Price $5.00 GARDNER-DENVER@ 13-9/1 0-641 4th Edition ELECTRA-SAVER@ ELECTRA-SAVER ll@ STATIONARY BASE-MOUNTED COMPRESSOR MODELS 40 THRU 100 HP EA_ & EB_ OPERATING AND SERVICE MANUAL COOPER Gardner-Denver Industrial Machinery
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Price $5.00
GARDNER-DENVER@13-9/1 0-6414th Edition
ELECTRA-SAVER@
ELECTRA-SAVER ll@
STATIONARY BASE-MOUNTED
COMPRESSOR
MODELS
40 THRU 100 HP
EA_ & EB_
OPERATING ANDSERVICE MANUAL
COOPERGardner-DenverIndustrial Machinery
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITHGENUINE GARDNER-DENVER AND JOY COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner-Denver and Joy Compressor genuine parts,engineered to original tolerances, are designed for opti-mum dependability --- specifically for Gardner-Denverand Joy compressor systems. Design and material inno-vations are the result of years of experience with hun-dreds of different compressor applications. Reliability inmaterials and quality assurance are incorporated in ourgenuine replacement parts.
Your authorized Gardner-Denver and Joy Compres-sor distributor offers all the backup you’ll need. Aworldwide network of authorized distributors providesthe finest product support in the air compressor industry.
Your local authorized distributor maintains a large inven-tory of genuine parts and he is backed up for emergencyparts by direct access to the Gardner-Denver IndustrialMachinery Master Distribution Center (MDC) in Mem-phis, Tennessee.
Your authorized distributor can support your Gardner-Denver or Joy air compressor with these services:
1.
2.
3.
4.
Trained parts specialists to assist you in selectingthe correct replacement parts.
Factory warranted new and remanufactured rotaryscrew air ends. Most popular model remanufac-tured air ends are maintained in stock at MDC forpurchase on an exchange basic with liberal corecredit available for the replacement unit.
A full line of factory tested AEON ‘“ compressorlubricants specifically formulated for use in Gard-ner-Denver and Joy compressors.
Repair and maintenance kits designed with the nec-essary parts to simplify servicing your compressor.
Authorized distributor service technicians are fac-tory-trained and skilled in compressor maintenanceand repair. They are ready to respond and assist youby providing fast, expert maintenance and repairservices.
For the location of your local authorized Gardner-Denver and Joy Air Compressor distributor refer to the yellowpages of your phone directory or contact:
Distribution Center: Factory:Gardner-Denver Gardner-DenverIndustrial Machinery Division Industrial Machinery DivisionMaster Distribution Center 1800 Gardner Expressway5585 East Shelby Drive Quincy, IL 62301Memphis, TN 38115 Phone: (217) 222-5400Phone: (901) 363-6100 Fax: (217) 223-5897Fax: (901) 393-1095
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, required per unit, quantity is indicated in parenthesis.
Method of Cooling, HORSEPOWER and SERIAL NUM- SPECIFY EXACTLY THE NUMBER OF PARTS RE-BER (see nameplate on unit). Serial Number is also QUIRED.stamped on top of the cylinder flange to the right of theinlet housing.
DO NOT ORDER BY SETS OR GROUPS.All orders for Parts should be placed with the nearestauthorized distributor.
To determine the Right Hand and Left Hand side of acompressor, stand at the motor end and look toward the
Where NOT specified, quantity of parts required per compressor. Right Hand and Left Hand are indicated incompressor or unit is one (1); where more than one is parenthesis following the part name, i.e. (RH) & (LH).
AIR ENDS
NOTE: Factory warranted new and rebuilt air ends are available from your authorized Gardner-Denver and JOYCompressor Distributor.
FOREWARD
Gardner-Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To beassured of receiving maximum service from this machine the owner must exercise care in its operation andmaintenance. This book iswritten to give the operator and maintenance department essential information for day-todayoperation, maintenance and adjustment. Careful adherence to these instructions will result in economical operationand minimum downtime.
DANGER
Danger is used to indicate the presence of a hazard which will cause severe personalinjury, death, or substantial propery damage if the warning is ignored.
I A WARNING II Warning is used to indicate the presence of a hazard which can cause severe personal
injury, death, or substantial propery damage if the warning is ignored. I
I ~cAuTION II Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or propery damage if the warning is ignored. I
I NOTICE INotice is used to notify people of installation, operation or maintenance informationwhich is important but not hazard-related.
This book covers the following models:
HP PSIG Air Cooled Water Cooled
40 HP 100, 125 EBHQHA EBHSHAEBHQHC EBHSHC
50 HP 100, 125, EBHQJA EBHSJA150 EBHQJC EBHSJC
60 HP 100, 125 EBMQKA EBMSKAEBMQKC EBMSKC
75 100, 125, EBMQLA EBMSLA150 EBMQLC EBMSLC
100 HP 100, 125,150
EBPQMAEBPQMCEAPQMD
Parts List
13-9-55513-9-550
13-9-55513-9-550
13-9-55713-9-551
13-9-55713-9-551
13-9-55613-9-54813-10-507
13-9/10-S41 Page i
TABLE OF CONTENTS
GENERAL INFORMATION .............................................................................................................................SECTlON 1
lNsTALMTloN ...............................................................................................................................................sEcTloN2
STARTING AND OPERATING PROCEDURES .............................................................................................. SECTlON 3
CONTROLS AND instruments ................................................................................................................. SECTlON 4
LUBRICATION, OIL COOLER, OIL FILTER AND SEPARATOR .................................................................... SECTlON 5
AIR FILTERS ...................................................................................................................................................SECTlON 6
COUPLING ......................................................................................................................................................SECTlON 7
MAINTENANCE SCHEDULE ..........................................................................................................................SECTlON 8
TROUBLE SHOOTING ...................................................................................................................................SECTlON 9
13-9/10-841 Page ii
INDEX
NOTE: Numbers preceding dash are Section Numbers - Numbers following dash are Page Numbers
Air Control Components ....................................4a-3. 4b-4Air Cooled Unit installation ............................................ 2-1Air Filter Element Life ....................................................6.lAir Filter Element - Service Instructions ........................ 6-1Air Filter Vacuum Switch ...................................4a-4. 4b-5AIR FILTERS (SECTION 6) ........................................... 6-1Air/Oil Flow Diagram ...............................................5.2. 5-3Air/Oil Flow Diagram - Remote Overhead
Cooler ....................................................................... 5-4Auto Sentry-ES, Controller Display ....................4a-5. 4b-6Auto Sentry-ES, operation .................................4a-5. 4b-5Auto Sentry-ES, Operation (Automatic
Male) .............................................................4a.5. 4b-6Auto Sentry-ES, Operation (Constant Run
Male) .............................................................4a.5. 4b-6Auto Sentry-ES, Operation (Low Demand
Male) .............................................................4a.5. 4b-6Auto Sentry-ES, Operation (Sequence Mode).. 4a-5, 4b-6Auto Sentry-ES, Programming And Set-Up
instruction ......................................................4a%. 4b-7Auxilia~Ar Receiver .....................................................2.3Basic information ........................................................... 1-1Blowdown Valve ................................................4a.4. 4b-4Blowdown Valve Piping ................................................2.4Cold Weather Operation ................................................2.2Control Schematics ................... 4a-9, 4a-10, 4b-10, 4b-11CONTROLS & INSTRUMENTS (SECTION 4) ....la-l. 4b-1COUPLING - DRIVE (SECTION 7) ............................... 7-1Decals .................................................................... 1-6, 1-7Discharge Service Line .................................................24Electrical Witing .............................................................2.5Enclosure ......................................................................2.2Filling Oil Reservoir .......................................................5.5Foundation ....................................................................2.2Gauges and Displays ..........................................4a.2. 4b-4GENERAL INFORMATION (SECTION 1) ..................... 1-1Grease Recommendations ..........................................2-6Grounding .....................................................................2.5High Temperature Operation .......................................5-1High Temperature Shutdown ............................4a-1. 4b-1Inlet Line .......................................................................2.3Inlet Valve Control ..............................................4a.3. 4b-4INSTALLATION (SECTION 2) ...................................... 2-1Lifting Unit .....................................................................2.lLocation ........................................................................2.lLubricant, Addition of Oil Between Changes ................ 5-5Lubricant, Changing Type of Oil ...................................5-5Lubricant, Draining and Cleaning System .................... 5-6Lubricant, Oil Specifications ........................................ 5-1Lubricant, Recommended ............................................. 5-1Lubricant Change lntewal .............................................5.6LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5) ......................................5-1
MAINTENANCE SCHEDULE (SECTION 8) .................8-1Minimum Pressure/Check Valve ........................ 4a-3, 4b-5Moisture inthe Oil System ........................................... 5-6Motor Lubrication ......................................................... 2-6Motor Protection Devices .................................4a-1. 4b-1Oil Cooler (Water Cld.) - Water Flow Control Valve ..... 5-8Oil Cooler (Water Cld.) - Water Shutoff Valve ..............5-9Oil Cooler- Radiator Type .......................................... 5-7Oil Cooler - Water Coold ............................................ 5-8Oil Filter ......................................................................... 5-7Oil Level Gauge ............................................................ 5-6Oil Reservoir ................................................................. 5-9Oil Reservoir Drain ...................................................... 2-2Oil Separator ................................................................. 5-9Oil Separator - Inspection .......................................... 5-1oOil Separator - Pressure Differential Gauging ...........5-10Oil Separator - Removal ............................................. 5-1oOil System Check ....................................................... 5-10Outline Drawings .................................................... 1-2, 1-3Piping, Aftercooler ......................................................... 5-4Piping, Heat Exchanger ................................................ 5-5Piping, Parallel ............................................................... 2-5Piping, Series ................................................................. 2-5Pressure Regulator ............................................4a-4. 4b-4Prestart-up Instructions ................................................ 3-1Protective Devices and Shutdown ....................4a-1. 4b-1Purge Air Valve ..................................................4a4. 4b-4Relief Valve .........................................................4a.l. 4b-2Remote Overhead Cooler ............................................ 5-1Reservoir Pressure Transducer ........................4a-4.4 b-5Safety Precautions ....................................................... 1-4Separator Differential Pressure Shutdown ....... 4a-1, 4b-2Sequencing, Automatic Change .................................. 3-4Sequencing, Installation ............................................... 3-2Sequencing, Operation ................................................ 3-3Sequencing, Other Features ........................................ 3-4Shuttle Valve ......................................................4a.4. 4b-4Solenoid Valves - IVC and IVO ........................... 4a-4, 4b-4Solenoid Valves -TVC and TVO ................................. 4b-4Starter/Control Panel ......................................... 4a-4, 4b-5STARTING & OPERATING PROCEDURES
(SECTION 3) ........................................................... 3-1Starting The Unit, Cold ................................................. 3-2Starting The Unit, Hot ................................................... 3-2Stopping Unit ................................................................ 3-2System Pressure Transducer ............................ 4a-4, 4b-5Thermostatic Mixing Valve ........................................... 5-7TROUBLE SHOOTING (SECTION 9) .......................... 9-1Turn Valve ....................................................................4b.4Turn Valve Actuator .....................................................4b4Water Cooled Unit Installation ..................................... 2-2Water Cooled Unit Piping ............................................. 2-5Wiring Diagrams .............................................4a.l2. 4b-13
13-9/10-641 Page iii
ILLUSTRATIONS
FIGURE # DESCRIPTION SECTION/PAGE #
1-1
1-21-31-41-51-6
2-12-22-32-42-52-6
4a-14a-24a-34a-44a-54a-64a-74a-84a-9
4b-14b-24b-34b-44b-54b-64b-74b-84b-94b-1 O
5-15-25-35-45-55-65-75-85-95-1o
6-1
7-1
Compression Cycle ........................................................................................................................Package - Starter Box .....................................................................................................................Package - Controller & Starters .....................................................................................................Package- Drive Motor &Air Filter..................................................................................................Package - Oil Filter, Oil Level Gauge, Mixing Valve, Minimum Pressure Valve & Check Valve...Package .Compressor &inlet Valve .............................................................................................
Typical Compressor Room .............................................................................................................Minimum Flow for Compression and Cooling ...............................................................................Cold Weather installation ...............................................................................................................Heat Exchanger and Aftercooler Flow Chafl .................................................................................Seties Piping ...................................................................................................................................Parallel Piping .................................................................................................................................
Schematic Tubing Diagram ............................................................................................................Blowdown Valve ..............................................................................................................................inlet Valve ........................................................................................................................................Minimum Discharge Pressure Valve ..............................................................................................ShuHle Valve ...................................................................................................................................Control Schematic - Compressor Unloaded - Constant Speed Mode .........................................Control Schematic -Compressor at Full Load ..............................................................................Control Schematic - Compressor Unloaded - Low Demand Mode ..............................................Wiring Diagram ...............................................................................................................................Auto Senty ES ................................................................................................................................
Schematic Tubing Diagram ............................................................................................................Blowdown Valve ..............................................................................................................................inlet Valve ........................................................................................................................................Shutile Valve ...................................................................................................................................Turn Valve Actuator ........................................................................................................................Minimum Discharge Pressure Valve ..............................................................................................Control Schematic - Compressor at Full Load ..............................................................................Control Schematic - Compressor Unloaded - Constant Speed Mode .........................................Control Schematic - Compressor Fully f_oaded - Low Demand Mode ........................................Wiring Diagram ...............................................................................................................................Auto Sentry ES ................................................................................................................................
Flow Diagram - EBH, EBM, EBP ..................................................................................................Flow Diagram - EAP ......................................................................................................................Oil Flow Diagram Remote Overhead Mounted .............................................................................Approximate Oil System Capacities ..............................................................................................Cooler Drain Detail ..........................................................................................................................Oil Level Gauge ...............................................................................................................................Thermostatic Mixing Valve .............................................................................................................Water Control Valve ........................................................................................................................Temperature Chafl ..........................................................................................................................Oil Separator ...................................................................................................................................
Heavy Duty Air Filter .......................................................................................................................
Installation of Coupling Cushions ..................................................................................................
1-11-21-21-21-31-3
2-12-12-22-42-52-5
4a-24a-24a-34a-34a-44a-9
4a-1 O4a-1 14a-1 24a-1 3
4b-14b-24b-24b-34b-34b-4
4b-1 O4b-114b-124b-134b-14
5-25-35-45-45-45-65-85-85-95-9
6-1
7-1
13-9/1 0-641 Page iv
SECTION 1GENERAL INFORMATION
FIGURE 1-1 - COMPRESSION CYCLE
COMPRESSOR - The Gardner-Denver” Rotary Screwcompressor is a single stage, positive displacementrotary machine using meshing helical rotors to effectcompression. Both rotors are supported between highcapacity roller bearings located outside the compres-sion chamber. Single width cylindrical roller bearings areused at the inlet end of the rotors to carry part of theradial loads. Tapered roller bearings at the dischargeend locate each rotor axially and carry all thrust loadsand the remainder of the radial loads.
COMPRESSION PRINCIPLE (Figure l-l) - Compres-sion is accomplished by the main and secondary rotorssynchronously meshing in a one-piece cylinder. Themain rotor has four (4) helical lobes 90° apart. Thesecondary rotor has six (6) matching helical grooves 60°apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressorcylinder near the drive shaft end. The discharge port isnear the bottom at the opposite end of the compressorcylinder. Figure 1-1 is an inverted view to show inlet anddischarge ports. The compression cycle begins as ro-tors unmesh at the inlet port and air is drawn into thecavity between the main rotor lobes and secondary rotorgrooves (A). When the rotors pass the inlet port cutoff,air istrapped in the interlobe cavity and flows axially withthe meshing rotors (B). As meshing continues, more ofthe main rotor lobe enters the secondary rotor grove,normal volume is reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-duction and pressure increase continues until the air/oilmixture trapped in the interlobe cavity by the rotorspasses the discharge port and is released to the oilreservoir (C). Each rotor cavity follows the same “fill-compress-discharge” cycle in rapid succession to pro-duce a discharge airflow that is continuous, smooth andshock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure5-1, page2, Section 5) -Air enters theairfilterand passesthrough the inlet unloader valve to the compressor. Aftercompression, the air/oil mixture passes into the oil res-ervoir where most of the entrained oil is removed byvelocity change and impingement and drops back intothe reservoir. The air and remaining oil passes into theseparator and separator housing where the oil is sepa-rated and passes through tubing connecting the sepa-rator housing and compressor. The air passes throughthe minimum pressure valve, discharge check valveand cooler, then to the plant air lines.
LUBRICATION, COOLING AND SEALING - Oil isforced by air pressure from the oil reservoir through theoil cooler, thermostatic mixing valve, and oil filter anddischarges into the compressor main oil gallery. A por-tion of the oil is directed through internal passages tothe bearings, gears and shaft oil seal. The balance of theoil is injected directly into the compression chamber toremove heat of compression, seal internal clearancesand lubricate the rotors.
13-9/10-641 Section 1 Page 1
f
INSTRUMENT DISPLAYWINDOW
I
/
ad
=
STARTERCONTROL
BOX
o
-EMERGENCY STOP
EMERGENCY STOP7
AUTO SENTRY ESCONTROL PANEL
\
CONTROL TRANSFORMER=
FIGURE 1-2 - STARTER BOX
.
.
a
o
—MAIN MOTORSTARTER
‘FAN MOTORSTARTER
FIGURE1-3 - PACXAGE -CONTROLLER&STARTERS
DRIVE MOTOR
AIR FILTER
11
rCOOLING FAN
\.–--–.-y-.~.--– j
FIGURE 1-4- PACKAGE - DRIVE MOTOR & AIR FILTER
13-9/1 0-641 Section 1 Page 2
SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstancescannot always be predicted and covered by established rules. Therefore, use your past experience, watch out forsafety 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 clothing a way from revolving fan, drive coupling, etc.
. Do not use the air discharge from this unit for breathing - not suitable forhuman consumption.
● Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostaticmixing valve or break any connections, etc. in the compressor air or oil systemuntil the unit is shut down and the air pressure has been relieved.
. Electrical shock can and may be fatal.
● Compressor unit must be arounded in accordance with the National ElectricalCode. Aground jumper equal in size to the equipment ground conductor mustbe used to connect the compressor motor base to the unit base.
● Fan motors and must remain arounded to the main base through the startermounting panel in accordance with the National Electrical Code.
. Open main disconnect switch and lockout before working on the control.
● Disco nnect the compresso r unit from its power source, tag and lockout beforeworking on the unit - this machine is automatically controlled and may start atany time.
13-9/10-641 Section 1 page 4
~WARNING
Failure to observe these notices could result in damage to equipment.
● Stop theunit if any repairs or adjustments on or around the compressor arerequired.
. Disconnect the compressor unit from its power source, tag and lockout beforeworking on the unit - this machine is automatically controlled and may start atany time.
. An Excess Flow Valve should be on all compressed air supply hoses exceed-ing 1/2 inch inside diameter. (OSHA Regulationj Section 1518.302)
. Do not exceed the rated maximum pressure values shown on the nameplate.
● Do not ope rate unit if safety devices are not operating properly. Checkperiodically. Never bypass safety devices.
13-9/10-641 Section 1 Page 5
DECALS
@
DiSCHARGE AIR USED FORBREATHING WILL CAUSESEVEREINJURY OR DEATH.CONSULT FILTRATIONSPECIALIST FORADDITIONALFILTRATIONANDTREATMENTEQUIPMENTTO MEET HEALTH ANDSAFETY REGULATIONS.
—
208 EAQ077
HIGH vOLTAGE.ROTATING MACHINERY.AIR AND 0ILUNDERPRESSURE.IMPROPERMODIFICATIONOF EQUIPMENTWILLCAUSESEVERE PERSONALINJURY OR DEATH.
ROTATING MACHINERYCANCAUSE INJURY OR DEATH.KEEP ALL GUARDSANDSAFETY DEVICES INPLACE.
211 EAQ077
AIR AND OIL UNDER PRESSUREWILL CAUSE SEVEREPERSONALINJURY OR OEATH.SHUTDOWNCOMPRESSORANDRELIEVE SYSTEM OF ALLPRESSURE BEFORE REMOVINGVALVES, CAPS, PLUGS,FITTINGS, BOLTS, AND FILTERS.
—
212EAQ077
DO NOT MODIFYUNIT WITHOUTWRITTEN PERMISSIONFROM MANUFACTURER.
218EAQ077
o
%
.0
0
UNIT CANAUTOMATICALLYRESTART.CAN CAUSE PERSONAL INJURYOR DEATH.KNOW MODE OF OPERATIONBEFORE WORKING ON ORNEAR THE MACHINE.
—
207 EAQ077
13-9/10-641 Section 1 Page 6
ELECTRICAL SHOCK FROMIMPROPER GROUNDING CANCAUSE INJURY OR DEATH.
GROUND UNIT ANDRELATEDEQUIPMENTACCORDINGTONATIONAL ELECTRIC CODEAND LOCAL REGULATIONS.
—
216EAQ077
AIR AND OIL UNDERPRESSURE.CAN CAUSE SEVEREPERSONAL INWRYOR OEATH.INSPECT OIL RESERVOIRFOR CRACKS AT LEASTANNUALLY.
I —
217EAQ077
ELECTRICAL ARCINGCANCAUSEA FIRE WHENUNIT ISMOUNTEDON A COMBUSTIBLESURFACERESULTING INPERSONAL INJURY ORPROPERTY DAMAGE.UNIT MUST BE MOUNTEDONA FLOOR PLATE EXTENDINGONALL SIDES.SEE INSTALLATIONDRAWINGFOR PROPERDIMENSIONS. —
221 EAQ077
ELECTRICAL SHOCKCANCAUSE INJURY OR DEATH.DISCONNECTALL CIRCUITSBEFORE WORKING ON T HISCONTROL.SEE WIRING DIAGRAM.
—
@
MACHINEDAMAGEOR INJURYCANOCCUR DUETO IMPROPERLIFTING.D0 NOT LIFT MACHINEWITHTHE MOTOREYEBOLT.
I —1
206EAQ077
13-9/10-641 Section 1 Page 7
SECTION 2INSTALLATION
GENERAL - On receipt of the unit, check for any dam-age that may have occurred during transit or handling.Report any damage or missing parts as soon as possi-ble.
~cAuTlON
Do not electric weld on the compressoror base; bearings can be damaged bypassage of current.
LIFTING UNIT - Proper lifting and/or transporting meth-ods must be used to prevent damage.
I ~CAUTION ILift compressor unit by base only. Donot use other places such as enclo-sure, motor, compressor oil dischargemanifold and piping as lifting points.
r t
~DANGER
The eyebolts or lugs provided on themotor are for lifting the motor only andshould not be used to lift any additionalweight. All eyebolts must be securelytightened. When lifting the motor thelifting angle must not exceed 15 de-grees. failure to observe this warningmay result in damage to equipment orpersonal injury.
Lifting slots are provided in the base for towmotor use.Unit fray also be moved into location by rolling on bars.
LOCATION - The compressor should be installed,whenever possible, in a clean, well-lighted, well-venti-lated area with ample space all around for maintenance.Select a location that provides a cool, clean, dry sourceof air. In some cases it may be necessary to install theair filter at some distance from the compressor to obtainproper air supply.
Both the air-cooled and water-cooled units require cool-ing air as well as air to the compressor inlet. Properventilation MUST be provided; hot air must be exhausted
from the compressor operating area. Atypical inlet-out-let air flow arrangement is shown in Figure 2-1.
AIR-COOLED UNIT - A combination oil/aftercooler issupplied as standard equipment on all air-cooled units.The air-cooled unit with the standard enclosure requiressufficient flow, Figure 2-2, for the compressoroil/aftercooling system and for electric motor cooling.Air is drawn into the unit at the motor side of the enclo-sure and is exhausted at the oil cooler side. Do not blockthe air flow to and from the unit. Allow three and one-half(3-1/2) feet to the nearest obstruction on the starter endand control box end of the unit. Allow three (3) feet tothe nearest obstruction above and on other sides of unit.For continuous efficiency, oil cooler cores must be peri-odically cleaned with either vacuum or compressed air.
~wARNING
For aluminum oil coolers, do not useany cleaning solution that is not com-patible with aluminum. Use of impropersolution may result in damage tocooler.
LOUVEREO EXHAUST FANLOUVERED
WINDOW
I bY -
Wlfioow
.*L~:,,,,,!.. ., :., ~ >i. 11 1 LJ..
AIR OUT k
*
.
$.
AIR AIR ‘lN IN ‘
~’
I UNIT I1
A75179 -
FIGURE 2-1 - TVPICAL COMPRESSOR ROOM
Minimum Air Flow* For CompressionAnd cooling (Cubic Feet/Minute) I
HP Air Cooled Water Cooled
40& 50 6,500 1,400
60,75, 100 12,500 1,700
* 80”F inlet airFIGURE 2-2
13-9/1 0-641 Section 2 Page 1
MOTOR COMPRESSOR
\/\/r
8 FT. PLYWOOD fENCE-8 FT. PLYWOOD “FENCE”
WELL MAN RADIANT 2-CLEMENTHEATER (OR EOUAL)RH400 WI TH (2) RH4502ELEMENTS - 2 REO”D.3.200 WATTS EACH
7
4 ET.
pb ‘._ ///L RESERVOIR
\’ ‘/
\ /
DIANT 2-ELEMENTHEATER (OR EOUAL) ELEVATION VIEWRH7000 WITH (2) RH7502ELEMENTS Z REOD6200 WATTS EACH
FIGURE 2-3 - COLD WEATHER INSTALLATION
If wet cleaning is required, shield motor and spray on amild soap solution and flush with clean water.
WATER-COOLED UNITS - The water-cooled unit withthe standard enclosure requires sufficient airflow, Figure2-2, previous page, for electric motor cooling. Air isdrawn into the unit at the top of the enclosure and isexhausted at the motor side. Do not block airflow to andfrom unit. Allow three and one-half (3-1/2) feet to thenearest obstruction on the starter end and control boxside of the unit. Allow three (8) feet to the nearestobstruction above and on other sides of the unit.
FOUNDATION - The G-D Rotary Screw compressorrequires no special foundation, but should be mountedon a smooth, solid surface. Whenever possible installtheunit near level. Temporary installation may be made ata maximum 10° angle lengthwise or 10° sidewise.
Mounting bolts are not normally required. However,installation conditions such as piping rigidity, angle oftilt, or danger of shifting from outside vibration or movingvehicles may require the use of mounting bolts andshims to provide uniform support for the base.
OIL RESERVOIR DRAIN - The oil drain is piped fromthe bottom of the reservoir to the side of the frame. Thisdrain is approximately 4.50 inches above the floor level.If this is not sufficient to conveniently drain the oil someother methods of providing drain are:
1. Elevate the compressor unit on raised blocks toobtain the desired drain height.
~CAUTION
If the compressor unit base is raisedabove floor level, the space betweenthe floor and the base bottom must beclosed with solid material all around toprevent recirculation of hot air from theoil cooler end and over temperatureoperation.
2. Construct an oil sump or trough below the floorlevel and pump or bail the drained oil.
3. Pump oil from the reservoir filler opening or drainto a container.
ENCLOSURE - The compressor, electric motor, oilcooler and aftercooler are mounted inside the enclo-sure.
Service doors are provided for maintenance access. Besure to allow enough space around the unit for the doorsto open completely.
Any of the enclosure doors maybe removed by openingthe door and lifting it up slightly to disengage the hinges.
The motor inspection/air filter service panel is held bytwo latches and lifts away from the enclosure. The airoutlet panel is attached by screws to the enclosure andis not readily removable.
INSTALLATION FOR COLD WEATHER OPERATION- Itis recommended that whenever possible the unit beinstalled inside a shelter that will be heated to tempera-
13-9/1 0-641 Section 2 Page 2
tures above freezing (32”F, O“C). This will eliminatemany of the problems associated with operating theunits outside in cold climates where freezing rain, driftingsnow, freezing condensate and bitter cold temperaturesare encountered.
Refer to Engineering Data Sheet 13-9-411 for the advan-tages of using the heat recovered from rotary compres-sors. This heat recovery could easily pay for an adequateshelter for the unit.
When an outside installation must be made, the precau-tions required will depend on how severe the environ-ment. The following are general guidelines for outsideinstallations:
Cold Weather (Down To + 10”F)
1.
2.
3.
4.
5.
6.
Be sure all control lines, drains and traps are heatedto avoid freezing of condensate. Heat tape withthermostat control is generally satisfactory for thispurpose and can be obtained at various localplumbing or hardware outlets at nominal cost.
If an air-cooled aftercooler isto be used, provisionsto bypass the aftercooler should be made. Sincecold air contains very little moisture, successfuloperation can be achieved without the aftercooler.
Provide at least some simple shelter such as aplywood windbreak to protect against driftingsnow.
Use only Gardner-Denver@ AEON ‘M 9000 lubri-cant.
Monitor unit carefully during start-up and operationto be sure it is functioning normally.
Specify NEMA 4 enclosure for electrical devices.
Extreme Cold Weather Operation (Down To -40”F)
In addition to the above, the following should be pro-vided:
1. It will probably be necessary to provide shutters orto block off part of the cooler in some manner sincethe cooler isgreatly oversized for operation intheselow temperatures. Since shutters are not providedas a factory option, blocking off a portion of thecooler with plywood should be satisfactory.
2. Auto operation should not be used in extremeenvironments.
3. Some means of providing heat during shutdownshould be provided. There are various methods toaccomplish this, but since openings are not pro-vided for sump heaters, the use of radiant heatersis recommended. The heaters should be sized toprovide at least a + 10°F environment for coolers,motor and sump. Figure 2-3, previous page,shows how these might be located in a typicalinstallation and sizes required.
Remember unsheltered (outside) installations should beavoided where possible. Installation next to a heatedbuilding where enough heat can be used to keep thecompressor room above freezing will save many com-plications in the operation and installation of the unit.
Refer to Engineering Data Sheet 13-9-411 for the advan-tages of using the heat recovered from rotary compres-sors. This heat recovery could easily pay for anadequate shelter for the unit.
AUXILIARY AIR RECEIVER - An auxiliary air receiver isnot required if the piping system is large and providessufficient 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 pressuregauge and a means of draining condensate.
MOISTURE SEPARATOR/TRAP - Since unit isequipped with a built-in aftercooler, a combination mois-ture separator and trap is furnished with the unit.
CONTROL PIPING - External control piping is not nec-essary since the unit is factory wired and piped for thecontrol system specified.
INLET LINE - Where an inlet line is used between the airfilter and the compressor, it must be thoroughly cleanedon the inside to prevent dirt or scale from entering thecompressor. If welded construction is used, the linemust be shot blasted and cleaned to remove weldingscale. In either case, the inlet line must be coatedinternally by galvanizing or painting with a moisture andoil-proof sealing lacquer. Up to ten (10) feet in length,the inlet line should be the full size of the inlet openingon the compressor. If an extra-long line is necessary,the pipe size should be increased according to Inlet LineChart below.
INLET LINE LENGTHS
Length of Inlet Line Diameter of Pipe Size
Oto 10 Feet .......................................................................................................... Same as Compressor Inlet Opening10to 17 Feet .......................................................................................................... One Size Larger Than Inlet Opening17t038 Feet .........................................................................................................Two Sizes Larger Than Inlet Opening
13-9/1 0-641 Section 2 Page 3
HP
40 HP40 HP
50 HP50 HP
60 HP60 HP
75 HP75 HP
100 HP100 HP100 HP
Model
EBHSHAEBHSHC
EBHSJAEBHSJC
EBMSKAEBMSKC
EBMSLAEBMSLC
EBPSMAEBPSMCEAPSMD
HEAT EXCHANGER
Water Temperature To Heat Exchanger
60”F
3.43.4
4.14.1
5.05.0
6.06.0
8.48.48.4
70”F
4.34.3
5.15.1
6.26.2
7.67.6
10.510.510.5
80”F
5.75.7
6.86.8
8.38.3
10.110.1
14.114.114.1
90”F
8.68.6
10.210.2
12.512.5
15.117.1
21.121.121.1
Max WaterFlow (GPM)
30.030.0
30.030.0
40.840.8
40.840.8
40.840.840.8
Approx. Water Press. Dro@ 90°F Water Temp. (PSI)
1.01.0
1.51.5
2.02.0
1.51.5
5.05.05.0
HP
40 HP40 HP
50 HP50 HP
60 HP60 HP
75 HP75 HP
100 HP100 HP100 HP
Model
EBHSHAEBHSHC
EBHSJAEBHSJC
EBMSKAEBMSKC
EBMSLAEBMSLC
EBPSMAEBPSMCEAPSMD
AFTERCOOLER
Water Temperature To Heat Exchanger
60”F
.5
.5
.7
.7
.8
.8
1.21.2
1.71.71.7
70”F
.7
.7
.9
.9
1.01.0
1.51.5
2.12.12.1
80°F
.9
.9
1.21.2
1.41.4
2.02.0
2.82.82.8
90”F
1.31.3
1.81.8
2.12.1
3.03.0
4.14.14.1
Max WaterFlow (GPM)
26.026.0
26.026.0
26.026.0
26.026.0
26.026.026.0
FIGURE 2-4- HEAT EXCHANGER (OIL COOLER-AFTERCOOLER)
APPROXIMATE WATER FLOW - U.S. GALLONS/MINUTE
Accessibility for inlet air filter servicing must be consid-ered when relocating the filters from the unit to a remotelocation.
DISCHARGE SERVICE LINE - The discharge serviceline connection on both water-cooled and air-cooledunits is made at the right hand corner of the unit, viewedfrom the opposite end from control panel side. Whenmanifolding two or more rotary screw units on the sameline, each unit is isolated by the check valve in the unitdischarge line. If a rotary screw unit is manifolded toanother compressor, be sure the other compressor hasa check valve in the line between the machine and themanifold. If a rotary screw and a reciprocating compres-sor are manifolded together, an air receiver must belocated between the two units.
Approx. Water Press. Drop@ 90F Water Temp. (PSI)
Less than 1 PSI for
any flow rate shown
in the table.
~DANGER
Discharge air used for breathing willcause severe injury or death.
Consult filtration specialists for addi-tional filtration and treatment equip-ment to meet health and safetystandards.
BLOWDOWN VALVE PIPING - The blowdown valve isfitted with a muffler for operation indoors. If the installa-tion requires, the muffler may be removed and the blow-down valve piped to the outside with a pipe size the sameas the blowdown valve outlet connection.
13-9/10-641 Section 2 Page 4
C76683
\ THERMOSTATICMIXINGVALVE
* WATER ~NTROL ““’ ‘“”~- ---— ---- —-- ______ _
,
A
HEAT EXCHANGER OUT1
V/UVL
VALVE
I*.ATER ~~.~J*~ L“’’?JER
AFTER COOLER
<,,, C76682 yq::::”~=
WATERIN
AIRIN
SEPARATOR / TRAP
* (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY.
FIGURE 2-5 - SERIES PIPING
WATER PIPING (Water-Cooled Heat ExchangerModels Only) - On machines equipped with water-cooled heat exchangers, the water inlet and outlet con-nections are located in the unit base flange on the leftside of the unit.
The water source should be capable of supplying up tothe maximum flow shown in Figure 2-4, previous page,at a minimum pressure of 40 psig; maximum allowablewater pressure is 150 psig. The water flow rates shownin Figure 2-4, previous page, are approximate and aguide to sizing piping, cooling tower and other watersystem equipment.
The heat exchanger system is designed to operate withwater inlet temperatures from 60”F to 90”F and a wateroutlet temperature not to exceed 11O“F. If water coolerthan 60°F is used, high water outlet temperatures (over110”F) will be experienced along with shottened heatexchanger life caused by tube fouling and corrosion. Ifwater warmer than 90”F is used, higher compressor oilinlet temperatures and high water usage will result.
Most water systems will require control of impurities:filtration, softening or other treatment. See “Compres-sor Oil Cooler - Water-Cooled Heat Exchanger” for moreinformation on the water system.
SERIES PIPING (Figure 2-5) - Water flow must bethrough aftercooler first for effective cooling of dis-charge air and is so piped on the standard water-cooledunit.
PARALLEL PIPING (Figure 2-6) - A separate watercontrol valve is required to control the discharge airtemperature. If a remote (externally mounted) water-
FIGURE 2-6- PARALLEL PIPING
cooled aftercooler is piped in parallel with the heat
exchanger, provide a separate water control valve for
the aftercooler and pipe separate inlet waterlines to both
the aftercooler and heat exchanger.
The water control valve is to be adjusted to maintain oil
out of the heat exchanger within the 140° to 150° F.
range regardless of inlet water flow or temperature as
long as a minimum flow for a given temperature is met
(Figure 2-4, page 4, this section). See Section 5 foradjustment instructions and maximum allowable lubri-cant temperature.
ELECTRICAL WIRING - Standard Units - The Electra-Saver” compressor is factory wired for all starter tomotor and control connections for the voltage specifiedon the order. It is necessary only to connect the unitstarter to the correct power supply. The standard unit issupplied with an open drip-proof motor, a NEMA 12starter and control enclosure. See “Location” paragraphfor distance to nearest obstruction on starter and controlbox sides of the unit.
Lower operating voltages (200/208) require that the unitstarter be remote mounted since the starter is too largeto be mounted within the control enclosure. If not sup-plied with the compressor unit, the starter is to be a size6 full voltage non-reversing type in NEMA (CEMA) en-closure suitable for the environment, with two (2) rejec-tion type control circuit fuses (size according to motorstarter manufacturer’s standard), a 200 (208) volt coil,and three (3) overload heaters for 200 (208) volt 100 HP,1.15 service factor motor. The overload heaters are tobe selected according to starter manufacturer’s tablesbased on motor nameplate full load amperage.
13-9/10-641 Section 2 Page 5
I A! WARNING
Electrical shock can cause injury ordeath. Open main disconnect switchbefore working on starter/control box.
GROUNDING - Equipment must be grounded in accordance with Table 250-95 of the National Electrical Code
~wARNING
Failure to properly ground the com-pressor package could result in con-troller malfunction.
MOTOR LUBRICATION - Long time satisfactory oper-ation of an electric motor depends in large measure onproper lubrication of the bearings. The charts on thenext page show recommended grease qualities andregressing intervals for ball bearing motors. For addi-tional information, refer to the motor manufacturer’sinstructions. The following procedure should be used inregressing:
1.
2.
3.
4.
5.
6.
7.
Stop the unit.
Disconnect the unit, tag and lockout from thepower supply.
Remove the relief plug and free hole of hardenedgrease.
Wipe lubrication fitting clean and add grease witha hand-operated grease gun.
Leave the relief plug temporarily off. Reconnectunit and run for about 20 minutes to expell theexcess grease.
Stop the unit. Replace the relief plug.
Restart the unit.
I ~WARNING
Rotating machinery can cause injury ordeath. Open main disconnect, tag andlockout before working on electricmotor.
ELECTRIC MOTOR GREASE RECOMMENDATIONS
StandardService
Worked Penetration .......................................................................... 265-296
Viscosity, SSU At 1000F..................................................................... 400-550
Soap Type ......................................................................................... Lithium
N-H Bomb, Minimum Hours For 20 PSI Drop at 21O”F.................... 750
Bleeding, Maximum Weight % In 500 Hours 212”F. ..... ................... 10
Rust inhibiting .................................................................................... Yes
Type of Service
Standard
Severe
Very Severe
ELECTRIC MOTOR REGREASING INTERVAL
Typical Examples
One- or Two-Shift Operation
Continuous Operation
Dirty Locations, HighAmbient Temperature
Rating
150 HP & Below
150 HP & Below
150 HP & Below
HighTemperature
220-240
475-525
Lithium
1000
3
Yes
Relubrication Interval
18 Months
9 Months
4 Months
13-9/10-641 Section 2 Page 6
SECTION 3STARTING & OPERATING PROCEDURES
PRESTART-UP INSTRUCTIONS - A new unit as re-
ceived from the factory has been prepared for shippingonly. Do not attempt to operate the unit until checkedand serviced as follows:
1. Compressor Oil - Check oil level in the reservoir.Add oil only if the oil level gauge reads in the red“ADD OIL’ range. Do not mix different type oils.Unit is shipped filled with Gardner-Denver”AEON ‘M9000 Lubricating Coolant which issuitablefor the first 8000 hours under normal operatingconditions.
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 “EX-CESS OIL” range. After start-up, the oil will fall intothe green operating range as system componentsare filled. if necessary, add oil to bring the level tothe top of the green range as read when the unit isoperating at full load and normal pressure. SeeFigure 5-4, page 4, Section 5.
NOTICE IRegular maintenance and replacementat required intervals of the oil filter, airfilter and air-oil separator is necessaryto achieve maximum service and ex-tended drain intervals of AEON 9000synthetic lubricant. Use only genuineGardner-Denver filters designed andspecified for this compressor.
~DANGER IAlways stop the unit and release airpressure before removing oil fillerplug. Failure to release pressure mayresult in personal injury or death.
2.
3.
4.
5.
6.
Air Filter - Inspect the air filter to be sure it is clean
and tightly assembled. Refer to Section 6, “Air
Filter,” for complete servicing instructions. Be surethe inlet line, if used, is tight and clean.
Coupling - Check all bolts and cap screws fortightness. See Section 7.
Piping - Refer to Section 2, “installation,” and makesure piping meets all recommendations.
Electrical - Check the wiring diagrams furnishedwith the unit to be sure it is properly wired. SeeSection 4, “Controls and Instruments,” for generalwiring diagrams and Section 2 for installation in-structions.
Groundina - Equipment must be arounded in ac-cordance with Table 250-95 of the National Electri-cal Code.
~WARNING
~
Failure to properly ground the com-pressor package could result in con-
7. Rotation - Check for correct motor rotation using“JOG MODE.” Compressor drive shaft rotationmust be clockwise standing facing the compressorsheave.
~wARNING
Operation with incorrect motor rotationcan damage equipment and cause oileruption from the compressor inlet.When checking motor rotation, induceminimum rotation (less than one revo-lution if possible). Never allow motor toreach full speed.
During unloaded operation and after shutdown, thesystem will partially drain back into the oil reservoirand the oil level may read higher than when oper-ating 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 operat-ing level.
8. System Pressure - Set the controls to the desiredunload pressure and differential. DO NOT EXCEEDMAXIMUM OPERATING PRESSURE ON COM-PRESSOR NAMEPLATE. See Section 4, “Controlsand Instruments,” for procedure.
13-9/10-641 Section 3 Page 1
~wARNING IOperation at excessive discharge airpressure can cause personal injury ordamage to equipment. Do not adjustthe full discharge air pressure abovethe maximum stamped on the unitnameplate.
9.
10.
Operating Mode - Refer to Section 4 for detailedinformation on the control system.
Enclosure - Check for damaged panels or doors.Check all screws and latches for tightness. Be suredoors are closed and latched.
STARTING THE UNIT- OBSERVE UNIT COLD OR HOTSTARTING 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 isequipped with a minimum (65 psig) pressure dischargevalve, no special procedure to maintain unit reservoirpressure is required.
Unit Hot - No warm-up period is required. If the unit is awater-cooled heat exchanger model, open any manualwater inlet valves wide open. Start the unit by pushingeither the “CONSTANT RUN” button or one of the“AUTO” buttons.
DAILY CHECK - Refer to Section 8, “MaintenanceSchedule.”
STOPPING THE UNIT - Press “STOP-RESET” button.The oil reservoir will automatically blow down as themotor stops. If the unit isa water-cooled heat exchangertype, close any manual water inlet valves.
SEQUENCING COMPRESSORS
Sequencing compressors with the AUTO SENTRY-EScontroller is as simple as plugging in a telephone to awall jack. The only item required to make the systemfunctional is a standard telephone cable identical tocables that connect nearly every telephone to its walljack. One less cable than the number of compressors tobe sequenced is required. For example, to sequencefour compressors, three cables are required. A kit,200 EAP752, is available which contains all materialneeded to sequence up to five compressors. This kitcontains 500 feet of cable, eight modular connectors anda crimping tool to install the connectors.
In spite of the fact that it is a standard feature, and itsinherent installation simplicity, the sequencing functionof a multi-compressor “AUTO SENTRY-ES” system isthe most fully-featured, functionally-complete availabletoday.
1. INSTALLATION
A proper sequencing installation requires two or moreGardner-Denver rotary air compressors complete with“AUTO SENTRY-ES” controllers, piped into a commonair system, interconnected as described above. All stan-dard practices common to sound air compressor instal-lations such as proper sizing of discharge piping, proper
electrical supply and conductor sizing, and groundingare to be observed. The serial communications interfacemeets RS-485 standards, the most widely used interfacein harsh, industrial environments today. However it isstillrecommended that the communications cables berouted through metallic conduit to provide them withboth mechanical protection and electromagnetic shield-ing.
Each control circuit board has two modular jacks whichaccept standard RJ-12 telephone plugs. One jack isvacant; the other has a short pigtail plugged into it. Tointerconnect two compressors, plug the cable into thevacant jack on each controller. For installations of morethan two units, the pigtail plug must be disconnected onall controllers except the two at each end of the commu-nications line. The order of interconnection has no effecton the system operation. The following conditions arenecessary and sufficient for proper operation:
1. Every compressor must have a cable connect-ing it to another compressor. One less cablethan the number of units sequenced, must beused.
2. Each board that has only one cable connectedto it must have its pigtail plugged into theunused jack. All installations will have two suchunits.
13-9/1 0-641 Section 3 Page 2
Il. OPERATION
A. ESTABLISHING THE INITIAL SEQUENCE
Operation of compressors in sequence requires only apress of the ‘sequence’ key on each compressor in thesystem. Since the sequencing algorithm includes provis-ions for automatic replacementof a failed master or ‘lead’compressor, it is important for the operator to be awareof the hierarchy of events when starting the system.
The first compressor placed in sequence mode will be-come the master. However, since any compressor firstplaced in sequence has no way of knowing whether ornot a master exists, itwill first assume the highest rotationnumber available. For example if the number of units tobe sequenced is programmed at four, any compressorwill start out in position four when placed in sequencemode. It will then listen on the communications line for acall from the master.
If no call is received, it will assume position three andagain wait for a call from the master. After another lackof master call, it assumes position two. Subsequently, itassumes position one which makes it the master. Assoon as a master is established, it immediately attemptsto call all other units and assigns them successive rota-tion positions. The system is now active.
Before a master isestablished, the system is not deprivedof air. This is due to one of the outstanding features ofthe “AUTO SENTRY-ES” sequencing system: pressurecontrol is always executed locally at each individualcompressor. The effective setpoint for compressor con-trol is the programmed setpoint minus 3(rotation number
1). So whiie a compressor (or compressors) is/arecounting down towards establishing a master, they arealso capable of delivering air at a pressure determinedby the above formula.
To insure that two or more machines do not simulta-neously decrement their rotation numbers and simulta-neously become masters, it is advisable to p!ace thedesired master in sequence mode first and wait until thefirst decrement in rotation number is seen (about 7 sec-onds) before placing subsequent compressors in se-quence mode. If it isdesired to dictate the complete initialsequence manually, wait until the previous machine dec-rements one position and then place the next desiredcompressor in sequence mode. If it is acceptable to letthe master determine the initial sequence, simply waituntil the master has decremented its rotation numberonce, and then place all remaining compressors in se-quence mode. Remember that once a master is estab-lished, no further self-decrementing is done by theindividual compressors. Instead, they will wait until themaster assigns them a rotation number.
Rotation numbers are displayed in the bottom displayline, with the mode indication. For example, the modeindication for the current master is SEQI; for the first lagcompressor, SEQ2; second lag SEQ3,etc.
B. HOW THE “AUTO SENTRY-ES” CONTROLSPRESSURE WHILE SEQUENCING
Each compressor operates exactly the same as if it werein AUTO mode with one exception: it has a dynamicsetpoint. The initial setpoint is determined by the equa-tion shown above. A compressor is started when thesystem pressure drops below its programmed resetpoint, after waiting for [’LAG START INTERVAL’ times(rotation number - 1)] seconds. This prevents all lagcompressors from starting at once. Note that acompressor’s [’LAG START INTERVAL’ times (rotationnumber 1)1timer is not reset to zero until that compressoris started. This means that the time for the next lagcompressor to come on is aiways somewhat less than‘LAG START INTERVAL’.
EXAMPLE:In a three compressor sequence system, SET PRES-SURE = 100 PSI; RESET PRESSURE = 90 PSI; LAGSTART INTERVAL = 15 seconds. The lead compressoris running alone, maintaining 100 PSI by modulationwhen an air tool is brought on line causing the air demandto exceed the capacity of the lead compressor. When thepressure drops to 90 PSI, the #2 unit times out its 15second timer and starts. It takes 5 additional seconds forthe pressure to rise above 90 PSI. The #3 unit whosetimer was initialiy set at 30 seconds (15 x [3 - 1]), hascounted down 20 seconds (the total time that systempressure was below 90 PSI). If air demand increasesagain, the pressure will have to fall below 90 PSI for only10 seconds more to start unit #3.
As was previously stated, a lag compressor’s modulationsetpoint (PSET for short) is [SET PRESSURE - 3(rotationnumber - 1)]. Thus in the above example, the first lagcompressor (rotation #2) has a PSET of 97 PSI; thesecond lag, 94 PSI, and so on. But look what happens inan eight compressor installation: The eighth compressorwill have an initial setpoint of [100 - 3(8 - 1)], or 79 PSI.Does this mean that an eight compressor installationmust operate 21 PSI below the desired operating pointwhen all compressors are running? NO! This iswhere the“AUTO SENTRY-ES” dynamic setpoint controi takesover. This is how it works: Whenever the system pres-sure is below the programmed RESET PRESSURE, thePSET of each lag compressor is incremented 1 PSI everythirty seconds. Thus, after a short interval (about fiveminutes in this example), the PSET of the last sequencedcompressor will ciimb up until either it equals the RESETPRESSURE, or a decrease in demand causes the actual
13-9/10-641 Section 3 Page 3
system pressure to rise above the RESET PRESSURE.It can be seen then, that except for short periods justafter a sudden increase in demand, the “AUTO SENTRY-ES”, with its dynamic setpoint control, will maintain sys-tem pressure between the limits of RESET PRESSUREand SET PRESSURE. Remember, RESET and SETPRESSURE values are programmed by the operator sothe operating range is completely programmable andpredictable.
Dynamic setpoint control will also work in reverse of theoperation described above. Obviously, incrementingsetpoints will cause overlap of the compressors’ modu-lation ranges. While this enables us to maintain a higherpressure than competitor’s sequencers, overlap is unde-sirable as demand decreases, because a system couldend up with several compressors running partiallyloaded instead of running the minimum number of fullyloaded compressors. To overcome this, as pressurerises through the range between RESET and SET, thelag compressors’ PSET’S are now decremented, revers-ing the effect described above during periods of highdemand. - The “AUTO SENTRY-ES’ keeps track of allfunctions at all times so there is never any mix-up ofsetpoints and the proper rotation sequence is alwaysmaintained.
ill. THE AUTOMATIC SEQUENCE CHANGE
After the master (lead) compressor has served for theduration programmed (TRANSFER INTERVAL), it relin-quishes control and assigns itself the highest availablerotation number. The lag compressors detect the loss ofthe master and decrement their rotation numbers. Num-ber 2 becomes number 1, the new master, number 3becomes number 2, etc.
It should be noted also that whenever the master detectsa missing rotation number, such as when a compressoris turned off that was previously in the rotation, it willautomatically ‘close the gap’ by decrementing the rota-tion numbers of all compressors whose rotation num-bers were greater than the missing number. Likewise, iffor whatever reason, the master compressor fails tocarry out its role, all lag compressors begin decrement-ing their rotation number until a new master is estab-lished. Regardless of the scenario, the end result willalways be that the compressors that remain in rotationwill always end up with the lowest possible rotationnumbers.
IV. OTHER FEATURES
Any air system will exhibit pressure differences from onepoint to the next. Even a well designed multi-compressorinstallation will show ‘minor’ pressure variations betweenone compressor’s discharge point and anothercompressor’s discharge. These points will also vary withthe central system (normally the air storage receiver).These pressure differences wreak havoc with conven-tional sequencers. If a central sequencer is used, it willbe sensing a lower pressure than is seen at each com-pressor. With such systems, there is always a chancethat the sequencer could cause a compressor to overpressure due to this pressure drop. The alternative hasbeen to set the control sequencer to a lower pressure toprevent this or allow local override of the sequencer bythe local pressure control, neither of which is desirablein the scheme of maintaining plant pressure efficientlywith sequencing.
The “AUTO SENTRY-ES” sequencing system lets eachcompressor control itself independent y about a setpoint(PSET) derived to cause staggered operation, or se-quencing. The aforementioned pressure drops can alsocause derogatory effects (mainly skewed, or out of se-quence operation) to the sequencing algorithm used bythe “AUTO SENTRY-ES”.
Since these pressure variations are not constant (theywill vary due to demand changes, compressor loadpercentage changes, and number of compressors run-ning), any scheme to compensate for the pressure vari-ations must be dynamic. That is, corrections must beapplied rather frequently, and on the fly. The exclusivedynamic setpoint control feature enables this error cor-rection scheme to be accomplished rather easily.
Here’s how it works: The master continually receivessystem pressure values from every machine in the se-quence rotation. The values are averaged and this aver-age is then distributed to all lag compressors. Thishappens approximately once per second. All compres-sors, lead and lag, then compare their local pressurereading to the average and adjust their PSET by theamount of error. The effect is that all compressors arecontrolling to a single pressure reading, a reading thatis not one that is picked up somewhere removed fromthe compressor, but an average of actual dischargepressures.
It should be noted that the pressure displayed on the topline by all sequenced compressors is this average.
13-9/10-641 Section 3 Page 4
SECTION 4a - EBH, EBM, EBP UNITSCONTROLS & INSTRUMENTS
GENERAL DESCRIPTION - The Gardner-Denver Ro-tary Screw compressor is prewired with all controls,motor and wiring, and starter for the voltage and horse-power specified at the time of the order. It is necessaryonly to connect the compressor unit to the correctpower supply, to the shop airline, and to the shop waterline, if the compressor is watercooled. A standard com-pressor unit consists of the compressor, oil reservoir, oilcooling system and oil filters, motor enclosure specified,NEMA 12 starter/control box, and controls as describedbelow.
This compressor features the programmable control,which integrates all the control functions under micro-processor control. Its functions include safety and shut-down, compressor regulation, operator control, andadvisory/maintenance indicators. The keypad and dis-play provide the operator with a logical and easily oper-ated control of the compressor and indication of itscondition.
PROTECTIVE DEVICES AND SHUTDOWN - The“Auto Sentry-ES” will shut down the unit following anyfault detected in the following devices. Following a shut-down, a message will be displayed to indicate the cause.The shutdown light will be on if the cause still exists, orwill flash if the cause has been cleared. To resumeoperation, the cause of shutdown must be corrected andthe controller reset by pressing the “STOP/RESET” key.
Motor Protection Devices - Overload heaters are fur-nished for the starter in the voltage range specified.There are three (3) overloads in the starter of proper sizefor the starter and its enclosure. Note that motor name-plate current must by multiplied by .577 for wye-deltastarters. The display will indicate which overload relaytripped. The overload relay is reset by pressing thebutton on the relay itself. Motor current (amps) andvoltage must be measured to locate the cause for highcurrent. Proper starter coil and contact action is alsomonitored and errors in operation will cause a shutdownwith the cause displayed.
High Temperature - The compressor is protected fromhigh discharge and separator temperature by two inde-pendent thermistor probes. One probe is located in thedischarge housing to sense the compressor dischargeair-oil mixture temperature. The second probe is lo-cated at the separator discharge and senses the tem-perature of the air at the oil separator. The “AutoSentry-ES” will shut the compressor down if tempera-ture sensed at either location exceeds 225° F. (or lowerper user adjustment) or if a rapid temperature rise isdetected. The location of the high temperature will bedisplayed. Shutdown will also occur if a shorted probe,open probe, or extreme low temperature is detected.The display will indicate the location of the defectivethermistor probe.
~CAUTION
Machine damage will occur if compres-sor is repeatedly restarted after hightemperature stops operation. Find andcorrect the malfunction before resum-ing operation.
Separator Differential Pressure - The separator differ-ential pressure is continually monitored by the “AutoSentry-ES”. At a differential pressure of approximately15 psi, the unit will be shut down.
High Pressure - The “Auto Sentry-ES” will shut downthe unit if excessive pressures are detected in the reser-voir or system. Shut down will occur if a defectivetransducer is detected. The display will indicate thelocation of the high sensed pressure or transducer(xducer) error. Check that all adjustments have beenmade, and all connections are secure.
Relief Valve - A pressure relief valve(s) is (are) installedin the final discharge line and set to approximately 120%of the unit’s full load operating pressure for protectionagainst overpressure. Periodic checks should be madeto ensure its (their) proper operation.
The relief valves should be tested for proper operationat least once every year. To test the relief valve, raise thesystem operating pressure to 75% of relief valve setpressure and manually open the valve with the handlever. Hold the valve open for a few seconds and allowt to snap shut. “
~WARNING
When relief valve opens, a stream ofhigh velocity air is released, resulting ina high noise level and possible dis-charge of accumulated dirt or other de-bris. Always wear eye and earprotection and stand clear of the dis-charge port when testing the reliefvalve to prevent injury.
~CAUTION
Never paint, lubricate or alter a reliefvalve. Do not plug vent or restrict dis-charge.
13-9/10-641 Section 4a Page 1
rMUFFLER
BLOW DOWN VALVE — P ORIFICE
\ 1 /PRESSURE
~ CHECK VA
REGuLAToR
SHUTTLE VALVE z
INLET VALVE7
‘URGEVALVE=1/1 \~ ‘–H
------- .-
I -1 1 II
7-I
IIII OIL COOLER
I ‘‘s””=u 1-
In OILRESERVOIR
FIGURE 4a-1 - SCHEMATIC TUBING DIAGRAM
~wARNING
Operation of unit with improper relietvalve setting can result in severe per-sonal injury or machine damage.
Ensure properly set valves are installedand maintained.
Low Oil Pressure - The programmable controller willshut down the unit if inadequate oil pressure to thecompressor is detected. If this occurs, check the wiringand piping to the solenoid valves.
Emergency Stop - Pressing the emergency stop buttonwill shut down the unit and the controller. To restart, pullthe button out to its normal position and reset thecontroller.
Power Failure - Following power interruptions, the con-troller will remain in a shutdown state.
High Vibration (optional) - This optional feature willshut down the unit if abnormally high vibration is de-tected.
CHECK CN 7 (8, 9) - This indicates a wiring error orconnection problem. Remove power and correct allwiring
VALVE
_ AIR FILTER SWITCH
TRANSDUCER
P/“FIGURE4a-2 - BLOWDOWNVALVE
Blowdown Valve -The blowdown solenoid valve re-leases pressure from the oil reservoir during any shut-down condition, and during some operating conditions.See Figure 4a-2 and description under “AirControl Com-ponents” in this section for construction and operationinformation.
GAUGES AND DISPLAYS
Oil Level - The oil level gauge is located on the side of
13-9110-641 Section 4a Page 2
FROM/
INLET VALVE
AIR FILTER(OPEN POSITION)
MUFFLER
ORIFICE
/ 11 < CHECK VALVE(
------- . . . . ..
SOLENOID VALVE IVCTO PRESSURE REGULATOR
SEPARATOR d
j L\sHuTTLEVALVE
HOUSING
TO SEPAiiTOR
AFTERCOOLER HOUSING
~ TOTRANSDUCER
FlGURE4a-3 - INLETVALVE
the reservoir. See Section 5, page 5, “Lubrication, OilCooler, Oil Filter and Separator” for information on howto correctly read the gauge. All other instruments arepart of the programmable controller.
AIR CONTROL COMPONENTS - Refer to Figures 4a-1,page 2, 4a-6, 4a-7 and 4a-8, pages 9, 10 and 11, thissection, for schematic tubing diagrams.
Inlet Valve (Figure 4a-3) - The inlet valve restricts theinlet to control capacity and closes to unload the com-pressor. At shutdown, the inlet valve closes to preventbackflow of air.
The inlet valve position is controlled by air pressure in itspiston cylinder, which is controlled by the “Auto Sentry-ES’ through solenoid valves IVC and IVO. As pressureto the piston is increased, the valve closes to restrict airflow and compressor delivery (Figures 4a-6, 4a-7 and4a-8, pages 9, 10 and 11, this section).
Minimum Discharge Pressure Valve (Figures 1-5,page 3, Section 1 and 4a-4) -An internal spring-loadedminimum pressure valve is used in the final dischargeline to provide a positive pressure on the oil system ofthe compressor even when the air service valve is fullyopen.
The valve incorporates an orifice which, when air isflowing through it, maintains approximately 65 psig inthe oil reservoir. A spring-loaded piston valve senses airpressure on the upstream (oil reservoir side) of the valve.When the system pressure rises above 65 psig, thespring 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 O-ringfor sealing, valve orifices for restriction, or valve and
AIR IN
VALVE
.VE IVO
FIGURE4a-4 - MINIMUMDISCHARGEPRESSUREVALVE
valve seat for burrs and dirt.
The valve isadjustable within a small range. It isadjustedby a screw on the side of the valve body. The minimumpressure can be adjusted as follows:
1. Start the compressor.
2. Reduce pressure downstream of minimum pres-sure valve to below desired minimum pressure. DONOT REDUCE UPSTREAM PRESSURE OR AD-JUST VALVE BELOW 65 PSIG.
3. Loosen locknut on adjusting screw.
4. Turn set screws into increase, or out to decreaseminimum pressure to be held.
13-9/10-641 Section 4a Page 3
FIGURE 4a-5 - SHUITLE VALVE
5. Hold set screw at desired point and tighten locknut.
Check Valve (Oil Reservoir) - A renewable seat swingtype check valve in the final discharge manifold preventsbackflow of air from the shop airline when the unit stops,unloads or is shut down.
Purge Air Valve - The purge valve is a normally closedtwo-way air actuated valve that admits purge air from thefinal discharge manifold to the compressor to counter-act the oil knock which occurs in oil-flooded rotary screwcompressors when they are completely unloaded withpressure in the oil reservoir. This valve is controlled bythe same control pressure which controls the inlet valve.
Solenoid Valves IVC and IVO - These valves controlposition of the inlet valve in response to signals from the“Auto Sentry-ES”. With both valves de-energized, thenormally open IVC valve allows control pressure to theinlet valve piston to close the valve. If IVC only is ener-gized, the inlet valve is held in its current position. If bothvalves are energized, control pressure is relieved fromthe inlet valve piston to allow the valve to open.
Pressure Regulator - The pressure regulator is used tosupply a constant and low control pressure to preventdamage to the inlet valve from “slamming.”The regulatorshould be set for 25-30 psig.
Shuttle Valve - (Figure 4a-5) Also known as a doublecheck valve, the shuttle valve is a device which will taketwo (2) supply signals and allow the one with the highestpressure to pass through. The shuttle valve is used toprovide control air pressure from either the reservoir orplant air system, as required during different operatingconditions.
Blowdown Valve - (Figure 4a-2, page 2, this section)The blowdown valve is a two-way solenoid valve whichis piped into the oil reservoir outlet but ahead of thecheck valve. When the solenoid is de-energized, thevalve opens and the oil system is blown down. When thesolenoid is energized, the valve closes to allow the oilsystem to pressurize. A control air check valve is pro-vided to ensure that the inlet valve closes during blow-down. See Figure 4a-6, page 9, this section.
System Pressure Transducer - This transducer is con-nected after the minimum pressure valve and dischargecheck valve. It converts the pressure in the plant airsystem to an electrical signal for use by the programma-ble controller for modulation and control.
Reservoir Pressure Transducer - This transducer isconnected to the oil reservoir. Its signal is used toprevent loaded starts, monitor oil pressure, and forseparator differential.
Air Filter Vacuum Switch - This switch is used tomonitor air filter condition and alert the user if the filterrequires service or replacement.
Vibration Switch (Optional Equipment) - The optionalvibration shutdown switch, mounted on the compressorcoupling cover, detects an increase in vibration thatcould bean indication of impending damage to the unit.The switch actuates when the selected level of vibrationis exceeded.
The switch MUST BE ADJUSTED when the unit is firstinstalled. Refer to switch manufacturer’s instructionmanual for complete details.
STARTER/CONTROL PANEL
The following items are located in the electrical enclo-sure and provide the main control of the compressor unitand switching of the motor(s). Refer to Figure 1-3, page2, Section 1.
AUTO SENTRY-ES - The “Auto Sentry-ES” is located onthe upper section of the panel. It provides all the controlof the motors and control devices for safe and efficientoperation of the compressor unit. Its display provides allgauging functions, shutdown causes, and maintenancerecommendations. The keypad provides the user withselection of operating modes and adjustment to tune thecontrols for the application. It is connected to otherdevices inside the panel and external devices throughthe terminal strip. The “Auto Sentry-ES” requires nomaintenance.
Emergency Stop -This isa maintained pushbutton, andremoves power from the controller outputs regardlessof controller status. It is located on the upper section ofthe panel, next to the keypad.
w
I ~WARNING
Automatic restarting or electrical shockcan cause injury or death. Open andlock main disconnect and any othercircuits before servicing unit.
Control Transformer - This changes the incomingpower voltage to 110/1 20 volts for use by all unit controldevices. Two primary and one secondary fuse are pro-vided. Refer to the adjacent Iabelling for replacementinformation.
13-9/1 0-641 Section 4a Page 4
Terminal Strip - This provides connections for all110/1 20 volt devices not contained within the controlpanel.
Fan Starter - (where applicable) The starter is used toprovide control and overload protection for the coolingfan on air-cooled units and ventilation fans ofwatercooled units with enclosure. Overload heatersshould be selected based on the nameplate current ofthe fan motor. Three fuses are provided. Refer to adja-cent Iabelling for replacement information.
Main Starter - This starter is used to provide control andoverload protection for the main drive motor. For wye-delta starters, overload heaters should be selectedbased on the motor nameplate current times .577 forproper protection. Wye-delta starters employ three con-tractorswhich are controlled sequentially to provide lowcurrent starting. Full-voltage starters employ a singlecontactor; overload selection should be based on thefull load current of the motor, and adjacent Iabelling.
OPERATION
Operation of the AUTO SENTRY-ES is dependent onselection of an operating mode from the controller key-pad. Prior to starting, the “STOP/RESET” key must bepressed to place the control in its ready state. Operationmay then be started by selecting an operating modefrom the controller keypad. Once operating, the operat-ing mode may be changed at any time. TheSTOP/RESET key may be pressed at any time to stopthe compressor under normal conditions.
An optional control may be wired to the control tointerrupt and restart the unit based on controls by others.When stopped by these controls, the display will indicate“REMOTE STOP.”
h i
I ~WARNING IAutomatic restarting or electrical shockcan cause injury or death. Open andlock main disconnect and any othercircuits before servicing unit.
In any mode, the compressor will start only if reservoirpressure is below 5 psig. The display will indicate if thecontrol is waiting for blowdown. The controls will keepthe compressor unloaded until the start cycle has been
completed.
Constant Run Mode Operation - This mode is bestused in applications where there are no long periods ofunloaded operation. The compressor unit will start andrun continuously, using its modulation controls to matchdelivery to demand.
As demand falls below the compressor capacity, thepressure will rise to the setpoint of the control. When thepressure reaches the setpoint the AUTO SENTRY-ES
controller operates the solenoid valves to pass pressureto the inlet valve piston and the inlet valve closes enoughto match air system demand. See Figure 4a-6, page 9,this section.
As demand increases, the controller will modulate theinlet valve by passing pressure with the solenoid valvesas required to provide the most economical means ofmatching delivery to demand. See Figure 4a-7, page 10,this section.
Low Demand Mode Operation -The Iowdemand modereduces power consumption by relieving pressure inthereservoir during unloaded operation. Under loaded con-ditions, it will operate identically to the constant-runmode described above.
During low demand periods, the controller will open theblowdown valve and fully close the inlet valve to mini-mize the motor load. See Figure 4a-8, page 11, thissection. A timer is started when this occurs. While in thisstate, control air pressure is supplied from the plant airsystem. When system air pressure drops due to in-creased demand, the blowdown valve recloses and thecontrols resume their normal modulation sequence.
Subsequent blowdown periods are not allowed until thetimer has completed its cycle. This cycle eliminates theproblems of oil foaming and carryover which can occurif the oil reservoir of an oil-flooded compressor is blowndown too often. The timer is adjustable from 5 to 20minutes.
Automatic Mode Operation - This mode provides au-tomatic start and timed stop, and is best used in appli-cations with long unloaded periods. Operation duringperiods of demand or moderately long unloaded periodsis identical to the low demand mode.
The Auto time delay is adustable from 5 to 30 minutes.If the controller operates unloaded for this period withno demand, the compressor drive motor is halted toeliminate its power consumption. The controls will re-main in this state until demand is again indicated by adrop in pressure.
Sequence Mode Operation - This mode provides forcommunication between controllers, operating only asmany as are required for economical operation. The leadunit operates identically to the automatic mode; opera-tion will be automatically staged for each lag unit.
Communication between controllers is achieved by in-terconnection of a communications link to circuit boardconnectors. A “unit number” must be assigned to eachunit to operate in this mode (see “Programming andSetup” in this section).
CONTROLLER DISPLAY
The display above the keypad is used to provide oper-ating information to the user. If a shutdown has oc-
13-9/10-641 Section 4a Page 5
curred, the display will indicate the cause as notedabove.
During normal operation the display will show the oper-ation mode, system pressure, compressor dischargetemperature, and total running hours. Alternate displaysare available by pressing keypad cursor keys, and willbe identified on the display. These include reservoirpressure, separator differential pressure, reservoir tem-perature, system pressure, and compressor dischargetemperature. In Low Demand, Automatic, and Sequencemodes, alternate displays also indicate remaining timesof delays. If no keys are pressed for 5 seconds, thedisplay will return to its normal mode.
The display isalso used as a service reminder for normalmaintenance items. These include the separator, airfilter, and oil filter change intervals. All intervals are basedon recommended parts as noted in the maintenancesection of this manual. Oil change intervals are alsoautomatically calculated, based on actual operatingconditions. This allows maximum utilization of AEON9000 oil. Messages will also be displayed ifoperation hasoccurred during low ambient temperatures, or if hightemperature operation has occurred.
Clearing Advisories - Temperature advisories may becleared while the unit is running by simply pressing theENTER key. To reset the service messages, press theSTOP/RESET key to stop operation of the compressor.Disconnect power and service the unit as required.Following service, put the enable switch in the downposition, restore power to the unit, and pressSTOP/RESET to clear the controller. Proceed throughthe service selection described in step 1 below. Activeadvisories will be displayed and may be cleared bypressing the ENTER key. After the messages have beencleared, press STOP/RESET and select an operatingmode to resume operation.
PROGRAMMING AND SETUP INSTRUCTIONS FORTHE AUTO SENTRY-ES (R) CONTROLLER
Programming and setup isaccomplished with the “PRO-GRAM” keys. In all steps, the “ENTER” key will cause thecontroller to accept the displayed value into memoryand advance to the next programming function. The plus“+“ and minus “ -“ keys will increase and decreasedisplayed values, respectively. The right and left arrowkeys, “-” and” —“, position the cursor (flashing digit).The number at the cursor will be the number that ischanged by the “+” and “-” keys. At any point in theprogramming and setup routine, the “STOP-RESET” keycan be pressed to exit and return to the ready mode.
In all steps of the programming routine, the top line ofthe display will give a description of the parameter to beprogrammed, while the bottom line shows the variablethat is capable of being altered by programming.
The following is a step by step guide to programing the“AUTO SENTRY-ES” Controller.
I NOTICE IBetween each step it is necessary topress the “ENTER” key to store the newvalue and advance to the next step.
1. Press the “ENTER” key to begin programming. Ifthe enable switch on the circuit board is in the setposition, the control proceeds to the setup adjust-ments starting with step 2 below. If the slide switchis down in the “+” position, push “ENTER” to gofrom OIL FILTER CHANGE to OIL CHANGE andthen push “ENTER” again to proceed to Step 2.Press “AUTO” to display the hours remaining untiloil change or filter change is recommended. Ifservice has been performed early, press the“AUTO” key to reset the timers to their full numberof hours. Press “ENTER” to proceed to the nextdisplay without affecting timers.
In the top line, DISPLAY UNITS is indicated. Thebottom line will indicate ENGLISH (PSIG, Fahren-heit) or METRIC (Bars, Celsius). Select the desiredmode and press ENTER to save and proceed.
3. In the top line, NUM OF SEQ UNITS is displayed.The bottom line will indicate a number in the rangeof one through eight. This will be factory set at”1”.This should be set to a number corresponding tothe number of compressors that are currently in-stalled on this air system that also have AUTOSENTRY-ES controllers. It should be noted that allAUTO SENTRY-ES compressors on the systemmust have the same number programmed here tooperate correctly in “SEQUENCE" mode.
NOTICE
Setting the value in step 1 to one indi-cates that no sequencing is to takeplace. Consequently, steps 4,5, and 6,which relate to sequencing, areskipped by the “AUTO SENTRY-ES”;Programming commences at step 7.
4. In the top line, UNIT NUMBER is displayed. Thebottom line will again indicate a number of onethrough eight. This will be factory set at”1”. Each“AUTO SENTRY-ES” in a sequenced system musthave a unique number here. The sequence modewill not function if two or more compressors havethe same UNIT NUMBER. Most efficient machine-to-machine communications will occur when thelowest possible numbers are used. Example: 1, 2,and 3 for a three compressor installation.
13-9/1 0-641 Section 4a Page 6
5. In the top line, TRANFER INTERVAL is displayed.The bottom line will indicate a number of hours inthe range of 1 to 5000. It is factory set at 24. This isthe number of hours that this machine will stay inthe role of “master” or “lead”compressor. Normallyit is desirable to set this value the same on allsequenced units to equalize running hours.
6. In the top line, LAG START DELAY is displayed.The bottom line will indicate a number in the rangeof 15 to 600 seconds. It is factory set at 30. This isthe length of time this machine will wait beforestarting when the pressure drops below the resetpoint. Again, this is normally set to the same valuefor all sequenced units. Its setting will depend onthe amount of air storage volume in the system.
7. In the top line, BLOWDOWN TIME is displayed.The bottom line will indicate a time between 5 and20 minutes. It is factory set at 10 minutes. This isthe minimum time interval between blowdowns.Limiting the blowdown frequency has been shownto prevent oil foaming and minimize wastefuldumping of compressed air when loading is likelyto occur in a short time.
8. In the top line, AUTO TIME is displayed. The bot-tom line will indicate a time between 5 and 30minutes. It too, is factory set at 10 minutes. Itsfunction is to prevent too frequent motor starting,and to allow the motor a ‘cool-down’ period beforestopping.
9. In the top line, START TIME is displaved. Thebottom line will indicate a time between 3 and 10seconds. This is the time that the wye-delta starterspends in the ‘start’ mode. It should be set totransfer the starter to the ‘run’ mode as soon as themotor reaches its maximum attainable speed in the‘start’ mode. If the set switch is off, the controlreturns to the “READY’ state and may then berestarted.
NOTICE
This concludes operator accessibleadjustments. The following are consid-ered ‘service adjustments’. The “SET’switch on the circuit board must beturned ‘on’ to proceed to the next set ofprogrammable adjustments. The “SET”switch is located beneath the powertransformer mounting plate on the leftedge of the main circuit board.
10. In the top line, HY SYS PRES LIM isdisplayed. Thisshould be set 20-25 PSI above nameplate pres-sure (equal to the relief valve setting). If this pres-sure is approached, the control will be forced to ablowdown and shutdown condition.
11.
12.
13.
14.
15.
16.
17.
18.
19.
In the top line, SET PRESSURE is displayed.Thebottom line will indicate a pressure value in therange of 50 to 180 PSI. It is to be set at the name-plate rating of the compressor for normal opera-tion. Under NO circumstances, is this adjustmentto be set in excess of the compressor nameplatepressure.
In the top line, RESET PRESSURE is displayed.The bottom line will indicate a pressure value in therange of 45 to 175 PSI. This setting determines thepoint at which machine startup occurs inAUTO andSEQUENCE modes and when the compressor willload up from the blown down condition. Note thatRESET PRESSURE cannot be set within 5 PSI ofthe SET PRESSURE. It is necessary that all ma-chines to be sequenced have the same SET andRESET PRESSURE setpoints.
The top line displays REMOTE STOP. Select ei-ther IMMEDIATE or TIMED STOP as the desiredresponse to the remote input.
Inthetop line, FILTER CHNG INT isdisplayed. Thebottom line will indicate a time interval of 1000hours. This may be adjusted lower (down to 500hours) if severe operating conditions are antici-pated. After the machine has run for the pro-grammed setting, an advisory will be displayedrequesting an oil filter change.
In the top line, OIL CHNG INTERVAL is displayed.The bottom line will indicate a time interval of 8000hours. 8000 hours is the maximum setting, and isthe proper change interval for AEON 9000 syntheticoil. See Section 5, page 4 for proper setting forAEON lubricants.
In the top line, HI TEMP LIMIT is displayed. Thebottom line will indicate 225 degrees F. This is themaximum (and proper) setting for compressor op-eration. It may be temporarily lowered to verify thefunction of the temperature shutdown system.
In the top line, FAN TYPE isdisplayed. The bottomline will indicate either AIR COOLED or WATERCOOLED. Selecting AIR COOLED places the fanunder thermostatic control while WATER COOLEDoperation runs the fan whenever the main motorruns.
In the top line, AUTO RESTART is displayed. Thebottom line will indicate either OFF or ON. Set thisfeature to ON when it is necessary to have thecompressor automatically restart after a power in-terruption. This feature shall only be enabled whenthe owner determines that it is safe to do so. It isrecommended that compressor access be limitedto only trained service personnel when this featureis enabled.
This step isonlv encountered ifthe AUTO RESTARTfunction was set to ON in step 13. In the top line,RESTART TIME is displayed. The bottom line willindicate a time between 5 and 60 seconds. It is
13-9/10-641 Section 4a Page 7
factory set at 10 seconds. This is the amount ofdelay introduced before restarting after power hasbeen restored.
20. In the top line, AIR END TYPE is displayed. Thebottom line will indicate either TURNVALVE or NONTURNVALVE. It is to be set as is appropriate for thecompressor.
21. In the top line, SYSTEM VOLUME isdisplayed. Thebottom line mav be selected as SMALL, MEDIUM,or LARGE. This’tunes the response of the modula-tion control loops to optimize loop stability. It isfactory set to MEDIUM. Set as follows:
NOTICE
The setting of this parameter is notcritical. When set to its most appropri-ate value, the controller will maintainthe discharge at the closest possiblevalue. If not set correctly, pressure willvary from the desired setpoint to asomewhat greater degree but the com-pressor and its components will not beadversely affected.
SMALL if estimated volume is less than .25 gallonper CFM.
MEDIUM if estimated volume is between .25 and
22.
23
24
1.0 gallon per CFM.
IARGE if estimated volume is greater than 1.0gallon per CFM.
In the top line, REMOVE SYS PRESS is displayed.The bottom line displays the current pressure beingsensed at the package discharge. At this pointsteps must be taken to ensure that the systempressure is, in fact, zero. If necessary, remove theline to the system pressure transducer. PressingENTER will now cause the “AUTO SENTRY-ES” tocalibrate the transducer output to zero PSI. Obvi-ously, pressure measurement errors will be en-countered if ‘zeroing’ is done with pressure at thetransducer.
In the top line, REMOVE RES PRESS is displayed.The bottom line displays the current pressure beingsensed in the air/oil reservoir. The reservoir pres-sure transducer may now be ‘zeroed’ by followingthe steps outlined in 19 above.
The display now reads PRESS CNST RUNTO JOGMOTOR. Pressing the “CONSTANT RUN” key will
briefly energize the starters, causing the compres-sor to rotate 1/4` to 1-1/2 revolutions to allow arotation check.
This completes the programming and setup proceduresfor the “AUTO SENTRY-ES” controller. Press the “STOP-RESET’ key to return the compressor to the ‘READY’mode.
13-9/10-641 Section 4a Page 8
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SECTION 4b - EAP UNITSCONTROLS & INSTRUMENTS
GENERAL - The Gardner-Denver rotary screw com-
pressor is prewired with all controls, motor and wiring,
and starter for the voltage and horsepower specified at
the time of the order. It is necessary only to connect thecompressor unit to the correct power supply, to the shopair line, and to the shop water line, if the compressor iswatercooled. A standard compressor unit consists of thecompressor, oil reservoir, oil cooling system and oilfilters, motor enclosure specified, NEMA 12 starter/con-
trol box, and controls as described below.
This compressor features the programmable control,
which integrates all the control functions under micro-
processor control. Its functions include safety and shut-
down, compressor regulation, operator control, and
advisory/maintenance indicators. The keypad and dis-play provide the operator with a logical and easily oper-ated control of the compressor and indication of itscondition.
PROTECTIVE DEVICES AND SHUTDOWN - The“AUTO SENTRY-ES” will shut down the unit followingany fault detected in the following devices. Following ashutdown, a message will be displayed to indicate thecause. The shutdown light will be on if the cause stillexists, or will flash if the cause has been cleared. Toresume operation, the cause of shutdown must be cor-
rected and the controller reset by pressing the“STOP/RESET” key.
Motor Protection Devices - Overload heaters are fur-nished for the starter in the voltage range specified.There are three (3) overloads in the starter of proper sizefor the starter and its enclosure. Note that motor name-plate current must by multiplied by .577 for wye-deltastarters. The display will indicate which overload relaytripped. The overload relay is reset by pressing thebutton on the relay itself. Motor current (amps) andvoltage must be measured to locate the cause for highcurrent. Proper starter coil and contact action is alsomonitored and errors in operation will cause a shutdownwith the cause displayed.
High Temperature - The compressor is protected fromhigh discharge and separator temperature by two inde-pendent thermistor probes. One probe is located in thedischarge housing to sense compressor discharge air-oil mixture temperature. The second probe is located atthe separator discharge and senses the temperature ofthe air at the oil separator. The “Auto-Sentry-ES” will shutthe compressor down if temperature sensed at eitherlocation exceeds 225° F. (or lower per user adjustment)or ifa rapid temperature rise is detected. The location ofthe high temperature will be displayed. Shutdown willalso occur if a shorted probe, open probe, or extreme
VE
IR FILTER SWITCH
TRANSDUCER
MlPR
u-OILRESERVOII
1I
I
TIFIGURE 4b-1 - SCHEMATIC TUBING DIAGRAM
13-9/1 0-641 Section 4b Page 1
Iowtemperature isdetected. The display will indicate thelocation of the defective thermistor probe,
~CAUTION
Machine damage will occur if compres-sor is repeatedly restarted after hightemperature stops operation. Find andcorrect the malfunction before resum-ing operation.
Separator Differential Pressure - The separator differ-ential pressure is continually monitored by the “AutoSentry-ES”. At a differential pressure of approximately15 psi, the unit will be shut down.
High Pressure - The “Auto Sentry-ES” will shut downthe unit if excessive pressures are detected in the reser-voir or system. Shut down will occur if a defectivetransducer is detected. The display will indicate thelocation of the high sensed pressure or transducer(xducer) error. Check that all adjustments have beenproperly made, and all connections are secure.
Relief Valve - A pressure relief valve(s) is (are) installedin the final discharge line and set to approximately 120%of the unit’s full load operating pressure for protectionagainst overpressure. Periodic checks should be madeto ensure its (their) proper operation.
The relief valves should be tested for proper operation
/“
/
FIGURE 4b-2 - BLOWDOWN VALVE
at least once every year. To test the relief valve, raise the
system operating pressure to 75% of relief valve setpressure and manually open the valve with the handlever. Hold the valve open for a few seconds and allowit to snap shut.
FROM[
INLET VALVE
AIR FILTER(OPEN POSITION)
m/-MUFFLER
/ /-oRIFlcE
w“”P
1 /
A ,’ 11 .- CHECK VALVE
ORIFICE
PuRGE VALVE YIL
I[
- BLOW DOWN
SOLENOID VAI
SOLENOID VALVE IVC
SEPARATORA ‘
J L\ SHUTTLEVALVE
HOUSING
TO SEPATiTORAFT~RCOOl~~ HOLISING
TO- T~ANS~U~[R
VAL
.VE
FIGURE 4b-3 - INLET VALVE
~WARNING
When relief valve opens, a stream ofhigh velocity air is released, resulting ina high noise level and possible dis-charge of accumulated dirt or other de-bris. Always wear eye and earprotection and stand clear of the dis-charge port when testing the reliefvalve to prevent injury.
I ~CAUTION I
Never paint, lubricate or alter a reliefvalve. Do not plug vent or restrict dis-charge.
~WARNING
Operation of unit with improper reliefvalve setting can result in severe per-sonal injury or machine damage.
Ensure properly set valves are installedand maintained.
Low Oil Pressure - The “Auto Sentry-ES” will shutdown the unit if inadequate oil pressure to the compres-sor is detected. If this occurs, check the wiring andpiping solenoid valves.
FIGURE 4b-4 - SHUTTLE VALVE
Emergency Stop - Pressing the emergency stop buttonwill shut down the unit and the controller. To restart, pullthe button out to its normal position and reset thecontroller.
Power Failure - Following power interruptions, thecontroller will remain in a shutdown state.
High Vibration (optional) - This optional feature willshut down the unit if abnormally high vibration is de-tected.
Check CN 7 (8, 9) - This indicates a wiring error orconection problem. Remove power and correct wiring.
Blowdown Valve - (Figure 4b-2, page 2, this section)The blowdown solenoid valve releases pressure fromthe oil reservoir during any shutdown condition, andduring some operating conditions. See descriptionunder “Air Control Components”, page 4, for construc-tion and operation information.
—_
bSOLENOID VALVE
‘No
FIGURE 4b-5 - TURN VALVE ACTUATOR (SECTIONED)
13-9/1 0-641 Section 4b Page 3
AIR IN
FIGURE 4b-6 - MINIMUM DISCHARGE PRESSURE VALVE
GAUGES AND DISPLAYS
Oil Level - The oil level gauge is located on the side ofthe reservoir. See Section 5, page 5, “Lubrication, OilCooler, Oil Filter and Separator” for information on howto correctly read the gauge. All other instruments arepart of the programmable controller.
AIR CONTROL COMPONENTS - Refer to Figures 4b-1,page 1, 4b-7, 4b-8 and 4b-9, pages 10, 11 and 12, thissection, for schematic tubing diagrams.
Inlet Valve (Figure 4b-3, page 3, this section) - The inletvalve restricts the inlet to control capacity and closes tounload the compressor. At shutdown, the inlet valvecloses to prevent backflow of air.
The inlet valve position is controlled by air pressure in itspiston cylinder, which is controlled by the programma-ble controller through solenoid valves IVC and IVO. Aspressure to the piston is increased, the valve closes to
restrict air flow and compressor delivery (Figures 4b-7,
4b-8 and 4b-9, pages 10, 11 and 12, this section).
Purge Air Valve - The purge valve is a normally closedtwo-way air actuated valve that admits purge air from thefinal discharge manifold to the compressor to counter-act the oil knock that occurs in oil-flooded rotary screwcompressors when they are completely unloaded withpressure in the oil reservoir. This valve is controlled bythe same control pressure which controls the inlet valve.
Solenoid Valves IVC and IVO - These valves controlposition of the inlet valve in response to signals from the“Auto Sentry-ES”. With both valves de-energized, thenormally open IVC valve allows control pressure to theinlet valve piston to close the valve. If IVC only is ener-gized, the inlet valve is held in its current position. If both
valves are energized, control pressure is relieved from
the inlet valve piston to allow the valve to open.
Pressure Regulator - The pressure regulator is used tosupply a constant and low control pressure to prevent
damage to the inlet valve from “slamming.’’The regulatorshould be set for 25-30 psig.
Shuttle Valve - (Figure 4b-4, page 3, this section) Alsoknown as a double check valve, the shuttle valve is adevice which will take two (2) supply signals and allowthe one with the highest pressure to pass through. Theshuttle valve is used to provide control air pressure fromeither the reservoir or plant air system, as requiredduring different operating conditions.
Blowdown Valve - (Figure 4b-2, page 2, this section)The blowdown valve is a two-way solenoid valve whichis piped into the oil reservoir outlet but ahead of thecheck valve. When the solenoid is de-energized, thevalve opens and the oil system is blown down. When thesolenoid is energized, the valve closes to allow the oilsystem to pressurize. A control air check valve is pro-vided to ensure that the inlet valve closes during blow-down. See Figure 4b-3, page 2, this section.
Solenoid Valves TVO and TVC - These valves controlposition of the turn valve in response to signals from the“Auto Sentry-ES”. With both valves de-energized, equalpressure is supplied to both sides of the actuator to holdit in its present position. IfTVC only isenergized, the rightside of the turn valve actuator is exhausted to the com-pressor inlet cavity, causing the turn valve to movetowards the full load position. If TVO only is energized,the left side of the turn valve actuator is exhausted to thecompressor inlet cavity, causing the turn valve to movetowards the unload position. See “Control System Op-eration” in this section for a description of how the turnvalve components respond during operation.
Turn Valve - The turn valve isa helical valve which, whenrotated, opens and closes a series of ports cast into thecompressor cylinder. When these ports are open, theydirect some of the air which would otherwise be com-pressed back to the inlet, reducing both capacity andpower consumption.
Turn Valve Actuator - (Figure 4b-5, page 3, this section)The turn valve actuator isa rotary rack and pinion devicewhich positions the turn valve according to systemdemand. Filtered oil from the compressor sump is di-rected to the outboard end of the two actuating cylindersto move the rack and rotate the valve. Located on theend of the cylinders are adjusting screws which limit thetravel of the actuator. When looking at the rear of thecompressor, the adjusting screw on the right on thecompressor adjusts the fully closed (full load) positionof the valve. The full load position of the actuator maybe checked by removing the adjusting screw at theunloaded end of the actuator (left side of the compres-sor) and using a rod to push the pistons to the full loadposition. The rod must be clean and free of burrs andscale. Take care not to scrape the cylinder walls whenmoving the pistons.
Minimum Discharge Pressure Valve (Figures 1-5,
page 3, Section 1 and 4b-6, above) -An internal spring-Ioaded minimum pressure valve is used in the finaldischarge line to provide a positive pressure on the oil
13-9/1 0-641 Section 4b Page 4
system of the compressor even when the air service
valve is fully open.
The valve incorporates an orifice which, when air isflowing through it, maintains approximately 65 psig inthe oil reservoir. A spring-loaded piston valve senses airpressure on the upstream (oil reservoir side) of the valve.When the system pressure 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 O-ringfor sealing, valve orifices for restriction, or valve andvalve seat for burrs and dirt.
The valve isadjustable within a small range. It isadjustedby a screw on the side of the valve body. The minimumpressure can be adjusted as follows:
1. Start the compressor.
2. Reduce pressure downstream of minimum pres-sure valve to below desired minimum pressure. DONOT REDUCE UPSTREAM PRESSURE OR AD-JUST VALVE BELOW 65 PSIG.
3. Loosen locknut on adjusting screw.
4. Turn set screws into increase, or out to decreaseminimum pressure to be held.
5. Hold the set screw at the desired point and tightenlocknut.
Check Valve (Oil Reservoir) - A renewable seat swingtype check valve in the final discharge manifold preventsbackflow of air from the shop airline when the unit stops,unloads or is shut down.
System Pressure Transducer - This transducer is con-nected after the minimum pressure valve and dischargecheck valve. It converts the pressure in the plant airsystem to an electrical signal for use by the programma-ble controller for modulation and control.
Discharge Pressure Transducer - This transducer isconnected to the oil reservoir. Its signal is used toprevent loaded starts, monitor oil pressure, and forseparator different ial.
Air Filter Vacuum Switch - This switch is used tomonitor air filter condition and alert the user if the filterrequires service or replacement.
Vibration Switch (Optional Equipment) - The optionalvibration shutdown switch, mounted on the compressorcoupling cover, detects an increase in vibration thatcould bean indication of impending damage to the unit.The switch actuates when the selected level of vibrationis exceeded.
The switch MUST BE ADJUSTED when the unit is firstinstalled. Refer to switch manufacturer’s instructionmanual for complete details.
STARTER/CONTROL PANEL
The following items are located in the electrical enclo-
sure and provide the main control of the compressor unitand switching of the motor(s). Refer to Figure 3-1.
AUTO SENTRY-ES - The “Auto Sentry-ES” is locatedon the upper section of the panel. It provides all thecontrol of the motors and control devices for safe andefficient operation of the compressor unit. Its displayprovides all gauging functions, shutdown causes, andmaintenance recommendations. The keypad providesthe user with selection of operating modes and adjust-ment to tune the controls for the application. It is con-nected to other devices inside the panel and externaldevices through the terminal strip. The “Auto Sentry-ES”requires no maintenance.
Emergency Stop - This isa maintained pushbutton, andremoves power from the controller outputs regardlessof controller status. It is located on the upper section ofthe panel, next to the keypad.
~WARNING
Automatic restarting or electrical shockcan cause injury or death. Open andlock main disconnect and any othercircuits before servicing unit.
Control Transformer - This changes the incoming powervoltage to 110/120 volts for use by all unit control de-vices. Two primary and one secondary fuse are pro-vided. Refer to the adjacent Iabelling for replacementinformation.
Terminal Strip - This provides connections for all110/1 20 volt devices not contained within the controlpanel.
Fan Starter - (where applicable) The starter is used toprovide control and overload protection for the coolingfan on air-cooled units and ventilation fans ofwatercooled units with enclosure. Overload heatersshould be selected based on the nameplate current ofthe fan motor. Three fuses are provided, Refer to adja-cent labelling for replacement information.
Main Starter - This starter is used to provide control andoverload protection for the main drive motor. For wye-delta starters, overload heaters should be selectedbased on the motor nameplate current times .577 forproper protection. Wye-delta starters employ three con-tractorswhich are controlled sequentially to provide lowcurrent starting. Full-voltage starters employ a singlecontactor; overload selection should be based on thefull load current of the motor, and adjacent Iabelling.
OPERATION
Operation of the “AUTO SENTRY-ES” is dependent onselection of an operating mode from the controller key-pad. Prior to starting, the “STOP/RESET” key must bepressed to place the control in its ready state. Operation
13-9/1 0-641 Section 4b Page 5
may then be started by selecting an operating modefrom the controller keypad. Once operating, the operat-ing mode may be changed at any time. TheSTOP/RESET key may be pressed at any time to stopthe compressor under normal conditions.
An optional control may be wired to the control tointerrupt and restart the unit based on controls by others.When stopped by these controls, the display will indicateREMOTE”STOP.-
~WARNING
Automatic restarting or electrical shockcan cause injury or death. Open andlock main disconnect and any othercircuits before servicing unit.
In any mode, the compressor will start only if reservoirpressure is below 5 psig. The display will indicate if thecontrol is waiting for blowdown. The controls will keepthe compressor unloaded until the start cycle has beencompleted.
Constant Run Mode Operation - This mode is bestused in applications where there are no long periods ofunloaded operation. The compressor unit will start andrun continuously, using its modulation controls to matchdelivery to demand.
As demand falls below the compressor capacity, thepressure will rise to the setpoint of the control. When thepressure reaches the setpoint the AUTO SENTRY-EScontroller operates the solenoid valves to pass pressureto the inlet valve piston and the inlet valve closes enoughto match air system demand. See Figure 4b-8, page 11,this section.
As demand increases, the controller will modulate theinlet valve by passing pressure with the solenoid valvesas required to match delivery to demand. See Figure4b-7, page 10, this section.
As demand further increases, the inlet valve is held open,and delivery is controlled by the turn valve solenoids.This provides the most efficient delivery to match de-mand under all conditions.
Low Demand Mode Operation -The low demand modereduces power consumption by relieving pressure in thereservoir during unloaded operation. Under loaded con-ditions, it will operate identically to the constant-runmode described above.
During low demand periods, the controller will open theblowdown valve and fully close the inlet valve to mini-mize the motor load. See Figure 4b-9, page 12, thissection. A timer is started when this occurs. While in thisstate, control air pressure is supplied from the plant airsystem. When system air pressure drops due to in-creased demand, the blowdown valve recloses and thecontrols resume their normal modulation sequence.
Subsequent blowdown periods are not allowed until thetimer has completed its cycle. This cycle eliminates theproblems of oil foaming and carryover which can occurif the oil reservoir of an oil-flooded compressor is blowndown too often. The timer is adjustable from 5 to 20minutes.
Automatic Mode Operation - This mode provides au-tomatic start and timed stop, and is best used in appli-cations with long unloaded periods. Operation duringperiods of demand or moderately long unloaded periodsis identical to the low demand mode.
The Auto time delay is adustable from 5 to 30 minutes.If the controller operates unloaded for this period withno demand, the compressor drive motor is halted toeliminate its power consumption. The controls will re-main in this state until demand is again indicated by adrop in pressure.
Sequence Mode Operation - This mode provides forcommunication between controllers, operating only asmany as are required for economical operation. The leadunit operates identically to the automatic mode; opera-tion will be automatically staged for each lag unit.
Communication between controllers is achieved by in-terconnection of a communications link to circuit boardconnectors. A “unit number” must be assigned to eachunit to operate in this mode (see “Programming andSetup” in this section).
CONTROLLER DISPLAY
The display above the keypad is used to provide oper-ating information to the user. If a shutdown has oc-curred, the display will indicate the cause as notedabove.
During normal operation the display will show the oper-ation mode, system pressure, compressor dischargetemperature, and total running hours. Alternate displaysare available by pressing keypad cursor keys, and willbe identified on the display. These include reservoirpressure, separator differential pressure, reservoir tem-perature, system pressure, and compressor dischargetemperature. In Low Demand, Automatic, or Sequencemodes, alternate displays also indicate remaining timesof delay. If no keys are pressed for 5 seconds, the displaywill return to its normal mode.
The display isalso used as a service reminder for normalmaintenance items. These include the separator, airfilter, and oil filter change intervals. All intervals are basedon recommended parts as noted in the maintenancesection of this manual. Oil change intervals are alsoautomatically calculated, based on actual operatingconditions. This allows maximum utilization of AEON9000 oil. Messages will also be displayed if operation hasoccurred during low ambient temperatures, or if hightemperature operation has occurred.
Clearing Advisories - Temperature advisories may becleared while the unit is running by simply pressing theENTER key. To reset the service messages, press the
13-9/10-641 Section 4b Page 6
STOP/RESET key to stop operation of the compressor.Disconnect power and service the unit as required.Following service, put the enable switch in the downposition, restore power to the unit, and pressSTOP/RESET to clear the controller. Proceed throughthe service section described in step 1 below. Activeadvisories will be displayed and may be cleared bypressing the ENTER key. After the messages have beencleared, press STOP/RESET and select an operatingmode to resume operation.
PROGRAMMING AND SETUP INSTRUCTIONS FORTHE AUTO SENTRY-ES (R) CONTROLLER
Programming and setup isaccomplished with the “PRO-GRAM” keys. In all steps, the “ENTER” key will cause thecontroller to accept the displayed value into memoryand advance to the next programming function. The plus“+” and minus “-” keys will increase and decrease dis-played values, respectively. The right and left arrowkeys, “—” and "-", position the cursor (flashingdigit). The number at the cursor will be the number thatis changed by the “+” and “-” keys. At any point in theprogramming and setup routine, the “STOP-RESET” keycan be pressed to exit and return to the ready mode.
In all steps of the programming routine, the top line ofthe display will give a description of the parameter to beprogrammed, while the bottom line shows the variablethat is capable of being altered by programming.
The following is a step by step guide to programing the“AUTO SENTRY-ES” Controller.
I NOTICE I
Between each step it is necessary topress the “ENTER” key to restore thenew value and advance to the next step.
1. Press the “ENTER” key to begin programming. Ifthe enable switch on the circuit board is in the setposition, the control proceeds to the setup adjust-ments starting with step 2 below. If the slide switchis down in the “+” position, push “ENTER” to gofrom OIL FILTER CHANGE to OIL CHANGE andthen push “ENTER” again to proceed to Step 2.Press “AUTO” to display the hours remaining untiloil change or filter change is recommended. Ifservice has been performed early, press the“AUTO” key to reset the timers to their full numberof hours. Press “ENTER” to proceed to the nextdisplay without affecting timers.
2. In the top line, DISPLAY UNITS is indicated. Thebottom line will indicate ENGLISH (PSIG, Fahren-heit) or METRIC (Bars, Celsius). Select the desiredmode and press ENTER to save and proceed.
3. In the top line, NUM OF SEQ UNITS is displayed.
The bottom line will indicate a number in the rangeof one through eight. This will be factory set at”1”.This should be set to a number corresponding tothe number of compressors that are currently in-stalled on this air system that also have AUTOSENTRY-ES controllers. It should be noted that allAUTO SENTRY-ES compressors on the systemmust have the same number programmed heretooperate correctly in “SEQUENCEY mode.
NOTICE
Setting the value in step 1 to one indi-cates that no sequencing is to takeplace. Consequently, steps 4,5, and 6,which relate to sequencing, areskipped by the “AUTO SENTRY-ES”;Programming commences at step 7.
4. In the top line, UNIT NUMBER is displayed. Thebottom line will again indicate a number of onethrough eight This will be factory set at”1”. Each“AUTO SENTRY-ES” in a sequenced system musthave a unique number here. The sequence modewill not function if two or more compressors havethe same UNIT NUMBER. Most efficient machine-to-machine communications will occur when thelowest possible numbers are used. Example: 1, 2,and 3 for a three compressor installation.
5. In the top line, TRANFER INTERVAL is displayed.The bottom line will indicate a number of hours inthe range of 1 to 5000. It is factory set at 24. This isthe number of hours that this machine will stay inthe role of “master” or “lead”compressor. Normallyit is desirable to set this value the same on allsequenced units to equalize running hours.
6. In the top line, LAG START DELAY is displayed.
The bottom line will indicate a number in the rangeof 15 to 600 seconds. It is factory set at 30. This isthe length of time this machine will wait beforestarting when the pressure drops below the resetpoint. Again, this is normally set to the same valuefor all sequenced units. Its setting will depend onthe amount of air storage volume in the system.
7. In the top line, BLOWDOWN TIME is displayed.The bottom line will indicate a time between 5 and20 minutes. It is factory set at 10 minutes. This isthe minimum time interval between blowdowns.Limiting the blowdown frequency has been shownto prevent oil foaming and minimize wastefuldumping of compressed air when loading is likelyto occur in a short time.
8. In the top line, AUTO TIME is displayed. The bot-tom line will indicate a time between 5 and 30minutes. It too is factory set at 10 minutes. Itsfunction is to prevent too frequent motor starting,
13-9/10-641 Section 4b Page 7
and to allow the motor a ‘cool-down’ period beforestopping.
9. In the top line, START TIME is displaved. Thebottom line will indicate a time between 3 and 10seconds. This is the time that the wye-delta starterspends in the ‘start’ mode. It should be set totransfer the starter to the ‘run’ mode as soon as themotor reaches its maximum attainable speed in the‘start’ mode. If the set switch is off, the controlreturns to the “READY’ state and mav then berestarted.
NOTICE
This concludes operator accessibleadjustments. The following are consid-ered ‘service adjustments’. The “SET’switch on the circuit board must beturned ‘on’ to proceed to the next set ofprogrammable adjustments. The “SET’switch is located beneath the powertransformer mounting plate on the leftedge of the main circuit board.
IO. In the top line, HY SYS PRES LIM is displaved. This
should be set 20-25 PSI above nameplate pres-sure (equal to the relief valve setting). If this pres-sure is approached, the control will be forced to ablowdown and shutdown condition.
11. In the top line, SET PRESSURE is displayed.Thebottom line will indicate a pressure value in therange of 50 to 180 PSI. It is to be set at the name-plate rating of the compressor for normal opera-tion. Under NO circumstances, is this adjustmentto be set in excess of the compressor nameplatepressure.
12. In the top line, RESET PRESSURE is displayed.The bottom line will indicate a pressure value in therange of 45 to 175 PSI. This setting determines thepoint at which machine startup occurs inAUTO andSEQUENCE modes and when the compressor willload up from the blown down condition. Note thatRESET PRESSURE cannot be set within 5 PSI ofthe SET PRESSURE. It is necessary that all ma-chines to be sequenced have the same SET andRESET PRESSURE setpoints.
13. The top line displays REMOTE STOP. Select ei-ther IMMEDIATE or TIMED STOP as the desiredresponse to the remote input.
14. In the top line, FILTER CHNG INT isdisplayed. Thebottom line will indicate a time interval of 1000hours. This may be adjusted lower (down to 500
15.
16.
17.
18.
19.
20.
21.
hours) if severe operating conditions are antici-
pated. After the machine has run for the pro-grammed setting, an advisory will be displayedrequesting an oil filter change.
In the top line, OIL CHNG INTERVAL is displayed.The bottom line will indicate a time interval of 8000hours. 8000 hours is the maximum setting, and isthe proper change interval for AEON 9000 syntheticoil. See Section 5, page 4 for proper setting forAEON lubricants.
In the top line, HI TEMP LIMIT is displayed. Thebottom line will indicate 225 degrees F. This is themaximum (and proper) setting for compressor op-eration. it may be temporarily lowered to verify thefunction of the temperature shutdown system.
In the top line, FAN TYPE isdisplayed. The bottomline will indicate either AIR COOLED or WATERCOOLED. Selecting AIR COOLED places the fanunder thermostatic control while WATER COOLEDoperation runs the fan whenever the main motorruns.
In the top line, AUTO RESTART is displayed. Thebottom line will indicate either OFF or ON. Set thisfeature to ON when it is necessary to have thecompressor automatically restart after a power in-terruption. This feature shall only be enabled whenthe owner determines that it is safe to do so. It isrecommended that compressor access be limitedto only trained service personnel when this featureis enabled.
This step isonly encountered ifthe AUTO RESTARTfunction was set to ON in step 13. In the top line,RESTART TIME is displayed. The bottom line willindicate a time between 5 and 60 seconds. It isfactory set at 10 seconds. This is the amount ofdelay introduced before restarting after power hasbeen restored.
In the top line, AIR END TYPE is displayed. Thebottom line will indicate either TURNVALVE or NONTURNVALVE. It is to be set as isappropriate for thecompressor.
Inthetop line, SYSTEM VOLUME isdisplayed. Thebottom line may be selected as SMALL, MEDIUM,or LARGE. This tunes the response of the modula-tion control loops to optimize loop stability. it isfactory set to MEDIUM. Set as follows:
SMALL if estimated volume is less than .25 gallonper CFM.
MEDIUM if estimated volume is between .25 and1.0 gallon per CFM.
13-9/10-641 Section 4b Page 8
LARGE if estimated volume is greater than 1.0gallon per CFM.
NOTICE
The setting of this parameter is notcritical. When set to its most appropri-ate value, the controller will maintainthe discharge at the closest possiblevalue. If not set correctly, pressure willvary from the desired setpoint to asomewhat greater degree but the com-pressor and its components will not beadversely affected.
22. In the top line, REMOVE SYS PRESS is displayed.The bottom Iinedisplaysthe current pressure beingsensed at the package discharge. At this pointsteps must be ta”kentoensure thatsystem pressureis, in fact, zero. If necessary, remove the line to the
23.
24.
system pressure transducer. Pressing ENTER willnow cause the “AUTO SENTRY-ES” to calibrate thetransducer output to zero PSI. Obviously, pressuremeasurement errors will be encountered if ‘zeroing’is done with pressure at the transducer.
In the top line, REMOVE RES PRESS is displayed.The bottom Iinedisplaysthe current pressure beingsensed in the air/oil reservoir. The reservoir pres-sure transducer may now be ‘zeroed’ by followingthe steps outlined in 19 above.
The displav now reads PRESS CNST RUN TOJOG MOTOR. Pressing the ‘ICONSTANT RUN”key will briefly energize the starters, causing com-pressor to rotate 1/4 to 1-1/2 revolutions to allow a
rotation check.
This completes the programming and setup proceduresfor the “AUTO SENTRY-ES” controller. Press the “STOP-RESET” key to return the compressor to the ‘READY’mode.
13-9/10-641 Section 4b Page 9
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SECTION 5LUBRICATIONOIL COOLER, OIL FILTER & SEPARATOR
COMPRESSOR OIL SYSTEM (Figures 5-1 and 5-2,pages 2 and 3, this section) cools the compressor,lubricates moving parts and seals internal clearances inthe compression chamber.
The oil inlet line is connected at the bottom of the oil
reservoir. Air pressure in the oil reservoir forces oilthrough the oil cooler, thermostatic mixing valve, oil filterand into the compressor main oil gallery.
The oil passes through internal passages for lubrication,cooling and sealing. The air-oil mixture is then dis-charged to the oil reservoir where a large part of theentrained oil drops out of the air stream; the air thenpasses through the final oil separator where most of theremaining oil is removed. The separated oil is returnedto the compressor and the air passes to the final dis-charge line.
RECOMMENDED LUBRICANT - Gardner-Denvercompressors are factory filled with AEON ‘M !ubricants.These lubricants are formulated to the highest qualitystandards and are factory authorized, tested and ap-proved for use in rotary screw compressors. AEONlubricants are avai!able through your authorized Gard-ner-Denver compressor distributor.
OIL SPECIFICATIONS - This compressor is factoryfilled with AEON ‘M9000 lubricating coolant. AEON 9000is a synthetic extended life lubricant which can extendlubricant change intervals 4 to 10 times that of a petro-leum based lubricant. A lubricant analysis program fora periodic check of lubricant quality and remaining lifecan maximize the change interval.
CAUTION
Use of improper lubricants will causedamage to equipment. Do not mix dif-ferent types of lubricants or use inferiorlubricants.
~cAuTloNImproper equipment maintenance withuse of synthetic lubricants will damageequipment. Oil filter and oil separatorchange intervals must be adhered tofor maximum compressor protectionand efficiency -- See maintenanceschedule, Section 8.
High Temperature Operation - Gardner-Denver@AEON 9000 lubricating coolant will operate at a sus-
tained discharge temperature up to 21O°F when unusu-
ally high ambient air temperature is encountered.
h
I ,,~i DANGER
Oil under pressure will cause severepersonal injury or death. Shut downcompressor and relieve system of allpressure before removing waives,caps, plugs, fittings, bolts and filters.
~WARNiNG
High temperature operation can causedamage 10 equipment or personal in-jury. Do not repeatedly restart afterhigh temperature stops operation. Findand correct the malfunction before re-suming operation.
~WARNING
All materials used in Gardner-Denvercompressor units are compatible withAEON 90(30 Lubricating Coolant. Usecaution when selecting downstreamcomponents such as air line lubricatingbowls, gaskets and valve trim.
AEON 9000 Synthetic Lubricant is notcompatible with low nitrile Buna N oracrylic paints. AEON 9000 is compati-ble with most air system down streamcomponents.
Material Safety Data Sheets (MSDS) are available for allAEON lubricants from your authorized Gardner-Denverdistributor or by calling 217-222-5400.
REMOTE MOUNTED ELEVATED COOLER ASSEM-BLY PROCEDURE - The compressor package will bebuilt and tested with the coolers mounted on the pack-age. On enclosed units, the fan motor will be discon-nected after test and the vent fan motor connected in itsplace. The vent fan will be mounted in the enclosure. Acontactor (starter) will be shipped loose and remotemounted with the cooler by others upon start-up at thejob site. The control box will be wired for remote ele-vated coolers at the factory.
13-9/10-641 Section 5 Page 1
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A - MAIN MOTOR
B - COMPRESSORC - INLET FILTERD - OIL RESERVOIRE - OIL SEPERATORF - OIL COOLER
G - AFT ERCOOLERH - MIXING VALVE BODY
J - OIL FILTERK - OIL STOP VALVE
L - CHECK VALVE
M - RELIEF VALVE
N - CHECK VALVEP - MIN PRESS VALVE
R - PNEUMATIC 3 WAY VALVE
[l EVAIFD COO1tRS
FIGURE 5-3 - OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED
40 &50 HP 60, 75, 100 HP
Refill Capacity For Normal Oil Change ............................... 5.5 U.S. Gallons 8.5 U.S. GallonsRedto Yeilow Range ............................................................ 1.25 U.S. Gallons 2.o U.S. Gallons
FIGURE 5-4 - APPROXIMATE OIL SYSTEM CAPACITIES
NOTICE
All requirements of local codes shouldbe followed.
When connecting pipe fittings to the cooler, support thethreaded coupling with a pipe wrench when tighteningthe connection. Use silicone sealant on all steel toaluminum threaded connections. All piping should befirmly supported to avoid strain on the cooler manifoldand connections. Flexible connections should be in-stalled in all interconnecting piping, adjacent to thecooler, to avoid transmitting piping weight or vibrationsto the cooler elements. Before beginning installation,check to be sure that no debris or foreign matter remainsin the couplings or cooler bodies. Be certain intercon-necting piping is clean to avoid clogging the coolerpassages.
AFTERCOOLER PIPING -At shutdown of the system,all units should be drained completely of condensate ifthere is any possibility of freezing or corrosion damage.To help remove the condensate, the cooler may betapped per Figure 5-5 and a drain cock installed Afteropening the drain cock blow air into the cooler from a
AFTERCOOLER
K
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11
/;‘\‘\ :’
‘. /’‘\ /“
. . ,/‘---- ------
+ .50
m’-J
.50
--
R(.339) DRILL THRU118 NPTONE HOLE
$WELO
FIGURE 5-5- COOLER DRAIN DETAIL
connection on the opposite side of the cooler. At thesame time the connection on the drain side of the coolershould be plugged. The drain cock should be left openuntil the machines are ready for start-up.
13-9/10-641 Section 5 Page 4
~WARNING
Failure to remove condensate from anidle cooler in freezing temperatures willcause permanent cooler damage.Drain condensate after system shut-down. It is the owner/operator’s re-sponsibility to ensure that condensatehas been drained and cooler dried outto prevent cooler damage.
HEAT EXCHANGER (OIL) PIPING - All remote ele-
vated cooler applications must be sent through Engi-neering for approval and for recommending the pipesize. When the cooling module is removed from thepackage, the thermal mixing valve (H) remains on thepackage. Control group part number 200 ECM4002 willbe mounted on the package at the factory. This groupcontrols the oil stop valve as well as not allowing themachine to run unloaded. See Figure 5-3, page 4, thissection.
NOTICE
Remote mounted elevated coolershave a maximum pipe length of 30 feet(each way) and a maximum height of 20feet with a minimum of fittings. Engi-neering will review all remote elevatedcooler applications and recommendpipe size on an individual basis. cus-tomer service should include the engi-neering recommendation in the specialorder sent to Engineering.
Kit number EAQ68330 includes the oil stop valve, checkvalve and flanges and must be installed on all remote
elevated coolers per Figure 5-3, page 4, this section, and
the following instructions. Mount the check valve(9oJl 13) as shown. Mount the drain valves in the lowestsection of the pipe on each side of the cooler connec-tions. Mount the oil stop valve (90AR243) in the line afterthe thermal mixing valve as shown. Modifications to thecontrol lines will be made at the factory per 288 ECM81 Oschematic. Air to the oil stop valve must come from theupper fitting in the separator housing, then pass throughthe 3-way pneumatic valve. Control air to the valve mustbe from the line between the tee and the orifice in theblowdown muffler line per Figure 5-3, page 4, this sec-tion. When the machine blows down, it will activate thepneumatic valve and it will shut off the air and vent theline between the pneumatic control valve and the oilstop valve to atmosphere. This will shut the oil stop valveand prevent excessive oil from running into the resevoir.
Failure to install these parts could result in high oilcarryover and causing the machine to shutdown on highdischarge temperature.
COLD AMBIENT OPERATION - See “installation forCold Weather Operation,” Section 2.
ADDITION OF OIL BETWEEN CHANGES must bemade when the oil level isat the bottom of the red rangeon the gauge as read while the unit is on. To add oil,follow these steps:
1. Be sure the unit is completely off and that no airpressure is in the oil reservoir.
2. Disconnect, tag and lockout the power supply tothe starter.
3. Wipe away all dirt around the oil filler plug.
4. Remove the oil filler plug and add oil as required toreturn the oil level to the center of the green rangeon the gauge.
DO NOT OVERFILL. The quantity required to raise theoil level from the red range to the center of the greenrange is shown in Figure 5-6, page 6, this section.Repeated addition of oil between oil changes may indi-cate excessive oil carry-over and should be investi-gated.
~DANGER
Air/oil under pressure will cause severepersonal injury or death. Shut downcompressor, relieve system of all pres-sure, tag and lockout power supply tostarter before removing valves, caps,plugs, fittings, bolts, and filters.
h
~CAUTION
Excess oil carryover can damageequipment. Never fill oil reservoirabove “FULL” marker.
LUBRICANT CHANGE PROCEDURE - Following arethe primary steps to be completed when upgrading orchanging the type of lubricant.
1. Thoroughly drain system:
- Drain oil from air end and cooler while hot.
- Break low point connections and drain oil frompipe runs.
13-9/1 0-641 Section 5 Page 5
2.
3.
4.
5.
6.
7.
- Dump oil from filter and reinstall used filter.
Fill system with 50 percent charge of new lubricant.- Start machine and stay there to observe.- Allow machine to run about five minutes at tem-perature, or until temperature stabilizes, then shutdown.
Thoroughly drain machine.
Change to new filter and separator.
Fill system with full charge of the new lubricant.
Machine should then be run normally, however,total run time after the initial changeout should be50 percent of normal anticipated service life of thenew lubricant.- Drain all lubricant from system, change filter andseparator, and replace with full charge of newlubricant.
Subsequent lubricant chanaeouts should be atnormal “intervals (see chart, this page).
OIL LEVEL GAUGE (Figure 1-5, Page 3, Section 1)
indicates the amount of oil in the oil reservoir. Read oil
level only when unit is on. In operation the oil level willfluctuate as the compressor loads and unloads. Add oilonly when the oil level is at the bottom of the red rangeon the gauge as read when the compressor is on. Drainoil only when the oil level is past the center of the greenrange when the compressor is on.
MOISTURE IN THE OIL SYSTEM -In normal humidityand with normal operating temperatures and pressures,the thermal mixing valve controls the oil temperatureand prevents moisture contamination of the oil. Un-usual cooling of the oil reservoir, short loaded cycle inhigh humidity, malfunctions of the thermal valve orcooling water system may result in moisture in the oilsystem which is detrimental to compressor lubrication.If moisture is observed in the oil reservoir, drain themoisture and correct the condition causing the accumu-lation. See “Compressor Oil System Check,” page 10,and “Thermal Control (Thermostatic Mixing) Valve, ”page 7, in this section.
OIL CHANGE INTERVAL - Recommended oil changeintervals based on oil temperature.
Discharge AEON 4000 AEON 9000Temperature Change Interval Change Interval
upto 180”F 6000 hrs. 8000180 to 190°F 4500 hrs. 6000190 to 200”F 3000 hrs. 4000200 + 1500 hrs. 2000
When operating conditions are severe (very dusty, highhumidity) it will be necessary to change the oil morefrequently. Operating conditions and the appearanceof the drained oil must be surveyed and the oil changeintervals planned accordingly by the user. A good lu-bricant analysis program is helpful in planning thechange interval.
~’o
0-0LO bHI
GARDNERDENVER
o 00,
FIGURE 5-6 - OIL LEVEL GAUGE
DRAINING AND CLEANING OIL SYSTEM -
~DANGER
Air/oil under pressure will cause se-vere personal injury or death. Shutdown compressor, relieve system ofall pressure, disconnect, tag and lock-out power supply to starter before re-moving valves, caps, plugs, fittings,bolts, and filters.
Always drain the complete system. Draining when theoil is hot will help to prevent varnish deposits and carryaway impurities. To drain the system, use one of thefollowing methods:
If the unit is not elevated high enough to use the oilreservoir drain line to drain oil, a small hand, electric orair operated pump should be used to drain reservoirthrough the oil filler opening or from the drain valve.
If the unit is elevated so that the oil reservoir drain canbe used, empty the oil reservoir through the drain valveto a suitable container or sump.
If drained oil and/or oil filter element are contaminatedwith dirt, flush the entire system: reservoir, oil cooler,mixing valve and lines. Inspect the oil separator elementfor dirt accumulation; replace if necessary. If a varnishdeposit exists, contact the factory for recommendationsor”removal of the deposit and prevention of varnish.
FILLING OIL RESERVOIR -
~DANGER
Air/oil under pressure will cause se-vere personal injury or death. Shutdown compressor, relieve system ofall pressure, disconnect, tag and lock-out power supply to starter before re-moving valves, caps, plugs, fittings,bolts, and filters.
13-9/10-641 Section 5 Page 6
1.
2.
3.
4.
5.
6.
7.
Be sure the unit is completely off and that no airpressure is in the oil reservoir.
Disconnect, tag and lockout the power supply tothe starter.
Wipe away all dirt around the oil filler plug.
Remove the oil filler plug and add oil as required toreturn the oil level to the center of the green rangeon the gauge.
Operate the unit for about a minute allowing oil tofill all areas of the system.
Shut down the unit, allowing the oil to settle, andbe certain all pressure is relieved.
Add oil, if necessary, to bring the level to the centerof the green range on the gauge.
On unloaded operation and after shutdown some oil willdrain back into the oil reservoir and the oil level will readover “FULL.” DO NOT DRAIN OIL TO CORRECT. Onthe next start, oil will again fill the system and the gaugewill indicate operating at the proper level. DO NOTOVERFILL as oil carryover will result. The quantity of oilrequired to raise the oil level from “ADD” to “FULL’ isshown in figure 5-6, page 6, this section. Repeatedaddition of oil between changes may indicate excessiveoil carryover and should be investigated.
Use only CLEAN containers and funnels so no dirtenters the reservoir. Provide for clean storage of oils.Changing the oil will be of little benefit if done in aslipshod manner.
CAUTION
Excessive oil carryover can damageequipment. Never fill oil reservoirabove “FULL” marker.
COMPRESSOR OIL FILTER (Figure 1-5, page 3, Sec-tion 1) - This replaceable element filter is a vital part inmaintaining a trouble-free compressor, since it removesdirt and abrasives from the circulated oil. The filter isequipped with a relief valve that opens in the event theelement becomes dirty enough to block the flow of oil.
~CAUTION
Improper oil filter maintenance willcause damage to equipment. Replacefilter element every 1000 hours of oper-ation. More frequent replacementcould be required depending on oper-ation conditions. Filter element left inservice too long may damage equip-ment.
Use only the replacement element shown on the filtertag or refer to the parts list for the part number. Use thefollowing procedure to replace the filter element. Do notdisturb the piping. “
I ~DANGER
Air/oil under pressure will cause severepersonal injury or death. Shut downcompressor, relieve system of allpressure, disconnect, tag and lockoutpower supply to starter before remov-ing valves, caps, plugs, fittings, bolts,and filters.
J
1. Stop unit and be sure no air pressure is in the oilreservoir.
2. Remove the spin-on element.
3. Clean the gasket face of the filter body.
4. Coat the new element gasket with clean lubricantused in the unit.
5. Screw new element on filter body and tighten byhand. DO NOT OVERTIGHTEN ELEMENT.
6. Run the unit and check for leaks.
COMPRESSOR OIL COOLER - RADIATOR TYPE(Figure 1-5, page 3, Section 1) - The oil cooler motorand fan is mounted on the oil cooler module; air isexhausted through the oil cooler and away from the unit.Do not obstruct airflow to and from the oil cooler. Allowa minimum of three (3) feet clearance around the cooler.Keep both faces of the cooler core clean for efficientcooling of the compressor oil.
THERMAL CONTROL (THERMOSTATIC MIXING)VALVE (Figure 5-7, page 8, this section) is installed inthe system as shown in Figure 1-5, Section 5, page 2.This valve is used to control temperature of the oil inboth air-cooled radiator and water-cooled heat ex-changer type oil cooler systems. On start-up with unitcold, element is open to bypass, allowing oil to passdirectly from the reservoir to compressor during warm--up. As oil warms, element gradually closes to thebypass allowing more of the oil from the cooler to mixwith oil from the bypass.
After the unit is warmed up, the mixing valve maintainsoil injection temperature into the compressor at a mini-mum of 160”F. This system provides proper compressorwarm-up and prevents moisture contamination of oil.
To check element, heat in oil -it should be fully extendedat 160° F. If unit shuts down due to high air dischargetemperature, the cause may be that the element is stuckopen to the bypass, in which case bypass lines (Figure5-1, page 2, this section) will be hot to touch and linesout of mixing valve much cooler. When flushing the oil
13-9/10-641 Section 5 Page 7
“c”OIL IN
FROM COOLER
“B“OIL lN-BYPASS
FROMRESERVOIR
OIL ‘OUT
“A’&8407
FIGURE 5-7 - THERMOSTATIC MIXING VALVE
system, remove mixing valve and clean all parts thor-oughly.
COMPRESSOR OIL COOLER - WATER-COOLEDHEAT EXCHANGER (Figure 5-1, page 2, this section)- The heat exchanger oil cooler is a multiple pass type,with water in the tubes and oil in the shell. The oiltemperature is controlled by the thermal (thermo-static mixing) valve. The optional water control valvemay be used to consetve water.
Oil cooler malfunction may be traced by checking pres-sure at oil inlet and outlet. At normal operating air servicepressure (65 to 150 psig) with the unit warm, a pressuredrop of 3 to 15 psi can be expected between the oil inletand 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. Anychange in the pressure drop from that normally heldmay indicate tube leakage or fouling and should beinvestigated.
In many instances, the cooling water supply for the heatexchanger will contain impurities in solution and/or sus-pension. These substances can cause scale formation,corrosion and plugging of any water-cooled heat ex-changer equipment. Disregarding the possibility thatone or more of these conditions exist may result inincreased maintenance and operation expense, re-duced equipment life and emergency shutdown. It isstrongly recommended that a reputable, local watertreatment concern be engaged to establish the corro-sion, scale forming and fouling tendency of the coolingwater and take steps necessary to remedy the situationif a problem does exist. The need for water treatmentmay involve only filtration (screening) to remove debris,
CAPILLARY TUBE
A74099A
WAADJuSTINGSCREW
wSCALE” ‘ \
SETTING
wD
VALVE BODY
HEAT SENSING BULB m
FIGURE 5-8 - WATER CONTROL VALVE
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 scaledeposits, or prevent the growth of microorganisms. Thenormal maintenance program for the unit should alsoinclude periodic cleaning of the tubes (waterside) of theheat exchanger to remove deposits which enhancefouling and corrosion.
Hex head zinc anodes are used in the return bonnet(opposite end to the water pipe connections) of heatexchangers to provide internal water system corrosionprotection. These anodes should be inspected periodi-cally and replaced when the zinc has been reduced toabout 1/2 inch in length.
WATER FLOW CONTROL VALVE FOR HEAT EX-CHANGER (Optional Equipment) (Figure 5-8) - Thewater flow control valve is adjustable to compensate forvarying water inlet temperatures and pressures and isto be mounted in the water outlet line after the oil cooler(Figure 5-1, page 2, this section). Use the compressordischarge air temperature gauge on the instrumentpanel in setting the flow control valve. The compressordischarge temperature must be maintained a minimumof 10° F above the dew point temperature at the maxi-mum anticipated ambient; refer to Figure 5-9, Section 5,page 9, for the dew point temperature at the operatingpressure and ambient temperature of the application.
To decrease water flow (increase compressor dis-charge air temperature) turn the adjusting screw fromleft to right, increasing spring tension. To increasewater flow (decrease compressor discharge air tem-perature) turn the adjusting screw in the opposite direc-tion. The groove at the lower edge of the adjusting screw
13-9/10-641 Section 5 Page 8
240-
220-
200.
180.
160.
140.
120.
100 “
80.
:1~20 40 60 80 100 120
AMBIENT TEMP. . “F
FIGURE 5-9- DEW POINT TEMPERATURE VS. AMBlENTTEMPERATURE (100% RELATIVE HUMIDITY)
is an index line for use with the index scale O to 8 inobtaining a desired setting.
These valves must be handled with care and propertools and techniques must be used when working onthe valve.
Care must be used when handling the capillary tube; akink or break in the tubing or connections will make thevalve inoperative. Never attempt to change capillarylength. Excess capillary tube should be carefully coiledand placed so that damage will not occur in normalmaintenance or traffic past the unit.
If the leak develops through the packing, tighten thepacking gland nut firmly with a wrench to reseat thepacking around the valve stem, then back off the nutuntil loose, and finally retighten the nut finger tight.Tightening the packing nut too tight may cause erraticoperation. An occasional drop of oil on the valve stemat the packing nut will prolong packing life.
If valve malfunctions, check for bent or binding (paintor corrosion) valve stem, foreign material in valve,erosion, or thermal system (capillary) failure. If foreignmaterial or scale is likely, the use of a strainer in the inletwater line is recommended.
WATER SHUTOFF VALVE - WATER-COOLED HEATEXCHANGER (Optional Equipment) (Figure 5-1, page2, this section) - A magnetic solenoid-operated watershutoff valve rated at 150 psig water pressure should bemounted in the water outlet line after the oil cooler. Thevalve should be wired into the compressor control cir-cuit so that the valve opens to allow water to flow anytime the compressor is running. When compressorstops under automatic control, or is shut off manually,the valve should close, stopping water flow through thesystem. See Wiring Diagrams, Section 4a, page 4a-12,
OIL SEPARATORHOUSING
AL AIRCHARGE
fATCD SEPARATOR
IL RETURN LINE
FIGURE 5-10 - OIL SEPARATOR
and Section 4b, page 13.
OIL RESERVOIR - The oil reservoir-separator com-
bines multiple functions into one vessel. The lower half
is the oil reservoir, providing oil storage capacity for thesystem and the top portion, a primary oil separationmeans. The reservoir also provides limited air storage
for control and gauge actuation.
COMPRESSOR (G-D ELIMINATOR) OIL SEPARA-TOR (Figure 5-1 O) located in a separate housing, con-sists of a renewable cartridge-type separator elementand provides the final removal of oil from the air stream.
Oil impinging on the inside of the separator elementdrains directly back into the oil reservoir by gravity. Oilcollected outside the element is returned through tubingto the compressor cylinder.
Oil carryover through the service lines may be causedby a faulty oil separator, faulty minimum pressurevalve, over-filling of the oil reservoir, oil that foams, oilreturn line malfunction or water condensate in the oil. Ifoil carryover occurs, inspect the separator only after itis determined that the oil level is not too high, the oil isnot foaming excessively, the oil return line from theseparator housing to the compressor cylinder is notclogged or pinched off, the check valve in the oil returnline is functioning properly, and there is not water or anoil/water emulsion in the oil.
Oil carryover malfunctions of the oil separator are usu-ally due to using elements too long, heavy dirt or varnishdeposits caused by inadequate air filter service, use ofimproper oil or using oil too long for existing conditions.A ruptured or collapsed separator element is usually dueto heavy dirt or varnish buildup in the filtering material.Excessive tilt angle of the unit will also hamper separa-tion and cause oil carryover.
13-9/10-641 Section 5 Page 9
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 deter-mined by pressure differential gauging or by inspection.
PressureDifferentialGauging- The “CHANGE SEPA-RATOR” advisory will flash when the pressure differentialacross the oil separator reaches approximately 8 PSI.Replace the oil separator element at this time. If ignored,the unit will shut down and the advisory will illuminatesteadily when the pressure differential reaches 15 PSI.
~CAUTION
Using an oil separator element at ex-cessive pressure differential can causedamage to equipment. Replace sepa-rator when “Change Separator” Advi-sory appears.
NOTICE
A sudden drop to zero pressure differ-ential or sudden heavy oil carryovermay indicate a ruptured element.
Inspection- After removal of separator element, shinea light inside the element to reveal areas of heavy dirt orvarnish deposits or breaks (ruptures) in the elementmedia.
Removal Of Oil Separator For InspectionOr Re-placement: -. .
~DANGER
Air/oil under pressure will cause severepersonal injury or death. Shut downcompressor, relievesystem of all pres-sure, disconnect, tag and lockoutpower supply to the starter before re-moving valves, caps, plugs, fittings,bolts, and filters.
1. Be certain unit is completely off and that no airpressure is in the oil reservoir.
2. Disconnect, tag and lockout the power supply tothe starter.
3. Remove screws holding the top plate to the sepa-rator housing. Lift the top plate from the separatorhousing.
4. Lift the separator from the separator housing.
5. Inspect and/or replace the separator as necessary.Be sure the o-ring is not damaged. Before install-ing (or re-installing) any separator, apply grease tothe o-ring. Oil will be wiped off by the chamfer andthe o-ring could be damaged.
6. Remove any gasket material adhering to the topplate or separator housing, and install new gasket.
7. Lower the separator into the housing and centerseparator on the chamfer. Press separator downinto the housing. Do not use excessive force asseparator damage can occur.
8. Place spacer on indent in the separator. Seat topplate to separator, spacer and separator housing.Install and tighten all cap screws.
9. Run unit and check for leaks.
COMPRESSOR OIL SYSTEM CHECK - The followingreadings are based on ambient temperature of 80”F forair-cooled oil cooler and 80°F inlet water on water-cooled oil cooler, with the system in good condition.Compressor should beat operating temperature at thetime of checks. One-half hour of loaded operation isusually sufficient to reach level-out operating tempera-tures.
Airand Oil DischargeTemperature-165° to 195° F -Read at gauge on the instrument panel or check with athermometer at the discharge housing.
CompressorOil Inlet Temperature-150° to 160° F -Install a tee at the oil filter outlet and check with athermometer.
Oil Inlet Pressure - Check at the fitting in the line nearthe compressor oil inlet. With air receiver pressure at100 psi, oil inlet pressure should be 55-60 psig.
ra Oil Cooler Oil Pressure Differential (Air-Cooled Ra-diator) - Check differential across oil system by measur-ing oil inlet pressure as described above.
Oil Cooler Oil Pressure Differential (Water-CooledHeat Exchanger) -2 to 25 PSI (65 to 150 PSIG ReceiverPressure) - Check that oil inlet pressure is correct ormeasure the differential between drains on the oil coolershell.
Oil Cooler Temperature Differential (Air-Cooled Ra-diator) - The oil temperature differential depends on thetemperature of the air at the oil cooler fan and cleanli-ness of the core faces. As ambient temperatures andcore restrictions increase, the oil cooler outlet temper-ature will increase. The oil inlet temperature is approxi-mately the same as air discharge temperature - seethegauge on the instrument panel. The outlet oil tempera-
13-9/10-641 Section 5 Page 10
ture may be checked by installing a tee at the oil filter
outlet.
Oil Cooler TemperatureDifferential(Water-CooledHeat Exchanger)- The oil temperature differential de-pends on the inlet water temperature and the water flowrate permitted by the water flow control valve setting.The oil inlet temperature is approximately the same asthe air discharge temperature - see the gauge on the
instrument panel. The oil outlet temperature may bechecked 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 thesupply pressure, flow rate, cooler tube cleanliness andoutlet pressure. The inlet and outlet water pressure maybe checked at the pipe fiiings supplied by the customer.
-: ...,,
13-9110-641 Section 5 Page 11
SECTION 6AIR FILTER
AIR IMTL[l
AIR OUTLET +
~
AUTOMATIC UNLOADER F
FIGURE 6-1 - HEAW DUTV AIR FILTER (STANDARD)
HEAVY-DUTY AIR FILTER (Figure 6-1 ) furnished asstandard equipment on units with an enclosure is aheavy-duty washable element dry type air filter. The airfilter must receive proper maintenance if maximum ser-vice is to be obtained from the unit. Establishing ade-quate and timely filter service is MOST IMPORTANT.Improperly maintained air filter can cause a loss ofcompressor air delivery.
Filter Element - Service the air filter element when the“CHANGE AIR FILTER” LED is illuminated. Clean every50 to 150 operating hours depending on dust condi-tions.
NOTICE
Use only genuine Gardner-Denver airfilter elements on Gardner-Denvercompressor units. Genuine parts areavailable through your authorizedGardner-Denver distributor.
pleated media; replace the element if any arefound. Inspect the gasket on the bottom (outletend) of the element; replace the entire element ifthe gasket is damaged, a spare element will keepdown time to a minimum.
5. Allow the element to air dry COMPLETELY. Do notexpose the element to heat over 150° F. Install theelement in the filter body and fasten securely withthe wing nut.
I ~WARNING
Do not oil this element. Do not wash ininflammable cleaning fluids. Do not usesolvents other than water. Impropercleaning may damage element.
~CAUTION
Never operate the unit without the ele-ment. Never use elements that aredamaged, ruptured or wet. Never usegaskets that won’t seal. Keep spareelements and gaskets on hand to re-duce downtime. Store elements in aprotected area free from damage, dirtand moisture. Handle all parts withcare.
Filter Element Life - The element should be replacedafter six (6) cleanings or if:
1. Visual inspection indicates a rupture, crack or pinhole in the pleated media. Inspection should bedone by placing a bright light inside the element.
2. Pressure drop throuah a filter with a freshlv cleanedToservice:
1.
2.
3.
4
Remove wingnut and pull out filter element.
Visually inspect the element. If cleaning is notnecessary, reinstall the filter element. If the elementrequires cleaning, go through steps 3, 4 and 5.
Wash the element by soaking about 15 minutes inwarm water with a mild nonsudsing detergent.Rinse the element thoroughly with clean water; ahose may be used if the water pressure does not
exceed 40 PSIG.
Inspect the element for ruptures or cracks in the
element is below 3 inches of water with compressorrunning at full load - this would indicate a ruptureor crack.
Inlet Tube - Inspect the inlet screen and tube for dirtaccumulation each time the filter is serviced. Clean thetube when required by ramming a clean dry cloththrough the tube. Wipe the inside of the filter body toremove any dirt falling from the inlet tube before reinstall-ing the element.
Causes of short element life include: severe dust con-ditions, infrequent servicing, improper cleaning, or con-tamination by oil or chemical fumes.
13-9/1 0-641 Section 6 Page 1
SECTION 7COUPLING
UP TOWARO OUTSIDEDIAMETER OF COUPLING
RADIUS EDGE
+DOWN TOWARD SHAFT
SET SCREWS
50 FT-LBS
4* l/16MiN l/8MAx
FIGURE 7-1 - INSTALLATION OF COUPLING CUSHIONS
/~DANGER
Rotating machinery can cause per-sonal injury or death. Turn the unitcompletely off, open main disconnect,tag and lockout before servicing cou-pling
COUPLING - The motor and compressor are directconnected bv a resilient type flexible coupling with sev-eral individual cushions, Figure 7-1. Coupling does notrequire lubrication.
If maintenance on mating parts is required, reassemblecoupling as follows:
Individual Cushion Design (Figure 7-1)
1. Slide coupling halves over shaft extensions. Besure collar is installed on shaft behind one couplingbody.
2. Assemble motor on compressor.
3. Working through coupling guard opening, center
coupling over gap between shafts, maintaining gap
as shown in Figure 1-7 between the ends of the jawson one coupling body and the flange on the oppo-site coupling body. Tighten set screws in eachcoupling body.
4. Insert individual cushions as shown in Figure 7-1and slide collar over cushions and secure with capscrews. Reinstall the coupling guard.
~DANGER
Rotating machinery can cause per-sonal injury or death. Do not operateunit with either the coupling guard orthe collar removed. All bolts andscrews must be properly tightened.
Alignment - The coupling is permanently aligned by theflanges on the compressor and motor.
13-9/1 0-641 Section 7 Page 1
SECTION 8MAINTENANCE SCHEDULE
SERVICE CHECK LIST -
Air Filter - Operating conditions determine frequency of
service. The “CHANGE AIR FILTER” LED will illuminateto signal that the air filter requires servicing or changing.See “Air Fiiter,” Section 6.
Oil Separator - Operating conditions determine fre-quency of service. The “CHANGE SEPARATOR” LED wil!flash to signal that oii separator element requires chang-ing. See “Compressor Oil Separator,” Section 5, page 8.
Motor Lubrication - Refer to Section 2 and MaintenanceSchedule Chart beiow.
Every 8 Hours Operation
1. Check the reservoir oil level - add oil if required.See Section 5, page 5. if oil consumption is high,refer to “Excessive Oil Consumptionr’ in Section 9,page 3. DO NOT MIX LUBRICANTS.
2. Observe if the unit ioads and unloads properly.
3. Check discharge pressure and temperature.
4. Drain the moisture trap in the control system.
5. Check Panei LED’s for advisories.
Every 125 Hours Operation
1. Check for dirt accumulation on oil/aftercooier core
faces and the cooling fan. If cieaning is required,clean the exterior fin surfaces of the cores by blow-ing compressed air carrying a nonflammable safetysolvent in a direction opposite that of the coolingfan air flow. This cieaning operation wiii keep theexterior cooiing surfaces ciean and ensure effec-tive heat dissipation.
Every 1000 Hours Operation
1. Change oii fiiter eiement.
Every 8000 Hours Operation
1. Change the compressor iubricant. UNDER AD-VERSE CONDITIONS, CHANGE MOREFREQUENTLY (refer to “Oii Change Interval” inSection 5). Flush system if required. DO NOT MIXLUBRICANTS.
Every 4000 Hours Operation
1. Inspect the oii separator element. See Section 5,page 8.
Every Year
1. Check the relief vaive for proper operation. SeeSection 4a, page 1 or Section 4b, page 2.
MAINTENANCE SCHEDULE (See detail notes above)
Maintenance Action
Change Air Filter
Change Oii Separator
Check Reservoir Oii Levei
Check For Proper Load/Unload
Check Discharge Pressure/Temp.
Check Dirt Accumulation on Cooler
Change Oii Fiiter Eiement
Inspect Oil Separator Eiement
Change Compressor Lubricant
Check Reiief Vaive
AsIndicated3y Auto-entry-ES
●
●
9
Every8
iours
●
●
6
Every125
Hours
●
Every1000
Hours
●
Every4000-lours
●
Every8000’Hours
●
EveryYear
●
* See Continuous Operating Temperature Chart, Section 5, page 5, for specific Iubricant life.
13-9/10-641 Section 8 Page 1
SECTION 9TROUBLE SHOOTING
Symptom Possible Cause Remedy
Compressor fails to start. 1.
2.
3.
4.
5.
6.
Compressor starts butstops after a short time.
Compressor does notunload (or load).
Wrong lead connections. 1.
Blown fuses in control 2.box.
Motor starter overload 3.heaters tripped.
Pressure in reservoir. 4.
Read error message on 5.control panel. See Section 4.
Remote contact is open 6.(terminals 6 & 9).
1. High discharge temperature.
2. High dischargetemperature switchmalfunction.
3. Blown fuse in starter/control box.
4. Motor starter overloadheaters trip.
Change leads.
Replace fuse.
Reset and investigatecause of overload.
Inspect blowdown valveand muffler.
Replace switch.
Replace switch or jumper.
1. See “High DischargeAir Temperature” inthis section.
2. Replace switch.
3. Replace fuse(investigate if fusescontinue to blow).
4. Reset and investigatecause of overload.
1. Improperly adjusted 1. Refer to Section 4control. and adjust control.
2. Air leak in control 2. Determine source oflines. leak and correct.
3. Restricted control line. 3. Clean control lines.
4. Blowdown valve malfunction. 4. Repair, clean or replacevalve.
13-9/10-641 Section 9 Page 1
Symptom Possible Cause
Compressor cycles from 1. Insufficient receiver capacity. 1. Increase receiver size.load to unload excessively.
2. Restriction in control 2. Inspect and cleantubing. control tubing.
Compressor is low ondelivery and pressure.
High discharge airtemperature.
Excessive Oil Consumption
1. Restricted air filter. 1. Clean or replace filter.
2. Sticking inlet valve. 2. Inspect and cleaninlet valve.
3. Unload pressure adjusted 3. Adjust unload pressure.too low. pressure. See
Section 4.
4. Minimum pressure valve 4. Disassemble and cleanstuck closed. valve.
1. Thermostatic mixing 1. Repair or replace valve.valve stuck open.
2. Dirty or clogged cooler face. 2. Clean cooler.
3. Insufficient cooling 3. Provide unrestrictedair flow. supply of cooling air.
4. Clogged oil filter 4. Replace filter oror cooler (interior). clean cooler.
5. Low Compressor oil. 5. Add oil to proper level.
1. Oil carryover through lines.
2. Oil leaks at all fittingsand gaskets.
1. See “Oil Carryoverin this section.
2. Tighten or replacefittings or gasket.
13-9/10-641 Section 9 Page 2
Symptom Possible Cause Remedy
Oil Carry-Over 1. Overfilling the reservoir. 1. Drain excess oilfrom system.
~DANGER IAir/oil under pressure will cause severe personal injury or death. Shut down com-pressor, relieve system of all pressure, disconnect, tag and lockout power supply tothe starter before removing valves, caps, plugs, fittings, bolts, and filters.
2.
3.
4.
5.
6.
7.
8.
9.
Clogged, broken or loose 2.
oil return lines
Ruptured oil separator 3.element.
Loose assembly. 4.
Foam caused by use of 5.incorrect oil.
Inoperative minimum 6.pressure valve, causing lowoperating pressure.
Operation at elevated 7.discharge temperatures.
Scavenge line check valve 8.failure.
Water condensate in oil. 9.
Tighten or replacefaulty lines.
Replace element.
Tighten all fittingsand gaskets.
Use Gardner-Denver”AEON 9000 LubricatingCoolant.
Clean out or replace.
Reduce temperature. SeeHigh Discharge Air Temper-ature - in this section.
Replace check valve.
Check oil reservoir temper-ature. If low, change thermalmixing valve element tohigher temperature.
13-9/1 0-641 Section 9 Page 3
AUTO SENTRY ES CONTROLLERTROUBLE SHOOTING GUIDE
ADVISORIES
READING ACTION
“CHANGE SEPARATOR” Light Separator differential is greater than 8 psid(Flashing or on steadily) Change separator.On Startup
CHANGE AIR FILTER
LOW AMBlENT
HIGH TEMPERATURE
Inspect/Replace -- air filter if needed
The advisory comes on -- if the receiver or air end discharge is lessthan 40° F (4.4° C). Refer to corrective measures for low ambientconditions in the Operator’s Manual.
The advisory comes on -- when the temperature exceeds210° F
(99° c.)
Probable cause -- plugged or dirty cooler, high ambient conditions,or blown fuses on fan motor.
I NOTICE IGardner-Denver factory remanufactured replacement compressor air end units areavailable from your authorized distributor, on an exchange basis, for all rotary screwcompressor units.
13-9/1 0-641 Section 9 Page 4
#COOPER
WARRANTYROTARY SCREW COMPRESSORS
OIL INJECTED ● OIL FREEGardner-Denver Industrial Machinery
GENERAL PROVISIONS AND LIMITATIONS
Gardner-Denver Industrial Machinerv Division (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 timeof delivery 10 the Purchaser, made with good material andworkmanship. No warranty is made with respect to:
1.
2.
3.
4.
5.
Any product which has been repaired or altered in
such a way, in the Company’s judgment, as to affectthe product adversely.
Any product which has, in the company’s judgment,
been subject to negligence, accident, improperstorage, or improper installation or application.
Any product which has not been operated ormaintained in accordance with the recommendationsof the Company.
Components or accessories manufactured, warrantedand serviced by others.
Any reconditioned or prior owned product.
Claims for items described in (4) above should be submitteddirectly to the manufacturer.
WARRANTY PERIOD
The Company’s obligation under this warranty is limitedto repairing or, at its oplion, replacing, during normalbusiness hours at an authorized service facility of theCompany, any part which in its judgment proved not tobe as warranted within the applicable Warranty Period asfollows.
COMPRESSOR AIR ENDS
Compressor air ends, consisting of ail parts within andincluding the compressor cylinder and gear housing, arewarranted for 24 months from date of initial use or 27 monthsfrom date of shipment to the first purchaser, whicheveroccurs first.
Any disassembly or partial disassembly of the air end, orfailure 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 fromdate of initial use or 15 months from date of shipment tofirst purchaser, whichever occurs first.
LABOR TRANSPORTATIONAND INSPECTION
The Companywillprovidelabor,by Company representativeor authorized service personnel, for repair or replacementof any product or part thereof which in the Company’sjudgment is proved not to be as warranted. Labor shallbe limited to the amount specified in the Company’s laborrate schedule.
Labor costs in excess of the Company rate scheduleamounts or labor provided by authorized service personnelis not provided for by this warranty.
All costs of transportation of product, labor or parts claimednot to be as warranted and, of repaired or replacementparts to or from such service facility shall be borne by thePurchaser. The Company may require the return of anypart claimed not to be as warranted 10 one of its facilitiesas designated by Company, transportation prepaid byPurchaser, to establish a claim under this warranty.
Replacement parts provided under the terms of this warrantyare warranted for the remainder of the Warranty Periodof the product upon which installed to the same extent asif such parts were original components.
WARRANTY REGfSTRATION VALIDATION
A warranty registration form is provided with each machine.The form must be completed by the Purchaser and mailedwithin ten days after machine start-up to validate thewarranty.
DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND ITIS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE,THE COMPANY MAKES NO OTHER WARRANTIES,EXPRESSED, IMPLIED OR STATUTORY, INCLUDINGANY IMPLIED WARRANTY OF MERCHANTABILITY.
THE REMEDY PROVIDED UNDER THIS WARRANTYSHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDYAVAILABLE TO THE PURCHASER AND IN NO CASESHALL THE COMPANY BE SUBJECT TO ANY OTHEROBLIGATIONS OR LIABILITIES. UNDER NOCIRCUMSTANCES SHALL THE COMPANY BE LIABLEFOR ANY SPECIAL, INDIRECT, INCIDENTAL ORCONSEQUENTiAL DAMAGES, EXPENSES, LOSSES ORDELAYS HOWSOEVER CAUSED.
No statement, representation, agreement or understanding,oral or written, made by any agent, distributor,representative, or employee of the Company which is notcontained in this Warranty will be binding upon the Companyunless made in writing and executed by an officer of theCompany.
This warranty shall not be effective as to any claim whichis not presented within 30 days after the date upon whichthe product is claimed not to have been as warranted. Anyaction for breach of this warranty must be commenced withinone year after the date upon which the cause of actionoccurred.
Any adjustment made pursuant to this warranty shall notbe construed as an admission by the Company that anyproduct was not as warranted.
AU-20 R 1/91
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