Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Troubleshooting
Related Manuals for Gardner Denver TWISTAIR EWDQ D
Summary of Contents for Gardner Denver TWISTAIR EWDQ D
- Page 1 13–11–602 GARDNER DENVER 3rd Edition June, 1996 TWISTAIR OIL–FREE ROTARY 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 –...
-
Page 2: Remanufactured Air Ends
They are ready to respond and assist you by pro- Your authorized distributor can support your Gardner viding fast, expert maintenance and repair services. For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact: Distribution Center: Factory: Gardner Denver Machinery Inc. -
Page 3: Foreword
FOREWORD Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine the owner must exercise care in its operation and main- tenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. -
Page 4: Instructions For Ordering Repair Parts
This book covers the following models: DOMESTIC MODELS: Air Cooled Water Cooled Parts List EWDQHD EWDSHD 13–11–503 EWDQJD EWDSJD 13–11–503 EWDQKD EWDSKD 13–11–503 EWDQLD EWDSLD 13–11–503 INTERNATIONAL MODELS: Air Cooled Water Cooled Parts List EWDQHE EWDSHE 13–11–504X EWDQJE EWDSJE 13–11–504X EWDQKE EWDSKE 13–11–504X... -
Page 5: Table Of Contents
TABLE OF CONTENTS Remanufactured Air Ends ................Foreword . -
Page 6: Index
INDEX Air and Water Discharge Temperature ..Compressor ....... AIR FILTER, SECTION 6 . - Page 7 INDEX Filter, Injection Water, Changing ... . . Motor Grease Recommendations ... Foreword ........Motor Lubrication .
- Page 8 INDEX Piping ....... . . Motor Protective Devices ....Other .
- Page 9 INDEX System Pressure ..... . . Water Cooler, Compressor Injection ..Water Filter Differential Shutdown .
- Page 10 LIST OF ILLUSTRATIONS Figure # Description Page Figure 1–1 Compression Cycle ............Figure 1–2 Cooler, Air/Water Separator and Relief Valve .
-
Page 11: Section 1, General Information
SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSION CYCLE COMPRESSOR – The Gardner Denver Rotary duction and pressure increase continues until the air/ Screw compressor is a single stage, positive displace- water mixture trapped in the interlobe cavity by the ro-... -
Page 12: Figure 1-2 Cooler, Air/Water Separator And Relief Valve
FIGURE 1–2 – COOLER, AIR/WATER SEPARATOR AND RELIEF VALVE FIGURE 1–3 – COMPRESSOR, DRIVE MOTOR, MINIMUM PRESSURE/CHECK VALVE, MOISTURE SEPARATOR 13–11–602 Page 2... -
Page 13: Figure 1-4 Inlet Valve, All Filters, Oil Level Gauge
FIGURE 1–4 – INLET VALVE, ALL FILTERS, OIL LEVEL GAUGE FIGURE 1–5 – STARTER/CONTROL BOX, OIL RESERVOIR, COOLING VALVE 13–11–602 Page 3... -
Page 14: Figure 1-6 Air/Water Schematic
FIGURE 1–6 – AIR/WATER SCHEMATIC FIGURE 1–7 – OIL SCHEMATIC 13–11–602 Page 4... - Page 15 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
- Page 16 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
- Page 17 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–11–602 Page 7...
- Page 18 DECALS 216EAQ077 222EAQ077 206EWD077 221EAQ077 208EAQ077 13–11–602 Page 8...
-
Page 19: Section 2, Installation
SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- age that may have occurred during transit or handling. Report any damage or missing parts as soon as pos- sible. Do not install this compressor in a location that may be subject to tem- peratures below 32 F. - Page 20 13 through 15. the floor and the base bottom must be FOUNDATION – The Gardner Denver Rotary Screw closed with solid material all around compressor requires no special foundation, but should to prevent recirculation of hot air from be mounted on a smooth, solid surface.
-
Page 21: Figure 2-3 Additional Water Limitations
for the doors to open completely. Any of the enclosure doors may be removed by opening the door and lifting it up slightly to disengage the hinges. Water may no longer be potable after The motor inspection service panel is held by two use in the compressor. -
Page 22: Figure 2-4 Inlet Line Lengths
Length of Inlet Line Diameter of Pipe Size 0 to 10 Feet (0 to 3 Meters) ........Same as Compressor Inlet Opening 10 to 17 Feet (3 to 5 Meters) . -
Page 23: Figure 2-6 Aftercooler Approximate Water Flow
AFTERCOOLER (DOMESTIC) Approximate Water Temperature to Heat Exchanger Water Pressure Gallons/minute Maximum Drop @ 90 F Water Flow Water Temp. Model 60 F. 70 F. 80 F. 90 F. GPM* 40 HP EWDSHD 26.0 Less than 1 PSI 50 HP EWDSJD 26.0 for any flow rate... -
Page 24: Figure 2-7 Series Piping
* (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY. FIGURE 2–7 – SERIES PIPING FIGURE 2–8 – PARALLEL PIPING exchanger 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. -
Page 25: Figure 2-9 Water Control Valve
solved solids, to alter the water’s tendency to form scale deposits, or prevent the growth of microorgan- isms. The normal maintenance program for the unit should also include periodic cleaning of the tubes (wa- ter side) of the heat exchanger to remove deposits which enhance fouling and corrosion. - Page 26 bar) water pressure should be mounted in the cooling tions increase, the injection water outlet temperature water outlet line after the compressor cooler. The injec- will increase. The injection water outlet temperature is tion water valve should be wired into the compressor approximately the same as the air discharge tempera- control circuit so that the valve opens to allow water to ture –...
- Page 27 GROUNDING – Equipment must be grounded in ac- Remove the relief plug and free hole of hardened cordance with Table 250–95 of the National Electrical grease. Code. Wipe lubrication fitting clean and add grease with a hand–operated grease gun. Leave the relief plug temporarily off. Reconnect the unit and run for about 20 minutes to expell the Failure to properly ground the com- excess grease.
- Page 28 U.S. EPA National Drinking Water Regulations * Primary Secondary Maximum Contaminant Level Constituents Constituents Parts Per Million Inorganic Arsenic 0.05 Barium Cadmium 0.01 Chromium 0.05 Fluoride Lead 0.05 Mercury 0.002 Nitrate–Nitrogen Selenium 0.01 Silver 0.05 Chloride Copper Iron Manganese 0.05 Sulfate Zinc Organics...
-
Page 29: Section 3, Starting & Operating Procedures
Use only gen- REPLACE OIL FILTER EVERY 8000 HOURS. uine Gardner Denver filters designed and specified for this compressor. Initial fill, or filling after a complete draining of the system, may show the oil level in the yellow “EX- CESS OIL”... - Page 30 9. Operating Mode – Refer to Section 4 for detailed information on the control system. 10. Enclosure – Check for damaged panels or doors. Operation with incorrect motor rota- Check all screws and latches for tightness. Be tion can damage equipment and sure doors are closed and latched.
-
Page 31: Section 4, Controls & Instrumentation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION – The Gardner Denver In any mode, the compressor will start only if reservoir TWISTAIR waterflooded rotary screw compressor is pressure is below 5 psig (.3 bars). The display will indi- prewired with all controls, motor, and starter for the volt- cate if the control is waiting for a reservoir blowdown, age and horsepower at the time of ordering. -
Page 32: Figure 4-1 Auto Sentry-Es Display
plications with long unloaded periods and adequate to each unit in this mode, but the display will indicate the storage to allow the compressor to be stopped for peri- unit’s actual operating ranking. ods. Operation during periods of moderate to heavy The automatic time delay is adjustable from 5 to 20 demands is identical to the low demand mode de- minutes. - Page 33 no keys are pressed for 5 seconds, the display will re- charge temperatures are also monitored, and will pro- vert to its normal mode. vide high temp shutdowns. Shutdown will also occur if the temperature at any of these locations falls below The display is also used as a service reminder for nor- freezing.
- Page 34 Power Failure – Following power interruptions, the required only at the time of unit installation. To prevent controller will remain in a shutdown state (unless pro- accidental access, these will not be available if the grammed for auto restart). “SET” switch is in the up position. The “SET” switch is located beneath the power transformer mounting plate External Device –...
-
Page 35: Figure 4-2 Flow Chart For Set-Up Programming
FIGURE 4–2 – FLOW CHART FOR SET–UP PROGRAMMING... - Page 36 Maintenance Adjustments will stay in the role of “master” or “lead” compres- sor. Normally it is desirable to set this to the same If any service advisories are in effect (yellow AD- value on all sequenced units to equalize running VISORY indicator is on), they will be displayed on hours.
- Page 37 A proper sequencing installation requires two or more compressor and its components will not be adversely Gardner Denver rotary air compressors complete with affected. “AUTO SENTRY –ES” controllers, piped into a com- In the top line, “AUTO RESTART”...
- Page 38 Each control circuit board has two modular jacks which To ensure that two or more machines do not simulta- accept RJ–12 telephone plugs. One jack is vacant, the neously decrement their rotation numbers and simulta- other has a short pigtail plugged into it. To interconnect neously become masters, it is advisable to place the two compressors, plug the cable into the vacant jack on desired master in sequence mode first and wait until...
- Page 39 the first lag compressor (rotation #2) has a PSET of 97 fails to carry out its role, all lag compressors begin PSI; the second lag, 94 PSI, and so on. But look what decrementing their rotation number until a new master happens in an eight compressor installation: The is established.
- Page 40 CONNECTION TO EXTERNAL CONTROLS tion, stopping, or power off conditions. The external connections from the controller are from an isolated The ES controller offers interconnection points for ex- form C (single–pole, double–throw) contact. This al- ternal controls and indicators. This allows simple con- lows control of either a “compressor okay”...
-
Page 41: Figure 4-3 Blowdown Valve
Never paint, lubricate or alter a relief valve. Do not plug vent or restrict dis- charge. Operation of unit with improper relief valve setting can result in severe per- sonal injury or machine damage. Insure properly set valves are in- stalled and maintained. -
Page 42: Figure 4-4 Inlet Valve
FIGURE 4–4 – INLET VALVE valve is used to provide control air pressure from either the reservoir or plant air system, as required during dif- ferent operating conditions. Blowdown Valve (FIGURE 4–3, page 31) – The blow- down valve is a two–way solenoid valve which is piped into the water reservoir outlet ahead of the minimum pressure valve. - Page 43 to monitor compressor temperature and shut down the compressor if a coolant problem is detected. Oil Thermistor – This sensor is located in the oil pip- Automatic restarting or electrical ing and is used to monitor lubrication oil temperature. shock can cause injury or death. Open, tag and lockout main discon- System Thermistor –...
-
Page 44: Figure 4-6 Control Tubing Schematic
206EWD797–A (Ref. Drawing) FIGURE 4–6 – CONTROL TUBING SCHEMATIC... -
Page 45: Figure 4-7 Control Schematic - Compressor At Full Load - Constant Speed Mode
207EWD797–A (Ref. Drawing) FIGURE 4–7 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD – CONSTANT SPEED MODE... -
Page 46: Figure 4-8 Control Schematic - Compressor Unloaded - Constant Speed Mode
208EWD797–A (Ref. Drawing) FIGURE 4–8 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – CONSTANT SPEED MODE... -
Page 47: Figure 4-9 Control Schematic - Compressor Unloaded - Low Demand Mode
209EWD797–A (Ref. Drawing) FIGURE 4–9 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – LOW DEMAND MODE... -
Page 48: Figure 4-10 Wiring Diagram - Full Voltage - 202Ewd546
FIGURE 4–10 – WIRING DIAGRAM – FULL VOLTAGE – 202EWD546 (REF. DRAWING) -
Page 49: Figure 4-11 Wiring Diagram - Wye Delta - 203Ewd546
FIGURE 4–11 – WIRING DIAGRAM – WYE DELTA – 203EWD546 (REF. DRAWING) -
Page 50: Figure 4-12 Auto Sentry Es Controller Display
FIGURE 4–12 – AUTO SENTRY ES CONTROLLER DISPLAY... -
Page 51: Section 5, Lubrication
Oil under pressure will cause severe personal injury or death. Shut down RECOMMENDED LUBRICANT – Gardner Denver compressor, relieve system of all compressors are factory filled with AEON lubricants. -
Page 52: Figure 5-1 Oil Level Gauge
OIL LEVEL GAUGE (FIGURE 1–5, Page 3, and FIG- URE 5–1) indicates the amount of oil in the oil reservoir. Read oil level only when unit is on. In operation the oil level will fluctuate as the compressor loads and un- loads. -
Page 53: Figure 5-2 Flow Diagram (Air Cooled)
202EWD797–B (Ref. Drawing) FIGURE 5–2 – FLOW DIAGRAM (AIR COOLED) -
Page 54: Figure 5-3 Flow Diagram (Water Cooled)
203EWD797–A (Ref. Drawing) FIGURE 5–3 – FLOW DIAGRAM (WATER COOLED) -
Page 55: Section 6, Air Filter
Never use elements that are damaged, ruptured or wet. Never use gaskets that won’t seal. Keep spare Use only genuine Gardner Denver air elements and gaskets on hand to re- filter elements on Gardner Denver duce downtime. Store elements in a compressor units. - Page 56 Pressure drop through a filter with a freshly tube when required by ramming a clean dry cloth cleaned element is below three (3) inches (76 through the tube. Wipe the inside of the filter body to mm) of water with the compressor running at full remove any dirt falling from the inlet tube before rein- load –...
-
Page 57: Section 7, Coupling
SECTION 7 COUPLING (17 N–M) (37 N–M) (1.6 mm to 3.2 mm) FIGURE 7–1 – INSTALLATION OF COUPLING CUSHIONS Working through the coupling guard opening, cen- ter the coupling over the gap between the shafts, maintaining the gap as shown in FIGURE 7–1 be- tween the ends of the jaws on one coupling body Rotating machinery can cause per- and the flange on the opposite coupling body. -
Page 58: Section 8, Maintenance Schedule
SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. The “CHANGE AIR FILTER” LED will illumi- Check for dirt accumulation on oil/aftercooler core nate to signal that the air filter requires servicing or faces and the cooling fan. -
Page 59: Section 9, Trouble Shooting
SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4. - Page 60 3. Clogged water injection filter 3. Replace filter or clean or cooler (interior). cooler. Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13–11–602...
-
Page 61: Section 10, Trouble Shooting Controls
SECTION 10 TROUBLE SHOOTING CONTROLS AUTO SENTRY ES CONTROLLER DISPLAY MODES The normal display indicates the package service pressure, the airend discharge, the total running hours, and one of the following operating modes. The green light will be on for any operating mode, whether the compressor is run- ning or not. - Page 62 ADVISORY TROUBLE SHOOTING GUIDE (Continued) Message Action Needed LOW AMB TEMP The temperature was less than 40 F (4 C) at: (1) the airend discharge, (2) oil injection or (3) the package service connection. Ensure that the compressor is located in a room kept above freezing. SHUTDOWN TROUBLE SHOOTING GUIDE Message Action Needed...
- Page 63 SHUTDOWN TROUBLE SHOOTING GUIDE (Continued) Message Action Needed HIGH OIL PRESS Pressure in excess of the programmed high pressure limit has been de- tected. Check for blockages in the oil injection piping. Other possible causes are loose connections to the transducer, electrical noise and tran- sients, or improper setting of the high pressure limit.
- Page 64 SHUTDOWN TROUBLE SHOOTING GUIDE (Continued) Message Action Needed LOW WATER PRESS The controller has attempted to start and load the compressor, but pres- sure is not building up in the water reservoir. This may indicate either a failure of the motor to turn the compressor, or a failure of the inlet valve to open.
- Page 65 SHUTDOWN TROUBLE SHOOTING GUIDE (Continued) Message Action Needed PUMP/FAN STARTER The controller has attempted to start the pump and fan, but did not receive a return 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.
- Page 66 CONTROLS TROUBLE SHOOTING GUIDE (Continued) Message Action Needed Display indicates If the display indicates “SHUTDOWN”, refer to the shutdown trouble– “SHUTDOWN” shooting section for assistance. In addition to the messages shown, there are several internal and system diagnostics performed by the controller. Consult the factory for additional assistance.
-
Page 67: Warranty
Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.
Need help?
Do you have a question about the TWISTAIR EWDQ D and is the answer not in the manual?
Questions and answers