Gardner Denver TWISTAIR EWDQ D, Operating And Service Manual

Page 1: ...SCREW COMPRESSORS DOMESTIC MODELS EWDQ_D 40 to 75 HP AIR COOLED EWDS_D 40 to 75 HP WATER COOLED INTERNATIONAL MODELS EWDQ_E 30 to 55 KW AIR COOLED EWDS_E 30 to 55 KW WATER COOLED OPERATING AND SERVICE...

Page 2: ...er Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Machinery Inc Gardner Denver Machinery Inc Master Distribution Cen...

Page 3: ...will result in economical operation and minimum downtime Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning...

Page 4: ...d of Cooling HORSEPOWER and SERIAL NUMBER see nameplate on unit The Serial Number is also stamped on top of the cylinder flange to the right of the inlet housing All orders for Parts should be placed...

Page 5: ...tions ix Section 1 General Information 1 Section 2 Installation 9 Section 3 Starting Operating Procedures 19 Section 4 Controls Instrumentation 21 Section 5 Lubrication 41 Section 6 Air Filter 45 Sect...

Page 6: ...l 10 Breather 41 Changing Injection Water Filter 16 Check Daily 20 Compressor 1 Compressor Injection Water Cooler Water Cooled Heat Exchanger 14 Compressor Injection Water Inlet Temperature 16 Compres...

Page 7: ...on Motor 17 LUBRICATION OIL COOLER OIL FILTER SEPARATOR SECTION 5 41 Main Starter 33 MAINTENANCE SCHEDULE SECTION 8 48 Minimum Discharge Pressure Valve 31 Moisture Separator Trap 11 Motor Grease Recom...

Page 8: ...ergency Stop 23 External Device 24 High Pressure 23 High Temperature 23 High Water Level 23 Low Oil Pressure 23 Low Water Pressure 23 Motor Protective Devices 23 Other 24 Power Failure 24 Water Filter...

Page 9: ...Injection 14 Water Filter Differential Shutdown 23 Water Flow Control Valve for Heat Exchanger 15 Water Injection Cooler Pressure Differential Air Cooled Radiator 16 Water Cooled Heat Exchanger 16 Wa...

Page 10: ...7 Series Piping 14 Figure 2 8 Parallel Piping 14 Figure 2 9 Water Control Valve 15 Figure 4 1 Auto Sentry ES Display 22 Figure 4 2 Flow Chart for Set Up Programming 25 Figure 4 3 Blowdown Valve 31 Fi...

Page 11: ...otor lobe enters the secondary rotor groove normal volume is reduced and pressure in creases Water is injected into the cylinder to remove the heat of compression and seal internal clearances Volume r...

Page 12: ...13 11 602 Page 2 FIGURE 1 2 COOLER AIR WATER SEPARATOR AND RELIEF VALVE FIGURE 1 3 COMPRESSOR DRIVE MOTOR MINIMUM PRESSURE CHECK VALVE MOISTURE SEPARATOR...

Page 13: ...13 11 602 Page 3 FIGURE 1 4 INLET VALVE ALL FILTERS OIL LEVEL GAUGE FIGURE 1 5 STARTER CONTROL BOX OIL RESERVOIR COOLING VALVE...

Page 14: ...13 11 602 Page 4 FIGURE 1 6 AIR WATER SCHEMATIC FIGURE 1 7 OIL SCHEMATIC...

Page 15: ...plug drain plugs covers the thermostat ic mixing valve or break any connections etc in the compressor air or oil sys tem until the unit is shut down and the air pressure has been relieved D Electrical...

Page 16: ...and lockout be fore working on the unit this machine is automatically controlled and may start at any time D An Excess Flow Valve should be on all compressed air supply hoses ex ceeding 1 2 inch insid...

Page 17: ...13 11 602 Page 7 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 18: ...13 11 602 Page 8 DECALS 216EAQ077 206EWD077 222EAQ077 221EAQ077 208EAQ077...

Page 19: ...OCATION The compressor should be installed in a clean well lighted well ventilated area with ample space all around the unit for maintenance Select a location that provides a cool clean dry source of...

Page 20: ...level Temporary installation may be made at a maximum 10o angle lengthwise or 10_ sidewise Mounting bolts are not normally required However installation conditions such as piping rigidity angle of ti...

Page 21: ...l Dissolved Solids 500 parts per million or Specific Conductance 800 Micormhos cm FIGURE 2 3 ADDITIONAL WATER LIMITATIONS In addition to the requirements of the National Primary Drinking Water Regulat...

Page 22: ...LINE The discharge service line connection on both water cooled and air cooled units is made from the left side at base level from the motor end of the package When manifolding two or more rotary scr...

Page 23: ...alve in the line between the machine and the manifold If a rotary screw and reciprocating compressor are man ifolded together an air receiver must be located be tween the two units Discharge air used...

Page 24: ...anger life caused by tube fouling and corrosion If water warmer than 90_ F 32_ C is used higher com pressor injection water inlet temperatures and high wa ter usage will result Most water systems will...

Page 25: ...eat ex changers to provide internal water system corrosion protection These anodes should be inspected periodi cally and replaced when the zinc has been reduced to about 1 2 inch 12 mm in length WATER...

Page 26: ...temperature of the air at the water injection cooler fan and the cleanliness of the core faces As ambient temperatures and core restric tions increase the injection water outlet temperature will incr...

Page 27: ...lubrication fitting clean and add grease with a hand operated grease gun 5 Leave the relief plug temporarily off Reconnect the unit and run for about 20 minutes to expell the excess grease 6 Stop the...

Page 28: ...Trichloroxypropionic Acid 2 4 5 Tp Silvex 0 01 Total Trihalomethanes 0 1 Toxaphene 0 005 Radionuclides Radium 226 and 228 combined 5 pCi L Alpha Particle 15 0 pCi l Beta Particle 4 mRem year Biologic...

Page 29: ...or lubrication recommendations Regular maintenance and replace ment at required intervals of the oil fil ter air filter and water filter is neces sary to achieve maximum service of this screw compress...

Page 30: ...ls or doors Check all screws and latches for tightness Be sure doors are closed and latched STARTING THE UNIT Observe the following starting procedures Unit Cold If the unit is a water cooled heat exc...

Page 31: ...The display will indi cate if the control is waiting for a reservoir blowdown along with the remaining pressure The controls also delay initial loading of the compressor until a startup delay has been...

Page 32: ...unications cable to circuit board connectors A unit number must be assigned to each unit in this mode but the display will indicate the unit s actual operating ranking The automatic time delay is adju...

Page 33: ...ted from high discharge temperature by a thermistor probe located in the compressor discharge elbow The AUTO SENTRYR ES will shut the compressor down if temperature exceeds 190_ F 88_ C or lower per u...

Page 34: ...adjustments detailed below Note Configuration adjustments are normally re quired only at the time of assembly or after parts have been replaced Unit setup adjustments are normally required only at the...

Page 35: ...13 11 602 Page 25 FIGURE 4 2 FLOW CHART FOR SET UP PROGRAMMING...

Page 36: ...is factory set at 24 This is the number of hours that this machine will stay in the role of master or lead compres sor Normally it is desirable to set this to the same value on all sequenced units to...

Page 37: ...been restored 7 The display now reads JOG MOTOR and indi cates the amount of time to energize the starter Adjust with the or key to the smallest value needed to bump the motor and check rotation 0 1 t...

Page 38: ...e determined by the above formula To ensure that two or more machines do not simulta neously decrement their rotation numbers and simulta neously become masters it is advisable to place the desired ma...

Page 39: ...ressors whose rotation numbers were greater than the missing number Like wise if for whatever reason the master compressor fails to carry out its role all lag compressors begin decrementing their rota...

Page 40: ...ich may cycle in less than 1 2 hour as the motor is always cooled evenly and rapid start cycles are pre vented Alarm Relay The ES controller is provided with an alarm relay which may be connected to a...

Page 41: ...ng which can result in personal injury or machine damage FIGURE 4 3 BLOWDOWN VALVE The valve does not require maintenance or adjustment If the valve fails to function check the valve stem O ring for s...

Page 42: ...owdown System Pressure Transducer This transducer is connected after the minimum pressure valve It con verts the pressure in the plant air system into an electri cal signal for use by the Auto Sentry...

Page 43: ...of controller status It is lo cated on the upper section of the panel next to the keypad This should be used for emergency purposes only use the keypad STOP RESET for normal con trolled stopping Autom...

Page 44: ...13 11 602 Page 34 FIGURE 4 6 CONTROL TUBING SCHEMATIC 206EWD797 A Ref Drawing...

Page 45: ...13 11 602 Page 35 FIGURE 4 7 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE 207EWD797 A Ref Drawing...

Page 46: ...13 11 602 Page 36 FIGURE 4 8 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE 208EWD797 A Ref Drawing...

Page 47: ...13 11 602 Page 37 FIGURE 4 9 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE 209EWD797 A Ref Drawing...

Page 48: ...13 11 602 Page 38 FIGURE 4 10 WIRING DIAGRAM FULL VOLTAGE 202EWD546 REF DRAWING...

Page 49: ...13 11 602 Page 39 FIGURE 4 11 WIRING DIAGRAM WYE DELTA 203EWD546 REF DRAWING...

Page 50: ...13 11 602 Page 40 FIGURE 4 12 AUTO SENTRY ES CONTROLLER DISPLAY...

Page 51: ...ion 8 page 48 Oil under pressure will cause severe personal injury or death Shut down compressor relieve system of all pressure disconnect tag and lockout power supply to the starter before removing v...

Page 52: ...pressor loads and un loads Add oil only when the oil level is at the bottom of the red range on the gauge as read when the compres sor is on Drain oil only when the oil level is in the yellow range wh...

Page 53: ...13 11 602 Page 43 FIGURE 5 2 FLOW DIAGRAM AIR COOLED 202EWD797 B Ref Drawing...

Page 54: ...13 11 602 Page 44 FIGURE 5 3 FLOW DIAGRAM WATER COOLED 203EWD797 A Ref Drawing...

Page 55: ...arm 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 2 8 bar 4 Inspect the element for ruptures or...

Page 56: ...ect the inlet screen and tube for dirt accumulation each time the filter is serviced Clean the tube when required by ramming a clean dry cloth through the tube Wipe the inside of the filter body to re...

Page 57: ...ions Be sure the collar is installed on the shaft behind one coupling body 2 Assemble the motor on the compressor 3 Working through the coupling guard opening cen ter the coupling over the gap between...

Page 58: ...ection opposite that of the cooling fan air flow This cleaning operation will keep the exterior cooling surfaces clean and en sure effective heat dissipation 2 Check the reservoir oil level add oil if...

Page 59: ...er a short time Air Temperature this section page 50 2 High discharge 2 Replace switch temperature switch malfunction 3 Blown fuse in starter 3 Replace fuse control box investigate if fuses continue t...

Page 60: ...inimum pressure valve 4 Disassemble and clean stuck closed valve High discharge air 1 Dirty or clogged cooler face 1 Clean cooler temperature 2 Insufficient cooling 2 Provide unrestricted supply air f...

Page 61: ...lowed AUTO TMR The time remaining of unloaded motor operation ADVISORY TROUBLE SHOOTING GUIDE All advisories are indicated on the keypad by a yellow indicator in the Status area and one of the followi...

Page 62: ...is is that the connector plug has been pulled out Plug the connector back in firmly CHNG H2O FILTER The differential pressure across the water filter has risen to over 40 psig Change the filter to ens...

Page 63: ...d transients or improper setting of the high pressure limit HIGH SYS TEMP This indicates that the controller has detected temperature in excess of the programmed high temperature limit at the package...

Page 64: ...signal from the starter s auxiliary contact If the starter does not pick up when attempting to start check that connector 9 of the controller is plugged in firmly and check the starter coil If the st...

Page 65: ...HOOTING GUIDE The following are recommended service actions Observe all instructions noted elsewhere in this manual All electri cal service is to be performed only by a qualified electrician Symptom R...

Page 66: ...tely sized storage Refer to the operating instructions for further information Display is illegible Extra segments or ghosting of characters indicate damage probably from excessive high voltage Replac...

Page 67: ...ment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedule amounts or labor provided b...

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