Manual de Operación & Mantenimiento EEG 345

Natural Gas Booster Compressor
EEG 345
Operation and Maintenance Manual
TABLE OF CONTENTS
1. Compressor Safety
2. Description
2.1 Compressor
2.2 Gas/Oil System
2.3 Cooling System
2.4 Control System
2.5 Machine Sequence
2.6 Front Panel Operations
2.7 Instrumentation
3. Installation
3.1 Site Requirements
3.2 Unpackaging/Handling
3.3 Storage
3.4 General Guidelines For Compressed Gas Systems
3.5 Wiring Diagram -Connection
3.6 Wiring Diagram
3.7 Installation Drawing
4. Operation
4.1 Initial Startup
4.2 Normal Operation
5. Maintenance
5.1 Routine Maintenance
5.2 Oil Change Schedule
5.3 Oil Filter
5.4 Gas/oil Separator
5.5 Lubricant
5.6 Oil Return Line
5.7 Minimum Pressure Valve
5.8 Gas Inlet Valve
5.9 Screw Compressor ( SEE SECTION 8 )
5.10 Bolt Torque Specifications
6. Trouble Shooting
6.1.1 Trouble Shooting Guide
6.1.2 P&ID Drawing
6.1.3 Wiring Diagram
7. Compressor Set Point Table
8. Compressor Repair Manual

1. COMPRESSOR SAFETY
A natural gas compressor is a rotating piece of machinery. The same common sense safety
precautions should be observed as with any piece of machinery of this type where carelessness
in operation or maintenance is hazardous to personnel. In addition to the obvious safety rules
that should be followed with this type of machinery, we are recommending the following additional
safety precautions:
Pull the main disconnect switch and disconnect any separate control lines, if used, prior to
attempting to work or perform maintenance on this unit.
Do not attempt to remove any pressurized system parts without first relieving the pressure within the
unit.
Do not attempt to service any part while the machine is in operation.
Do not operate the compressor at pressures in excess of its rating as indicated on the compressor
nameplate.
Do not operate the compressor at speed in excess of its rating as indicated on the compressor
nameplate.
Do not remove guards, shields, or screens while the compressor is operating. If removed for
maintenance, replace before resuming operation.
Observe the delivery pressure gauge daily to be sure the automatic control system is operating
within proper limits.
Periodically check all safety and relief devices for proper operation.
Be sure no tools, rags, or loose parts are left on the compressor or drive parts.
Do not use flammable solvents for cleaning parts.
Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts and
exposed openings by covering with clean cloth or draft paper.
Do not operate the compressor without guards, shields, and screens in place.
Make sure code requirements are investigated to ensure compliance prior to operating the
compressor.
The owner, lessor, or operator of this compressor is hereby notified and forewarned that any
failure to observe these safety precautions may result in injury or property damage.
GrimmerSchmidt Compressors expressly disclaims responsibility or liability for any injury or
damage caused by failure to observe these specified precautions or by failure to exercise
ordinary caution and due care required in operating or handling the compressor even though not
expressly specified above.
GrimmerSchmidt Natural Gas Compressor
Operation and Maintenance
2. DESCRIPTION
The GrimmerSchmidt rotary screw compressor is an electric motor driven single stage dual screw
type heavy-duty industrial compressor. It is sold as a complete package unit mounted on a steel
base. The package includes the compressor, motor, gas intake system, electrical starting unit,
control system, cooling system, gas/oil separator, and instrumentation.
Installation requires only the connection of electric power, a service line; and when applicable a
water line and drain.
2.1 COMPRESSOR PRINCIPLE OF OPERATION

The gas end is a positive displacement compressor. The meshing of two screw type rotors
synchronized by timing gears provide controlled compression of the gas for maximum efficiency
and pulsation-free discharge
Compression is achieved by the main rotor and gate rotors meshing enclosed in the housing. The
timing gears maintain close rotor clearances. The rotors do not touch each other, the housing, or
the bearing carriers.
The compression cycle (Figure 1) begins as the rotors decouple at the inlet port. Gas is drawn
into the rotor cavities as rotation continues. When proper compression is made, the cavities cross
the discharge port, completing the cycle. The cycle occurs four times each rotation and is
continuous.
The screw is also oil flooded. This means that oil is rejected into the gas stream at the screw
rotors. The oil does three equally important things: lubricate, cool, and seal. The lubrication
function is obvious. The oil flow holds the discharge gas temperature to approximately 100 ? F.
above ambient. The necessary clearances between moving parts are filled with oil, thereby
sealing against gas leakage.
2.2 GAS/OIL SYSTEM
2.2.1 Scrubber Tank

The compressor unit has a pre filtering scrubber tank. This tank removes larger oil droplets
before they enter the compressor stream. As the gas passes through a coarse metal mesh
screen, droplets attach to the mesh and accumulate into drops that fall to the bottom of the tank.
A level sensor is present in the lower region of the tank to signal a high oil level is reached and
needs to be drained
2.2.2 Discharge Check Valve

The discharge check valve is part of the gas end, located just prior to the discharge pipe
connection. It prevents discharge pressure from the sump from going back into the gas end on
shutdown that can counter rotate the gas end and motor.
2.2.3 Sump and Gas/Oil Separator

From the discharge check valve, the gas/oil mixture flows into a pressure vessel. This acts as a
reservoir for the gas and separates out the oil. The bulk of the oil settles to the bottom of the
vessel that serves as a sump for the oil. From the bottom of this oil sump the oil leaves the
vessel on its way to the oil cooler.
The gas, and the slight oil mist still entrained in the gas, flow through the separator element that
removes the last of the oil from the gas. The gas flows through the aftercooler before passing on
out to its final use and the separated oil goes to the compressor intake to re-enter the system.
2.2.4 Minimum Pressure Valve

As the compressed gas leaves the sump, it goes through a minimum pressure valve that is set to
maintain 65 psig (4.5 bar) in the sump when the compressor is running. The purpose of this
pressure is to insure that velocities do not become excessive in the gas/oil separator element.
This velocity would increase the oil carryover. Also in the event of a sudden demand for gas, it
prevents a collapse of the separator due to high differential pressures. The minimum pressure
valve also acts as a check valve prohibiting gas from flowing back into the compressor.
2.3 COOLING SYSTEM
The compressor is equipped with both an aftercooler and an oil cooler.
The oil goes through the compressor with the gas where it picks up the heat generated by the
compression process then seals the spaces between moving parts and lubricates bearings. This
hot oil must be cooled. The cooler will return the oil temperature to approximately 60? F. over the
ambient temperature.
The aftercooler cools the gas reducing the gas’s ability to hold water. It is generally designed
with an approach temperature of 15? F; this means the gas discharged from the cooler is usually
15? higher in temperature than the entering temperature of the cooling media.
2.4 CONTROL SYSTEM
2.4.1. Overview
This compressor is supplied with a skid mounted ANGI OCS microprocessor control system. The
ANGI control system is provided to perform as compressor sequence control and shutdown
monitoring. The compressor control system is provided with a simple front panel interface for
placing the compressor in service (ON/OFF) and for resetting faults (RESET). Additionally, the
front panel is provided with a LCD screen from reporting machine status information, process
values and fault details.
The main components, which are under direct control of the control system, are: the compressor
inlet valve, “load/unload” solenoid valve, the compressor motor starter, and the fan motor starter.
The system is designed to provide simple and reliable starting and stopping and/or load/unload
compressor.
The control system monitors the discharge pressure by means of a transducer installed
downstream of the minimum pressure regulator to determine when the compressor is to start,
load/unload or stop.
When control system determines that the discharge pressure is below the START PSI set point,
the compressor will automatically start-up. As the system pressure is built up, the pressure will
rise above the STOP PSI point at which point the compressor will unload by closing the inlet
valve and re-circulating a portion of the discharge gas from the compressor. After operating in
unloaded condition for a period of time, the compressor will then shut down.
2.4.2. Optional VFD Operation

The compressor control system has been designed for use with Variable Frequency Drives (VFD)
to control the speed of the compressor motor and fan motor. When VFD’s are applied, the
compressor motor speed and fan motor may be modulated between a minimum and maximum
speed based on the system demand.
The speed of the compressor motor is maintained to regulate the gas discharge flow in attempt to
maintain a specific discharge pressure. If the discharge pressure drops below the pressure
target, the system responds by increasing the motor speed to increase the flow. If the discharge
pressure raises up above the pressure target, then the system responds to lower the motor speed
to reduce the flow.
The speed of the fan motor is regulated to maintain a target oil temperature. If the oil/gas
discharge temperature drops below a target temperature set point then the fan slows down. As
the gas temperature heats up, the speed of the fan is increased.
2.4.3. Modes of Operation – Compressors and Boosters

The control system allows for the compressors to be operated in one of two modes of operation.
The two modes of operation are LOCAL MODE or REMOTE MODE as determined by the
position of the LOCAL/REMOTE keyswitch on the front panel of each machine. LOCAL operation
allows the compressor or booster to operator independently of other activity based on a demand
that is determined by monitoring the discharge pressure transducer mounted on each machine.
REMOTE operation allows the compressor or booster be remotely controlled by the Master
Controller thru command start and stop signals.
REMOTE MODE operation is reserved for further use should the customer elect to coordinate
control of several compressors thru the addition of a Master Control Panel.
LOCAL MODE operation is intended to be the standard operating mode for this machinery.
2.4.4 Sequence of Operation
IMPORTANT! THIS MACHINERY IS DESIGNED TO START AND STOP AUTOMATICALLY

AND WILL DO SO WITH LIMITED WARNING IF NOT PROPERLY DEACTIVATED FOR
SERVICING.
2.4.4.1 Compressor Start/Stop Conditions

The compressor is available to automatically start-up if each of the following conditions is true:
? Control Power is Applied to the Compressor or Booster Station

? The Station is Not In ESD Condition
? The COMPRESSOR ON/OFF switch is in the ON position
? The station is not faulted.
To prevent the station from starting, switch the COMPRESSOR ON/OFF switch to OFF and
remove the Key to lockout the machine. In event of an emergency, depress any one of the
EMERGENCY STOP pushbuttons.
2.4.4.1.1 Local Mode Start/Stop Conditions

While in LOCAL MODE and when each of the four criteria defined in section 2. 4.4.1 are met, then
the station will automatically start when either of the following conditions are met.
? The final discharge transducer on the machine is less than the LOCAL START PSI setting in
the local machine register map.
? The FORCED START switch on the front panel is received while the station is in STAND-BY.
IT IS IMPORTANT THAT CERTAIN VALVES IN THE VALVE PANEL BE MANUALLY SET INTO
THE OPEN POSITIONS PRIOR TO USING A COMPRESSOR IN LOCAL MODE.
The compressor may operate in LOCAL MODE, however starts and stops will not be coordinated
to match the starts and stops of other compressors or devices in the system.
The compressor will stop compressing gas in a normal, controlled fashion when the discharge
pressure of the compressor exceeds the LOCAL MODE STOP PSI.
2.4.4.1.2. Remote Mode Start/Stop Conditions

The compressor may be operated in LOCAL MODE or REMOTE MODE as determined by the
position of the LOCAL/REMOTE keyswitch on the front panel of each machine.
While in REMOTE MODE and each of the four criteria above in section 2.4.4.1.1 are met, then
the station will automatically start when a Master Controller sends a COMMAND START signal to
the booster or compressor
A COMMAND START signal will be sent from the Master Controller to the compressor when the
Master has determined compression is required.
The compressor will stop compressing gas in a normal, controlled fashion when the COMMAND
START signal sent by the master is removed. The compressor does not immediately stop when
this COMMAND START signal is removed. There will remain some delay after the COMMAND
START signal is removed prior to the motors turning off. This delay assures the compressors
have unloaded and have completed their respective cool-down cycles.
2.4.4.1.3. Compressor Abnormal Stop

A compressor will immediately stop operation anytime any of the following conditions are true:
? An EMERGENCY STOP pushbutton is depressed.

? The COMPRESSOR ON/OFF switch on the compressor or booster is set of OFF.
? A compressor or booster related fault is detected.
Should an EMERGENCY STOP pushbutton be depressed, all machinery, all compressors, and
boosters will immediately stop.
2.4.4.2. Compressor Start and Stop Levels

The table below summarizes the START and STOP levels that have been established for this
machinery. The LOCAL MODE start and stop levels are maintained in registers in the local
compressor control panel.
2.5. MACHINE SEQUENCE
2.5.1 COMPRESSOR SEQUENCE – LOCAL MODE
The basic operations in LOCAL MODE is as identified in the sequence chart below:
MODES OF CONTROL
1) OFF
2) ON - LOCAL MODE MACHINE STATUS MACHINE SEQUENCE STEP ID'S
3) ON - REMOTE MODE 1) OFF 1) OFF
2) STANDBY 2) STANDBY
3) RUNNING 3) WARM-UP
(SEE DETAIL
4) FAULTED (SEE FAULT SEQ. DESCRIPTION) 4) WARM-UP - FULL MONITOR BELOW)
5) LOADED OPERATION
MACHINE WARNING 6) COOL-DOWN
1) PROCESS (SEE WARNING SEQ. DESCRIPTION) 7) FAULTED
2) MAINTENANCE (SEE MAINT. SEQ. DESCRIPTION)
3) PAGE FOR HELP
BASIC LOCAL MODE SEQUENCE

0 STATION KEY SWITCH IS IN THE ON POSITION AND MODE SWITCH IS IN LOCAL MODE
1 STATION IS IN STANDBY MODE AND STANDBY LIGHT IS ON
STANDBY
2 FINAL DISCHARGE PSI DROPS BELOW THE START PRESSURE SETPOINT
MODE
3 STANDBY LIGHT GOES OUT
4 WARNING LIGHT FLASHES AND OCS BUZZER SOUNDS
(START-UP STEP DELAY TIMER #1 ACTIVATES AND EXPIRES)
5 RUN LAMP TURNS ON RELATED LOGIC - FAN SPEED
6 SUCTION AND RECIRC. VALVE OPENS CONTROL
(START-UP STEP DELAY TIMER #2 ACTIVATES AND EXPIRES) Running speed is determined by
7 FAN MOTOR OUTPUT TURNS ON P & ID loop and 4-20 mA output
WARM-UP MODE
(WARM-UP DELAY TIMER #1 ACTIVATES AND EXPIRES) to VFD. P & ID Input is Final
8 (NOT USED) Pressure Transducer
(START-UP TIMER DELAY #3 ACTIVATES AND EXPIRES)
9 (NOT USED)
10 (NOT USED)
11 WARNING LIGHT STOPS FLASHING AND BUZZER STOPS RELATED LOGIC -
12 COMPRESSOR RUN OUTPUT TURNS ON COMPRESSOR SPEED
(TOTAL COMPRESSOR RUN TIMER ACTIVATES) Running speed is determined by
RUN MODE
13 COMPRESSOR SPEED RAMPS UP TO RUNNING SPEED P & ID loop and 4-20 mA output
MONI
(LOADED OPERATION TIMER ACTIVATE)

M-UP
FULL
to VFD. P & ID Input is Final

WAR
TOR
14 LOAD VALVE OUTPUT TURNS ON Discharge Temp.

(RUN TIME HOURMETER ACTIVATES)
OPERATION
15 COMPRESSOR COMPRESSES IN LOADED OPERATION

LOADED
I/O
16 FINAL DISCHARGE PSI RAISES ABOVE STOP PRESSURE

17 (NOT USED)
(LOADED OPERATION TIMER STOPS)
COOL DOWN
(COOL DOWN DELAY ACTIVATES AND EXPIRES)

18 COMPRESSOR RUN OUTPUT TURNS OFF
MODE
(TOTAL COMPRESSOR RUN TIME HOUR TIMER TURNS OFF)

(FAN RUN AFTER STOP TIMER RUNS AND EXPIRES)
19 FAN MOTOR OUTPUT TURNS OFF
20 RUN LAMP TURNS OFF
21 STANDBY LIGHT GOES ON
STANDBY
(SEQUENCE RETURNS TO STEP 3 UPON FINAL PSI DROP)

MODE
2.5.2 COMPRESSOR SEQUENCE – REMOTE MODE
The basic booster operations in REMOTE MODE is as identified in the sequence chart below:
MODES OF CONTROL
1) OFF
2) ON - LOCAL MODE MACHINE STATUS MACHINE SEQUENCE STEP ID'S
3) ON - REMOTE MODE 1) OFF 1) OFF
2) STANDBY 2) STANDBY
3) RUNNING 3) WARM-UP
(SEE DETAIL
4) FAULTED (SEE FAULT SEQ. DESCRIPTION) 4) WARM-UP - FULL MONITOR BELOW)
5) LOADED OPERATION
MACHINE WARNING 6) COOL-DOWN
1) PROCESS (SEE WARNING SEQ. DESCRIPTION) 7) FAULTED
2) MAINTENANCE (SEE MAINT. SEQ. DESCRIPTION)
3) PAGE FOR HELP
BASIC REMOTE MODE SEQUENCE

0 STATION KEY SWITCH IS IN THE ON POSITION AND MODE SWITCH IS IN REMOTE MODE
1 STATION IS IN STANDBY MODE AND STANDBY LIGHT IS ON
STANDBY
2 COMPRESSOR DEMAND INPUT GOES ON
MODE
3 STANDBY LIGHT GOES OUT
4 WARNING LIGHT FLASHES AND OCS BUZZER SOUNDS
(START-UP STEP DELAY TIMER #1 ACTIVATES AND EXPIRES)
5 RUN LAMP TURNS ON
6 SUCTION AND RECIRC. VALVE OPENS
(START-UP STEP DELAY TIMER #2 ACTIVATES AND EXPIRES) RELATED LOGIC - FAN SPEED CONTROL
7 FAN MOTOR OUTPUT TURNS ON Running speed is determined by
WARM-UP MODE
(WARM-UP DELAY TIMER #1 ACTIVATES AND EXPIRES) P & ID loop and 4-20 mA output
8 (NOT USED) to VFD. P & ID Input is Final
(START-UP TIMER DELAY #3 ACTIVATES AND EXPIRES) Pressure Transducer
9 (NOT USED)
10 (NOT USED)
11 WARNING LIGHT STOPS FLASHING AND BUZZER STOPS
12 COMPRESSOR RUN OUTPUT TURNS ON
(TOTAL COMPRESSOR RUN TIMER ACTIVATES) RELATED LOGIC - FAN SPEED CONTROL
RUN MODE
13 COMPRESSOR SPEED RAMPS UP TO RUNNING SPEED Running speed is determined by
MONI
(LOADED OPERATION TIMER ACTIVATE) M-UP
FULL
P & ID loop and 4-20 mA output
WAR
TOR
14 (NOT USED) to VFD. P & ID Input is Final
(RUN TIME HOURMETER ACTIVATES) Pressure Transducer
OPERATION
15 COMPRESSOR COMPRESSES IN LOADED OPERATION

LOADED
I/O
(PRIORITY ROUTINE START - IF USED)

16 COMPRESSOR DEMAND INPUT GOES OFF
17 LOAD VALVE OUTPUT TURNS OFF
(LOADED OPERATION TIMER STOPS)
COAL DOWN
(COOL DOWN DELAY ACTIVATES AND EXPIRES)

18 COMPRESSOR RUN OUTPUT TURNS OFF
MODE
(TOTAL COMPRESSOR RUN TIME HOUR TIMER TURNS OFF)

( COOLDOWN DELAY TIMER RUNS AND EXPIRES)
19 FAN MOTOR OUTPUT TURNS OFF
20 RUN LAMP TURNS OFF
21 STANDBY LIGHT GOES ON
STANDBY
(SEQUENCE RETURNS TO STEP 3 UPON CMPRS. DEMAND INPUT TURNING ON)

MODE
2.6 FRONT PANEL OPERATIONS
2.6.1. Basic Operation

The control panel has low number of operators and indicates to provide basic control of the
compressor.
An EMERGENCY STOP BUTTON is provided in the center of the panel to allow for quick and full
stop of the compressor. To stop in machine in event of an emergency, press this button. To
reset the system after an emergency stop event, twist the pushbutton to release it from it’s
latched and depressed position.
An RESET/ OFF/ON key switch is provided to place the compressor in service or remove it from
service and prevent it from running and to reset the machine after occurrence of a Fault. For the
compressor or operator in either mode of operation, the ON/OFF keyswitch must be placed in the
ON position. To prevent the machine from operating, place the ON/OFF in the OFF position and
remove the key from the switch. In event of a fault, the operator can only reset the compressor
by turning the RESET/OFF/ON switch to the RESET position (LEFT). The key switch will return
to the OFF (center) position.
A FORCE START/LOCAL/REMOTE key switch is provided to reset faults and to place the
machine in one of the two operating modes. Should a fault occur on the machine, an operator
may reset the fault by turning the key switch to the REST position (LEFT) and then returning the
key to the LOCAL or REMOTE MODE position. Additionally, should be compressor be in the
STANDBY condition, an operator may force the machine to start and run by turning the key to the
FORCE position. This action will cause the machine to start and run until the discharge pressure
reaches the STOP Pressure level.
A
1
B
2
3
C
4
D
CCS Control Panel
Indicators Operators
1 4 x 20 Character Display A Keypad (Functions and Numbers)
2 COMPRESSOR FAULT Lamp B FORCE/LOCAL/REMOTE
3 COMPRESSOR RUN Lamp C EMERGENCY STOP
4 COMPRESSOR STANDBY Lamp D RESET/ON/OFF
2.7 INSTRUMENTATION
The compressor is equipped with the following instrumentation.
Analog Inputs
Suction Pressure, 4-20 mA Pressure Transducer
Discharge Pressure, 4-20 mA Pressure Transducer
Discharge Temperature, 4-20 mA RTD and Transmitter
These instruments are connected to the control system and are used to monitor the machine for
an abnormal condition. Additionally, these instruments are used for sequence control of the
machine. The process values for these instruments may be read on the LCD display on the
control panel.
In addition, mechanical gauges are provided to indicate pressure at the following points:
Mechanical Gauges
Suction Pressure
Discharge Pressure
Oil/Gas Separator Pressure
The gas inlet, separator, and oil filter gauges indicate the pressure drop across these filter
elements. This will help determine the maximum effective life of these elements without the
concerns of changing too early or late when depending on the hour meter.
The hour meter records the number of hours the machine has been in operation. The hour meter
can be read from the LCD screen on the controller.
The status lamps on the front panel provide basic machine status indication.
3. INSTALLATION
3.1 SITE REQUIREMENTS
Foundation
Your GrimmerSchmidt compressor does not require a special foundation. However, it is
necessary for the floor to be level and the frame be adequately supported. We do recommend
that the compressor and scrubber tank be bolted to the floor.
Room
The room should be of adequate size to provide full access to the machine for routine
maintenance. It should have ventilation to keep the room as cool as possible. Operating at
elevated temperatures can result in nuisance overload or temperature shutdowns. Ambient
should be between 32-115 degree F. If running in low temperature conditions a cold weather kit
is required.
Cooling Air Discharge

The cooling air discharge must be restriction free. Any restriction from ducting or louvers must
not exceed a quarter of an inch of water static head. The use of this air for heating will require a
booster fan, so you should consult your HVAC contractor prior to installation. Excessive
restriction to the discharge cooling air will cause the unit to operate at elevated temperatures that
could result in high temperature shutdowns. Ducting of cooling air to the unit is not generally
recommended.
Electrical
A qualified electrician in compliance with standards and local codes as applicable should do all
electrical wiring. Be sure to investigate the local requirements before installing the machine. The
power supply should be adequate and free of parasitic loads that will cause an under voltage
condition during the operation of the compressor. Otherwise you will have nuisance electrical
shutdowns.
GrimmerSchmidt recommends that you always connect to the compressor to its power source via
a fusible disconnect.
3.2 UNPACKAGING AND HANDLING

Occasionally damage will occur during shipping. Be sure to carefully inspect the unit before and
after unpackaging. If any damage has occurred contact your GrimmerSchmidt representative
immediately.
To move your compressor to its installation site we recommend that you leave it on its shipping
skid if possible. The forks should extend the width of the compressor and padding should be
placed between the compressor and the fork truck boom.
If it is necessary to lift the compressor with a crane we recommend the use of a spreader bar and
chains. The spreader bar should be greater than the width of the compressor and padding
should be placed on the edges of the unit to prevent chain damage. Consult the installation
drawing at the end of this section for approximate location of the center of gravity.
3.3 STORAGE
In some cases it may be necessary to store the compressor for extended periods of several
months before placing the unit in operation. When this is required do the following:
1. Cover and seal all machine openings to prevent the entrance of water and dirt.
2. Cover all openings in open drip proof motors to prevent the entrance of rodents.
3. If the storage conditions are below freezing, drain off aftercoolers, traps, water-cooled
heat exchangers and attendant piping. We do not recommend outside storage.
4. Cover with a waterproof tarpaulin that can be easily removed for in-storage
maintenance.
5. While in storage, every two to three months hand rotate the compressor and motor to
prevent flat spots on the bearings that will lead to premature failure.
At the end of the storage period, follow the uncrating and startup procedures. If the unit has been
stored for more than eighteen months you should contact GrimmerSchmidt before restarting the
compressor.
3.4 GUIDELINES FOR COMPRESSED GAS SYSTEMS

a. The pressure drop between the compressor and the point of use are not
recoverable.
b. Pipe size should be large enough that pressure drop does not exceed 10%
between the receiver and the point of use.
c. Arrange the distribution piping to avoid the following types of strains:
1. Strains due to dead weight of the pipe itself.
2. Strains due to expansions or contraction of the piping with
temperature change.
3. Strains due to internal pressure within the piping.
d. Design inlet and discharge piping for smooth flow.
e. Plan for future emergencies and establish an area of the loop to install a
temporary compressor.
f. Consider bypass lines on all items that may require future maintenance.
g. Slope all piping so that it drains toward a drip leg or moisture trap away from
the compressor.
3.5 WIRING DIAGRAM

3.6 INSTALLATION DRAWING

3.6.1 INSTALLATION DRAWING
3.6.2 INSTALLATION DRAWING

4. OPERATION
Every GrimmerSchmidt compressor is operated and thoroughly tested at the factory prior to
shipment. The test assures that the compressor will deliver its rated capacity and is in good
working order. However, there is a possibility that damage may occur during shipment. For this
reason, it is recommended that the unit be carefully inspected for evidence of damage or
malfunction before installation and during the first few hours of operation.
4.1 PREPARATION FOR INITIAL START-UP

1. Pull main disconnect switch and insure that no power is connected to the unit.
2. Review installation instructions to see that all instructions have been complied with.
3. Inspect unit for visible signs of damage that could have happened during shipment or
installation.
4. Make sure any protective coverings required for shipment or painting is removed
from the compressor.
5. Fill the sump to the proper oil level. Do not overfill; if it is, drain to proper level.
Tighten the fill fitting securely.
6. On water cooled units, make sure that the water is connected and open to give the
correct flow.
7. Reconnect the main disconnect switch.
8. Refer to control section, and check out the panel components.
9. “Jog” the motor (press the start and Emergency stop quickly in succession) and
check the correct direction of rotation. Reverse the L1 and L2 connections if
incorrect.
10. Run the unit for several minutes and shutdown. Check the oil level and add oil if
necessary to compensate for filling the oil system.
11. Begin normal operation.
4.2 NORMAL OPERATION
Normal Start-Up
1. Drain off condensate from the sump and check the oil level. Refill as necessary.
2. Check for any oil leaks. Correct as necessary.
3. Press the start button.
Normal Stopping
1. Push the “STOP” button.
Emergency Stopping
1. Push the “EMERGENCY” button.
2. Pull main disconnect if possible.
CAUTION
UNIT CAN AUTOMATICALLY RESTART CAUSING PERSONAL INJURY
OR MACHINE DAMAGE. DISCONNECT POWER BEFORE PERFORMING
MAINTENANCE.
5. MAINTENANCE
5.1 ROUTINE MAINTENANCE
Daily, or every 8 hours, check the gas/oil separator for correct oil level. It should be in the center
of the sight glass when the compressor is off.
In Operation: Observe oil return line tubing for oil flow. Check pressure gauge to insure proper
operating point.
Periodically check:
1. Clean oil return line orifice.
2. Clean the coolers.
3. Check the pressure relief valve for operation. This valve is factory set and no attempt
should be made to adjust it.
4. Check the machine for oil leaks and loose fastenings and connections. Also note the
hose condition and replace if necessary.
5. Check maintenance gauges and take action as necessary.
5.2 OIL CHANGE SCHEDULE
Due to varying operating conditions, the oil change schedule will change according to installation.
Under ideal conditions the oil should be good for 8000 hours. An OIL SAMPLING PROGRAM is
the best way to determine the frequency of oil changes. We recommend an oil analysis every
1000 hours to develop a trend as to oil condition. When this is determined, scheduled changes
can be established.
Initially use the following schedule:
After First 100 hours: Change oil, have Oil analyzed.

First 1000 and 2000, 3000 and 4000 hours: Perform oil analysis
Every 1000 hours:
1. Change the oil filter, and the gas/oil separator element, unless maintenance
indicators show continued acceptable performance. Sample oil for analysis.
Every 4000 hours:
1. Change the compressor oil, (or change as indicated by an oil-sampling program).
Initial fill requires approximately 7.5 US gallons. Oil change requires approximately 5 US gallons.
WARNING
SYSTEM UNDER PRESSURE CAN CAUSE PERSONAL INJURY
RELIEVE SYSTEM PRESSURE BEFORE WORKING ON THE UNIT.
5.3 OIL FILTER

The oil filter should be changed every 1000 hours, or sooner, under harsh operating conditions.
This element protects the compressor bearings and the cooler from plugging.
5.3.1 OIL FILTER REPLACEMENT

The element is located close to the cooler on the discharge side of the machine. Turn power off to
ensure the unit will not start. Close manual gas inlet and outlet valves. Open purge valve and let
pressure dissipate. Check gauge on tank, it should now read “0”. Do not proceed if pressure
still exists. Close purge valve. Unscrew filter cartridge. Clean filter head gasket mating surface.
Lightly lubricate cartridge gasket and install until gasket contacts surface. Tighten filter ¼ turn
after contact. Check oil level and correct if necessary. Start compressor, check for pressure.
Check for leaks from filter
5.4 GAS/OIL SEPARATOR

The gas/oil separator element should be changed every 2,000 hours of operation or as indicated
by the OCS controller. You should inspect it for dirt and any holes. Either condition indicates the
probability of an oil carryover problem; never attempt to wash this element.
5.4.1 ELEMENT REPLACEMENT

The element is located inside the Separator tank. Turn power off to ensure the unit will not start.
Close manual gas inlet and outlet valves. Open purge valve and let pressure dissipate. Check
gauge on tank, it should now read “0”. Do not proceed if pressure still exists. To access the
element, remove cover from top of the enclosure. Disconnect and remove tubing to solenoid
valve and purge valve. Disconnect scavenge line from sight glass. Note position of dip tube in
fitting. Mark insertion depth. Loosen ferrule at tank to remove dip tube. Loosen 1 ½ pipe union.
Remove 8 cap screws from cover of tank. Remove cover. Change element. Reassemble in
reverse order. Take note not to insert dip tube to deep. Pressurize tank and check for leaks.
Restart machine
DIP TUBE FERRULE SCAVENGE LINE PURGE VALVE

DANGER
DO NOT OPERATE THE MACHINE WITHOUT ALL FILTER
ELEMENTS PROPERLY INSTALLED. MACHINE FAILURE WILL RESULT
THAT CAN CAUSE SEVERE PERSONAL INJURY, DEATH, OR PROPERTY
DAMAGE.
5.5 LUBRICANT
Your compressor has been filled and tested with a high quality compressor lubricant.
GrimmerSchmidt has carefully selected this oil for use in our natural gas compressors and it is
strongly recommended that this oil be used.
The lubricant is Summit NGSH150. Summit NGSH Series lubricants are formulated from the
highest quality synthetic hydrocarbon base stocks. NGSH lubricants are extended life fluids with
special additives to protect equipment from wear, rust and hydrogen sulfide corrosion. These
fluids are designed for rotary screw and reciprocating compressors in natural gas service. Summit
NGSH Series lubricants are compatible with commonly used seal materials and equipment
designed for use with petroleum oils.
NOTICE
GRIMMERSCHMIDT DOES NOT RECOMMEND MIXING DIFFERENT
TYPES OR BRANDS OF LUBRICANTS DUE TO POSSIBILITY OF A
DILUTION OF THE ADDITIVES OR A REACTION BETWEEN
ADDITIVES OF DIFFERENT TYPES.
5.5.1 GRIMMERSCHMIDT Oil Analysis

GrimmerSchmidt Oil Analysis is an excellent tool to add to your compressor maintenance
program. At any desired interval of detailed report is prepared in answer to submitted oil samples
showing oil condition, wear metals and contaminants. Changes in this information over time
provide the basis for statistical process control of the compressor.
5.6 OIL RETURN LINE (Scavenger)

On the compressor, a line comes from the dry side of the separator and goes to the inlet valve.
During loaded operation the flow of oil in the line is visible. If no droplets can be seen, the orifice
located in this line should be checked for plugging. Oil not returned ends up in the system.
WARNING
SYSTEM UNDER PRESSURE CAN CAUSE PERSONAL
INJURY.
RELIEVE SYSTEM PRESSURE BEFORE WORKING ON UNIT.
5.7 MINIMUM PRESSURE VALVE

The minimum pressure valve is a non-adjustable spring biased check valve. It has been designed
to maintain a minimum sump pressure of 65 psig. If the pressure is allowed to get too low the oil
carryover rate would increase and the separator could be damaged.
5.7.1 MINIMUM PRESSURE VALVE DISASSEMBLY

The Minimum Pressure Valve is rebuildable. BEFORE DISASSEMBLING CONFIRM
PRESSURE ON SYSTEM IS RELIEVED AND MACHINE IS DISABLED. To
disassemble, unscrew cap (Item 1 above), use caution when removing, cap under spring
pressure. Remove cap and two springs. Remove piston. Lubricate with white lithium
grease before re-assembly
5.8 GAS INLET VALVE

Installed at the compressor inlet, Air-Con Intake Valves control compressor capacity.
At start-up the valve stays open until a control signal is applied to close the valve and
restrict the flow.
During normal operation, the valve opens and closes in response to a control signal to
meet the downstream air demands.
At shut down, a built-in check valve stays closed to prevent back flow through the
compressor.
5.8.1 GAS INLET VALVE DISASSEMBLY

The Gas Inlet Valve is rebuildable. BEFORE DISASSEMBLING CONFIRM PRESSURE
ON SYSTEM IS RELIEVED AND MACHINE IS DISABLED. To disassemble, depress
CV plate (Item 1); remove retaining ring and seal (Item 1 and 2). Remove CV assembly.
Depress cap (Item 4) and remove retaining ring (Item 6), use caution when removing, cap
under spring pressure. Remove cap and two springs. Remove piston. Lubricate with
white lithium grease before reassembly
5.9 SCREW COMPRESSOR
For repair instructions on the Enduro 25 screw compressor, see section 8

5.10 RECOMMENDED BOLT TORQUE SPECIFICATIONS
CAPSCREW TIGHTENING TORQUE

Dry Lubricated
¼-20UNC 90 IN-LBS 75 IN-LBS
5/16-18UNC 17 FT-LBS 13 FT-LBS
3/8-16UNC 30 FT-LBS 23 FT-LBS
½-13UNC 75 FT-LBS 55 FT-LBS
¾-10UNC 260 FT-LBS 200 FT-LBS
6. TROUBLESHOOTING
6.1 TROUBLE SHOOTING GUIDE
This guide may be used for reference to assist in resolving possible field problems. The OCS
controller should show all faults and/or shutdowns.
Compressor will not start

a. No power
b. Fuses blown in control circuit
c. Motor overload (starter) latch not reset
d. Heaters not installed in starter
e. Loose and missing wires or components in electrical circuit
f. Low voltage – using 230 volt in 460 volt system
g. Faulty temperature sensor or pressure transducer(s).
Unit starts, but stalls immediately

a. OCS controller failure
b. Incorrect heaters or adjusted too low in starter
c. High temperature shutdown due to;
i. Low oil levels
ii. Fan motor protection fuses blown
d. Loose or missing electrical components
e. Motor overload (starter) heaters trip out – “seized” gas end
f. Low voltage
Compressor does not build up to desired pressure

a. Inlet valve partially closed
b. Restricted inlet
c. Defective pressure sensor
d. Excessive gas demand (compressor size too small)
e. Unload set point set too low
f. Excessive pressure drop across separator (restricted element)
g. Gas end malfunction-excessive clearance or rotor movement
h. Solenoid valve stuck in open position
Capacity (delivery) is below stated amount

a. Restricted inlet
b. Inlet valve partially closed
c. Gas pressure set too high (defective pressure gauge)
d. Insufficient oil flow
e. Pneumatic control (bleed, control cylinder, etc.) malfunction
f. Faulty gas end discharge check valve
g. Worn gas end
h. Restriction in gas flow system (separator)
Compressor will not unload

a. Regulator set too high (or jammed in closed position)
b. Unload set point set too high
c. Inlet valve malfunction – will not close
d. Restriction in gas line to inlet valve, regulator or switch
e. Solenoid valve faulty
TROUBLESHOOTING (CONT.)
Compressor surges
a. Erratic gas demand
b. Faulty minimum pressure valve
c. Load/Unload set point’s differential is set too low for the system conditions
d. Regulator opening setting too close to Unload set point.
e. Load set point set below opening setting of regulator
f. Loose electrical connection between OCS controller’s output and solenoid
valve
g. Faulty “Line” pressure transducer or solenoid valves
h. Faulty pressure relief valve
High temperature shutdown

a. Low sump oil level
b. Plugged oil filter
c. Restricted cooling gas flow
d. Clogged heat exchanger
e. Thermal bypass is leaking
f. Faulty gas temperature sensor
g. Delivery pressure is set too high
Excessive oil consumption

a. Overfilled sump
b. Broken oil line
c. Plugged oil return line (scavenger)
d. Oil return line not bottomed in the separator element
e. Operating below rated pressure
f. Damaged separator
g. Lightly loaded or excessive load/unload cycles
High power consumption

a. Plugged separator
b. Plugged aftercooler
c. Improper gas pressure setting
d. Low line voltage
e. Electrical phase imbalance
f. Imminent motor failure
6.2 P&ID
6.3 WIRING DIAGRAM

6.3.1 WIRING DIAGRAM






7. COMPRESSOR SET POINT CHART
Description Register Setpoint Min Max
Start PSIG %R1102 65 60 72

Stop PSIG %R1103 75 N/A N/A
Max Starts per hour %R1117 3 N/A N/A
DIGITAL’S
ESD Active (%I006) %R1212 32831 (DO NOT
CHANGE
THIS
SETTING
)
Oil Level Switch (%I007) %R1214 32831 (Change
to "0" to
Ignore
Switch)
Comp. Motor Healthy (%I008) %R1216 32816 (Change
to "0" to
Ignore
Switch)
ANALOGS
Inlet PSIG (%AI001) %R1500 32816
Zero %R1502 -8 0
Span %R1503 38 30
ID %R1504 1
Broken Wire %R1505 -4
Low Alarm %R1506 -2
Low Warning %R1507 -2
Hi Warning %R1508 7
Hi Alarm %R1509 8
Discharge PSIG (%AI002) %R1510 32944

Zero %R1512 -25 0
Span %R1513 128 100
ID %R1514 2
Low Alarm %R1516 -8
Low Warning %R1517 -5
Hi Warning %R1518 80
Hi Alarm %R1519 90
Oil Temp (%AI004) %R1530 32816

Zero %R1532 -58 32
Span %R1533 461 392
ID %R1534 4
Low Alarm %R1536 -5
Low Warning %R1537 45
Hi Warning %R1538 210
Hi Alarm %R1539 220
8. COMPRESSOR REPAIR INSTRUCTIONS

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Natural Gas Booster Compressor

7. Compressor Set Point Table

8. Compressor Repair Manual

Do not attempt to service any part while the machine is in operation.

Do not use flammable solvents for cleaning parts.

2.1 COMPRESSOR PRINCIPLE OF OPERATION

2.2 GAS/OIL SYSTEM

2.2.1 Scrubber Tank

2.2.2 Discharge Check Valve

2.2.3 Sump and Gas/Oil Separator

2.2.4 Minimum Pressure Valve

2.3 COOLING SYSTEM

The compressor is equipped with both an aftercooler and an oil cooler.

2.4 CONTROL SYSTEM

2.4.2. Optional VFD Operation

2.4.3. Modes of Operation – Compressors and Boosters

2.4.4 Sequence of Operation

IMPORTANT! THIS MACHINERY IS DESIGNED TO START AND STOP AUTOMATICALLY

2.4.4.1 Compressor Start/Stop Conditions

? Control Power is Applied to the Compressor or Booster Station

2.4.4.1.1 Local Mode Start/Stop Conditions

2.4.4.1.2. Remote Mode Start/Stop Conditions

2.4.4.1.3. Compressor Abnormal Stop

? An EMERGENCY STOP pushbutton is depressed.

2.4.4.2. Compressor Start and Stop Levels

2.5. MACHINE SEQUENCE

2.5.1 COMPRESSOR SEQUENCE – LOCAL MODE

3) PAGE FOR HELP

BASIC LOCAL MODE SEQUENCE

(LOADED OPERATION TIMER ACTIVATE)

to VFD. P & ID Input is Final

14 LOAD VALVE OUTPUT TURNS ON Discharge Temp.

15 COMPRESSOR COMPRESSES IN LOADED OPERATION

16 FINAL DISCHARGE PSI RAISES ABOVE STOP PRESSURE

(COOL DOWN DELAY ACTIVATES AND EXPIRES)

(TOTAL COMPRESSOR RUN TIME HOUR TIMER TURNS OFF)

(SEQUENCE RETURNS TO STEP 3 UPON FINAL PSI DROP)

2.5.2 COMPRESSOR SEQUENCE – REMOTE MODE

3) PAGE FOR HELP

BASIC REMOTE MODE SEQUENCE

13 COMPRESSOR SPEED RAMPS UP TO RUNNING SPEED Running speed is determined by

15 COMPRESSOR COMPRESSES IN LOADED OPERATION

(PRIORITY ROUTINE START - IF USED)

(COOL DOWN DELAY ACTIVATES AND EXPIRES)

(TOTAL COMPRESSOR RUN TIME HOUR TIMER TURNS OFF)

(SEQUENCE RETURNS TO STEP 3 UPON CMPRS. DEMAND INPUT TURNING ON)

2.6 FRONT PANEL OPERATIONS

2.6.1. Basic Operation

CCS Control Panel

The compressor is equipped with the following instrumentation.

3.1 SITE REQUIREMENTS

Cooling Air Discharge

3.2 UNPACKAGING AND HANDLING

3.4 GUIDELINES FOR COMPRESSED GAS SYSTEMS

3.5 WIRING DIAGRAM

3.6 INSTALLATION DRAWING

3.6.2 INSTALLATION DRAWING

4.1 PREPARATION FOR INITIAL START-UP

4.2 NORMAL OPERATION

5.1 ROUTINE MAINTENANCE

5.2 OIL CHANGE SCHEDULE

After First 100 hours: Change oil, have Oil analyzed.

5.3 OIL FILTER

5.3.1 OIL FILTER REPLACEMENT

Manual de Operación & Mantenimiento EEG 345

Manual de Operación & Mantenimiento EEG 345