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Summary of Contents for Gardner Denver PUREAIR EWC99C
- Page 1 13-11-607 GARDNER DENVER ® Version: 05 August 1, 2003 ® PUREAIR OIL-FREE ROTARY SCREW COMPRESSORS MODELS EWC99C OPERATING AND SERVICE MANUAL...
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Page 2: Remanufactured Airends
Authorized distributor service technicians are factory 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 Air Compressor distributor, refer to the yellow pages of your phone directory or contact:... -
Page 3: Foreword
FOREWORD Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. -
Page 4: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ..............i Remanufactured Airends ........................i Foreword............................ii List Of Illustrations ..........................i v Section 1, General Information......................1 Section 2, Installation, Coolers And Water Systems ................5 Section 3, Starting &... -
Page 5: List Of Illustrations
LIST OF ILLUSTRATIONS Figure 1-1 – Typical Compression Cycle ....................1 Figure 1-2 – Package Illustration......................2 Figure 1-3 – Air/Water Schematic ......................3 Figure 2-1 – Typical Compressor Room ....................6 Figure 2-2 – Air Flow Chart ........................6 Figure 2-3 – Inlet Line Lengths......................8 Figure 2-4 –... -
Page 6: Section 1, General Information
GENERAL INFORMATION Figure 1-1 – TYPICAL COMPRESSION CYCLE COMPRESSOR - The Gardner Denver Rotary Screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads. -
Page 7: Figure 1-2 - Package Illustration
307EWC797-B (Ref. Drawing) Figure 1-2 – PACKAGE ILLUSTRATION... -
Page 8: Figure 1-3 - Air/Water Schematic
308EWC797-F (Ref. Drawing) Figure 1-3 – AIR/WATER SCHEMATIC... - Page 9 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: DANGER Failure to observe these notices could result in injury to or death of personnel.
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Page 10: Section 2, Installation, Coolers And Water Systems
SECTION 2 INSTALLATION, COOLERS AND WATER SYSTEMS GENERAL - On receipt of the unit, check for any damage that may have occurred during transit or handling. Report any damage or missing parts as soon as possible. CAUTION Do not electric weld on the compressor or base; bearings can be damaged by passage of current. -
Page 11: Figure 2-1 - Typical Compressor Room
heat exchanger at the top of the unit. The air-cooled unit with the standard enclosure requires sufficient flow, Figure 2-2, page 6, for the compressor water/aftercooling system and for electric motor cooling. Do not block the air flow to and from the unit. Allow three and one-half (3-1/2) feet to the nearest obstruction on the control box end of the unit. - Page 12 FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible, install the unit near level. Temporary installation may be made at a maximum 10° angle lengthwise or 10° sidewise.
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Page 13: Figure 2-3 - Inlet Line Lengths
WARNING The use of make-up water exceeding the quality units outlined in the “RO Water filter”, Section 8, may result in damage to critical compressor components by corrosion and/or scaling action of impurities in the water. NOTICE Water may no longer be potable after use in the compressor. AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and provides sufficient storage capacity to prevent rapid cycling. - Page 14 DISCHARGE SERVICE LINE - The discharge service line connection on the unit is made from the right side at base level from the motor end of the package. 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.
- Page 15 Air and Water Discharge Temperature - 105° F to 125° F - Read on the “AUTO SENTRY W” control panel. Compressor Injection Water Inlet Temperature - 90° F to 110° F - Check anywhere on the line from the heat exchanger to the compressor inlet. Water Injection Cooler Temperature Differential (Air Cooled Heat Exchanger - The water temperature differential depends on the temperature of the air at the water injection cooler fan and the cleanliness of the core faces.
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Page 16: Figure 2-4 - Grease Recommendations
MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The charts below show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information, refer to the motor manufacturer’s instructions. -
Page 17: Section 3, Starting & Operating Procedures
Regular maintenance and replacement at required intervals of the air and water filters are necessary to achieve maximum service of this screw compressor. Use only genuine Gardner Denver filters designed and specified for this compressor. 2. Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to Section 6, page 39, for complete servicing instructions. - Page 18 6. Grounding - Equipment must be grounded in accordance with Section 250 of the National Electrical Code. WARNING Failure to properly ground the compressor package could result in controller malfunction. 7. Rotation - Check for correct motor rotation using “JOG MODE.” An arrow on the compressor/motor belt guard shows correct rotation.
- Page 19 11. Initial Water Fill/Adjusting RO Timer - You package is shipped with all water drained. The water receiver must be filled with filtered water (reverse osmosis filter) prior to operating the compressor unit: • Ensure that the make-up water feed line is installed and the ball valve is open. •...
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Page 20: Section 4, Controls & Instrumentation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver PureAir water-flooded rotary screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply, to the shop air line, and to the appropriate water supply. - Page 21 When first starting, the controller will keep the compressor fully unloaded and blown down until the system pressure drops below the load pressure. Low Demand Mode Operation - This mode is similar to the “Continuous Run” mode, except for its behavior under unloaded conditions.
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Page 22: Figure 4-1 - Auto Sentry W Controller Display
Remaining blowdown and auto times are only available in Low Demand, Automatic, and Sequence modes, as appropriate. If no keys are pressed for 5 seconds, the display will revert to its normal mode. The display is also used as a service reminder for normal maintenance items. If service is recommended, the yellow LED next to the service symbol will come on, and a message will alternate with the normal lower line message. - Page 23 SERVICE ADVISORIES The AUTO SENTRY W controller turns on an advisory when it detects operation which needs service attention, but does not warrant shutting down the compressor. Some of these are normal maintenance procedures, and are intended to serve as a reminder to perform routine service. Others are conditions which can reduce the maximum compressor performance.
- Page 24 Water Filter Differential Pressure - The pressure drop across the water filter is continually monitored by the AUTO SENTRY W. The unit will be shut down at a differential pressure of approximately 40 psid (2.8 bars). This becomes active only after the compressor has been running and pressures have had time to stabilize.
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Page 25: Figure 4-2 - Flow Chart For Setup Programming
300EWC1255 (Ref. Drawing) Figure 4-2 – FLOW CHART FOR SETUP PROGRAMMING... - Page 26 PROGRAMMING AND SETUP FOR THE AUTO SENTRY W CONTROLLER Programming and setup is accomplished with the PROGRAM keys. See Figure 4-2, page 20. In all steps, the [ENTER] key will cause the controller to accept the displayed value into memory and advance to the next programming function.
- Page 27 7. In the top line, “REMOTE STOP” is displayed. The bottom line indicates either “TIMED” or “IMMEDIATE”. Refer to the description of “Remote On/Off” later in this section for additional details. Select the desired response to the remote input and press [ENTER] to proceed. 8.
- Page 28 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 load point.
- Page 29 This step is only encountered if the AUTO RESTART function was set to ON in the previous step. In the top line, “RESTART DELAY” 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.
- Page 30 Installation A proper sequencing installation requires two or more Gardner Denver rotary air compressors complete with AUTO SENTRY W controllers, piped into a common air system, interconnected as described above. For best performance, the units must be piped directly to the receiver, without any intervening check valves, dryers, or other restrictions.
- Page 31 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 sequence mode. Remember that once a master is established, no further self-decrementing is done by the individual compressors.
- Page 32 The Automatic Sequence Change After the master (lead) compressor has served for the duration programmed (TRANSFER INTERVAL), it relinquishes control and assigns itself the highest available rotation number. The lag compressors detect the loss of the master and decrement their rotation numbers. Number 2 becomes number 1, the new master, number 3 becomes number 2, etc.
- Page 33 The expansion board also provides the data port for communications in sequencing. The expansion board is pre-installed on any unit with factory-mounted Wye-Delta starters. To install on other units, stack the expansion board over the main control board, and mount with the hardware included.
- Page 34 If remote control is not desired, this input must be jumpered to operate the compressor. Connect a jumper between terminals 9 and 31. Auxiliary Shutdown - This input allows factory or field connection of shutdown switches not included on the standard package. Simply connect a two-wire switch to terminals 9 and 31. The switch must be selected which has contacts closed for normal conditions, and open to shutdown the compressor.
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Page 35: Figure 4-3 - Auxiliary Pressure Switch/Receiver Unloaded Pressure Tabulation
CAUTION Never paint, lubricate or alter a relief valve. Do not plug vent or restrict discharge. WARNING Operation of unit with improper relief valve setting can result in severe personal injury or machine damage. Insure properly set valves are installed and maintained. - Page 36 • Operate the compressor until the desired discharge pressure is achieved – in case the supply of air exceeds the demand, bleed some of the discharge air to achieve the target system pressure. • Back-out the adjustment stem until the subtractive valve starts to bypass air – the adjacent pressure gauge should register movement of less than 1 psig.
- Page 37 PLC (RO timer function) – This device governs the frequency and duration of the water-fill cycles. It shares use of the fill water solenoid valve with the AUTO SENTRY W controller and governs the dump water solenoid valve. It is located in the starter enclosure. Refer to the RO Filtration System, SECTION 8, for details on its operation and adjustments.
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Page 38: Figure 4-4 - Wiring Diagram - Full Voltage
305EWC546-B (Ref. Drawing) Page 1 of 2 Figure 4-4 – WIRING DIAGRAM – FULL VOLTAGE 13-11-607 Page 33... - Page 39 305EWC546-B (Ref. Drawing) Page 2 of 2 13-11-607 Page 34...
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Page 40: Figure 4-5 - Wiring Diagram - Full Voltage Less Starter
306EWC546-B (Ref. Drawing) Page 1 of 2 Figure 4-5 – WIRING DIAGRAM – FULL VOLTAGE LESS STARTER 13-11-607 Page 35... - Page 41 306EWC546-B (Ref. Drawing) Page 2 of 2 13-11-607 Page 36...
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Page 42: Section 5, Lubrication
A tag on the reservoir fill cap indicates the type of oil in the reservoir as it left the factory. 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 approved for use in rotary screw compressors. -
Page 43: Figure 5-1 - Oil Level Sight Glass
LUBRICANT MAINTENANCE INTERVAL - The oil reservoir at the discharge end of the airend has a capacity of approximately 32 oz. (.8 liters). The oil bath type lubrication utilized does not require an oil filter or dedicated circulation hardware. As such, discharge end lubricant change intervals of 2000 hours are recommended as the only maintenance requirement in lieu of filter changes and circulation system maintenance. -
Page 44: Section 6, Air Filter
Clean every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. - Page 45 Inspect the element for ruptures or cracks in the pleated media; replace the element if any are found. Inspect the gasket on the bottom (outlet end) of the element; replace the entire element if the gasket is damaged. A spare element will keep down time to a minimum. Allow the element to air dry COMPLETELY.
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Page 46: 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 before initial start-up. Sheaves should align straight across the front with a straight edge. The best tension is just enough tension to keep belts from “squealing”... -
Page 47: Figure 7-1 - Belt Tension 3Vx Belts
Deflection Force (Lbs.) (N) Deflection (Inches) (mm) Deflection Deflection Motor Force Pounds (Newtons) H.P. (Kw) No. of Belts (per belt) Inches (mm) 20 (15 kW) 6 to 7 (1.3 to 1.5) 5/16 (8) 25 (19 kW) 6 to 8.5 (1.3 to 1.9) 5/16 (8) 30 (22 kW) 6 to 7 (1.3 to 1.5) -
Page 48: Section 8, Ro Water Filtration System
SECTION 8 RO WATER FILTRATION SYSTEM General Information: The water mass utilized by the water-flooded screw compressor typically contains solids in dissolved and suspended forms. These solids, of organic and inorganic nature, are present in the local water supply or are deposited by the air stream pumped through the compressor, and usually contain corrosive and fouling agents. - Page 49 The capillary tube (mm) controls the flow of wash water used to flush away the contaminants captured by the RO membrane. The flushing process, active whenever the membrane is filtering water, requires 3.5 gpm of treated water for every 1 gpm of treated water delivered. The fast-flush valve (ll) is provided to intensify the flushing process during periodic maintenance.
- Page 50 CAUTION Ensure that the PLC “run/stop” mode selection switch remains in the “run” position at all times – except during reprogramming. Failure to do so will halt the timed operation of the RO Filter System and will damage its membrane by fouling. RO System Specifications : Clean water flow capacity: 73 gpd (192ml/min) at 50 psig, 70°...
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Page 51: Figure 8-1 - Plc Connections And Cycle Time Combinations
Initial Set-Up and Operation: The RO system is fully assembled and integrated into the compressor package. As delivered, the new RO membrane contains a FDA approved preservative solution to prevent microbiological growth and freezing. This preservative will be flushed during the initial hours of operation. Adjusting the cycle timer. - Page 52 Maintenance: Monitoring the water quality. The performance of the RO system is directly related to the quality of the incoming raw water. It is critical that an on-site water-sampling schedule be originated to monitor the performance of the RO system. By comparing specified rejection rates to those experimentally observed, the performance of the RO system is determined.
- Page 53 Monitoring the water flow In addition to the water quality, it is important that the filtered water flow be checked monthly: • Turn off the isolation valve (pp) on the water tank (nn). • If the compressor is not running, just open the filtered water test point (qq), let it run for a few seconds to depressurize the line, and then time-collect a sample of the steady stream.
- Page 54 RO membrane The operational live of the RO membrane also varies with the quality of the raw feed water. As a general rule, it should be replaced every 1-2 years. Typical signs that the device is plugging up are a decrease of clean water flow and a decrease of rejection of levels of compounds found in the site water.
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Page 55: Section 9, Maintenance Schedule
SECTION 9 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter - Operating conditions determine frequency of service. When the air pressure differential across the filter reaches 25” H O, the “CHANGE AIR FILTER” message appears on the display accompanied by a yellow indicator in the status area of the keypad signaling that the air filter requires servicing or changing. - Page 56 Every 125 Hours Operation 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 blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow. This cleaning operation will keep the exterior cooling surfaces clean and ensure effective heat dissipation.
- Page 57 MAINTENANCE SCHEDULE (See Detail Notes) indicated Every Every Every Every by AUTO 2000 * Every Maintenance Action SENTRY Hours Hours Hours Hours Year • Change Air Filter • Change Water Filter • Check for Proper Load/Unload • Check Discharge Pressure/Temp •...
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Page 58: Section 10, Troubleshooting
SECTION 10 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start 1. Wrong lead connections. Change leads. 2. Blown fuses in control box. Replace fuse. 3. Motor starter overload Reset and investigate heaters tripped. cause of overload 4. Pressure in reservoir. Inspect blowdown valve. - Page 59 Condensate return strainer 1. Inspect and clean. in package discharge air and/or orifice plugged. NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13-11-607 Page 54...
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Page 60: Section 11, Troubleshooting Auto Sentry W Controller
SECTION 11 TROUBLESHOOTING AUTO SENTRY W CONTROLLER W DISPLAY MODES A green power on light is located in the lower right corner of the keypad. It lights whenever the controls are energized. A steady light indicates that automatic restarting is not enabled, the compressor must be restarted manually following a power failure. - Page 61 ADVISORY TROUBLESHOOTING GUIDE All advisories are indicated on the keypad by a yellow indicator in the Status area, and one of the following messages alternating with the normal lower line display. Perform service or maintenance as indicated, the clear the advisory as instructed in Section 4. Message Action Needed CHNG AIR FILTER...
- Page 62 Message Action Needed EXTERNAL DEVICE 120 volts has been removed from J1-4 of the expansion board. This is normally jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch. HIGH DIS TEMP R This indicates that the controller has detected a rapid temperature rise in the airend discharge.
- Page 63 Message Action Needed LV RELAY 120 volts has been removed from J1-4 of the expansion board. This is normally jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch. MOTOR CONTACT The controller has attempted to turn off the compressor, but is still receiving a return signal from the starters’...
- Page 64 Message Action Needed WATER PRESS 120 volts has been removed from J1-4 of the expansion board. This is normally jumpered directly to terminal 9, but the jumper may be removed to add a field installed shutdown switch. Reset the external switch. ZERO XDUCER Signal voltage has fallen too low at transducer: (A) Final discharge, (B) Water Injection, or (C) Reservoir.
- Page 65 Message Action Needed Compressor runs, but In the CONSTANT RUN and LOW DEMAND modes, the compressor will not does not load load until the pressure drops below load pressure. Refer to the operating instructions for further information. If pressure is below the load pressure, check that the inlet valve operates freely.
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Page 66: Section 12, Troubleshooting The Ro Filtration System
SECTION 12 TROUBLESHOOTING THE RO FILTRATION SYSTEM Problem: None or low water production Reasons: Solutions: Raw water feed (gg) turned off......Open raw feed water valve. Pre-filters (ll, hh) fouled or plugged...... Replace cartridges. Raw water feed pressure below 50psig....Improve pressure condition. - Page 67 INDEX Air Filter, Section 6 ............39 Electrical Wiring............. 10 Air Flow In The Compressor System........1 Enclosure ................ 7 Auto Sentry W Controller Foundation............... 7 Alarm Relay ..............29 General................5 Automatic Sequence Change........27 Grounding..............10 Auxiliary Shutdown............29 Inlet Line ................
- Page 68 GENERAL PROVISIONS AND LIMITATIONS Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty is made with respect to: Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.
- Page 69 For additional information contact your local representative or Gardner Denver Compressor and Pump Division, 1800 Gardner Expressway, Quincy, Illinois 62301 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 224-7814 Sales and Service in all major cities. Specifications subject to change without notice.
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