Gardner Denver EBHQHA, EBHQHB, EBHQJB, EBHQJA, EBMQKC Operating And Service Manual

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GARDNER DENVER@

ELECTRA-SAVER@

ELECTRA-SAVER Il@

STATIONARY BASE-MOUNTED

COMPRESSOR

DOMESTIC MODELS

13-9/1 0-641

7th Edition

May, 1995

40- IOOHP

EBH, EBM, EBP & EAP

INTERNATIONAL MODELS

EBM B - 60-100 HP(45-75K~

OPERATING AND SERVICE MANUAL

MAINTAIN COMPRESSOR RELIABILlTY AND PERFORMANCE WITH

GENUINE GARDNER DENVER AND JOY COMPRESSOR

PARTS AND SUPPORT SERVICES

Gardner Denver and Joy Compressor genuine parts, engineered to original tolerances, are designed foroptimum dependability -–- specifically for Gardner Denver and Joy compressor systems. Design and material innovations are the result of years of experience with hundreds of different compressor applications. Reliability in materials and quality assurance are 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 Gardner Denver Machinery Inc. Master Distribution Center (MDC) in Memphis, Tennessee.

Your authorized distributor can support your Gardner

For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact:

Denver or Joy air compressor with these services:

Trained parts specialists to assist you in selecting

1. the correct replacement parts.

Factory warranted new and remanufactured rotary screw air ends. Most popular model remanufactured air ends are maintained in stock at M DC for purchase on an exchange basic with liberal core credit available for the replacement unit.

A fullline of factory tested AEON compressor lubricants specifically formulated for use in Gardner

Denver and Joy compressors.

Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.

Authorized distributor service technicians are factorytrained and skilled in compressor maintenance and repair. They are ready to respond and assist you by providing fast, expert maintenance and repair services.

Distribution Center: Gardner Denver Machinery Inc. Master Distribution Center 5585 East Shelby Drive Quincy, IL 62301 Memphis, TN 38141 Phone:

Fax: (901) 542-6159

Whenever an air end requires replacement or repair,

Gardner Denver offers an industry unique, factory remanufactured air end exchange program. From its modern Remanufacturing Center in Indianapolis, IN, Gardner Denver is committed to supplying you with the highest quality, factory remanufactured air ends that

are guaranteed to save you time, aggravation and

money. Immediately Available

Repair downtime costs you money, which is why there are over 200 remanufactured units in inventory at all times, ready for immediate delivery.

Skilled Craftsmen

Our Remanufacturing assembly technicians average

over 20 years experience with air compression products.

Precision Remanufacturing

All potentially usable parts are thoroughly cleaned, in-

spected and analyzed. Only those parts that can be

brought back to original factory specifications are re-

manufactured. Every remanufactured air end receives

(901) 542-6100 (800) 245-4946

REMANUFACTURED AIR ENDS

Factory: Gardner Denver Machinery Inc. 1800 Gardner Expressway

Phone: (217) 222-5400 Fax: (217) 223-5897

anew overhaul kit: bearings, gears, seals, sleeves and gaskets.

Extensive Testing Gardner Denver performs testing that repair houses

just don’t do. Magnaflux and ultrasonic inspection spot cracked or stressed castings, monochromatic light analysis exposes oil leaks, and coordinate measurement machine inspects to +/– .0001”, insuring that all remanufactured air ends meet factory performance specifications.

Warranty Gardner Denver backs up every remanufactured air

end with a new warranty . . . 18 months from purchase,

12 months from service.

Gardner Denver remanufactured air ends deliver quality without question. . . year in and year out.

Call Gardner Denver for information on the air end exchange program and the name of your authorized distributor.

Phone Number: FAX: 901-542-6159

800-245-4946 or

13-9/1 0-641 Page

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 itsoperation and maintenance. This book iswritten to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical operation and minimum downtime.

DANGER

Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

WARNING

Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored.

~CAUTION

Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored.

NOTICE

Notice is used to notify people of installation, operation or maintenance information

which is important but not hazard-related.

13-9/10-641 Page ii

This book covers the following models:

DOMESTIC MODELS:

HP PSIG Air Cooled

50 100, 125, 150 EBHQJA

75 100,125,150

100 100,125,150

HP (KW)

(45) (6.9, 8.6, 10.3)

100, 125 EBHQHA

EBHQHB EBHSHB

EBHQJB EBHSJB

100, 125, 150

PSIG(BARS) Air Cooled Water Cooled

100,125,150

EBMQKA EBMSKA EBMQKC EBMSKC

EBMQLA EBMSLA EBMQLC EBMSLC

EBPQMA EBPQMB EAPQMC

INTERNATIONAL MODELS:

EBMQKB

Water Cooled

EBHSHA

EBHSJA

EBPSMA EBPSMB EAPSMC

EBMSKB

Parts List

13-9-555 13-9-550

13-9-557 13-9-551

13-9-556 13-9-548 13-10-507

Parts List

13-9-557X

100,125,150 EBMQLB EBMSLB

(55) (6.9, 8.6, 10.3)

100 (75) (6.9, 8.6, 10.3)

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 to the right of the inlet housing.

All orders for Parts should be placed with the nearest

authorized distributor.

Where NOT specified, quantity of parts required per

compressor or unit is one (l); where more than one is

100,125,150

INSTRUCTIONS FOR ORDERING REPAIR PARTS

EBMQMB

13-9/1 0-641

13-9-557X

EBMSMB

required per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED.

DO NOT ORDER BY SETS OR GROUPS.

To determine the Right Hand and Left Hand side of a

compressor, stand at the motor end and look toward the compressor, Right Hand and Left Hand are indicated in parenthesis following the part name, i.e. (RH)

& (LH) .

Page iii

13-9-557X

TABLE OF CONTENTS

REMANUFACTURED AIR ENDS..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . .

FOREWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

INSTRUCTIONS FOR ORDERING REPAIR PARTS . . . .

INDEX . . . . . . . . . . . . . . . . . . . .

LIST OF ILLUSTRATIONS . .

. . . . .

. . . . . . . . . . . .

. . . . . . . . . .

SECTION 1, GENERAL INFORMATION . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . .

. .

. . . . .

. . . .

,...

. .

. . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . ii

. .

. . . . . .

. . . . . . .. . . . . . . .,

. .

. . .

. .

,..

.,.

. . .

. ix

SECTION 2,1 NSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

SECT1ON 3, STARTlNG&OPERATlNG PROCEDURES . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..’ . ...16

SECT1ON 4, CONTROLS &lNSTRUMENTAT10N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...18

SECTION 5,LUBRICATION,

OIL FILTER&SEPARATOR

. . . .

, . . . . . . ,

,’. . , . . , . . , 42

...

Ill

. .

SECTION 6, AIR FILTER ,..

SECTION 7, COUPLING . ..

. . . . . . . .

,.,.., .

. . . . . . ,

. . . . . . . .,

SECTION 8, MAINTENANCE SCHEDULE ,..

SECTION9,TROUBLE SHOOTING . . . . . . . . . .

SECTION1O,TROUBLE SHOOTING CONTROLS . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . .

. .

. . . .

. .

. . . .

.s.

. .

. . .

. .

..,. . ..,,.,, . . . .

..,.,. . . . .

. .

. . . . .

. . . . . .

. . .

. . . . . . . . . . . . . . ..,..,

. . . . . . .

. .

. . .

. .

. . . . 57

. . . . 58

. . . .

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

13-9/10-641 Pageiv

Actuator, Turn Valve . . . . . . . . . . . . . ., . . . . ...30

Addition of Oil Between Changes . . . . . . . . . . . 46

Advisories

Clearing . . . . . . . . . . . . . . . . . . . . . . .....20

Service and Maintenance . . . . . . . . . . . . . . . 20

AIR FILTER, SECTION 6........ . . . . . . . ...54

Air Filter Element Life ..,.,.... . . . . . . . . . ...54

Air Filter Vacuum Switch . . . . . . . . . . . . . . . ...31

Air Filter, Heavy Duty (Standard) . . . . . . . . . . . 54

Compression Principle . . . . . . . . . . . . . . . . . . . . . 1

Air Flow in the Compressor System . . . . . . . . . . 1

Air Receiver, Auxiliary......,,. . . . . . . . . . . . . 10

Air-Cooled Units, Location . . . . . . . . . . . . . . . . . . 8

Alarm Relay, . . . . . . . . . . . . . . . . . . . . . . . . . ...27

Auto Sentry-ES Control Display . . . . . . . . . . . . 19

Auto Sentry-ES Controller

Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . ...27

Automatic Sequence Change . . . . . . . . . . . 26

Connection to External Controls . . . . . . . . . 26

Establishing Initial Sequence . . . . . . . . . . . . 24

HowAuto Sentry-ES Controls Pressure while

Sequencing, . . . . . . . . . . . . . . . . . . ,.,.25

Installation ......,.. . ....24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . ...24

Other Features . . . . . . . . . . . . . . . . . . . . . . . . 26

Programming and Setup ... . . . . . . . . 21

Programming Steps . . . . . . . . . . . . . . . . . ...21

RemoteOn/Off.., . . . . . . . . . . . . . . . . . ...26

Serial Communications . . . . . . . . . . . . . . . . . 27

Auto Sentry-ES Operation.,,. . . . . . . . . . . . . . 18

Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . 19

Constant Run Mode . . . . . . . . . . . . . . . . . . . 18

Low Demand Mode . . . . . . . . . . . . . . . . . . . . 18

Sequence Mode . . . . . . . . . . . . . . . . . . . . . . . 19

Automatic Mode Operation . . . . . . . . . . . . . . . . 19

Auxiliary Air Receiver . . . . . . . . . . . . . . . . . . . . . 10

Blowdown Valve . . . . . . . . . . . . . . . . . . . . ...28

Change Procedure, Lubricant . . . . . . . . . . . . . . 46

Check, Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cleaning and Draining Oil System . . . . . . . . . . 48

Clearing Advisories . . . . . . . . . . . . . . . . . . . . . . . 20

Cold Ambient Operation . . . . . . . . . . . . . . . . . . . 46

Cold Weather Operation . . . . . . . . . . . . . . . . . . . 10

Cold Weather Operation, installation for . . . . . . 9

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Compressor (GDEliminator) Oil Separator . . . 52

Compressor Capacity Control -Turn Valve

Units Only . . . . . . . . . . . . . . . . . . . . . . . . ...32

Compressor Oil Cooler....,.. . . . . . . . . . . ...49

Compressor Oil Filter . . . . . . . . . . . . . . . . . . ...49

Compressor Oil System . . . . . . . . . . . . . . . . . . . 42

Compressor Oil System Check. . . . . . . . . . . . . 53

Constant Run Mode Operation . . . . . . . . . . . . . 18

Control Devices, Other . . . . . . . . . . . . . . . . . . . . 27

Control Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Control Transformer . . . . . . . . . , . . . . . . . . . ...31

CONTROLS &lNSTRUMENTS, SECTION 4 18 Controls &instruments, General Description . 18

Cooler, Compressor Oil . . . . . . . . . . . . . . . . ...49

Cooling, Seaiing and Lubrication . . . . . . . . . . . . . 1

COUPLING, SECTION 7... . . . . . . . . . . 56

Coupling, . . . . . . . . . . . . . . . . . . . , . . . . . . . . ...56

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . ...56

Individual Cushion Design . . . . . . . . . . . . . . 56

Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6.7

Discharge Service Line . . . . . . . . . . . . . . . . . . . . 12

Discharge Thermistor .,,,.... . . . . . . . . . . . . . 31

Drain, Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 9

Draining and Cleaning Oil System . . . . . . . . . . 48

Electric Motor Grease Recommendations . . . . 15

Electric Motor Regreasinglnterval . . . . . . . . . . 15

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Standard Units . . . . . . . . . . . . . . . . . . . . . . . . 14

Element Life, Air Filter . . . . . . . . . . . . . . . . . . . . 54

Emergency Stop Push-Button . . . . . . . . . . . . . 31

13-9/10-641 Pagev

Emergency Stop Shutdown . . . . . . . . . . . . . . . . 21

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

External Device Shutdown . . . . . . . . . . . . . . . . . 21

Fan Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Filter, Compressor Oil . . . . . . . . . . . . . . . . . . ...49

Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . ...54

Filter, Heavy DutyAir (Standard) . . . . . . . . . . . 54

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..ii

Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

LUBRICATION, OIL COOLER, OIL FILTER &

SEPARATOR, SECTION 5 . . . . . . . . . . . . . 42

Main Starter . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

MAINTENANCE SCHEDULE,SECTION 8 . . 57

Minimum Discharge Pressure Valve . . . . . . . . . 28

Moisture in the Oil System . . . . . . . . . . . . . . . . . 47

MoistureSeparator/Trap . . . . . . . . . . . . . . . . . . . 10

Motor Grease Recommendations . . . . . . . . . . . 15

Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 14

Motor Protective Devices . . . . . . . . . . . . . . . . . . 20

Motor Regreasinglnterval . . . . . . . . . . . . . . . . . 15

Gauge, Oil Level . . . . . . . . . . . . . . . . . . . ...28.47

GENERAL INFORMATION, SECTION 1 . . . . . 1

Grease Recommendations, Electric Motor . . . 15

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

High Pressure Shutdown . . . . . . . . . . . . . . . . . . 21

High Temperature Operation . . . . . . . . . . . . . . . 42

High Temperature Shutdown . . . . . . . . . . . . . . . 20

Inlet Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

inlet Screen and Tube . . . . . . . . . . . . . . . . . . ...55

Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...29

INSTALLATION, SECTION2 . . . . . . . . . . . . . . . 8

installation, General . . . . . . . . . . . . . . . . . . . . . . . 8

installation for Cold Weather Operation . . . . . . . 9

Lifting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Line, Discharge Service . . . . . . . . . . . . . . . . . . . 12

Line, inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Air-Cooled Units . . . . . . . . . . . . . . . . . . . . ...8

Water-Cooled Units . . . . . . . . . . . . . . . . . . . . 9

Low Demand Mode Operation.. . . . . . . . . . . . . 18

Low Oil Pressure Shutdown . . . . . . . . . . . . . . . 21

Lubricant, Recommended . . . . . . . . . . . . . . . . . 42

Lubricant Change Procedure.. . . . . . . . . . . . . . 46

Lubrication, Motor . . . . . . . . . . . . . . . . . . . . . . . . 14

Lubrication, Cooling and Sealing. . . . . . . . . . . . . 1

Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . . 47

Oil Cooler, Compressor . . . . . . . . . . . . . . . . ...49

Oil Filter, Compressor . . . . . . . . . . . . . . . . . . . . . 49

Oil Level Gauge . . . . . . . . . . . . . . . . . . . . ...28.47

Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Oil Reservoir Drain . . . . . . . . . . . . . . . . . . . . . ...9

Oil Separator

Compressor (GD Eliminator) . . . . . . . . . . . . 52

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . ...52

Oil Carryover . . . . . . . . . . . . . . . . . . . . . . ...52

Removal for inspection or Replacement . . 53

Oil Specifications . . . . . . . . . . . . . . . . . . . . .

Oil System

Compressor . . . . . . . . . . . . . . . . . . . . . .

Draining and Cleaning . . . . . . . . . . . . . .

Oil System Check . . . . . . . . . . . . . . . . . . . .

Air and Oil Discharge Temperature ... Compressor Oil lnletTemperature . . . Oil Cooler Oil Pressure Differential . . . Oil CoolerTemperature Differential ... Oil Cooler Water Pressure Differential

Oil inlet Pressure, . . . . . . . . . . . . . . . . .

Operation

Automatic Mode . . . . . . . . . . . . . . . . . . .

Cold Ambient.............,.. . . . . .

Constant Run Mode . . . . . . . . . . . . . . .

High Temperature . . . . . . . . . . . . . . . . .

Low Demand Mode....,,,,,. . . . . . .

. . . .

..,. ..,. 48

. . . . 53

. . . .

.s.. 53

. . . .

..,. 53

. . . . 53

. . . . 19

. . . . 46

. . . . 18

.,..

. . . . 18

13-9/10-641 Pagevi

Sequence Mode . . . . . . . . . . . . . . . . . . . . . . . 19

Optional Switches . . . . . . . . . . . . . . . . . . . . . ...31

Piping, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power Failure . . . . . . . . . . . . . . . .

Pressure Differential Gauging . . . . . . . . . . . . . . 52

Pressure Regulator . . . . . . . . . . . . . . . . . . . . ...29

Prestart-Up Instructions . . . . . . . . . . . . . . . . . . . 16

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operating Mode . . . . . . . . . . . . . . . . . . . . . . . 17

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

System Pressure . . . . . . . . . . . . . . . . . . . . . . 17

Programming and Setup, AutoSentry-ES

Controller . . . . . . . . . . . . . . . . . . . . . . . . . ...21

Protective Shutdowns . . . . . . . . . . . . . . . . . . ...20

Purge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Recommended Lubricant . . . . . . . . . . . . . . . . . . 42

Regressing interval, Electric Motor . . . . . . . . . 15

Regulator, Pressure . . . . . . . . . . . . . . . . . . . ...29

ReliefValve . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

RemoteOn/Off . . . . . . . . . . . . . . . . . . . . . . ...26

Repair Parts, Ordering instructions . . . . . . . . . . iii

Reservoir, Oil . . . . . . . . . . . . . . . . . . . . . . . . . ...52

Reservoir Pressure Transducer . . . . . . . . . . . . 31

Safety Precautions . . . . . . . . . . . . . . . . . . . ...4.5

Sealing, Lubrication and Cleaning . . . . . . . . . . . 1

Separator, Compressor (GD Eliminator) Oil . . 52 Separator Differential Pressure Shutdown . . . 21

Separator/Trap,Moisture . . . . . . . . . . . . . . . . . . 10

Sequence Mode Operation . . . . . . . . . . . . . . . . 19

Sequencing Compressors with

Auto Sentry-ES . . . . . . . . . . . . . . . . . . . ...24

Serial Communications . . . . . . . . . . . . . . . . . ...27

. .. . . . . . ....21

Service Advisories . . . . . . . . . . . . . . . . . . . . . . . . 20

SERVICE CHECK LIST, AIR FILTER . . . . . . . 57

Service Check List . . . . . . . . . . . . . . . . . . . . . ...57

Every 1000 Hours Operation . . . . . . . . . . . . 57

Every 125 Hours Operation : . . . . . . . . . . . . 57

Every 6000 Hours Operation . . . . . . . . . . . . 57

Every 8 Hours Operation . . . . . . . . . . . . . . . 57

Every Year . . . . . . . . . . . . . . . . . . . . . . . . ...57

Motor Lubrication . . . . . . . . . . . . . . . . . . . ...57

Oil Separator . . . . . . . . . . . . . . . . . . . . . . ...57

Shutdowns

Emergency Stop . . . . . . . . . . . . . . . . . . . ...21

External Device . . . . . . . . . . . . . . . . . . . . ...21

High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 21

High Temperature . . . . . . . . . . . . . . . . . . ...20

Low Oil Pressure . . . . . . . . . . . . .

Motor Protective Devices . . . . . . . . . . . . . . . 20

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Power Failure . . . . . . . . . . . . . . . . . . . . . . . . . 21

Separator Differential Pressure . . . . . . . . . . 21

Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Solenoid Valves lVCandlVO . . . . . . . . . . . . . . 29

Solenoid Valves TVCandTVO . . . . . . . . . . . . . 31

Specifications, Oil . . . . . . . . . . . . . . . . . . . . . ...42

Starter

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

STARTING&OPERATING PROCEDURES,

SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Unit Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Unit Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Stopping the Unit . . . . . . . . . . . . . . . . . . . . . . . . . 17

Strip, Terminal . . . . . . . . . . . . . . . . . . . . . . . . ...31

Switch

Air Filter Vacuum . . . . . . . . . . . . . . . . . . . . . . 31

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Switches, Optional . . . . . . . . . . . . . . . . . . . . . . . . 31

System Pressure Transducer . . . . . . . . . . . . . . 31

System Thermistor . . . . . . . . . . . . . . . . . . . . ...31

. . .. . . ...21

13-9/10-641

Page vii

INDEX

Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Thermistor

Discharge . . . . . . . . . . . . . . . . . . . . . . . . . ...31

System . . . . . . . . . . . . . . . . . . . . . . . . . . . ...31

Transducer

Reservoir Pressure . . . . . . . . . . . . . . . . . ...31

System Pressure . . . . . . . . . . . . . . . . . . . ...31

Transformer, Control . . . . . . . . . . , . . . . . . . . ...31

TROUBLE SHOOTING,SECTION 9 . . . . . . . . 58

TROUBLESHOOTING CONTROLS,

SECTION 10 . . . . . . . . . . . . . . . . . . . . . . . . . 61

Tube, inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...55

Turn Valve . . . . . . . . . . . . . . . . . . . . . . . . . . ...1.30

Turn Valve Actuator . . . . . . . . . . . . . . . . . . . . ...30

Valve

Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . ...28

Inlet, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...29

Minimum Discharge Pressure . . . . . . . . . . . 28

Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Solenoid lVC and lVO . . . . . . . . . . . ,..,... 29

Solenoid TVC and TVO . . . . . . . . . ...31

Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Vibration Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Warranty, . . . . . . . . . . . . . . . . . . . . . . . .. Last Page

Water-Cooled Units, Location. . . . . . . . . . . . . . . 9

Wiring, Electrical, . . . . . . . . . . . . . . ., . . . . . ...14

13-9/10-641 Pageviii

LIST OF ILLUSTRATIONS

Figure #

Figure 1-1

Figure 1-2

Figure 1-3

Figure 1-4

Figure 1-5

Figure 1-6

Figure 2-1

Figure 2-2

Figure 2-3

Figure 2-4

Figure 2-5

Figure 2-6

Figure 2-7

Figure 2-8

Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8

Figure 4-9

Figure 4-10

Figure 4-11 Figure 4-12

Figure 4-13

Figure 4-14 Figure 4-15 Figure 4-16 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4

Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 6-1 Figure 7-1

Description Page

Compression Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1

Starter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . ...2

Package -Controller&Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2

Package -Drive Motor &Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2

Package - Oil Filter, Oil Level Gauge, Mixing Valve, Minimum Pressure Valve

and Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Package -Air/Oil Flow Diagram .,, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Typical Compressor Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8

Air Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Cold Weather installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . . . ...10

inlet Line Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . . . ...11

Heat Exchanger (Oil Cooler) Approximate Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . 11

Aftercooler Approximate Water Flow . . . . . . . . . . . . . . . . . . . . . . . . .,, , . . . . . . . . . ...12

Series Piping . . . . . . . . . . . . . . . . . . . . . . . . . .. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...13

Parallel Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .’. . . . . . . . . . . . . . . . . . . . . . ...13

Auto Sentry-ES Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...19

Schematic Tubing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...27

Blowdown Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...28

Minimum Discharge Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...28

Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...29

Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,,, . . . . . . . . . ...30

Turn Valve -Turn Valve Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...30

Control Schematic -Compressor Unloaded -Constant Speed Mode,

EBH&EBM Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . ...33

Control Schematic -Compressorat Full Load -Constant Speed Mode,

EBH&EBM Units Only .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...34

Control Schematic -Compressor Unloaded -LowDemand Mode orAuto Mode

EBH&EBM Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...35

Control Schematic-Compressor at Full Load, Turn Valve Units Only . . . . . . . . . . . . 36

Control Schematic -Compressor Fully Unload -Low Demand Mode Switch Off,

Turn Valve Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...37

Control Schematic -Compressor Fully Loaded -Low Demand Mode Sw”tch On,

Turn Valve Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . . ...38

Wiring Diagram -207ECP546 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...39

Wiring Diagram -209ECP546 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . ...40

Wiring Diagram -202EAQ546 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . ...41

Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...43

Oil Flow Diagram -Remote Overhead Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,44

Cooler Drain Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...45

Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,, , . . . . . . . . ...47

Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...47

Approximate Oil System Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...48

Thermostatic Mixing Valve Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...50

Water Control Valve.......,,, . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . ...51

Dew Point Temperaturevs. Ambient Temperature, (100% Relative Humidity) . . . . . 51

Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ., . . . . . . . . . ...52

Heavy Duty Air Filter (Standard), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . ...54

installation of Coupling Cushions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...56

13-9/10-841 Pageix

SECTION 1 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. Tapered roller bearings at the discharge end locate each rotor axially and carry all thrust loads and the remainder of the radial loads.

COMPRESSION PRINCIPLE (FIGURE l-l) - Compression is accomplished by the main and secondaty rotors synchronously meshing in a one-piece cylinder. The main rotor has four (4) helical lobes 90° apart. The secondary rotor has six (6) matching helical grooves 60° apart to allow meshing with main rotor lobes.

The air inlet port is located on top ofthe compressor cylinder near the drive shaft end. The discharge port is near the bottom at the opposite end of the compressor cylinder. Figure 1-1 is an invetted view to show inlet and discharge ports. The compression cycle begins as rotors unmesh at the inlet port and 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 istrapped in the interlobe cavity and flows axially with the meshing rotors (B). As meshing continues,

more of the main rotor lobe enters the secondary rotor grove, normal volume is reduced and pressure in-

creases.

Oil is injected into the cylinder 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 discharge port and is released to the oil res-

ervoir (C). Each rotor cavity follows the same “fill–compress-discharge” cycle in rapid succession to produce a discharge air flow that is continuous, smooth and shock free.

AIR FLOW IN THE COMPRESSOR SYSTEM (FIGURE 5-1, page 42) - Air enters the air filter and passes through the inlet unloader valve to the compressor. After compression, the air/oii mixture passes into the oil reservoir where most of the entrained oil is removed by velocity change and impingement and drops back into the reservoir. The air and remaining oil passes into the separator and separator housing where the oil is separated and passes through tubing connecting the separator housing and compressor. The air passes through the minimum pressure valve, discharge check valve and cooler, then to the plant air lines.

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,

TURN VALVE (EAP UNITS ONLY) - The turn valve is a rotary helical valve located on the discharge side of the cylinder toward the inlet end, The valve opens and closes ports in the cylinder which communicates with the inlet passage. This varies the compressor rotor volume to match the demand for air, thus reducing the part-load power requirement.

13-9/1 0-641

Page 1

EKRENCY STOP

rA’RF’LTERrc

SUTTON

FIGURE 1-2- STARTER BOX

LED. CONTROLPANEL~

TWSFORMER

CONTROL

FIGURE 1-3-

~ EMERGENCYSTOP

SLJTTON

~ FM MOTOR

PACXAGE - CONTROLLER & STARTERS

STARTER

COMPKSSOR

INLET VAVE ~

cOwL’N’G”MDl

FIGURE 1-4- PACKAGE - DRIVE MOTOR & AIR FILTER

~lVE MOTOR

1/-

13-9/10-641 Page 2

MINIMUN OISCHARG[ PRESS~ CHECK VALVE

OIL FILTER

\“’L::’:::L------L -------

I /

— OIL LEVEL GAUGE

FIGURE 1-5- PACKAGE - OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE,

FINAL

SCHAR

MINIMUM PRESSURE VALVE & CHECK VALVE

-NLETVAL’E

PRESS I

VALVE ‘

MIXINQ

VALVE

FIGURE 1-6 - PACKAGE - AIR/OIL FLOW DIAGRAM

13-9/1 0-641 Page 3

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.

. Keep fingers and clothinq awav from revolving fan, drive coupling, etc.

● Donotuse the air discharge from this unit for breathing - not suitable for hu-

man consumption.

● Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostat-

ic mixing valve or

tem until the unit is shut down and the air pressure

break any connections, etc., in the compressor air or oil sys-

has been relieved. . Electrical shock can and may be fatal. . Compressor unit must be carounded in accordance with the National Electrical

Code. Aground jumper equal to the size of the equipment ground conductor must be used to connect the compressor motor base to the unit base.

. Fan motors must remain grounded to the main base through the starter

mounting panel in accordance with the National Electrical Code. . Open main disconnect switch, tag and lockout before working on the control. . Disconnect the compressor unit from its power source, tag and lockout be-

fore working on the unit

- this machine is automatically controlled and may

start at any time.

13-9/1 0-641 Page 4

WARNING

Failure to observe these notices could result in damage to equipment.

●

Stop the unit if any repairs or adjustments on or around the compressor are

required.

●

Disconnect the compressor unit from its power source, tag and lockout before working on the unit start at any time.

●

An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)

●

Do not exceed the rated maximum Pressure values shown on the nameplate.

●

Do not operate unit if safety devices are not operating properly. Check periodically. Never bypass safety devices.

- this machine is automatically controlled and may

13-9/10-641 Page 5

DECALS

DISCHARGEAIR USED FOR BREATHINGWILL CAUSE SEVERE INJURY ORDEATH. CONSULTFILTRATION SPECIALIST FOR ADDITIONALFILTRATION ANDTREATMENT EQUIPNENT

TO MEET HEALTH AND

SAFETY REGULATIONS.

206EAQ077

HIGH VOLTAGE, ROTATING MACHINERY. AIR AND OIL UNDER PRESSURE.

IMPROPER MODIFICATION OF EQUIPMENT WILL CAUSE SEVERE PERSONAL

INJURY OR DEATH.

218EAQ077

DO NOT MODIFY UNIT WITHOUT WRITTENPERMISSION FROMMANUFACTURER.

AIR AND OIL UNDER PRESSURE WILL CAUSE SEVERE PERSONA INJURY OR DEATH. SHUTDOWNCOMPRESSORAND RELIEVE

SYSTEMOF ALL PRESSUREBEFOREREMOVING VALVES.CAPS,PLUGS, FITTINGS, BOLTSANDFILTERS

212 EAQ077

ROTATING MACHINERY CAN CAUSE INJURY OR DEATH. KEEP ALL GUARDSAND SAFETY DEVICES IN PLACE.

211 EAQ077

13-9/10-641 Page 6

UNIT CANAUTOMATICALLY RESTART.

CANCAUSEPERSONALINJURY

ORDEATH. KNOWMODEOF OPERATION BEFOREWORKINGON OR NEARTHE MACHINE.

—

207 EAQ077

/’

ELECTRICAL SHOCK FROM

IMPROPER GROUNDING CAN

CAUSE INJURY OR DEATH.

GROUND UNIT AND RELATED EQUIPMENT ACCORDING TO NATIONAL ELECTRIC CODE AND LOCAL REGULATIONS.

AIR AND OIL UNDER PRESSURE. CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. INSPECT OIL RESERVOIR FOR CRACKS AT LEAST ANNUALLY.

216EAQ077

WARNING

DECALS

1 I

ELECTRICAL SHOCK CAN CAUSE INJURY OR DEATH. DISCONNECT ALL CIRCUITS BEFORE WORKINQON THIS CONTROL. SEE WIRING DIAGRAM.

222EAQ077

217EAQ077

ELECTRICAL ARCING CAN CAUSE A FIRE WHEN UNIT IS MOUNTED ON A COMBUSTIBLE SURFACE RESULTING IN PERSONAL INJURY OR PROPERTY OAMAGE. UNIT MUST BE MOUNTEOON

A FLOOR PLATE EXTENDING

ON ALL SIDES. SEE INSTALLATION DRAWINGFOR PROPER DIMENSIONS.

221EAQ077

MACHINE OAMAGEOR INJURY CAN OCCURDUE TO IMPROPER LIFTING. DO NOT LIFT MACHINE WITH THE MOTOR EYEBOLT.

208EAQ077

13-9/10-641 Page7

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.

LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Lifting slotS are provided in the base for towmotor use. The unitmay also be moved into location by rolling on bars. -

~CAUTION

Lift compressor unit by base only. Do

not use other places such as motor, compressor or discharge manifold piping as lifting points.

~DANGER

The eyebolts or lugs provided on the motor are for lifting the motor only and should not be used to lift any additional weight. All eyebolts must be securely tightened. 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.

LOCATION - The compressor should be installed,

whenever possible, in a clean, well-lighted, well–venti-

Iated 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 compres-

sor to obtain proper air supply.

Both the air-cooled and water-cooled units require cooling air as well as air to the compressor inlet. Proper ventilation MUST be provided; hot air must be exhausted from the compressor operating area. Atypical inlet–outlet air flow arrangement is shown in FIGURE 2-1,

Air-Cooled Units - A combination oil/aftercooler is supplied as standard equipment on all air-cooled units. The air-cooled unit with the standard enclosure requires sufficient flow, FIGURE 2-2, page 9, for the compressor oil/aftercooling system and for electric mo-

tor cooling. Air is drawn into the unit at the motor side

of the enclosure and is exhausted at the oil cooler side. Do not block 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 obstruction above and on other sides of unit. For continuous efficiency, oil cooler cores must be periodically cleaned with either vacuum or compressed air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with clean water.

LO UVERFD

WINDOW WINDOW

EXHAUST FAN

LOUVERED

~DANGER

Compressor, air/oil reservoir, separa-

tion chamber and all piping and tub-

ing may beat high temperature during and after operation.

13-9/10-641 Page 8

A75119

FIGURE 2-1 - TYPICAL COMPRESSOR ROOM

Minimum Air Flow * For Compression

And Cooling - Cubic Feet/Minute

(Cubic Meters/Minute)

HP (KW)

40& 50 HP 60-100 HP 12,500 (45-75 Kw)

* 80° F (27° C) Inlet Air

I Air Cooled ] Water Cooled I

6,500 1,400

1,700

(354)

(48)

~CAUTION

If the compressor unit base is raised

above floor level, the space between the floor and the base bottom must be closed with solid material all around to prevent recirculation of hot air from the oil cooler end and over temperature operation.

FIGURE 2-2 - AIR FLOW CHART

~wARNING

For aluminum oil coolers, do not use any cleaning solution that is not compatible with aluminum. Use of improper solution may result in damage to the cooler.

Water-Cooled Units - The water-cooled unit with the standard enclosure requires sufficient air flow, FIGURE 2-2, for electric motor cooling. Air is drawn intothe unit at the top of the enclosure and is exhausted at the motor side, Do not block airflow to and from unit. Allow three and one-half (3-1/2) feet (1.1 M) to the nearest obstruction on the starter end and control box side of the unit. Allow three (3) feet (.9 M) to the nearest obstruction above and on other sides of the unit.

FOUNDATION - The G-D 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° angle lengthwise or 10° sidewise.

Mounting bolts are not normally required. However, installation conditions such as piping rigidity, angle of tilt, or danger of shifting from outside vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform support for the base.

OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the side of the frame. This

drain is approximately 4.50 inches(115 mm) above the floor level, If this is not sufficient to conveniently drain the oil some other methods of providing drain are:

Elevate the compressor unit on a suitable struc-

ture to obtain the desired drain height.

Construct an oil sump or 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.

ENCLOSURE - The compressor, electric motor, oil cooler and aftercooler are mounted inside the enclosure. Service doors are provided for maintenance access. Be sure to allow enough space around the unit for the doors to open completely. Any of the enclosure

doors may be removed by opening the door and lifting it up slightly to disengage the hinges.

~DANGER

Do not operate the compressor with

the fan and coupling guard removed.

Exposed fan and belts may cause injury to personnel.

The motor inspection/air filter service panel is held by two latches and lifts away from the enclosure, The air outlet panel is attached by screws to the enclosure and is not readily removable.

INSTALLATION FOR COLD WEATHER OPERA-

TION (FIGURE 2-3, page 10) - It is recommended that the unit be installed inside a shelter that will be heated to temperatures above freezing (32° F, O°C). This will eliminate many of the problems associated with operating units in cold climates where freezing rain, drifting snow, freezing condensate and bitter cold temperatures are encountered.

Refer to Engineering Data Sheet 13-9-411 for the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit,

When an outside installation must be made, the precautions required will depend on the severity of the environment. The following are general guidelines for outside installations:

13-9/10-841 Page 9

@FT PLWOW FENCC

(2.4 M)

~LLMffl wlANT 2+LEMEN1 tEATER (OR EcUAL) RH400 WITH ~ RH4~ ELEMENTS - Z SfOD 3200 wATTS EACH

WLLMN WINT 2-ELEMENT

HLATER (OR EOUAL) RH7~ WITH 121 RH7W ELWEN1.S -2 REOD 6ZC4 WATTS EACH

/“

3 FT

MOTOR

‘\

AWAY FROM PREVAIL ING WIND

\ _COMPKSS~

+“ 4

FIGURE 2-3- COLD WEATHER INSTALLATION

Cold Weather (Down To +IO” F, -12°C)

Be sure all drains, traps, and control lines, including pressure transducer lines are heated to avoid freezing of condensate. Heat tape with thermostat control is generally satisfactory for this purpose and can be obtained at various local plumbing or hardware outlets at nominal cost.

If an air-cooled aftercooler is to be used, provisions to bypass the aftercooler must be made. Since cold air contains very little moisture, successful operation can be achieved without the af-

tercooler.

Provide at least some simple shelter such as a ply-

wood windbreak to protect against drifting snow.

Use only Gardner Denver@ AEON 9000 SP lu-

bricant.

Monitor the unit carefully during start-up and op-

eration to be sure it is functioning normally.

Specify 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 pro-

vided:

It will be necessary to provide shutters or to block off part of the cooler in some manner since the cooler is greatly oversized for operation in these

low temperatures. Since shutters are not provided as a factory option, blocking off a portion of the cooler with plywood should be satisfactory.

8 FT. (2.4M)

PLYWOOD ““F ENCEoo

4 FT.

~’(1.2M)

ELEVATION VIEW

Auto operation should not be used in extreme en-

2. vironments.

Some means of providing heat during shutdown

3. should be provided. There are various methods to accomplish this, but since openings are not provided for sump heaters, the use of radiant heaters is recommended, The heaters should be sized to provide at leasta+1O”F(-12°C) environment for coolers, motor and sump. FIGURE 2-3, page 10, shows how these might be located in a typical installation and sizes required.

Remember unsheltered (outside) installations should be avoided where possible. Installation next to a heated building where enough heat can be used to keep the compressor 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 the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit.

AUXILIARY AIR RECEIVER - An auxiliary air receiver is notrequired ifthe piping system is large and provides sufficient storage capacity to prevent rapid cycling. When used, an air receiver should be of adequate size,

provided with a relief valve of proper setting, a pressure

gauge and a means of draining condensate. A means

of draining condensate will need to be provided for.

MOISTURE SEPARATOR/TRAP - Since the unit is

equipped with a built–in aftercooler, a combination

moisture separator and trap is furnished with the unit.

13-9/10-641 Page 10

Length of Inlet Line

Diameter of Pipe Size

OtolOFeet (Oto3 Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 to 17 Feet (3 t05 Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One Size LargerThan Inlet Opening

17 t038Feet (5 toll,5 Meters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2-4 - INLET LINE LENGTHS

CONTROL PIPING - Control piping is not necessary since the Electra–Screw@ unit is factory wired and piped for the control system specified.

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 dirtor scale from enter-

ing the compressor. If welded construction is used,

HEAT EXCHANGER (DOMESTIC)

Water Temperature to Heat Exchanger

Model

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, Up to ten (1O)feet (3 meters) in length, the inlet line should be the full size of

the inletopening on the compressor. If an extra-long line

isnecessary, the pipe size should be increased according

to Inlet Line Length Chart, FIGURE 2-4,

Same as Compressor Inlet Opening

Two Sizes Larger Than Inlet Opening

Approx.

Water Pressure

Drop @ 90° F

Water Temp.

Psl

40 HP 40 HP

50 HP 50 HP

60 HP 60 HP

75 HP 75 HP

100 HP 100 HP 100 HP

Kw 45 Kw 55 Kw

75 Kw

EBHSHA EBHSHB

EBHSJA EBHSJB

EBMSKA EBMSKC

EBMSLA EBMSLC

EBPSMA EBPSMB

EAPSMC

Model 16° C. 21° c. 27° C, EBMSKB EBMSLB .44 .54

EBMSMB

3.4 I 4.3 I 5.7 I 8.6 I 30.0

3.4

4.1

4.1 5,1

5.0

5.0 6.2 6,0 7,6

6.0 7,6

8.4 10.5

8.4 10.5 8,4 10,5

HEAT EXCHANGER (INTERNATIONAL)

Water Temperature to Heat Exchanger

.32 .39

.58

4.3

5,1

6.2

Liters/Second Maximum

.73 .97

5.7

6.8

8.3

10.1

10,1

14.1

.52 .73

8.6

10.2

10.2 30.0

12.5

12.5 40.8

15.1 40.8

17.1

21.1 40.8

21.1 40,8

32° C. L/s * Temp. Bar

.79 2,57 .14 Bar

1.09 2.57 .10 Bar

1.44 2.57 .35 Bar

30.0

40.8

Water Flow

Approx.

Water Press. Drop

@ 32° C. Water

1.0

1,5

1.5

2.0

1.5

5.0

* Flows exceeding “Maximum Water FIow" will cause severe erosion and will void unit warranty.

FIGURE 2-5- HEAT EXCHANGER (OIL COOLER) APPROXIMATE WATER FLOW

13-9/1 0-641 Page 11

AFTERCOOLER (DOMESTIC)

I I

Water Temperature to Heat Exchanger

Gallons/minute

HP Model 600 F.

40 HP EBHSHA 40 HP

50 HP EBHSJA .7 .9 50 HP EBHSJB .7 .9 1.2

60 HP 60 HP

75 HP EBMSIA 1.2 75 HP EBMSLC

100 HP EBPSMA 1.7 2.1 2.8 100 HP EBPSMB 1.7 100 HP EAPSMC 1.7

Kw Model 16° C.

EBHSHB .5 .7 .9

EBMSKA EBMSKC .8 1.0 1.4

.5 .7 .9 1.3

1.2

Water Temperature to Heat Exchanger

70° F. 80° F, 90° F.

1.2 1.8

1.0 1.4

1,5 2.0 3.0

1.5 2.0

2.1 2.8

2.1 2.8 4.1

AFTERCOOLER (INTERNATIONAL)

Liters/Second

210 c. 27° C.

Maximum

Water Flow

GPM*

26.0

1,3

1.8

2.1

3.0

4.1

32° C. L/s *

26.0

Maximum

Water Flow

Approx.

Water Pressure

Drop @ 90° F

Water Temp.

Psl

Less than 1 PSI

for any flow rate

shown in the table.

Approx.

Water Press. Drop

@ 32° C. Water

Temp. Bar

45 Kw EBMSKB .05 ,06 .09 55 Kw EBMSLB ,08 .09 ,13 75 Kw EBMSMB .11 .13 .18

* Flows exceeding “Maximum Water Flow" will cause severe erosion and will void unit warranty,

FIGURE 2-6- AFTERCOOLER APPROXIMATE WATER FLOW

Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a remote location,

DISCHARGE SERVICE LINE - The discharge service line connection on both water-cooled and air-cooled units is made at the right hand corner of the unit, viewed from the opposite end from control panel side. When manifolding two or more rotary screw units on the same line, each unit is isolated by the check valve in the unit discharge line. If a rotary screw unit is manifolded to another compressor, be sure the other compressor has a check valve in the line between the machine and the manifold. If a rotary screw and a reciprocating compressor are manifolded together, an air receiver must be located between the two units. Iation requires, the muffler may be removed and the

Discharge air used for breathing will

cause severe injury or death. Consult filtration specialists for addi-

tional filtration and treatment equip-

ment to meet health and safety standards.

BLOWDOWN VALVE PIPING - The blowdown valve

isfitted with a muffler for operation indoors. Ifthe instal-

.13 .19 .26

1.64

~DANGER

Less than .1 Bar for any flow rate

shown in the table.

13-9/10-641 Page 12

OILWT

OILIN

C76683

THERMOSTATIC

MIXING WLVE

4------------4~ -----

tiEAT EXCHAMER

AIR

* (OPTIONAL) WATER CONTROL VALVE AND WATER

FIGURE 2-7 - SERIES PIPING

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 watercooled heat exchangers, the water inlet and outlet connections are located in the unit base flange on the left side of the unit.

*WATER CmTROL

VATER WOFF WLVE

WATER

OUT

WVE

C76682

~wATER C~TROL VALVE

WATER ~UTOFF WLVE

‘wATE R

HEAT ExCJiAffiER

WAT EQ

CUT

***~.T,.c::v

AlR

SHUTOFF VALVE MUST BE ORDERED SEPARATELY,

FIGURE 2-8 - PARALLEL PIPING

(43° C). If water cooler than 60° F is used, high water outlet temperatures (over 110° F, 43° C) will be experienced along with shortened heat exchanger life caused bytube fouling and corrosion. Ifwater warmer than 90° F (32° C) is used, higher compressor oil inlet temperatures and high water usage will result.

Most water systems will require control of impurities: filtration, softening or other treatment. See “Compressor Oil Cooler - Water-Cooled Heat Exchanger” for more information on the water system.

~:~?

‘&SEPARATOR/TRAP

~WARNING

It is mandatory that any water cooled unit be installed in a shelter heated to

temperatures above freezing (32° F.,

0°c).

The water source should be capable of supplying up to the maximum flow shown in FIGURE 2-5, page 11, and FIGURE 2-6, page 12, at a minimum pressure of 40 psig (2.8 Bars); maximum allowable water pressure

is 150 psig (10.3 Bars). 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 temperatures from 60° to 90° F (16° to 32°

C) and a water outlet temperature not to exceed 11O°F

13-9/10-841 Page 13

SERIES PIPING (FIGURE 2-7) - Water flow must be through aftercooler first for effective cooling of discharge air and is so piped on the standard watercooled unit.

PARALLEL PIPING (FIGURE 2-8) - A separate water control valve is required to control the discharge air temperature. If a remote (externally mounted) watercooled 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,

The water control valve isto be adjusted to maintain oil out of the heat exchanger within the 140° to 150° F (60° to 66° C) range regardless of inlet water flow or temperature as long as a minimum flow for a given temperature is met (FIGURE 2-5, page 11, and FIGURE 2-6, page 12. See Section 5, page 41, for ad-

justment instructions and maximum allowable lubricant temperature.

~wARNING

ELECTRICAL WIRING - Standard Units - The Elec-

tra-Saver@ compressor is factory wired for all starter

to motor and control connections for the voltage specified on the order. It is necessary only to connect the unit starter to the correct power supply. The standard unit is supplied with an open drip-proof motor, a NEMA 12 starter and control enclosure. See “Location” para-

graph, page 8, for distance to the nearest obstruction

on starter and control box sides of the unit.

Lower operating voltages (200/208) require that the unit starter be remote mounted since the starter is too large to be mounted within the control enclosure. If not supplied with the compressor unit, the starter is to be a size 6 full voltage non-reversing type in NEMA

(CEMA) enclosure suitable for the environment, with

two (2) rejection type control circuit fuses (size accord-

ing to motor starter manufacturer’s standard), a 200 (208) volt coil, and three (3) overload heaters for 200 (208) volt 100 HP (75 KW), 1.15 service factor motor.

The overload heaters are to be selected according to

starter manufacturer’s tables based on motor nameplate full load amperage.

Failure to properly ground the compressor package could result in con-

troller malfunction.

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 regressing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s

instructions. The following procedure should be used

in regressing:

Stop the unit.

Disconnect, tag and lockout the unitfrom the power supply.

Remove the relief plug and free hole of hardened grease.

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 harmfull as insufficient grease. The grease cavity should be about 1/2 full.

~wARNING

Electrical shock can cause injury or

death. Open main disconnect switch, tag and lockout before working on starter/control box.

GROUNDING - Equipment must be grounded in accordance with Table 250-95 of the National Electrical Code.

Leave the relief plug temporarily off. Reconnect the unit and run for about 20 minutes to expell the excess grease.

Stop the unit. Replace the relief plug,

Restart the unit.

~wARNING

Rotating machinery can cause injury or death. Open main disconnect, tag and lockout power supply to the starter before working on the electric motor.

13-9/10-841 Page 14

ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30° to 50° C)

Type of Service

Standard

MANUFACTURER

CHEVRON

SHELL EXXON EXXON

ELECTRIC MOTOR REGRESSING INTERVAL

Typical Examples

One- or Two-Shift Operation

150 HP(112KW)

Above 150 HP (112 KW)

TRADE NAME

SRI #2

DOLIUM R

UNIREX #2

POLYREX

Rating

Relubrication

Interval

18 Months

12 Months

Severe

Very Severe Dirty Locations, High

Continuous Operation

Ambient Temperature

150 HP(112KW)

Above 150 HP (112 KW)

150HP (112 KW)

Above 150 HP (112 KW)

9 Months

6 Months

4 Months

2 Months

13-9/10-841 Page 15

SECTION 3 STARTING & OPERATING PROCEDURES

PRESTART-UP INSTRUCTIONS - A new unit as re-

ceived from the factory has been tested and then pre-

pared for shipping only. Do not attempt to operate the unit until checked and serviced as follows:

1. Compressor Oil - Check the oil level inthe reservoir. Add oil only ifthe 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 9000 SP Lubricating Coolant which is

suitable for the first 8000 hours under normal operating conditions.

REPLACE OIL FILTER EVERY 1000 HOURS.

Initial fill, or filling after a complete draining of the system, may show the oil level in the yellow “EXCESS OIL” range. After start-up, the oil will fall into the green operating range as system components are filled. If necessary, add oil to bring the level to the top of the green range as read when

the unit is operating at full load and normal pres-

sure. See FIGURE 5–5, page 46.

NOTICE

ervoir and the oil level may read higher than when operating on load. DO NOT DRAIN OIL TO CORRECT; on the next loaded cycle or start, oil will again fillthe system and the gauge will indicate the operating level.

2. Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to Section 6, “Air Filter,” page 53, for complete servicing instructions. Be sure the inlet line, if used, is tight and clean.

3. Coupling - Check all bolts and cap screws for tightness. See Section 7, page 55.

4. Piping - Refer to Section 2, “installation,” page 8, and make sure piping meets all recommendations.

5, Electrical - Check the wiring diagrams furnished

with the unit to be sure it is properly wired. See FIGURE 4-14thru FIGURE 4-16, pages 38 thru 40, for general wiring diagrams and Section 2, page 8 for installation instructions,

6. Grounding - Equipment must be properly grounded according to Table 250-95 of the National Electrical Code.

Regular maintenance and replacement at required intervals of the oil fil-

ter, air filter and air-oil separator is

necessary to achieve maximum service and extended drain intervals of AEON ‘M9000 SP synthetic lubricant.

Use only genuine Gardner Denver filters designed and specified for this

compressor.

DANGER

Before removing the oil filler plug,

always stop the unit and release air

pressure, tag and lockout the power

supply to the starter. Failure to

release pressure or properly dis-

connect the power may result in

personal injury or death.

During unloaded operation and after shutdown,

the system will partially drain back into the oil res-

~wARNING

Failure to properly ground the compressor package could result in con-

troller malfunction.

7. Rotation - Check for correct motor rotation using “JOG MODE.” Compressor drive shaft rotation must be clockwise standing facing the compressor coupling,

~wARNING

Operation with incorrect motor rota-

tion can damage equipment and

cause oil eruption from the compres-

sor inlet. When checking motor rotation, induce minimum rotation (less than one revolution if possible). Nev-

er allow motor to reach full speed.

13-9/1

0-641

Page 16

8. System Pressure - Set the controls to the desired load pressure. DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE. See Section 4, “Controls and Instruments” for procedure.

~WARNING

Operation at excessive discharge air

pressure can cause personal injury or damage to equipment. Do not adjust the full discharge air pressure above the maximum stamped on the unit nameplate.

Check all screws and latches for tightness. Be sure doors are closed and latched.

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 Bars) pressure discharge valve, no special procedure to maintain unit reservoir pressure is required.

Unit Hot - No warm-up period is required. 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.

DAILY CHECK - Refer to Section 8, ‘iMaintenance Schedule,” page 56.

Operating Mode - Refer to Section 4 for detailed

9. information on the control system.

Enclosure - Check for damaged panels or doors.

10.

STOPPING THE UNIT - Press “STOP-RESET” button. The oil reservoir will automatically blow down as the motor stops. If the unit is a water-cooled heat exchanger type, close any manual water inlet valves.

13-9/10-641 Page 17

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, to the shop air line, and to the appropriate shop water line, if the compressor is water-cooled. A standard compressor unit consists of the compressor, oil reservoir, oil cooling system and filters, motor type as specified,

NEMA 12 starter /control box, and control components

as described below.

This compressor unit features the “AUTO SENTRY-

ES controller, which integrates allthe control functions under microprocessor control. Its functions include safety and shutdown, compressor regulation, operator control, and advisory / maintenance indicators. The keypad and display provide the operator with a logical and easily operated control of the compressor and indication of its condition.

AUTO SENTRY'-ES OPERATION

Operation of the “Auto Sentry-ES’ is dependent on selection of an operating mode (described below) from the controller keypad.

[STOP/RESET] key to place the controller into its

READY state (as indicated on the display). Compressor operation may then be started by pressing an operating mode key. Once operating, the mode may be changed at any time by pressing a key, and the se-

lected mode will be displayed in the lower right corner ofthe message window. Press the [STOP/RESET] key at anytime to stop the compressor under normal conditions,

An optional control maybe wired into the “Auto Sentry-

ES controller to interrupt and restart the unit based on controls by others. When stopped by these controls, the display indicates “REMOTE STOP”.

Before starting, press the

~WARNING

Automatic restarting or electrical shock can cause injury or death.

Open, tag and lockout main disconnect and any other circuits before

servicing the unit.

control is waiting for a reservoir blowdown, along with

the remaining pressure, The controls also delay initial

loading of the compressor until a startup delay has been completed.

Constant Run Mode Operation - Use this mode in applications where there are no long periods of unloaded operation, orfor minimum response time to sudden demands. The compressor unit will start and run

continuously, using its modulation controls to match

delivery to demand.

As demand falls below the compressor capacity, the

pressure will rise to the setpoint of the control. When

the pressure reaches the setpoint, the “Auto Sentry-

ES controller operates the solenoid valves IVO and

IVC to pass pressure to the inlet valve piston, and the inlet valve willclose enough to match itto the air system demand.

As demand increases, the controller will modulate the inlet valve by relieving pressure with the solenoid valves IVO and IVC as required to match delivery to demand. Once the compressor has been first loaded, it will maintain pressure within a few psi of the setpoint pressure. This is true for any demand within its rated capacity.

On units equipped with turn valve control, further increase in demand will cause the inlet valve to be held fully open. Turn valve solenoid valves TVC and TVO control compressor delivery. The controller automatically controls the two methods of modulation to provide the most efficient means of delivery to match the demand of the system under all conditions.

Low Demand Mode Operation - The low demand mode reduces power consumption by relieving pressure in the reservoir during unloaded operation. Use

this mode where there is moderate air storage and there are unloaded periods during the day, but frequent

motor starting and stopping is undesirable. During peri-

ods of moderate to high demands, this mode is identical to the constant-run mode described above.

During Iowdemand periods, the controller will open the

blowdown valve and fully close the inlet valve to minimize the motor load. A timer is reset when this occurs. While inthis state, the plant air system supplies control air pressure (as well as any plant loads). When the system air pressure drops to the reset pressure due to increased demand, the blowdown valve recloses and the controls resume their normal modulation sequence.

In any mode, the compressor will start only if reservoir

pressure is below5 psig. The display will indicate ifthe

13-9/1

0-641

Subsequent blowdown periods are not allowed untilthe timer has completed its cycle. This cycle eliminates frequent blowdowns during moderate loads, and the

Page 18

energy required to re pressurize the reservoir. It also eliminates the problems of oil foaming and carryover

that can occur if the oil reservoir of an oil-flooded com-

pressor is blown down too often. The timer is adjust-

able from 5 to 20 minutes.

Automatic Mode Operation - This mode provides automatic start and timed stop, and is best used in applications with long unloaded periods and adequate storage to allow stopping the compressor for periods. Operation during periods of moderate to heavy demands is identical to the low demand mode described above.

The automatic time delay is adjustable from 5 to 20 minutes. Ifthe controller operates unloaded for this period with no demand, the compressor drive motor is halted to eliminate its power consumption. The controls will remain in this state until demand is again indicated by a drop in pressure.

Sequence Mode Operation - This mode provides for communication between controllers, operating only as many as are required for economical operation. Use this on applications with large storage capacity and diverse loads. The lead unit will operate identically to the

automatic mode; operation will be automatically staged

for each lag unit (up to 8 total). For more information,

refer to the sequencing instructions later inthis chapter.

Communication between controllers is achieved by interconnection of a communication cable to circuit board connectors. A “unit number” must be assigned to each unit in this mode, but the display will indicate the unit’s actual operating ranking.

AUTO-SENTRY@ -ES CONTROL DISPLAY The display above the keypad is used to provide oper-

ating information to the user. During normal operation, the display will show the sys-

tem pressure, compressor discharge temperature, total running hours, and operation mode. If one of the operating modes has been selected, the green “RUN” indicator will be lit.

Alternate displays are available by pressing keypad cursor keys, and will be identified on the display. These include system pressure, reservoir pressure, separator differential pressure, total hours, compressor discharge temperature, and reservoir temperature. In Low Demand, Automatic, and Sequence modes, alternate displays also include the appropriate remaining

FIGURE 4-1 - AUTO SENTRY -ES DISPLAY

13-9/10-841 Page 19

times of the time delays. If no keys are pressed for 5

seconds, the display will revert to its normal mode.

The display is also used as a service reminder for nor-

mal maintenance items. When these conditions are sensed, the yellow “ADVISORY” light will come on, and

the message will alternate with the normal lower line

message. These messages are intended to advise of conditions that require service or may lead to a shutdown.

If a shutdown has occurred, the display will indicate “SHUTDOWN” and the cause and the red shutdown indicator will be lit. The compressor may not be operated until the conditions are corrected and the controller is

reset.

SERVICE ADVISORIES The AUTO SENTRY-ES controller continually moni-

tors operation of the compressor unit, and will indicate

when service is required. These conditions willnot stop the operation of the compressor unit, but need attention

and service.

Service and Maintenance - These include the change separator, change air filter, and change oil filter messages, which are based on measured pressures or recommended service intervals. The controller automatically calculates oilchange intervals based on actual operating conditions. This allows maximum utiliza-

tion of AEON 9000SP oil. The advisory messages also

indicate low or high temperature operation, if the unit has operated near its tolerable limits.

Refer to the service instructions in this manual for ser-

vice details in response to these advisory messages. Clearing Advisories - Temperature advisories may

be cleared while the unit is running by simply pressing

the [ENTER] key. To reset the service advisories -CHANGE SEPARATOR, CHANGE AIR FILTER, CHANGE OIL, CHANGE OIL FILTER -- perform the following steps:

Press the [STOP/RESET] key to stop operation of

the compressor.

Relieve all air pressure.

Disconnect, tag, and lock out power supply.

Perform necessary maintenance, and record it on

maintenance log.

Following service, put the enable switch in the

down, “+” position.

Restore power to the unit. The display will read: “SHUTDOWN-POWER FAILURE”

(or “READY” if auto-restart is enabled).

Press the [STOP/RESET] key. The display will in-

7. dicate “READY’ in the lower right hand corner,

Press [ENTER], The display will read:

“ENTER TO SETUP - AUTO TO SERVICE Press [AUTO]. The display will read:

9. “OIL FILTER - HOURS TILL CHANGE

Press [ENTER]. The display will read:

10.

“HOURS TILL NEXT OIL CHANGE

Press [ENTER]. If an advisory is present, it will be

11. displayed at this time.

Press [ENTER] to clear the advisory. When all

12. are cleared, the display will read: “ENTER TO SETUP - RESET TO EXIT”

Press [STOP/RESET] to return to the READY

13. state.

prevent unauthorized programming, disconnect, tag,”and lockout power supply and return the ENABLE switch to the up, SET position. Restore power, press [STOP/RESET] to place the controller into the READY state, and select an operating mode to start compressor operation.

PROTECTIVE SHUTDOWNS The “AUTO SENTRY-ES” will shut down the unit fol-

lowing any fault detected in the following devices, Following a shutdown, a message will be displayed, with

the top line indicating “SHUTDOWN” and the lower line

indicating the cause, The shutdown lightwill be steadily litifthe cause stillexists, or will flash if the cause has been cleared. To resume operation, the cause of the shutdown must be corrected and the controller reset by pressing the [STOP/RESET] key.

Refer to the service instructions in this manual for addi-

tional details on what service is required in response to these shutdown messages.

Motor Protective Devices - Overload heaters are

furnished for the starter in the voltage range specified. There are three (3) overloads in the starter of proper

size for the starter and its enclosure. Note that motor nameplate current must be multiplied by 0.577 for wyedelta starters. The display will indicate which overload relay has tripped. The overload relay is reset by pressing the button on the relay itself, then the controller may be reset, Measure motor current (amps) and voltage in the affected motor wiring to locate the cause for high current. Overload relays provided in standard units are sensitive to both overload and phase imbalance for improved motor protection.

Proper starter coil and contact action are also moni-

tored and errors in operation will cause a shutdown with the cause displayed as a start error.

High Temperature - The compressor is protected

from high discharge temperature by two independent thermistor probes. One probe is located in the com-

pressor discharge to sense compressor discharge

temperature. The second probe is located at the sepa-

13-9/10-641

Page 20

rator discharge and senses the temperature of the air at the oil separator. The “AUTO SENTRY-ES will shut the compressor down if temperature exceeds 225° F (or lower per user adjustment) or if rapid temperature rise is detected. The location of the high temperature

fault will be displayed. Thermistor probes are also checked for open or

shorted circuits, or extreme low temperature, and the display will indicate the location of the defective probe.

~cAuTI0N

diagnostic checks of its own operation and the sensors to which it is connected. Refer to the service section for a complete listing of shutdowns and remedial actions.

PROGRAMMING AND SETUP INSTRUCTIONS

FOR THE AUTO SENTRY”-ES CONTROLLER All compressor control adjustments are made through

the controller keypad. This provides a single location for alladjustments, coordinates all related controls, and

eliminates the need for additional gauges and meters. The controller stores all adjustments digitally. These

are permanent unless changed by further program-

ming.

Machine damage will occur if compressor is repeatedly restarted after high temperature stops operation. Find and correct the malfunction be-

fore resuming operation.

Separator Differential Pressure - The “AUTO SENTRY-ES continually monitors the pressure drop across the oil separator. The unit shuts down at a differential pressure of approximately 15 psid. This becomes active only after the compressor has been running and pressures have had time to stabilize.

High Pressure - The “AUTO SENTRY-ES will first attempt to unload and blow down the unit if excessive pressures are detected inthe reservoir or the plant system, If unsuccessful, a shutdown will occur.

Shut down will also occur if a defective transducer is detected. The display will indicate the location of the high sensed pressure or transducer (xducer) error. Check that all adjustments have been properly made, and all connections are secure.

General - Programming and setup is accomplished with the PROGRAM keys. In all steps, the [ENTER]

key willcause the controller to accept the displayed val-

ue into memory and advance to the next programming function. The plus [+] and minus [-] keys will increase

and decrease displayed numeric values, or step through menu selections. During numeric adjust-

ments, the right [ < ] and left [ > ] arrow keys, move the cursor (flashing digit) to the position desired. The

number at the cursor will be the number that is changed

bythe [+] and [-] keys. At any point inthe programming

and setup routine, press the [STOP-RESET] key to

exit and return to the READY state without altering the

adjustment.

In all steps of the programming routine, the top line of the display will give a description of the parameter to be

programmed, while the bottom line shows the variable that is capable of being altered by programming.

The following is a step by step guide to programming the “AUTO SENTRY-ES controller.

NOTICE

Low Oil Pressure - The “AUTO SENTRY-ES will shutdown the unit if inadequate oil reservoir pressure is detected after starting and loading. If this occurs, check the wiring and piping to the solenoid valves.

Emergency Stop - Pressing the emergency stop button will shut down the unit and the controller. To restart, pull the button out to its normal position and reset the controller. Use this for emergency purposes only -use the keypad [STOP/RESET] key for normal controlled stopping.

Power Failure - Following power interruptions, the controller will remain in a shutdown state (unless programmed for auto restart).

High Vibration (optional) - This optional feature will shut down the unit if abnormally high vibration is detected.

Other Shutdowns - The controller runs continuous

13-9/10-641 Page 21

Between each step it is necessary to press the “ENTER” key to restore the new value and advance to the next

step.

Programming Steps:

1. Stop the compressor before making any adjustments. Ifthe unit is running, press the [STOP/RESET] key to place the control in the “READY” state. Adjustments can also be performed while in the “SHUTDOWN” state.

2. Press the [ENTER] key to begin programming. if the enable switch on the circuit board is in the set (up) position, the control proceeds to step 7 below. If the switch is in the “+” (down) position, the controller willdisplay “ENTER TO SETUP - AUTO TO

SERVICE”. Press [ENTER] to go directly to step 7 below, Press [AUTO] to perform the following steps.

3. The display shows “OIL FILTER” and the hours remaining until the next advisory are displayed on the bottom line, Press [ENTER] to go to step 4 without any change.

Press [AUTO] only if the oil filter change has been performed early. This will reset this timer back to the oil filter interval (see step 19).

4. The display shows “OIL CHANGE and the hours remaining until the next advisory are displayed on the bottom line. Press [ENTER] to go to step 5 without any change.

Press [AUTO] only if the oil change has been performed early. This will reset this timer back to the oil change interval (see step 20).

5. If any service advisories are in effect (yellow ADVISORY indicator is on), they will be displayed.

Press [ENTER] to clear the advisory.

The display will indicate “ENTER TO SETUP -

RESET TO EXIT”. This indicates that all the main-

tenance adjustments have been completed.

Press [STOP/RESET] to go back to the READY state, or press [ENTER] to go on to step 7.

7. The top line shows “DISPIAY UNITS. The bottom line indicates “ENGLISH” (PSIG, Fahrenheit)

or “METRIC (Bars, Celsius) units of measurement, Select the desired display units and press [ENTER] to proceed.

8. The top line displays “NUM OF SEQ UNITS. The

bottom line indicates a number inthe range of one through eight. This will be factory set at “l”. Set this to a number corresponding to the number of

compressors that are currently installed on this air

system that also have AUTO SENTRY-ES con-

trollers. It should be noted that all” AUTO

SENTRY-ES compressors on the system must

have the same number programmed hereto oper-

ate correctly in SEQUENC-E mode.

NOTICE

Setting the value instep 8 to one indicates that no sequencing is to take place. Consequently, steps 9, 10, and 11, which relate to sequencing, are skipped by the ES”; Programming commences at step 12.

“AUTO SENTRY-

9. The top line displays “UNIT NUMBER”, The bottom line will again indicate a number of one through eight and be factory set at “1”. Each “AUTO SENTRY-ES in a sequenced system

must have a unique number here. The sequence mode will not function iftwo or more compressors have the same UNIT NUMBER. Use low numbers

for the most efficient machine-to-machine com-

munications. Example: Use 1, 2, and 3 for a three

compressor installation,

10. The top line displays “TRANSFER INTERVAL”. The bottom line indicates a number of hours from

1to 5000. It is factory set at 24. This is the number of hours that this machine will stay in the role of ‘[master” or “lead compressor. Normally it is desirable to set this to the same value on all sequenced units to equalize running hours.

11. The top line displays "LAG START DELAY”. The bottom line indicates a number from 15 to 600 seconds. It is factory set at 30. This is the length of

time this machine will wait before starting when

the pressure drops below the reset point, Set this to the same value for all sequenced units. Its setting will depend on the amount of air storage volume in the system. Too small a number will result in more compressors being started than is necessary to satisfy demand. See “SEQUENCING COMPRESSORS WITH THE AUTO SENTRY-

ES” for more details on optimizing a sequenced

installation.

12.

The top line displays “BLOWDOWN TIME. The bottom line indicates a time between 5 and 20 minutes. It is factory set at 10 minutes. This is the minimum time interval between blowdowns. A longer blowdown time minimizes wasteful dumping of compressed air when loading is likely to occur ina short time. Longer periods also have been shown to prevent oil foaming.

13,

The top line displays “AUTO TIME. The bottom line indicates a time between 5 and 20 minutes.

It too, is factory set at 10 minutes. Its function is to prevent frequent motor starting, and to allow the motor a ‘cool-down’ period before stopping.

14.

The top line displays “START TIMER”. The bottom line indicates a time between 3 and 10 seconds. This is the time that the controller spends

in the unloaded ‘start’ mode. On units with facto-

ry-furnished wye-delta starters, this is the time that the starter is in its ‘start’ mode. Set this for the time when the motor reaches its maximum speed.

On all other starter types, this should be set for the time that the motor takes to reach full speed. Ifthe

setup switch is in the up position, the controller re-

turns to the READY state after this adjustment.

13-9/10-641 Page 22

NOTICE

Unit setup adjustments are normally required only atthetime of unit instal-

lation. To prevent accidental access, these will not be available if the “SET” switch is in the up position. The .

“SET” switch is located beneath the

power transformer mounting plate on the left edge of the main circuit board.

15,

Ifthe switch isinthe down position, “HI SYS PRES

LIM” is displayed on the top line, The bottom line indicates a value that is factory set 20-25 PSI above name plate. This is the pressure that will cause a forced blowdown if approached due to a malfunction such as a stuck inlet valve or broken control line. The controller will shut down if this pressure is exceeded.

The upper limits for the following two adjustments are based on the setting of the high system pressure limit, If necessary, the controller automatically reduces them following this step, and the display will briefly indicate “ADJUSTING PSET AND

PRES”

16,

The top line displays’’SET PRESSURE. The bottom line indicates a pressure value. Set at the nameplate rating of the compressor for normal operation. Under NO circumstances, is this adjustment to be set more than the compressor nameplate pressure.

17,

The top line displays, “RESET PRESSURE, The bottom line indicates a pressure value. This setting determines the point at which machine startup occurs in AUTO and SEQUENCE modes and when the compressor will load up from the blown down condition. Note that RESET PRESSURE cannot be set within 5 PSI of the SET PRESSURE. It is necessary that all machines to be sequenced have the same SET and RESET PRESSURE setpoints,

The top line displays “REMOTE STOP. The bot-

18,

tom line indicates either “TIMED or “lMMEDlATE. Select the desired response to the remote input and press [ENTER] to proceed.

19,

The top line displays “FILTER CHNG INTERVAL”. The bottom line indicates a time interval of 500 to

1000 hours. After the machine has run for the programmed setting, an advisory requesting an oil filter change. and press [ENTER] to go on.

will be displayed,

Adjust as desired

The top line displays “OIL CHANGE INTERVAL”.

20,

The bottom line indicates a time interval of 1000 to 8000 hours. After the machine has run for the programmed setting, an advisory will be displayed, requesting an oil change. Adjust as desired and press [ENTER] to proceed. 8000 hours is the proper change interval for AEON 9000SP synthetic oil. See section 5 for proper setting for AEON lubricants.

21.

The top line displays “HI TEMP LIMIT”. The bottom line indicates 225 degrees F. This isthe maximum (and proper) setting for compressor operation. It may be temporarily lowered to verify the function of the temperature shutdown system.

22.

The top line displays “FAN TYPE. The bottom line indicates either “AIR COOLED or “WATER COOLED”. Select aircooled to place the fan un-

der thermostatic control. This is the preferred setting for air cooled units, Select water cooled to run the (enclosure vent) fan whenever the main motor runs. This is the mandatory setting for water cooled compressors or compressors with remote elevated coolers. Select the type according to the type of compressor model.

23.

The top line displays “AUTO RESTART”. The bottom line indicates either “OFF or “ON”. Set this feature to ON when it is necessary to have the compressor automatically restart after a power interruption. This feature shall only be enabled when the owner determines that it is safe to do so,

It is recommended that compressor access be limited to only trained service personnel when this feature is used.

24,

This step happens only if the AUTO RESTART function was set to ON in step 23, The top line displays “RESTART TIME. The bottom line indicates a time between 5 and 60 seconds. It is factory set at 10 seconds. This isthe amount of delay introduced before restarting after power has been restored to ensure a stable supply and staggered starting. Adjust to any value per user preference,

25.

The top line displays “AIR END TYPE. The bottom line indicates either “TURNVALVE or “NON TURN VALVE. Set as appropriate for the compressor.

26.

In the top line, “SYSTEM VOLUME is displayed.

The bottom line may be selected as “SMALL”, “MEDIUM”, or “lARGE. This tunes the response of the modulation control loops to optimize loop stability. It is factory set to MEDIUM. Set as fol-

lows: SMALL ifestimated volume is less than ,25 gallon

per CFM.

MEDIUM if estimated volume is between .25 and

1.0 gallon per CFM.

13-9/10-841 Page 23

LARGE if estimated volume is greater than 1.0 gallon per CFM.

This setting is not critical. When set to

its most appropriate value, the controller will maintain discharge at the closest possible value. If not set cor-

rectly, pressure will vary from the de-

sired setpoint to a somewhat greater

degree but the compressor and its

components will not be adversely af-

fected.

27. The top line displays “REMOVE SYS PRESS. The bottom line displays the current pressure being sensed at the package discharge. At this point steps must be taken to ensure that system pressure is really zero psig. Remove the line to the system pressure transducer. Pressing [ENTER] will now cause the “AUTO SENTRY-ES to calibrate the transducer output to zero PSIG. Obviously, pressure measurement errors will occur if ‘zeroing’ is done with pressure at the transducer.

If large errors are detected, the controller will de-

mand that the transducer be checked.

28. The top line shows "REMOVE RES PRESS. The bottom line displays the current pressure being sensed in the reservoir. The reservoir pressure transducer may now be ‘zeroed’ by following the steps outlined in 27 above.

29. The display now reads “PRESS CNST RUN TO JOG MOTOR,” Press the [CONSTANT RUN] key to briefly energize the starters, and rotate the compressor 1/4 to 1-1/2 revolutions to allow a rotation check, This is limited to three tests.

30. This completes the programming and setup procedures for the “AUTO SENTRY-ES controller.

Press the [STOP/RESET] key to return the com-

pressor to the READY state.

SEQUENCING COMPRESSORS WITH THE AUTO SENTRY-ES

Sequencing compressors with the AUTO SENTRY-

ES controller is as simple as plugging in a telephone to a wall jack. The only item required to make the system functional is a standard telephone cable similar to cables that connect nearly every telephone to its wall jack. One less cable than the number of compressors to be sequenced is required. For example, four com-

pressors require three cables. A kit, 200 EAP752, is

available that contains all material needed to sequence up to five compressors. This kit contains 500 feet of cable, eight modular connectors, and a crimping tool to install the connectors. Note that this cable is designed specifically for this type of communication, and is a higher grade than most standard phone cables.

In spite of the fact that it is a standard feature and its inherent installation simplicity, the sequencing function of a multi-compressor “AUTO SENTRY-ES system is the most fully featured, functionally complete available today.

Installation A proper sequencing installation requires two or more

Gardner Denver rotary air compressors complete with

“AUTO SENTRY-ES controllers, piped into a com-

mon air system, interconnected as described above.

For best performance, pipe the units directly to the re-

ceiver, without any intervening check valves, dryers, or

other restrictions. Size the receiver to prevent exces-

sive drops or rapid rises in pressures during the opera-

tion as described below. All standard practices com-

mon to sound air compressor installations such as

proper sizing of discharge piping, proper electrical sup-

ply and conductor sizing, and grounding are to be ob-

served. The serial communications interface meets

RS-485 standard. This is the most widely used interface in harsh, industrial environments today. However, communications cables should be routed through metallic conduit to provide them with both mechanical

protection and electromagnetic shielding.

Each control circuit board has two modular jacks that accept RJ-12 telephone plugs, One jack is vacant; the other has a short pigtail plugged into it. To interconnect two compressors, plug the cable into the vacant jack on each controller. For installations of more than two

units, disconnect the pigtail plug on all controllers except the two at each end of the line. The order of interconnection has no effect on the system operation. The following conditions are necessary and sufficient for

proper operation:

1, Every compressor must have a cable connecting

itto another compressor. One less cable than the number of units sequenced must be used.

2. Each board that has only one cable connected to it must have its pigtail plugged into the unused jack. All installations will have two such units.

Operation

1. ESTABLISHING THE INITIAL SEQUENCE

Operation of compressors in sequence requires only a

press of the ‘sequence’ key on each compressor in the system. Since the sequencing algorithm includes provisions for automatic replacement of a failed master or

‘lead’ compressor, it is important for the operator to be aware of the hierarchy of events when starting the system.

13-9/1

0-841

Page 24

The first compressor placed into sequence mode will become the master. However, since any compressor first placed into sequence has no way of knowing whether a master exists, itwill first assume the highest rotation number available. For example if the number of units to be sequenced is programmed at four, any compressor will start out in position four when placed in sequence mode.

nications line for a call from the master. If no call is received, it will assume position three and

again wait for a call from the master. After another lack of a master call, it assumes position two. Subsequently, it assumes position one, which makes itthe master. As soon as a master is established, it immediately attempts to call all other units and assigns them successive rotation positions. The system is now active.

Before a master is established, the system is not deprived of air. This is due to one of the outstanding fea-

tures of the “AUTO SENTRY-ES sequencing system:

pressure control is always executed locally at each compressor. The effective setpoint for compressor

control is the programmed setpoint minus 3 *(rotation number – 1). So while a compressor is counting down towards establishing a master, it is also capable of delivering air at a pressure determined by the above formula.

To ensure that two or more machines do not simulta-

neously decrement their rotation numbers and simultaneously become masters, place the desired master in sequence mode first and wait until the first decrement in rotation number is seen (about 7 seconds). Then place subsequent compressors in sequence mode. To dictate the complete initial sequence manually, wait until the previous machine decrements one position and then place the next desired compressor in sequence

mode. To let the master determine the initial sequence, simply wait until the master has decremented its rota-

tion number once, and then place all remaining com-

pressors in sequence mode. Remember that once a master is established, no further self-decrementing is done by the individual compressors. Instead, they wait until the master assigns them a rotation number.

Rotation numbers are displayed in the bottom display line, with the mode indication. For example, the mode indication for the current master is SEQ1; for the first lag compressor, SEQ2; second lag, SEQ3.

2. HOW THE “AUTO SENTRY-ES” CONTROLS PRESSURE WHILE SEQUENCING

Each compressor operates exactly the same as if it

were in AUTO mode with one exception: it has a dy-

namic setpoint. The initial setpoint is determined by the

equation shown above. A compressor starts when the

system pressure drops below its programmed reset point, after waiting for [ ‘LAG START INTERVAL’ times (rotation number - 1)] seconds. This prevents all lag

It will then listen on the commu-

will

compressors from starting at once. Note that a com-

pressor’s ['LAG START INTERVAL’ times (rotation number - 1)] timer is not reset to zero until that compressor is started or until another unit in the system stops. This means that the time for the next lag compressor to come on may be somewhat less than ‘LAG START INTERVAL’.

EXAMPLE: In a three compressor sequence system, SET PRES-

SURE = 100 PSI; RESET PRESSURE= 90 PSI; LAG START INTERVAL = 15 seconds. The lead compressor is running alone, maintaining 100 PSI by modula-

tion when an air tool comes on line and causes the air

demand to exceed the capacity of the lead compressor. When the pressure drops to 90 PSI, the #2 unit times out its 15 second timer and starts. It takes 5 additional

seconds for the pressure to rise above 90 PSI. The #3 unit whose timer was initially set at 30 seconds (15x [3

- 1]), has counted down 20 seconds (the total time that system pressure was below 90 PSI). If air demand increases again, the pressure will have to fall below 90 PSI for only 10 seconds more to start unit #3.

As was previously stated, a lag compressor’s modulation setpoint (PSET for short) is [SET PRESSURE 3(rotation number the first lag compressor (rotation #2) has a PSET of 97 PSI; the second lag, 94 PSI, and so on. But look what happens in an eight compressor installation: The eighth compressor will have an initial setpoint of [100

- 3(8 - l)], or 79 PSI. Does this mean that an eight compressor installation must operate 21 PSI below the

desired operating point when all compressors are running? NO! This is where the “AUTO SENTRY–ES dynamic setpoint control takes over, This is how itworks:

Whenever the system pressure is below the pro-

grammed RESET PRESSURE, the PSET of each lag compressor is incremented 1 PSI every thirty seconds. Thus, after a short interval (about five minutes in this example), the PSET of the last sequenced compressor will climb until either it equals the RESET PRESSURE, or a decrease in demand causes the actual system

pressure to rise above the RESET PRESSURE. The

“AUTO SENTRY-ES, with its dynamic setpoint con-

trol, will maintain system pressure between the limits of RESET PRESSURE and SET PRESSURE. Remember, RESET and SET PRESSURE values are programmed by the operator so the operating range is completely programmable and predictable.

Dynamic setpoint control will also work in reverse of the operation described above. Obviously, incrementing setpoints will cause overlap of the compressors’ modulation ranges. While this enables us to maintain a higher pressure than competitor’s sequencers, overlap is undesirable as demand decreases, because a system could end up with several compressors running partiallyloaded instead of running the minimum number of fully loaded compressors. To overcome this, as pressure

1)], Thus in the above example,

13-9/1 0-641

Page 25

rises through the range between RESET and SET, the lag compressors’ PSET’S are now decremented. This reverses the effect described above during periods of high demand. The “AUTO SENTRY-ES keeps track of all functions so there is never any mix-up of setpoints and the proper rotation sequence is always maintained.

The Automatic Sequence Change

After the master (lead) compressor has served for the duration programmed (TRANSFER INTERVAL), it relinquishes control and assigns itself the highest available rotation number. The lag compressors detect the loss of the master and decrement their rotation numbers. Number 2 becomes number 1, the new master; number 3 becomes number 2, etc.

Whenever the master detects a missing rotation num-

ber, such as when a compressor is turned off that was previously in the rotation, it will automatically ‘close the gap’ by decrementing the rotation numbers of all com-

pressors whose rotation numbers were greater than the missing number. Likewise, if for whatever reason, the master compressor fails to carry out its role, all lag compressors begin decrementing their rotation num-

ber until a new master is established. Regardless of the scenario, the result will always be that the compressors that remain in rotation will always end up with the

lowest possible rotation numbers.

Other Features

Any air system will exhibit pressure differences from one point to the next. compressor installation will show ‘minor’ pressure variations between one compressor’s discharge point and another compressor’s discharge. These points will also vary from the central system (normally the air storage receiver). The “AUTO SENTRY-ES sequencing system is designed to tolerate minor variations. These pressure differences wreak havoc with conventional sequencers. Central sequencers sense a lower pressure than is seen at each compressor. With such sys-

tems, there is always a chance that the sequencer

could cause a compressor to over pressure due to this pressure drop. The alternative has been to set the cen-

tral sequencer to a lower pressure to prevent this or al-

low local override of the sequencer by the local pressure control, neither of which is desirable in the scheme of maintaining plant pressure efficiently with sequencing. The “AUTO SENTRY-ES sequencing system will automatically adjust the system to prevent over pressures in any individuals.

The “AUTO SENTRY-ES” sequencing system lets each compressor control itself independently about a setpoint (PSET) derived to cause staggered operation, or sequencing. The aforementioned pressure drops can also cause derogatory effects (main!y skewed, or

Even a well-designed multi-

out of sequence operation) to the sequencing algorithm

used by the “AUTO SENTRY-ES.

Since these pressure variations are not constant (they willvary due to demand changes, compressor load percentage changes, and number of compressors run-

ning), any scheme to compensate for the pressure variations must be dynamic. setpoint control feature accomplishes this error correction scheme rather easily.

Here’s how it works: The master continually receives system pressure values from every machine in the se-

quence rotation. The values are averaged and this average is distributed to all lag compressors. All compressors, lead and lag, then compare their local pressure reading to the average and adjust their PSET by the amount of error. The effect is that all compressors are controlling to a single pressure reading, a reading that is not one that is picked up somewhere removed from the compressor, but an average of actual discharge pressures.

The pressure displayed on the top line by all sequenced

compressors is this average, CONNECTION TO EXTERNAL CONTROLS

The “AUTO SENTRY-ES controller offers intercon-

nection points for external controls and indicators. This

allows simple connection to remote controls and indicators, or integration into any plantwide controls system.

Remote On/ Off - Remote on-off control of the sys-

tem requires only a simple two-wire control, with an isolated contact suitable for 120 volts, 1 amp. This may be a switch, a timer contact, a relay contact, or a PLC output. To connect, simply run the two wires to the control enclosure, remove the jumper between terminal 6 and terminal 9 on the terminal strip, and connect the two wires to terminal 6 and terminal 9.

The air compressor will operate normally in its selected mode whenever this contact is closed (turned on). Note that the keypad is always the master control; the operating mode must be selected at the keypad, and

the remote is not capable of starting a unit after the

STOP/RESET key has been pressed to place the con-

troller inthe READY state. When the contact isopened

(turned off), operation depends on how the controller

has been programmed and what it is doing prior to opening the contact.

If the compressor was already stopped in automatic or

sequence modes, itwill remain stopped and will not restart until the contact is closed. The display will flash

the message “REMOTE STOP to indicate that it is

waiting for the remote signal. If the compressor was running in any mode when the

contact was opened, and the remote response is programmed for “IMMEDIATE, the compressor will im-

The exclusive dynamic

13-9/10-641 Page 26

PUR

MINIMUM PRESSURE

)

FIGURE 4-2- SCHEMATIC TUBING DIAGRAM

mediately unload, blowdown and stop the motors. The unit isthen in the “REMOTE STOP mode as indicated

above.

If the compressor was running in any mode when the contact was opened, and the remote response is programmed for “TIMED UNLOAD, the compressor will immediately unload and blowdown. Itwillthen continue to run unloaded for whatever period has been programmed for “AUTO TIME (or will complete the remaining auto time if already blown down). After completion, the motors will stop, and the unit will be in the “REMOTE STOP mode as indicated above, This is the preferred setting for automatic remote controls that may cycle in less than 1/2 hour, as the motor is always cooled evenly and rapid start cycles are prevented.

Alarm Relay - The “AUTO SENTRY-ES controller provides an alarm relay that maybe connected to a remote mounted indicator light, horn, or into a PLC input of a plantwide control system. The contact is commercial rated 2 amps at 120 volts. The relay turns on whenever there is a shutdown condition requiring service at the compressor, and remains off during normal operation, stopping, or power off conditions. The external connections from the controller are from an isolated

form C (single-pole, double-throw) contact. This al-

lows control of either a “compressor okay” or a “compressor shutdown” remote indicator,

To use this relay, connect the supply wire for the remote circuit to terminal 21 (relay common) on the terminal strip. Connect a wire to the indicator from either termi-

nal 19 (normally open) or from terminal 20 (normally

closed). Connect the other side of the indicator to its

neutral.

Serial Communications

If units are NOT connected in sequence, the serial port is available for communications of compressor data to external monitoring systems. Data available include all pressures and temperatures, and a report of internat service data. This is accessible with a PC or PLC with an RS-485 communications port. For protocol information, request drawing 200 EAP1255.

OTHER CONTROL DEVICES Besides the electronic controller noted above, the fol-

lowing components are also used to control operation of the compressor unit.:

Relief Valve - A pressure relief valve(s) is (are) installed in the final discharge line and set to approximately 120-1 25% of the unit’s full load operating pres-

13-9/10-641

Page 27

O-RI N

MAIN SPRING

CV SPRING

.,/

FIGURE 4-3- BLOWDOWN VALVE

sure 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. To 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 snap shut,

Cv AS

SEMBL

FIGURE 4-4- MINIMUM DISCHARGE PRESSURE /

CHECK VALVE

~WARNING

Operation of unit with improper relief valve setting can result in severe personal injury or machine damage.

Insure properly set valves are installed and maintained.

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 oth-

er debris. Always wear eye and ear

protection and stand clear of the discharge port when testing the relief valve to prevent injury.

~CAUTION

Never paint, lubricate or alter a relief

I valve. Do not plug vent or restrict dis- I

charge.

13-9/1

0-641 Page 28

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. When the solenoid is energized, the valve closes to al-

low the coolant system to pressurize. A control air check valve is provided to ensure that the inlet valve is closed during blowdown.

Oil Level Gauge (FIGURE 1-6, Section 1, page 3) This gauge is located on the oil reservoir and indicates the oil level. See section 5 for information on how to correctly read the gauge and proper lubrication.

Minimum

(FIGURE 4-4) - An internal spring-loaded minimum

pressure valve is used in the final discharge line to provide a positive pressure on the coolant system of the

compressor even ifthe air service valve is fully open to

Discharge Pressure/Check Valve

FROM

AIR FILTER

n~ll

VALVE

IFICE.

BLOW DOW

VALVE

,—!

‘0 -1

SEPARATOR

HOUSING

INLET VALVE

! k%

FIGURE 4-5 - INLET VALVE

atmospheric pressure. This valve also functions asa check valve to prevent back flow of air from the shop air line when the unit stops, unloads, or is shut down.

The valve incorporates a spring-loaded piston which maintains approximately 65 psig in the oil reservoir. When the air pressure on the upstream (reservoir) side of the valve rises above 65 psig, the spring is overridden and the valve opens to full porting.

The valve does not require maintenance or adjustment,

If the valve fails to function, check the valve stem Oring for sealing, valve orifices for restriction, or valve and valve seat for burrs and dirt.

The valve is adjustable within a small range. It is adjusted by a screw on the side of the valve. By turning the screw, the minimum pressure to open the valve increases.

Conversely, backing it out decreases the

minimum pressure required to open the valve,

–SOLENOIO

HOUSING

VALVE

224ECM797

(Ref. Drawing)

inlet Valve (FIGURE 1-4, page 2, and FIGURE 4-5)

- The Inlet valve restricts the inlet to control delivery and closes to unload the compressor. At shutdown, the inlet valve closes to prevent the back flow of air.

The inlet valve position is controlled by air pressure in its piston cylinder, which is controlled by the “Auto Sentry-ES” through solenoid valves IVC and IVO. As Pressure to the piston is increased, the valve closes to restrict air flow and compressor delivery.

Solenoid Valves IVC and IVO - These valves control position of the inlet valve in response to signals from

the “Auto Sentry -ES.

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 posi-

tion. If both valves are energized, control pressure is

relieved from the inlet piston to allow the valve to open.

To service the valve, 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 Machinery distributor,

13-9/10-641 Page 29

Pressure Regulator - The pressure regulator is used to supply a constant and low control pressure to prevent damage to the inlet valve from “slamming.” The regulator should be set for 25-30 psig.

FIGURE 4-6- SHUITLE 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 allow the one with the highest pressure to pass through. The shuttle valve is used to provide control air pressure from either the reservoir or plant air system, as required during different operating conditions.

Purge Air Valve - The purge valve isa 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.

Turn Valve (Electra-Saver only) (FIGURE 4-7)- The turn valve isa 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.

Turn Valve Actuator (Electra-Saver only) - The turn valve actuator is a rotary rack and pinion device which positions the turn valve according to system demand. Filtered oil from the compressor sump is directed to the outboard end of the two actuating cylinders to move the rack and rotate the valve. Located on the ends of the cylinders are adjusting screws which limit the travel of the actuator. When looking at the rear of the compressor, the adjusting screw on the right on the compressor adjusts the fully closed (full-load) position of the valve. The full load position of the actuator may be checked by removing the adjusting screw at the unloaded end of the actuator (left side of the compressor) and using a rod to push the pistons to the full load position. The rod must be clean and free of burrs and scale. Take care not to scrape the cylinder walls when moving the pistons.

J I

I I I

I I

FIGURE 4-7- TURN VALVE - ELECTRA-SAVER ONLY

13-9/10-641 Page 30

SOLENOID VALVE

-lvc-

213ECM797

(Ref. Drawing)

Solenoid Valves TVC and TVO (Electra-Saver only)

- These valves control the position of the turn valve in

response to signals from the “AUTO SENTRY-ES controller. With both valves de-energized, equal pressure is applied to both ends of the actuator to hold it in its present 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. If TVO only is energized, the left end of the turn valve actuator is exhausted to the compressor inlet cavity, causing the turn valve to move towards the unload position. SENTRY-ES OPERATION” in this section for a description of how the turn valve position iscontrolled during normal operation.

System Pressure Transducer - This transducer is connected after the minimum pressure valve. It converts the pressure in the plant air system into an electrical signal for use by the “Auto Sentry-ES controller for modulation and control.

Reservoir Pressure Transducer - This transducer is connected to the coolant system. Its signal is used to prevent loaded starts, monitor reservoir pressure, and monitor the condition of the air/oiI separator.

Air Filter Vacuum Switch - This switch is used to monitor air filter condition and alert the user if the filter requires service or replacement.

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.

Emergency Stop Push-Button - This is a maintained push-button, and removes power from the controller outputs regardless of controller status. It is located on the upper section of the panel, next to the keypad. This should be used for emergency purposes only - use the keypad “STOP/RESET” for normal controlled stopping.

See “AUTO

~WARNING

Automatic restarting or electrical shock can cause injury or death. Open, tag and lockout main discon-

nect and any other circuits before

servicing the unit.

Vibration Switch - The “Auto Sentry-ES controller

has one additional input available for dealer or user installed optional shutdown switches. The switch is

simply wired in place of the jumper between terminals 7 and 9 of the terminal strip, If the contact is opened, the compressor will be shut down, and will display “SHUTDOWN - HIGH VIBRATION”.

The vibration shutdown switch is to be mounted on the compressor coupling cover, and detects an increase in vibration that could bean indication of impending dam-

age to the unit. The switch actuates when the selected

level of vibration is exceeded.

The switch must be adjusted when the unit is first

installed. Refer to the switch manufacturer’s instruction manual for complete details.

Control Transformer the incoming power voltage to 110-120 volts for use by

all unit control devices. The transformers employed

are usually connectable for several input voltages, refer to the transformer label for connection prior to ener-

gizing. Two primary and one secondary fuse are provided. Refer to adjacent labeling for replacement

information.

Terminal Strip - This provides connections for all

110-120 volt devices not contained within the enclosure.

Fan Starter - The starter is used to provide control and overload protection for the cooling fan or the ventilation fan of water-cooled units with enclosure. Over-

load heaters should be selected and adjusted based on the motor nameplate amps and the instructions located

inside the cover of the electrical enclosure. Three fuses are provided. Refer to adjacent labeling for re-

placement information.

Main Starter - This starter is used to provide control and overload protection for the main drive motor. Full voltage starters employ a single contactor, overload

heaters should be selected and adjusted based on the

motor nameplate amps and the instructions located inside the cover of the enclosure. Wye-delta starters employ three contractorswhich are controlled sequentially to provide low current starting. For wye-delta starters, the motor nameplate amps must be first multi-

plied by 0,577 before using the heater table.

Optional Switches - The “Auto Sentry-ES control-

ler has one additional input available for dealer or user

installed optional shutdown switches. If the contact is opened, the compressor will be shutdown, and will dis-

play “HIGH VIBRATION.”

This control device changes

13-9110-641

Page 31

COMPRESSOR CAPACITY CONTROL - TURN VALVE UNITS ONLY

The capacity of the compressor iscontrolled 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 O% to 40% ofthe compressors maximum capacity.

Example with normal setting of 100 PSIG:

Compressor

Delivery

Full Capacity 70% Capacity 40% Capacity

30% Capacity

20% Capacity

0% Capacity

Inlet Valve I Turn Valve

Open Open

Open Closing Closing

Closed

50% Open

Full Open Full Open Full Open Full Open

Discharge

Manifold

Pressure

100 100

100

103 103 103

13-9/1 0-641 Page 32

ORIFICE

CHECK VALVE

EXHAUST MUFFLER

SOLENOID VALVE ~ BDV” (ON)

SOLENOIDVALVE_

‘IVO” (OFF)

SOLENOIDVALVE> “IVC-(OFF)

PRESSURE REGWATOR>

SHUTTLE VALVE_

SERVICE

VALVE

MINIMUM DISCHARGE

PRESSURE CHECK

II \ / I I

VALVE VALVE

ORIFICE

SYSTEM PRESSK TRANSDUCER

RESERVOIR PRESSW TRANSDUCER

AIR FILTER VACW WITCH

[

AIR INLET CLOSEO

225ECM797

(Ref. Drawing)

A. FULL OIL PRESSURE B. FULL AIR PRESSURE C. CONTROL AIR PRESSURE (15-20 PSI) D. ATMOSPHERIC PRESSURE OR EXHAUSTING

FIGURE 4-8 - CONTROL Schematic- COMPRESSOR UNLOADED -CONSTANT SPEED MODE

OIL

RESERVOIR

EBH & EBM UNITS ONLY

OIL

FILTER

REAR VIEW OF COMPRESSOR ‘

EXHAUST MUFFLER>

OR IFICL

1 / I

CHECK VALVE

/-- ORIFICE

SOLENOID VALVE~ %DV” (ON)

SOLENOID VALVE= “IVO”(ON)

SOLENOID VALVE> “IVC”(ON)

PRESSUREREGULATOR

SHUTTLE VALVE>

SERVICC

VALVE

A, FULL OIL PRESSURE B. FULL AIR PRESSURE C. CONTROL AIR PRESSURE D. ATMOSPHERIC PRESSURE

MINIMUM

PRESSURE

VALVE VALVE

(15-20 PSI)

OR EXHAUSTING

DISCHARGE

CHECK

(

SYSTEM

PRESSURE TRANSDUCER

_ RESERVOIR

PRESSURE TRANSDUCER

‘AIR FILTER

VACUUM SWITCH

AIR INLET OPEN

FILTER

226ECM797

(Ref. Drawing)

REAR VIEW OF COMPRESSOR

FIGURE 4-9 - CONTROL SCHEMATIC - COMPRESSOR AT FULL LOAD - CONSTANT SPEED MODE

EBH & EBM UNITS ONLY

EXHAUST MUFFLER

ORIFICE

CHECKVALVE

ORIFICE

SOLE BDV’

SOLE “Ivo”

SOLE “Ivr

PRESSm

SHU

SERVICE

VALVE

A. FULL OIL PRESSURE B. FULL AIR PRESSURE

C. CONTROL AIR D. ATMOSPHERIC

PRESSURE (15-20 PSI)

PRESSURE OR EXHAUSTING

n A

MINIMUM

PRESSURE

VALVE

DISCHARGE

CHECK VALVE

/ / I

[

OIL

RESERVOIR

SYSTEM PRESS~E TRANSMtCER

> ~sERvolR p~’jsuRE

TRAN$DUC[R

> AIR FILTER

VACUW SWITCH

AIR INLET CLOSED

OIL

FILTER

227ECM797

(Ref. Drawing)

FIGURE 4-10-

CONTROL SCHEMATIC - COMPRESSOR UNLOADED - LOW DEMAND MODE OR AUTO MODE

EBH & EBM UNITS ONLY

EXHAUSTMUFFLER_

SOLENOIDVALVE ~V”~

SOLENOID VALVE “lV&~

SOLENOIOVALVE “IV’”~

~SS~E KGULATOR

SHUTTLE VALVE>

—

+ I n

SERVICE MINIMUM DISCHARGE

VALVE PRESSURE CHECK

II 1 I II.

VALVE VALVE

‘R’F’CE7rcHEcKvMvE

I /

ORIFICE

A v

PURGE VALVE

B D

AIR INLET VALVE

(OPEN)

~ SYSTEM

PRESSURE TRANS~ER

- RESERVO1’ PRESSUK

TRANSWER

‘AIR FILTER

VACWM SWITCH

214ECM797

(Ref. Drawing)

FULL OIL PRESSURE

FULL AIR PRESSURE

CONTROL AIR PRESSURE (15-20 PSI)

ATMOSPHERIC PRESSURE OR EXHAUSTING

[

(SECTIONED)

FIGURE 4-11 - CONTROL SCHEMATIC - COMPRESSOR AT FULL LOAD

EAP UNITS ONLY

- SOLENOID VWVE “IVC”

ORIFICE

CHECKVALVE

EXHAUST MUFFLER

[r \ I t I

SOLENOID

VALVE WV”—

VALVE ‘IVO”—

‘OLENO’D‘“vE‘lVC”Wrr

PRESSmE REGULATOR>

SHUTTLE VALVEy

VALVE

PRESSURE CHEC

VALVE VALV

ORIFICE

(

~ ESERVOIR PRESSURE

TRMSOUCER

~ AIR FILTER

VACUM SWITCH

215 ECM797

(Ref. Drawing)

AIR INLET VALVE

PURGE

VALVE

(CLOSED)

A. FULL OIL PRESSURE B. FULL AIR PRESSURE C. CONTROL AIR PRESSURE D. ATMOSPHERIC PRESSURE

(15-20 Psi) OR EXHAUSTING

FIGURE 4-12- CONTROL SCHEMATIC - COMPRESSOR FULLY UNLOADED - LOW DEMAND MODE SWITCH OFF

EAP UNITS ONLY

TURN VALVE ACTUATOR

(. SECTIONED)

SOLENOID

VALVE “IVC”

EXHAUST MUFFLER~

SOLENOIO VAIVE BDV”~

SOLENOID VALVE “lVO-~

SOLENOID VALVE “IVC”_

PRESS~E REGU-ATOR -

SHUTTLE VALVE_

ORIFICE~ /- CHECK VALVE

ORIFICE

SYSTEM PRESSURE TRANSDUCER

- RESERVOIRPRESSURE TRNSWCER

c AIR FILTER

VACU SWITCH

SERVICE

VALVE PRESSURE

A. FULL OIL PRESSURE

B. FULL AIR PRESSURE C. CONTROL AIR PRESSURE D. ATMOSPHERIC PRESSURE

MINIMUM OISCHARGE

VALVE VALVE

)

n u

A v

CHECK

{

PURGE

VALVE D

2[ W1_

*‘>

(15-20 PSI)

OR EXHAUST I

FIGURE 4-13- CONTROL SCHEMATIC - COMPRESSOR FULLY LOADED - LOW DEMAND MODE SWITCH ON

EAP UNITS ONLY

AIR INLET VALVE

(CLOSED)

216ECM797

(Ref. Drawing)

— SOLENOID VflVE “IVC”

•1 .CON”[,TIWTocam vOARO.

0. ?*,1 1U221NN Uocw

Lcmb

WV - AIR flLIU VM WITCH

WV - K- SOL~lD VMK

Ivc - 1=1 VALE U02c $Wllolb vAlv2

IVO - lVLtT VkVt OUll SOL9101D VM~

L2M C~CC1lti FOR WVi-LthV UOTO~

LOU VOLTAV2 H14H VWIU

Collmcllws Cmtcllans

,2Ivc

, Iv

w ,@

FIGURE 4-14 - WIRING DIAGRAM - 207ECP546

(WYE-DELTA - EBH & EBM UNITS ONLY)

l~&P

CoNlmLmlznnlw $1!

.“,

NOIC If FM C CONTACT FM M BY 0TH2M,

CWIAC1 0K~72S F~LOMN@ CCU~SSOR WTOOH

RATlll@ 1’20VAC. 2 M.

NOIE Z Fm u82 WITH WTIONN. vIMATIOH WITCIA

KMOVE .BNIKR 42~[N ~l12Al$ 7 & 9, COk NCC1 4.2, V14RA110N SAllCH C0N7ACT TO T2W

INNS 719.

N07C 9 fOR CU21ROL IV R2MOK COMIAC1, R2K0v2

MtR X~# ~lKNS 6 1 !. CONN2C7 CON-

TACT TO T2RNIIIALS 6 & +.

N07t 4 W*A & mb m FOR M OF WTIMN

cqlcATlw$ CMLL

MOT1 $ V’t12MA WA~ COMTROl $0L2N01b VUVC

1$ u420. WIK 10 rmlnu$ 1; A 10,

s CONUECTIM TO CONTROL 20~.

•1

o s PAN,, 72MlNAl 4L0CKS

M42nb

AIV - AIR FILER VACU92 $MICH Wv - W*W sm0201B VMV[

lVC - 12U27 Vuvl ao$c $012M01b VUVE lvo - lKC1 VALV2 m $OL2NOID VNV[

-—

,1mv ,0

IVC ,0

,3 Ivo

W ‘“

FIGURE 4-15 - WIRING DIAGRAM - 209ECP546

(FULL VOLTAGE - EBH & EBM UNITS)

—-

co R

•1 .

cow,,,,,” TO CO”m mm.

0. Pm lCRNINU NOcu

If.M CONECIIOM FOR ~Vi-llAO II070RS

LOW VOLTA= H16tl V017A0f

Cwccllws

11 14

Cwuiclfluls

~t-KLTA

8 J

,. -

‘“0

uOTOM

FIGURE 4-16- WIRING DIAGRAM - 206EAP546

(WYE-DELTA - EAP UNITS ONLY)

SECTION 5

LUBRICATION

OIL COOLER, OIL FILTER & SEPARATOR

COMPRESSOR OIL SYSTEM (FIGURE 5-1, page

43) cools the compressor, lubricates moving parts and seals internal clearances in the compression chamber.

~CAUTION

The oil inlet line is connected at the bottom of the oilreservoir. Air pressure inthe oil reservoir forces oilthrough the oil cooler, thermostatic mixing valve, oil filter and into the compressor main oil gallery.

The oil passes through internal passages for lubrication, cooling and sealing. The air-oil mixture is then

discharged to the oil reservoir where a large part of the entrained oil drops out of the air stream; the air then passes through the final oil separator where most of the remaining oil is removed. The separated oil is returned to the compressor and the air passes to the final

discharge line.

RECOMMENDED LUBRICANT - Gardner Denver compressors are factory filled with AEON lubricants. These lubricants are formulated to the highest quality standards and are factory authorized, tested and ap-

proved for use in rotary screw compressors. AEON lu-

bricants are available through your authorized Gardner

Denver compressor distributor.

OIL SPECIFICATIONS (Domestic and International) The factory fill compressor lubricant is Gardner Denver AEON m 9000 SP lubricating coolant which can be used for year-round operation. AEON m 9000 SP is a

synthetic, extended life lubricant which can extend lu-

bricant change intervals up to 4 times that of a petroleum based lubricant.

Improper equipment maintenance with use of synthetic lubricants will damage equipment. Oil filter and oil separator change intervals remain the same as for AEON m 4000 -- See

Maintenance Schedule, page 57.

HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000 SP lubricating coolant will operate at a sustained discharge temperatureupto210° F (99°C) when unusually high ambient air temperature is encountered.

~DANGER

Air/oil under pressure will cause

severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, tag and lockout power supply to the starter before removing valves, caps, plugs,

fittings, bolts, and filters.

A lubricant analysis program for a periodic check of lubricant quality and remaining life can maximize the change interval,

~CAUTION

Use of improper lubricants will cause damage to equipment. Do not mix different types of lubricants or use infe-

rior lubricants.

13-9/10-641 Page 42

~wARNING

High temperature operation can cause damage to equipment or personal injury. Do not repeatedly restart the unit after high temperature stops operation. Find and correct the mal-

function before resuming operation.

(EAP UNITSONLY)

I,&

A-MOTOR B-COMPRESSOR C-AIR FILTER D-OIL RESERVOIR E-OIL SEPARATOR F-OIL COOLER G-AFTERCOOLER H-THERMAL MIXING VALVE J-OIL FILTER iA:AIR ilLTER VACUUMSWITCH K-SEPARATOR TO CYLINDER

OIL RETURN LINE L-CHECK VALVE M-PRESSURE RELIEF VALVE N-OISCHARGE CHECK VALVE P-NINIMUN DISCHARGE

PRESSURE VALVE R-PURGC AIR VALVE

S-PNEUMATIC BLOW DOWN VALVE T-ORIFICE U-BLOW DOWN VALVE V-SHUTTLE VALVE W-PRESSURE REGULATOR X-SOLENOID VALVE “IVC” V-SOLENOID VALVE “IVO’ Z-ORIFICE

BB-SYSTEM PRESSURE TRANSDUCER CC-OISCHARGEPRESSURE TRANSDUCER DO-FANAND MOTOR EE-WATER FLOW CONTROL VALVE FF-MAGNETIC WATER SHUTOFF VALVE GG-TURN VALVE ACTUATOR HH-SOLENOID VALVE “TVOJJ-SOLENOID VALVE “TVC”

—

AIR ----o

OIL —

AIR/OIL ----D

WATER ~

—

a----

+---

)

221 ECM797

(Ref. Drawing)

FIGURE 5-1 - FLOW DIAGRAM

‘~A’EV~mE:[O

K- /cOOL’NG ‘OmE

2“ HARDPIPE

SUPPLIEDBY CUSTOMER ~lNIF’RE$$ cHECK VAVE)

~.<~q~

‘“’’-”- “’’’’” AIR DISCHARGE

KLMUVL rnvm t ,,8. 7,-I

ACTC1

LIIIL IU w ,LACOOLER

\ /

OIL FILL TEE

WITH PLUG

CLOSE TO COOLER

FROM

OIL COOLE~ OIL STOP VALVE

OIL COOLER

GATE VALVE

SUGGESTED CUSTOMER SUPPLIED

PIPING ARRANGEMENT

1-1/2 HARDPIPE

SRLIEDBY CUSTOMER

201 EAP797

(Ref. Drawing)

o----AIR

-OIL

- AIR/OIL

—

-1

-.,

‘$

A - HAIN HOTOR B - COMPRESSOR C - INLET FILTER D - OIL RESERVOIR E - OIL SEPARATOR F - OIL COOLER Q - AFTERCOOLER H- HIXIN6 VALVE BODY J- OIL FILTER K - OIL STOP VALVE

L - CHECKVALVE M - RELIEF VALVE N - CHECKVALVE P - HIN PRESS VALVE R - PNEUMATIC3 WAYVALVE

AIR FLOW

I,&

—

GATEVALVE

ELEVATED COOLERS

“

FIGURE 5-2- OIL FLOW DIAGRAM - REMOTE OVERHEAD MOUNTED

13-9/10-641 Page 44

218ECM797

(Ref. Drawing)

~wARNING

—___--—--

All materials used in Gardner Denver@ compressor units are compatible with AEON” 9000 SP Lubricating Coolant.

Use caution when selecting downstream components such as air line lubricating bowls, gaskets and valve

trim.

AEON” 9000 SP Synthetic Lubricant

is not compatible with Iownitrile Buna Nor acrylic paints. AEON” 9000 SP is

compatible with most air system

downstream components.

Material Safetv Data Sheets (MSDS) are available for all AEON Iubricants from your authorized Gardner Denver distributor or by calling 217-222-5400.

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. A contactor (starter) will be shipped loose and remote mounted with the cooler by others upon start-up at the job site. The control box will be wired for remote elevated coolers at the factory.

NOTICE

AFTERCOOLER

,/’

--—-.—--.-—

‘\\

)

+ .50

\ R(,339) DR[LL THRu

1/8 NPT ONE HOLE

FIGURE 5-3 - COOLER DRAIN DETAIL

the sys-AFTERCOOLER PIPING - At shutdown of

tern, all units should be drained completely of conden-

sate if there is any possibility of freezing or corrosion damage. To help remove the condensate, the cooler may be tapped per FIGURE 5-3 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. At the same time the connection on the drain side of the cooler should be plugged. The drain cock should be left open until the machines are ready for start-up,

All requirements 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 alu-

minum threaded connections. All piping should be firmIy supported to avoid strain on the cooler manifold and connections. Flexible connections should be installed in all interconnecting piping, adjacent to the cooler, to avoid transmitting piping weight or vibrations to the cooler elements. Before beginning installations, check

to be sure that no debris or foreign matter remains in the couplings or cooler bodies. necting piping is clean to avoid clogging the cooler passages.

Be certain intercon-

13-9/10-641 Page 45

, WARNING

Failure to remove condensate from an idle cooler in freezing temperatures

will cause permanent cooler damage.

Drain condensate after system shutdown. It is the owner/operator’s responsibility to ensure that condensate has been drained and cooler dried out to prevent cooler damage.

HEAT EXCHANGER (OIL) PIPING - All remote ele-

vated cooler applications must be sent through Engi-

neering for approval and for recommending pipe size.

When the cooling module is removed from the pack-

age, the thermal mixing valve (H) remains on the package. Control group part number 200 ECM4002 will be mounted on package at the factory. This group controls the oilstop valve as well as not allowing machine to run

blowndown. See FIGURE 5-2, page 44.

NOTICE

Remote mounted elevated coolers have a maximum pipe length of 30feet (9 M) (each way) and a maximum height of 20 feet (6 M) with a minimum of fittings. Engineering will review all remote elevated cooler applications and recommend pipe size on an individual basis. should include the engineering recommendation in the special order sent to Engineering.

Customer Service

ADDITION OF OIL BETWEEN CHANGES

made when the oil level is in

as read while the unit is on. To add oil, follow these steps:

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

2. the starter.

Wipe away all dirt around the oil filler plug.

3. Remove the oil filler plug and add oil as required

4. to return the oil level to the center of the green range on the ,gauge.

Install the oil filler plug, restore power, run and

5. check for leaks.

DO NOT OVERFILL. The quantity required to raise the

oil level from the red range center of the green range

is shown in FIGURE 5-4, page 47. Repeated addition of oil between oil changes may indicate excessive oil

:arry-over and should-be investigated.

the red range on the gauge

must be

~DANGER

Kit number EAQ68330 includes the oil stop valve, check valve and flanges and must be installed on all remote elevated coolers per See FIGURE 5-2, page 44, and the following instructions.

1. Mount the check valve (90J1 13) as shown.

Mount the drain valves in the lowest section of the

2. pipe on each side of the cooler connections.

Mount the oil stop valve (90AR243) in the line after

3. the thermal mixing valve as shown.

Modifications to the control Iines willbe made at the fac-

tory per 288 ECM81 Oschematic. Air to the oilstop valve

must come from the upper fitting inthe separator housing, then pass through the 3-way pneumatic valve. Control air to the valve must be from the line between the tee and the orifice in the blowdown muffler line per

FIGURE 5-2, page 44. down, itwill activate the pneumatic valve and itwill shut offthe air and vent the line between the pneumatic controlvalve and the oil stop valve to atmosphere. This will shut the oil stop valve and prevent excessive oil from

running into the reservoir.

Failure to install these parts could result in high oil carryover and cause the machine to shutdown on high discharge temperature.

When the machine blows

Air/oil under pressure will cause

severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, tag and lockout power supply to the starter before removing valves, caps, plugs,

fittings, bolts, and filters.

~DANGER

Compressor, air/oil reservoir, separa-

tion chamber and all piping and tub-

ing may beat high temperature during and after operation.

~CAUTION

Excessive oil carry-over can damage equipment. Never fill oil reservoir above the “FULL” marker.

COLD AMBlENT OPERATION - See “installation for Cold Weather Operation,” page 9.

13-9/10-641 Page 46

LUBRICANT CHANGE PROCEDURE - Upgrading to

a longer life lubricant is essentially a very worthwhile

practice. Following are the primary steps to be com-

pleted when upgrading or changing the type of lubricant.

Thoroughly drain system:

1. Drain oil from air end and cooler while hot. Break low point connections and drain oil

from pipe runs.

—

Dump oil from the filter and reinstall used fil-

ter.

Fillthe system with a 50 percent charge of the new

2. lubricant:

—

Start the machine and stay there to observe.

Allow the machine to run about five minutes at temperature, or until temperature stabilizes, then shut down.

3. Thoroughly drain the machine. Change to a new filter and separator.

FIGURE 5-4- OIL LEVEL GAUGE

5, Fill the system with a full charge of the new lubri-

cant, then reinstall drain plug. Machine should then be run normally, however,

total run time after the initial changeout should be

50 percent of normal anticipated service life of the new lubricant.

Drain all lubricant from the system, change

the filter and separator, and replace with a full

charge of the new lubricant.

7. Subsequent lubricant changeouts should be at normal intervals. (See “Oil Change Interval” and

chart below.)

OIL LEVEL GAUGE (FIGURE 1-6, page 3, and

FIGURE 5-4) 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. Add oil only when the oil is at the bottom of

the red range on the gauge as read when the compres-

sor is on. Drain oil only when the oil level is above the

Discharge

Temperature

center of the green range on the gauge as read when the compressor is on.

MOISTURE IN THE OIL SYSTEM - In normal humidity and with normal operating temperatures and pressures, the thermal mixing valve controls the oil temperature and prevents moisture contamination of the oil.

Unusual cooling of the oil reservoir, short loaded cycle in high humidity or malfunctions of the thermal valve may result in moisture in the oil system which is detrimental to compressor lubrication and could cause oil carryover. If moisture is observed in the oil reservoir, drain the moisture and correct the condition causing

the accumulation. See “Compressor Oil System

Check,” page 53 and “Thermal Control (Thermostatic Mixing) Valve,” page 49.

OIL CHANGE INTERVAL - Recommended oil change intervals are based on oil temperature. FIGURE 5-5, shows how the change interval is affected by tempera-

ture.

AEON 4000 AEON 9000 SP

Change Interval Change Interval

to 180°F (82”C)

Up 180° to 190°F (82° to 88°C) 190° to 200° F (88° to 93°C)

200° F+ (93'C)

6000 hrs. 8000 hrs. 4500 hrs. 6000 hrs. 3000 hrs. 4000 hrs.

1500 hrs. 2000 hrs.

FIGURE 5-5- OIL CHANGE INTERVAL

13-9/10-841 Page 47

When operating conditions are severe (very dusty, high humidity, etc.), it will be necessary to change the oil

‘ more frequently. Operating conditions and the appear-

ance 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 and we recommend a sam-

ple be sent in at 100 hours on a new unit,

DRAINING AND CLEANING OIL SYSTEM

~DANGER

drain reservoir through the oil filler opening or from the drain valve.

Ifthe unit is elevated so that the oil reservoir drain

can be used, empty the oil reservoir through the drain valve to a suitable container or sump.

If the drained oil and/or the oil filter element are contaminated with dirt, flush the entire system:

reservoir, oil cooler, mixing valve and lines, inspect the oil separator elements for dirt accumulation; replace if necessary. If a varnish deposit exists, contact the factory for recommendations for removal of the deposit and prevention of varnish.

Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, tag and lockout power supply to the starter before removing valves, caps, plugs, fittings, bolts, and filters.

~DANGER

Compressor, air/oil reservoir, separa-

tion chamber and all piping and tub-

ing may beat high temperature during and after operation.

Always drain the complete system, Draining when the

hot will help to prevent varnish deposit< and carry

oil is

away impurities.

To drain the system, use one of the following methods:

if the unit is not elevated high enough to use the

1. oil reservoir drain line to drain oil, a small hand, electric or air operated pump should be

used to

FILLING

OIL RESERVOIR

~DANGER

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.

Wipe away all dirt around the oil filler plug.

Remove the oil filler plug and add oil as required to return the oil level to the center of the green range on the gauge.

Install the oil filler plug and operate the unit for about a minute allowing oil to fill all areas of the system. Check for leaks.

Shut down unit, allowing the oil to settle, and be

certain all pressure is relieved.

60, 75& 100 HP

40& 50 HP

(45, 55& 75 Kw)

Refill Capacity For Normal Oil Change . . . . . . . 5.5 U.S. Gallons 8.5 U.S. Gallons

(32 Liters)

Redto Yellow Range . . . . . . . . . . . . . . . . . . . . . . . 1.25 U.S. Gallons

2.0 U.S. Gallons (7.5 Liters)

FIGURE 5-6- APPROXIMATE OIL SYSTEM CAPACITIES

13-9/10-641 Page 48

7. Add oil, if necessary, to bring level to the center of the green range on the gauge.

On unloaded operation and after shutdown some oilwill drain back into the oil reservoir and the oil level gauge will read “FULL.” DO NOT DRAIN OIL TO CORRECT. On the next start, oil will again fill the system and the gauge will indicate operating at the proper level. DO

NOT OVERFILL as oil carryover will result. The quantity of oil required to raise the oil level from “ADD to “FULL” is shown in FIGURE 5-6, page 48. Repeated addition of oil between changes may indicate excessive oil carryover and should be investigated.

Use only CLEAN containers and funnels so no dirt en-

ters the reservoir. Provide for clean storage of oils.

Changing the oil W-llbe of little benefit if done in a careless manner.

~CAUTION

Excessive oil carry-over can damage equipment. above the “FULL” marker.

Never fill oil reservoir

~DANGER

Air/oil under pressure will cause

severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, tag and lockout power supply to the starter before removing valves, caps, plugs,

fittings, bolts, and filters.

~DANGER

Compressor, air/oil reservoir, separa-

tion chamber and all piping and tub-

ing may beat high temperature during and after operation.

Stop the unit and be sure no air pressure is in the

oil reservoir.

COMPRESSOR OIL FILTER (FIGURE 5-1) - This

screw on oil filter is a vital part in maintaining a trouble-

free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is located

in the oil filter head. The relief valve opens in the event

the element becomes dirty enough to block the flow of

oil.

~cAuTlON

Improper oil filter maintenance will cause damage to equipment. Replace

filter element every 1000 hours of op-

eration. More frequent replacement could be required depending on operating conditions. A filter element left in service too long may damage equipment.

Use onlv the replacement element shown on the filter tag or refer to the parts list for the part number. Use the following procedure to not disturb the piping,

replace the filter element. Do

Remove the spin-on element.

Clean the gasket face of the filter body.

Coat the new element gasket with clean lubricant used in the unit.

Screw the new element on the filter body and tighten by hand. DO NOT OVERTIGHTEN THE ELEMENT.

Run the unit and check for leaks.

COMPRESSOR OIL COOLER - RADIATOR TYPE

(FIGURE 1-5, page 3) - The oil cooler motor and fan is mounted on the oil cooler module; air is exhausted through the oil cooler and away from the unit. Do not obstruct air flow to and from the oil cooler. Allow a minimum of three (3) feet clearance around the cooler. Keep both faces of cooler core clean for efficient cooling of compressor oil.

THERMAL CONTROL (THERMOSTATIC MIXING) VALVE (FIGURE 5-7, page 50) is installed in system as shown in FIGURE 5-1, page 43. This valve is used to control temperature of the oil in both air-cooled radiator and water-cooled heat exchanger type oilcooler 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. As oil warms, element gradually closes to the bypass allowing more of the oil from the cooler to mix with oil from the bypass.

13-9/10-641 Page 49

OIL”lN

FROM COOLER

“B’

OIL lN B;:~~S

~wARNiNG

It is mandatory that any water cooled unit be installed in a shelter heated to

temperatures above freezing (32° F.,

0°c).

RESERVOIR

OIL ‘OUT

A58407

“A’

FIGURE 5-7 - THERMOSTATIC MIXING VALVE ELEMENT

After the unit is warmed up, the mixing valve maintains oil injection temperature into the compressor at a mini-

mum of 150° F (66° C). This system provides proper compressor warm-up and helps prevent moisture contamination of oil.

To check element, heat in oil - it should be fully extended at 150° F (66° C). If unit shuts down due to high air discharge temperature, it may be that one or both thermostatic mixing valve elements (FIGURE 5-1, page 43) are stuck open. Remove mixing valve and clean all parts thoroughly when flushing the oil system.

~DANGER

Compressor, air/oil reservoir, separa-

tion chamber and all piping and tub-

ing may be a high temperature during and after operation.

COMPRESSOR OIL COOLER - WATER-COOLED HEAT EXCHANGER (FIGURE 5-1, page 43) - The heat exchanger oil cooler is a multiple pass type, with water in the tubes and oil in the shell. The oil temperature is controlled by the thermal (thermostatic mixing) valve. The optional water control valve may be used to conserve water.

Oil cooler malfunction may be traced by checking pressure at oil inlet and outlet. At normal operating air service pressure (65 to 150 psig, 4,5 to 10.3 Bars) with the unit warm, a pressure drop of 3 to 15 psi (.2 to 1 Bar) can be expected between the oil inlet and the oil outlet.

Water pressure drop from water inlet to outlet will vary with the inlet pressure and amount of water flowing. A normal pressure drop may range from 5 to 10 psi (.3 to

.7 Bar). Any change in the pressure drop from that normally held may indicate tube leakage or fouling and should be investigated.

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. It is strongly recommended that a reputable, local water treatment concern be engaged to establish the corrosion, scale forming and fouling tendency of the cooling water and take steps necessary to remedy the situation if a problem does exist. The need for water treatment may involve only filtration (screening) to remove debris, sand and/or salt in the cooling water supply. However, chemical treatment methods may be necessary in cer-

tain instances to inhibit corrosion and/or remove dis-

solved solids, to alter the water’s tendency to form scale deposits, or prevent the growth of microorganisms, The normal maintenance program for the unit should also include periodic cleaning of the tubes (wa-

ter side) of the heat exchanger to remove deposits which enhance fouling and corrosion,

Hex head zinc anodes are used in the return bonnet (opposite endtothe water pipe connections) of heat ex-

changers to provide internal water system corrosion

protection. These anodes should be inspected periodi-

cally and replaced when the zinc has been reduced to about 1/2 inch (13mm) in length.

WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) (FIGURE 5-8, page 51) - 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

13-9/10-641 Page 50

CAPILLARY TUBE

A74099A

ADJUSTING

SCREW

SETTING SCALE -

VALVE BODY= I j

HEAT SENSING BULB

FIGURE 5-8- WATER CONTROL VALVE

❑!

To decrease water flow (increase compressor discharge air temperature) turn the adjusting screw from

left to right, increasing spring tension. To increase water flow (decrease compressor discharge air temperature) turn the adjusting screw in the opposite direction. The groove at the lower edge of the adjusting screw is an index line for use with the index scale Oto 8 inobtain-

[

ing a desired setting. These valves must be handled with care and proper

tools and techniques must be used Men wor~ng. on the valve.

Care must be used when handling the capillary tube; a kink or break in the tubing or connections will make the

valve inoperative. Never attempt to change capillary

length. Excess capillary tube should be carefully coiled

and placed so that damage will not occur in normal maintenance or traffic past the unit.

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 W-IIprolong packing life.

after the oil cooler (FIGURE 5-1, page 43). Use the

compressor discharge air temperature gauge on the

instrument panel in setting the flow control valve. The compressor discharge temperature must be maintained a minimum of 10° F (5° C) above the dew point temperature at the maximum anticipated ambient; referto FIGURE 5-9 for the dew point temperature at the operating pressure and ambient temperature of the application.

If valve malfunctions, check for bent or binding, paint or corrosion on valve stem, foreign material in valve, erosion, orthermal system (capillary) failure. If foreign material or scale is likely, the use of a strainer inthe inlet water line is recommended.

WATER SHUTOFF VALVE - WATER-COOLED

HEAT

(FIGURE 5-1, page 43) - A magnetic solenoid-operated water shutoff valve rated at 150 psig (10.3 Bars) water pressure should be mounted in the water outlet

EXCHANGER (Optional

Equipment)

MBIENT TEMP. - ‘C

m 10.3 - + 6.3 EAR

FIGURE 5-9- DEW POINT TEMPERATURE VS. AMBlENT TEMPERATURE

(100% RELATIVE HUMIDITY)

13-9/10-841 Page 51

MBIENT TEMP. - “F

0 150 ?81G

+ 100 =lG

OIL SEPARATOR

PLATE

COVER

separator housing to the compressor cylinder is not clogged or pinched off, the check valve in the oil return line is functioning properly, and there is not water or an oil/water emulsion in the oil.

OIL SEPARATOR—

HOMING

FIGURE 5-10- OIL SEPARATOR

line after the oil cooler. The valve should be wired into

the compressor control circuit so that the

valve opens to allow water to flow any time the compressor is running. When compressor stops under automatic control, or isshut off manually, the valve should close, stopping water flow through the system. See Wiring Diagrams in Section 4, pages 39 through 41.

Oil carryover malfunctions of the oil separator are usually due to using elements too long, heavy dirt or varnish deposits caused by inadequate air filter service, use of improper oil or using oil too long for existing

conditions. A ruptured or collapsed separator element

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 predicted; it will vary greatly depending on the conditions of operation, the quality of the oil used and the maintenance of the oil and air filters. The condition of the separator can be determined by pressure differential gauging or by inspection.

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 advisorv will illuminate steadily when the pressure

differential reaches 15 PSID (1 Bar).

OIL RESERVOIR - The oil reservoir-separator combines multiple functions into one vessel. The lower half isthe oil reservoir, providing oil storage capacity for the system and the top portion, a primary oil separation means. The reservoir also provides limited air storage

for control and gauge actuation.

COMPRESSOR (GD ELIMINATOR) OIL SEPARATOR located in a separate housing, consists of a renewable cartridge-type separator element and pro-

vides the final removal of oil from the air stream

(FIGURE 5-10).

impinging on the inside of the separator element

Oil

drains directly back into the oil reservoir by gravity, Oil collected outside the element is returned through tubing to the compressor cylinder.

Oil carryover through the service lines may be caused by a faulty oil separator, faulty minimum pressure

valve, over-filling ofthe oil reservoir, oilthat foams, oil

return line malfunction or water condensate in the oil, If oil carryover occurs, inspect the separator only after it is determined that the oil level is not too high, the oil is not foaming excessively, the oil return line from the

~CAUTiON

Using an oil separator element at excessive pressure differential can cause damage to equipment. Replace the separator when the “Change Separator” advisory appears.

NOTICE

A sudden drop of zero pressure differential or sudden heavy oil carryover may indicate a ruptured element.

Inspection - After removal of separator element, shine alight inside the element to reveal areas of heavy dirt or varnish deposits or breaks (ruptures) in the element media.

13-9/10-841 Page 52

Removal Of Oil Separator For Inspection Or Replacement:

condition. Compressor should beat operating temperature at the time of checks. One-half hour of loaded op-

eration is usually sufficient to reach level-out operating

temperatures.

~DANGER

Air/oil under pressure will cause severe personal injury or death. Shut

down compressor, relieve system of all pressure, disconnect, tag and lockout power supply to the starter before removing valves, caps, plugs,

fittings, bolts, and filters.

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 pIate to the separator housing. Liftthe top plate from the separator housing.

Lift the separator from the separator housing.

Inspect and/or replace the separator as neces-

sary. Be sure the o-ring is not damaged. Before

installing (or reinstalling) any separator apply grease to the o-ring. Oil will be wiped off by the chamfer and the o-ring could be damaged.

Remove any gasket material adhering to top plate or separator housing, and install new gasket.

Air and Oil Discharge Temperature -165° to 195°

F (74° to 910 C) - Read at gauge on the instrument panel or check with a thermometer at the discharge housing.

Compressor Oil Inlet Temperature -150° to 160° F (66° to710 C) - Install a tee at the oil filter outlet and check with a thermometer.

Oil Inlet Pressure - Check at the fitting in the line near the compressor oil inlet. With air receiver pressure at

100 psi (6.9 Bar), oil inlet pressure should be 55-60

psig(3.8-4.l Bar). Oil Cooler Oil Pressure Differential (Air-Cooled

Radiator) - Check differential across oil system by measuring oil inlet pressure as described above.

Oil Cooler Oil Pressure Differential (Water-Cooled Heat Exchanger) -2 to 25 PSID (,1 to 1.7 Bar) (65 to

150 PSIG, 4.5 to 10.3 Bars Receiver Pressure) Check that oil inlet pressure is corrector measure the differential between drains on the oil cooler shell.

Oil Cooler Temperature Differential (Air-Cooled

Radiator) - The oil temperature differential depends on the temperature of the air at the oil cooler fan and cleanliness of core faces, As ambient temperatures and core restrictions increase, the oilcooler outlet tem-

perature will increase. The oil inlet temperature is approximately the same as air discharge temperature

- see the gauge on the instrument panel. The outlet oil

temperature may be checked by installing a tee at the

oil filter outlet.

Lower the separator into the housing and center

the separator on the chamfer. Press separator

down into the housing. Do not use excessive force as separator damage can occur.

Place the spacer on the indent in the separator. Seat the top plate to the separator, spacer and separator housing. screws.

Run the unit and check for leaks.

COMPRESSOR OIL SYSTEM CHECK - The following readings are based on ambient temperature of 80°

F (27° C) for air-cooled oil cooler and 80° F inlet water

on water–cooled oil cooler, with the system in good

Install and tighten all cap

13-9/10-641 Page 53

Oil Cooler Temperature Differential (Water-Cooled

Heat Exchanger) - The oiltemperature differential de-

pends 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. The oil outlet temperature may be

checked by installing a tee at the oil filter outlet.

Oil Cooler Water Pressure Differential (Water-

Cooled Heat Exchanger) - The water pressure differ-

ential 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 cus-

tomer.

SECTION 6

AIR FILTER

AIR OUTLET +

AIR INTLET

Wash the element by soaking about 15 minutes in warm water with a mild nonsudsing detergent.

Rinse the element thoroughly with clean water; a hose may be used if the water pressure does not exceed 40 psig (2.8 Bars).

4. Inspect the element for ruptures or cracks in the pleated media; replace the element if any are found. Inspect the gasket on the bottom (outlet end) of the element; replace the entire element if the gasket is damaged. A spare element will keep down time to a minimum.

AUTOMATIC UNLOAOER

FIGURE 6-1 - HEAW DUTY AIR FILTER (STANDARD)

HEAVY-DUTY AIR FILTER (FIGURE 6-1) furnished

as standard equipment on units with an enclosure is a

heavy-duty washable element dry type air filter. The air filter must receive proper maintenance ifmaximum service is to be obtained from the unit. Establishing adequate and timely filter service is MOST IMPORTANT. An improperly maintained air filter can cause a loss of compressor air delivery.

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 con-

ditions.

NOTICE

Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor.

5. Allow the element to air dry COMPLETELY. Do not expose the element to heat over 1500 F (66° C).

Install the element in the filter body and fasten se-

curely with the wing nut.

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. Store elements in a

protected area free from damage, dirt

and moisture. Handle all parts with care.

To service:

1. Remove the wingnut and pull out the filter element,

2. Visually inspect the element. If cleaning is not necessary, reinstall the filter element. If the element requires cleaning, follow steps 3, 4 and 5.

13-9/10-641 Page 54

Filter Element Life - The element should be replaced

after six (6) cleanings or if:

1. Visual inspection 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 element is below three (3) inches (76

mm) of water with the compressor running at full Ioad - this would indicate a rupture or crack.

Inlet Tube - Inspect the inlet screen and tube for dirt accumulation each time the filter is serviced. Clean the

tube when required by ramming a clean dry cloth through the tube. Wipe the inside of the filter body to

remove any dirt falling from the inlet tube before reinstalling the element.

Causes of short element life include: severe dust conditions, infrequent servicing, improper cleaning, or contamination by oil or chemical fumes.

13-9/10-641 Page 55

SECTION 7 COUPLING

RADIUS EDGE

UP TOWARO OUTSIDE

DIAMETER OF COUPLING

~co”” ‘CR’”

-1

23 FT-LBS

(17 N-M)

SET SCREUS

50 FT-LBS

(37 N-M)

DOWN TOWARD SHAFT

FIGURE 7-1 - INSTALLATION OF COUPLING CUSHIONS

~DANGER

Rotating

machinery personal injury or death. Turn the unit completely off, open the main disconnect, tag and lockout before servicing the coupling.

COUPLING - The motor and compressor are direct connected by a resilient type flexible coupling with several individual cushions. The coupling does not require lubrication.

Ifmaintenance on mating parts is requires, reassemble

coupling as follows:

Individual Cushion Design (FIGURE 7-1)

can cause

3.4.Working through the coupling guard opening, center the coupling over the gap between the shafts, maintaining the gap as shown in FIGURE 7-1 between the ends of the jaws on one coupling body and the flange on the opposite coupling body. Tighten set screws in each coupling body.

Insert individual cushions as shown in FIGURE 7-1 and slide the collar over the cushions and secure with cap screws. Reinstall the cover plate.

1/16 MIN 1/8 MAX (1,6 mm to 3.2 mm)

/~\ DANGER

Rotating machinery can cause person-

al injury or death. Do not operate unit with either the coupling guard or the collar removed. All bolts and screws

must be properly tightened.

1. Slide coupling halves over shaft extensions. Be sure the collar is installed on the shaft behind one coupling body,

Assemble the motor to the compressor.

13-9/10-641

Alignment - The coupling is permanently

the flanges on the compressor and motor.

Page 56

aligned by

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, page 54.

Oil Separator - Operating conditions determine frequency of service. If the “CHANGE SEPARATOR” message is displayed, the oil separator element requires changing. See “Compressor Oil Separator” in

Section 5, page 52, for further details. Motor Lubrication - Refer to Section 2, page 14, and

Maintenance Schedule Chart below. Every 8 Hours Operation

1. Check the reservoir oil level - add oil if required. See Section 5, page 57. Ifoil consumption is high, refer to “Excessive Oil consumption, page 59. DO NOT MIX LUBRICANTS.

2. Observe if the unit loads and unloads properly.

3. Check discharge pressure and temperature.

4. Check Panel LEDs for advisories.

Every 125 Hours Operation

Check for dirt accumulation on oil/aftercooler core

1. 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 opposite that of the cooling fan air flow, This cleaning operation will

keep the exterior cooling surfaces clean and en-

sure effective heat dissipation.

Every 1000 Hours Operation

Change the oil filter element.

1. Every 8000 Hours Operation

Change the compressor lubricant. UNDER AD-

VERSE CONDITIONS, CHANGE MORE FRE-

QUENTLY (refer to “Oil Change Interval”, page

47). Flush system if required.

Every Year

Check the relief valve for proper operation. See

1. Section 4, page 27. “

MAINTENANCE SCHEDULE (See detail notes above)

Maintenance Action

Change Air Filter Change Oil Separator

Check Reservoir Oil Level Check For Proper Load/Unload Check Discharge Pressure/Temp Check Dirt Accumulation on Cooler

Change Oil Filter Element Change Compressor Lubricant

(AEON 9000 SP)

Check Relief Valve

See Oil Change Interval Chart, FIGURE 5-5, Page 47, for specific lubricant life.

Indicated

By Auto-

Sentry-ES

●

Every

Hours

●

Every

125

Hours

●

Every

1000

Hours

Every 8000*

Hours

●

Every

Year

●

13-9/10-841 Page 57

SECTION 9

TROUBLE SHOOTING

SYMPTOM

Compressor fails to start. 1.

Compressor starts but

stops after a short time.

POSSIBLE CAUSE

Wrong lead connections.

Blown fuses in control

2. box.

Motor starter overload

heaters tripped.

Pressure in reservoir.

Read error message on

5. control panel.

Remote Contact is open (terminals 6 & 9).

High discharge temperature.

REMEDY

Change leads.

1. Replace fuse,

Reset and investigate

3. cause of overload.

Inspect blowdown valve.

4. and muffler.

Take appropriate action.

5. See Section 4.

Replace switch or jumper.

See “High Discharge

1. Air Temperature,” this section, page 59.

Compressor does not unload (or load).

Compressor cycles from load to unload excessively.

High discharge

2. temperature switch

malfunction.

Blown fuse in starter/

control box.

Motor starter overload heaters trip.

Improperly adjusted

1. control.

Air leak in control lines.

Restricted control line.

Blowdown valve malfunction.

Insufficient receiver capacity.

Restriction in control tubing.

Replace switch.

Replace fuse (investigate if fuses

continue to blow).

Reset and investigate

4. cause of overload.

Refer to Section 4

and adjust control.

Determine source of leak and correct.

Clean control lines.

Repair, clean or replace

valve.

Increase receiver size.

Inspect and clean control

tubing.

13-9/10-841 Page 58

SYMPTOM

Compressor is low on

delivery and pressure.

High discharge air

temperature.

POSSIBLE CAUSE

Restricted air filter.

Sticking inlet valve.

Unload pressure adjusted

too low,

Minimum pressure valve

4. stuck closed.

Thermostatic mixing valve stuck

Dirty

Insufficient cooling air flow.

Clogged oil filter or

cooler (interior).

Low compressor oil.

open.

or clogged cooler face.

REMEDY

Clean or replace filter.

Inspect and clean inlet

2. valve.

Adjust the unload pressure.

See Section 4, page 18. Disassemble and clean

4. valve.

Repair or replace valve.

Clean cooler.

2. Provide unrestricted supply

of cooling air.

Replace filter or clean

cooler. Add oil to proper level.

See “Oil Carryover”, below.

Excessive Oil Consumption

Oil Carry-Over

Oil carryover through lines.

Oil leaks at all fittings

and gaskets.

Overfilling the reservoir.

1. Tighten or replace fittings

or gasket.

Drain excess oil from

1. system.

~DANGER

Air/oil under pressure will cause severe personal injury or death. Shutdown com-

pressor, relieve system of all pressure, disconnect, tag and lockout power supply

to the starter before removing valves, caps, plugs, fittings, bolts, and filters.

Clogged, broken or loose

2. oil return lines

Ruptured oil separator

3. element.

Loose assembly.

Foam caused by use of 5.

incorrect oil.

Inoperative minimum 6,

pressure valve.

Tighten or replace faulty

lines.

Replace element.

Tighten all fittings and

gaskets. Use Gardner Denver@

AEON m 9000 SP Lubricating Coolant.

Clean out or replace valve.

13-9/10-641 Page 59

SYMPTOM

Oil Carry-Over (Continued)

POSSIBLE CAUSE REMEDY

7, Operation atelevated

discharge temperatures.

8. Scavenge line check valve failure.

9. Water condensate in oil.

Reduce temperature. See

High Discharge Air Temperature, page 59, this section.

Replace check valve.

Check oil reservoir temperature and if low, change”

thermal mixing valve element to higher temperature.

NOTICE

Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary

screw compressor units.

13-9/10-641 Page 60

SECTION 10

TROUBLE SHOOTING CONTROLS

AUTO SENTRY ES CONTROLLER

DISPLAY MODES

The normal display indicates the package service pressure, the airend discharge, the total running hours, and one of the following operating modes, The green lightwill be on for any operating mode, whether the compressor is run-

ning or not.

READY

The compressor has been stopped by pressing the [STOP/RESET] key. CON LDM AUTO SEQ n

The following alternate displays may be called by pressing a cursor [<] or [>] key

SYS PRES

RES PRES DIF PRES

TOT HRS

DIS TMP RES TMP BD TMR

AUTO TMR

The compressor is operating in the Constant Run mode.

The compressor is operating in the Low Demand mode.

The compressor is operating in the Automatic mode.

The compressor is operating in the sequence mode.

The pressure at the service connection

The pressure in the oil reservoir

The pressure drop across the air/oil separator

The total hour of compressor running

The temperature at the airend discharge

The temperature in the reservoir/ separator The time remaining before a blowdown will be allowed

(Low Demand, Auto, Sequence Modes) The time remaining of unloaded motor operation

(Auto, Sequence Modes)

ADVISORY TROUBLESHOOTING GUIDE

All advisories are indicated on the keypad by a yellow indicator in the Status area, and one of the following messages alternating with the normal lower line display. Perform service or maintenance as indicated, then clear the advisory as instructed in Section 4.

Message

CHNG AIR FILTER

CHNG SEPARATOR

CHNG OIL FILTER

CHANGE OIL

Action Needed

Excessive vacuum has been detected after the air filter, indicating it has become full. Change the air filter to ensure maximum air delivery.

The differential pressure across the air/oil separator has risen to over 8

psid. Change the separator to ensure maximum performance. The unit has been operated for the programmed number of hours since

the last filter replacement, Change the filter to ensure an adequate flow of lubricant.

The unit has been operated for the programmed number of hours since the last oil change. If high operating temperatures are encountered, the “AUTO SENTRY-ES controller will automatically adjust the time interval for the change oil advisory. Change the oil to ensure lubricant quality.

13-9/10-641 Page 61

ADVISORY TROUBLESHOOTING GUIDE (Continued)

Message

HIGH TEMP OPER

LOW AMB TEMP

SHUTDOWN TROUBLESHOOTING GUIDE

All shutdowns are indicated on the keypad by the word “SHUTDOWN on the top line of the display, and one of the following messages on the lower line of the display. The red indicator in the Status area will be steadily lit while the conditions exist, and will flash after the condition has been corrected. Perform service as indicated. Press the

[STOP/RESET] key to clear the shutdown.

Message

CHANGE SEPARATOR

CHECK CN7

Action Needed

The temperature was greater than 210° F (99° C) at the airend discharge or the separator. Ensure that the compressor receives adequate cooling air or water, and that the coolers are not plugged.

The temperature was less than 40° F (4° C) at the airend discharge or the separator, Ensure that the compressor is located in a room kept above freezing.

Action Needed

The differential pressure across the air /oil separator has risen to over 15 psid. Change the separator to ensure maximum compressor performance.

All inputs at connector 7 of the controller are off. The most common cause for this isthat the connector plug has been pulled out. Plug the connector back in firmly.

CHECK CN8

EMERGENCY STOP

FAN OVERLOAD

FAN START ERROR

(while stopped)

FAN START ERROR

(while running)

120 volts has been removed from ALL inputs to connector 8 of the controller. The most common cause for this is that the connector plug has been pulled out, Plug the connector back in firmly.

The Emergency Stop button has been pressed. Pull it back out to its normal position. If the button has not been pressed, check that the contact block is firmly mounted in the right or left (not center) position of the operator. Check for loose connections which would remove 120 volts from connector 8-8 of the controller.

The motor overload relay for the fan motor, located within the electrical control box, has tripped. This indicates high motor shaft load, low voltage, or excessive imbalance in the incoming power (such as a blown fuse).

Disconnect and lock out power, open the box, and press the reset button

- itwill click when reset. Measure motor amps, and take corrective actions to get all currents within the motor nameplate rating. If overload relay has not tripped, check for the cause that 120 volts was removed from connector 8-1 of the controller.

The controller has attempted to turnoff the fan, but isstillreceiving a return signal from the starter’s auxiliary contact. Check that the starter operates freely and that the contact block is properly installed on the starter.

The controller has attempted to start the fan, but did not receive a return signal from the starter’s auxiliary contact. If the starter does not pick up when attempting to start, check that connector 9 of the controller is plugged infirmly, and check the starter coil. If the starter does pick up, but this message appears, check that the auxiliary contact block is properly installed on the starter and wired to connector 8, terminal 3.

13-9/10-641 Page 62

SHUTDOWN TROUBLESHOOTING GUIDE (Continued)

Message

HIGH DISCH TEMP

HIGH RESVR PRESS

HIGH RESRVR TEMP

HIGH SYSTEM PRESS

Action Needed

This indicates that the controller has detected temperature in excess of the programmed high temperature limit,or a high temperature rate of rise, at the airend discharge. The most common cause for this is inadequate package cooling. Ensure proper air flow for aircooled units, or adequate water for water cooled units. Monitor temperature carefully during restarts after servicing.

Pressure in excess of the programmed high pressure limit has been de-

tected. This shutdown will

Check

the inlet valve, all control piping, solenoid valves, and all other con-

occur if a loss of pneumatic controls occurs.

trol devices to find the cause for the inlet valve not closing. Other possible causes are loose connections to the transducer, electrical noise and transients, or improper setting of the high pressure limit.

This indicates that the controller has detected temperature in excess of the programmed high temperature limit, or a high temperature rate of rise, at the air/oil separator. The most common cause for this is inadequate package ventilation. Monitor the temperature carefully during restarts after servicing.

Pressure in excess of the programmed high pressure limit has been detected. The most likely cause is other, higher pressure compressors on the same air system; separate these from this compressor unit. Other possible causes are loose connections to the transducer, electrical noise and transients, or improper setting of the high pressure limit.

HIGH VIBRATION

LOW OIL PRESS

MAIN OVERLOAD

MAIN START ERROR (while stopped)

MAIN START ERROR (while running)

120 volts has been removed from terminal 7 of the terminal strip. This is normally shipped jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch,

The controller has attempted to start and load the compressor, but pressure is not building up in the oil reservoir. This may indicate either a failure of the motor to turn the compressor, or a failure of the inlet valve to open.

If the latter, check also the wiring and piping to solenoid valves IVO and IVC; these are both turned on to load up the compressor.

The motor overload relay for the main compressor drive motor, located within the electrical control box, has tripped. This indicates high motor shaft load, low voltage, or excessive imbalance in the incoming power (such as a blown fuse). Disconnect and lockout power, open the box, and press the reset button - itwill click when reset. Measure motor amps, and take corrective actions to get all currents within the motor nameplate rating. If overload relay has not tripped, check for the cause that 120 volts was removed from connector 8-2 of the controller.

The controller has attempted to turn off the compressor, but is still receiving a return signal from the starter’s auxiliary contact. Check that the starter operates freely and that the contact block is properly installed on the starter.

The controller has attempted to start the compressor, but did not receive a return signal from the starter’s auxiliary contact, If the starter does not pick up when attempting to start, check that connector 9 of the controller is plugged in firmly, and check the starter coil. If the starter does pick up, but the message appears, check that the auxiliary contact block is properly installed on the starter and wired to connector 8, terminal 4.

13-9/10-641 Page 63

SHUTDOWN TROUBLESHOOTING GUIDE (Continued)

Message

OPEN THERM

OPEN XDUCER

POWER FAiLURE

SHORTED THERM

SHORTED XDUCER

Action Needed

The controller has detected an open connection to thermistor: (A) airend

discharge, or (B) separator. This normaiiy indicates a ioose or broken con-

nection at the controller connector 7; check and correct the connection. This couid also be indicating a broken wire or thermistor probe. This may also occur from excessively iow temperature.

Signai voltage has faiien too iow at transducer: (A) Finai discharge, or (B)

Reservoir. This error is frequently the resuit of the transducers being improperly zeroed. Disconnect the air lines to the transducers and foiiowthe procedure indicated inthe adjustment instructions, This may also indicate a ioose connection of the red wire to the transducer or a defective transducer. Check connections, or repiace transducer if necessary.

The power to the compressor unit has been turned off and back on. Press

[STOP/RESET] and select an operating mode. The controller has detected a shorted connection to thermistor: (A) airend

discharge or (B) separator. This normaiiy indicates a fauity connection

(e.g. wire strands touching) at the controller connector 7; check and correct the connection. This could also be indicating a damaged wire or thermistor probe.

Signai voltage has exceeded approximately 4.6 volts at transducer: (A)

Finai discharge or (B) Reservoir. This may indicate a loose connection of

the black wire to the transducer or a defective transducer. Check

tions, or replace transducer

if necessary.

connec-

CONTROLS TROUBLESHOOTiNG GUiDE

The following are recommended service actions. Observe aii instructions noted elsewhere inthis manual. Aii electrical service is to be performed oniy by a quaiified electrician.

Symptom Recommended Action

No display,

Check incoming

power to the compressor unit. Ensure that the disconnect

compressor stopped. is on and that fuses have not blown (or circuit breaker tripped). if power

is being properiy suppiied to the control box, check the fuses iocated at the fan starter, the controi transformer fuses, and the fuse located on the

ES controller chassis near connector CN-6.

Compressor wiil not start.

To operate, the controller must be piaced into an operating mode (e.g. “AUTO); press the [STOP/RESET] to put the control in the READY state, then seiect a mode with the operating mode keys. In AUTOMATIC and SEQUENCE modes, compressors wiii not start until the pressure drops below the reset pressures.

Display indicates “NOT BLOWN DOWN”

The controller prevents attempts to start the main motor if the reservoir pressure is over 5 psig (.35 Bar). Pressure continues to be reiieved from the reservoir while this message is on, and the compressor wili start automatically after the pressure has dropped. if this message remains with NO pressure in the reservoir, foiiow the transducer zeroing procedure found in the controis adjustment section.

13-9/10-641 Page 64

CONTROLS TROUBLESHOOTING GUIDE

Symptom

Display indicates “REMOTE STOP

Display indicates “SHUTDOWN”

Compressor runs, but

does not load

Compressor runs,

unloads at low pressure

Compressor does not

modulate

Compressor cycles rapidly

between load and unload

Display is illegible

Erratic pressures in SEQUENCE only

Compressor cycles rapidly in SEQUENCE mode only

LOW OIL PRESSURE

in SEQUENCE mode only

Pressure display error

Recommended Action

The controller is provided with an input for user-furnished remote controls. This display indicates that 120 volt is removed from terminal 6 of the terminal strip. Check all connections of the factory installed jumper, or the customer-provided controls, if applicable.

If the display indicates “SHUTDOWN”, refer to the shutdown troubleshooting section for assistance. In addition to the messages shown, there are several internal and system diagnostics performed by the controller. Consult the factory for additional assistance.

In the CONSTANT RUN and LOW DEMAND modes, the compressor will not load untilthe pressure drops below reset pressure. Refer to the operating instructions for further information, If pressure is below the reset pressure, check that the inlet valve operates freely. Check that the IVO and IVC valves are wired and operating properly.

If the inlet valve closes at low pressure, check the wiring to the blowdown valve and the piping and check valves in its discharge line.

The ES controller operates the inlet valve to maintain pressure near the set pressure, matching delivery to demand. If the pressure continues to rise above set pressure, check that the inlet valve operates freely, and that control air is supplied to the IVC valve. If modulation does not close the valve, itwill be closed during a blowdown as pressure approaches the high pressure limit.

The external air receiver should be sized appropriately to prevent rapid cycles. The rapid response time in CONSTANT RUN mode will operate with small receivers, but any plant air system will operate more efficiently with adequately sized storage. Refer to the operating instructions for further information.

Extra segments or “ghosting” of characters indicates damage probably from excessive high voltage. Replace the controller, and install protection to prevent further damage to electrical equipment,

The sequencing system transmits low-level signal between units to communicate pressures. Units must be properly grounded to a good ground system, the communications cable should use only appropriate quality cable, and the cable should be run in its own conduit.

In the sequence mode, the operating system requires all compressors be piped directly to receiver, such that all transducers sense the same pressure. Check valves or restrictions between compressors and the storage will cause system instability. Run units inAUTOMATIC mode until the system is corrected.

If this shutdown occurs in the sequence mode only, it indicates instability due to rapid changes in pressure of the system. Remove restrictions between the compressor and receiver, increase receiver size if necessary to slow down the pressure,swings.

Accuracy of the pressure display and controls requires that the controller and transducers be calibrated together. This MUST be done with no pressure at the transducer, or errors will all pressure removed. All pressure displays should indicate O psi (0.0 Bar)

+/- 1 PSI. If the display indicates greater pressures, recalibrate the system as instructed in the configuration adjustments. Note: reservoir pressure may drop below zero psig when the compressor is stopped, but will

return slowty to zero as the vacuum is relieved.

occur. This is easiest to check with

13-9/10-641 Page 65

WARRANTY

ROTARY SCREW COMPRESSORS

OIL INJECTED - OIL FREE

GENERAL PROVISIONS AND LIMITATIONS

Gardner Denver Machinery Inc. (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.

Any product which has, in the Company’s judgment,

been subject to negligence, accident, improper

storage, or improper installation or application.

Any product which has not been operated or

maintained in accordance with the recommendations

of the Company.

Components or accessories manufactured, warranted and serviced by others.

Any reconditioned or prior owned product.

Claims for items described in (4) above should be submitted directly to the manufacturer.

WARRANTY PERIOD

The Company’s obligation under this warranty is limited to repairing or, at its option, replacing, during normal business hours at an authorized service facility of the Company, any part which in its judgment proved not to be as warranted within the applicable Warranty Period as follows.

COMPRESSOR AIR ENDS

Compressor air ends, consisting of all parts within and including the compressor cylinder and gear housing, are warranted for 24 months from date of initial use or27 months

from date of shipment to the first purchaser, whichever

occurs first.

Any disassembly or partial disassembly of the air end, or failure to return the “unopened” air end per Company instructions, will be cause for denial of warranty.

OTHER COMPONENTS All other components are warranted for 12 months from

date of initial use or 15 months from date of shipment to first purchaser, whichever occurs first.

LABORTRANSPORTATIONANDINSPECTION

The Company will provide labor, by Company representative

or authorized service personnel,

of any product or part thereof which in the Company’s

judgment is proved not to be as warranted. Labor shall

be limited to the amount specified in the Company’s labor rate schedule.

for repair or replacement

Labor costs in excess of the Company rate schedules caused by, but not limited to, location or inaccessibility of the equipment, or labor provided by unauthorized service personnel is not provided by this warranty.

All costs of transportation of product or parts claimed not to be as warranted and, of repaired or replacement parts

to or from such service facility shall be borne by the

Purchaser. The Company may require the return of any part claimed not to be as warranted to one of its facilities as designated by Company, transportation prepaid by Purchaser, to establish a claim under this warranty.

Replacement parts provided under the terms of this warranty

are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such parts were original components.

WARRANTY REGISTRATION VALIDATION

A warranty registration form is provided with each machine. The form must be completed by the Purchaser and mailed within ten days after machine start-up to validate the warranty.

DISCLAIMER

THE FOREGOING WARRANTY IS EXCLUSIVE AND IT

IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE COMPANY MAKES NO OTHER WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY.

THE REMEDY PROVIDED UNDER THIS WARRANTY

SHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDY

AVAILABLE TO THE PURCHASER AND IN NO CASE

SHALL THE COMPANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES. UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES OR

DELAYS HOWSOEVER CAUSED.

No statement, representation, agreement or understanding, oral or written, made by any agent, distributor, representative, or employee of the Company which is not

contained inthis Warranty willbe binding upon the Company

unless made in writing and executed by an officer of the Company.

This warranty shall not be effective as to any claim which

is not presented within 30 days after the date upon which the product is claimed not to have been as warranted. Any action for breach ofthis warranty must be commenced within one year after the date upon which the cause of action occurred.

Any adjustment made pursuant to this warranty shall not be construed as an admission by the Company that any product was not as warranted.

AU-20 R 1/94

Gardner Denver EBHQHA, EBHQHB, EBHQJB, EBHQJA, EBMQKC Operating And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual