Gardner Denver ELECTRA-SCREW EBE DH-15 HP Operating And Service Manual
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Gardner Denver ELECTRA-SCREW EBE DH-15 HP Operating And Service Manual

Stationary base–mounted & tank mounted compressors
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GARDNER DENVER
ELECTRA–SCREW STATIONARY
BASE–MOUNTED & TANK MOUNTED
COMPRESSORS
DOMESTIC MODELS
EBE_DH – 15 HP
EBE_EH – 20 HP
EBE_FH – 25 HP
EBE_GH – 30 HP
INTERNATIONAL MODELS
EBEQEJ – 20 HP (15 KW)
EBEQFJ – 25 HP (19 KW)
EBEQGJ – 30 HP (22 KW)
OPERATING AND
SERVICE MANUAL
13–8–609
5th Edition
March, 1997

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Summary of Contents for Gardner Denver ELECTRA-SCREW EBE DH-15 HP

  • Page 1 13–8–609 GARDNER DENVER 5th Edition March, 1997 ELECTRA–SCREW STATIONARY BASE–MOUNTED & TANK MOUNTED COMPRESSORS DOMESTIC MODELS EBE_DH – 15 HP EBE_EH – 20 HP EBE_FH – 25 HP EBE_GH – 30 HP INTERNATIONAL MODELS EBEQEJ – 20 HP (15 KW) EBEQFJ –...

  • Page 2: Parts And Support Services

    They are ready to respond and assist you by pro- Your authorized distributor can support your Gardner viding fast, expert maintenance and repair services. For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact: Distribution Center: Factory: Gardner Denver Machinery Inc.

  • Page 3: Foreword

    FOREWORD Gardner Denver Electra–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 operator and maintenance department essential information for day–...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Maintain Compressor Reliability and Performance With Genuine Gardner Denver Compressor Parts and Support Services ...............

  • Page 5: Index

    INDEX Addition of Oil Between Changes ....Control Piping ....... Air Control Components .
  • Page 6 INDEX Grease Recommendations, Electric Motor ..Motor Regreasing Interval ..... Grounding ........Oil Change Interval .
  • Page 7 INDEX Rotation ....... . . Every Year ....... System Pressure .
  • Page 8 LIST OF ILLUSTRATIONS Figure 1–1 Compressor Cycle ..............Figure 1–2 Minimum Pressure/Check Valve, Separators &...

  • Page 9: Section 1, General Information

    SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSOR CYCLE COMPRESSOR – The Gardner Denver compres- Oil is injected into the cylinder to remove the heat of sor is a single stage, positive displacement rotary ma- compression and seal internal clearances. Volume re-...
  • Page 10 200EBE797 (Ref. Drawing) FIGURE 1–2 – PACKAGE – MINIMUM PRESSURE/CHECK VALVE, SEPARATORS & OIL FILTER 13–8–609 Page 2...
  • Page 11 200EBE797 (Ref. Drawing) FIGURE 1–3 – PACKAGE – OIL LEVEL GAUGES, STARTER/CONTROL BOX & AIR FILTER 13–8–609 Page 3...
  • Page 12 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
  • Page 13 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
  • Page 14 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–8–609 Page 6...
  • Page 15 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–8–609 Page 7...

  • Page 16: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- LOCATION (FIGURE 2–1) – The compressor should age that may have been incurred during transit. Report be installed where it is protected from rain, snow and any damage or missing parts as soon as possible.
  • Page 17 Elevate the compressor unit on a suitable struc- Minimum Air Flow* For Compressor ture to obtain the desired drain height. And Cooling – Cubic Feet/Minute (Cubic Meters/Minute) Air Cooled All Models 3000 cfm (170 M /min.) If the compressor unit base is raised * 80 F (27 C) Inlet Air above floor level, the space between...
  • Page 18 Refer to Engineering Data Sheet 13–9–411, available sate has been drained and cooler from an authorized Gardner Denver distributor, for the dried out to prevent cooler damage. advantages of using the heat recovered from rotary compressors.
  • Page 19 A means of draining condensate will need to be pro- BLOWDOWN VALVE PIPING – The blowdown valve vided for. is fitted with a muffler for operation indoors. If the instal- lation requires, the muffler may be removed and the CONTROL PIPING – Control piping is not necessary blowdown valve piped to the outside with a pipe size the since the Electra–Screw unit is factory wired and...
  • Page 20 greasing intervals for ball bearing motors. For addition- Stop the unit. Replace the relief plug. al information refer to the motor manufacturer’s Restart the unit. instructions. The following procedure should be used in regreasing: Stop the unit. Disconnect, tag and lockout the unit from the pow- er supply.

  • Page 21: Section 3, Starting & Operating Procedures

    Rotation – Check for correct motor rotation us- AEON 4000 lubricant. Use only gen- ing “JOG MODE.” Compressor drive shaft rota- uine Gardner Denver filters designed tion must be clockwise standing facing the com- pressor sheave. See Section 4, page 20, Step and specified for this compressor.
  • Page 22 System Pressure – Set the controls to the de- Run for approximately five minutes or until the sired load pressure. DO NOT EXCEED THE temperature stabilizes and then open the air ser- MAXIMUM OPERATING PRESSURE ON THE vice valve. COMPRESSOR NAMEPLATE. See Section 4, The unit is equipped with a minimum (65 psig, 4.5 Bars) pages 19 through 21, “Programming the Load–...

  • Page 23: Section 4, Controls & Instrumentation

    SECTION 4 CONTROLS & INSTRUMENTATION GENERAL – The Gardner Denver Electra–Screw voltage range specified. There are three (3) overloads compressor is supplied with a factory mounted starter in the starter of proper size for the starter and its enclo- and complete controls as standard equipment. The sure.
  • Page 24 300EBE797 (Ref. Drawing) FIGURE 4–2 – INLET VALVE the compressor discharge housing to sense compres- sor 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. When the relief valve opens, a stream of high velocity air is released, result- The microprocessor controller will shut the compressor...
  • Page 25 pressure on the oil system even when the air service valve is fully open. The valve senses upstream pres- sure. If demand for air exceeds the compressor capac- ity, the valve throttles the flow to maintain a minimum pressure on the upstream (oil reservoir) side of the valve.
  • Page 26 compressor or oil separator discharge. At the time of a high temperature shutdown, the LED is illuminated and the temperature digital readout is locked on to the of- fending temperature. Illumination of the decimal point Damage will occur to the machine if it in the lower right hand corner of the digital readout indi- is repeatedly restarted after any one cates that the temperature displayed is at the oil sepa-...
  • Page 27 Pressure And Temperature Digital Readouts – These readouts normally indicate pressure at the mini- mum pressure check valve and temperature at the air end discharge. See “High Air Temperature LED”, page Electrical shock can cause injury or 18, for a description of readout action during a high death.
  • Page 28 Step 4: Press the “AUTO LEAD” button to raise the giving a slight rotation that is short enough in unload setpoint. Press “AUTO LAG” to lower duration to prevent reverse oil flow in the the unload setpoint. See FIGURE 4–8, page event that rotation is reversed.
  • Page 29 Step 12: Stop the compressor and disconnect, tag and lockout the power supply to the starter. Step 13: Move the circuit board slide switch back to the “set” position (right). You may now pro- ceed with normal start up procedure. To readjust, the slide switch must be in the “+”...
  • Page 30 FIGURE 4–6 – SUBTRACTIVE PILOT (CLOSED) FIGURE 4–7 – SUBTRACTIVE PILOT (OPENED) The downstream pressure is maintained equal to the upstream pressure minus a constant which is adjust- able. In the example shown in FIGURE 4–5, page 21, the downstream pressure equals the upstream pres- Operation at excessive discharge air sure minus 95 psi (6.6 Bars).
  • Page 31 NAMEPLATE CONTROL SYSTEM PRESSURE FULL LOAD OPERATING PRESSURE LOAD UNLOAD 100 PSI (6.9 Bars) 100 PSI (6.9 Bars) 108 PSI (7.5 Bars) 125 PSI (8.6 Bars) 125 PSI (8.6 Bars) 133 PSI (9.2 Bars) 150 PSI (10.4 Bars) 150 PSI (10.4 Bars) 158 PSI (10.9 Bars) 175 PSI (12.1) Bars) 167 PSI (11.5 Bars)
  • Page 32 218EBE546 (Ref. Drawing) FIGURE 4–10 – WIRING DIAGRAM – DUAL CONTROL...
  • Page 33 220EBE546 (Ref. Drawing) FIGURE 4–11 – WIRING DIAGRAM – WYE DELTA...
  • Page 34 OIL SPECIFICATIONS – The recommended com- pressor lubricant is Gardner Denver AEON 4000 Lubri- The oil inlet line is connected at the bottom of the oil res- cating Coolant which can be used for year–round op- ervoir.
  • Page 35 210 F (93 to 99 C) for a period of more than four (4) Subsequent lubricant changeouts should be at hours due to continuing high ambient air temperature, normal intervals. (See “Oil Change Interval” and use Gardner Denver AEON 9000 SP Lubricating chart, page 29.) Coolant which is a superior synthetic lubricant. Short...
  • Page 36 Material Safety Sheets (MSDS) are available for all Excessive oil carry–over can damage AEON lubricants from your authorized Gardner Denver equipment. Never fill oil reservoir distributor or by calling 217–222–5400. above the “FULL” marker.
  • Page 37 Gardner Denver If the drained oil and/or the oil filter element are with the AEON lubricants and we recommend a sam- contaminated with dirt, flush the entire system: ple be sent in at 100 hours on a new unit.
  • Page 38 Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, tag and lockout the power supply to Improper oil filter maintenance will the starter. cause damage to equipment. Replace filter element every 1000 hours of op- Wipe away all dirt around the oil filler plug.
  • Page 39 case bypass lines (FIGURE 5–1, page 26) will be hot to touch and lines out of mixing valve much cooler. When flushing the oil system, remove the mixing valve and clean all parts thoroughly. OIL RESERVOIR – The oil reservoir–separator com- bines multiple functions into one vessel.
  • Page 40 Disconnect, tag and lockout the power supply to the starter. At the bottom of the separator, disconnect the oil return (scavenge) tube and remove the tube el- bow. Using an oil separator element at ex- Remove the spin–on element. cessive pressure differential can Clean the gasket seating surface of the head.

  • Page 41: Section 6, Air Filter

    Never use gaskets that won’t seal. Keep spare elements and gaskets on hand to re- Use only genuine Gardner Denver air duce downtime. Store elements in a filter elements on Gardner Denver protected area free from damage, dirt compressor units.
  • Page 42 (b) Place the element into the cleaning solution and allow to soak for five minutes. Agitate in solution for two more minutes. Elements contaminated with oil or greasy dirt de- posits: (a) Mix a sufficient amount of the following cleaning solution to allow the element to be 201EDE797 fully submerged.

  • Page 43: Section 7, Belt Drive

    SECTION 7 BELT DRIVE Proper drive belt tension and alignment are provided at the factory, however, good practice dictates checking the drive alignment and tension after shipment and be- fore initial start–up. Interference between the fan and the orifice can damage equipment. Be Sheaves should align straight across the front with a certain the orifice has even clearance straight edge.

  • Page 44: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. The “CHANGE AIR FILTER” display will Check for dirt accumulation on oil/aftercooler core flash to signal that the air filter requires servicing or faces and the cooling fan.

  • Page 45: Section 9, Trouble Shooting

    SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
  • Page 46 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 4000 or 9000 SP Lubricating Coolant. 6. Inoperative minimum 6. Replace valve.
  • Page 47 SYMPTOM POSSIBLE CAUSE REMEDY Oil Carry–Over (Continued) 7. Operation at elevated 7. Reduce temperature. See discharge temperatures. High Discharge Air Temperature, page 38, this section. 8. Scavenge line check 8. Replace check valve. valve failure. 9. Water condensate in oil. 9.
  • Page 48 SYMPTOM POSSIBLE CAUSE REMEDY “MOTOR OVERLOAD” 1. Running compressor at a 1. Lower pressure to nameplate. shutdown. pressure over nameplate pressure. 2. Incoming voltage low or 2. Consult your power company. high. 3. Imbalanced voltage 3. If imbalance exceeds 5%, (check phase to phase).
  • Page 49 1. If fuse does not blow, check meter, starter coil, for shorted coils. or blowdown valve. 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. 13–8–609...
  • Page 50 Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.

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