Gardner Denver Electra-Screw EDEQHF, Operating And Service Manual

Page 1: ...GARDNER DENVER 13 8 610 3rd Edition January 1994 ELECTRA SCREW STATIONARY BASE MOUNTED COMPRESSORS MODELS EDEQHF 40 HP EDEQJF 50 HP 60 HZ OPERATING AND SERVICE MANUAL...

Page 2: ...in Gardner Denver and Joy compressors Repair and maintenance kits designed with the necessary parts to simplify servicing Your compres sor Authorized distributor service technicians are fac tory trai...

Page 3: ...te the presence of a hazard which can cause severe personal injury death or substantial propery damage if the warning is ignored I CAUTION Caution is used to indicate the presence of a hazard which wi...

Page 4: ...on Principal l l Compressor Oil Cooler 5 5 Compressor Oil Filter 5 4 Compressor Oil System 5 1 Compressor System Air Flow l l CONSTANT RUN Button with LED 4 3 Control Piping 2 3 CONTROLS AND INSTRUMEN...

Page 5: ...r 5 5 Oil Reservoir Drain 2 2 Oil Reservoir Filling 5 3 Oil Separator 5 5 Oil Separator Inspection 5 6 Oil Separator Pressure Differential Gauging 5 5 Oil Separator Removal 5 6 Oil Sight Gauge 4 2 5 3...

Page 6: ...h LED 4 3 Auto Sentry S Controller with Keypad 4 3 CHANGE AIR FILTER LED 4 4 CHANGE SEPARATOR LED 4 4 CONSTANT RUN Button with LED 4 3 Emergency Stop Pushbutton 4 3 HIGH AIR TEMPERATURE LED 4 3 Hourme...

Page 7: ...n 2 2 Control Schematic 4 1 Inlet Valve 4 2 Minimum Pressure Check Valve 4 2 Definitions of Error Messages 4 4 Pressure Chati 4 6 Subtractive Pilot Closed 4 6 Subtractive Pilot Opened 4 6 Maximum Setp...

Page 8: ...e main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volu...

Page 9: ...LVE 1 M A r III II F T F RI A 1111111111 A Uu 11111 IIIIl i l l i pflLF 1111111111 I II o IL c o0 LER I OIL RESERVOIR 1 By_pAss pipING OIL FILTER THERMAL CONTROL MIXING VALVE FIGURE 1 2 PACKAGE MINIMU...

Page 10: ...AIR OIL SEPERATOR OIL FILLER PLUG AIR FILTER I 1 OIL LEVEL FLOAT GAUGE RESERVOIROIL DRAIN FIGURE 1 3 PACKAGE OIL LEVELGAUGE SEPARATOR AIR FILTER 13 8 610 Section 1 Page 3...

Page 11: ...STARTER CONTROL BOX CONTROL PANEL HOURMETER EMERGENCY STOP BUTTON FIGURE 1 4 PACXAGE CONTROLLER STARTER BOX 13 8 610 Sectionl Page4...

Page 12: ...covers the thermo static mixing valve or break any connections etc in the compressor air or oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may...

Page 13: ...ore working on the unit this machine is automatically controlled and may start at any time An Excess Flow Valve should be on all compressed air supply hoses exceed ing 1 2 inch inside diameter OSHA Re...

Page 14: ...DEATH ROTATING MACHINERY CAH CAUSE 1NJUR OR DEATH KEEP ALL GUAROS AND SAFETY DEVICES IN PLACE a 211EAQ077 AIR AND OIL UNOER PRESSURE WILL CAUSE SEVERE PERSONAL NJURY OR DEATH HUTDOWN COMPRESSOR ANO EL...

Page 15: ...ICAL SHOCK CAN CAUSE INJURY OR DEATH DISCONNECT ALL CIRCUITS BEFORE WORKING ON THIS CONTROL SEE WIRING DIAGRAM 222EAQ077 ELECTRICAL ARCING CAN CAUSE A FIRE WHEN UNIT IS MOUNTEO ON A cOMBUSTIBLE SURFAC...

Page 16: ...IR COOLED UNIT A combination oil aftercooler is supplied as standard equipment on all air cooled units The air cooled unit with the standard enclosure requires sufficient flow Figure 2 2 for the compr...

Page 17: ...iner ENCLOSURE The compressor electric motor oil cooler and afTercooler are mounted insidethe enclosure Service doors are provided for maintenance access Be sure to allow enough space around the unitf...

Page 18: ...cycling When used an air receiver should be of adequate size provided with a relief valve of proper setting a pressure gauge and a means of draining condensate MOISTURE SEPARATOR TRAP Since unit is e...

Page 19: ...ode WARNING Failure to properly ground the com pressor package could result in con troller malfunction MOTOR LUBRICATION Long time satisfactory oper ation of an electric motor depends in large measure...

Page 20: ...ical Examples Rating Relubrication Interval Standard One or Two Shift Operation 150 HP Below 18 Months Severe Continuous Operation 150 HP Below 9 Months Very Severe Dirty Locations High 150 HP Below 4...

Page 21: ...on and after shutdown the system will partially drain back into the oil reservoir and the oil level may read higher than when operat ing on load DO NOT DRAIN OIL TO CORRECT on the next loaded cycle or...

Page 22: ...rvice valve customer furnished between the main air system and the check valve on the package 2 If the unit is water cooled open any manual water inlet valves wide open 3 Start the unit by pushing eit...

Page 23: ...on Separator Differential Pressure The Separator dif ferential pressure is continually monitored by the microprocessor controller At a differential of ap proximately 8 PSI the CHANGE SEPARATOR LED lo...

Page 24: ...truction and operation information INSTRUMENTS All units incorporate the following instruments and indicators Oil Level Gauge Figure 1 3 page 3 Section 1 The oil level gauge is located on the side of...

Page 25: ...ault LED s that are il luminated in addition it is used in the procedure to adjust the operating pressure See Adjusting the Operating Pressure The LED is illuminated whenever the unit is stopped for a...

Page 26: ...eadout action during a high temperature condition Alternate y these readouts can be selected to display oil reservoir pressure and sepa rator air temperature To obtain such display while the compresso...

Page 27: ...Pressure the current load setpoint adjust able 50 167 psig Temperature indicating that the pressure value is the load value SteP 6 Raise or lower the load setPoint in the same manner as the unload se...

Page 28: ...the position B If procedure is repeated the transducer zero operation may be bypassed by not pressing STOP RESET while the dashes are displayed C To zero the transducer discon nect the control lines t...

Page 29: ...and downstream line vented Figure 7 4 previous page shows the pilot with valve seat open holding a down stream pressure which is adjustable with the screw In this position it is normal for the valve t...

Page 30: ...5 I 133 150 I 150 I 158 175 I 167 I 175 I 1 NOTE Load setpoint cannot be set within 8 psi of the unload setpoint Minimum operating pressure is 60 65 PSIG FIGURE 4 8 MAXIMUM SETPOINTS FOR AUTO SENTRYS...

Page 31: ...13 8 610 Section 4 Page 9...

Page 32: ...IONS The recommended compres sor lubricant is Gardner Denver AEON 4000 Lubricat ing Coolant which can be used for year round operation except as noted in the High Temperature Operation paragraph below...

Page 33: ...peatedly restart after high temperature stops operation Find and correct the malfunction before resum ing operation AWARNING All materials used in Gardner Denver compressor units are compatible with A...

Page 34: ...up to 180 F 6000 hrs 8000 hrs 180 to 190 F 45OOhrs 6000 hrs 190 to 200 F 3000 hrs 4000 hrs 200 1500 hrs 2000 hrs When operating conditions are severe very dusty high humidity it will be necessary to...

Page 35: ...manner A CAUTION Excessive oil carryover can damage equipment Never fill oil reservoir above FULL marker COMPRESSOR OIL FILTER Figure 1 2 Section 1 page 2 This replaceable element filter is a vital pa...

Page 36: ...provides limited air storage for control and gauge actuation OIL SE COVER OIL SEPA HOUSING PLEATED SEPARATOR OIL RETURN LINE FIGURE 5 5 OIL SEPARATOR COMPRESSOR G D ELIMINATOR OIL SEPARA TOR located...

Page 37: ...l the new gasket Lower the separator into the housing and center the separator on the chamfer Press the separator down into the housing Do not use excessive force as separator damage can occur Place t...

Page 38: ...nutes in warm water with a mild nonsudsing detergent Rinse the element thoroughly with clean water a hose may be used if the water pressure does not exceed 40 psig Inspect the element for ruptures or...

Page 39: ...e minutes Agitate in solution for two more minutes a b c d Mix a sufficient amount of the followin clean i ing solution to allow the element to e fully submerged To one gallon of lukewarm water add fo...

Page 40: ...e the belts over the fan CAUTION Interference between the fan and the orifice can damage equipment Be cer tain the orifice has even clearance around the fan before starting the unit CHECKING BELT TENS...

Page 41: ...is required clean the exterior fin surfaces of the cores by blow ing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow This cleaning operat...

Page 42: ...l box 4 Motor starter overload heaters trip 1 Improperly adjusted control 2 Air leak in control lines 3 Restricted control line 4 Subtractive pilot or blow down valve malfunction 1 2 3 4 5 1 2 3 4 1 2...

Page 43: ...ed too low 4 Minimum pressure valve stuck closed 1 Thermostatic mixing valve stuck open 2 Dirty or clogged cooler face 3 insufficient cooling air flow 4 Clogged oil filter or cooler interior 5 Low Com...

Page 44: ...ured oil separator element 4 Loose assembly 5 Foam caused by use of incorrect oil 6 Inoperative minimum pressure valve 7 Operation at elevated discharge temperatures 8 Scavenge line check valve failur...

Page 45: ...ompressor at a pressure over nameplate pressure 2 Incoming voltage low or high 3 Imbalance voltage check phase to phase 1 Change Separator 2 Verify readings with mechan ical gauges If defective replac...

Page 46: ...5 Set overload to motor name plate amps 1 Clean or replace 1 Measure the AC voltage between wire number 7 and connector 6 at board If the reading is zero replace the vacuum switch 2 Measure the AC vo...

Page 47: ...ressure on the transducer If 460 to 540 volts replace the plug gable connector that connects transducers to the board Measure the DC voltage between the white and black wires of the corresponding tran...

Page 48: ...n the Company s labor rate schedule Labor costs in excess of the Company rate schedules caused by but not limited to location or inaccessibility of the equipment or labor provided by unauthorized serv...

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Page 51: ...act Gardner Denver Machinery Inc 1800 Gardner Expreaaway Quincy Illinois 62301 Telephone 217 Z4 300 Fax 217 224 7814 Specifications subject to change without notice COPYRIGHT 1994 Gardner Denver Machi...