Gardner Denver ELECTRA-SAVER EAY, Operating And Service Manual

Page 1: ...GARDNER DENVER ELECTRA SAVER STATIONARY BASE MOUNTED COMPRESSORS AUTO SENTRY ES CONTROLS AUTO SENTRY ES CONTROLS MODEL EAY OPERATING AND SERVICE MANUAL 13 10 613 3rd Edition January 1998...

Page 2: ...er Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Machinery Inc Gardner Denver Machinery Inc Master Distribution Cen...

Page 3: ...ignored Warning is used to indicate the presence of a hazard which can cause severe person al injury death or substantial property damage if the warning is ignored Caution is used to indicate the pres...

Page 4: ...ORDERING REPAIR PARTS When ordering parts specify Compressor MODEL Method of Cooling HORSEPOWER and SERIAL NUMBER see nameplate on unit The Serial Number is also stamped on top of the cylinder flange...

Page 5: ...18 Control Transformer 22 Controller 18 CONTROLS INSTRUMENTS SECTION 4 18 Controls Instruments General Description 18 Cooler Compressor Oil 33 Cooling Sealing and Lubrication 1 COUPLING SECTION 7 41 C...

Page 6: ...cifications 28 Oil System Compressor 28 Draining and Cleaning 31 Oil System Check 38 Air and Oil Discharge Temperature 38 Oil Cooler Oil Pressure Differential 38 Oil Cooler Temperature Differential 38...

Page 7: ...tch Air Filter Vacuum 22 Vibration 22 System Pressure Transducer 22 System Thermistor 22 Terminal Strip 23 Thermistor Discharge 22 System 22 Transducer Reservoir Pressure 22 System Pressure 22 Transfo...

Page 8: ...e 4 2 Blowdown Valve 19 Figure 4 3 Minimum Discharge Pressure Valve 20 Figure 4 4 Inlet Valve 20 Figure 4 5 Shuttle Valve 21 Figure 4 6 Turn Valve Control 21 Figure 4 7 Turn Valve Actuator 22 Figure 4...

Page 9: ...rotor groove normal vol ume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volume re duction and pressure increase c...

Page 10: ...13 10 613 Page 2 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...

Page 11: ...13 10 613 Page 3 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...

Page 12: ...plug drain plugs covers the thermostat ic mixing valve or break any connections etc in the compressor air or oil sys tem until the unit is shut down and the air pressure has been relieved D Electrical...

Page 13: ...and lockout be fore working on the unit this machine is automatically controlled and may start at any time D An Excess Flow Valve should be on all compressed air supply hoses ex ceeding 1 2 inch insid...

Page 14: ...13 10 613 Page 6 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 15: ...13 10 613 Page 7 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 16: ...area with ample space all around for maintenance Select a location that provides a cool clean dry source of air In some cases it may be necessary to install the air filter at some distance from the co...

Page 17: ...trough below the floor level and pump or bail the drained oil 3 Pump oil from the reservoir filler opening or drain to a container ACOUSTIC ENCLOSURE The Electra Saverr unit is furnished with an acou...

Page 18: ...n included in numbers 3 through 6 above All remote piping should be of adequate size to insure a minimum pressure loss Number 4 above lists the minimum pipe size to be used Long runs of pipe and the u...

Page 19: ...te size provided with a relief valve of proper setting a pressure gauge and a means of draining conden sate AFTERCOOLER FIGURE 1 2 and FIGURE 1 5 pages 2 and 3 An aftercooler will provide control of m...

Page 20: ...fy NEMA 4 enclosure for electrical devices Extreme Cold Weather Operation Down To 40_F 40_C In addition to the above the following should be provided 1 A temperature switch to control the fan should b...

Page 21: ...a mois ture and oil proof sealing lacquer The inlet line should be the full size of the inlet opening on the compressor If an extra long line is necessary the pipe size should be increased according...

Page 22: ...n aftercooler is used the maximum allowable water flow through the aftercooler is 100 gallons per minute on all 350 500 HP units and the maximum water inlet pressure is 150 PSIG If another aftercooler...

Page 23: ...erated grease gun The amount and type of grease added is very im portant Only enough grease should be added to replace the grease used by the bearing Too much grease can be as harmful as insufficient...

Page 24: ...ilure to release pressure may result in personal injury or death During unloaded operation and after shutdown the system will partially drain back into the oil res ervoir and the oil level may read hi...

Page 25: ...COLD OR HOT STARTING PROCEDURES Unit Cold If the unit is a water cooled heat exchang er model open any manual water inlet valves wide open Start the unit by pushing either the CONSTANT RUN button or o...

Page 26: ...en tag and lockout main discon nect and any other circuits before servicing the unit CONTROL DEVICES Controller This compressor unit features the AUTO SENTRY controller which integrates all the contro...

Page 27: ...lant system to pressurize A control air check valve is provided to ensure that the inlet valve is closed during blowdown Oil Level Gauge FIGURE 1 5 Section 1 page 3 This gauge is located on the oil re...

Page 28: ...urning the screw the minimum pressure to open the valve in creases Conversely backing it out decreases the minimum pressure required to open the valve To service the valve unscrew the valve cap from t...

Page 29: ...same control pressure which controls the inlet valve Turn Valve Electra Saver only FIGURE 4 6 The turn valve is a helical valve which when rotated opens and closes a series of ports cast into the comp...

Page 30: ...temperatures are de tected Emergency Stop Push Button This is a main tained push button and removes power from the con troller outputs regardless of controller status It is lo cated on the upper secti...

Page 31: ...l and overload protection for the main drive motor Refer to the manufacturer s instructions for proper overload protection and to manual 13 9 10 647 for connection information COMPRESSOR CAPACITY CONT...

Page 32: ...13 10 613 Page 24 FIGURE 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD 204EAY797 B Ref Drawing...

Page 33: ...13 10 613 Page 25 FIGURE 4 9 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED CONSTANT SPEED MODE 205EAY797 B Ref Drawing...

Page 34: ...13 10 613 Page 26 FIGURE 4 10 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE 206EAY797 B Ref Drawing...

Page 35: ...13 10 613 Page 27 FIGURE 4 11 WIRING DIAGRAM 202EAY546 Ref Drawing...

Page 36: ...final oil separator where most of the remaining oil is removed The separated oil is re turned to the compressor and the air passes to the final discharge line RECOMMENDED LUBRICANT Gardner Denver comp...

Page 37: ...run about five minutes at temperature or until temperature stabi lizes then shut down 3 Thoroughly drain the machine 4 Change to a new filter and separator 5 Fill the system with a full charge of the...

Page 38: ...o Capacity Capacity Centerline Size Initial Fill Refill of RUN 350 HP Air Cld 61 55 11 Water Cld 59 55 11 400 HP Air Cld 61 55 11 Water Cld 59 55 11 500 HP Air Cld 61 55 11 Water Cld 59 55 11 System c...

Page 39: ...high temperature during and after operation Always drain the complete system Draining when the oil is hot will help to prevent varnish deposits and carry away impurities To drain the system use one o...

Page 40: ...a vital part in maintaining a trouble free compressor since it re moves dirt and abrasives from the circulated oil The oil filter relief valve is located in the oil filter head The relief valve opens...

Page 41: ...nicks or cuts and replace if necessary Wipe tee handle 9 and O ring groove Then oil and replace O ring 10 insert tee handle 9 into head assembly 1 and replace snap ring 11 BEARING OIL FILTER An oil fi...

Page 42: ...and must be installed on all remote elevated coolers per FIGURE 5 5 page 33 and the following instructions Remote mounted elevated coolers have a maximum pipe length of 30 feet each way and a maximum...

Page 43: ...vice pressure 65 to 150 psig with the unit warm a pressure drop of 3 to 15 psi can be expected between the oil inlet and the oil outlet Water pressure drop from water inlet to outlet will vary with th...

Page 44: ...ut 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...

Page 45: ...ential or sudden heavy oil carryover may indicate a ruptured element Inspection After removal of separator element shine a light inside the element to reveal areas of heavy dirt or varnish deposits or...

Page 46: ...water flows or temperatures will not be noted in the dis charge temperature since the water control valve will tend to hold a constant oil temperature A significant change in the discharge temperatur...

Page 47: ...40_F maximum for at least 15 minutes Swish the element around in the solution 2 minutes to help remove dirt Warm solution gives best results Rinse the element with a stream of water 40 PSI maximum opp...

Page 48: ...0_ F Install the element in the filter body and fasten securely with the wing bolt Reinstall the dust cup and re taining band clamp Make sure the clamp is tight ened securely to prevent leakage Filter...

Page 49: ...on one coupling body and the flange on the opposite coupling body Tighten set screws in each coupling body b Insert individual cushions as shown in FIGURE 7 1 and slide the collar over the cushions an...

Page 50: ...n on oil aftercooler core faces and the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction...

Page 51: ...ter a short time Air Temperature this section page 44 2 High discharge 2 Replace switch temperature switch malfunction 3 Blown fuse in starter 3 Replace fuse control box investigate if fuses continue...

Page 52: ...ent cooling 3 Provide unrestricted supply air flow of cooling air 4 Clogged oil filter or 4 Replace filter or clean cooler interior cooler 5 Low compressor oil 5 Add oil to proper level Excessive Oil...

Page 53: ...minimum 6 Clean out or replace valve pressure valve causing low operating pressure 7 Operation at elevated 7 Reduce temperature See discharge temperatures High Discharge Air Temperature page 44 this s...

Page 54: ...gment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedule amounts or labor provided...

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