Gardner Denver PUREAIR EWD99E Operating And Service Manual Download

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GARDNER DENVER

13-11-608

Version: 05

August 1, 2003

PUREAIR



OIL-FREE ROTARY SCREW

COMPRESSORS

MODELS

EWD99E

OPERATING AND

SERVICE MANUAL

Summary of Contents for PUREAIR EWD99E

Page 1: ...GARDNER DENVER 13 11 608 Version 05 August 1 2003 PUREAIR OIL FREE ROTARY SCREW COMPRESSORS MODELS EWD99E 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: ...Danger 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 prese...

Page 4: ...Information 1 Section 2 Installation Coolers And Water Systems 7 Section 3 Starting Operating Procedures 17 Section 4 Controls Instrumentation 20 Section 5 Lubrication 44 Section 6 Air Filter 46 Sect...

Page 5: ...erval 16 Figure 4 1 Auto Sentry W Controller Display 22 Figure 4 2 Flow Chart For Setup Programming 25 Figure 4 3 Auxiliary Pressure Switch Receiver Unloaded Pressure Tabulation 35 Figure 4 4 Wiring D...

Page 6: ...duced and pressure increases Water is injected into the cylinder to remove the heat of compression and seal internal clearances Volume reduction and pressure increase continues until the air water mix...

Page 7: ...13 11 608 Page 2 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED 302EWD797 A Ref Drawing...

Page 8: ...13 11 608 Page 3 Figure 1 3 PACKAGE ILLUSTRATION WATER COOLED 303EWD797 A Ref Drawing...

Page 9: ...13 11 608 Page 4 Figure 1 4 WATER COOLED SCHEMATIC 300EWD797 D Ref Drawing...

Page 10: ...13 11 608 Page 5 Figure 1 5 AIR COOLED SCHEMATIC 301EWD797 D Ref Drawing...

Page 11: ...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 12: ...rge manifold piping as lifting points DANGER The eyebolts or lugs provided on the motor are for lifting the motor only and should not be used to lift any additional weight All eyebolts must be securel...

Page 13: ...nit with the standard enclosure requires sufficient flow Figure 2 2 page 8 for the compressor water aftercooling system and for electric motor cooling Do not block the air flow to and from the unit Al...

Page 14: ...support for the base OIL RESERVOIR DRAIN The oil drain is piped from the bottom of the reservoir to the frame See Package Illustrations on pages 2 and 3 for details The drain connection is about 4 inc...

Page 15: ...peak efficiency the incoming water supply must meet a number of requirements Please refer to the RO Water Filter Section 8 of this manual for details WARNING Back flow Preventers must be installed on...

Page 16: ...adequate cooler core performance Water Cooler Pressure 40 HP 50 HP 60 HP Water flow for 30 F rise gpm All 7 2 8 9 10 6 Water Flow for 15 F rise gpm All 14 4 17 9 21 3 Maximum water flow and pressure l...

Page 17: ...e 0 to 8 index scale Use the compressor discharge temperature display to monitor the adjustments made to water flow These valves are delicate instruments Care must be used when handling the capillary...

Page 18: ...hart Figure 2 4 page 13 Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a remote location Length of Inlet Line Diameter of Pipe Size 0 to 1...

Page 19: ...of the checks One half hour of loaded operation is usually sufficient to reach level out operating temperatures Air and Water Discharge Temperature 120 F to 155 F Read on the AUTO SENTRY W control pan...

Page 20: ...dure should be used in regreasing 1 Stop the unit 2 Disconnect tag and lockout the unit from the power supply 3 Remove the relief plug and free hole of hardened grease 4 Wipe lubrication fitting clean...

Page 21: ...o 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 6 Months Up to 150 HP 112 kW 4...

Page 22: ...ons NOTICE 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 filt...

Page 23: ...l Water Fill Adjusting RO Timer Your 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 Ensur...

Page 24: ...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 DA...

Page 25: ...to interrupt and restart the unit based on controls by others When stopped by these controls the display indicates remote stop WARNING Automatic restarting or electrical shock can cause injury or dea...

Page 26: ...valves for flow modulation See Subtractive Valve page 35 under Other Control Devices for details Sequence Mode Operation This mode provides for communication between controllers operating only as man...

Page 27: ...DISPLAY 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 ar...

Page 28: ...freezing The thermistor probe is also checked for open or shorted circuits and the display will indicate a fault if found CAUTION Machine damage will occur if compressor is repeatedly restarted after...

Page 29: ...osed contacts which open to shut down the package Additional external devices must be wired in series with the oil pressure switch Triggering anyone or more of the external devices will be confirmed b...

Page 30: ...13 11 608 Page 25 Figure 4 2 FLOW CHART FOR SETUP PROGRAMMING 300EWC1255 Ref Drawing...

Page 31: ...programming This enters the adjustments menu The adjustments are broken into five groups as shown in Figure 4 2 page 25 To select a group press or until the desired group is shown on the bottom line...

Page 32: ...SETUP if service was performed early Press ENTER to proceed 3 This completes the maintenance adjustments The controller will return to the main adjustments menu Sequence Adjustments See SEQUENCING COM...

Page 33: ...the pressure from reaching this limit 2 In the top line REMOVE SYS PRESS is displayed The bottom line displays the current pressure being sensed at the package discharge At this point steps must be t...

Page 34: ...or user furnished shutdown devices and press ENTER to proceed 7 This completes the unit setup adjustments The controller will return to the main adjustments menu OTHER CONTROL FEATURES Auto restart af...

Page 35: ...ave its pigtail plugged into the unused jack All installations will have two such units Operation 1 ESTABLISHING THE INITIAL SEQUENCE Operation of compressors in sequence requires only selection of th...

Page 36: ...ystem pressure was below 90 PSI If air demand increases again the pressure will have to fall below 90 PSI for only 10 seconds more to start unit 3 As was previously stated a lag compressor s unload po...

Page 37: ...ant pressure efficiently with sequencing The AUTO SENTRY W sequencing system will automatically adjust the system to prevent over pressures in any individuals The AUTO SENTRY W sequencing system lets...

Page 38: ...STOP RESET key has been pressed to place the controller in the READY state When the contact is opened turned off operation depends on how the controller has been programmed and what it is doing prior...

Page 39: ...ta communications are accessible with a PC or PLC with an appropriate communications port For protocol information request Drawing 301EWC1255 OTHER CONTROL DEVICES In addition to the electronic contro...

Page 40: ...r cooling and sealing The valve also prevents back flow of system air when the compressor is not running Inlet Valve b This device modulates the flow of air entering the compressor and checks the back...

Page 41: ...level triggers the switch It is located in the starter enclosure Discharge Thermistor v This device measures the compressor discharge temperature The AUTO SENTRY W controller uses this measurement for...

Page 42: ...ormer This 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 informatio...

Page 43: ...13 11 608 Page 38 Figure 4 4 WIRING DIAGRAM FULL VOLTAGE WITH EXPANSION BOARD 301EWD546 B Ref Drawing Page 1 of 2...

Page 44: ...13 11 608 Page 39 301EWD546 B Ref Drawing Page 2 of 2...

Page 45: ...13 11 608 Page 40 Figure 4 5 WIRING DIAGRAM WYE DELTA WITH EXPANSION BOARD 302EWD546 B Ref Drawing Page 1 of 2...

Page 46: ...13 11 608 Page 41 302EWD546 B Ref Drawing Page 2 of 2...

Page 47: ...13 11 608 Page 42 Figure 4 6 WIRING DIAGRAM FULL VOLTAGE LESS STARTER 303EWD546 B Ref Drawing Page 1 of 2...

Page 48: ...13 11 608 Page 43 303EWD546 B Ref Drawing Page 2 of 2...

Page 49: ...A lubricant analysis program for a periodic check of lubricant quality and remaining life can maximize the change interval Material Safety Data Sheets MSDS are available for all AEON lubricants from...

Page 50: ...sor against damage by contaminated lubricant Oil Filter Maintenance Interval The oil filter element should be replaced when the oil is changed The screw on type cartridge must be set firmly against th...

Page 51: ...rdner Denver compressor units Genuine parts are available through your authorized Gardner Denver distributor To service 1 Remove the wing nut and pull out the filter element 2 Visually inspect the ele...

Page 52: ...nspection indicates a rupture crack or pin hole in the pleated media Inspection should be done by placing a bright light inside the element 2 Pressure drop across a filter with a freshly cleaned eleme...

Page 53: ...e collar is installed on the shaft behind one coupling body 2 Assemble the motor on the compressor 3 Working through the coupling guard opening center the coupling over the gap between the shafts main...

Page 54: ...vice 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 compr...

Page 55: ...er 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 of...

Page 56: ...ter to discharge 1 gal of treated water Working pressure 40 to 100 psig Working temperature 40 F to 104 F Holding tank capacity 3 0 gal 20 psig membrane air pressure 90 psig feed 2 5 gal 20 psig membr...

Page 57: ...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 58: ...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 59: ...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 60: ...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 61: ...e water from the filter housing by either 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 hous...

Page 62: ...ensate in the control air filter bowl Use the manual 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...

Page 63: ...Seals Change Oil Filter Element 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 Se...

Page 64: ...n 2 High discharge temperature switch malfunction 2 Replace switch 3 Blown fuse in starter control box 3 Replace fuse investigate if fuses continue to blow 4 Motor starter overload heaters trip 4 Rese...

Page 65: ...2 Provide unrestricted supply of cooling air 3 Clogged water injection filter or cooler interior 3 Replace filter or clean cooler 4 Insufficient water cooling flow 4 Cooling water must meet minimum fl...

Page 66: ...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 67: ...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 68: ...solenoid valves and all other control devices to find the cause for the inlet valve not closing Other possible causes are loose connections to the transducer electrical noise and transients or imprope...

Page 69: ...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 70: ...into an operating mode e g AUTO press the STOP RESET key to put the control into the READY state then start by pressing the START key In AUTOMATIC and SEQUENCE modes compressors will not start until...

Page 71: ...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 72: ...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 73: ...Switches 36 Water Pressure Relief Valve 36 Water Solenoid Valves 36 Controls Instrumentation Section 4 20 Coolers Water Systems Section 2 7 Compression Injection Water System Check 14 Compressor Water...

Page 74: ...ncy Stop 23 External Device 24 High Pressure 23 High Temperature 23 High Water Level 23 Motor Protective Devices 23 Other 24 Power Failure 24 Water Filter Differential Pressure 23 Starting Operating P...

Page 75: ...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 76: ...epresentative 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...

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