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Gardner Denver PUREAIR EWD99E, Руководство по эксплуатации и обслуживанию

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13-11-608    Page 44

SECTION 5
LUBRICATION

COMPRESSOR OIL SYSTEM 

 -  The oil reservoir is filled with oil at the factory before shipment.  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.

AEON  lubricants are available through your authorized Gardner Denver compressor distributor.

OIL SPECIFICATIONS

  -  The airend reservoir is factory filled with AEON 9000SP lubricant.  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 your authorized Gardner
Denver distributor or by calling 217-222-5400.

CAUTION

Use of improper lubricants will cause damage to equipment.  Do not mix
different types of lubricants or use inferior lubricants.

CAUTION

Improper equipment maintenance with use of synthetic lubricants will damage
equipment.  Oil change intervals must be adhered to for maximum compressor
protection and efficiency.  See “Maintenance Schedule”, page 56

WARNING

High temperature operation can cause damage to equipment or personal injury.

Do not repeatedly restart the unit after high temperature stops the operation.
Find and correct the malfunction before resuming operation.

Содержание PUREAIR EWD99E

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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