveniently drain the oil some other methods of providing drain are 1 Elevate the compressor unit on a suitable structure to obtain the desired drain height If the compressor unit ba...

Page 17: ...nvironment The following are general guidelines for outside installations Cold Weather Down To 10 F 12 C 1 Be sure all drains traps and control lines including pressure transducer lines are heated to...

Page 18: ...ssor room above freezing will save many complications in the operation and installation of the unit Refer to Engineering Data Sheet 13 9 411 available from an authorized Gardner Denver distributor for...

Page 19: ...nd corner of the unit viewed from the opposite end from control panel side When connecting two or more GD rotary screw units on a common manifold each unit is isolated by the check valve in the unit d...

Page 20: ...mate Water Pressure Drop 90 F Water Temperature psi HP Model 60 F 70 F 80 F 90 F 200 EAU99T 3 0 3 7 5 0 7 5 110 Less than 1 psi for any flow rate shown in the table 250 EAU99T 3 8 4 8 6 4 9 5 110 300...

Page 21: ...g 10 3 bar The water flow rates shown are approximate and a guide to sizing piping cooling tower and other water system equipment The heat exchanger system is designed to operate with water inlet temp...

Page 22: ...low must be through aftercooler first for effective cooling of discharge air and is so piped on the standard water cooled unit Figure 2 8 PARALLEL PIPING OPTIONAL WATER CONTROL VALVE AND WATER SHUTOFF...

Page 23: ...nce the starter is too large to be mounted within the control enclosure If not supplied with the compressor unit the starter must be a Size 6 full voltage non reversing type in NEMA CEMA enclosure sui...

Page 24: ...g machinery can cause injury or death Open main disconnect lockout and tagout power supply to starter before working on the electric motor ELECTRIC MOTOR GREASE RECOMMENDATIONS 30 C to 50 C MANUFACTUR...

Page 25: ...aintenance and replacement at required intervals of the oil filter air filter and air oil separator is necessary to achieve maximum service and extended drain intervals of AEON 9000SP synthetic lubric...

Page 26: ...on with incorrect motor rotation can damage equipment and cause oil eruption from the compressor inlet When checking motor rotation induce minimum rotation less than one revolution if possible Never a...

Page 27: ...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 Unit Hot No warm up period is r...

Page 28: ...n of the compressor the machine must be stopped and in the Ready mode Stop the compressor by pressing the Stop Reset button The front panel display should read READY on line 3 Next press the Enter but...

Page 29: ...at were made press the Enter button If the Stop Reset button is pressed the parameter changes will be lost the next time the compressor power is turned off Setting The Unload and Load Pressure After s...

Page 30: ...he operating light will be on Press the STOP RESET key at any time to stop the compressor under normal conditions AUTOMATIC is the most common selected mode of operation as it automatically will opera...

Page 31: ...test the relief valve raise the system operating pressure to 75 of the relief valve set pressure and manually open the valve with the hand lever Hold the valve open for a few seconds and allow it to...

Page 32: ...tion 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 Figure 4 2 SCHEMATIC TUBING DIAGRAM 2...

Page 33: ...re that the inlet valve is closed during blowdown Oil Level Gauge Figure 1 2 page 10 and Figure 5 6 page 54 This gauge is located on the oil reservoir and indicates the oil level See Section 5 for inf...

Page 34: ...mum pressure required to open the 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 Th...

Page 35: ...he regulator should be set for 25 30 psig Figure 4 6 SHUTTLE VALVE Shuttle Valve Figure 4 6 Also known as a double check valve the shuttle valve is a device which will take two 2 supply signals and al...

Page 36: ...not to scrape the cylinder walls when moving the pistons Solenoid Valves TVC and TVO Electra Saver only These valves control the position of the turn valve in response to signals from the AirSmart con...

Page 37: ...ng for replacement information Fuse Blocks Two Class CC fuse blocks provide line side protection for the power supply and control transformer as applicable Control Transformer This control device chan...

Page 38: ...ps must be first multiplied by 0 577 before using the heater table COMPRESSOR CAPACITY CONTROL TURN VALVE UNITS ONLY The capacity of the compressor is controlled by the action of the turn valve and th...

Page 39: ...13 10 618 Page 38 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD 206EAU797 B Ref Drawing...

Page 40: ...13 10 618 Page 39 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF 207EAU797 B Ref Drawing...

Page 41: ...13 10 618 Page 40 Figure 4 10 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH ON 208EAU797 B Ref Drawing...

Page 42: ...13 10 618 Page 41 Figure 4 11 WIRING DIAGRAM WYE DELTA 329EAU546 A Ref Drawing Page 1 of 2...

Page 43: ...13 10 618 Page 42 329EAU546 A Ref Drawing Page 2 of 2...

Page 44: ...13 10 618 Page 43 Figure 4 12 WIRING DIAGRAM WYE DELTA 330EAU546 A Ref Drawing Page 1 of 2...

Page 45: ...13 10 618 Page 44 330EAU546 A Ref Drawing Page 2 of 2...

Page 46: ...ted to the highest quality standards and are factory authorized tested and approved for use in rotary screw compressors AEON lubricants are available through your authorized Gardner Denver compressor...

Page 47: ...oil temperature and prevents moisture accumulation in the oil Unusual cooling of the oil reservoir light duty cycles high humidity gross compressor over sizing or malfunctions of the thermal mixing v...

Page 48: ...W POINT CHART F Figure 5 2 DEW POINT CHART C These charts are easily used by reading the ambient temperature along the bottom axis of the chart and then reading the appropriate pressure curve to deter...

Page 49: ...13 10 618 Page 48 Figure 5 3 FLOW DIAGRAM 210EAU797 B Ref Drawing...

Page 50: ...13 10 618 Page 49 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED 205EDM797 Ref Drawing 202EAU797 Ref Drawing...

Page 51: ...ts of local codes should be followed When connecting pipe fittings to the cooler support the threaded coupling with a pipe wrench when tightening the connection Use silicone sealant on all steel to al...

Page 52: ...he minimum pressure check valve then into piping to the cooler with a flexible connection between the minimum pressure check valve and aftercooler to keep the weight of the piping off of the cooler HE...

Page 53: ...nstallations with pipe lengths and or vertical runs outside the recommended limits could result in high oil carryover and cause the machine to shutdown on high discharge temperature COLD AMBIENT OPERA...

Page 54: ...ter and reinstall used filter 2 Fill the system with a 50 percent charge of the new lubricant Start the machine and stay there to observe Allow the machine to run about five minutes at temperature or...

Page 55: ...on oil temperature Figure 5 7 shows how the change interval is affected by temperature When operating conditions are severe very dusty high humidity etc it will be necessary to change the oil more fr...

Page 56: ...ystem use one of the following methods 1 If the unit is not elevated high enough to use the oil reservoir drain line to drain oil a small hand electric or air operated pump should be used to drain res...

Page 57: ...sary to bring level to the center of the green range on the gauge On unloaded operation and after shutdown some oil will drain back into the oil reservoir and the oil level gauge will read FULL DO NOT...

Page 58: ...bolts and filters Compressor air oil reservoir separation chamber and all piping and tubing may be at high temperature during and after operation Improper oil filter maintenance will cause damage to...

Page 59: ...abs on the filter element with the channels in the filter head and snap the element into the filter head 7 Press the filter assembly into the filterstat assembly Using a 1 socket tighten down the oil...

Page 60: ...ath 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 Compressor air oil reserv...

Page 61: ...eriodically and replaced when the zinc has been reduced to about 1 2 inch 13mm in length Figure 5 10 WATER CONTROL VALVE WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER Optional Equipment Figure 5 10 The...

Page 62: ...solenoid operated water shutoff valve rated at 150 psig 10 3 bar water pressure should be mounted in the water outlet line after the oil cooler The valve should be wired into the compressor control c...

Page 63: ...nt is usually due to heavy dirt or varnish buildup in the filtering material Excessive tilt angle of the unit will also hamper separation and cause oil carryover Oil separator element life cannot be p...

Page 64: ...rating temperature at the time of checks One half hour of loaded operation is usually sufficient to reach level out operating temperatures Air and Oil Discharge Temperature 165 F to 195 F 74 C to 91 C...

Page 65: ...same as the air discharge temperature see the gauge on the instrument panel The oil outlet temperature may be checked by installing a tee at the oil filter outlet Oil Cooler Water Pressure Differentia...

Page 66: ...ine parts are available through your authorized Gardner Denver distributor To service 1 Unfasten the clips and pull out the filter element 2 Visually inspect the element If cleaning is not necessary r...

Page 67: ...nspection indicates a rupture crack or pin hole in the pleated media Inspection should be done by placing a bright light inside the element 2 Pressure drop through a filter with a freshly cleaned elem...

Page 68: ...n 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...

Page 69: ...sher This is very important since it will significantly reduce the rubber stresses around the metal bushings when torquing down the cap screws 5 Check to see if element is centered between shaft ends...

Page 70: ...c element the hardened washer and the cap screw head free from dirt 4 Check to see if element is centered between shaft ends If element is centered using the loctite supplied with the coupling lock al...

Page 71: ...is high refer to Excessive Oil Consumption page 73 DO NOT MIX LUBRICANTS 2 Observe if the unit loads and unloads properly 3 Check discharge pressure and temperature 4 Check Panel LED s for advisories...

Page 72: ...ller Every 8 Hours Every 125 Hours Every 1000 Hours Every 8000 Hours Every Year Change Air Filter Change Oil Separator Check Reservoir Oil Level Check for Proper Load Unload Check Discharge Pressure T...

Page 73: ...discharge temperature switch malfunction 2 Replace switch 3 Blown fuse in starter control box 3 Replace fuse investigate if fuses continue to blow 4 Motor starter overload heaters trip 4 Reset and in...

Page 74: ...s found 5 Aftercooler is frozen 5 Thaw out This machine cannot operate in temperatures below 32 F 0 C 6 Unload pressure adjusted too low 6 Adjust the unload pressure See Manual 13 17 600 Excessive oil...

Page 75: ...00SP lubricating coolant 6 Inoperative minimum pressure valve 6 Clean out or replace valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See High Discharge Air Temperature this s...

Page 76: ...initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized ser...

Page 77: ...For additional information contact your local representative or visit www contactgd com compressors 2013 Gardner Denver Inc Printed in U S A...