5636_SED SET SEQ Parts Only 0111 - wo all cut pages

5636_SED SET SEQ Parts Only 0111 - wo all cut pages
10 HP to 20 HP Scroll Enclosure Air Compressors
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DESCRIPTION
GENERAL
Powerex Scroll Enclosure Air Compressors are designed to
supply continuous oil-free air by using the most advanced
scroll technology. These turn-key packages are extremely quiet
and offer electronic control that will reduce electrical power
consumption.
The Powerex Oil-less Rotary Scroll Air Compressor has
advanced scroll compressor technology through the
development of a completely oil-less unit. The Powerex Scroll
Compressor offers a dynamically balanced air end which
insures vibration-free operation. The rotary design permits a
continuous 100% duty cycle. No oil separation, oil filtration,
or inlet valves are required on the Powerex Scroll unit. The
compressor is virtually maintenance free.
The Powerex Oil-less Rotary Scroll Air Compressor is based
on the theory of scroll compression. A scroll is a free standing,
intricate spiral bounded on one side by a solid, flat plane or
base. A scroll set, the basic compression element of a scroll
compressor, is made up of two identical spirals which form
right and left hand parts. One of these scroll components is
indexed or phased 180° with respect to the other so the scrolls
can mesh. Crescent-shaped gas pockets are formed and
bounded by the spirals and the base plate of both scrolls. As
the moving scroll is orbited around the fixed scroll, the pockets
formed by the meshed scrolls follow the spiral toward the
center and diminish in size. The moving scroll is prevented
from rotating during this process so the 180° phase
relationship of the scrolls is maintained. The compressor’s
inlet is at the outer boundary of the scrolls. The entering gas is
trapped in two completely opposite gas pockets and
compressed as the pockets move toward the center. The
compressed gas is discharged through the outlet at the center
of the fixed scroll so no valves are needed.
SPECIFICATIONS
Product
SE Series Enclosed Scroll Air
Compressor
Lubrication
Grease-filled Bearing
Operating
Voltages
3Ø - 208-230/460/575 Volts, 60 Hz
Compression
Cycle
Scroll
Motor Overload
Protection
Motor Protector/Circuit Breaker
Pressure Settings
Cut in: 90 psig Cut out: 116 psig
Cut in: 116 psig Cut out: 145 psig
(High Pressure Units)
Overpressure
Protection
Safety Valve Factory Set and Sealed
Drive
3V Belt
Control Panel
UL508A Listed for Medical Units
Powerex - 150 Production Drive - Harrison, Ohio 45030 - USA
1-888-769-7979 - www.powerexinc.com
Pg 1
IN563600AV
01/11
10HP - 20HP Scroll Enclosure Air Compressors
TROUBLESHOOTING GUIDE
Problem
Possible Cause
Corrective Action
Compressor does not operate
Compressor starts but then stops
No Display on the
Operating Panel
1. The electric source is not turned on
2. Transformer primary or secondary fuse open
3. Electric source is not correctly connected
4. Failure of display or PLC
1. Turn on electric source
2. Replace
3. Connect correctly
4. Inspect, repair or replace
It does not operate
despite displays
1. Failure or wiring failure of magnetic starter
2. Motor failure
3. Low voltage
1. Inspect, repair or replace
2. Inspect, repair or replace
3. Check electric source capacity and the size of
electric source cable and change to proper one
Alarm Screen
Active
1. High temperature condition
2. Motor Overload condition
3. High temperature indicated but unit is cool,
has never been hot
1.Allow to cool and reset, determine cause
2. Reset motor overload, reset alarm and
determine root cause of overload
3. A temperature switch may be disconnected or
defective, check wiring
Alarm Screen
High Temperature
1. High ambient temperature or bad ventilation
2. Clogging of aftercooler fins or intake wire
screen
3. Failure of ventilating fan
4. Damage to intake hose
5. Cooling passage of air end clogged
6. High exhaust pressure
1.Improve installation environment & ventilation
2. Clean
3. Replace
4. Replace
5. Inspect and clean
6. Inspect– control malfunction likely
Alarm Screen
Motor Overload
1. Low voltage
2. Motor Failure
3. Air end failure
4. Loosened wiring screw
5. High exhaust pressure
6. Failure of thermal overload
1. Check electric source capacity, size of electric
source cable and change to proper one
2. Inspect, repair or replace
3. Inspect, repair or replace
4. Tighten
5. Inspect - control failure likely
6. Replace
Exhaust pressure
does not increase
1. Air leaks from exhaust piping
2. Air-end rotates backward
3. Wrong pressure setting
4. Clogged intake filter
1. Inspect, repair
2. Change phases
3. Readjust
4. Clean or replace
Safety valve
activates
1. Failure of safety valve
2. Failure of pressure setting
1. Replace
2. Inspect - control failure likely
Abnormal sound
1. Air-end rotates backward
2. Air end failure
3. Belt slips
4. Motor failure
5. Cooling fan contacting frame
6. Loosened bolts
1. Change phases
2. Inspect, repair or replace
3. Check tension and readjust
4. Inspect, repair or replace
5. Inspect and repair
6. Inspect and tighten
Pg 2
10HP - 20HP Scroll Enclosure Air Compressors
MAINTANANCE SCHEDULE
Item
Action Needed
Operating Hours
500
Intake Filter
2500
5000
10,000
20,000
Remarks
Replace
Every 2500 hours or less
Ventilation Screen
Clean
Every 500 hours or less
Air End/Blower Fan
Clean
Every 5000 hours or less
Fan Duct
Clean
Every 5000 hours or less
Compressor Fins
Clean
Every 2500 hours or less
Replace Pump
Compressor
Grease
Tip Seal
Replace
(every 5000 hours for High
Pressure Models)
Dust Seal
Inspect, Replace
(every 5000 hours for High
Pressure Models)
V-belt
Inspect, Replace
*
Use genuine Powerex grease
(every 5000 hours for High
Pressure Models)
*Readjust
Pressure Sensor
Confirm
Operation
Check touchscreen for pressure rise
and fall
Magnetic Starter
Inspect
Replace if contact points are
deteriorated/excessive arching
Check Valve
Inspect
Confirm operation by watching pump
and motor shut off and stop turning
Safety Valve
Confirm
Operation
Every 500 hours or less. Pull ring to
make sure not stuck or closed.
Inspect
Confirm ventilation air is exiting
cabinet
Inspect Groove/
Make sure tight
Replace if abnormal wear is detected
Motor
Inspect
Replace if abnormal noise is
detected./ Make sure electrical
Intake Hose
Inspect
Replace if damaged or deteriorating
Inspect, Replace
Make sure there are no leaks
Clean outside
Every 5000 hours or less
Operating Panel
Inspect monitor
daily
Verify pressure/Check for alarm
notification
Piping
Inspect for leaks
Ventilation Fan
Motor Pulley
Braided Hose
Aftercooler
Inspect
Replace
NOTES:
1. Inspect and perform maintenance periodically according to the maintenance schedule.
2. The maintenance schedule relates to the normal operating conditions. If the circumstances and load condition are adverse,
shorten the cycle time and perform maintenance accordingly.
3. *Marked “Readjust” means the tension of the V-belt should be adjusted during the initial stage and inspected every 2,500
hours afterwards.
Pg 3
10HP - 20HP Scroll Enclosure Air Compressors
SCHEDULED MAINTENANCE
Per OSHA regulations, lockout
compressor system from all power sources BEFORE
performing any maintenance.
MAINTENANCE INDICATORS
The PUMP MAINT indicator will activate when the running
hours of any pump accumulates to a required maintenance
interval. The system is designed for multiple pumps to accumulate hours evenly and for maintenance intervals to be approached simultaneously. To prevent nuisance PUMP
MAINT indications, all applicable maintenance counters
should be reset after the required maintenance actions are
performed.
Use only Powerex genuine
grease. Pump grease gun before
feeding to eliminate air from grease passage of the needle
adaptor.
NOTE: Each pump of the grease gun equals 0.65g of grease.
The volume of grease is less after the 2nd pump since some
of the grease supply will remain in the grease passage.
INTAKE FILTER
1. Remove the small rear access panel.
2. Remove the wingnut on the filter housing and drop the
cover down. Remove the element without removing the cover
from the enclosure cavity.
3. Clean the inlet filter element with compressed air or
replace with a new element.
NOTE: Never clean filter element with solvents or water.
VENTILATION SCREEN
1. Remove the ventilation screen located at rear of the unit.
2. Clean with compressed air or soap and water if necessary.
INSPECT V-BELT TENSION
1. See page 9 of Operation Manual, IN562802AV.
GREASE COMPRESSOR BEARINGS (Figure 7)
1. Remove the plastic dust cap from the airend.
2. Move the compressor pulley until the grease fitting is
visible through the dust cap hole.
3. Use a grease gun extension adapter to engage the grease
fitting and supply the proper volume of grease as indicated on
the grease delivery chart. See chart below.
Model
1st Time
2nd Time
O.S. Bearing
7 times
6 times
Pin Crank Bearing O.S. Side
7 times
7 times
GREASE PIN CRANK BEARING (Figure 6)
1. Remove fan duct (2) (Key #5)
2. Remove the nuts and bolts and then the fixed scroll from
the air end.
3. Grease all three pin crank bearings as indicated on the
grease delivery chart above.
Pg 4
10HP - 20HP Scroll Enclosure Air Compressors
SCHEDULED MAINTENANCE (Cont’d)
REPLACE TIP SEAL
1. Remove intake hose
2. Remove the discharge hose.
3. Remove nuts and bolts that secure fixed scroll.
4. Remove the fixed scroll housing.
5. Take out the old tip seal from the orbiting scroll housing
and fixed scroll housing, see Figure 8.
6. Remove the old dust seals from fixed scroll, see Figure 9.
Install the new tip seals and dust seals in the stationary and
orbiting scroll housings in the following manner:
NOTE: Tips seals for Fixed Scroll and Orbit Scroll have
opposing seal cut angles (See NOTE and explanatory
diagram below).
Insert tip seal so that the lip of tip seal is on the bottom of seal
groove and inner side of involute and the direction of lip
faces the center of involute (curving spiral). See Figure 9.
This is to be done for both FS and OS sets.
Use caution not to tear or distort lip.
1. Insert new HP tip seal from the center section for OS or
Orbit Scroll so that there will be no clearance at the tip (start)
section (See Figure 8 and 9).
2. Insert so that new LP tip seal will contact closely with HP
tip seal inside Scroll Groove.
Insert approximately half of
the LP tip seal and remove the tip seal to confirm that a
notch in the tip seal has been created. This will prevent
movement during installation (See Figure 8).
3. Repeat the same procedure for FS or Fixed Scroll tip seal
set, remove both the dust seal and the backup tube located on
outermost side FS set.
4. Insert new backup tube in FS in the 6 o’clock position (See
figure 10).
NOTE: In order to distinguish between the tip seal for Fixed Scroll and the tip seal for Orbit Scroll place the tip seal as shown
below then view from the arrow direction and refer to the figure on the right.
Pg 5
10HP - 20HP Scroll Enclosure Air Compressors
SCHEDULED MAINTENANCE (Cont’d)
5. Insert new dust seal on the backup tube (See Figure 11).
6. After replacing tip seal set, reassemble Fixed Scroll set to
the Orbit Scroll. Tighten nuts and bolts temporarily and
confirm if pump pulley rotates smoothly by hand and tighten
them firmly. Tightening torques are in the chart below:
Bolt Torque
First
Second
175 in lbs.
265 in lbs.
NOTE: Assemble so that dust seal and tip seal will not drop
between Orbit Scroll set and Fixed Scroll set.
Pg 6
10HP - 20HP Scroll Enclosure Air Compressors
PARTS DIAGRAM
6 Intake
Filter
Element
10 Safety Valve
8 Pressure Sensor
5 V Belt
3 Motor
Pulley
11.2 Motor
Protector
4.1 PLC
11.1 Magnetic
Contactor
15 Control Transformer
4.2 HMI
Touch Screen
12.1 Distribution Block
12.2 Distribution Block Cover
2 Motor
13 Inlet Plate
16 Inlet Gasket
1 Air End
7 Temp Switch
17 Braided Hose
14 Exhaust Fan
9 Check Valve
18 Aftercooler
Pg 7
10HP - 20HP Scroll Enclosure Air Compressors
REPLACEMENT PARTS LIST
10HP
15 HP
20 HP
Ref.
No.
Description
SED1007E
SED1007EHP
SET1507E
SET1507EHP
SEQ2007E
1
Air End
SL016502AJ
SL016511AJ
SL016502AJ
SL016511AJ
SL016502AJ
2.1
Motor
208-230/460V
MC303305AV
2,3,4
Motor
575V
MC303307AV
2,34
3
Motor Pulley
PU009754AV
2,3,4
4.1
PLC
PE000420AV
1
4.2
Touch Screen
HMI panel
PE000417AV
1
5
3VX-belt
BT012900AV
4,6,8
6
Intake filter
element
ST073907AV
1
7
Temp Switch
8
Pressure Sensor
PE000440AV
1
9
Check Valve
IP087700AV
2,3,4
10
Safety Valve
11.1
Magnetic
Contactor
PE000102AV
2,3,4
11.2
Motor Protector
208-230V
PE000307AV
2,3,4
Motor Protector
460V/575V
PE000305AV
2,3,4
12.1
Distribution
Block
PE000622AV
1
12.2
Distribution
Block Cover
PE000640AV
1
13
Inlet Plate
IP088400AV
2,3,4
14
Exhaust fan
SM001301AV
2,3,4
15
Control
Transformer
PS005850AV
1
16
Inlet Gasket
IP088200AV
2,3,4
17
Braided Hose
SM001501AV
2,3,4
18
Aftercooler
SL300100AV
2,3,4
2.2
SEQ2007EHP Qty.
SL016511AJ
2,3,4
AM003011AV AM003012AV AM003011AV AM003012AV AM003011AV AM003012AV 2,3,4
V-215400AV
V-215401AV
V-215400AV
V-215401AV
V-215400AV
V-215401AV
1
Pg 8
10HP - 20HP Scroll Enclosure Air Compressors
PARTS DIAGRAM & LIST
* NOT SHOWN
Pg 9
Ref.
No.
Description
SLAE05E
1
Air End Pulley
02549110
1
2
Key
IP600600AV
1
3
Centrifugal Fan
IP601300AV
1
4
Fan Duct (1)
IP601400AV
1
5
Fan Duct (2)
02519042
1
6
Fan Cover
IP601700AV
1
7
Fan Dust Gasket (1)
IP601900AV
1
8
Heat Insulation Pipe
IP602000AV
1
9
Fan Duct Gasket (2)
IP602400AV
1
10
Long Nipple
96647011
1
11
Dust Cap
IP603500AV
1
12
Tip Seal Set
*
Grease Gun Kit
IP616201AJ
*
Grease Gun
IP616101AJ
*
Grease
IP600000AV
92832070
SLAE05EHP
92832080
Qty.
1
10HP - 20HP Scroll Enclosure Air Compressors
NOTES:
Pg 10
10HP - 20HP Scroll Enclosure Air Compressors
NOTES:
Pg 11
Pg 12
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