Gardner Denver PUREAIR EWC99C Operating And Service Manual Download

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GARDNER DENVER

13-11-607

Version: 05

August 1, 2003

PUREAIR



OIL-FREE ROTARY SCREW

COMPRESSORS

MODELS

EWC99C

OPERATING AND

SERVICE MANUAL

Summary of Contents for PUREAIR EWC99C

Page 1: ...GARDNER DENVER 13 11 607 Version 05 August 1 2003 PUREAIR OIL FREE ROTARY SCREW COMPRESSORS MODELS EWC99C OPERATING AND SERVICE MANUAL...

Page 2: ...uthorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Master Distribution Center 5585 East Shelby...

Page 3: ...anger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Warning is used to indicate the presen...

Page 4: ...Information 1 Section 2 Installation Coolers And Water Systems 5 Section 3 Starting Operating Procedures 12 Section 4 Controls Instrumentation 15 Section 5 Lubrication 37 Section 6 Air Filter 39 Secti...

Page 5: ...Figure 2 5 Regreasing Interval 11 Figure 4 1 Auto Sentry W Controller Display 17 Figure 4 2 Flow Chart For Setup Programming 20 Figure 4 3 Auxiliary Pressure Switch Receiver Unloaded Pressure Tabulat...

Page 6: ...lobe enters the secondary rotor grove normal volume is reduced and pressure increases Water is injected into the cylinder to remove the heat of compression and seal internal clearances Volume reducti...

Page 7: ...13 11 607 Page 2 Figure 1 2 PACKAGE ILLUSTRATION 307EWC797 B Ref Drawing...

Page 8: ...13 11 607 Page 3 Figure 1 3 AIR WATER SCHEMATIC 308EWC797 F Ref Drawing...

Page 9: ...st be performed only by qualified electricians Open main disconnect switch tag and lockout before working on the control Disconnect the compressor unit from its power source tag and lockout before wor...

Page 10: ...s Failure to observe this warning may result in damage to equipment or personal injury LOCATION The compressor should be installed in a clean well lighted and ventilated area with ample space all arou...

Page 11: ...other sides of unit For continuous efficiency the heat exchanger and aftercooler cores must be periodically cleaned with either vacuum or compressed air If wet cleaning is required shield the motor a...

Page 12: ...rs 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...

Page 13: ...moisture from the trap is piped to the compressor inlet flange INLET LINE Where an inlet line is used between the air filter and the compressor it must be thoroughly cleaned on the inside to prevent...

Page 14: ...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 Since the drain solenoid valve may o...

Page 15: ...eservoir and the cooler Water Injection Cooler Pressure Differential Air Cooled Heat Exchanger 5 to 7 psid Check injection water pressure differential in the same place as temperature See above ELECTR...

Page 16: ...d run for about 20 minutes to expel the excess grease 6 Stop the unit Replace the relief plug 7 Restart the unit WARNING Rotating machinery can cause injury or death Open main disconnect tag and locko...

Page 17: ...f improper lubricants will cause damage to equipment Do not mix different types of lubricants or use inferior lubricants See Section 5 page 37 for lubrication recommendations NOTICE Regular maintenanc...

Page 18: ...ressor inlet When checking motor rotation induce minimum rotation less than one revolution if possible Never allow motor to reach full speed 8 System Pressure Set the controls to the desired unload an...

Page 19: ...l power Toggle PLC run stop mode switch off and on to reset the timer and start the selected fill cycle After the on fill cycle times out the off rest cycle will follow If necessary the mode switch ca...

Page 20: ...l stop An optional control may be wired into the AUTO SENTRY W controller to interrupt and restart the unit based on controls by others When stopped by these controls the display indicates remote stop...

Page 21: ...sequenced and rotated it is not recommended to engage the pneumatic pilot valves for flow modulation See Subtractive Valve page 30 under Other Control Devices for details Sequence Mode Operation This...

Page 22: ...ance 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 These messages are intended to advise of con...

Page 23: ...ition no longer exists Refer to the troubleshooting section for detailed information about each shutdown To resume operation the cause of the shutdown must be corrected and the controller reset by pre...

Page 24: ...cessive pressures are detected in the reservoir or the plant system If unsuccessful a shutdown will occur Shut down will also occur if a defective transducer is detected The display will indicate the...

Page 25: ...13 11 607 Page 20 Figure 4 2 FLOW CHART FOR SETUP PROGRAMMING 300EWC1255 Ref Drawing...

Page 26: ...lect a group press or until the desired group is shown on the bottom line of the display Press ENTER to proceed to the group adjustments detailed below Operation Adjustments 1 In the top line DISPLAY...

Page 27: ...set to a number corresponding to the number of compressors that are currently installed on this air system that also have AUTO SENTRY W controllers It should be noted that all AUTO SENTRY W compressor...

Page 28: ...rge errors are detected the controller will demand that the transducer be checked 3 In the top line REMOVE RES PRESS is displayed The bottom line displays the current pressure being sensed in the rese...

Page 29: ...s and begins counting down when power is restored This time is adjustable in the programming steps noted above This must be at least several seconds but may be set longer to allow other plant loads to...

Page 30: ...uence operating mode during adjustments and a press of the RUN key on each compressor in the system Since the sequencing algorithm includes provisions for automatic replacement of a failed master or l...

Page 31: ...90 PSI for only 10 seconds more to start unit 3 As was previously stated a lag compressor s unload point PSET for short is UNLOAD PRESSURE 3 rotation number 1 Thus in the above example the first lag c...

Page 32: ...r to a lower pressure to prevent this or allow local override of the sequencer by the local pressure control neither of which is desirable in the scheme of maintaining plant pressure efficiently with...

Page 33: ...ally in its selected mode whenever this contact is closed turned on Note that the keypad is always the master control the RUN key must be pressed to place the control into an operating mode The remote...

Page 34: ...icator from either terminal 19 normally open or from terminal 20 normally closed Connect the other side of the indicator to its neutral Serial Communications If units are NOT connected in sequence the...

Page 35: ...25 25 30 30 30 Line Pressure psig 100 125 150 100 125 150 100 125 150 Receiver Pressure psig 41 32 26 46 40 32 51 48 37 Figure 4 3 AUXILIARY PRESSURE SWITCH RECEIVER UNLOADED PRESSURE TABULATION Check...

Page 36: ...eservoir Pressure Transducer t This device measures the discharge pressure from the water cooler The AUTO SENTRY W controller uses this measurement to prevent loaded starts and to monitor coolant pres...

Page 37: ...changes the incoming power voltage to 110 120 volts for use by all unit control devices Two primary and one secondary fuse are provided Refer to adjacent labeling for replacement information Terminal...

Page 38: ...13 11 607 Page 33 Figure 4 4 WIRING DIAGRAM FULL VOLTAGE 305EWC546 B Ref Drawing Page 1 of 2...

Page 39: ...13 11 607 Page 34 305EWC546 B Ref Drawing Page 2 of 2...

Page 40: ...13 11 607 Page 35 Figure 4 5 WIRING DIAGRAM FULL VOLTAGE LESS STARTER 306EWC546 B Ref Drawing Page 1 of 2...

Page 41: ...13 11 607 Page 36 306EWC546 B Ref Drawing Page 2 of 2...

Page 42: ...nt analysis program for a periodic check of lubricant quality and remaining life can maximize the change interval For grease specifications refer to Electric Motor Grease Specifications page 11 Materi...

Page 43: ...IS NOT ANALYZED at the end of any interval it must be changed The drive end bearings of the airend should be lubricated with the prescribed grease every 2000 hours of operation until a small amount co...

Page 44: ...rs on the display accompanied by a yellow indicator in the status area of the keypad Clean every 50 to 150 operating hours depending on dust conditions NOTICE Use only genuine Gardner Denver air filte...

Page 45: ...ts on hand to reduce downtime Store elements in a protected area free from damage dirt and moisture Handle all parts with care Filter Element Life The element should be replaced after six 6 cleanings...

Page 46: ...ove the belt guard and loosen but do not remove the four motor foot nuts Next use the adjusting screws in the motor base to loosen belt tension Remove the belts and replace with new belts Check for co...

Page 47: ...ction Force Pounds Newtons per belt Deflection In Inches mm 20 15 kW 4 6 to 7 1 3 to 1 5 5 16 8 25 19 kW 4 6 to 8 5 1 3 to 1 9 5 16 8 30 22 kW 4 6 to 7 1 3 to 1 5 5 16 8 Figure 7 1 BELT TENSION 3VX BE...

Page 48: ...service life It provides regular repeatable and programmable means to drain water from the close loop system thus flushing away any suspended solids It operates the filtration system independent of co...

Page 49: ...r in the field 4 hour and 8 hour on cycles These cycles allow the field user to fill the reservoir unattended at the end of the on period the cycle freezes in time until the mode switch is toggled off...

Page 50: ...ture 40 F to 104 F Holding tank capacity 5 gal model holds 3 0 gal 10 psig membrane air pressure 90 psig feed 5 gal model holds 2 5 gal 10 psig membrane air pressure 50 psig feed 7 gal model holds 7 0...

Page 51: ...d no suspended solids form To conserve water longer off time cycles may be used if the resulting injection water quality does not exceed 60 ppm and no suspended solids form Adjustment of the timer for...

Page 52: ...fferent water parameters total chlorine free chlorine total hardness total alkalinity and pH in a single paper strip Cat No 27552 50 One other vial with 25 strips monitors total iron Cat No 27453 25 a...

Page 53: ...the valve ff feeding raw water to the RO system Open the raw and RO water test drains gg qq to depressurize the water charge from the reservoir nn and lines Unscrew the filter housing sumps by hand or...

Page 54: ...must be replaced Replacing the RO membrane Turn off the valve ff feeding raw water to the RO system Open the raw and RO water test drains gg qq to depressurize the water charge from the reservoir nn...

Page 55: ...turning the petcock or removing the plug on the bottom of the filter assembly 4 Remove the nut at the top of the filter assembly while holding the filter housing to keep it from dropping When the nut...

Page 56: ...l pet cock to evacuate any accumulation and check the operation of the automatic float valve Cleanse the automatic float valve as needed 4 Check the quality of the raw incoming RO treated and injectio...

Page 57: ...rings Check Water Quality Check Water Flow RO Filter Discharge Check Condensate Flow at Aftercooler Separator Drain Check Condensate Level in Control Air Filter Bowl Check Setting of Buffer Air Pressu...

Page 58: ...ch 3 Blown fuse in starter control box 3 Replace fuse investigate if fuses continue to blow 4 Motor starter overload heaters trip 4 Reset and investigate cause of overload Compressor does not unload o...

Page 59: ...gged cooler face 1 Clean cooler 2 Insufficient cooling air flow 2 Provide unrestricted supply of cooling air 3 Clogged water injection filter or cooler interior 3 Replace filter or clean cooler 4 Rese...

Page 60: ...ed by pressing the STOP RESET key CON The compressor is operating in the Constant Run mode LDM The compressor is operating in the Low Demand mode AUTO The compressor is operating in the Automatic mode...

Page 61: ...n the keypad by the word SHUTDOWN on the top line of the display and one of the following messages on the lower line of the display The red indicator in the Status area will be steadily lit while the...

Page 62: ...transducer electrical noise and transients or improper setting of the high pressure limit HIGH RESVR PRESS Pressure in excess of the programmed high pressure limit has been detected This shutdown will...

Page 63: ...at the auxiliary contact block is properly installed on the starter and wired to connector 1 terminal 4 OPEN THERMISTOR The controller has detected an open connection to the airend discharge thermisto...

Page 64: ...W keypad chassis Compressor will not start To operate the controller must be placed into an operating mode e g AUTO press the STOP RESET key to put the control into the READY state then start by press...

Page 65: ...efer to the operating instructions for further information Display is illegible The LCD contrast is adjustable from all black to all green To adjust find the small adjustment screw located on the larg...

Page 66: ...nk nn under pressurized Adjust membrane air pressure 15 20 psi Storage tank membrane ruptured Replace storage tank Isolation valve pp turned off Open isolation valve Fill valve tt leaking or stuck ope...

Page 67: ...ation Section 1 1 Installation Section 2 5 Air Water Reservoir With Integral Moisture Separator 9 Air Cooled Units 5 Auxiliary Air Receiver 8 Compressor Injection Water System Check 9 Compressor Water...

Page 68: ...initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized ser...

Page 69: ...rvice Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all major cities For parts information contact Gardner Denver Master Distribution Center Memphis TN Telephone 800 245 4946...

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