Gardner Denver ELECTRA-SAVER ESMF, Operating And Service Manual

Page 1: ...R DENVER ELECTRA SAVE STATIONARY BASE MOUNTED COMPRESSOR ESM ESNF ESOF MODELS 100 HP EAQPM EAQQM EAQSM 125 HP EAQPN EAQQN EAQSN 150 HP EAQPO EAQQO EAQSO L A COOPER INDUSTRIES 13 10 601 2nd Edition IND...

Page 2: ...AVER Il EA ELECTRA SAVER EB ET ELECTRA SCREW SE ST PACKAGES Any product which has not been operated or maintained in accordance with normal practice and with the recom mendations of the Company Compon...

Page 3: ...TICE COULD RESULT IN INJURY TO OR DEATH OF PERSONNEL A WARNING FAILLURE TO OBSERVE A WARNING NOTICE COULD RESULT IN DAMAGE TO EQUIPMENT ACAUTION CAUTION NOTICES SET FORTH GENERAL REMINDERS OF GOOD SAF...

Page 4: ...pressor OverhauI 1 1 Constant Speed Control System With Low Demand Mode 4 8 Constant Speed Operation 4 8 Control Compressor Capacity 4 5 Control Low Starting Torque Unloaded Start 4 8 Control Piping 2...

Page 5: ...e Differential 5 8 Oil Cooler Water Pressure Differential Watercooled Heat Exchanger 5 8 Oil Filter Compressor 5 3 Oil Filter Indicator 4 5 OIL FILTER SEPARATOR OIL COOLER LUBRICATION SECTION 5 5 1 Oi...

Page 6: ...ature Gauge Discharge Air 4 4 Thermal Control Thermostatic Mixing Valve 5 4 Thermostatic Mixing Valve Thermal Control 5 4 Three Way Valve 4 9 Time Delay Switch Low Oil Pressure 4 4 Trap Moisture Separ...

Page 7: ...to remove the heat of compression and seal internal clearances Volume reduction and pressure increase continues until the air oil mixture trapped in the interlobe cavity by the rotors passes the disc...

Page 8: ......

Page 9: ...JUR Y TO OR DEATH OF PERSONNEL o 0 0 0 0 0 0 0 KEEP FINGERS AND CLOTHING AWAY FROM REVOLVING FAN DRIVE COUPLING ETC DO NOT USE THE AIR DISCHARGE FROM THIS UNIT FOR BREATHING NOT SUITABLE FOR HUMAN CON...

Page 10: ...ation remote from the compressor unit be sure that adequate ventilation is provided Figure 2 2 Hot air must be exhausted from the oil cooler area r Open Unit Open With Compressor Oil Cooler Oil Cooler...

Page 11: ...ire larger than the minimum pipe sizes in the system to keep the pressure loss low All pipe and fittings used in a remote oil cooler system should be galvanized or treated internally to pre vent rust...

Page 12: ...ll save many complications in the operation and installation of the unit AUXILIARY AIR RECEIVER The unit requires an auxiliary air receiver unless the piping system is large and provides sufficient st...

Page 13: ...essure Water Maximum Flow PSIG 80 F 70 F 80 F 90 F Flow Psi ALL 11 0 13 5 17 5 26 0 40 18 ALL 12 0 15 5 20 5 32 0 60 20 I 1 1 ALL I 15 5 19 0 I 25 5 I 37 5 I 60 I 20 150 HP The Maximum Water Flow Show...

Page 14: ...nomical water use separate water inlet lines are piped to the aftercooler and heat exchanger Accessability for inlet air filter servicing must be consid ered when relocating the filters from the unit...

Page 15: ...SHOCK MOTOR LUBRICATION Long time satisfactory opera tion of an electric motor depends in large measure on the bearings and timely lubrication The following charts show recommended grease qualities an...

Page 16: ...ms and Section 2 for installation Instructions Rotatlon Check the motor rotation by momen tarlly starting the motor Compressor drive shaft rote tion is counterclockwise standing at the motor end 7 Ope...

Page 17: ...re is connected to change the specified user s power supply voltage to 115 volt control voltage RESET The Reset Button must be pushed whenever power is interrupted or turned off For circuit interrupti...

Page 18: ...third overload derates each overload for a given enclosure due to the extra heat An overload from a 2 overload heater table would be undersize The overload heaters are in a common overload block in t...

Page 19: ...checks should be made to insure its proper operation Never operate the unit without a proper safety valve setting Low Demand Mode Pressure Switch Figure 1 4 The low demand mode switch when turned ON w...

Page 20: ...arge air temperature shutdown to re start these units press the black bar marked RESET and then press the ON button A DANGER DO NOT CONTINUE TO RESTART THE UNIT IF THE SAME MALFUNCTION OCCURS WITHIN A...

Page 21: ...a set screw secured by a locknut on the side of the valve body The minimum pressure can be adjusted as follows 1 2 3 4 5 Start the compressor Reduce pressure downstream of minimum pressure valve to b...

Page 22: ...onnecting the turn valve system is shown in Figure 11 4 TURN VALVE ACTUATOR Figure 5 4 The turn valve actuator is a double acting hydraulic operated rack and pinion type rotary actuator with approx im...

Page 23: ...UATOR TO SLAM RESULTING IN GEAR AND SHAFT DA MAGE Operating Air Pressure Adjustment Turn low demand mode switch OFF Start the unit Close the air service line valve furnished by customer allow the unit...

Page 24: ...ical Wiring Figures 12 4 13 4 14 4 and 15 4 are the wiring diagrams for the units with Constant Speed Control System AUTOMATIC START TIMED STOP CONTROL SYS TEM WITH LOW DEMAND MODE This control system...

Page 25: ...huttle valve The Flow Control Check Valve consists of a check valve and an adjustable orifice in one body see Figure 8 4 The Three Way Valve Figure 9 4 requires 15 PSIG con trot pressure to shift the...

Page 26: ...RT EA p m RT B T E2021192X FIGURE 11 4 CONTROL TUBING WITH LOW STARTING TORQUE CONTROL 13 10 601 Section 4 Page 10...

Page 27: ...1 1 a L 4 k II 13 10 601 Section 4 Page 11...

Page 28: ...I I 13 10 601 Section 4 Page 12...

Page 29: ...13 10 601 Section 4 Page 13...

Page 30: ...n z I 13 10 601 Section 4 Page 14...

Page 31: ...o f 1 13 10 601 Section 4 Page 15...

Page 32: ...9 w x _ 0 _ ___ l _ 1 J 13 10 601 Section 4 Page 16...

Page 33: ...e starter Is ordered with its own fused control transformer The contact relay or fan oil cooler starter interlock from the compres sor control panel to the remote mounted starter control circuit is ra...

Page 34: ...er The aftercooler when sized for an individual com pressor starter coil is 120 volts and is wired and interlocked with the rest of the control wiring as shown in the Schematic Wiring diagram and per...

Page 35: ...mpressor Starter MU B D V Magnetic Unloader Blowdown Solenoid Valve 110 1 20 V 50 60 Hz Four Way 91B34 The LOW DEMAND MODE switch should be in the OFF position when starting the unit to keep the compr...

Page 36: ...ther or not these N O Aux contacts are required look at the typical wiring diagram shown in most starter manufacturer control handbook digest catalog etc If the typical wiring diagram shows two or mor...

Page 37: ...rged to the oil reservoir where most of the entrained 011is removed by impingement and velocity change The air and remaining oil then passes through the final oil separator The sep arated oil IS retur...

Page 38: ...ischarge temperatures up to 210 F do not require a change from the recommended year round lubricant GD800 When installing GD8000 the original lubricant should be drained completely and the system flus...

Page 39: ...e oil is hot will help to prevent varnish deposits and to carry away impurities To drain the system use one of the following methods If the unit is not elevated high enough to use the oil reservoir dr...

Page 40: ...the Ieakage the cannister may be nicked or distorted by overtorquing and should be replaced COMPRESSOR OIL COOLER RADIATOR TYPE MODULE The air cooled oil cooler module is remote mounted The oil cooler...

Page 41: ...ion and fouling plugging of any water cooled heat exchanger equipment Disregarding the possibility that one or more of these conditions exists may result in Increased maintenance and operation expense...

Page 42: ...located in the vertical section of the oil reservoir consists of two re newable cartridge type separator elements and provides the final removal of oil from the air stream Oil from inside the separato...

Page 43: ...en the fitting nut securely Connect the other end of the tube to the compressor oil return tee trim any excess from new tube to fit into tee do not bend tube to fit or raise tube any further from bott...

Page 44: ...Cooled Ra dlaton The oil temperature differential depends on the temperature of the air at the oil cooler fan and clean Iiness of the core faces As ambient temperatures and core restrictions increase...

Page 45: ...ent thoroughly with clean water a hose maybe used if the water pressure does not exceed 40 PSIG Inspect the element for ruptures or cracks in the pleated media replace with new element if any are foun...

Page 46: ...er servicing After servicing reset the indicator by pushing the reset button all the way in then release ACAUTION THE AIR FILTER SERVICE INDICATOR IS AN EFFEC TIVE DEVICE ONLY AS LONG AS THE INLET SYS...

Page 47: ...ween the ends of the jaws on one coupling body and the flange on the opposite coupling body Tighten set screws in each coupling body 4 Insert individual cushions as shown in Figure 1 7 and slide colla...

Page 48: ...t valve pilots and on separate air receiver and moisture sep arator if used 4 If moisture is noted in the oil level gauge drain accumulated moisture and see Section 5 Moisture in the Oil System Every...

Page 49: ...ming relay for low oil pressure shut down set too short a time MAXIMUM DELAY SETTING IS 15 SECONDS Timing relay setting screw not engaged a Faulty or intermittent HDTS or probe b Incorrect HDTS settin...

Page 50: ...7 u 4 INDUSTRIAL MACHINERY COOPER INDUSTRIES 1800 GARDNER EXPRESSWAY QUINCY ILLINOIS 82305 4024 217 222 5400 Specifications subject to change without notice COPYRlGHT 1987 Cooper Industries Inc Litho...