Home

13-9/10-641/4 COMPRESSOR OPERATING AND SERVICE MANUAL

1. 2 1 2 2 Minimum Flow for Compression and 0 20 012020 2 0 00 2 1 2 3 Cold Weather Installation 4 22222 222 2 0 2202 000000000000000000000000000000000000100 0 2 2 2 4 Heat Exchanger and Aftercooler Flow Chart sss enne 2 4 2 5 Series PIPING sess sees ee iA ahd ee ete eal e a ee qr te ate ah eae 2 5 2 6 Parallel PIping uer tritt e eerte 2 5 4a 1 Schematic Tubing 2 0 0 1 1 1 000 0 100000000000 4 2 4 2 Blowdown Valve 4 2 4a 3 Irlet ValVe niet a repere baa le eie Fe Hn ET e dp A 4a 3 4a 4 Minimum Discharge Pressure Valve ccccccccessccesecesseeesecceaceecuseessceesseeceseeeesseceusessnseeeseteeseeats 4a 3 4a 5 SHUTS VAG is 4a 4 4a 6 Control Schematic Compressor Unloaded Constant Speed 4a 9 4a 7 Control Schematic Compressor at Full 2 2 0042 2 1 4 11 5 0 00000 n 4a 10 4a 8 Control Schematic Compressor Unloaded Low Demand 4a 11 4a 9 Wiring Diagtarmi eterne n vegeta ne Se ai egeo IE een 4a 12 A to Sent ES teeth ti t ndi d E
2. 5 5 Lubricant Changing Type of 5 5 Lubricant Draining and Cleaning System 5 6 Lubricant Oil Specifications 5 1 Lubricant 5 1 Lubricant Change Interval esses 5 6 LUBRICATION OIL COOLER OIL FILTER amp SEPARATOR SECTION 5 5 1 13 9 10 641 MAINTENANCE SCHEDULE SECTION 8 8 1 Minimum Pressure Check Valve 4a 3 4b 5 Moisture in the Oil System 5 6 Motor Lubrication 2 6 Motor Protection Devices 4a 1 4b 1 Oil Cooler Water Cld Water Flow Control Valve 5 8 Oil Cooler Water Cld Water Shutoff Valve 5 9 Oil Cooler Radiator Type 5 7 Oil Cooler Water 5 8 Oll Filter rccte eter rece EE eere Eee 5 7 Oil Level Gauge eese 5 6 Oil Reservolr oe sie eae eee ens 5 9 Oil Reservoir Drain 2222 22222 4 2 2 Oll fed bd miens 5 9 Oil Separator Inspection 5 10 Oil Separator Pressur
3. 110 9 9 4 T m DRIVE 130 po MOTOR hi 15 14 T6 5 MOTOR FUSES 02 FAN 112 o X Cams 13 113 iL i PRI PRI FUSES FUSES BDV BLOWDOWN SOLENOID VALVE IVC INLET VALVE CLOSE SOLENOID VALVE IVO INLET VALVE OPEN SOLENOID VALVE VALVE CLOSE SOLENOID VALVE TVO TURN VALVE OPEN SOLENOiD VALVE LEAD CONNECTION FOR TWELVE LEAD MOTORS LOW VOLTAGE HIGH VOLTAGE CONNECTIONS CONNECTIONS T4 TO T5 T3 T6 11 14 12 T5 T3 16 FIGURE 46 10 WIRING DIAGRAM 208 546 TRANSDUCER A FINAL DISCHARGE TRANSDUCER B RESERVOIR THERMISTOR A RESERVOIR THERMISTOR 8 COMPRESSOR MOTOR ARE RRR TEST NNS Fe SONATE SSS REE AUTO SENTRY ES Cc OS ANS STOP RESET CONSTANT RUN LOW DEMAND AUTOMATIC SEQUENCE PURO STS AEE RAE SEAR 13 9 10 641 Section 4b Page 14 SECTION 5 LUBRICATION OIL 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 in the compression chamber The oil inlet line is connected at the bottom of t
4. 4b 4 Starter Control Panel 4a 4 4b 5 STARTING amp OPERATING PROCEDURES SECTION 3 e cecidere 3 1 Starting The Unit Cold 3 2 Starting The Unit Hot 22 22 2 2 2 3 2 Stopping Unit ee 3 2 System Pressure Transducer 4 4 4b 5 Thermostatic Mixing Valve 5 7 TROUBLE SHOOTING SECTION 9 9 1 TUM Valve preside eise b xii io 4b 4 Turn Valve Actuator esses 4b 4 Water Cooled Unit Installation 2 2 Water Cooled Unit Piping 2 5 Wiring 2 4a 12 4b 13 Page iii ILLUSTRATIONS FIGURE DESCRIPTION SECTION PAGE 1 1 Gompressiorn OyCcle seda Hoster ee eene Hinh da ure e e p Re ERR SEDENS 1 1 1 2 Package Starter BOX aste e da edv 1 2 1 3 Package Controller amp Starters 22 4 2 11 2800 00000000 1 2 1 4 Package Drive Motor amp Air Filter nnne nnn 1 2 1 5 Package Cil Filter Oil Level Gauge Mixing Valve Minimum Pressure Valve amp Check Valve 1 3 1 6 Package Compressor amp Inlet Valve sse enne tnn 1 3 2 1 Typical Compressor
5. CHECK VALVE EXHAUST MUFFLER ORIFICE SOLENOID VALVE BDV SYSTEM PRESSURE TRANSDUCER SOLENOID VALVE IVO RESERVOIR PRESSURE SOLENOID VALVE TRANSDUCER PRESSURE REGULATOR AIR FILTER SHUTTLE VALVE VACUUM SWITCH AIR INLET VALVE CLOSED MINIMUM DISCHARGE NT SERVICE 624 f VAENE PRESSURE CHECK E B VALVE VALVE oH eS 22 I 2 E Ix SOLENOID VALVE FULL AIR PRESSURE ATMOSPHERIC PRESSURE OR EXHAUSTING SOLENOID VALVE TVC OIL SERVOI 1 FIGURE 4b 8 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED CONSTANT SPEED MODE TURN VALVE ACTUATOR SECTIONED 9 01 6 2 6 EXHAUST MUFFLER SOLENOID VALVE BDV SOLENOID VALVE VO SOLENOID VALVE UC PRESSURE REGULATOR SHUTTLE VALVE WZ ZN SERVICE MINIMUM VALVE PRESSURE VALVE FULL OIL PRESSURE FULL AIR PRESSURE CONTROL AIR PRESSURE 15 20 PSI ATMOSPHERIC PRESSURE OR EXHAUSTING CHECK VALVE ORIFICE ORIFICE SYSTEM PRESSURE TRANSDUCER RESERVOIR PRESSURE TRANSDUCER D AIR FILTER VACUUM SWITCH AIR INLET VALVE CLOSED DISCHARGE 74 CHECK EE VALVE SOLENOID VALVE TVO e n RESERVOIR UN PME SOLENOID FILTER VL KW VALVE TURN V
6. 4a 13 4b 1 Schematic Tubing Diagram sse eene eene nnne mettent 4b 1 4b 2 Blowdown Valve tti teet e fecere ERU ERE UT epis eoe eR e qe educ etes Poen cuan 4b 2 4b 3 Uv eere pue qi ce apvd e 4b 2 4b 4 Shuttle en te de ee EN Des RA ili etu ts vn 4b 3 4b 5 Turn c oec tette E D EE ee LEE Dese tier ed 4b 3 4b 6 Minimum Discharge Pressure Valve ccccccccscescescesceeeeeceseeseeaeeaseseeseesaeeseeeeeneeeeseeneetantenerates 4b 4 4b 7 Control Schematic Compressor at Full Load sessi eene 4b 10 4b 8 Control Schematic Compressor Unloaded Constant Speed 4b 11 4b 9 Control Schematic Compressor Fully Loaded Low Demand Mode 4b 12 45 10 Wiring Diagram ict ederet enr E ESSE DR RH Ve RE cep adea uix e 4b 13 Auto Serilty ES onu e ec eer p HH ENE 4b 14 5 1 Flow Diagram EBH EBM 5 2 5 2 Flow Diagram EAP i oet ttv iie 5 3 5 3 Oil Flow Diagram Remote Overhead Mounted 5 4 5 4 Approcimate Oil System Capacities 5 4 5 5 Gooler Drain Deve Tu
7. Soap Type 5a eene atta d PR ERE leet Bomb Minimum Hours For 20 PSI Drop at 210 F Bleeding Maximum Weight In 500 Hours 212 F Rust Inhibiting 5 eost ttes Standard High Service Temperature 265 296 220 240 400 550 475 525 Lithium Lithium suisse 750 1000 E 10 3 Yes Yes ELECTRIC MOTOR REGREASING INTERVAL Standard Severe Continuous Operation Very Severe Dirty Locations High Ambient Temperature 13 9 10 641 Type of Service Typical Examples Relubrication Interval One or Two Shift Operation 150 HP amp Below 18 Months 150 HP amp Below 9 Months 150 HP amp Below 4 Months Section 2 Page 6 SECTION 3 STARTING amp OPERATING PROCEDURES PRESTART UP INSTRUCTIONS A new unit as re ceived from the factory has been prepared for shipping only Do not attempt to operate the unit until checked and 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 9000 Lubricating Coolant which is suitable for the first 8000 hours under normal operating conditions REPLACE OIL FILTER EVERY 1000 HOURS Initial fill or filling after a complete draining of the system may show the oil level in the yellow EX CESS OIL range After start up the oil will fall into the green op
8. AIR OUTLET AUTOMATIC UNLOADER FIGURE 6 1 HEAVY DUTY AIR FILTER STANDARD HEAVY DUTY AIR FILTER Figure 6 1 furnished as standard equipment on units with an enclosure is a heavy duty washable element dry type air filter The air filter must receive proper maintenance 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 of compressor air delivery Filter Element Service the air filter element when the CHANGE AIR FILTER LED is illuminated Clean every 50 to 150 operating hours depending on dust condi tions NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units Genuine parts are available through your authorized Gardner Denver distributor To service 1 Remove wingnut and pull out filter element 2 Visually inspect the element If cleaning is not necessary reinstall the filter element If the element requires cleaning go through steps 3 4 and 5 3 Wash the element by soaking about 15 minutes in warm water with a mild nonsudsing detergent Rinse the element thoroughly with clean water a hose may be used if the water pressure does not exceed 40 PSIG 4 Inspect the element for ruptures or cracks in the 13 9 10 641 pleated media replace the element if any are found Inspect the gasket on the bottom outlet end of the element rep
9. SYSTEM PRESSURE TRANSDUCER RESERVOIR a PRESSURE TRANSDUCER D AIR FILTER VACUUM SWITCH SS 21 il A OIL FILTER REAR VIEW OF COMPRESSOR FIGURE 4a 7 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD Lp9 01 6 1 LL 6 FULL OIL PRESSURE FULL AIR PRESSURE CONTROL AIR PRESSURE 15 20 PSI ATMOSPHERIC PRESSURE OR EXHAUSTING CHECK VALVE ORIFICE EXHAUST MUFFLER SOLENOID VALVE BDV OFF SYSTEM PRESSURE TRANSDUCER SOLENOID VALVE IVO OFF SOLENOID VALVE OFF RESERVOIR PRESSURE TRANSDUCER PRESSURE REGULATOR SHUTTLE VALVE AIR FILTER VACUUM SWITCH SERVICE MINIMUM DISCHARGE VALVE PRESSURE CHECK VALVE VALVE REAR VIEW OF COMPRESSOR FIGURE 4a 8 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE 1979 01 6 1 21 epuonoes 19 THERMISTOR A RESERVOIR TRANSDUCER AFINAL DISCI TRANSDUCER 6 RESERVOIR THERMISTOR B COMPRESSOR TO sov Wo TO we MOTE 4 TRANSDUCER FINAL DISCHI CMERGENCY STOP TRANSDUCER amp RESERVOIR THEN RESY BAER 8 COMP CONTROL CIRCUIT CONTROL xt mtm ove MOTOR NOTE 5 WHEN A WATER CONTROL SOLLNOID VALVE 15 USED WIRE TO TERMINALS 18 amp 10 NOTE 1 FORM CONTACT FOR USE BY OTHERS CONTACT OPERATES FOLLOWING COMPRESSOR SHUTOOWN RATI
10. Using an oil separator element at ex cessive pressure differential can cause damage to equipment Replace sepa rator when Change Separator Advi sory appears A sudden drop to zero pressure differ ential or sudden heavy oil carryover may indicate a ruptured element Inspection After removal of separator element shine a light inside the element to reveal areas of heavy dirt or varnish deposits or breaks ruptures in the element media Removal Of Oil Separator For Inspection Or Re placement A DANGER Air oil under pressure will cause severe personal injury or death Shut down compressor relieve system of all pres sure disconnect tag and lockout power supply to the starter before re moving valves caps plugs fittings bolts and filters 1 Be certain unit is completely off and that no air pressure is in the oil reservoir 2 Disconnect tag and lockout the power supply to the starter 3 Remove screws holding the top plate to the sepa rator housing Lift the top plate from the separator housing 13 9 10 641 4 Liftthe 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 to the o ring Oil will be wiped off by the chamfer and the o ring could be damaged 6 Remove any gasket material adhering to the top plate or separator housing and install n
11. When connecting pipe fittings to the cooler support the threaded coupling with a pipe wrench when tightening the connection Use silicone sealant on all steel to aluminum threaded connections All piping should be firmly supported to avoid strain on the cooler manifold and connections Flexible connections should be in stalled in all interconnecting piping adjacent to the cooler to avoid transmitting piping weight or vibrations to the cooler elements Before beginning installation check to be sure that no debris or foreign matter remains in the couplings or cooler bodies Be certain intercon necting piping is clean to avoid clogging the cooler passages AFTERCOOLER PIPING At shutdown of the system all units should be drained completely of condensate if there is any possibility of freezing or corrosion damage To help remove the condensate the cooler may be tapped per Figure 5 5 and a drain cock installed After opening the drain cock blow air into the cooler from a 13 9 10 641 NOTICE AF TERCOOLER LOWER NOZZLE OUTLET R339 DRILL THRU 1 8 NPT ONE HOLE WELD FIGURE 5 5 COOLER DRAIN DETAIL connection on the opposite side of the cooler At the same time the connection on the drain side of the cooler should be plugged The drain cock should be left open until the machines are ready for start up Section5 Page 4 Failure to remove condensate from an idle cooler in freezing temperatures will c
12. OIL RETURN LINE CHECK VALVE 9 o 9 0 5 M PRESSURE RELIEF VALVE N P R DISCHARGE CHECK VALVE MINIMUM DISCHARGE PRESSURE VALVE PURGE AIR VALVE S PNEUMATIC BLOW DOWN VALVE T ORIFICE U BLOW DOWN MUFFLER V SHUTTLE VALVE W PRESSURE REGULATOR X SOLENOID VALVE IVC Y SOLENOID VALVE IVO Z ORIFICE AA AIR FILTER VACUUM SWITCH BB SYSTEM PRESSURE TRANSDUCER CC DISCHARGE PRESSURE TRANSDUCER 00 AND MOTOR EE WATER FLOW CONTROL VALVE FF MAGNETIC WATER SHUTOFF VALVE GG TURN VALVE ACTUATOR HH SOLENOID VALVE TYO JJ SOLENOID VALVE FIGURE 5 2 FLOW DIAGRAM EAP AIR AIR OIL WATER gt ser AIR 2 lt AIRIOIL GATE VALVE OIL FILL je AIR FLOW GATE VALVE ELEVATED COOLERS A MAIN MOTOR B COMPRESSOR C INLET FILTER D OIL RESERVOIR OIL SEPERATOR F OIL COOLER G AFTERCOOLER H MIXING VALVE BODY J OIL FILTER K OIL STOP VALVE L CHECK VALVE M RELIEF VALVE N CHECK VALVE P MIN PRESS VALVE R PNEUMATIC 3 WAY VALVE FIGURE 5 3 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED H Refill Capacity For Normal Oil Change Red to Yellow Range 40 amp 50 HP 60 75 100 HP 5 5 U S Gallons 1 25 U S Gallons 8 5 U S Gallons 2 0 U S Gallons FIGURE 5 4 APPROXIMATE OIL SYSTEM CAPACITIES All requirements of local codes should be followed
13. REMOVE RES PRESS is displayed The bottom line displays the current pressure being sensed in the air oil reservoir The reservoir pres sure transducer may now be zeroed by following the steps outlined in 19 above The display now reads PRESS CNST RUN TO JOG MOTOR Pressing the CONSTANT 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 procedures for the AUTO SENTRY ES controller Press the STOP RESET key to return the compressor to the READY mode Section 4b Page 9 99 01 6 01 qr 6 FULL AIR PRESSURE ATMOSPHERIC PRESSURE OR EXHAUSTING CHECK VALVE ORIFICE ORIFICE EXHAUST MUFFLER SOLENOID VALVE BDV SYSTEM PRESSURE TRANSDUCER RESERVOIR VALVE PRESSURE TRANSDUCER SOLENOID VALVE PRESSURE REGULATOR SHUTTLE VALVE VACUUM SWITCH AIR INLET VALVE OPEN MINIMUM DISCHARGE PRESSURE CHECK VALVE VALVE SERVICE VALVE FULL OIL PRESSURE CONTROL AIR PRESSURE 15 20 PSI SOLENOID VALVE EX m S S TURN VALVE ACTUATOR SECTIONED FIGURE 4b 7 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD Lv9 01 6 1 LL qpuonoeg FULL OIL PRESSURE CONTROL AIR PRESSURE 15 20 PSD ORIFICE
14. RH400 WITH 2 RH4502 ELEMENTS 2 REQD 3 200 WATTS EACH RESERVOIR WELLMAN RADIANT 2 ELEMENT EQUAL RH RH7000 WITH 2 ELEMENTS 2 6 200 WATTS EACH REO 8 FT PLYWOOD FENCE ELEVATION VIEW 7502 FIGURE 2 3 COLD WEATHER INSTALLATION If wet cleaning is required shield motor and spray on a mild soap solution and flush with clean water WATER COOLED UNITS The water cooled unit with the standard enclosure requires sufficient air flow Figure 2 2 previous page for electric motor cooling Air is drawn into the unit at the top of the enclosure and is exhausted at the motor side Do not block air flow to and from unit Allow three and one half 3 1 2 feet to the nearest obstruction on the starter end and control box side of the unit Allow three 3 feet to the nearest obstruction above and on other sides of the unit FOUNDATION The G D Rotary Screw compressor requires no special foundation but should be mounted ona smooth solid surface Whenever possible install the unit near level Temporary installation may be made at a maximum 10 angle lengthwise or 10 sidewise Mounting bolts are not normally required However installation conditions such as piping rigidity angle of tilt or danger of shifting from outside vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform support for the base OIL RESERVOIR DRAIN The oil drain is piped from the bottom
15. The turn valve is a helical valve which when rotated opens and closes a series of ports cast into the compressor cylinder When these ports are open they direct some of the air which would otherwise be com pressed back to the inlet reducing both capacity and power consumption Turn Valve Actuator Figure 40 5 page 3 this section Theturn valve actuator is a rotary rack and pinion device which positions the turn valve according to system demand Filtered oil from the compressor sump is di rected to the outboard end of the two actuating cylinders to move the rack and rotate the valve Located on the end of the cylinders are adjusting screws which limit the travel of the actuator When looking at the rear of the compressor the adjusting screw on the right on the compressor adjusts the fully closed full load position of the valve The full load position of the actuator may be checked by removing the adjusting screw at the unloaded end of the actuator left side of the compres sor and using a rod to push the pistons to the full load position The rod must be clean and free of burrs and scale Take care not to scrape the cylinder walls when moving the pistons Minimum Discharge Pressure Vaive Figures 1 5 page 3 Section 1 and 4b 6 above An internal spring loaded minimum pressure valve is used in the final discharge line to provide a positive pressure on the oil Section 4b Page 4 system of the compressor even when the ai
16. fouling and corrosion Hex head zinc anodes are used in the return bonnet opposite end to the water pipe connections of heat exchangers to provide internal water system corrosion protection These anodes should be inspected periodi cally and replaced when the zinc has been reduced to about 1 2 inch in length WATER FLOW CONTROL VALVE FOR HEAT EX CHANGER Optional Equipment Figure 5 8 The water flow control valve is adjustable to compensate for varying water inlet temperatures and pressures and is to be mounted in the water outlet line after the oil cooler Figure 5 1 page 2 this section Use the compressor discharge air temperature gauge on the instrument panel in setting the flow control valve The compressor discharge temperature must be maintained a minimum of 10 F 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 operating pressure and ambient temperature of the application To decrease water flow increase compressor dis charge air temperature turn the adjusting screw from left to right increasing spring tension To increase water flow decrease compressor discharge air tem perature turn the adjusting screw in the opposite direc tion The groove atthe lower edge ofthe adjusting screw Section 5 8 F DEW POINT TEMP AMBIENT TEMP F FIGURE 5 9 DEW POINT TEMP
17. helical lobes 90 apart The secondary rotor has six 6 matching helical grooves 60 apart to allow meshing with main rotor lobes The air inlet port is located on top of the compressor cylinder near the drive shaft end The discharge port is near the bottom at the opposite end of the compressor cylinder Figure 1 1 is an inverted view to show inlet and discharge ports The compression cycle begins as ro tors unmesh at the inlet port and air is drawn into the cavity between the main rotor lobes and secondary rotor grooves A When the rotors pass the inlet port cutoff air is trapped in the interlobe cavity and flows axially with the meshing rotors B As meshing continues more of the main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of 13 9 10 641 Section 1 compression and seal internal clearances Volume re duction and pressure increase continues until the air oil mixture trapped in the interlobe cavity by the rotors passes the discharge port and is released to the oil reservoir C Each rotor cavity follows the same fill compress discharge cycle in rapid succession to pro duce a discharge air flow that is continuous smooth and shock free AIR FLOW IN THE COMPRESSOR SYSTEM Figure 5 1 page 2 Section 5 Air enters the air filter and passes through the inlet unloader valve to the compressor After compression the air
18. sonal injury or death Do not operate unit with either the coupling guard or the collar removed All bolts and screws must be properly tightened Alignment The coupling is permanently aligned by the flanges on the compressor and motor Section 7 1 SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter Operating conditions determine frequency of service The CHANGE AIR FILTER LED will illuminate to signal that the air filter requires servicing or changing See Air Filter Section 6 Oil Separator Operating conditions determine fre quency of service The CHANGE SEPARATOR LED will flash to signal that separator element requires chang ing See Compressor Cil Separator Section 5 page 8 Motor Lubrication Referto Section 2 and Maintenance Schedule Chart below 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 Consumption in Section 9 page 3 DO NOT MIX LUBRICANTS 2 Observe if the unit loads and unloads properly 3 Check discharge pressure and temperature 4 Drainthe moisture trap in the control system 5 Check Panel LED s for advisories Every 125 Hours Operation 1 Check for dirt accumulation on oil aftercooler core faces and the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blow ing compressed air carrying a nonflammable s
19. 10 641 Section 1 Page4 Failure to observe these notices could result in damage to equipment e Stop the unit if any repairs or adjustments on or around the compressor are required e Disconnectthe compressor unit from its power source tag and lockout before working on the unit this machine is automatically controlled and may start at any time e An Excess Flow Valve should be on all compressed air supply hoses exceed ing 1 2 inch inside diameter OSHA Regulation Section 1518 302 e Do not exceed the rated maximum pressure values shown on the nameplate not operate unit if safety devices are not operating properly Check periodically Never bypass safety devices 13 9 10 641 Section 1 Page5 DECALS DISCHARGE AIR USED FOR BREATHING WILL CAUSE SEVERE INJURY OR DEATH CONSULT FILTRATION SPECIALIST FOR ADDITIONAL FILTRATION AND TREATMENT EQUIPMENT TO MEET HEALTH AND SAFETY REGULATIONS AIR AND OIL UNDER PRESSURE WILL CAUSE SEVERE PERSONAL INJURY OR DEATH SHUTDOWN COMPRESSOR AND RELIEVE SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES CAPS PLUGS FITTINGS BOLTS AND FILTERS tuum 206 0077 212 0077 HIGH VOLTAGE ROTATING MACHINERY AIR AND 01 x UNDER PRESSURE DO NOT MODIFY IMPROPER MODIFICATION OF EQUIPMENT WILL UNIT WITHOUT CAUSE SEVERE PERSONAL WRITTEN PERMISSION INJURY OR DEATH FROM MANUFACTURER 218EAQ077 AMARNING UNIT CAN AUTOMATICALLY ROTATING MACHINERY CAN RESTART
20. 10 psi Any change in the pressure drop from that normally held may indicate tube leakage or fouling and should be investigated In many instances the cooling water supply for the heat exchanger will contain impurities in solution and or sus pension These substances can cause scale formation corrosion and plugging of any water cooled heat ex changer equipment Disregarding the possibility that one or more of these conditions exist may result in increased maintenance and operation expense re duced equipment life and emergency shutdown It is strongly recommended that a reputable local water treatment concern be engaged to establish the corro sion scale forming and fouling tendency of the cooling water and take steps necessary to remedy the situation if a problem does exist The need for water treatment may involve only filtration screening to remove debris 13 9 10 641 CAPILLARY TUBE A74099A ADJUSTING SCREW SETTING SCALE VALVE BODY HEAT SENSING BULB 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 scale deposits or prevent the growth of microorganisms The normal maintenance program for the unit should also include periodic cleaning of the tubes water side of the heat exchanger to remove deposits which enhance
21. 7 Operation at elevated 7 Reduce temperature See discharge temperatures High Discharge Air Temper ature in this section 8 Scavenge line check valve 8 Replace check valve failure 9 Water condensate in oil 9 Check oil reservoir temper ature If low change thermal mixing valve element to higher temperature 13 9 10 641 Section9 Page3 AUTO SENTRY ES CONTROLLER TROUBLE 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 Inspect Replace air filter if needed LOW AMBIENT The advisory comes on if the receiver or air end discharge is less than 40 F 4 4 C Refer to corrective measures for low ambient conditions in the Operator s Manual HIGH TEMPERATURE The advisory comes on when the temperature exceeds 210 F 99 C Probable cause plugged or dirty cooler high ambient conditions or blown fuses on fan motor NOTICE Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor on an exchange basis for all rotary screw compressor units 13 9 10 641 Section9 4 p COOPER Gardner Denver Industria Machinery GENERAL PROVISIONS AND LIMITATIONS Gardner Denver Industrial Machinery Division the Company warrants to each original retail purchaser Purchaser of its new products from
22. AUTO to display the hours remaining until oil change or filter change is recommended If service has been performed early press the AUTO key to reset the timers to their full number of hours Press ENTER to proceed to the next display without affecting timers In the top line DISPLAY UNITS is indicated The bottom line will indicate ENGLISH PSIG Fahren heit or METRIC Bars Celsius Select the desired mode and press ENTER to save and proceed 3 Inthe top line NUM OF SEQ UNITS is displayed The bottom line will indicate a number in the range of one through eight This will be factory set at 1 This should be set to a number corresponding to the number of compressors that are currently in stalled on this air system that also have AUTO SENTRY ES controllers It should be noted that all AUTO SENTRY ES compressors on the system must have the same number programmed here to operate correctly in SEQUENCE mode NOTICE Setting the value in step 1 to one indi cates that no sequencing is to take place Consequently steps 4 5 and 6 which relate to sequencing are skipped by the AUTO SENTRY ES Programming commences at step 7 4 the top line UNIT NUMBER is displayed The bottom line will again indicate a number of one through eight This will be factory set at 1 Each AUTO SENTRY ES in a sequenced system must have a unique number here The sequence mode will not function if two or more compressors have the s
23. CAUSE INJURY OR DEATH CAN CAUSE PERSONAL INJURY KEEP ALL GUARDS AND OR DEATH SAFETY DEVICES N KNOW MODE OF OPERATION PLACE BEFORE WORKING ON OR NEAR THE MACHINE WERL 211EAQ077 207EAQ077 13 9 10 641 Section 1 Page 6 DECALS ELECTRICAL SHOCK FROM AWA RANING AMARNING IMPROPER GROUNDING CAN CAUSE INJURY OR DEATH EA GROUND UNIT AND RELATED EQUIPMENT ACCORDING TO NATIONAL ELECTRIC CODE AND LOCAL REGULATIONS 216 0077 ELECTRICAL SHOCK CAN CAUSE INJURY OR DEATH DISCONNECT ALL CIRCUITS BEFORE WORKING ON THIS CONTROL SEE WIRING DIAGRAM AIR AND OIL UNDER ANWARINING 222EAQ077 PRESSURE CAN CAUSE SEVERE PERSONAL INJURY OR DEATH INSPECT OIL RESERVOIR FOR CRACKS AT LEAST ANNUALLY 217EAQ077 A CAUTION S A CAUTION ELECTRICAL ARCING CAN CAUSE A FIRE WHEN UNIT 15 MOUNTED ON A COMBUSTIBLE SURFACE RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE UNIT MUST BE MOUNTED ON A FLOOR PLATE EXTENDING ON ALL SIDES SEE INSTALLATION DRAWING FOR PROPER DIMENSIONS MACHINE DAMAGE OR INJURY CAN OCCUR DUE TO IMPROPER LIFTING DO NOT LIFT MACHINE WITH THE MOTOR EYEBOLT 221EAQ077 208EAQ077 13 9 10 641 Section 1 Page7 SECTION 2 INSTALLATION 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 Do not electric weld on
24. It is located on the upper section of the panel next to the keypad Automatic restarting or electrical shock can cause injury or death Open and lock main disconnect and any other circuits before servicing unit Control Transformer This changes the incoming power voltage to 110 120 volts for use by all unit control devices Two primary and one secondary fuse are pro vided Refer to the adjacent labelling for replacement information Section 4a 4 Terminal Strip This provides connections for all 110 120 volt devices not contained within the control panel Fan Starter where applicable The starter is used to provide control and overload protection for the cooling fan on air cooled units and ventilation fans of watercooled units with enclosure Overload heaters should be selected based on the nameplate current of the fan motor Three fuses are provided Refer to adja cent labelling for replacement information Main Starter This starter is used to provide control and overload protection for the main drive motor For wye delta starters overload heaters should be selected based on the motor nameplate current times 577 for proper protection Wye delta starters employ three con tactors which are controlled sequentially to provide low current starting Full voltage starters employ a single contactor overload selection should be based on the full load current of the motor and adjacent labelling OPERATION Op
25. SECTION 7 MAINTENANCE SCHEDULE si SECTION 8 TROUBLE SHOOTING 5 SECTION 9 13 9 10 641 Page ii INDEX NOTE Numbers preceeding dash are Section Numbers Numbers following dash are Page Numbers Air Control Components 4a 3 4b 4 Air Cooled Unit 2 1 Air Filter Element Life 6 1 Air Filter Element Service Instructions 6 1 Air Filter Vacuum Switch 4a 4 4b 5 AIR FILTERS SECTION 6 6 1 Air Oil Flow Diagram eese 5 2 5 3 Air Oil Flow Diagram Remote Overhead e E 5 4 Auto Sentry ES Controller Display 4 5 4b 6 Auto Sentry ES Operation 4a 5 4b 5 Auto Sentry ES Operation Automatic es S 4a 5 4b 6 Auto Sentry ES Operation Constant Run Mode 4a 5 4b 6 Auto Sentry ES Operation Low Demand 4a 5 4b 6 Auto Sentry ES Operation Sequence Mode 4a 5 4b 6 Auto Sentry ES Programming And Set Up Instr ctlon eed tes 4a 6 4b 7 Auxiliary Air Receiver esses 2 3 Bas
26. air end per Company instructions will be cause for denial of warranty OTHER COMPONENTS other components are warranted for 12 months from date of initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized service personnel for repair or replacement of any product or part thereof which in the Company s judgment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule AU 20 R 1 91 WARRANTY ROTARY SCREW COMPRESSORS OIL INJECTED OIL FREE Labor costs in excess of the Company rate schedule amounts or labor provided by authorized service personne is not provided for by this warranty All costs of transportation of product labor or parts claimed not to be as warranted and of repaired or replacement parts to or from such service facility shall be borne by the Purchaser The Company may require the return of any part claimed not to be as warranted to one of its facilities as designated by Company transportation prepaid by Purchaser to establish a claim under this warranty Replacement parts provided under the terms of this warranty are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such parts were original components WARRANTY REGISTRATION VALIDATION A war
27. and horsepower specified at the time of the order It is necessary only to connect the compressor unit to the correct power supply to the shop air line and to the shop water line if the compressor is watercooled A standard compressor unit consists of the compressor oil reservoir oil cooling system and oil filters motor enclosure specified NEMA 12 starter con trol box and controls as described below This compressor features the programmable control which integrates all the contrc 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 its condition PROTECTIVE DEVICES AND SHUTDOWN The AUTO SENTRY ES will shut down the unit following any fault detected in the following devices Following a shutdown a message will be displayed to indicate the cause The shutdown light will be on if the cause still exists or will flash if the cause has been cleared To resume operation the cause of shutdown must be cor BLOW DOWN YALVE PRESSURE REGULATOR SHUTTLE VALVE INLET VALVE q E FILTER l PURGE VALVE MINIMUM DISCHARGE PRESSURE CHECK VALVE lt am AFTERCOOLER OIL COOLER OIL RESERVOIR rected and the controller reset by press
28. appli cations with long unloaded periods Operation during periods of demand or moderately long unloaded periods is 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 with no demand the compressor drive motor is halted to eliminate its power consumption The controls will re main in this state until demand is again indicated by a drop in pressure Sequence Mode Operation This mode provides for communication between controllers operating only as many as are required for economical operation The lead unit 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 board connectors A unit number must be assigned to each unit to operate in this mode see Programming and Setup 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 Section 4a Page 5 curred the display will indicate the cause as noted above During normal operation the display will show the oper ation mode system pressure compressor discharge temperature and total running hours Alternate displays are available by pressing keypad cursor keys and will be identified on the display These include reservoir pressure separator differen
29. is factory set at 10 minutes This is the minimum time interval between blowdowns Limiting the blowdown frequency has been shown to prevent oil foaming and minimize wasteful dumping of compressed air when loading is likely to occur in a short time In the top line AUTO TIME is displayed The bot tom line will indicate a time between 5 and 30 minutes It too is factory set at 10 minutes Its function is to prevent too frequent motor starting 13 9 10 641 Section 4b Page7 10 11 12 13 14 and to allow the motor a cool down period before stopping in the top line START TIME is displayed The bottom line will indicate a time between 3 and 10 seconds This is the time that the wye delta starter spends in the start mode It should be set to transfer the starter to the run mode as soon asthe motor reaches its maximum attainable speed in the start mode If the set switch is off the control returns to the READY state and may then be restarted NOTICE This concludes operator accessible adjustments The following are consid ered service adjustments The SET switch on the circuit board must be turned on to proceed to the next set of programmable adjustments The SET Switch is located beneath the power transformer mounting plate on the left edge of the main circuit board In the top line HY SYS PRES LIM is displayed This should be set 20 25 PSI above nameplate pres sure equal to
30. oil mixture passes into the oil res ervoir where most of the entrained oil is removed by velocity change and impingement and drops back into the reservoir The air and remaining oil passes into the separator and separator housing where the oil is sepa rated and passes through tubing connecting the sepa rator housing and compressor The air passes through the minimum pressure valve discharge check valve and cooler then to the plant air lines LUBRICATION COOLING AND SEALING Oil is forced by air pressure from the oil reservoir through the oil cooler thermostatic mixing valve and oil filter and discharges into the compressor main oil gallery A por tion of the oil is directed through internal passages to the bearings gears and shaft oil seal The balance of the oil is injected directly into the compression chamber to remove heat of compression seal internal clearances and lubricate the rotors Page 1 INSTRUMENT DISPLAY WINDOW EMERGENCY STOP STARTER EMERGENCY STOP CONTROL AUTO SENTRY ES CONTROL PANEL CONTROL TRANSF ORMER FIGURE 1 2 STARTER BOX MAIN MOTOR STARTER FAN MOTOR STARTER FIGURE 1 3 PACKAGE CONTROLLER amp STARTERS DRIVE MOTOR AIR FILTER D COOLING FAN IL Jd E FIGURE 1 4 PACKAGE DRIVE MOTOR amp AIR FILTER 13 9 10 641 Section 1 2 SAFETY PRECAUTIONS Safety
31. operates the solenoid valves to pass pressure tothe inlet valve piston and the inlet valve closes enough to match air system demand See Figure 4a 6 page 9 this section As demand increases the controller will modulate the inlet valve by passing pressure with the solenoid valves as required to provide the most economical means of matching delivery to demand See Figure 4a 7 page 10 this section Low Demand Mode Operation The low demand mode reduces power consumption by relieving pressure in the reservoir during unloaded operation Under loaded con ditions it will operate identically to the constant run mode described above During low demand periods the controller will open the blowdown valve and fully close the inlet valve to mini mize the motor load See Figure 4a 8 page 11 this section Atimer is started when this occurs While in this state control air pressure is supplied from the plant air system When system air pressure drops due to in creased demand the blowdown valve recloses and the controls resume their normal modulation sequence Subsequent blowdown periods are not allowed until the timer has completed its cycle This cycle eliminates the problems of oil foaming and carryover which can occur if the oil reservoir of an oil flooded compressor is blown down too often The timer is adjustable from 5 to 20 minutes Automatic Mode Operation This mode provides au tomatic start and timed stop and is best used in
32. s tables based on motor nameplate full load amperage Section 2 5 Electrical shock can cause injury or death Open main disconnect switch before working on starter controi box GROUNDING Equipment must be grounded in accor dance with Table 250 95 of the National Electrical Code 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 on proper lubrication of the bearings The charts on the next page show recommended grease qualities and regreasing intervals for ball bearing motors For addi tional information refer to the motor manufacturer s instructions The following procedure should be used in regreasing 1 Stopthe unit 2 Disconnect the unit tag and lockout from the power supply 3 Remove the relief plug and free hole of hardened grease 4 Wipe lubrication fitting clean and add grease with ahand operated grease gun 5 Leave the relief plug temporarily off Reconnect unit and run for about 20 minutes to expell the excess grease 6 Stopthe unit Replace the relief plug 7 Restart the unit Rotating machinery can cause injury or death Open main disconnect tag and lockout before working on electric motor ELECTRIC MOTOR GREASE RECOMMENDATIONS Worked Penetration Viscosity SSU At 100
33. starters employ three con tactors which are controlled sequentially to provide low current starting Full voltage starters employ a single contactor overload selection should be based on the full load current of the motor and adjacent labelling OPERATION Operation of the AUTO SENTRY ES is dependent on selection of an operating mode from the controller key pad Prior to starting the STOP RESET key must be pressed to place the control in its ready state Operation Section 4b Page 5 may then be started by selecting an operating mode from the controller keypad Once operating the operat ing mode may be changed at any time The STOP RESET key may be pressed at any time to stop the compressor under normal conditions An optional control may be wired to the control to interrupt and restart the unit based on controls by others When stopped by these controls the display will indicate REMOTE STOP Automatic restarting or electrical shock can cause injury or death Open and lock main disconnect and any other circuits before servicing unit In any mode the compressor will start only if reservoir pressure is below 5 psig The display will indicate if the control is waiting for blowdown The controls will keep the compressor unloaded until the start cycle has been completed Constant Run Mode Operation This mode is best used in applications where there are no long periods of unloaded operation The compressor unit will st
34. substantial propery damage if the warning is ignored A CAUTION 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 Notice is used to notify people of installation operation or maintenence information which is important but not hazard related This book covers the following models PSIG Air Cooled Water Cooled Parts List 100 125 EBHQHA EBHSHA 13 9 555 EBHQHC EBHSHC 13 9 550 50 HP 100 125 EBHSJA 13 9 555 150 EBHQJC EBHSJC 13 9 550 60 HP 100 125 EBMQKA EBMSKA 13 9 557 EBMQKC EBMSKC 13 9 551 75 100 125 EBMQLA EBMSLA 13 9 557 150 EBMQLC EBMSLC 13 9 551 100 HP 100 125 EBPQMA EBPSMA 150 EBPQMC EBPSMC EAPQMD EAPSME 13 9 556 13 9 548 13 10 507 13 9 10 641 Pagei TABLE OF CONTENTS GENERAL INFORMATION itte in e erede ea rii etx bad Dee deesse deles ud Seni SECTION 1 D upHFfqpec SECTION 2 STARTING AND OPERATING SECTION 3 CONTROLS AND INSTRUMENTS otn iet etant rmt e use each uc et Dern SECTION 4 LUBRICATION OIL COOLER OIL FILTER AND SECTION 5 P lskglhiclc H QN SECTION 6 ee B c
35. the Company or its authorized distributor that such products are at the time of delivery to the Purchaser made with good material and workmanship No warranty is made with respect to 1 Any product which has been repaired or altered in such a way in the Company s judgment as to affect the product adversely Any product which has in the Company s judgment been subject to negligence accident improper storage or improper installation or application Any product which has not been operated or maintained in accordance with the recommendations of the Company 4 Components or accessories manufactured warranted and serviced by others 5 Any reconditioned or prior owned product Claims for items described in 4 above should be submitted directly to the manufacturer WARRANTY PERIOD The Company s obligation under this warranty is limited to repairing or at its option replacing during normal business hours at an authorized service facility of the Company any part which in its judgment proved not to be as warranted within the applicable Warranty Period as follows COMPRESSOR AIR ENDS Compressor air ends consisting of all parts within and including the compressor cylinder and gear housing are warranted for 24 months from date of initial use or 27 months from date of shipment to the first purchaser whichever occurs first Any disassembly or partial disassembly of the air end or failure to return the unopened
36. the correct replacement parts 2 Factory warranted new and remanufactured rotary screw air ends Most popular model remanufac tured air ends are maintained in stock at MDC for purchase on an exchange basic with liberal core credit available for the replacement unit 3 A full line of factory tested AEON compressor lubricants specifically formulated for use in Gard ner Denver and Joy compressors 4 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 maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Gardner Denver and Joy Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Gardner Denver Industrial Machinery Division Master Distribution Center 5585 East Shelby Drive Memphis TN 38115 Phone 901 363 6100 Fax 901 393 1095 Factory Gardner Denver Industrial Machinery Division 1800 Gardner Expressway Quincy IL 62301 Phone 217 222 5400 Fax 217 223 5897 INSTRUCTIONS FOR ORDERING REPAIR PARTS When ordering parts specify Compressor MODEL Method of Cooling HORSEPOWER and SERIAL NUM BER see nameplate on unit Serial Number is also stamped on top of the cylinder flange to the right of the in
37. the oil If oil carryover occurs inspect the separator only after it is determined that the oil level is not too high the oil is not foaming excessively the oil return line from the separator housing to the compressor cylinder is not clogged or pinched off the check valve in the oil return line is functioning properly and there is not water or an oil water emulsion in the oil Oil carryover malfunctions of the oil separator are usu ally dueto using elements too long heavy dirt or varnish deposits caused by inadequate air filter service use of improper oil or using oil too long for existing conditions Aruptured or collapsed separator element is usually due to heavy dirt or varnish buildup in the filtering material Excessive tilt angle of the unit will also hamper separa tion and cause oil carryover 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 r by inspection Pressure Differential Gauging The CHANGE SEPA RATOR advisory will flash when the pressure differential across 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 illuminate steadily when the pressure differential reaches 15 PSI
38. to 200 F 3000 hrs 4000 200 1500 hrs 2000 When operating conditions are severe very dusty high humidity it will be necessary to change the oil more frequently Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user A good lu bricant analysis program is helpful in planning the change interval 13 9 10 641 LO GARDNER DENVER FIGURE 5 6 OIL LEVEL GAUGE DRAINING AND CLEANING OIL SYSTEM 4 DANGER Air oil under pressure will cause se vere personal injury or death Shut down compressor relieve system of all 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 the oil is hot will help to prevent varnish deposits and carry away impurities To drain the system use one of the following methods If the unit is not elevated high enough to use the oil reservoir drain line to drain oil a small hand electric or air operated pump should be used to drain reservoir through the oil filler opening or from the drain valve If the unit is elevated so that the oil reservoir drain can be used empty the oil reservoir through the drain valve to a suitable container or sump If drained oil and or oil filter element are contaminated with dirt flush the entire system reservoir oil cooler mixing valve an
39. up to the maximum flow shown in Figure 2 4 previous page at a minimum pressure of 40 psig maximum allowable water pressure is 150 psig The water flow rates shown in Figure 2 4 previous page are approximate and a guide to sizing piping cooling tower and other water system equipment The heat exchanger system is designed to operate with water inlet temperatures from 60 F to 90 F and a water outlet temperature not to exceed 110 F If water cooler than 60 F is used high water outlet temperatures over 110 will be experienced along with shortened heat exchanger life caused by tube fouling and corrosion If water warmer than 90 F is used higher compressor inlet 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 more information on the water system SERIES PIPING Figure 2 5 Water flow must be through aftercooler first for effective cooling of dis charge air and is so piped on the standard water cooled unit PARALLEL PIPING Figure 2 6 A separate water control valve is required to control the discharge air temperature If a remote externally mounted water 13 9 10 641 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 water line
40. valve with the hand lever Hold the valve open for a few seconds and allow it to snap shut INLET VALVE OPEN POSITION MUFFLER ORIFICE CHECK VALVE ORIFICE BLOW DOWN VALVE SOLENOID VALVE SOLENOID VALVE IVC PRESSURE REGULATOR SEPARATOR SHUTTLE VALVE HOUSING ch To SEPARATOR AFTERCOOLER HOUSING TRANSDUCER FIGURE 4b 3 INLET VALVE 13 9 10 641 Section 4b 2 A WARNING When relief valve opens a stream of high velocity air is released resulting in a high noise level and possible dis charge of accumulated dirt or other de bris Always wear eye and ear protection and stand clear of the dis charge port when testing the relief valve to prevent injury A CAUTION Never paint lubricate or alter a relief valve Do not plug vent or restrict dis charge Operation of unit with improper relief valve setting can result in severe per sonal injury or machine damage Ensure properly set valves are installed and maintained Low Oil Pressure The Auto Sentry ES will shut down the unit if inadequate oil pressure to the compres sor is detected If this occurs check the wiring and piping solenoid valves FIGURE 4b 4 SHUTTLE VALVE Emergency Stop Pressing the emergency stop button will shut down the unit and the controller To restart pull the button out to its normal position and reset the controller Power Failure Following power interruptions the controller wil
41. AGRAM 13 9 10 641 Section 4b Page 1 lowtemperature is detected The display will indicate the location of the defective thermistor probe Machine damage will occur if compres sor is repeatedly restarted after high temperature stops operation Find and correct the malfunction before resum ing operation Separator Differential Pressure The separator differ ent al pressure is continually monitored by the Auto Sentry ES At a differential pressure of approximately 15 psi the unit will be shut down High Pressure The Auto Sentry ES will shut down the unit if excessive pressures are detected in the reser voir or system Shut down will occur if a defective transducer is detected The display will indicate the location of the high sensed pressure or transducer xducer error Check that all adjustments have been properly made and all connections are secure Relief Valve A pressure relief valve s is are installed inthe final discharge line and set to approximately 12096 of the unit s full load operating pressure for protection against overpressure Periodic checks should be made to ensure its their proper operation The relief valves shouid be tested for proper operation FROM AIR FILTER PURGE VALVE TO 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 set pressure and manually open the
42. ALVE ACTUATOR SEC TIONED FIGURE 4b 9 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE 19 01 6 1 qruonoes 20 pag osse CNI CONTROL CIRCUIT BOARD I3 0110 7 5 3 1 SEE NOTE 4 FINAL DISCH TRANSDUCER E BLACK RED BLACK idi TRANSDUCER RESERVOIR THERM RESVR THERM B COMP EMERGENCY STOP THERMISTOR COMPRESSOR TO Boy 1715 THERMISTOR A RESERVOIR TRANSDUCER A FINAL DISCH s WHT BLK TRANSDUCER B RESERVOIR RED WHT BLK TO Ivo 10 TO 15 1 Ive 1 TVO amp 0 14 15 10 MOTOR TO FAN MOTOR 888 21 10 7 27 NOTE 1 FORM C CONTACT FOR USE 8Y OTHERS CONTACT OPERATES FOLLOWING COMPRESSOR SHUTDOWN RATING 120 2 NOTE 2 FOR USE WITH OPTIONAL VIBRATION SWITCH REMOVE JUMPER BETWEEN TERMINALS 7 amp 9 CON NECT MC VIBRATION SWITCH CONTACT TO TERM INALS 7 amp 9 NOTE 3 FOR CONTROL BY REMOTE CONTACT REMOVE JUMPER BETWEEN TERMINALS 6 amp 9 CONNECT TACT TO TERMINALS 6 amp 9 NOTE 4 D69A 1 0898 ARE FOR USE OF OPTIONAL COMMUNICATIONS CABLE NOTE 5 WHEN WATER CONTROL SOLENOID VALVE 15 USED WIRE TO TERMINALS 18 amp 10 g CONNECTION TO CONTROL BOARD C PANEL TERMINAL BLOCKS LEGEND AIR FILTER VACUUM SWITCH WYE DELTA
43. COOLER ASSEM BLY PROCEDURE The compressor package will be built 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 its place The vent fan will be mounted in the enclosure A contactor starter will be shipped loose and remote mounted with the cooler by others upon start up at the job site The control box will be wired for remote ele vated coolers at the factory Section 5 Page 1 179 01 6 1 8 A MOTOR B COMPRESSOR C AIR FILTER D OIL RESERVOIR E OIL SEPARATOR F OiL COOLER G AFTERCOOLER H THERMAL MIXING VALVE J OlL FILTER K SEPARATOR TO CYLINDER OIL RETURN LINE L CHECK VALVE M PRESSURE RELIEF VALVE N DISCHARGE CHECK VALVE P MINIMUM DISCHARGE PRESSURE VALVE R PURGE AIR VALVE S PNEUMATIC BLOW DOWN VALVE T ORIFICE U BLOW DOWN MUFFLER V SHUTTLE VALVE W PRESSURE REGULATOR X SOLENOID VALVE Y SOLENOIO VALVE IVO Z ORIFICE AA AIR FILTER VACUUM SWITCH B8 SYSTEM PRESSURE TRANSDUCER CC DISCHARGE PRESSURE TRANSDUCER 00 AND MOTOR EE WATER FLOW CONTROL VALVE FF MAGNETIC WATER SHUTOFF VALVE FIGURE 5 1 FLOW DIAGRAM EBH EBM amp EBP AIR OQIL AIR OIL WATER gt 179 01 6 1 guonoeg L M OMPRESSOR AIR FILTER IL RESERVOIR L SEPARATOR L COOLER AF TERCOOLER THERMAL MIXING VALVE IL FILTER EPARATOR TO CYLINDER
44. ERATURE VS AMBIENT TEMPERATURE 100 RELATIVE HUMIDITY is an index line for use with the index scale 0 to 8 in obtaining a desired setting These valves must be handled with care and proper tools and techniques must be used when working on the valve Care must be used when handling the capillary tube a kink or break in the tubing or connections will make the valve inoperative Never attempt to change capillary length Excess capillary tube should be carefully coiled and placed so that damage will not occur in normal maintenance or traffic past the unit If the leak develops through the packing tighten the packing gland nut firmly with a wrench to reseat the packing around the valve stem then back off the nut until loose and finally retighten the nut finger tight Tightening the packing nut too tight may cause erratic operation An occasional drop of oil on the valve stem at the packing nut will prolong packing life If valve malfunctions check for bent binding paint or corrosion valve stem foreign material in valve erosion or thermal system capillary failure If foreign material or scale is likely the use of a strainer in the inlet water line is recommended WATER SHUTOFF VALVE WATER COOLED HEAT EXCHANGER Optional Equipment Figure 5 1 page 2 this section A magnetic solenoid operated water shutoff valve rated at 150 psig water pressure should be mounted in the water outlet line after the oil cooler The va
45. Filter Vacuum Switch This switch is used to monitor air filter condition and alert the user if the filter requires service or replacement Vibration Switch Optional Equipment The optional vibration shutdown switch mounted on the compressor coupling cover detects an increase in vibration that could be an indication of impending damage to the unit The switch actuates when the selected level of vibration is exceeded The switch MUST BE ADJUSTED when the unit is first installed Refer to switch manufacturer s instruction manual for complete details STARTER CONTROL PANEL The following items are located in the electrical enclo sure and provide the main contro of the compressor unit and switching of the motor s Refer to Figure 1 3 page 2 Section 1 AUTO SENTRY ES The Auto Sentry ES is located on the upper section of the panel It provides all the control of the motors and control devices for safe and efficient operation of the compressor unit Its display provides all gauging functions shutdown causes and maintenance recommendations The keypad provides the user with selection of operating modes and adjustment to tune the controls for the application It is connected to other devices inside the panel and external devices through the terminal strip The Auto Sentry ES requires no maintenance Emergency Stop This is a maintained pushbutton and removes power from the controller outputs regardless of controller status
46. HANGER Water Temperature To Heat Exchanger Max Water 60 F 70 F 80 F 90 F Flow GPM EBHSHA EBHSHC EBHSJA EBHSJC EBMSKA EBMSKC EBMSLA EBMSLC EBPSMA EBPSMC EAPSMD Approx Water Press Dro 90 F Water Temp PSI pey e oom aa a n mo oo mo o AFTERCOOLER EBHSHA EBHSHC EBHSJA EBHSJC EBMSKA EBMSKC EBMSLA EBMSLC EBPSMA EBPSMC EAPSMD Water Temperature To Heat Exchanger Max Water HP 60 F 70 F 80 F 90 F Flow GPM 5 7 9 NNN GL ina 900 NNN NN gt gt aa OO BA hh Approx Water Press Drop 90 F Water Temp PSI Less than 1 PSI for any flow rate shown in the table Qao 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 remote location DISCHARGE SERVICE LINE The discharge service line connection on both water cooled and air cooled units is made at the right hand corner of the unit viewed from the opposite end from control panel side When manifolding two or more rotary screw units on the same line each unit is isolated by the check valve in the unit discharge line If a rotary screw unit is manifolded to another compressor be sure the other compressor has a check valve in the line between the machine and the manifold If a rotar
47. NG 120VAC 2 NOTE 2 FOR USE WITH OPTIONAL VIBRATION SWITCH REMOVE JUMPER BETWEEN TERMINALS 747 CON VIBRATION SWITCH CONTACT TO TERM WAS 749 NOTE 3 FOR CONTROL SY REMOTE CONTACT REMOVE AMPER BETWEEN TERMINALS amp CONNECT CON TACT TO TERMINALS 4 9 NOTE 4 DOTA amp DB B ARE FOR USE Of OPTIONAL COMMUNICATIONS CABLE NOTE 5 WHEN WATER CONTROL SOLENOID VALYE 1 USED WIRE TO TERMINALS 18 amp 10 g CONNECTION TO CONTROL BOARD Q BLOCKS LEGEND AIR FILTER VACUUM SWITCH BOY BLOWDOWN SOLENOID VALVE INLET YALYE CLOSE SOLENOID VALVE IYO INLET VALVE SOLENOID VALVE LEAD CONNECTION FOR MOTORS LOW VOLTAGE HIGH VOLTAGE CONNECTIONS CONNECTIONS 11 14 2 1 T3 74 11 T4 72 T5 73 T 51519 FIGURE 4a 9 WIRING DIAGRAM 207ECP546 TRANSDUCER FINAL DISCHARGE WYE DELTA TRANSDUCER 8 RCSERVOIRD THERMISTOR A RESERVOIR THERMISTOR COMPRESSOR SRR EES EERE RRR ST ESTERS EE SR RANT Ee stan SED TREE 25 AUTO SENTRY ESO SHUTDOWN STOP RESET CONSTRNT RUN LOW AUTOMATIC SEQUENCE EEE RRA CS EEE BAIR ESTE 13 9 10 641 Section 4a Page 13 SECTION 4b EAP UNITS CONTROLS amp INSTRUMENTS GENERAL The Gardner Denver rotary screw com pressor is prewired with all controls motor and wiring and starter for the voltage
48. PROGRAMMING AND SETUP INSTRUCTIONS FOR THE AUTO SENTRY ES R CONTROLLER Programming and setup is accomplished with the PRO GRAM keys In all steps the ENTER key will cause the controller to accept the displayed value into memory and advance to the next programming function The plus and minus keys will increase and decrease displayed values respectively The right and left arrow keys and position the cursor flashing digit The number at the cursor will be the number that is changed by the and keys At any point in the programming and setup routine the STOP RESET key can be pressed to exit and return to the ready mode In all steps of the programming routine the top line of the display will give a description of the parameter to be programmed while the bottom line shows the variable that is capable of being altered by programming The following is a step by step guide to programing the AUTO SENTRY ES Controller 13 9 10 641 Between each step it is necessary to press the ENTER key to store the new value and advance to the next step 1 Press the ENTER key to begin programming If the enable switch on the circuit board is in the set position the control proceeds to the setup adjust ments starting with step 2 below If the slide switch is down in the position push ENTER to go from OIL FILTER CHANGE to OIL CHANGE and then push ENTER again to proceed to Step 2 Press
49. RVE UNIT COLD OR HOT STARTING PROCEDURES Unit Cold If the unit is a water cooled heat exchanger model open any manual water inlet valves wide open Start the unit by pushing either the CONSTANT RUN button or one of the AUTO buttons Since the unit is equipped with a minimum 65 psig pressure discharge valve no special procedure to maintain unit reservoir pressure is required Unit Hot No warm up period is required if the unit is a water cooled heat exchanger model open any manual water inlet valves wide open Start the unit by pushing either the CONSTANT RUN button or one of the AUTO buttons DAILY CHECK Refer to Section 8 Maintenance Schedule STOPPING THE UNIT Press STOP RESET button The oil reservoir will automatically blow down as the motor stops If the unit is a water cooled heat exchanger type close any manual water inlet valves SEQUENCING COMPRESSORS Sequencing compressors with the AUTO SENTRY ES controller is as simple as plugging in a telephone to a wall jack The only item required to make the system functional is a standard telephone cable identical to cables that connect nearly every telephone to its wall jack One less cable than the number of compressors to be sequenced is required For example to sequence four compressors three cables are required A kit 200EAP752 is available which contains all material needed to sequence up to five compressors This kit contains 500 feet of cable
50. afety solvent in a direction opposite that of the cooling fan air flow This cleaning operation will keep the exterior cooling surfaces clean and ensure effec tive heat dissipation Every 1000 Hours Operation 1 Change oil filter element Every 8000 Hours Operation 1 Change the compressor lubricant UNDER AD VERSE CONDITIONS CHANGE MORE FREQUENTLY refer to Oil Change Interval in Section 5 Flush system if required DO NOT MIX LUBRICANTS Every 4000 Hours Operation 1 Inspect the oil separator element See Section 5 page 8 Every Year 1 Check the relief valve for proper operation See Section 4a page 1 or Section 4b page 2 MAINTENANCE SCHEDULE See detail notes above Maintenance Action Change Air Filter Change Separator Check Reservoir Cil Level Check For Proper Load Unload Check Discharge Pressure Temp Check Dirt Accumulation on Cooler Change Oil Filter Element Inspect Oil Separator Element Change Compressor Lubricant Check Relief Valve See Continuous Operating Temperature Chart Section 5 page 5 for specific lubricant life 13 9 10 641 Section 8 1 SECTION 9 TROUBLE SHOOTING Symptom Possible Cause Remedy Compressor fails to start Compressor starts but stops after a short time Compressor does not unioad or load 13 9 10 641 Wrong lead connections Blown fuses in control box Motor starter overload heaters tripped Pres
51. ag and lockout power supply to starter before remov ing valves caps plugs fittings bolts and filters 1 Stop unit and be sure no air pressure is in the oil reservoir 2 Remove the spin on element Clean the gasket face of the filter body 4 Coat the new element gasket with clean lubricant used in the unit 5 Screw new element on filter body and tighten by hand 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 motor and fan is mounted on the oil cooler module air is exhausted through the oil cooler and away from the unit Do not obstruct air flow to and from the oil cooler Allow a minimum of three 3 feet clearance around the cooler Keep both faces of the cooler core clean for efficient cooling of the compressor oil THERMAL CONTROL THERMOSTATIC MIXING VALVE Figure 5 7 page 8 this section is installed in the system as shown in Figure 1 5 Section 5 page 2 This valve is used to control temperature of the oil in both air cooled radiator and water cooled heat ex changer type oil cooler systems On start up with unit cold element is open to bypass allowing oil to pass directly from the reservoir to compressor during warm As oil warms element gradually closes to the bypass allowing more of the oil from the cooler to mix with oil from the bypass After the unit is warmed up the mixing valve mainta
52. ame UNIT NUMBER Most efficient machine to machine communications will occur when the lowest possible numbers are used Example 1 2 and 3 for a three compressor installation Section 4a Page 6 NOTICE This concludes operator accessible adjustments The following are consid ered service adjustments The SET Switch on the circuit board must be turned on to proceed to the next set of programmable adjustments The SET switch is located beneath the power transformer mounting plate on the left edge of the main circuit board 10 In the top line TRANFER INTERVAL is displayed The bottom line will indicate a number of hours in the range of 1 to 5000 It is factory set at 24 This is the number of hours that this machine will stay in the role of master or lead compressor Normally it is desirable to set this value the same on all sequenced units to equalize running hours In the top line LAG START DELAY is displayed The bottom line will indicate a number in the range of 15 to 600 seconds It is factory set at 30 This is the length of time this machine will wait before starting when the pressure drops below the reset point Again this is normally set to the same value for all sequenced units Its setting will depend on the amount of air storage volume in the system In the top line BLOWDOWN TIME is displayed The bottom line will indicate a time between 5 and 20 minutes It is factory set at 10 minutes This is th
53. an be seen then that except for short periods just after a sudden increase in demand the AUTO SENTRY ES with its dynamic setpoint control will maintain sys tem pressure between the limits of RESET PRESSURE and SET PRESSURE Remember RESET and SET PRESSURE values are programmed by the operator so the operating range is completely programmable and predictable Dynamic setpoint control will also work in reverse of the operation described above Obviously incrementing setpoints will cause overlap of the compressors modu lation ranges While this enables us to maintain a higher pressure than competitor s sequencers overlap is unde sirable as demand decreases because a system could end up with several compressors running partially loaded instead of running the minimum number of fully loaded compressors To overcome this as pressure rises through the range between RESET and SET the lag compressors PSET s are now decremented revers ing the effect described above during periods of high demand The AUTO SENTRY ES keeps track of all functions at all times so there is never any mix up of setpoints and the proper rotation sequence is always maintained THE AUTOMATIC SEQUENCE CHANGE After the master lead compressor has served for the duration programmed TRANSFER INTERVAL it relin quishes control and assigns itself the highest available rotation number The lag compressors detect the loss of the master and decremen
54. art and run continuously using its modulation controls to match delivery to demand As demand falls below the compressor capacity the pressure will rise to the setpoint of the control When the pressure reaches the setpoint the AUTO SENTRY ES controller operates the solenoid valves to pass pressure to the inlet valve piston and the inlet valve closes enough to match air system demand See Figure 4b 8 page 11 this section As demand increases the controller will modulate the inlet valve by passing pressure with the solenoid valves as required to match delivery to demand See Figure 4b 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 ow demand mode reduces power consumption by relieving pressure in the reservoir during unloaded operation Under loaded con ditions it will operate identically to the constant run mode described above During low demand periods the controller will open the blowdown valve and fully close the inlet valve to mini mize the motor load See Figure 4b 9 page 12 this section A timer is started when this occurs While in this state control air pressure is supplied from the plant air system When system air pressure drops due to in creased demand the blowdown valve recioses and the controls resume
55. ating information to the user If a shutdown has curred the display will indicate the cause as noted above During normal operation the display will show the oper ation mode system pressure compressor discharge temperature and total running hours Alternate displays are available by pressing keypad cursor keys and will be identified on the display These include reservoir pressure separator differential pressure reservoir tem perature system pressure and compressor discharge temperature In Low Demand Automatic or Sequence modes aiternate displays also indicate remaining times of delay If no keys are pressed for 5 seconds the display will return to its normal mode The display is also used as a service reminder for normal maintenance items These include the separator air filter and oil filter change intervals All intervals are based on recommended parts as noted in the maintenance section of this manual Oil change intervals are also automatically calculated based on actual operating conditions This allows maximum utilization of AEON 9000 oil Messages will also be displayed if operation has occurred during low ambient temperatures or if high temperature operation has occurred Clearing Advisories Temperature advisories may be cleared while the unit is running by simply pressing the ENTER key To reset the service messages press the Section 4b Page 6 STOP RESET key to stop operation of the compressor Disc
56. ause permanent cooler damage Drain condensate after system shut down It is the owner operator s re sponsibility to ensure that condensate has been drained and cooler dried out to prevent cooler damage HEAT EXCHANGER OIL PIPING All remote ele vated cooler applications must be sent through Engi neering for approval and for recommending the pipe size When the cooling module is removed from the package the thermal mixing valve H remains on the package Control group part number 200ECM4002 will be mounted on the package at the factory This group controls the oil stop valve as well as not allowing the machine to run unloaded See Figure 5 3 page 4 this section NOTICE Remote mounted elevated coolers have a maximum pipe length of 30 feet each way and a maximum height of 20 feet with a minimum of fittings Engi neering will review all remote elevated cooler applications and recommend pipe size on an individual basis cus tomer service should include the engi neering recommendation in the special order sent to Engineering Kit number EAQ68330 includes the oil stop valve check valve 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 90J113 as shown Mount the drain valves in the lowest section of the pipe on each side of the cooler connec tions Mount the oil stop valve 90AR243 inthe line after the therma
57. cal When set to its most appropri ate value the controller will maintain the discharge at the closest possible value If not set correctly pressure will vary from the desired setpoint to a somewhat greater degree but the com pressor and its components will not be adversely affected SMALL if estimated volume is less than 25 gallon per CFM MEDIUM if estimated volume is between 25 and 13 9 10 641 22 23 24 1 0 gallon per CFM LARGE if estimated volume is greater than 1 0 gallon per CFM In the top line REMOVE SYS PRESS is displayed The bottom line displays the current pressure being sensed at the package discharge At this point steps must be taken to ensure that the system pressure is in fact zero If necessary remove the line to the system pressure transducer Pressing ENTER will now cause the AUTO SENTRY ES to calibrate the transducer output to zero PSI Obvi ously pressure measurement errors will be en countered if zeroing is done with pressure at the transducer Inthetop line REMOVE RES PRESS is displayed The bottom line displays the current pressure being sensed in the air oil reservoir The reservoir pres sure transducer may now be zeroed by following the steps outlined in 19 above The display now reads PRESS CNST RUNTO JOG MOTOR Pressing the CONSTANT key will briefly energize the starters causing the compres sor to rotate 1 4 to 1 1 2 revolutions to allow a rotat
58. ce pressure downstream of minimum pres sure valve to below desired minimum pressure DO NOT REDUCE UPSTREAM PRESSURE OR AD JUST VALVE BELOW 65 PSIG 3 Loosen locknut on adjusting screw 4 Turn set screws in to increase or out to decrease minimum pressure to be held Section 4a Page 3 FIGURE 4a 5 SHUTTLE VALVE 5 Holdsetscrew at desired point and tighten locknut Check Valve Reservoir A renewable seat swing type check valve in the final discharge manifold prevents backflow of air from the shop air line when the unit stops unloads or is shut down Purge Air Valve The purge valve is a normally closed two way air actuated valve that admits purge air from the final discharge manifold to the compressor to counter actthe oil knock which occurs in oil flooded rotary screw compressors when they are completely unloaded with pressure in the oil reservoir This valve is controlled by the same control pressure which controls the inlet valve Solenoid Valves IVC and IVO These valves control position of the inlet valve in response to signals from the Auto Sentry ES With both valves de energized the normally open IVC valve allows control pressure to the inlet 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 re
59. ce with use of synthetic lubricants will damage equipment Oil filter and oil separator change intervals must be adhered tc for maximum compressor protection and efficiency See maintenance schedule Section 8 High Temperature Operation Gardner Denver amp AEON 9000 lubricating coolant will operate at a sus 13 9 10 641 tained discharge temperature up to 210 F when unusu ally high ambient air temperature is encountered DANGER Oil under pressure will cause severe personal injury or death Shut down compressor and relieve system of aii pressure before removing valves caps plugs fittings bolts and filters A WARNING High temperature operation can cause damage io equipment or personal in jury Do not repeatedly restart after high temperature stops operation Find and correct the malfunction before re suming operation N WARNING All materials used in Gardner Denver compressor units are compatible with AEON 9000 Lubricating Coolant Use caution when selecting downstream components such as air line lubricating bowis gaskets and valve trim AEON 9000 Synthetic Lubricant is not compatible with low nitrile Buna or acrylic paints AEON 9000 is compati ble with most air system down stream components Materiai Safety Data Sheets MSDS are available for all AEON lubricants from your authorized Gardner Denver distributor or by calling 217 222 5400 REMOTE MOUNTED ELEVATED
60. combination oil aftercooler is supplied as standard equipment on all air cooled units The air cooled unit with the standard enclosure requires sufficient flow Figure 2 2 for the compressor oil 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 block the air flow to and from the unit Allow three and one half 8 1 2 feet to the nearest obstruction on the starter end and control box end of the unit Allow three 3 feet to the 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 For aluminum oil coolers do not use any cleaning solution that is not com patible with aluminum Use of improper solution may result in damage to cooler LOUVEREO WINDOW EXHAUST FAN LOUVERED WINDOW Gem em vmm im vu m vum wy 77 UA a wa 1 Cr D sth TES 2 A75119 FIGURE 2 1 TYPICAL COMPRESSOR ROOM Minimum Air Flow For Compression And cooling Cubic Feet Minute Air Cooled 6 500 60 75 100 12 500 BO F inlet air FIGURE 2 2 Section 2 1 COMPRESSOR MOTOR COOLER AWAY FROM PREVAILING WINDS HEATER OR FT PLYWOOD FENCE WELLMAN RADIANT 2 ELEMENT HEATER OR EQUAL
61. d lines Inspectthe oil separator element for dirt accumulation replace if necessary If a varnish deposit exists contact the factory for recommendations for removal of the deposit and prevention of varnish FILLING OIL RESERVOIR DANGER Air oil under pressure will cause se vere personal injury or death Shut down compressor relieve system of all pressure disconnect tag and lock out power supply to starter before re moving valves caps plugs fittings bolts and filters Section 5 Page 6 1 Be sure the unit is completely off and that no air pressure is in the oil reservoir 2 Disconnect tag and lockout the power supply to the starter Wipe away all dirt around the oil filler plug Remove the oil filler plug and add oil as required to return the oil level to the center of the green range on the gauge 5 Operate the unit for about a minute allowing oil to fill all areas of the system 6 Shut down the unit allowing the oil to settle and be certain all pressure is relieved Add oil if necessary to bring the level to the center of the green range on the gauge On unloaded operation and after shutdown some oil will drain back into the oil reservoir and the oil level will read over FULL DO NOT DRAIN OIL TO CORRECT On the next start oil will again fill the system and the gauge will indicate operating at the proper level DO NOT OVERFILL as oil carryover will result The quant
62. e Differential Gauging 5 10 Oil Separator REMOVAL 5 10 Oil System Check eese 5 10 Outline Drawings eese 1 2 1 3 Piping 2 4 1 5 4 Piping Heat 5 5 Piping Parallel emere 2 5 Piping Serles eae carotte etes 2 5 Pressure Regulator 4a 4 4b 4 Prestart up Instructions esses 3 1 Protective Devices and Shutdown 4a 1 4b 1 Purge Air Valve 4a 4 4b 4 Relief Valve e eret rn 4a 1 4b 2 Remote Overhead Cooler 5 1 Reservoir Pressure Transducer 4 4 4b 5 Safety Precautions 2 44 4 40202 1 4 Separator Differential Pressure Shutdown 4a 1 4b 2 Sequencing Automatic Change 3 4 Sequencing Installation 3 2 Sequencing Operation 3 3 Sequencing Other Features 3 4 Shuttle Valve esses 4a 4 4b 4 Solenoid Valves IVC and IVO 4a 4 4b 4 Solenoid Valves and
63. e minimum time interval between blowdowns Limiting the blowdown frequency has been shown to prevent oil foaming and minimize wasteful dumping of compressed air when loading is likely to occur in a short time In the top line AUTO TIME is displayed The bot tom line will indicate a time between 5 and 30 minutes It too is factory set at 10 minutes Its function is to prevent too frequent motor starting and to allow the motor a cool down period before stopping In the top line START TIME is displayed The bottom line will indicate a time between 3 and 10 seconds This is the time that the wye delta starter spends in the start mode It should be set to transfer the starter to the run mode as soon as the motor reaches its maximum attainable speed in the start mode If the set switch is off the control returns to the READY state and may then be restarted In the top line HY SYS PRES LIM is displayed 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 a blowdown and shutdown condition 13 9 10 641 11 12 14 15 16 17 18 19 In the top line SET PRESSURE is displayed The bottom line will indicate a pressure value in the range 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 adjustment to be set
64. eight modular connectors and a crimping tool to install the connectors In spite of the fact that it is a standard feature and its inherent installation simplicity the sequencing function of a multi compressor AUTO SENTRY ES system is the most fully featured functionally complete available today l INSTALLATION A proper sequencing installation requires two or more Gardner Denver rotary air compressors complete with AUTO SENTRY ES controllers piped into a common air system interconnected as described above All stan dard practices common to sound air compressor instal lations such as proper sizing of discharge piping proper 13 9 10 641 electrical supply and conductor sizing and grounding areto be observed The serial communications interface meets RS 485 standards the most widely used interface in harsh industrial environments today However it is still recommended that the communications cables be routed through metallic conduit to provide them with both mechanical protection and electromagnetic shield ing Each control circuit board has two modular jacks which accept standard RJ 12 telephone plugs One jack is vacant the other has a short pigtail plugged into it To interconnect two compressors plug the cable into the vacant jack on each controller For installations of more than two units the pigtail plug must be disconnected on all controllers except the two at each end of the commu nications line The order
65. ember that once a master is estab lished no further self decrementing is done by the individual compressors Instead they will wait until the master assigns them a rotation number 13 9 10 641 Rotation numbers are displayed in the bottom display line with the mode indication For example the mode indication for the current master is SEQI for the first lag compressor SEQ2 second lag SEQ3 etc B HOW THE AUTO SENTRY ES CONTROLS PRESSURE WHILE SEQUENCING Each compressor operates exactly the same as if it were in AUTO mode with one exception it has a dynamic setpoint The initial setpoint is determined by the equa tion shown above A compressor is started when the system pressure drops below its programmed reset point after waiting for LAG START INTERVAL times rotation number 1 seconds This prevents all lag compressors from starting at once Note that a compressor s LAG START INTERVAL times rotation number 1 timer is not reset to zero until that compressor is started This means that the time for the next lag compressor to come on is always somewhat less than START INTERVAL EXAMPLE In a three compressor sequence system SET PRES SURE 100 PSI RESET PRESSURE 90 PSI LAG START INTERVAL 15 seconds The lead compressor is running alone maintaining 100 PSI by modulation when an air tool is brought on line causing the air demand to exceed the capacity of the lead compressor When the pressure dr
66. en for a few seconds and allow it to snap shut When relief valve opens a stream of high velocity air is released resulting in a high noise level and possible dis charge of accumulated dirt or other de bris Always wear eye and ear protection and stand clear of the dis charge port when testing the relief valve to prevent injury Never paint lubricate or alter a relief valve Do not piug vent or restrict dis charge Section 4a Page 1 BLOW DOWN YALVE PRESSURE REGULATOR SHUTTLE VALVE INLET VALVE q PURGE VALVE MINIMUM DISCHARGE PRESSURE CHECK VALVE a 1 AFTERCOOLER OIL COOLER eel MUFFLER ORIFICE CHECK VALVE ORIFICE SOLENOID VALVE AIR FILTER SWITCH TRANSDUCER FIGURE 4a 1 SCHEMATIC TUBING DIAGRAM Operation of unit with improper reliet valve setting can result in severe per sonal injury or machine damage Ensure properly set valves are installed and maintained Low Oil Pressure The programmable controller will shut down the unit if inadequate oil pressure to the compressor is detected If this occurs check the wiring and piping to the solenoid valves Emergency Stop Pressing the emergency stop button will shut down the unit and the controller To restart pull the button out to its normal position and reset the controller Power Failure Following power interruptions the con troller will remain in a shutdown state High Vibration optional Th
67. en to set the control sequencer to a lower pressure to prevent this or allow local override of the sequencer by the local pressure control neither of which is desirable in the scheme of maintaining plant pressure efficiently with sequencing The AUTO SENTRY ES sequencing system lets each compressor control itself independently about a setpoint PSET derived to cause staggered operation or se quencing The aforementioned pressure drops can also cause derogatory effects mainly skewed or out of se quence operation to the sequencing algorithm used by the AUTO SENTRY ES Since these pressure variations are not constant they will vary due to demand changes compressor load percentage changes and number of compressors run ning any scheme to compensate for the pressure vari ations must be dynamic That is corrections must be applied rather frequently and on the fly The exclusive dynamic setpoint control feature enables this error cor rection scheme to be accomplished rather easily Here s how it works The master continually receives system pressure values from every machine in the se quence rotation The values are averaged and this aver age is then distributed to all lag compressors This happens approximately once per second All compres sors lead and lag then compare their local pressure reading to the average and adjust their PSET by the amount of error The effect is that all compressors are controlling to a single pr
68. erating range as system components are filled If necessary add oil to bring the level to the top of the green range as read when the unit is operating at full load and normal pressure See Figure 5 4 page 4 Section 5 Regular maintenance and replacement at required intervals of the oil filter air filter and air oil separator is necessary to achieve maximum service and ex tended drain intervals of AEON 9000 synthetic lubricant Use only genuine Gardner Denver filters designed and specified for this compressor Always stop the unit and release air pressure before removing oil filler plug Failure to release pressure may result in personal injury or death During unloaded operation and after shutdown the system will partially drain back into the oil reservoir and 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 fili the system and the gauge will indicate the operat ing level 13 9 10 641 2 AirFilter Inspect the air filter to be sure it is clean and tightly assembled Refer to Section 6 Air Filter for complete servicing instructions Be sure the inlet line if used is tight and clean 3 Coupling Check all bolts and cap screws for tightness See Section 7 4 Piping Refer to Section 2 Installation and make sure piping meets all recommendations 5 Electrical Check the wiring diagrams furnished with the uni
69. eration of the AUTO SENTRY ES is dependent on selection of an operating mode from the controller key pad Prior to starting the STOP RESET key must be pressed to place the control in its ready state Operation may then be started by selecting an operating mode from the controller keypad Once operating the operat ing mode may be changed at any time The STOP RESET key may be pressed at any time to stop the compressor under normal conditions An optional control may be wired to the control to interrupt and restart the unit based on controls by others When stopped by these controls the display will indicate REMOTE STOP N WARNING Automatic restarting or electrical shock can cause injury or death Open and lock main disconnect and any other circuits before servicing unit In any mode the compressor will start only if reservoir pressure is below 5 psig The display will indicate if the control is waiting for blowdown The controls will keep the compressor unloaded until the start cycle has been completed Constant Run Mode Operation This mode is best used in applications where there are no long periods of unloaded operation The compressor unit will start and run continuously using its modulation controls to match delivery to demand As demand falls below the compressor capacity the pressure will rise to the setpoint of the control When the pressure reaches the setpoint the AUTO SENTRY ES 13 9 10 641 controller
70. essure reading a reading that is not one that is picked up somewhere removed from the compressor but an average of actual discharge pressures It should be noted that the pressure displayed on the top line by all sequenced compressors is this average Section 3 Page4 SECTION 4a EBH EBM EBP UNITS CONTROLS amp 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 necessary only to connect the compressor unit to the correct power supply to the shop air line and to the shop water line if the compressor is watercooled A standard com pressor unit consists of the compressor oil reservoir oil cooling system and oil filters motor enclosure specified NEMA 12 starter control 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 its condition PROTECTIVE DEVICES AND SHUTDOWN The Auto Sentry ES will shut down the unit following any fault detected in the following devices Following a shut down a message will be d
71. ew gasket 7 Lower the separator into the housing and center separator on the chamfer Press separator down into the housing Do not use excessive force as separator damage can occur 8 Place spacer on indent in the separator Seat top plate to separator spacer and separator housing Install and tighten all cap screws 9 Run unit and check for leaks COMPRESSOR OIL SYSTEM CHECK The following readings are based on ambient temperature of 80 F for air cooled oil cooler and 80 F inlet water on water cooled oil cooler with the system in good condition Compressor should be at operating temperature at the time of checks One half hour of loaded operation is usually sufficient to reach level out operating tempera tures Air and Oil Discharge Temperature 165 to 195 F Read at gauge on the instrument panel or check with a thermometer at the discharge housing Compressor Oil Inlet Temperature 150 to 160 F Install a tee at the oil filter outlet and check with a thermometer Cil Inlet Pressure Check at the fitting in the line near the compressor oil inlet With air receiver pressure at 100 psi oil inlet pressure should be 55 60 psig 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 Cooled Heat Exchanger 2 to 25 PSI 65 to 150 PSIG Receiver Pressure Check tha
72. gulator is used to supply a constant and low control pressure to prevent damage to the inlet valve from slamming The regulator should be set for 25 30 psig Shuttle Valve Figure 4a 5 Also known as a double check valve the shuttle valve is a device which will take two 2 supply signals and allow the one with the highest pressure to pass through The shuttle valve is used to provide control air pressure from either the reservoir or plant air system as required during different operating conditions Blowdown Valve Figure 4a 2 page 2 this section The blowdown valve is a two way solenoid valve which is piped into the oil reservoir outlet but ahead of the check valve When the solenoid is de energized the valve opens and the oil system is blown down When the solenoid is energized the valve closes to allow the oil system 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 13 9 10 641 System Pressure Transducer This transducer is con nected after the minimum pressure valve and discharge check valve It converts the pressure in the plant air system to an electrical signal for use by the programma ble controller for modulation and control Reservoir Pressure Transducer This transducer is connected to the oil reservoir Its signal is used to prevent loaded starts monitor oil pressure and for separator differential Air
73. he inlet valve closes to prevent backflow of air The inlet valve position is controlled by air pressure in its piston cylinder which is controlled by the Auto Sentry ES through solenoid valves IVC and IVO As pressure to the piston is increased the valve closes to restrict air flow and compressor delivery Figures 4a 6 4a 7 and 4a 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 loaded minimum pressure valve is used in the final discharge line to provide a positive pressure on the oil system of the compressor even when the air service valve is fully open 4 The valve incorporates an orifice which when air is flowing through it maintains approximately 65 psig in the oil reservoir A spring loaded piston valve senses air pressure on the upstream oil reservoir side ofthe 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 ring for sealing valve orifices for restriction or valve and 13 9 10 641 FIGURE 4a 4 MINIMUM DISCHARGE PRESSURE VALVE valve seat for burrs and dirt The valve is adjustable within a small range It is adjusted by a screw on the side of the valve body The minimum pressure can be adjusted as follows Start the compressor 2 Redu
74. he oil reservoir Air pressure in the oil reservoir forces oil through the oil cooler thermostatic mixing valve oil filter and into the compressor main gallery The oil passes through internal passages for lubrication cooling and sealing air oil mixture is then dis charged to the reservoir where a large part of the entrained oil drops out of the air stream the air then passes through the final oil separator where most of the remaining oil is removed The separated oil is returned to the compressor and the air passes to the final dis charge line RECOMMENDED LUBRICANT Gardner Denver compressors are factory filled with AEON lubricants These lubricants are formulated to the highest quality standards and are factory authorized tested and ap proved for use in rotary screw compressors AEON lubricants are available through your authorized Gard ner Denver compressor distributor OIL SPECIFICATIONS This compressor is factory filled with AEON 9000 lubricating coolant AEON 9000 is a synthetic extended life lubricant which can extend lubricant change intervals 4 to 10 times that of a petro leum based lubricant A lubricant analysis program for a periodic check of lubricant quality and remaining life can maximize the change interval N CAUTION Use of improper lubricants wil cause damage to equipment Do not mix dif ferent types of iubricants or use inferior lubricants Improper equipment maintenan
75. i EPI vines ee 5 4 5 6 Oll Eevel Gauge x45 ie ett eie tene tee et etie e nies Me edet 5 6 5 7 Thermostatic Mixing Valve enirn Fee pe eret err Rates pda REE 5 8 5 8 Water Control Valve eee ede ce paste e eta tee a E ERR eS MAP 5 8 5 9 Temperature Chlart 5 eden ne de 5 9 5 10 Oil SO 5 9 6 1 Heavy Duty Air Filter aede trai ari eiie eec 6 1 7 1 Installation of Coupling CUSHIONS 7 1 13 9 10 641 Page iv SECTION 1 GENERAL INFORMATION _ DISCHARGE PORT B74959A DISCHARGE PORT US DISCHARGE PORT FIGURE 1 1 COMPRESSION CYCLE COMPRESSOR The Gardner Denver Rotary Screw compressor is a single stage positive displacement rotary machine using meshing helical rotors to effect compression Both rotors are supported between high capacity roller bearings located outside the compres sion chamber Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads Tapered roller bearings at the discharge end locate each rotor axially and carry all thrust loads and the remainder of the radial loads COMPRESSION PRINCIPLE Figure 1 1 Compres sion is accomplished by the main and secondary rotors synchronously meshing in a one piece cylinder The main rotor has four 4
76. ic 442 1 1 Blowdown Valve eese 4a 4 4b 4 Blowdown Valve Piping 2 4 1 2 4 Cold Weather 2 2 Control Schematics 4a 9 4a 10 4b 10 4b 11 CONTROLS amp INSTRUMENTS SECTION 4 4a 1 4b 1 COUPLING DRIVE SECTION 7 7 1 Decals esae 1 6 1 7 Discharge Service Line 2 4 Electrical Wiring esee 2 5 EnclOSUre dee iet 2 2 Filling Reservoir 5 5 Fouridatlon 2 2 Gauges and 4a 2 4b 4 GENERAL INFORMATION SECTION 1 1 1 Grease Recommendations 2 6 Grounding 2 5 e edt 2 5 High Temperature Operation 5 1 High Temperature Shutdown 4a 1 4b 1 Inlet Line 2 3 Inlet Valve 2222 22 20 1 4a 3 4b 4 INSTALLATION SECTION 2 2 1 Lifting Unit cerne etis 2 1 E ooz ila n E 2 1 Lubricant Addition of Oil Between
77. idend opp M x o de 5 4 5 00 GARDNER DENVER ath Edition ELECTRA SAVER ELECTRA SAVER 11 STATIONARY BASE MOUNTED COMPRESSOR MODELS 40 THRU 100 HP EA amp EB OPERATING AND SERVICE MANUAL p COOPER Gardner Denver Industrial Machinery MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER AND JOY COMPRESSOR PARTS AND SUPPORT SERVICES Gardner Denver and Joy Compressor genuine parts engineered to original tolerances are designed for opti mum dependability specifically for Gardner Denver and Joy compressor systems Design and material inno vations are the result of years of experience with hun dreds of different compressor applications Reliability in materials and quality assurance are incorporated in our genuine replacement parts Your authorized Gardner Denver and Joy Compres sor distributor offers all the backup you ll need A worldwide network of authorized distributors provides the finest product support in the air compressor industry Your local authorized distributor maintains a large inven tory of genuine parts and he is backed up for emergency parts by direct access to the Gardner Denver Industrial Machinery Master Distribution Center MDC in Mem phis Tennessee Your authorized distributor can support your Gardner Denver or Joy air compressor with these services 1 Trained parts specialists to assist you in selecting
78. in excess of the compressor nameplate pressure In the top line RESET PRESSURE is displayed The bottom line will indicate a pressure value in the range of 45 to 175 PSI This setting determines the point at which machine startup occurs in AUTO and SEQUENCE modes and when the compressor will load up from the blown down condition Note that RESET PRESSURE cannot be set within 5 PSI of the SET PRESSURE It is necessary that all ma chines to be sequenced have the same SET and RESET PRESSURE setpoints The top line displays REMOTE STOP Select ei ther IMMEDIATE or TIMED STOP as the desired response to the remote input Inthe top line FILTER CHNG INT is displayed The bottom line will indicate a time interval of 1000 hours This may be adjusted lower down to 500 hours if severe operating conditions are antici pated After the machine has run for the pro grammed setting an advisory will be displayed requesting an oil filter change Inthe top line OIL CHNG INTERVAL is displayed The bottom line will indicate a time interval of 8000 hours 8000 hours is the maximum setting and is the proper change interval for AEON 9000 synthetic oil See Section 5 page 4 for proper setting for AEON lubricants In the top line HI TEMP LIMIT is displayed The bottom line will indicate 225 degrees F This is the maximum and proper setting for compressor op eration It may be temporarily lowered to verify the function of the temperature shutdown
79. ing 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 size for the starter and its enclosure Note that motor name plate current must by multiplied by 577 for wye delta starters The display will indicate which overload relay tripped The overload relay is reset by pressing the button on the relay itself Motor current amps and voltage must be measured to locate the cause for high current Proper starter coil and contact action is also monitored and errors in operation will cause a shutdown with the cause displayed High Temperature The compressor is protected from high discharge and separator temperature by two inde pendent thermistor probes One probe is located in the discharge housing to sense compressor discharge air oil mixture temperature The second probe is located at the separator discharge and senses the temperature of the air at the oil separator The Auto Sentry ES will shut the compressor down if temperature sensed at either location exceeds 225 F or lower per user adjustment or if a rapid temperature rise is detected The location of the high temperature will be displayed Shutdown will also occur if a shorted probe open probe or extreme MUFFLER ORIFICE CHECK VALVE ORIFICE SOLENOID VALVE AIR FILTER SWITCH TRANSDUCER FIGURE 4b 1 SCHEMATIC TUBING DI
80. ins oil injection temperature into the compressor at a mini mum of 160 F This system provides proper compressor warm up and prevents moisture contamination of oil To check element heat in oil it should be fully extended at 160 F If unit shuts down due to high air discharge temperature the cause may be thatthe element is stuck open to the bypass in which case bypass lines Figure 5 1 page 2 this section will be hot to touch and lines out of mixing valve much cooler When flushing the oil Section 5 Page 7 OIL IN FROM COOLER BA B OIL IN BYPASS FROM RESERVOIR A58407 FIGURE 5 7 THERMOSTATIC MIXING VALVE System remove mixing valve and clean all parts thor oughly COMPRESSOR OIL COOLER WATER COOLED HEAT 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 oil temperature is controlled by the thermal thermo static mixing valve The optional water control valve may be used to conserve water Oil cooler malfunction may be traced by checking pres sure at oil inlet and outlet At normal operating air service pressure 65 to 150 psig with the unit warm a pressure drop of 3 to 15 psi can be expected between the oil inlet and the oil outlet Water pressure drop from water inlet to outlet will vary with the inlet pressure and amount of water flowing A normal pressure drop may range from 5 to
81. ion check This completes the programming and setup procedures for the AUTO SENTRY ES controller Press the STOP RESET key to return the compressor to the READY mode Section 8 Lp9 01 6 1 6 epuonoes FULL AIR PRESSURE 2007 CHECK VALVE ORIFICE ORIFICE EXHAUST MUFFLER SOLENOID VALVE BDV ON SYSTEM PRESSURE TRANSDUCER SOLENOID VALVE IVO OFF SOLENOID VALVE RESERVOIR IVC OFF PRESSURE TRANSDUCER PRESSURE REGULATOR SHUTTLE VALVE AIR FILTER VACUUM SWITCH 0 IR INLET CLOSED SERVICE MINIMUM DISCHARGE VALVE PRESSURE CHECK A VALVE VALVE 222 5 KZA Gs 4 5 Mee Im FULL OIL PRESSURE CONTROL AIR PRESSURE 15 20 PSD ATMOSPHERIC PRESSURE OR EXHAUSTING OIL RESERVOIR REAR VIEW OF COMPRESSOR FIGURE 4a 6 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE Lv9 01 6 1 OL 5 EXHAUST MUFFLER SOLENOID VALVE BDV ON SOLENOID VALVE IVO ON SOLENOID VALVE CON PRESSURE REGULATOR SHUTTLE VALVE MINIMUM SERVICE DISCHARGE VALVE PRESSURE CHECK VALVE VALVE FULL OIL PRESSURE FULL AIR PRESSURE CONTROL AIR PRESSURE 15 20 PSI ATMOSPHERIC PRESSURE OR EXHAUSTING OIL RESERVOIR RIFICE CHECK VALVE ORIFICE
82. is everybody s business and is based on your use of good common sense All situations or circumstances cannot always be predicted and covered by established rules Therefore use your past experience watch out for safety hazards and be cautious Some general safety precautions are given below DANGER Failure to observe these notices could result in injury to or death of personnel e Keep fingers and clothing away from revolving fan drive coupling etc e Do not use the air discharge from this unit for breathing not suitable for human consumption e Do not loosen or remove the oil filler plug drain plugs covers the thermostatic mixing valve or break any connections etc in the compressor air or oil system until the unit is shut down and the air pressure has been relieved e Electrical shock can and may be fatal e Compressor unit must be grounded in accordance with the National Electrical Code A ground jumper equal in size to the equipment ground conductor must be used to connect the compressor motor base to the unit base e Fan motors and must remain grounded to the main base through the starter mounting panel in accordance with the National Electrical Code e Open main disconnect switch and lockout before working on the control e Disconnect the compressor unit from its power source tag and lockout before working on the unit this machine is automatically controlled and may start at any time 13 9
83. is optional feature will shut down the unit if abnormally high vibration is de tected CHECK CN 7 8 9 This indicates a wiring error or connection problem Remove power and correct all wiring 13 9 10 641 P FIGURE 4a 2 BLOWDOWN VALVE 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 Air Control Com ponents in this section for construction and operation information GAUGES AND DISPLAYS Cil Level The oil level gauge is located on the side of Section 4a 2 FROM PURGE VALVE T SEPARATOR TO AFTERCOOLER HOUSING INLET VALVE tOPEN POSITION MUFFLER ORIFICE CHECK VALVE ORIFICE BLOW DOWN VALVE SOLENOID VALVE IVO SOLENOID VALVE IVC PRESSURE REGULATOR SHUTTLE VALVE TO SEPARATOR HOUSING TRANSDUCER FIGURE 4a 3 INLET VALVE the reservoir See Section 5 page 5 Lubrication Oil Cooler Oil Filter and Separator for information on how to correctly read the gauge All other instruments are part 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 this section for schematic tubing diagrams Inlet Valve Figure 4a 3 The inlet valve restricts the inlet to control capacity and closes to unload the com pressor At shutdown t
84. isplayed The bottom line will indicate either TURNVALVE or NON TURNVALVE It is to be set as is appropriate for the compressor Inthe top line SYSTEM VOLUME is displayed The bottom line may be selected as SMALL MEDIUM or LARGE This tunes the response of the modula tion control loops to optimize loop stability It is factory set to MEDIUM Set as follows SMALL if estimated volume is less than 25 gallon per CFM MEDIUM if estimated volume is between 25 and 1 0 gallon per CFM Section Page 8 22 LARGE if estimated volume is greater than 1 0 gallon per CFM The setting of this parameter is not critical When set to its most appropri ate value the controller will maintain the discharge at the closest possible value If not set correctly pressure will vary from the desired setpoint to a somewhat greater degree but the com pressor and its components will not be adversely affected In thetop line REMOVE SYS PRESS is displayed The bottom line displays the current pressure being sensed at the package discharge At this point steps must betakento ensure that system pressure is in fact zero If necessary remove the line to the 13 9 10 641 23 24 System pressure transducer Pressing ENTER will now cause the AUTO SENTRY ES to calibrate the transducer output to zero PSI Obviously pressure measurement errors will be encountered if zeroing is done with pressure at the transducer Inthe top line
85. isplayed to indicate the cause The shutdown light will be on if the cause still exists or will flash if the cause has been cleared To resume operation the cause of shutdown must be corrected 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 size for the starter and its enclosure Note that motor name plate current must by multiplied by 577 for wye delta starters The display will indicate which overload relay tripped The overload relay is reset by pressing the button on the relay itself Motor current amps and voltage must be measured to locate the cause for high current Proper starter coil and contact action is also monitored and errors in operation will cause a shutdown with the cause displayed High Temperature The compressor is protected from high discharge and separator temperature by two inde pendent thermistor probes One probe is located in the discharge nousing to sense the compressor discharge air 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 Auto Sentry ES will shut the compressor down if tempera ture sensed at either location exceeds 225 F or lower per user adjustment or if a rapid temperature rise is detected The location of the high temperat
86. ition to the above the following should be pro vided 1 probably be necessary to provide shutters or to block off part of the cooler in some manner since the cooler is greatly oversized for operation in these low temperatures Since shutters are not provided as a factory option blocking off a portion of the cooler with plywood should be satisfactory 2 Auto operation should not be used in extreme environments 3 Some means of providing heat during shutdown should be provided There are various methods to accomplish this but since openings are not pro vided for sump heaters the use of radiant heaters is recommended The heaters should be sized to provide at least a 10 F environment for coolers motor and sump Figure 2 3 previous page shows how these might be located in a typical installation and sizes required Remember unsheltered outside installations should be avoided where possible Installation next to a heated building where enough heat can be used to keep the compressor room above freezing will save many 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 an adequate shelter for the unit AUXILIARY AIR RECEIVER An auxiliary air receiver is not required if the piping system is large and provides sufficient storage capacity to prevent rapid c
87. its piston cylinder which is controlled by the programma ble controller through solenoid valves IVC and IVO As pressure 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 closed two way air actuated valve that admits purge air from the final discharge manifold to the compressor to counter act the oil knock that occurs in oil flooded rotary screw compressors when they are completely unloaded with pressure in the oil reservoir This valve is controlled by the same control pressure which controls the inlet valve Solenoid Valves IVC and IVO These valves control position of the inlet valve in response to signals from the Auto Sentry ES With both valves de energized the normally open IVC valve allows control pressure to the inlet 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 to supply a constant and low control pressure to prevent 13 9 10 641 damage to the inlet valve from slamming The regulator should be set for 25 30 psig Shuttle Valve Figure 4b 4 page 3 this section Also known as a double check valve the shuttle valve is a device which will
88. ity of oil required to raise the oil level from ADD to FULL is shown in figure 5 6 page 6 this section Repeated addition of oil between changes may indicate excessive oil carryover and should be investigated Use only CLEAN containers and funnels so no dirt enters the reservoir Provide for clean storage of oils Changing the oil will be of little benefit if done in a slipshod manner A CAUTION Excessive oil carryover can damage equipment Never fill oil reservoir above FULL marker COMPRESSOR OIL FILTER Figure 1 5 page 3 Sec tion 1 This replaceable element filter is a vital part in maintaining a trouble free compressor since it removes dirt and abrasives from the circulated oil The filter is equipped with a relief valve that opens in the event the element becomes dirty enough to block the flow of oil Improper oil filter maintenance will cause damage to equipment Replace filter element every 1000 hours of oper ation More frequent replacement could be required depending on oper ation conditions Filter element left in service too long may damage equip ment 13 9 10 641 Use only the replacement element shown on the filter tag or refer to the parts list for the part number Use the following procedure to replace the filter element Do not disturb the piping Air oil under pressure will cause severe personal injury or death Shut down compressor relieve system of all pressure disconnect t
89. l mixing valve as shown Modifications to the control lines will be made at the factory per 288ECM810 schematic Air to the oil stop valve must come from the upper fitting in the separator housing then pass through the 3 way pneumatic valve Control air to the valve must be from the line between the tee and the orifice in the blowdown muffler line per Figure 5 3 page 4 this sec tion When the machine blows down it will activate the pneumatic valve and it will shut off the air and vent the line between the pneumatic control valve and the oil stop valveto atmosphere This will shutthe oil stop valve and prevent excessive oil from running into the resevoir 13 9 10 641 Failure to install these parts could result in high oil carryover and causing the machine to shutdown on high discharge temperature COLD AMBIENT OPERATION See Installation for Cold Weather Operation Section 2 ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is at the bottom of the red range on 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 air pressure is in the oil reservoir 2 Disconnect tag and lockout the power supply to the starter Wipe away all dirt around the oil filler plug Remove the oil filler plug and add oil as required to return the oil level to the center of the green range on the gauge DO NOT OVERFILL The quantity required to raise the oil le
90. l remain in a shutdown state High Vibration optional This optional feature will shut down the unit if abnormally high vibration is de tected Check CN 7 8 9 This indicates a wiring error or conection problem Remove power and correct wiring Blowdown Valve Figure 4b 2 page 2 this section The blowdown solenoid valve releases pressure from the oil reservoir during any shutdown condition and during some operating conditions description under Air Control Components page 4 for construc tion and operation information SOLENOID VALVE REAR VIEW OF COMPRESSOR ei FIGURE 4b 5 TURN VALVE ACTUATOR SECTIONED 13 9 10 641 Section 4b Page 3 FIGURE 4b 6 MINIMUM DISCHARGE PRESSURE VALVE GAUGES AND DISPLAYS Oil Level The oil level gauge is located on the side of the reservoir See Section 5 page 5 Lubrication Oil Cooler Oil Filter and Separator for information on how to correctly read the gauge All other instruments are part 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 this section for schematic tubing diagrams Inlet Valve Figure 4b 3 page 3 this section The inlet valve restricts the inlet to control capacity and closes to unload the compressor At shutdown the inlet valve closes to prevent backflow of air The inlet valve position is controlled by air pressure in
91. lace the entire element if the gasket is damaged a spare element will keep down time to a minimum 5 Allowthe element to air dry COMPLETELY Do not expose the element to heat over 150 F Install the element in the filter body and fasten securely with the wing nut Do not oil this element Do not wash in inflammable cleaning fluids Do not use solvents other than water Improper cleaning may damage element Never operate the unit without the ele ment Never use elements that are damaged ruptured or wet Never use gaskets that won t seal Keep spare elements and gaskets on hand to re duce downtime Store elements in a protected area free from damage dirt and moisture Handie all parts with care Filter Element Life The element should be replaced after six 6 cleanings or if 1 Visual inspection indicates a rupture crack or pin hole in the pleated media Inspection should be done by placing a bright light inside the element 2 Pressure drop through a filter with a freshly cleaned element is below inches of water with compressor running at full load this would indicate a rupture or crack Inlet Tube Inspect the inlet screen and tube for dirt accumulation each time the filter is serviced Clean the tube when required by ramming a clean dry cloth through the tube Wipe the inside of the filter body to remove any dirt falling from the inlet tube before reinstall ing the element Causes of short elemen
92. ler face Insufficient cooling air flow Clogged oil filter or cooler interior Low Compressor oil carryover through lines Oilleaks at all fittings and gaskets Section 9 2 Increase receiver size Inspect and clean control tubing Clean or replace filter Inspect and clean inlet valve Adjust unload pressure pressure See Section 4 Disassemble and clean valve Repair or replace valve Clean cooler Provide unrestricted supply of cooling air Replace filter or clean cooler Add oil to proper level See Oil Carryover in this section Tighten or replace fittings or gasket Symptom Possible Cause Remedy Oil Carry Over 1 Overfilling the reservoir 1 Drain excess oil from system Air 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 to the starter before removing valves caps plugs fittings bolts and filters 2 Clogged broken or loose 2 Tighten or replace oil return lines faulty lines 3 Ruptured oil separator 3 Replace element element 4 Loose assembly 4 Tighten all fittings and gaskets 5 Foam caused by use of 5 Use Gardner Denver incorrect oil AEON 9000 Lubricating Coolant 6 Inoperative minimum 6 Clean out or replace pressure valve causing low operating pressure
93. let housing All orders for Parts should be placed with the nearest authorized distributor Where NOT specified quantity of parts required per compressor or unit is one 1 where more than one is required per unit quantity is indicated in parenthesis SPECIFY EXACTLY THE NUMBER OF PARTS RE QUIRED DO NOT ORDER BY SETS OR GROUPS To determine the Right Hand and Left Hand side of a compressor stand at the motor end and look toward the compressor Right Hand and Left Hand are indicated in parenthesis following the part name i e RH amp LH AIR ENDS NOTE Factory warranted new and rebuilt air ends are available from your authorized Gardner Denver and Joy Compressor Distributor FOREWARD Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing To be assured of receiving maximum service from this machine the owner must exercise care in its operation and maintenance This book is written to give the operatorand maintenance department essential informationfor day to day operation maintenance and adjustment Careful adherence to these instructions will result in economical operation and minimum downtime DANGER Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial propery damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severe personal injury death or
94. line will indicate a time interval of 8000 hours 8000 hours is the maximum setting and is the proper change interval for AEON 9000 synthetic oil See Section 5 page 4 for proper setting for AEON lubricants In the top line HI TEMP LIMIT is displayed The bottom line will indicate 225 degrees F This is the maximum and proper setting for compressor op eration It may be temporarily lowered to verify the function of the temperature shutdown system In the top line FAN TYPE is displayed The bottom line will indicate either AIR COOLED or WATER COOLED Selecting AIR COOLED places the fan under thermostatic control while WATER COOLED operation runs the fan whenever the main motor runs In the top line AUTO RESTART is displayed The bottom line will indicate either OFF or ON Set this feature to ON when it is necessary to have the compressor automatically restart after a power in terruption This feature shall only be enabled when the owner determines that it is safe to do so It is recommended that compressor access be limited to only trained service personnel when this feature is enabled This step is only encountered ifthe AUTO RESTART function was set to ON in step 13 In the top line RESTART TIME is displayed The bottom line will indicate a time between 5 and 60 seconds It is factory set at 10 seconds This is the amount of delay introduced before restarting after power has been restored In the top line AIR END TYPE is d
95. lve should be wired into the compressor control cir cuit so that the valve opens to allow water to flow any time the compressor is running When compressor stops under automatic control or is shut off manually the valve should close stopping water flow through the system See Wiring Diagrams Section 4a page 4a 12 13 9 10 641 OIL SEPARATOR COVER PLATE FINAL AIR DISCHARGE OIL SEPARATOR HOUSING PLEATED SEPARATOR OIL RETURN LINE XXX 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 the system and the top portion a primary oil separation means The reservoir also provides limited air storage for control and gauge actuation COMPRESSOR G D ELIMINATOR OIL SEPARA TOR Figure 5 10 located in a separate housing con sists of a renewable cartridge type separator element and provides the final removal of oil from the air stream Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity collected outside the element is returned through tubing to the compressor cylinder carryover through the service lines may be caused by a faulty oil separator faulty minimum pressure valve over filling of the oil reservoir oil that foams oil return line malfunction or water condensate in
96. ly steps 4 5 and 6 which relate to sequencing are skipped by the AUTO SENTRY ES Programming commences at step 7 In the top line UNIT NUMBER is displayed The bottom line will again indicate a number of one through eight This will be factory set at 1 Each AUTO SENTRY ES in a sequenced system must have a unique number here The sequence mode will not function if two or more compressors have the same UNIT NUMBER Most efficient machine to machine communications will occur when the lowest possible numbers are used Example 1 2 and 3 for a three compressor installation In the top line TRANFER INTERVAL is displayed The bottom line will indicate a number of hours in the range of 1 to 5000 It is factory set at 24 This is the number of hours that this machine will stay in the role of master or lead compressor Normally it is desirable to set this value the same on all sequenced units to equalize running hours In the top line LAG START DELAY is displayed The bottom line will indicate a number in the range of 15 to 600 seconds It is factory set at 30 This is the length of time this machine will wait before starting when the pressure drops below the reset point Again this is normally set to the same value for all sequenced units Its setting will depend on the amount of air storage volume in the system In the top line BLOWDOWN TIME is displayed The bottom line will indicate a time between 5 and 20 minutes It
97. of interconnection has no effect on the system operation The following conditions are necessary and sufficient for proper operation 1 Every compressor must have a cable connect ing it to another compressor One less cable than the number of units sequenced must be used 2 Each board that has only one cable connected to it must have its pigtail plugged into the unused jack All installations will have two such units Section 3 2 ll OPERATION A ESTABLISHING THE INITIAL SEQUENCE Operation of compressors in sequence requires only a press of the sequence key on each compressor in the system Since the sequencing algorithm includes provis ions for automatic relacement of a failed master or lead compressor it is important for the operator to be aware of the hierarchy of events when starting the system The first compressor placed in sequence mode will be come the master However since any compressor first placed in sequence has no way of knowing whether or not a master exists it will first assumethe highest rotation number available For example if the number of units to be sequenced is programmed at four any compressor will start out in position four when placed in sequence mode It will then listen on the communications line for a call from the master If no cail is received it will assume position three and again wait for a call from the master After another lack of master call it assumes position two Sub
98. of the reservoir to the side of the frame This drain is approximately 4 50 inches above the floor level If this is not sufficient to conveniently drain the oil some other methods of providing drain are 1 Elevate the compressor unit on raised blocks to obtain the desired drain height 13 9 10 641 If the compressor unit base is raised above floor level the space between the floor and the base bottom must be closed with solid material all around to prevent recirculation of hot air from the oil cooler end and over temperature operation 2 Construct an oil sump or trough below the floor level and pump or bail the drained oil 3 Pump oil from the reservoir filler opening or drain to a container ENCLOSURE The compressor electric motor oil cooler and aftercooler are mounted inside the enclo sure Service doors are provided for maintenance access Be sureto allow enough space around the unit for the doors to open completely Any of the enclosure doors may be removed by opening the door and lifting it up slightly to disengage the hinges The motor inspection air filter service panel is held by two latches and lifts away from the enclosure The air outlet panel is attached by screws to the enclosure and is not readily removable INSTALLATION FOR COLD WEATHER OPERATION It is recommended that whenever possible the unit be installed inside a shelter that will be heated to tempera Section 2 2 tures ab
99. onnect power and service the unit as required Following service put the enable switch in the down position restore power to the unit and press STOP RESET to clear the controller Proceed through the service section described in step 1 below Active advisories will be displayed and may be cleared by pressing the ENTER key After the messages have been cleared press STOP RESET and select an operating mode to resume operation PROGRAMMING AND SETUP INSTRUCTIONS FOR THE AUTO SENTRY ES R CONTROLLER Programming and setup is accomplished with the PRO GRAM keys In all steps the ENTER key will cause the controller to accept the displayed value into memory and advancetothe next programming function The plus and minus keys will increase and decrease dis played values respectively The right and left arrow keys and position the cursor flashing digit The number at the cursor will be the number that is changed by the and keys At any point in the programming and setup routine the STOP RESET key can be pressed to exit and return to the ready mode In all steps of the programming routine the top line of the display will give a description of the parameter to be programmed while the bottom line shows the variable that is capable of being altered by programming The following is a step by step guide to programing the AUTO SENTRY ES Controller NOTICE Between each step it is necessary to pres
100. ops to 90 PSI the 2 unit times out its 15 second timer and starts It takes 5 additional seconds for the pressure to rise above 90 PSI The 3 unit whose timer was initially set at 30 seconds 15 x 3 1 has counted down 20 seconds the total time that system pressure was below 90 PSI If air demand increases again the pressure will have to fall below 90 PSI for only 10 seconds more to start unit 3 As was previously stated a lag compressor s modulation setpoint PSET for short is SSET PRESSURE 3 rotation number 1 Thus in the above exampie the first lag compressor rotation 2 has a PSETof 97 PSI the second lag 94 PSI and so on But look what happens in an eight compressor installation The eighth compressor will have an initial setpoint of 100 3 8 1 or 79 PSI Does this mean that an eight compressor installation must operate 21 PSI below the desired operating point when all compressors are running NO This is where the AUTO SENTRY ES dynamic setpoint control takes over This is how it works Whenever the system pres sure is below the programmed RESET PRESSURE the PSET of eachlag compressor is incremented 1 PSI every thirty seconds Thus after a short interval about five minutes in this example the PSET of the last sequenced compressor will climb up until either it equals the RESET PRESSURE or a decrease in demand causes the actual Section3 Page 3 system pressure to rise above the RESET PRESSURE It c
101. ove freezing 32 F 0 C This will eliminate many of the problems associated with operating the units outside in cold climates where freezing rain drifting snow freezing condensate and bitter cold temperatures are encountered Refer to Engineering Data Sheet 13 9 411 for the advan tages of using the heat recovered from rotary compres sors This heat recovery could easily pay for an adequate shelter 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 outside installations Cold Weather Down To 10 F 1 Besureall control lines drains and traps are heated to avoid freezing of condensate Heat tape with thermostat control is generally satisfactory for this purpose and can be obtained at various local plumbing or hardware outlets at nominal cost 2 Ifan air cooled aftercooler is to be used provisions to bypass the aftercooler should be made Since cold air contains very little moisture successful operation can be achieved without the aftercooler 3 Provide at least some simple shelter such as a plywood windbreak to protect against drifting Snow 4 Use only Gardner Denver AEON 9000 lubri cant 5 MMonitorunit carefully during start up and operation to be sure it is functioning normally 6 Specify NEMA 4 enclosure for electrical devices Extreme Cold Weather Operation Down To 40 F In add
102. plication It is con nected to other devices inside the panel and external devices through the terminal strip The Auto Sentry ES requires no maintenance Emergency Stop This is a maintained pushbutton and removes power from the controller outputs regardless of controller status It is located on the upper section of the panel next to the keypad Automatic restarting or electrical shock can cause injury or death Open and lock main disconnect and any other circuits before servicing unit Control Transformer This changes the incoming power voltage 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 labelling for replacement information Terminal Strip This provides connections for all 110 120 volt devices not contained within the control panel Fan Starter where applicable The starter is used to provide control and overload protection for the cooling fan on air cooled units and ventilation fans of watercooled units with enclosure Overload heaters should be selected based on the nameplate current of the fan motor Three fuses are provided Refer to adja cent labelling for replacement information Main Starter This starter is used to provide control and overload protection for the main drive motor For wye delta starters overload heaters should be selected based on the motor nameplate current times 577 for proper protection Wye delta
103. r service valve is fully open The valve incorporates an orifice which when air is flowing through it maintains approximately 65 psig in the oil reservoir A spring loaded piston valve senses air pressure 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 ring for sealing valve orifices for restriction or valve and valve seat for burrs and dirt The valve is adjustable within a small range It is adjusted by a screw on the side of the valve body The minimum pressure can be adjusted as follows 1 Start the compressor 2 Reduce pressure downstream of minimum pres sure valve to below desired minimum pressure DO NOT REDUCE UPSTREAM PRESSURE OR AD JUST VALVE BELOW 65 PSIG 3 Loosen locknut on adjusting screw 4 Turn set screws in to increase or out to decrease minimum pressure to be held 5 Holdthe set screw at the desired point and tighten locknut Check Valve Oil Reservoir A renewable seat swing type check valve in the final discharge manifold prevents backflow of air from the shop air line when the unit stops unloads or is shut down System Pressure Transducer This transducer is con nected after the minimum pressure valve and discharge check valve It converts the pressure in the plant air s
104. ranty registration form is provided with each machine The form must be completed by the Purchaser and mailed within ten days after machine start up to validate the warranty DISCLAIMER THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT EXCEPT AS TO TITLE THE COMPANY MAKES NO OTHER WARRANTIES EXPRESSED IMPLIED OR STATUTORY INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE EXCLUSIVE AND ONLY REMEDY AVAILABLE TO THE PURCHASER AND IN NO CASE SHALL THE COMPANY SUBJECT TO ANY OBLIGATIONS OR LIABILITIES UNDER CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES EXPENSES LOSSES OR DELAYS HOWSOEVER CAUSED No statement representation agreement or understanding oral or written made by any agent distributor representative or employee of the Company which is not contained in this Warranty will be binding upon the Company unless made in writing and executed by an officer of the Company This warranty shall not be effective as to any claim which is not presented within 30 days after the date upon which the product is claimed not to have been as warranted Any action for breach of this warranty must be commenced within one year afler the date upon which the cause of action occurred Any adjustment made pursuant to this warranty shall not be construed as an admission by the Company tha
105. s the ENTER key to restore the new value and advance to the next step 1 Press the ENTER key to begin programming If the enable switch on the circuit board is in the set position the control proceeds to the setup adjust ments starting with step 2 below Ifthe slide switch is down in the position push ENTER to go from OIL FILTER CHANGE to OIL CHANGE and then push ENTER again to proceed to Step 2 Press AUTO to display the hours remaining until oil change or filter change is recommended If service has been performed early press the AUTO key to reset the timers to their full number of hours Press ENTER to proceed to the next display without affecting timers 2 Inthe top line DISPLAY UNITS is indicated The bottom line will indicate ENGLISH PSIG Fahren heit or METRIC Bars Celsius Select the desired mode and press ENTER to save and proceed 3 Inthe top line NUM OF SEQ UNITS is displayed The bottom line will indicate a number in the range of one through eight This will be factory set at 1 This should be set to a number corresponding to the number of compressors that are currently in stalled on this air system that also have AUTO SENTRY ES controllers It should be noted that all AUTO SENTRY ES compressors on the system must have the same number programmed here to operate correctly in SEQUENCE mode Setting the value in step 1 to one indi cates that no sequencing is to take place Consequent
106. s 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 for adjustment instructions and maximum allowable lubri cant temperature ELECTRICAL WIRING Standard Units The Electra Saver compressor is factory wired for all starter to motor and control connections for the voltage specified on the order It is necessary only to connect the unit starter to the correct power supply The standard unit is supplied with an open drip proof motor a NEMA 12 starter and control enclosure See Location paragraph for distanceto nearest obstruction on starter and control box sides of the unit Lower operating voltages 200 208 require that the unit starter be remote mounted since the starter is too large to be mounted within the control enclosure If not sup plied with the compressor unit the starter is to be a size 6 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 motor starter 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 to be selected according to starter manufacturer
107. separator and replace with full charge of new lubricant 7 Subsequent lubricant changeouts should be at normal 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 will fluctuate as the compressor loads and unloads Add oil only when the oil level is at the bottom of the red range on the gauge as read when the compressor is on Drain oil only when the oil level is past the center of the green range when the compressor is on MOISTURE IN THE OIL SYSTEM In normal humidity and with normal operating temperatures and pressures the thermal mixing valve controls the oil temperature and prevents moisture contamination of the oil Un usual cooling of the oil reservoir short loaded cycle in high humidity malfunctions of the thermal valve or cooling water system may result in moisture in the oil system which is detrimental to compressor lubrication If moisture is observed in the oil reservoir drain the moisture and correct the condition causing the accumu lation See Compressor System Check page 10 and Thermal Control Thermostatic Mixing Valve page 7 in this section OIL CHANGE INTERVAL Recommended oil change intervals based on oil temperature Discharge AEON 4000 AEON 9000 Temperature Change Interval Change Interval Up to 180 F 6000 hrs 8000 180 to 190 F 4500 hrs 6000 190
108. sequently it assumes position one which makes it the master soon as a master is established it immediately attempts to call all other units and assigns them successive rota tion positions The system is now active Before a master is established the system is not deprived of air This is due to one of the outstanding features of the AUTO SENTRY ES sequencing system pressure controi is always executed locally at each individual compressor The effective setpoint for compressor con trol is the programmed setpoint minus 3 rotation number 1 So while a compressor or compressors is are counting down towards establishing a master they are also capable of delivering air at a pressure determined by 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 place the desired master in sequence mode first and wait until the first decrement in rotation number is seen about 7 sec onds before placing subsequent compressors in se quence mode If it is desired to dictate the complete initial sequence manually wait until the previous machine dec rements one position and then place the next desired compressor in sequence mode if it is acceptable to let the master determine the initial sequence simply wait until the master has decremented its rotation number once and then place all remaining compressors in se quence mode Rem
109. sure in reservoir Read error message on control panel See Section 4 Remote contact is open terminals 6 amp 9 High discharge temperature High discharge temperature switch malfunction Blown fuse in starter control box Motor starter overload heaters trip Improperly adjusted control Air leak in control lines Restricted control line Blowdown valve malfunction Section 9 1 Change leads Replace fuse Reset and investigate cause of overload Inspect blowdown valve and muffler Replace switch Replace switch or jumper See High Discharge Air Temperature in this section Replace switch Replace fuse investigate if fuses continue to blow Reset and investigate cause of overload Referto Section 4 and adjust control Determine source of leak and correct Clean control lines Repair clean or replace valve Symptom Possible Cause Compressor cycles from load to unload excessively Compressor is low on delivery and pressure High discharge air temperature Excessive Oil Consumption 13 9 10 641 Insufficient receiver capacity Restriction in control tubing Restricted air filter Sticking inlet valve Unload pressure adjusted too low Minimum pressure valve stuck closed Thermostatic mixing valve stuck open Dirty or clogged coo
110. system Inthe top line FAN TYPE is displayed The bottom line will indicate either AIR COOLED or WATER COOLED Selecting AIR COOLED places the fan under thermostatic control while WATER COOLED operation runs the fan whenever the main motor runs In the top line AUTO RESTART is displayed The bottom line will indicate either OFF or ON Set this feature to ON when it is necessary to have the compressor automatically restart after a power in terruption This feature shall only be enabled when the owner determines that it is safe to do so It is recommended that compressor access be limited to only trained service personnel when this feature is enabled This step is only encountered if the AUTO RESTART function was set to ON in step 13 In the top line RESTART TIME is displayed The bottom line will indicate a time between 5 and 60 seconds It is Section 4a 7 20 21 factory set at 10 seconds This is the amount of delay introduced before restarting after power has been restored In the top line AIR END TYPE is displayed The bottom line will indicate either TURNVALVE or NON TURNVALVE It is to be set as is appropriate for the compressor Inthetop line SYSTEM VOLUME is displayed The bottom line may be selected as SMALL MEDIUM or LARGE This tunes the response of the modula tion control loops to optimize loop stability It is factory set to MEDIUM Set as follows The setting of this parameter is not criti
111. t any product was not as warranted
112. t life include severe dust con ditions infrequent servicing improper cleaning or con tamination by oil or chemical fumes Section6 Page 1 SECTION 7 COUPLING UP TOWARD OUTSIDE DIAMETER OF COUPLING RADIUS EDGE A DOWN TOWARD SHAFT COLLAR SCREWS 4 23 FT LBS SET SCREWS 50 FT LBS zal 1 16 MIN 1 8 MAX FIGURE 7 1 INSTALLATION OF COUPLING CUSHIONS DANGER Rotating machinery can cause per sonal injury or death Turn the unit completely off open main disconnect tag and lockout before servicing cou pling COUPLING The motor and compressor are direct connected by a resilient type flexible coupling with sev eral individual cushions Figure 7 1 Coupling does not require lubrication If maintenance on mating parts is required reassemble coupling as follows Individual Cushion Design Figure 7 1 1 Slide coupling halves over shaft extensions Be sure collar is installed on shaft behind one coupling body 13 9 10 641 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 jaws on one coupling body and the flange on the oppo site coupling body Tighten set screws in each coupling body 4 Insert individual cushions as shown in Figure 7 1 and slide collar over cushions and secure with cap screws Reinstall the coupling guard Rotating machinery can cause per
113. t oil inlet pressure is correct or measure the differential between drains on the oil cooler shell Oil Cooler Temperature Differential Air Cooled Ra diator The oil temperature differential depends on the temperature of the air at the oil cooler fan and cleanli ness of the core faces As ambient temperatures and core restrictions increase the oil cooler outlet temper ature will increase The oil inlet temperature is approxi mately the same as air discharge temperature see the gauge on the instrument panel The outlet oil tempera Section 5 Page 10 ture may be checked by installing a tee at the oil filter outlet Cil Cooler Temperature Differential Water Cooled Heat Exchanger The oil temperature differential de pends on the inlet water temperature and the water flow rate permitted by the water flow control valve setting The oil inlet temperature is approximately the same as the air discharge temperature see the gauge on the 13 9 10 641 instrument panel The oil outlet temperature may be checked by installing a tee at the oil filter outlet Oil Cooler Water Pressure Differential Water Cooled Heat Exchanger The water pressure differ ential through the heat exchanger will depend on the supply pressure flow rate cooler tube cleanliness and outlet pressure The inlet and outlet water pressure may be checked at the pipe fittings supplied by the customer Section5 Page 11 SECTION 6 AIR FILTER AIR INTLET
114. t their rotation numbers Num ber 2 becomes number 1 the new master number 3 becomes number 2 etc It should be noted also that whenever the master detects a missing rotation number such as when a compressor is turned off that was previously in the rotation it will automatically close the gap by decrementing the rota tion numbers of all compressors whose rotation num bers were greater than the missing number Likewise if for whatever reason the master compressor fails to carry 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 will always be that the compressors that remain in rotation will always end up with the lowest possible rotation numbers 13 9 10 641 IV OTHER FEATURES Any air system will exhibit pressure differences from one pointto ihe next Even a well designed multi compressor installation will show minor pressure variations between one compressor s discharge point and another compressor s discharge These points will also vary with the central system normally the air storage receiver These pressure differences wreak havoc with conven tional sequencers If a central sequencer is used it will be sensing a lower pressure than is seen at each com pressor With such systems there is always a chance that the sequencer could cause a compressor to over pressure due to this pressure drop The alternative has be
115. t to be sure it is properly wired See Section 4 Controls and Instruments for general wiring diagrams and Section 2 for installation in structions 6 Grounding Equipment must be grounded in ac cordance with Table 250 95 of the National Electri cal Code Failure to properly ground the com pressor package could result in con troller malfunction 7 Rotation Check for correct motor rotation using JOG MODE Compressor drive shaft rotation must be clockwise standing facing the compressor sheave Operation with incorrect motor rotation can damage equipment and cause oil eruption from the compressor inlet When checking motor rotation induce minimum rotation less than one revo lution if possible Never allow motor to reach full speed 8 System Pressure Set the controls to the desired unload pressure and differential DO NOT EXCEED MAXIMUM OPERATING PRESSURE ON COM PRESSOR NAMEPLATE See Section 4 Controls and Instruments for procedure Section3 1 Operation at excessive discharge air pressure can cause personal injury or damage to equipment Do not adjust the full discharge air pressure above the maximum stamped on the unit nameplate 9 Operating Mode Refer to Section 4 for detailed information on the control system 10 Enclosure Check for damaged panels or doors Check all screws and latches for tightness Be sure doors are closed and latched STARTING THE UNIT OBSE
116. take two 2 supply signals and allow the one with the highest pressure to pass through The shuttle valve is used to provide control air pressure from either the reservoir or plant air system as required during different operating conditions Blowdown Valve Figure 4b 2 page 2 this section The blowdown valve is a two way solenoid valve which is piped into the oil reservoir outlet but ahead of the check valve When the solenoid is de energized the valve opens and the oil system is blown down When the solenoid is energized the valve closes to allow the oil system 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 control position of the turn valve in response to signals from the Auto Sentry ES With both valves de energized equal pressure is supplied to both sides of the actuator to hold itin its present position If TVC only is energized the right side of the turn valve actuator is exhausted to the com pressor inlet cavity causing the turn valve to move towards the full load position If TVO only is energized the left side of the turn valve actuator is exhausted to the compressor inlet cavity causing the turn valve to move towards the unload position See Control System Op eration in this section for a description of how the turn valve components respond during operation Turn Valve
117. the compressor or base bearings can be damaged by passage of current LIFTING UNIT Proper lifting and or transporting meth ods must be used to prevent damage Lift compressor unit by base only Do not use other places such as enclo sure motor compressor oil discharge manifold and piping as lifting points DANGER The eyebolts or lugs provided on the motor are for lifting the motor only and should not be used to lift any additional weight All eyebolts must be securely tightened When lifting the motor the lifting angle must not exceed 15 de grees failure to observe this warning may result in damage to equipment or personal injury Lifting slots are provided in the base for towmotor use Unit may 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 source of air some cases it may be necessary to install the air filter at some distance from the compressor to obtain proper air supply Both the air cooled and water cooled units require cool ing air as well as air to the compressor inlet Proper ventilation MUST be provided hot air must be exhausted 13 9 10 641 from the compressor operating area A typical inlet out let air flow arrangement is shown in Figure 2 1 AIR COOLED UNIT A
118. the relief valve setting If this pres sure is approached the control will be forced to a blowdown and shutdown condition In the top line SET PRESSURE is displayed The bottom line will indicate a pressure value in the range 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 adjustment to be set in excess of the compressor nameplate pressure In the top line RESET PRESSURE is displayed The bottom line will indicate a pressure value in the range of 45 to 175 PSI This setting determines the point at which machine startup occurs in AUTO and SEQUENCE modes and when the compressor will load up from the blown down condition Note that RESET PRESSURE cannot be set within 5 PSI of the SET PRESSURE It is necessary that all ma chines to be sequenced have the same SET and RESET PRESSURE setpoints The top line displays REMOTE STOP Select ei ther IMMEDIATE or TIMED STOP as the desired response to the remote input Inthe top line FILTER CHNG INT is displayed The bottom line will indicate a time interval of 1000 hours This may be adjusted lower down to 500 13 9 10 641 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 displayed requesting an oil filter change In the top line OIL CHNG INTERVAL is displayed The bottom
119. their normal modulation sequence 13 9 10 641 Subsequent blowdown periods are not allowed until the timer has completed its cycle This cycle eliminates the problems of oil foaming and carryover which can occur if the oil reservoir of an oil flooded compressor is blown down too often The timer is adjustable from 5 to 20 minutes Automatic Mode Operation This mode provides au tomatic start and timed stop and is best used in appli cations with long unloaded periods Operation during periods of demand or moderately long unloaded periods is 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 with no demand the compressor drive motor is halted to eliminate its power consumption The controls will re main in this state until demand is again indicated by a drop in pressure Sequence Mode Operation This mode provides for communication between controllers operating only as many as are required for economical operation The lead unit 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 board connectors A unit number must be assigned to each unit to operate in this mode see Programming and Setup in this section CONTROLLER DISPLAY The display above the keypad is used to provide oper
120. tial pressure reservoir tem perature system pressure and compressor discharge temperature In Low Demand Automatic and Sequence modes alternate displays also indicate remaining times of delays If no keys are pressed for 5 seconds the display will return to its normal mode The display is also used as a service reminder for normal maintenance items These include the separator air filter and oil filter change intervals All intervals are based on recommended parts as noted in the maintenance section of this manual Oil change intervals are also automatically calculated based on actual operating conditions This allows maximum utilization of AEON 9000 oil Messages wili also be displayed if operation has occurred during low ambient temperatures or if high temperature operation has occurred Clearing Advisories Temperature advisories may be cleared while the unit is running by simply pressing the ENTER key To reset the service messages press the 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 down position restore power to the unit and press STOP RESET to clear the controller Proceed through the service selection described in step 1 below Active advisories will be displayed and may be cleared by pressing the ENTER key After the messages have been cleared press STOP RESET and select an operating mode to resume operation
121. ure will be displayed Shutdown will also occur if a shorted probe open probe or extreme low temperature is detected The display will indicate the location of the defective thermistor probe 13 9 10 641 Machine damage will occur if compres sor is repeatedly restarted after high temperature stops operation Find and correct the malfunction before resum ing operation Separator Differential Pressure The separator differ ential pressure is continually monitored by the Auto Sentry ES At a differential pressure of approximately 15 psi the unit will be shut down High Pressure The Auto Sentry ES will shut down the unit if excessive pressures are detected in the reser voir or system Shut down will occur if a defective transducer is detected The display will indicate the location of the high sensed pressure or transducer xducer error Check that all adjustments have been made and all connections are secure Relief Valve A pressure relief valve s is are installed in the final discharge line and set to approximately 12096 of the unit s full load operating pressure for protection against overpressure Periodic checks should be made to ensure its their proper operation The relief valves should be tested for proper operation atleast once every year To test the relief valve raise the system operating pressure to 7596 of relief valve set pressure and manually open the valve with the hand lever Hold the valve op
122. vel from the red range to the center of the green range 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 severe personal injury or death Shut down compressor relieve system of all pres sure tag and lockout power supply to starter before removing valves caps plugs fittings bolts and filters Excess oil carryover can damage equipment Never fill oil reservoir above FULL marker LUBRICANT CHANGE PROCEDURE Following are the primary steps to be completed when upgrading or changing the type of lubricant 1 Thoroughly drain system Drain oil from air end and cooler while hot Break low point connections and drain oil from pipe runs Section 5 Page 5 Dump oil from filter and reinstall used filter 2 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 shut down 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 be 50 percent of normal anticipated service life of the new lubricant Drain all lubricant from system change filter and
123. y screw and a reciprocating compres sor are manifolded together an air receiver must be located between the two units 13 9 10 641 Discharge air used for breathing will cause severe injury or death Consult filtration specialists for addi tional filtration and treatment equip ment to meet health and safety standards BLOWDOWN VALVE PIPING The blowdown valve is fitted with a muffler for operation indoors Ifthe installa tion requires the muffler may be removed and the blow down valve piped to the outside with a pipe size the same as the blowdown valve outlet connection Section2 Page 4 OIL OIL OUT IN THERMOSTATIC MIXING VALVE co CONTROL VALVE WATER SHUTOFF VALVE Eum wie eae Se See Rm WATER OUT WATER 076682 AIR OUT SEPARATOR TRAP OIL OUT C76683 1 THERMOSTATIC MIXING VALVE WATER CONTROL VALVE AWATER SHUTOFF VALVE WATER OUT WATER OUT pw WATER SHUTOFF VALVE NER IN WATER CONTROL VALVE AFTERCOOLER 7 AIR OUT SEPARATOR TRAP OPTIONAL WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY FIGURE 2 5 SERIES PIPING WATER PIPING Water Cooled Heat Exchanger Models 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 left side of the unit The water source should be capable of supplying
124. ycling When used an air receiver should be of adequate size provided with a relief valve of proper setting a pressure gauge and a means of draining condensate MOISTURE SEPARATOR TRAP Since unit is equipped 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 the control system specified INLET LINE Where an inlet line is used between the air filter and the compressor it must be thoroughly cleaned on the inside to prevent dirt or scale from entering the compressor If welded construction is used the line must be shot blasted and cleaned to remove welding scale In either case the inlet line must be coated internally by galvanizing or painting with a moisture and oil proof sealing lacquer Up to ten 10 feet in length the inlet line should be the full size of the inlet opening on the compressor If an extra long line is necessary the pipe size should be increased according to Inlet Line Chart below INLET LINE LENGTHS Length of Inlet Line Diameter of Pipe Size O to tO Feet x ederent nte ie im arcane ce Oe coats Same as Compressor Inlet Opening 10 to 1X Eeet 5 ses BID Ae e RAE One Size Larger Than Inlet Opening 1710 38EGet cde ee eos e e ten sted decedent Tete epa isse lados Two Sizes Larger Than Inlet Opening 13 9 10 641 Section2 Page3 HEAT EXC
125. ystem to an electrical signal for use by the programma ble controller for modulation and control Discharge Pressure Transducer This transducer is connected to the oil reservoir Its signal is used to prevent loaded starts monitor oil pressure and for separator differential Air Filter Vacuum Switch This switch is used to monitor air filter condition and alert the user if the filter requires service or replacement Vibration Switch Optional Equipment The optional vibration shutdown switch mounted on the compressor coupling cover detects an increase in vibration that could be an indication of impending damage to the unit The switch actuates when the selected level of vibration is exceeded The switch MUST BE ADJUSTED when the unit is first installed Refer to switch manufacturer s instruction manual for complete details STARTER CONTROL PANEL The following items are located in the electrical enclo 13 9 10 641 sure and provide the main control of the compressor unit and switching of the motor s Refer to Figure 3 1 AUTO SENTRY ES The Auto Sentry ES is located on the upper section of the panel It provides all the control of the motors and control devices for safe and efficient operation of the compressor unit Its display provides all gauging functions shutdown causes and maintenance recommendations The keypad provides the user with selection of operating modes and adjust ment to tune the controls for the ap

13-9/10-641/4 COMPRESSOR OPERATING AND SERVICE MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents