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WhisperAir™ Oil-free Rotary Tooth Compressor

Model Series PCC & PCCMD – 50 HP

Powerex • 150 Production Drive • Harrison, OH 45030 • USA

(T) 1.888.769.7979 • (F) 513.367.3125 • www.powerexinc.com

IN594501AV • 02/2016

Page 27 of 32

Troubleshooting

The Powerex Whisper-Air Rotary Tooth compressor has Caution and Emergency modes programmed into the

controller.

The CAUTION modes will allow the compressor to continue to run, but will indicate what the condition is.
An emergency shut-down will occur if conditions are detected that could be damaging to the compressor unit.

Caution Conditions

Problem

Cause

Corrective Action

High Temperature

Ambient temperature too high

Room ventilation inadequate, or no circulation in room so

warm air is being recirculated.

Insufficient cooling

Cooling air inlet or outlet of unit restricted by nearby wall or

other items.

Outlet duct from unit cooling outlet too restrictive. Check

backpressure

Intercooler, oil cooler or aftercooler fins are clogged with dirt

or dust

Poor room ventilation or insufficient room ventilation

Pressure ration of 1

stage to 2

stage is

incorrect

One or both air ends are malfunctioning and providing

insufficient compression

Other

Discharge pressure is too high. (Important for units operated at

high altitude above 3000 ft.)

Low Inlet pressure

Inlet system

Filter element is clogged
Other restriction, check hoses and silencer box. (check remote

inlet if present)

Drain Valve

Electronic drains

Outlet restricted
Malfunction of liquid sensor or solenoid

Maintenance required

Early warning

Message indicates maintenance is required within the next 200

hours

Unit can be operated with a maintenance override, Failure to

perform maintenance may void warranty

Содержание WhisperAir PCC Series

Страница 1: ...mper PD and flows into aftercooler Ca Air cooled in the aftercooler Ca is then discharged to the drain separator for aftercooler DS2 removing the water and is delivered to the air outlet The water separated by the drain separators DS1 DS2 will be discharged through electronic drain valves EV1 EV2 When the compressor switches to unload operation the air trapped in the pulsation damper PD and the hi...

Страница 2: ...tem pressure will continue to rise and the unload control will take over Speed is maintained at 40 while unloaded When demand returns the control will increase speed and reload the compressor If the unit remains unloaded an automatic shutdown will occur after 7 minutes of total run time The system will automatically restart when pressure drops The VFD reduces wear on the intake valve parts reduces...

Страница 3: ...Oil free Rotary Tooth Compressor Model Series PCC PCCMD 50 HP Powerex 150 Production Drive Harrison OH 45030 USA T 1 888 769 7979 F 513 367 3125 www powerexinc com IN594501AV 02 2016 Page 3 of 32 Model Description ...

Страница 4: ...level of ground vibration dB Below 45 the front side of the air compressor above concrete Electrical Equipment Power supply Three phase AC rated voltage 10 60 Hz Starting method Electromagnetic Star Delta starter or VFD Compressor motor Specification Horizontal shaft D flange 3 phase totally enclosed fan cooled 2 pole type F insulation IP55 Power HP 50 Service Factor S F 1 25 Cooling fan motor Spe...

Страница 5: ... The level of ground vibration dB Below 45 the front side of the air compressor above concrete Electrical Equipment Power supply Three phase AC rated voltage 10 60 Hz Starting method Electromagnetic Star Delta starter or VFD Compressor motor Specification Horizontal shaft D flange 3 phase totally enclosed fan cooled 2 pole type F insulation IP55 Power HP 50 Service Factor S F 1 25 Cooling fan moto...

Страница 6: ...e sure the electrical supply is configured and installed according to national and local codes and has local service disconnect that can be easily accessed and operated when maintenance must be performed The Powerex unit does not include a built in power disconnect 7 Do not use this compressor as is to provide breathing air get the rest of this warning from other manuals 8 Make sure the environmen...

Страница 7: ... compressor a Instruction Manual 1 b Air outlet valve 1 c Panel key 2 Moving and Lifting Do not lift or move unit without appropriately rated equipment Be sure the unit is securely attached to lifting device used Moving with a forklift Before moving the compressor remove the front and the back panels and insert forks in the slots Make sure that the forks protrude from the other side of the frame L...

Страница 8: ...Oil free Rotary Tooth Compressor Model Series PCC PCCMD 50 HP Powerex 150 Production Drive Harrison OH 45030 USA T 1 888 769 7979 F 513 367 3125 www powerexinc com IN594501AV 02 2016 Page 8 of 32 Dimension Drawing ...

Страница 9: ...mpressor Model Series PCC PCCMD 50 HP Powerex 150 Production Drive Harrison OH 45030 USA T 1 888 769 7979 F 513 367 3125 www powerexinc com IN594501AV 02 2016 Page 9 of 32 Identification of Major Components Internal components front view ...

Страница 10: ...e Rotary Tooth Compressor Model Series PCC PCCMD 50 HP Powerex 150 Production Drive Harrison OH 45030 USA T 1 888 769 7979 F 513 367 3125 www powerexinc com IN594501AV 02 2016 Page 10 of 32 Internal components rear view ...

Страница 11: ...free Rotary Tooth Compressor Model Series PCC PCCMD 50 HP Powerex 150 Production Drive Harrison OH 45030 USA T 1 888 769 7979 F 513 367 3125 www powerexinc com IN594501AV 02 2016 Page 11 of 32 Details of Outlet Ports ...

Страница 12: ... ventilation system is contained in the condensate 2 When determining the diameter and the length of compressed air outlet pipes consider the pressure drop and allow for the possible expansion of piping network in the future Avoid sharp bends Keep pressure drop to less than 1 5 psi Refer to pipe sizing charts as needed 3 When installing branch pipes make sure the pipes are connected to the top sid...

Страница 13: ...nimum amount of ventilation required to prevent temperature rise is 16 500cfm for model PCC500 3 When installing ventilation fans consider the positions of cooling air inlet and cooling air outlet Inappropriate installation of fans will disturb the air circulation in the workplace and may affect performance of the compressor 4 The ventilation air speed at cooling air inlet must be slower than 980 ...

Страница 14: ...by the compressor enclosure Wiring Internal electrical wiring of the compressor has been completed Refer to the internal wiring circuit diagram that is packed into the control panel in the document pocket A service disconnect must be installed ahead of the compressor The service disconnect may be a circuit breaker RISK OF ELECTRICAL SHOCK Lock out and tag out all sources of energy before servicing...

Страница 15: ...terminal numbers Alarm Signals Terminals on the terminal strip provide external alarm connection points as indicated on the wiring diagram Commissioning Preparation 1 Open the center front panel and the back panels 2 Unscrew the yellow bolts on the gear case and the motor and remove the shipping supports yellow 4 3 Check the oil level on the sight glass a Appropriate oil level is above the center ...

Страница 16: ...or a total run time of 7 minutes the compressor will automatically stop Check the status of the compressor by touching STATUS on the touch panel 3 Open the air outlet valve slowly Check the display of the touch panel to confirm the outlet pressure decreases 4 When outlet pressure drops to the loading pressure the compressor will be automatically switched to loaded operation If the compressor stopp...

Страница 17: ...ker Removal At the end of service life of the compressor perform the following procedures 1 Stop the compressor and close the air outlet valves 2 Disconnect the circuit breaker and then remove the wires 3 Discharge the pressure in pipes connected to air outlet valves 4 Remove the pipes 5 Drain the oil 6 Remove the compressor Control Panel Components Automatic Control Depending on air consumption t...

Страница 18: ...ovides the function that can change the pressure band of the compressor Remote Control Remote control is the function that you can start stop the compressor remotely The setting of the compressor needs to be changed in order to activate the function Use the SET UP menu Automatic Restart after Voltage Failure Automatic restart is the function that automatically restarts the compressor after the vol...

Страница 19: ... up value Motor is overloaded with the emergency value set up Outlet temperature sensor of low pressure high pressure air end or inlet temperature sensor of high pressure air end malfunctions Inlet pressure of high pressure air end malfunctions Outlet pressure sensor of the compressor malfunctions Oil pressure sensor malfunctions Protection device is activated by overload of cooling fan motor or o...

Страница 20: ...y a history of Alarms and warnings SETUP will allow changing the operating pressures and enabling REMOTE CONTROL and AUTOMATIC RESTART The SYSTEM STATUS screen shows the condition of pressure and temperature and other operating parameters At the lower right is the operating indicator that shows whether the unit is loaded unloaded or off waiting for an automatic restart The blue rectangles are butt...

Страница 21: ...larm events You can scroll through the list after pressing SELECT ALARM The Diagnostics screen shows the status of the PLC inputs and outputs This is normally only used to troubleshoot control problems The SYSTEM SETUP screen allows you to customize the operating pressure of your compressor It also allows selection of the Auto Restart mode and operation by remote control The blue fields are button...

Страница 22: ...se screens can help you understand how your system is operating You can use the blue buttons to change the scale and zoom in or out and to move the cursor left and right The indicator field shows the value at the cursor Use the LOAD DEFAULTS button to restore the screen to its factory scale conditions The System Maintenance screen will automatically appear when maintenance is due The screen will g...

Страница 23: ... document inspections and actions may void warranty For items with check measure or clean items with replace to maintain warranty coverage or to assure future reliability Maintenance Schedule Item Action Needed Maintenance Intervals time hours whichever comes first Remarks Every day Every 6 months or 4000 Every year or 8000 Every 2 years or 16000 Every 3 years or 24 000 Every 4 years or 32 000 Eve...

Страница 24: ...ck for presence of oil in condensate discharge Investigate reason for oil content Replace element Y type strainers Clean Replace if damaged or clogged Inlet valve Switching diaphragm replacement Replace Operating diaphragm Replace Valve and spring clean and inspect Replace if damaged Valve and spring replace Slide bearing replacement Shaft Inspect Replace if damaged or worn Temperature sensors Ver...

Страница 25: ...nload silencer clean replace Oil seal at gearbox input shaft Check for leakage Replace Coupling Element Check for wear debris Replace early if significant wear debris is detected Replace Rubber isolation mounts Under compressor gear case feet motor mount and cooler assembly Replace if cracked or damaged Main Motor Check phase to phase resistance Check phase to ground resistance Add Grease to main ...

Страница 26: ...e of filter housing replace with new filter 3 Install filter cover 4 Replace panel Oil and Oil Filter Replacement 1 Run compressor until warm 2 Turn off unit lock and tag out electric power and all sources of energy 3 Connect a hose or position a pan to collect oil form oil drain valve 4 Remove plug and open oil drain valve 5 Remove oil filter and clean surfaces Apply a film of clean oil to new fi...

Страница 27: ...t cooling Cooling air inlet or outlet of unit restricted by nearby wall or other items Outlet duct from unit cooling outlet too restrictive Check backpressure Intercooler oil cooler or aftercooler fins are clogged with dirt or dust Poor room ventilation or insufficient room ventilation Pressure ration of 1st stage to 2nd stage is incorrect One or both air ends are malfunctioning and providing insu...

Страница 28: ...il pump Oil pipe or hose If there is a leak or restriction the oil pressure may be low Contact an authorized Powerex service technician to replace if necessary Oil filter If the oil filter becomes clogged the oil pressure may be low Replace the filter Oil level too low Add oil to proper level Incorrect oil If the oil type is incorrect low oil pressure may result Drain the incorrect oil and install...

Страница 29: ...lve VFD type Confirm unit goes to low speed before unload Contact an authorized Powerex technician to adjust settings or replace VFD Compressor unit runs will not load Pressure not low enough to reach load setting Check settings and actual pressure correct as needed Air leak on signal line to inlet valve Contact an authorized Powerex service technician to repair or replace air signal lines Diaphra...

Страница 30: ...e is high during load operation Failure of high pressure air end Verify the condensate separator and automatic drain is working Water intake into high pressure air end will damage compressor Contact an authorized Powerex technician to replace malfunctioning air end and separator components Mist in Compressor discharge air Condensate drain lines restricted Eliminate restrictions assure that lines r...

Страница 31: ...rranty Powerex warrants and represents all Products shall be free from Defects for the first thirty 30 months from the date of shipment by Powerex or twenty four 24 months from the documented date of startup or eight thousand 8 000 hours of use whichever occurs first During such warranty period Powerex shall be fully liable for all Defects in the Products the Product Defects i e all costs of repai...

Страница 32: ...ulations and be sure that the Product installation and use will comply with them Claims Any non warranty claims pertaining to the Products must be filed with Powerex within 6 months of the invoice date or they will not be honored Prices discounts and terms are subject to change without notice or as stipulated in specific Product quotations Powerex shall not be liable for any delay or failure arisi...

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