Gardner Denver PUREAIR EWD99E Operating And Service Manual
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Gardner Denver PUREAIR EWD99E Operating And Service Manual

Gardner Denver PUREAIR EWD99E Operating And Service Manual

Oil-free rotary screw compressors
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13-11-608
GARDNER DENVER
®
Version: 05
August 1, 2003
®
PUREAIR
OIL-FREE ROTARY SCREW
COMPRESSORS
MODELS
EWD99E
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver PUREAIR EWD99E

  • Page 1 13-11-608 GARDNER DENVER ® Version: 05 August 1, 2003 ® PUREAIR OIL-FREE ROTARY SCREW COMPRESSORS MODELS EWD99E OPERATING AND SERVICE MANUAL...

  • 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 ................7 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 ......................4 Figure 2-1 – Typical Compressor Room ....................8 Figure 2-2 – Air Flow Chart ........................8 Figure 2-3 – Water Control Valve ....................... 12 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

    302EWD797-A (Ref. Drawing) Figure 1-2 – PACKAGE ILLUSTRATION – AIR-COOLED...
  • Page 8 303EWD797-A (Ref. Drawing) Figure 1-3 – PACKAGE ILLUSTRATION – WATER-COOLED...

  • Page 9: Figure 1-3 - Air/Water Schematic

    300EWD797-D (Ref. Drawing) Figure 1-4 – WATER-COOLED SCHEMATIC...
  • Page 10 301EWD797-D (Ref. Drawing) Figure 1-5 – AIR-COOLED SCHEMATIC...
  • Page 11 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.

  • Page 12: 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 13: Figure 2-1 - Typical Compressor Room

    The air-cooled unit requires cooling air as well as air to the compressor inlet. Proper ventilation MUST be provided; hot air must be exhausted from the compressor operating area. A typical inlet-outlet air flow arrangement is shown in Figure 2-1, page 8. Air-Cooled Units - A combination water/aftercooler is supplied as standard equipment on all air-cooled units.
  • Page 14 A small air-cooled motor and fan are used to ventilate the enclosed package. See “Air Cooled Units” for location recommendations. 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°...
  • Page 15 Service doors are provided for maintenance access. Be sure to allow enough space around the unit for the doors to be opened and removed as necessary for service procedures. The enclosure doors are held by two latches and lift away from the enclosure. The air filter, water filters, and water treatment cartridge are easily accessible through a side or end door.
  • Page 16 Water Quality - In order to protect the package components in contact with the cooling water against attack by corrosive and fouling agents, we recommend that the cooling water meet the following quality standards Total Dissolved Solids (TDS)....<500 ppm Iron............

  • Page 17: Figure 2-3 - Water Control Valve

    COOLING WATER PIPING - On packages equipped with water-cooled cores, the water inlet and outlet are located on the base frame side – See “Package Illustrations”, Figure 1-2 and Figure 1-3, pages 2 & 3, for details. The pipe network shall be sized to support the maximum required water flow, pressure and temperature limits listed under the “Water Flow Requirements”...

  • Page 18: Figure 2-4 - Inlet Line Lengths

    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. 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.
  • Page 19 UNIT WATER DRAIN - The unit drain ports should be connected to a floor drain(s). Drain line(s) must slope downward, away from the unit, to allow effluent to flow by gravity, and must be vented to the atmosphere to avoid the accidental back flow of said effluent into the package. As necessary, the automatic water management system will open the drain solenoid valve to drain excess water.

  • Page 20: Figure 2-5 - Grease Recommendations

    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. MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings.

  • Page 21: Figure 2-6 - Regreasing Interval

    ELECTRIC MOTOR REGREASING INTERVAL Type of Service Typical Examples Rating Relubrication Interval Up to 150 HP (112 kW) 18 Months Standard One or Two-Shift Operation Above 150 HP (112 kW) 12 Months Up to 150 HP (112 kW) 9 Months Severe Continuous Operation Above 150 HP (112 kW)

  • Page 22: 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 46, for complete servicing instructions.
  • Page 23 8. Rotation - Check for correct motor rotation using “JOG MODE.” An arrow on the compressor/motor adaptor shows correct rotation. Compressor drive shaft rotation must be clockwise standing facing the compressor coupling.. WARNING Operation with incorrect motor rotation can damage equipment and cause water eruption from the compressor inlet.
  • Page 24 13. Water-Cooled Models - Make sure to open any manual valves feeding cooling water to the package. STARTING THE UNIT - Start the unit by pushing the [RUN] key. The unit will reach normal operating temperature in approximately 5 minutes. Check the package operating information by pressing the [INFO] key or keypad cursor [<] [>] keys at any time during unit operation.

  • Page 25: 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 26 Low Demand Mode Operation - This mode is similar to the “Continuous Run” mode, except for its behavior under unloaded conditions. If the blowdown timer has completed its cycle when the next unload operation takes place, the controller will not reload the package until the line pressure has reached the “load” level. Otherwise, if the blowdown timer is still active, the machine will reload the package when the line pressure falls halfway between the “unload”...

  • Page 27: 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 28 PROTECTIVE SHUTDOWNS The AUTO SENTRY W will shut down the unit following any fault detected in the following devices. Long- term problems will have a brief blowdown period before fully shutting down. Following a shutdown, a message will be displayed, with the top line indicating “SHUTDOWN” and the lower line indicating the cause.
  • Page 29 Power Failure - Following power interruptions, the controller will remain in a shutdown state (unless programmed for auto restart). External Device - This input is used by a fixed-point (5 psig) oil pressure switch which shuts the package down if the oil pressure does not exceed the set point within 10 seconds after starting the compressor –...

  • Page 30: Figure 4-2 - Flow Chart For Setup Programming

    300EWC1255 (Ref. Drawing) Figure 4-2 – FLOW CHART FOR SETUP PROGRAMMING...
  • Page 31 PROGRAMMING AND SETUP FOR THE AUTO SENTRY W CONTROLLER Programming and setup is accomplished with the PROGRAM keys. See Figure 4-2, page 25. 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 32 6. In the top line, “BLOWDOWN TIME” is displayed. The bottom line will indicate a time between 1 and 20 minutes. It is factory set at 10 minutes. This is the minimum time interval between blowdowns. A longer blowdown time minimizes wasteful dumping of compressed air when loading is likely to occur in a short time.
  • Page 33 In the top line, “TRANSFER 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 to the same value on all sequenced units to equalize running hours.
  • Page 34 In the top line, “AUTO RESTART” is displayed. The bottom line will indicate either ”OFF” or ”ON” The factory setting is ”OFF”, and the controller will display a power failure shutdown after power has been restored. Set this feature to ON when it is necessary to have the compressor automatically restart after a power interruption.
  • Page 35 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 36 compressors in sequence mode. If it is desired to dictate the complete initial sequence manually, wait until the previous machine decrements 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 sequence mode.
  • Page 37 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 38 SENTRY W controller automatically detects the presence or absence of the expansion board, but 120V input circuits must be connected to the expansion board for proper operation. Spare terminals are provided at the control terminal strip in the box for connection of the following 120v circuits. Connect either to unused existing terminals, or mark blank terminal locations for new points shown.
  • Page 39 Auxiliary Shutdown - See “External Device” details, page 24. Alarm Relay - The expansion board is provided with an alarm relay which may be connected to a remote mounted indicator light, horn, or into a PLC input of a plant wide control system. The contact is commercial rated 2 amps at 120 volts.

  • Page 40: Figure 4-3 - Auxiliary Pressure Switch/Receiver Unloaded Pressure Tabulation

    Blowdown Valve (g) - This solenoid valve provides purging air to the compressor during unloaded operation. It also depressurizes the air/water reservoir during unloaded or halted operation. It is governed by the AUTO SENTRY W controller. Aux. Blowdown Valve (h) – This solenoid valve depressurizes rapidly the air/water reservoir during the initial phase of the unloading cycle.
  • Page 41 Water Pressure Relief Valve (ss) – This device protects the water treatment filtration system against 75 psig overpressure in the line common with the compressor inlet. Air Pressure Regulator (All Seal Purge) (n) - This device regulates the pressure of the air buffer signal fed to all seals.
  • Page 42 PLC (Additional logic functions) - This device provides a 10 second time delay period in which the oil pressure switch output is shorted, thus allowing the oil pump to build minimum pressure (5 psig) before a shutdown signal must take place to protect the compressor. This device also provides power to the auxiliary blowdown pressure switch while the compressor is running.

  • Page 43: Figure 4-4 - Wiring Diagram - Full Voltage With Expansion Board

    301EWD546-B (Ref. Drawing) Page 1 of 2 Figure 4-4 – WIRING DIAGRAM – FULL VOLTAGE WITH EXPANSION BOARD 13-11-608 Page 38...
  • Page 44 301EWD546-B (Ref. Drawing) Page 2 of 2 13-11-608 Page 39...

  • Page 45: Figure 4-5 - Wiring Diagram - Wye Delta With Expansion Board

    302EWD546-B (Ref. Drawing) Page 1 of 2 Figure 4-5 – WIRING DIAGRAM – WYE DELTA WITH EXPANSION BOARD 13-11-608 Page 40...
  • Page 46 302EWD546-B (Ref. Drawing) Page 2 of 2 13-11-608 Page 41...

  • Page 47: Figure 4-6 - Wiring Diagram - Full Voltage Less Starter

    303EWD546-B (Ref. Drawing) Page 1 of 2 Figure 4-6 – WIRING DIAGRAM – FULL VOLTAGE LESS STARTER 13-11-608 Page 42...
  • Page 48 303EWD546-B (Ref. Drawing) Page 2 of 2 13-11-608 Page 43...

  • Page 49: Section 5, Lubrication

    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 50: Figure 5-1 - Oil Level Gauge

    LUBRICANT MAINTENANCE INTERVAL - The recommended oil change interval is 2000 hours or one year, whichever comes first, based on normal operating conditions. The refill capacity of the oil system is 5 gallons (19 liters). NOTICE IF OIL IS ANALYZED at the end of a maintenance interval (2000 hr. max.), and is found in good condition, it may be used for the next 2000 hour interval –...

  • Page 51: 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 52 WARNING Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water. Improper cleaning may damage the element. NOTICE Never operate the unit without the element. Never use elements that are damaged, ruptured or wet. Never use gaskets that won’t seal. Keep spare elements and gaskets on hand to reduce downtime.

  • Page 53: Section 7. Coupling

    SECTION 7 COUPLING Figure 7-1 – INSTALLATION OF COUPLING CUSHIONS DANGER Rotating machinery can cause personal injury or death. Turn the unit completely off, open the main disconnect, tag and lockout before servicing the coupling. COUPLING - The motor and compressor are direct connected by a resilient type flexible coupling with several individual cushions, Figure 7-1.

  • Page 54: 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 55 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 56 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°...

  • Page 57: 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 58 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 59 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 60 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.

  • Page 61: 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 62 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 63 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 • •...

  • Page 64: Section 10, Troubleshooting

    SECTION 10 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control box. 2. Replace fuse. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
  • Page 65 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. 13-11-608 Page 60...

  • Page 66: 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 67 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 68 Message Action Needed EXTERNAL DEVICE The oil pressure switch detected low (5 psig) oil pressure and opened, removing 120 volts from J1-4 at the expansion board. Investigate the cause for the event or replace the switch. If other devices are series-wired to the oil switch, each event that triggers the corresponding switch must be investigated and the switch reset or replaced.
  • Page 69 Message Action Needed LV RELAY See “External Device”, page 24, for details. MOTOR CONTACT The controller has attempted to turn off the compressor, but is still receiving a return signal from the starters’ auxiliary contacts. Check that the starter operates freely and that the contact blocks are properly installed on the starter. MOTOR OVERLOAD One of the motor overload relays within the electrical control box has tripped, indicating high motor shaft load, low voltage, or excessive imbalance in the...
  • Page 70 Message Action Needed WATER PRESS See “External Device”, page 24, for details. ZERO XDUCER Signal voltage has fallen too low at transducer: (A) Final discharge, (B) Water Injection, or (C) Reservoir. This error is usually the result of the transducers being improperly zeroed.
  • Page 71 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.

  • Page 72: 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 73 INDEX Air Filter, Section 6 ............46 Cooling Water Control Devices .......12 Air Flow In The Compressor System ......1 Cooling Water Piping ..........12 Auto Sentry W Controller Cooling Water Specifications ........10 Alarm Relay..............34 Water Flow Requirements........11 Automatic Sequence Change ........32 Water Quality..............11 Auxiliary Shutdown............34 Water System ...............1 Configuration Adjustments ........28...
  • Page 74 Water-Cooled Models ..........19 High Water Level ............23 Motor Protective Devices..........23 Other ................24 RO Water Filtration, Section 8 ........49 Power Failure .............24 General Information...........49 Water Filter Differential Pressure......23 Initial Set-Up And Operation ........52 Starting & Operating Procedures, Section 3....17 Maintenance...............53 Starting The Unit............19 Principles Of Operation..........49 Stopping The Unit............19 RO Membrane............55...
  • Page 75 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 76 For additional information contact your local representative or For additional information contact your local representative or Gardner Denver Compressor and Pump Division, Gardner Denver Compressor and Pump Division, 1800 Gardner Expressway, Quincy, Illinois 62301 1800 Gardner Expressway, Quincy, Illinois 62301...

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