Gardner Denver ELECTRA-SCREW 60 HP Service Manual Download

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Summary of Contents for ELECTRA-SCREW 60 HP

Page 1: ...07 8th Edition ELECTra SCREW STATIONARY BASE MOUNTED COMPRESSOR 60Hp Models ECK_ K ESK 75 HP Models ECK_L ESL 100 HP Models ECK_M ESM 13 9 607 GARDNER DENVER COOPER INDUSTRIES INDUSTRIAL MACHINERY DIV...

Page 2: ...provided under the terms of this warranty are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such parts were original components there...

Page 3: ...tion 2 1 Air Filter 3 1 6 1 8 1 Air Filter Heavy Dutyj 6 1 AI RFILTERS SECTION6 6 1 Air Flow 1 1 Air Oil Discharge Temperature 5 8 Air Oil Systems Flow Diagram 5 1 Air Pressure Adjustment Operating Au...

Page 4: ...neral Controls 4 1 GENERAL INFORMATION SECTION 1 1 1 General installation 2 1 Grease Recommendations 2 6 Grounding 2 6 Heat Exchanger Water Cooled Compressor Oil Cooler 5 4 Heat Exchanger Water Flow C...

Page 5: ...servoir Check Valve 0il 4 8 Reservoir Drain Oil 2 2 Reservoir Oil 5 5 Reservoir Pressure Switch 4 12 Rotation 3 1 Running Clearances 10 10 Safety Devices 4 1 Safety Valve 4 8 Sectional View of Compres...

Page 6: ...he main rotor lobe enters the secondary rotor groove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Vo...

Page 7: ...13 9 607 Section 1 Page 2...

Page 8: ...60 56 76 70 54 48 t FIGURE 1 2 13 9 607 Section 2 A75119 FIGURE 2 2 TYPICAL COMPRESSOR ROOM LOCATION The compressor should be installed where ever possible in a clean well lighted well ventilated area...

Page 9: ...penetrates the em closure At the time of installation other openings for electrical conduit oil drain piping and water piping are to be cut into the enclosure at convenient positions for con nection...

Page 10: ...of the cooler with plywood should be satisfactory 3 Lo Demand operation should be used in extreme en vironments SAFETY VALVE I A T II b AIR RECEIVER GAUGE OUTLET 3 411 1 DROP LEGS i RAIN VALVES THIS T...

Page 11: ...ve to the aftercooler and passes through the aftercooler then the heat exchanger and finally exits through the water flow control valve See Section 5 for a discussion of the functions and setting of t...

Page 12: ...at allowable through the heat exchanger Model ESK ECKSK ESL ECKSL ESM ECKSM U S Gallon Minute Water Temperature Max To Heat Exchanger imum Water 60 F 70 F 80 F 90 F Flow 5 5 6 8 9 1 13 6 40 8 6 9 8 6...

Page 13: ...depends in large measure on the bearings and timely lubrication The following charts show the recommended grease csualities and reareasina intervals for motor equipped w ith ball additional informatio...

Page 14: ...ater prior to initial start up of unit Electrical Check the wiring diagrams furnished with the unit to be sure it is properly wired See Section 4 Controls and Instruments for general wiring diagrams S...

Page 15: ...manual water inlet valves Open the air service valve Unit Operating On Automatic Start iStop If the unit is operating close the air service valve allow the unit to build up to full receiver pressure a...

Page 16: ...All four control systems incorporate these safety devices Motor Protection Devices Overload heaters are furnished for the starter in the voltage range specified There are three 3 overloads in the star...

Page 17: ...SET OFF ON ON T 7 CONSTANT SPEED CONTROL AE 4ccQQL R4c S Q 4 3 LW VJ E S g 13 I 3 n 12 L1 L2 c 6 L 7 _ MTR OIL c COOLER 13 ON 4 0 APS t M3 A b 12 LcOOLER Ml 5 Ml 6 oMp 4 BDv lR AFT COOLER IF USED L KK...

Page 18: ...SFORMER 2 CA 59 250vA OR 2 2A139 750vA1 H3 H4 230v 460v 575v 24 CA160 250vA OR 2 140 750 VA 208V 2 V 3 V r m 1 5 l OVER TEMPERATuRE MANuAL RESET BUTTON ON TEMPERATuRE SWITCH PRESS TO RESET OFF 6 L 1 C...

Page 19: ...2 120 L1 L2 5 14R 1 4 9 11 13 A Mw H N 1S REMOTE MOUNTED AND WIRED BY CUSTOMER 4 2 4R G 5645 H DTS n s COMP c NC C N C DSA 4 13A SEE NOTE C AFTER COOLER E c 4L FJ Li3_____________ _ _ l m FTC LER POWE...

Page 20: ...D WITH FuSE BLOCK AND FuSES h 13 r l 2Y T I 12 2 r L 0L2 3 2 DSA I i w L J D75292 13 DSA rTl 2A SEE NOTE C AFTER COOLER Tir T POWER SUPPLY r Li2 47FD ___ 3 12B LI L2 6 4 14R 2 9 11 REMov E POWER SUPPL...

Page 21: ...e diagram on inside of starter or diagram supplied with starter D 1 An ESG66459 Electrical Group with Buss Lim E E3 F G H J When the compressor motor starter is remote mounted the starter coil voltage...

Page 22: ...et Button Jumpers o n Terminal Blocks T B Indicating Light 24CA40 Sylvania 120 PSB or Equal A P S Air Pressure Switch 2009353 NEMA 1 Alternate for NEMA 4 12 88A303 Reset Set and or Reset per order Exc...

Page 23: ...JUST VALVE BELOW 40 PSIG Loosen locknut on adjusting screw Turn set screw in to increase or out to decrease minimum pressure to be held Hold set screw at desired point and tighten locknut CHECK VALVE...

Page 24: ...INSTRUMENT PANEL CONSTANT SPEED CONTROL 1 Loosen the subtractive pilot locknut Back the ad justing screw out about one turn 2 Open the air service line valve and bleed air from the unit so that the co...

Page 25: ...re switch cover WARNING DO NOT SET THE FULL PRESSURE MOTOR stop POINT HIGHER THAN THE MAXIMUM STAMPED ON THE UNIT NAMEPLATE MINIMUM OPER A TING PRESSURE IS 65 PSIG BLOCK V RING BLEED LINE Electrical W...

Page 26: ...stant Speed When the timer is set in the space between 30 and O the unit will run continuously The inlet valve will open and allow the compressor to load when the pressure switch low setting is reache...

Page 27: ...d pressure 2 Close the shop air line valve and allow the air reciever pressure to build until the compressor unloads 3 Note air receiver pressure shown on the instrument panel gauge If not the pressur...

Page 28: ...roughout the system A B c D E F G H J K L M N P Q QI R s T u v w x Y z AA SYNTHETIC LUBRICANTS Mot or Compressor Alr Filter Oil Reservoir Oil Separator Oil cooler Fan and Motor Thermal Control Thermos...

Page 29: ...8000 is necessary in the temper ature range of 10 F to 40 F The lighter viscosity lubri cant must have foam depressant oxidation and corrosion inhibiting characteristics equal to those of GD800 and me...

Page 30: ...commended Use the replacement element shown on the filter tag or refer to the parts list for the part number Use the following procedure to replace the filter element 1 Loosen the clamp screws remove...

Page 31: ...RVOIR OIL OUT FIGURE 5 5R THERMOSTATIC MIXING VALVE A58407 Some models use a nonadjustable valve shown in Figure 5 5 Et The valve element is set to hold oil injected into the compressor at a minimum o...

Page 32: ...rrect installation position The bulb MUST be placed in the horizontal oil pipe so that the groove is in the UP position on the top side of the bulb The valve will not operate if the groove is not prop...

Page 33: ...gauging or by inspection In dual oil separator systems the second stage inner smaller element may not need replacement as often as the first stage element Careful inspection or pressure differ ential...

Page 34: ...material adhering to top plate or reservoir tower flange from old separators Connect the flexible oil return tubing to the metal pickup tube in the first stage separator Make sure fitting is tight at...

Page 35: ...gree for degree with the ambient temperature For water cooled oil systems the water flows at various temperatures outlined in Section 2 will hold the oil inlet temperature below the 80 F ambient tempe...

Page 36: ...1 C74831 FILTER BODY w FIGURE 2 6 HEAVY DUTY AIR FILTER HEAVY DUTY AIR FILTER Figure 2 6 Extremely dusty locations require a heavy duty two stage dry type air filter If a unit has been so equipped se...

Page 37: ...elements in a protected area free from damage dirt and moisture Handle allfilter parts with care Filter E1ement Life The element should be replaced after six cleanings or if a Visual inspection indica...

Page 38: ...ling body Motor shaft and compressor shaft ends are set flush with the inner face of the coupling body Dis tance between the shaft ends will be approximately 1 Position the compressor and motor so tha...

Page 39: ...the opposite flange at the three points of proximity Shim and adjust the motor and compressor so that the gaps are uniform Views A and C Figure2 7 Max imum recommended gap variation is 015 4 Check pa...

Page 40: ...re faces and the fan and fan motor If clean ing is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflam mable safety solvent in a direction opposite that...

Page 41: ...overloads COMPRESSOR DOES NOT UNLOAD check 1 Magnetic unloader or pressure switch for malfunction 2 Control lines for restriction 3 Air leaks in control system 4 Inlet valve stuck 5 Pilot or pressure...

Page 42: ...10 COMPRESSOR OVERHAUL 2 Remove coupling half from drive shaft remove key Check for and remove any burrs from shaft Remove seal retainer plate and seal seat from seal housing oil seal seat may stick i...

Page 43: ...not to damage gear teeth 6 Support gear cover with hoist Remove all gear cover I I I H T DRAULIC JACK ADAPrOR PLATE kETCH A to inlet end plate screws With two 2 jack bolts one 1 either side jack cover...

Page 44: ...ge end coverplate gasket may be used to lay out the four 4 holes at the corners of the plate 12 Remove bearing retainer plates and outer race shims With hydraulic jack and plate rigged as shown press...

Page 45: ...E RECOMMENDATIONS All screws on the compressor should be tightened to the torque values shown in the above table to insure a correctly assembled and leak free machine All the hex head cap screws used...

Page 46: ...Record measure ments of each bore in relationship to rotor mea surements in Step 4 Inspect shoulder of bore for burrs to assure proper seating of bearing If deep anvil outside micrometer is available...

Page 47: ...Faces marked SUPPORT go together This gives a fixed bearing holding rotors in a fixed position Observe disassembly tags so bearings go back in same relation if original bearings are used Never use wo...

Page 48: ...and inlet opening to keep out dirt place assembly in horizontal position on substantial blocking for the following steps of assembly Lower unit carefully to prevent damage to internal parts 16 Lightly...

Page 49: ...in keyway of shaft and gear Key may have to be dressed to fit one or both keyways Stand drive shaft on coupling end or clamp in vice making sure shaft is protected to pre vent burrs HEAT IN OIL OR ELE...

Page 50: ...ing body Tighten the set screw over the key securely A WARNING Do not drive coupling body on shaft as damage to beating and coupling face will result It may be necessary to warm coupling slightly to s...

Page 51: ...Shaft Inner Bearing Length 869 956 Drive Shaft Gear Diameter 2 2495 2 2490 Drive Shaft Gear Diameter Length 1 380 1 420 Drive Shaft Coupling Diameter 2 125 2 124 Drive Shaft Coupling Diacneter Length...

Page 52: ...Litho in U S A 12C 3 33 GARDNER DENVER INDUSTRIAL MACHINERY DIVISION 1800 GARDNER EXPRESSWAY QUINCY ILLINOIS 62301 217 222 5400 SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES...

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