Gardner Denver PUREAIR EWC99C Operating And Service Manual

GARDNER DENVER®
PUREAIR
OIL-FREE ROTARY SCREW
COMPRESSORS
MODELS
EWC99C
OPERATING AND
SERVICE MANUAL
13-11-607
Version: 05
August 1, 2003
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER® COMPRESSOR PARTS AND SUPPORT SERVICES
Gardner Denver Compressor genuine parts, manufactured to design tolerances, are developed for optimum dependability –
specifically for Gardner Denver compressor systems. Design and material innovations are the result of years of experience with
hundreds of different compressor applications. Reliability in materials and quality assurance is incorporated in our genuine
replacement parts.
Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. A worldwide network of authorized
distributors provides the finest product support in the air compressor industry. Your local authorized distributor maintains a large
inventory of genuine parts and he is backed up for emergency parts by direct access to the Master Distribution Center (MDC) in
Memphis, Tennessee.
Your authorized distributor can support your Gardner Denver air compressor with these services:
1.
Trained parts specialists to assist you in selecting the correct replacement parts.
2.
Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured airends are maintained
in stock at the Remanufacturing Center in Indianapolis, IN., for purchase on an exchange basis with liberal core credit available
for the replacement unit.
3.
A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.
4.
Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.
Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They are ready to
respond and assist you by providing 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:
Gardner Denver
Master Distribution Center
5585 East Shelby Drive
Memphis, TN 38141
Phone:
(901) 542-6100
(800) 245-4946
Fax:
(901) 542-6159
Factory:
Gardner Denver
1800 Gardner Expressway
Quincy, IL 62301
Phone:
(217) 222-5400
Fax:
(217) 224-7814
REMANUFACTURED AIRENDS
Whenever an airend requires replacement or repair, Gardner Denver offers an industry unique, factory remanufactured airend
exchange program. From its modern Remanufacturing Center in Indianapolis, IN., Gardner Denver is committed to supplying you
with the highest quality, factory remanufactured airends that are guaranteed to save you time, aggravation and money.
Immediately Available
Repair downtime costs you money, which is why there are over 200 remanufactured units in inventory at all times, ready for
immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, inspected and analyzed. Only those parts that can be brought back to original
factory specifications are remanufactured. Every remanufactured airend receives a new overhaul kit: bearings, gears, seals,
sleeves and gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses just don’t do. Magnaflux and ultrasonic inspection spot cracked or stressed
castings, monochromatic light analysis exposes oil leaks, and coordinate measurement machine inspects to +/- .0001”, insuring that
all remanufactured airends meet factory performance specifications.
Warranty
Gardner Denver backs up every remanufactured airend with a new warranty…18 months from purchase, 12 months from service.
Gardner Denver remanufactured airends deliver quality without question…year in and year out.
Call Gardner Denver for information on the airend exchange program and the name of your authorized distributor.
Phone Number: 800-245-4946 or
Fax: 901-542-659
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Page i
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 maintenance. This book is written to give the operator and maintenance
department essential information for day-to-day operation, maintenance and adjustment. Careful
adherence to these instructions will result in economical operation and minimum downtime.
DANGER
Danger is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored.
WARNING
Warning is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard which will or can cause
minor personal injury or property damage if the warning is ignored.
NOTICE
Notice is used to notify people of installation, operation or maintenance
information which is important but not hazard-related.
This book covers the following models:
HP
PSI
MODEL
PARTS LIST
20, 25, 30
100, 125, 150
EWC99C
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Page ii
TABLE OF CONTENTS
Maintain Compressor Reliability And Performance With Genuine
Gardner Denver Compressor Parts And Support Services .................................................................i
Remanufactured Airends ......................................................................................................................i
Foreword............................................................................................................................................ ii
List Of Illustrations ............................................................................................................................. i v
Section 1, General Information.............................................................................................................1
Section 2, Installation, Coolers And Water Systems ..............................................................................5
Section 3, Starting & Operating Procedures ........................................................................................ 12
Section 4, Controls & Instrumentation................................................................................................. 15
Section 5, Lubrication........................................................................................................................ 37
Section 6, Air Filter............................................................................................................................ 39
Section 7, Belt Drive.......................................................................................................................... 41
Section 8, RO Water Filtration System ............................................................................................... 43
Section 9, Maintenance Schedule...................................................................................................... 50
Section 10, Troubleshooting .............................................................................................................. 53
Section 11, Troubleshooting Auto Sentry W Controller......................................................................... 55
Section 12, Troubleshooting The RO Filtration System........................................................................ 61
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LIST OF ILLUSTRATIONS
Figure 1-1 – Typical Compression Cycle ..............................................................................................1
Figure 1-2 – Package Illustration..........................................................................................................2
Figure 1-3 – Air/Water Schematic ........................................................................................................3
Figure 2-1 – Typical Compressor Room ...............................................................................................6
Figure 2-2 – Air Flow Chart ..................................................................................................................6
Figure 2-3 – Inlet Line Lengths.............................................................................................................8
Figure 2-4 – Grease Recommendations ............................................................................................. 11
Figure 2-5 – Regreasing Interval ........................................................................................................ 11
Figure 4-1 – Auto Sentry W Controller Display .................................................................................... 17
Figure 4-2 – Flow Chart For Setup Programming ................................................................................ 20
Figure 4-3 – Auxiliary Pressure Switch/Receiver Unloaded Pressure Tabulation ................................... 30
Figure 4-4 – Wiring Diagram – Full Voltage......................................................................................... 33
Figure 4-5 – Wiring Diagram – Full Voltage Less Starter...................................................................... 35
Figure 5-1 – Oil Level Sight Glass...................................................................................................... 38
Figure 6-1 – Heavy Duty Air Filter (Standard)...................................................................................... 39
Figure 7-1 – Belt Tension 3VX Belts................................................................................................... 42
Figure 8-1 – PLC Connections And Cycle Time Combinations ............................................................. 46
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SECTION 1
GENERAL INFORMATION
Figure 1-1 – TYPICAL COMPRESSION CYCLE
COMPRESSOR - The Gardner Denver Rotary Screw compressor is a single stage, positive displacement rotary
machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller
bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end
of the rotors to carry part of the radial loads. Angular contact ball bearings at the discharge end locate each rotor
axially and carry all thrust loads and the remainder of the radial loads.
COMPRESSION PRINCIPLE (Figure 1-1) - Compression is accomplished by the main and secondary rotors
synchronously meshing in a one-piece cylinder. The main rotor has six (6) helical lobes 60° apart. The secondary
rotor has eight (8) matching helical grooves 45° apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor cylinder near the drive shaft end. The discharge port is at the
bottom on the opposite end of the compressor cylinder. Figure 1-1 is an inverted view to show inlet and discharge
ports. The compression cycle begins as rotors unmesh at the inlet port and air is drawn into the cavity between the
main rotor lobes and secondary rotor grooves (A). When the rotors pass the inlet port cutoff, air is trapped in the
interlobe cavity and flows axially with the meshing rotors (B). As meshing continues, more of the main rotor lobe
enters the secondary rotor grove, normal volume is reduced and pressure increases.
Water is injected into the cylinder to remove the heat of compression and seal internal clearances. Volume reduction
and pressure increase continues until the air/water mixture trapped in the interlobe cavity by the rotors passes the
discharge port and is released to the air/water reservoir (C). Each rotor cavity follows the same “fill-compressdischarge” cycle in rapid succession to produce a discharge air flow that is continuous, smooth, and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 1-3, page 3) - Air enters the air filter and passes through the
inlet unloader valve to the compressor. After compression, the air/water mixture flows to the separator/reservoir tank
where most of the water is removed by velocity change and impingement. The air flows to the aftercooler, then to the
moisture separator where the water that has condensed out is removed from the air stream. The air then flows
through the package discharge check valve and to the plant air system.
WATER SYSTEM (Figure 1-3, page 3) - Water is forced by air pressure from the separator/reservoir tank through
the heat exchanger, the system water filter and into the water injection manifold where the water is distributed to the
compression chamber injection ports. The water removes the heat of compression and seals internal clearances.
Seals minimize water leakage out of the compression chamber.
LUBRICATION - Oil in the oil reservoir at the discharge end of the airend lubricates the discharge end bearings.
Grease fittings are located at the inlet end of the airend for periodic lubrication of the inlet end bearings.
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307EWC797-B
(Ref. Drawing)
Figure 1-2 – PACKAGE ILLUSTRATION
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308EWC797-F
(Ref. Drawing)
Figure 1-3 – AIR/WATER SCHEMATIC
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:
DANGER
Failure to observe these notices could result in injury to or death of personnel.
•
Keep fingers and clothing away from revolving fan, drive coupling, etc.
•
Do not use the air discharge from this unit for breathing – not suitable for human consumption.
•
Do not loosen or remove the oil filler plug, drain plugs, covers the thermostatic 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 be fatal.
•
Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.
•
Open main disconnect switch, tag and lockout before working on the control.
•
Disconnect the compressor unit from its power source, tag and lockout before working on the
unit – this machine is automatically controlled and may start at any time.
WARNING
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 before 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 exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).
•
Do not exceed the rated maximum pressure values shown on the nameplate.
•
Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.
•
Do not disconnect the compressor unit from its power source for more than two days. During
normal operation or fouling, reverse osmosis of the membrane may occur. Refer to your
Operating and Service manual for details concerning the reverse osmosis water filtration
system.
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SECTION 2
INSTALLATION, COOLERS AND WATER SYSTEMS
GENERAL - On receipt of the unit, check for any damage that may have occurred during transit or
handling. Report any damage or missing parts as soon as possible.
CAUTION
Do not electric weld on the compressor or base; bearings can be damaged by
passage of current.
LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Tow motor
fork clearance is provided by the equipment isolators bolted to the base of the unit. The unit may also be
moved into location by rolling on bars.
CAUTION
Lift compressor unit by base only. Do not use other places such as motor,
compressor or discharge manifold piping as lifting points.
DANGER
The eyebolts or lugs provided on the motor are for lifting the motor only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motor, the lifting angle must not exceed 15 degrees.
Failure to observe this warning may result in damage to equipment or personal
injury.
LOCATION - The compressor should be installed in a clean, well-lighted, and ventilated area with ample
space all around the unit for maintenance. Select a location that provides a cool, clean, and dry source of
air. In some cases it may be necessary to install the air filter at some distance from the compressor to
obtain proper air supply.
WARNING
Do not install this compressor in a location that may be subject to temperatures
below 32° F. (0° C).
Below freezing temperatures will cause damage to the compressor.
The air-cooled unit requires cooling air as well as air to the compressor inlet. Proper ventilation MUST be
provided; hot air must be exhausted from the compressor operating area. A typical inlet-outlet air flow
arrangement is shown in Figure 2-1, page 6.
Air-Cooled Units - An air cooled heat exchanger and aftercooler is supplied as standard equipment on
all air-cooled units. The air cooled motors and fans are mounted within the cooling module; air is drawn
into the enclosure through louvers in the side panels, through the aftercooler and exhausted through the
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Page 5
heat exchanger at the top of the unit. The air-cooled unit with the standard enclosure requires sufficient
flow, Figure 2-2, page 6, for the compressor water/aftercooling system and for electric motor cooling. Do
not block the air flow to and from the unit. Allow three and one-half (3-1/2) feet to the nearest obstruction
on the control box end of the unit. Allow three (3) feet to the nearest obstruction above and on other
sides of unit. For continuous efficiency, the heat exchanger and aftercooler cores must be periodically
cleaned with either vacuum or compressed air. If wet cleaning is required, shield the motor and spray on
a mild soap solution, then flush with clean water.
Figure 2-1 – TYPICAL COMPRESSOR ROOM
Minimum Air Flow * For Compression and Cooling
Cubic Feet/Minute (Cubic Meters/Minute)
HP (kW)
Air Cooled
20 – 30 (15 – 22)
5,200 (147)
* 80° F (27° C) Inlet Air
Figure 2-2 – AIR FLOW CHART
WARNING
For copper water coolers, do not use any cleaning solution that is not
compatible with copper. Use of improper solution may result in damage to the
cooler.
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FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but
should be mounted on a smooth, solid surface. Whenever possible, install the unit near level. Temporary
installation may be made at a maximum 10° angle lengthwise or 10° sidewise.
Mounting bolts are not normally required. However, installation conditions such as piping rigidity, angle of
tilt, or danger of shifting from outside vibration or moving vehicles may require the use of mounting bolts
and shims to provide uniform support for the base.
OIL RESERVOIR DRAIN - The oil drain plug is located at the bottom of the discharge end of the
compressor. (See Figure 5-1, page 38.)
ENCLOSURE - The compressor, electric motor, water cooler and aftercooler are mounted inside the
enclosure.
Service doors are provided for maintenance access. Be sure to allow enough space around the unit for
the doors to be opened and removed as necessary for service procedures. The enclosure doors are held
by two latches and lift away from the enclosure. The air filter, water filters, and water treatment cartridge
are easily accessible through a side or end door.
DANGER
Do not operate the compressor with the belt guard removed. Exposed belts
may cause injury to personnel.
COMPRESSOR WATER SPECIFICATION - The compressor unit is supplied with an integral filtration
system (by reverse osmosis) to ensure adequate quality levels for the injection water system. In order to
maintain the water filtration system working at peak efficiency, the incoming water supply must meet a
number of requirements. Please refer to the “RO Water Filter”, Section 8, of this manual for details.
WARNING
Back flow Preventers must be installed on the potable water supply line to the
compressor to prevent high pressure air from blowing into the water supply.
WARNING
Use of compressor initial fill and make-up water not meeting all water
specification standards noted may result in contamination of the discharge air
stream.
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Page 7
WARNING
The use of make-up water exceeding the quality units outlined in the “RO Water
filter”, Section 8, may result in damage to critical compressor components by
corrosion and/or scaling action of impurities in the water.
NOTICE
Water may no longer be potable after use in the compressor.
AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and
provides sufficient storage capacity to prevent rapid 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. A system with adequate volume would produce consecutive compressor unload cycles of
no less than 30 seconds.
MOISTURE SEPARATOR/ORIFICE- Since the unit is equipped with a built-in aftercooler, an integral
moisture separator and drain trap is furnished with the unit. The moisture from the trap is piped to the
compressor inlet flange.
INLET LINE - Where an inlet line is used between the air filter and the compressor, it must be
thoroughly cleaned on the inside to prevent dirt or scale from entering the compressor. If welded
construction is used, the line must be shot blasted and cleaned to remove welding scale. In either
case, the inlet line must be coated internally by galvanizing or painting with a moisture and oil-proof
sealing lacquer. Up to ten (10) feet in length, the inlet line should be the full size of the inlet opening on
the compressor. If an extra-long line is necessary, the pipe size should be increased according to “Inlet
Line” chart, Figure 2-3, page 8.
Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a
remote location.
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)..............................
One size Larger Than Inlet Opening
17 to 38 Feet (5 to 11.5 Meters) .........................
Two Sizes Larger Than Inlet Opening
Figure 2-3 – INLET LINE LENGTHS
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DISCHARGE SERVICE LINE - The discharge service line connection on the unit is made from the right
side at base level from the motor end of the package. When manifolding two or more rotary screw units
on the same line, each unit is isolated by the check valve in the unit discharge line. If a rotary screw unit
is manifolded to another compressor, be sure the other compressor has a check valve in the line between
the machine and the manifold. If a rotary screw and reciprocating compressor are manifolded together,
an air receiver must be located between the two units.
DANGER
Discharge air used for breathing will cause severe injury or death. Consult
filtration specialists for additional filtration and treatment equipment to meet
health and safety standards.
The oil-free air discharging from the EWC package is saturated with water vapor at discharge
temperature. An air dryer may be required if the air is used in a moisture sensitive process. In addition,
the compressed air may be mixed with atmospheric contaminants entering the intake of the compressor.
UNIT WATER DRAIN - The unit drain ports should be connected to a floor drain(s). Drain line(s) must
slope downward, away from the unit, to allow effluent to flow by gravity, and must be vented to the
atmosphere to avoid the accidental back flow of said effluent into the package. As necessary, the
automatic water management system will open the drain solenoid valve to drain excess water. Since the
drain solenoid valve may open at any point during compressor operation, high temperature water under
pressure may be discharge from the unit. During operation, a small, steady stream of wash water is
normally discharged by the water treatment filter via the drain port.
DANGER
Hot water under pressure will cause severe personal injury or death. Do not
operate compressor until a water drain line is installed from compressor water
drain port to a floor drain.
AIR/WATER RESERVOIR WITH INTEGRAL MOISTURE SEPARATOR - The air/water reservoirseparator combines multiple functions into one vessel. On one end of the vessel, the lower half functions
as a reservoir, providing water storage capacity for the system and the upper portion serves as primary
air/water separation. The reservoir also provides limited air storage for control and gauge actuation.
Secondary moisture separation is achieved downstream of the aftercooler on the other end of the vessel.
COMPRESSOR INJECTION WATER SYSTEM CHECK - The following readings are based on an
ambient temperature of 80° F inlet cooling air on air-cooled units with the cooling system in good, clean
condition. The compressor should be at operating temperature at the time of the checks. One-half hour
of loaded operation is usually sufficient to reach level-out operating temperatures.
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Air and Water Discharge Temperature - 105° F to 125° F - Read on the “AUTO SENTRY W” control
panel.
Compressor Injection Water Inlet Temperature - 90° F to 110° F - Check anywhere on the line from
the heat exchanger to the compressor inlet.
Water Injection Cooler Temperature Differential (Air Cooled Heat Exchanger - The water
temperature differential depends on the temperature of the air at the water injection cooler fan and the
cleanliness of the core faces. As ambient temperatures and core restrictions increase, the injection water
outlet temperature will increase. The injection water outlet temperature is approximately the same as the
package exhaust air temperature. The outlet temperature may be checked by installing a tee in the water
line between the separator/reservoir and the cooler.
Water Injection Cooler Pressure Differential (Air Cooled Heat Exchanger) - 5 to 7 psid - Check
injection water pressure differential in the same place as temperature. (See above.)
ELECTRICAL WIRING - Standard Units - The PureAir compressor is factory wired for all starter to
motor and control connections for the voltage specified on the order. It is necessary only to connect the
unit starter to the correct power supply. The standard unit is supplied with an open drip-proof motor, a
NEMA 12 starter and control enclosure. See “Location” paragraph, page 5, for distance to nearest
obstruction on starter and control box sides of the unit.
WARNING
Electrical shock can cause injury or death. Open main disconnect switch, tag
and lockout before working on starter/control box.
GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical
Code.
WARNING
Failure to properly ground the compressor package could result in controller
malfunction.
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MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large
measure on proper lubrication of the bearings. The charts below show recommended grease qualities
and regreasing intervals for ball bearing motors. For additional information, refer to the motor
manufacturer’s instructions.
The following procedure should be used in regreasing:
1.
2.
3.
4.
5.
Stop the unit.
Disconnect, tag and lockout the unit from the power supply.
Remove the relief plug and free hole of hardened grease.
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 expel
the excess grease.
Stop the unit. Replace the relief plug.
Restart the unit.
6.
7.
WARNING
Rotating machinery can cause injury or death. Open main disconnect, tag and
lockout power supply to the starter before working on the electric motor.
ELECTRIC MOTOR GREASE RECOMMENDATION (-30° C TO 50° C)
Manufacturer
Trade Name
Chevron
SRI #2
Shell
Dolium R
Exxon
Unirex #2
Exxon
Polyrex
Figure 2-4 – GREASE RECOMMENDATIONS
ELECTRIC MOTOR REGREASING INTERVAL
Type of Service
Standard
Severe
Very Severe
Typical Examples
One or Two-Shift Operation
Continuous Operation
Dirty Locations, High Ambient
Temperature
Rating
Up to 150 HP (112 kW)
18 Months
Above 150 HP (112 kW)
12 Months
Up to 150 HP (112 kW)
9 Months
Above 150 HP (112 kW)
6 Months
Up to 150 HP (112 kW)
4 Months
Above 150 HP (112 kW)
2 Months
Figure 2-5 – REGREASING INTERVAL
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Relubrication Interval
Page 11
SECTION 3
STARTING & OPERATING PROCEDURES
PRESTART-UP INSTRUCTIONS - A new unit as received from the factory has been tested and then
prepared for shipping. Do not attempt to operate the unit until checked and serviced as follows:
1.
Compressor Oil - Check airend oil level. The normal oil level is in the center of the sight glass. Oil
level must be within the operating range. Add or drain oil to correct level using the same type of oil.
(See Figure 5-1, page 38).
DANGER
Air and water 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 valves, caps, plugs, fittings, bolts
and filters.
CAUTION
Use of improper lubricants will cause damage to equipment. Do not mix
different types of lubricants or use inferior lubricants. See Section 5, page 37,
for lubrication recommendations.
NOTICE
Regular maintenance and replacement at required intervals of the air and water
filters are necessary to achieve maximum service of this screw compressor.
Use only genuine Gardner Denver filters designed and specified for this
compressor.
2.
Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to Section 6, page
39, for complete servicing instructions. Be sure the inlet line, if used, is tight and clean.
3.
Piping - Refer to Section 2, “Installation”, page 5, and make sure piping meets all recommendations.
4.
Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired.
5.
See Figure 4-4 and Figure 4-5, pages 33 and 35, for general wiring diagrams and Section 2, page 5,
for installation instructions.
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Page 12
6.
Grounding - Equipment must be grounded in accordance with Section 250 of the National Electrical
Code.
WARNING
Failure to properly ground the compressor package could result in controller
malfunction.
7.
Rotation - Check for correct motor rotation using “JOG MODE.” An arrow on the compressor/motor
belt guard shows correct rotation. Compressor drive shaft rotation must be counterclockwise
standing facing the compressor sheave.
WARNING
Operation with incorrect motor rotation can damage equipment and cause
water eruption from the compressor inlet. When checking motor rotation,
induce minimum rotation (less than one revolution if possible). Never allow
motor to reach full speed.
8.
System Pressure - Set the controls to the desired unload and load pressures. DO NOT EXCEED
MAXIMUM OPERATING PRESSURE ON COMPRESSOR NAMEPLATE. See Section 4, “Controls
and Instrumentation”, for procedure.
WARNING
Operation at excessive discharge air pressure can cause personal injury or
damage to equipment. Do not adjust the full discharge air pressure above the
maximum stamped on the unit nameplate.
9.
Operating Mode - Refer to Section 4 for detailed information on the control system.
10. Enclosure - Check for damaged panels or doors.
sure doors are closed and latched.
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Check all screws and latches for tightness. Be
Page 13
11. Initial Water Fill/Adjusting RO Timer - You package is shipped with all water drained. The water
receiver must be filled with filtered water (reverse osmosis filter) prior to operating the compressor
unit:
•
Ensure that the make-up water feed line is installed and the ball valve is open.
•
Engage the Emergency Stop button to avoid accidental operation of the compressor.
•
Disconnect package from electrical power.
•
Select a suitable water fill cycle – see RO Filter System, Section 8, for details on operating
and adjusting the PLC and its timing operation. Under normal conditions, the 4 hour-fill cycle
would be adequate. Note the current (or desired) running cycle setting on the PLC – it
must be reset after completing the filling operation.
•
Reconnect package to electrical power.
•
Toggle PLC “run/stop” mode switch off and on to reset the timer and start the selected fill
cycle. After the “on” (fill) cycle times out, the “off” (rest) cycle will follow. If necessary, the
mode switch can be cycled at any time to reset the timer and re-start a new fill cycle.
•
After the tank is filled to the proper level (half-way up the reservoir-mounted sight tube),
disconnect electrical power, and reconnect the original (or desired) running timer cycle
settings on the PLC.
•
Re-connect package to electrical power and disengage the Emergency Stop button.
STARTING THE UNIT - Start the unit by pushing the [RUN] key. The unit will reach normal operating
temperature in approximately 5 minutes. Check the package operating information by pressing the
[INFO] key or keypad cursor [<] [>] keys at any time during unit operation.
DAILY CHECK - Refer to Section 9, “Maintenance Schedule”, page 50.
STOPPING THE UNIT - Press [STOP/RESET] key. The air/water reservoir will automatically blow down
as the motor stops.
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SECTION 4
CONTROLS & INSTRUMENTATION
GENERAL DESCRIPTION - The Gardner Denver PureAir water-flooded rotary screw compressor is
prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is
necessary only to connect the compressor unit to the correct power supply, to the shop air line, and to the
appropriate water supply. A standard compressor unit consists of the compressor, water reservoir, water
cooling system and filters, lubrication reservoir, motor type as specified, NEMA 12 starter/control box, and
control components as described below.
This compressor unit features the AUTO SENTRY W controller, which integrates all the control functions
under microprocessor control. Its functions include safety and shutdown, compressor regulation, operator
control, and advisory/maintenance indicators. The keypad and display provide the operator with a logical
and easily operated control of the compressor and indication of its condition.
AUTO SENTRY W OPERATION
Normal operation is controlled by the keys in the OPERATE island of the AUTO SENTRY W controller.
Prior to starting, press the [STOP/RESET] key to place the controller into its READY state (as indicated
on the display). Press the [RUN] key to start the compressor. The green LED will light near the
automatic operation symbol whenever operation is enabled.
The [STOP/RESET] key may be pressed at any time to stop the compressor under normal conditions. If
the compressor has been running, the reservoir pressure is relieved before stopping the motor. The
display will count down to zero during the normal stop.
An optional control may be wired into the AUTO SENTRY W controller to interrupt and restart the unit
based on controls by others. When stopped by these controls, the display indicates remote stop.
WARNING
Automatic restarting or electrical shock can cause injury or death. Open, tag
and lockout main disconnect and any other circuits before servicing the unit.
In any mode, the compressor will start only if reservoir pressure is below 5 psig (0.3 bars). The display
will indicate 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 completed.
All modes of operation provided by the AUTO SENTRY W controller produce load/unload flow control.
An independent pneumatic pilot valve is also supplied to provide flow modulation and thus match
package air supply to the system demand. If simple load/unload operation is desired, the pneumatic pilot
valve can be deactivated by setting its opening pressure beyond the unload pressure setting programmed
in the controller. See “Subtractive Valve”, page 30, under “Other Control Devices” for details.
Constant Run Mode Operation - This mode is best used in applications where there are no long
periods of unloaded operation. The compressor unit will start and run continuously, using its controls to
load and unload the compressor. This matches average delivery to demand. When the air demand is
less than the compressor capacity, the air pressure rises to the unload point of the controller, which will
then unload, blow down, and stop delivery of air to the system. Air demands are supplied by air stored in
receivers and plant piping. When the pressure falls halfway between the unload and load pressures, the
W controller again fully loads the compressor.
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When first starting, the controller will keep the compressor fully unloaded and blown down until the
system pressure drops below the load pressure.
Low Demand Mode Operation - This mode is similar to the “Continuous Run” mode, except for its behavior
under unloaded conditions. If the blowdown timer has completed its cycle when the next unload operation
takes place, the controller will not reload the package until the line pressure has reached the “load” level.
Otherwise, if the blowdown timer is still active, the machine will reload the package when the line pressure falls
halfway between the “unload” and “load” levels.
Automatic Mode Operation - This mode provides automatic start and timed stop, and is best used in
applications with long unloaded periods and adequate storage to allow the compressor to be stopped for
periods of light demands. Operation during periods of moderate to heavy demands is identical to the low
demand and constant run modes described above.
The automatic time delay is adjustable from 5 to 20 minutes. If the controller operates unloaded for this
period with no demand, the compressor drive motor is halted to eliminate its power consumption. The
controls will remain in this state until pressure drops below the load pressure.
This is the most common selected mode of operation, as it automatically will operate the compressor unit
in the most efficient manner for the demand of the air system.
When packages are sequenced and rotated, it is not recommended to engage the pneumatic pilot valves
for flow modulation. See “Subtractive Valve”, page 30, under “Other Control Devices” for details.
Sequence Mode Operation - This mode provides for communication between controllers, operating
only as many as are required for economical operation. This is best used on applications with large
storage capacity and diverse loads. The lead unit will operate identically to the automatic mode;
operation will be automatically staged for each lag unit (up to 8 total). For more information, refer to the
sequencing instructions later in this chapter.
An optional expansion board must be installed for sequencing operation. Communication between
controllers is achieved by interconnection of a communications cable to expansion 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.
AUTO-SENTRY W CONTROL DISPLAY
The display above the keypad is used to provide operating information to the user. If a shutdown has
occurred, the display will indicate the cause.
During normal operation, the display will show the system pressure, compressor discharge temperature,
total running hours, and operation mode. Alternate displays are available by pressing the [?] INFO or the
keypad cursor [<] [>] keys, and will be identified on the display. These include:
Water Filter Differential Pressure
DIF PRES
Reservoir Pressure
RES PRES
Water Injection Pressure
INJ PRES
System Pressure
SYS PRES
Compressor Discharge Temperature
DIS TMP
Total Hours
TOT HRS
Loaded Hours
LOAD HRS
Remaining Blowdown Time
BD TMR
Remaining Auto Time
AUTO TMR
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Remaining blowdown and auto times are only available in Low Demand, Automatic, and Sequence
modes, as appropriate.
If no keys are pressed for 5 seconds, the display will revert to its normal mode.
The display is also used as a service reminder for normal maintenance items. If service is recommended,
the yellow LED next to the service symbol will come on, and a message will alternate with the normal
lower line message. These messages are intended to advise of conditions which may lead to a
shutdown.
If a protective shutdown occurs, the red LED next to the shutdown symbol will be on and the top line of
the display will indicate “SHUTDOWN.” The lower line will indicate the cause of the shutdown.
Figure 4-1 – AUTO SENTRY W CONTROLLER DISPLAY
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SERVICE ADVISORIES
The AUTO SENTRY W controller turns on an advisory when it detects operation which needs service
attention, but does not warrant shutting down the compressor. Some of these are normal maintenance
procedures, and are intended to serve as a reminder to perform routine service. Others are conditions
which can reduce the maximum compressor performance. It will remain in effect until reset. Check the
display during routine inspections, and perform maintenance as suggested. Refer to the troubleshooting
section for detailed information about each advisory.
Temperature advisories may be cleared while the unit is running by simply pressing the [ENTER] key. To
reset the service advisories, press the [STOP/RESET] key to stop operation of the compressor. After it
has stopped, disconnect power and service as required. After servicing, restore power and reset the
controller as indicated in the programming / maintenance section below.
PROTECTIVE SHUTDOWNS
The AUTO SENTRY W will shut down the unit following any fault detected in the following devices. Longterm problems will have a brief blowdown period before fully shutting down. Following a shutdown, a
message will be displayed, with the top line indicating “SHUTDOWN” and the lower line indicating the
cause. The shutdown light will be steadily lit while the shutdown condition is present, or will flash if the
condition no longer exists. Refer to the troubleshooting section for detailed information about each
shutdown. To resume operation, the cause of the shutdown must be corrected and the controller reset by
pressing the [STOP/RESET] key.
Motor Protective Devices - Overload heaters are furnished for the starter in the voltage range
specified. There are three (3) overloads in the starter of proper size for the starter and its enclosure.
Note that motor nameplate current must be multiplied by 0.577 for Wye-Delta starters. The display will
indicate that an overload relay has tripped. The overload relay is reset by pressing the button on the
relay itself, then the controller may be reset. Motor current (amps) and voltage must be measured in the
affected motor wiring to locate the cause for high current. Proper starter coil and contact action is also
monitored and errors in operation will cause a shutdown with the cause displayed as a starter or contact
error.
High Temperature - The compressor is protected from high discharge temperature by a thermistor
probe located in the compressor discharge. The AUTO SENTRY W will shut the compressor down if
temperature exceeds 150° F (66° C) (or lower per user adjustment) or if rapid temperature rise is
detected. Shutdown will also occur if the temperature falls below freezing. The thermistor probe is also
checked for open or shorted circuits, and the display will indicate a fault, if found.
CAUTION
Machine damage will occur if compressor is repeatedly restarted after high
temperature stops operation. Find and correct the malfunction before resuming
operation.
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Water Filter Differential Pressure - The pressure drop across the water filter is continually monitored
by the AUTO SENTRY W. The unit will be shut down at a differential pressure of approximately 40 psid
(2.8 bars). This becomes active only after the compressor has been running and pressures have had
time to stabilize.
The pressure drop can be monitored at any time by selecting the alternate display “DIF PRES” (water
filter differential pressure) with the [?] HELP key. This should be checked while the compressor is
delivering at full capacity. A service advisory comes on to recommend maintenance prior to this
shutdown.
High Water Level - If the water management controls are unable to maintain proper water levels, the
compressor will shutdown to prevent damage. Check wiring and piping of the drain and fill solenoid
valves. A shutdown also occurs if wiring errors are detected in the float switch, and the display will
indicate a bad float switch.
High Pressure - The AUTO SENTRY W will first attempt to unload and blow down the unit if excessive
pressures are detected in the reservoir or the plant system. If unsuccessful, a shutdown will occur. Shut
down will also occur if a defective transducer is detected. The display will indicate the location of the high
sensed pressure or transducer (xducer) error. Check that all adjustments have been properly made, and
all connections are secure.
Emergency Stop - Press the emergency stop button to shut down the unit and the controller. To
restart, pull the button out to its normal position and reset the controller. This should be used for
emergency purposes only - use the keypad [STOP/RESET] for normal controlled stopping.
Power Failure - Following power interruptions, the controller will remain in a shutdown state (unless
programmed for auto restart).
External Device - This input is provided for user- or dealer- installed devices needed by specific
applications. Other shutdown field selectable messages include: high vibration, phase relay, low voltage
relay, and water press. An optional expansion board must be installed to use this feature.
Other Shutdowns - The controller runs continuous diagnostic checks of its own operation and the
sensors to which it is connected. Refer to the service section for a complete listing of shutdowns and
remedial actions.
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300EWC1255
(Ref. Drawing)
Figure 4-2 – FLOW CHART FOR SETUP PROGRAMMING
PROGRAMMING AND SETUP FOR THE AUTO SENTRY W CONTROLLER
Programming and setup is accomplished with the PROGRAM keys. See Figure 4-2, page 20. In all
steps, the [ENTER] key will cause the controller to accept the displayed value into memory and advance
to the next programming function. The plus [+] and minus [-] keys will increase and decrease displayed
numeric values, or step through menu selections. During numeric adjustments, the right [>] and left [<]
arrow keys move the cursor (flashing digit) to the position desired. Use the [+] and [-] keys to change the
number at the cursor. At any point in the programming and setup routine, the [STOP/RESET] key can be
pressed to exit and return to the ready mode without altering the adjustment. In all steps of the
programming routine, the top line of the display will give a description of the parameter to be
programmed, while the bottom line shows the variable that is capable of being altered by programming.
The following is a step by step guide to programming the AUTO SENTRY W. Remember, between each
step, it is necessary to press the [ENTER] key to store the new value and advance to the next step.
Main Adjustments Menu
1.
The compressor must be stopped prior to making any adjustments. If the unit is running, press
the [STOP/RESET] key to place the control in the “READY” state.
Adjustments can also be performed while in the “SHUTDOWN” state. After the adjustments are
completed, the W controller returns to this state until the cause is repaired and the controller is
manually reset.
2.
Press the [ENTER] key to begin programming. This enters the adjustments menu. The
adjustments are broken into five groups as shown in Figure 4-2, page 20. To select a group,
press [+] or [-] until the desired group is shown on the bottom line of the display. Press [ENTER]
to proceed to the group adjustments detailed below.
Operation Adjustments
1.
In the top line, “DISPLAY UNITS” is indicated. The bottom line will indicate “ENGLISH” (PSIG,
Fahrenheit) or “METRIC” (Bars, Celsius) units of measurement. Select the desired display units and
press [ENTER] to proceed.
2.
The top line displays, “OPERATING MODE”. The bottom line will indicate the selected mode. Refer
to the description of modes at the beginning of this chapter, and select the desired mode, using the
[+] or [-] keys. When the desired mode is shown, press the [ENTER] key to save and proceed.
3.
In the top line, “START TIMER” is displayed. The bottom line will indicate a time between 2 and 10
seconds. This is the time that the controller spends in the unloaded ‘start’ mode. If reduced-voltage
starting is used, it should be set longer than the starter’s timer.
4.
In the top line, “UNLOAD PRESSURE” is displayed. The bottom line will indicate a pressure value. It
is to be set at the nameplate rating of the compressor for normal operation. Under NO
circumstances, is this adjustment to be set in excess of the compressor nameplate pressure.
5.
In the top line, “LOAD PRESSURE” is displayed. The bottom line will indicate a pressure value. This
setting determines the point at which machine startup occurs in AUTO and SEQUENCE modes and
when the compressor will load up from the blown down condition. Note that LOAD PRESSURE
cannot be set within 7 PSI of the UNLOAD PRESSURE. It is necessary that all machines to be
sequenced have the same UNLOAD and LOAD PRESSURE setpoints.
6.
In the top line, “AUTO TIME” is displayed. The bottom line will indicate a time between 5 and 20
minutes. It too, is factory set at 10 minutes. Its function is to prevent too frequent motor starting, and
to allow the motor a ‘cool-down’ period before stopping.
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7.
In the top line, “REMOTE STOP” is displayed. The bottom line indicates either “TIMED” or
“IMMEDIATE”. Refer to the description of “Remote On/Off” later in this section for additional details.
Select the desired response to the remote input and press [ENTER] to proceed.
8.
This completes the operational adjustments. The controller will return to the main adjustments menu.
Maintenance Adjustments
1.
If any service advisories are in effect (yellow ADVISORY indicator is on), they will be displayed on
the top line. The bottom line indicates “LEAVE ADVISORY” (do not reset) or “CLEAR ADVISORY”
(turn it off). Select the desired action and press [ENTER] to proceed.
2.
The top line displays “NEXT RELUBE” and the hours remaining are displayed on the bottom line.
Press the [+] or [-] keys to switch to the lubrication change interval (see UNIT SETUP) if service was
performed early. Press [ENTER] to proceed.
3.
This completes the maintenance adjustments. The controller will return to the main adjustments
menu.
Sequence Adjustments
See “SEQUENCING COMPRESSORS WITH THE AUTO SENTRY W, page 24, for more details on
setting up and optimizing a sequenced compressor installation.
1.
In the top line, “NUM OF SEQ UNITS” is displayed. The bottom line will indicate a number in the
range of one through eight. This will be factory set at “1”. This should be set to a number
corresponding to the number of compressors that are currently installed on this air system that also
have AUTO SENTRY W controllers. It should be noted that all AUTO SENTRY W compressors on
the system must have the same number programmed here to operate correctly in SEQUENCE
mode. Adjust as required, and press [ENTER] to proceed.
NOTICE
Setting the value in Step 1 to one indicates that no sequencing is to take place.
Consequently, Steps 2, 3 & 4, which relate to sequencing, are skipped by the
AUTO SENTRY W; the controller will return to the main adjustments menu.
2.
In the top line, “UNIT NUMBER” is displayed. The bottom line will again indicate a number of one
through eight and be factory set at “1”. Each AUTO SENTRY W in a sequenced system must have
a unique number here. The sequence mode will not function if two or more compressors have the
same UNIT NUMBER. The most efficient machine-to-machine communications will occur when the
lowest possible numbers are used. Example: 1, 2, and 3 for a three compressor installation.
All other settings should normally be the same for all units.
3.
In the top line, “TRANSFER INTERVAL” is displayed. The bottom line will indicate a number of
hours in the range of 1 to 5000. It is factory set at 24. This is the number of hours that this machine
will stay in the role of “master” or ”lead” compressor.
Normally it is desirable to set this to the same value on all sequenced units to equalize running
hours. Different values may be programmed, if desired, to help equalize hours.
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4.
In the top line, “LAG START DELAY” is displayed. The bottom line will indicate a number in the
range of 15 to 600 seconds. It is factory set at 30. This is the length of time this machine will wait
before starting when the pressure drops below the load point. This should be set to the same value
for all sequenced units. Its setting will depend on the amount of air storage volume in the system.
Too small a number will result in more compressors being started than is necessary to satisfy the
demand.
5.
This completes the sequence adjustments. The controller will return to the main adjustments menu.
Configuration Adjustments
1.
In the top line, “HI SYS PRES LIM” is displayed. The bottom line will indicate a value that is factory
set 20 - 25 PSI above name plate. This is the pressure that will cause a shutdown if exceeded due
to a malfunction such as a stuck inlet valve or broken control line. This should be set at or slightly
below the rating of the pressure relief valve. The controller will attempt a number of actions as it
approaches to prevent the pressure from reaching this limit.
2.
In the top line, “REMOVE SYS PRESS” is displayed. The bottom line displays the current pressure
being sensed at the package discharge. At this point, steps must be taken to ensure that system
pressure is, in fact, zero psig. Remove the line to the system pressure transducer. Pressing
[ENTER] will now cause the AUTO SENTRY W to calibrate the transducer output to zero PSIG.
Obviously, pressure measurement errors will be encountered if ’zeroing’ is done with pressure at the
transducer. If large errors are detected, the controller will demand that the transducer be checked.
3.
In the top line, “REMOVE RES PRESS” is displayed. The bottom line displays the current pressure
being sensed in the reservoir. The reservoir pressure transducer may now be ’zeroed’ by following
the steps outlined in 2 above.
4.
In the top line, “REMOVE INJ PRESS” is displayed. The bottom line displays the current pressure
being sensed in the water line. The water injection pressure transducer may now be ‘zeroed’ by
following the steps outlined in #2 above.
5.
This completes the configuration adjustments. The controller will return to the main adjustments
menu.
Unit Setup Adjustments
1.
In the top line, “RELUBE INTERVAL” is displayed. The bottom line will indicate a time interval of
1000 to 2000 hours. After the machine has run for the programmed setting, an advisory will be
displayed, requesting relubrication. Adjust as desired and press [ENTER] to proceed.
2.
In the top line, “OVER TEMP LIMIT” is displayed. The bottom line will indicate 150° F. This is the
maximum (and proper) setting for compressor operation. It may be temporarily lowered to verify the
function of the temperature shutdown system.
3.
In the top line, “AUTO RESTART” is displayed. The bottom line will indicate either ”OFF” or ”ON”
The factory setting is ”OFF”, and the controller will display a power failure shutdown after power has
been restored.
Set this feature to ON when it is necessary to have the compressor automatically restart after a
power interruption. There will be a brief delay, then the control resumes the mode it was in prior to
the interruption. This feature shall only be enabled when the owner determines that it is safe to do
so. It is recommended that compressor access be limited to only trained service personnel when
this feature is used.
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4.
This step is only encountered if the AUTO RESTART function was set to ON in the previous step. In
the top line, “RESTART DELAY” is displayed. The bottom line will indicate a time between 5 and 60
seconds. It is factory set at 10 seconds. This is the amount of delay introduced before restarting
after power has been restored. Set it as desired to allow for power to stabilize before starting
compressors.
5.
The display now reads “JOG MOTOR?” and indicates 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
o 0.2 seconds is normally adequate for factory-furnished full-voltage starters; Wye-Delta or remote
starters may require a little more time. Set back to zero to proceed to the next step.
6.
In the top line, “AUX SD MESSAGE” is displayed. The bottom line will display the message which
will appear if power is removed from the shutdown input on the optional expansion board. Select the
most appropriate message for user-furnished shutdown devices, and press [ENTER] to proceed.
7.
This completes the unit setup adjustments. The controller will return to the main adjustments menu.
OTHER CONTROL FEATURES
Auto restart after power failure - The AUTO SENTRY W controller normally displays “SHUTDOWN POWER FAILURE” after power has been interrupted and restored. Press the [STOP/RESET] key and
select an operating mode to restart the compressor.
If programmed for automatic restart, the controller pauses and begins counting down when power is
restored. This time is adjustable in the programming steps noted above. This must be at least several
seconds, but may be set longer to allow other plant loads to start up first. After the countdown is
complete, the controller resumes the mode of operation prior to the power interruption.
When auto restart is enabled, the green power indicator will blink whenever power is on. With auto
restart disabled, the power indicator lights steadily while power is on.
SEQUENCING COMPRESSORS WITH THE AUTO SENTRY W
An accessory expansion board, part number 301EWC1173, is required in each controller for sequencing
operation. This is included with any package ordered with wye-delta starters, and may be ordered
separately and installed on other packages. Refer to expansion board connection instructions later in this
section.
Sequencing compressors with the AUTO SENTRY W controller is as simple as plugging in a telephone to
a wall jack. The only item required to make the system functional is a standard telephone cable identical
to cables that connect nearly every telephone to its wall jack. One less cable than the number of
compressors to be sequenced is required. For example, to sequence four compressors, three cables are
required. A kit, 200EAP752, is available which contains all material needed to sequence up to five
compressors. This kit contains 500 feet of cable, eight modular connectors, and a crimping tool to install
the connectors.
In spite of its inherent installation simplicity, the sequencing function of a multi-compressor AUTO
SENTRY W system provides all the necessary features for maintaining pressure over a wide range of
plant demands.
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Installation
A proper sequencing installation requires two or more Gardner Denver rotary air compressors complete
with AUTO SENTRY W controllers, piped into a common air system, interconnected as described above.
For best performance, the units must be piped directly to the receiver, without any intervening check
valves, dryers, or other restrictions. The receiver should also be sized to prevent excessive drops or
rapid rises in pressures during the operation as described below. All standard practices common to
sound air compressor installations such as proper sizing of discharge piping, proper electrical supply and
conductor sizing, and grounding are to be observed. The serial communications interface meets RS-485
standards, the most widely used interface in harsh, industrial environments today. However it is still
recommended that the communications cables be routed through metallic conduit to provide them with
both mechanical protection and electromagnetic shielding.
Each expansion circuit board has two modular jacks which accept RJ-12 telephone plugs. One jack is
vacant, the other has a short pigtail plugged into it. To interconnect two compressors, plug the cable into
the vacant jack on each controller. For installations of more than two units, the pigtail plug must be
disconnected on all controllers except the two at each end of the communications line. The order of
interconnection has no effect on the system operation. The following conditions are necessary and
sufficient for proper operation:
1.
Every compressor must have a cable connecting it to another compressor. One less cable than the
number of units sequenced must be used.
2.
Each board that has only one cable connected to it must have its pigtail plugged into the unused
jack. All installations will have two such units.
Operation
1.
ESTABLISHING THE INITIAL SEQUENCE
Operation of compressors in sequence requires only selection of the sequence operating mode during
adjustments and a press of the [RUN] key on each compressor in the system. Since the sequencing
algorithm includes provisions for automatic replacement of a failed master or ’lead’ compressor, it is
important for the operator to be aware of the hierarchy of events when starting the system.
The first compressor placed into sequence mode will become the master. However, since any
compressor first placed into sequence has no way of knowing whether or not a master exists, it will first
assume the highest rotation number available. For example if the number of units to be sequenced is
programmed at four, any compressor will start out in position four when placed in sequence mode. It will
then listen on the communications line for a call from the master.
If no call is received, it will assume position three and again wait for a call from the master. After another
lack of a master call, it assumes position two. Subsequently, it assumes position one which makes it the
master. As soon as a master is established, it immediately attempts to call all other units and assigns
them successive rotation positions. The system is now active.
Before a master is established, the system is not deprived of air. This is due to one of the outstanding
features of the AUTO SENTRY W sequencing system: pressure control is always executed locally at
each individual compressor. The effective unload point for compressor control is the programmed unload
point minus 3 (rotation number - 1). So while compressors count down towards establishing a master,
they are also capable of delivering air at a pressure determined by the above formula.
To ensure that two or more machines do not simultaneously decrement their rotation numbers and
simultaneously become masters, it is advisable to place the desired master in sequence mode first and
wait until the first decrement in rotation number is seen (about 7 seconds) before placing subsequent
compressors in sequence mode. If it is desired to dictate the complete initial sequence manually, wait
until the previous machine decrements one position and then place the next desired compressor in
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sequence mode. If it is acceptable to let the master determine the initial sequence, simply wait until the
master has decremented its rotation number once, and then place all remaining compressors in
sequence mode. Remember that once a master is established, no further self-decrementing is done by
the individual compressors. Instead, they will wait until the master assigns them a rotation number.
Rotation numbers are displayed in the bottom display line, with the mode indication. For example, the
mode indication for the current master is SEQ1; for the first lag compressor, SEQ2; second lag, SEQ; etc.
2.
HOW THE “AUTO SENTRY W” CONTROLS PRESSURE WHILE SEQUENCING
Each compressor operates exactly the same as if it were in AUTO mode with one exception: it has a
dynamic unload point. The initial unload point is determined by the equation shown above. A
compressor is started when the system pressure drops below its programmed load point, after waiting for
[ ‘LAG START INTERVAL’ times (rotation number - 1)] seconds. This prevents all lag compressors from
starting at once. Note that a compressor’s [‘LAG START INTERVAL’ times (rotation number - 1)] timer is
not reset to zero until that compressor is started or until another unit in the system stops. This means that
the time for the next lag compressor to come on may be somewhat less than ‘LAG START INTERVAL’.
EXAMPLE:
In a three compressor sequence system, UNLOAD PRESSURE = 100 PSI; LOAD PRESSURE = 90 PSI;
LAG START INTERVAL = 15 seconds. The lead compressor is running alone, maintaining 90-100 PSI
when an air tool is brought on line causing the air demand to exceed the capacity of the lead compressor.
When the pressure drops to 90 PSI, the #2 unit times out its 15 second timer and starts. It takes 5
additional seconds for the pressure to rise above 90 PSI. The #3 unit whose timer was initially set at 30
seconds (15 x [3 - 1]), has counted down 20 seconds (the total time that system pressure was below 90
PSI). If air demand increases again, the pressure will have to fall below 90 PSI for only 10 seconds more
to start unit #3.
As was previously stated, a lag compressor’s unload point (PSET for short) is [UNLOAD PRESSURE 3(rotation number - 1)]. Thus in the above example, the first lag compressor (rotation #2) has a PSET of
97 PSI; the second lag, 94 PSI, and so on. But look what happens in an eight compressor installation:
The eighth compressor will have an initial unload point of [100 - 3(8 - 1)], or 79 PSI. Does this mean that
an eight compressor installation must operate 21 PSI below the desired operating point when all
compressors are running? NO! This is where the AUTO SENTRY W dynamic unload point control takes
over.
This is how it works: Whenever the system pressure is below the programmed LOAD PRESSURE, the
PSET of each lag compressor is incremented 1 PSI every thirty seconds. Thus, after a short interval
(about five minutes in this example), the PSET of the last sequenced compressor will climb up until either
it equals the LOAD PRESSURE, or a decrease in demand causes the actual system pressure to rise
above the LOAD PRESSURE. It can be seen then, that except for short periods just after a sudden
increase in demand, the AUTO SENTRY W, with its dynamic unload point control, will maintain system
pressure between the limits of LOAD PRESSURE and UNLOAD PRESSURE. Remember, LOAD and
UNLOAD PRESSURE values are programmed by the operator so the operating range is completely
programmable and predictable.
Dynamic unload point control will also work in reverse of the operation described above. Obviously,
incrementing unload points will cause overlap of the compressors’ modulation ranges. While this enables
us to maintain a higher pressure than competitor’s sequencers, overlap is undesirable as demand
decreases, because a system could end up with several compressors cycling instead of running the
minimum number of fully loaded compressors. To overcome this, as pressure rises through the range
between LOAD and UNLOAD, the lag compressors’ set points are now decremented, reversing the effect
described above during periods of high demand. The AUTO SENTRY W keeps track of all functions at all
times so there is never any mix-up of unload points and the proper rotation sequence is always
maintained.
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The Automatic Sequence Change
After the master (lead) compressor has served for the duration programmed (TRANSFER INTERVAL), it
relinquishes control and assigns itself the highest available rotation number. The lag compressors detect
the loss of the master and decrement their rotation numbers. Number 2 becomes number 1, the new
master, number 3 becomes number 2, etc.
It should be noted also that whenever the master detects a missing rotation number, such as when a
compressor is turned off that was previously in the rotation, it will automatically ’close the gap’ by
decrementing the rotation numbers of all compressors whose rotation numbers were greater than the
missing number. Likewise, if for whatever reason, the master compressor fails to carry out its role, all lag
compressors begin decrementing their rotation number until a new master is established. Regardless of
the scenario, the end result will always be that the compressors that remain in rotation will always end up
with the lowest possible rotation numbers.
Other Features
Any air system will exhibit pressure differences from one point to the next. Even a well designed multicompressor installation will show ‘minor’ pressure variations between one compressor’s discharge point
and another compressor’s discharge. These points will also vary from the central system (normally the air
storage receiver). The AUTO SENTRY W sequencing system is designed to tolerate minor variations.
These pressure differences wreak havoc with conventional sequencers. If a central sequencer is used, it
will be sensing a lower pressure than is seen at each compressor. With such systems, there is always a
chance that the sequencer could cause a compressor to over pressure due to this pressure drop. The
alternative has been to set the central sequencer to a lower pressure to prevent this or allow local
override of the sequencer by the local pressure control, neither of which is desirable in the scheme of
maintaining plant pressure efficiently with sequencing. The AUTO SENTRY W sequencing system will
automatically adjust the system to prevent over pressures in any individuals.
The AUTO SENTRY W sequencing system lets each compressor control itself independently between
setpoints derived to cause staggered operation, or sequencing. The aforementioned pressure drops can
also cause derogatory effects (mainly skewed, or out of sequence operation) to the sequencing algorithm
used by the AUTO SENTRY W.
Since these pressure variations are not constant (they will vary due to demand changes, compressor load
/ unload changes, and number of compressors running), any scheme to compensate for the pressure
variations must be dynamic. The exclusive dynamic unload point control feature enables this error
correction scheme to be accomplished rather easily.
Here’s how it works: The master continually receives system pressure values from every machine in the
sequence rotation. The values are averaged and this average is then distributed to all lag compressors.
All compressors, lead and lag, then compare their local pressure reading to the average and adjust their
PSET by the amount of error. The effect is that all compressors are controlling to a single pressure
reading, a reading that is not one that is picked up somewhere removed from the compressor, but an
average of actual discharge pressures.
It should be noted that the pressure displayed on the top line by all sequenced compressors is this
average.
CONNECTION OF EXPANSION BOARD AND EXTERNAL CONTROL CIRCUITS
The AUTO SENTRY W controller has a connection port for use with an expansion board, part number
301EWC1173. This provides interconnection points for external controls and indicators. This allows
simple connection to remote controls and indicators, or integration into any plant wide controls system.
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The expansion board also provides the data port for communications in sequencing. The expansion
board is pre-installed on any unit with factory-mounted Wye-Delta starters.
To install on other units, stack the expansion board over the main control board, and mount with the
hardware included. Use the cable to connect the expansion board to the main board. The AUTO
SENTRY W controller automatically detects the presence or absence of the expansion board, but 120V
input circuits must be connected to the expansion board for proper operation. Spare terminals are
provided at the control terminal strip in the box for connection of the following 120v circuits. Connect
either to unused existing terminals, or mark blank terminal locations for new points shown.
Connect from the expansion board plug to terminals as follows:
Expansion Plug
Panel Terminal
J1-1
8 (existing)
J1-2
no connection
J1-3
23 (new)
J1-4
24 (new)
J1-5
10 (existing)
J1-6
21 (new)
J1-7
20 (new)
J1-8
19 (new)
Remote On / Off - Remote on-off control of the system requires only a simple two-wire control, with an
isolated contact suitable for 120 volts, 1 amp. This may be a switch, a timer contact, a relay contact, or a
PLC output. To connect, simply run the two wires to the control enclosure, remove the jumper (if present)
between terminal 9 and 31, and connect the pair of wires from the switch to terminals 9 and 31.
The air compressor will operate normally in its selected mode whenever this contact is closed (turned on).
Note that the keypad is always the master control; the [RUN] key must be pressed to place the control
into an operating mode. The remote is not capable of starting a unit after the [STOP/RESET] key has
been pressed to place the controller in the READY state. When the contact is opened (turned off),
operation depends on how the controller has been programmed and what it is doing prior to opening the
contact.
If the compressor was already stopped in automatic or sequence modes, it will remain stopped and will
not restart until the contact is closed. The display will flash the message “REMOTE STOP” to indicate
that it is waiting for the remote signal.
If the compressor was running in any mode when the contact was opened, and the remote response is
programmed for “IMMEDIATE”, the compressor will immediately unload and blowdown. After completion
of blowdown, the motors will stop, and the unit will be in the “REMOTE STOP” mode as indicated above.
If the compressor was running in any mode when the contact was opened, and the remote response is
programmed for “TIMED UNLOAD”, the compressor will immediately unload and blowdown. It will then
continue to run unloaded for whatever period has been programmed for “AUTO TIME” (or will complete
the remaining auto time if already blown down). After completion, the motors will stop, and the unit will be
in the “REMOTE STOP” mode as indicated above. This is the preferred setting for automatic remote
controls which may cycle in less than 1/2 hour, as the motor is always cooled evenly and rapid start
cycles are prevented.
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If remote control is not desired, this input must be jumpered to operate the compressor. Connect a
jumper between terminals 9 and 31.
Auxiliary Shutdown - This input allows factory or field connection of shutdown switches not included on
the standard package. Simply connect a two-wire switch to terminals 9 and 31. The switch must be
selected which has contacts closed for normal conditions, and open to shutdown the compressor. If the
contact is opened, the compressor will be shut down, and will display a user selectable message (refer to
unit setup adjustments for list of messages).
If no additional switch is desired, this input must be jumpered to operate the compressor. Connect a
jumper between terminals 9 and 24.
Alarm Relay - The expansion board is provided with an alarm relay which may be connected to a
remote mounted indicator light, horn, or into a PLC input of a plant wide control system. The contact is
commercial rated 2 amps at 120 volts. The relay is turned on whenever there is a shutdown condition
requiring service at the compressor, and remains off during normal operation, stopping, or power off
conditions. The external connections from the controller are from an isolated form C (single-pole, doublethrow) contact. This allows control of either a ”compressor okay” or a ”compressor shutdown” remote
indicator.
To use this relay, connect the supply wire for the remote circuit to terminal 21 (relay common) on the
terminal strip. Connect a wire to the indicator from either terminal 19 (normally open) or from terminal 20
(normally closed). Connect the other side of the indicator to its neutral.
Serial Communications – If units are NOT connected in sequence, the RS-485 port may be used for
multi-drop communications of compressor data to external monitoring system. Data available include all
pressures and temperatures, and a report of internal service data. Version 1.10 or later software is
required in the controller. Data communications are accessible with a PC or PLC with an appropriate
communications port. For protocol information, request Drawing 301EWC1255.
OTHER CONTROL DEVICES
In addition to the electronic controller noted above, the following components are also used to control
operation of the compressor unit. Refer to air/water schematic, Figure 1-3, page 3, for their relative
location.
Relief Valve (vv) - A pressure relief valve is installed in the final discharge line and set to approximately
120-125% of the unit’s full load operating pressure for protection against over pressure. Periodic checks
should be made to ensure its operation.
The relief valve should be tested for proper operation at least once every year. To test the relief valve,
raise the system operating pressure to 75% of the relief valve set pressure and manually open the valve
with the hand lever. Hold the valve open for a few seconds and allow it to snap shut.
WARNING
When the relief valve opens, a stream of high velocity air is released, resulting
in a high noise level and possible discharge of accumulated dirt or other debris.
Always wear eye and ear protection and stand clear of the discharge port when
testing the relief valve to prevent injury.
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CAUTION
Never paint, lubricate or alter a relief valve. Do not plug vent or restrict
discharge.
WARNING
Operation of unit with improper relief valve setting can result in severe personal
injury or machine damage. Insure properly set valves are installed and
maintained.
Blowdown Valve (g) - This solenoid valve provides purging air to the compressor during unloaded
operation. It also depressurizes the air/water reservoir during unloaded or halted operation. It is
governed by the AUTO SENTRY W controller.
Aux. Blowdown Valve (h) – This solenoid valve depressurizes rapidly the air/water reservoir during the
initial phase of the unloading cycle. It is energized by the auxiliary pressure switch.
Aux. Pressure Switch (j) – This device senses the air reservoir pressure and controls the closing level
of the auxiliary blowdown valve during the latter phase of the unloading cycle. Its setting (see Figure 4-3,
page 30) is adjusted to maintain the compressor inlet pressure within 0 to 11” Hgv during unloaded
operation. It is housed in the starter control box, but it is independent from the AUTO SENTRY W
controller.
Model Power – bhp
20
20
20
25
25
25
30
30
30
Line Pressure – psig
100
125
150
100
125
150
100
125
150
Receiver Pressure – psig
41
32
26
46
40
32
51
48
37
Figure 4-3 – AUXILIARY PRESSURE SWITCH/RECEIVER UNLOADED PRESSURE TABULATION
Check Valve (Aux Blowdown) (i, next to b) – This check valve prevents back flow of air from the
airend immediately after halting operation.
Check Valve (Main Discharge) (k) – This check valve prevents back flow of air from the customer’s air
line when the unit stops, unloads, or is shut down.
Inlet Valve (b) – This device modulates the flow of air entering the compressor and checks the back
flow of air immediately after halting compressor operation. Its piston assembly is energized with air from
the subtractive valve (during modulation) or with air from the main blowdown valve (during unloaded
operation).
Subtractive Valve (q) – This device produces a variable pneumatic signal (0 to 20 psig) in proportion to
a system pressure rise (0 to 10 psig) above its set pressure. It is used to control the flow modulating
action of the inlet valve. The device is adjusted as follows:
•
Loosen the locknut securing the adjusting stem of the subtractive valve and screw the latter
in several turns – this will prevent the valve from opening during adjustment. This is also the
way to deactivate the device by adjusting its pressure setting beyond the expected package
operating range.
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•
Operate the compressor until the desired discharge pressure is achieved – in case the supply
of air exceeds the demand, bleed some of the discharge air to achieve the target system
pressure.
•
Back-out the adjustment stem until the subtractive valve starts to bypass air – the adjacent
pressure gauge should register movement of less than 1 psig. Now the device is ready to
feed a proportional air signal to the inlet poppet valve as the system pressure builds beyond
the present level.
•
Tighten the lockout to secure the position of the adjustment stem.
The subtractive valve can be disassembled and the diaphragm and ports cleaned.
Water Pressure Relief Valve (ss) – This device protects the water treatment filtration system against
75 psig overpressure in the line common with the compressor inlet.
Air Pressure Regulator (All Seal Purge) (n) - This device regulates the pressure of the air buffer
signal fed to all seals. It should be set to 5 to 7 psig.
Water Pressure Regulator (Inlet Seal Purge) (w) - This device regulates the pressure of water buffer
signal fed to the inlet seals. It should be set to 2 to 3 psig.
Pressure Gauge (o) – This 0 to 15 psig device displays the output signal from the pressure regulators.
Shuttle Valve (l) - Also known as a double check valve, the shuttle valve is a device which will take two
(2) supply signals and allow the one with the highest pressure to pass through.
System Pressure Transducer (s) - This device measures the delivery air pressure supplied to the
customer. The AUTO SENTRY W controller uses this measurement for loading/unloading logic. It is
located in the starter enclosure.
Reservoir Pressure Transducer (t) - This device measures the discharge pressure from the water
cooler. The AUTO SENTRY W controller uses this measurement to prevent loaded starts and to monitor
coolant pressure. It is located in the starter enclosure.
Injection Pressure Transducer (u) - This device measures the recirculation water filter discharge
pressure, prior to injection into the compressor. The AUTO SENTRY W controller uses this
measurement, in conjunction with that from the reservoir pressure transducer, to monitor the pressure
losses across the recirculation water filter. The AUTO SENTRY W controller displays a service warning
at 30 psig differential and shuts the package down at 40 psig differential. It is located in the starter
enclosure.
Air Filter Vacuum Switch (ww) - This device senses the air pressure at the discharge side of the air
filter. The AUTO SENTRY W controller displays a service warning when a 25” H20 pressure level triggers
the switch. It is located in the starter enclosure.
Discharge Thermistor (v) - This device measures the compressor discharge temperature. The AUTO
SENTRY W controller uses this measurement for display and shutdown logic purposes. It is located at
the compressor discharge port.
Water Level Switches (z) - This assembly (three level switches) senses water level in the reservoir.
The AUTO SENTRY W controller uses the individual signals to drain or fill the reservoir with water and to
shut the system down if an exceedingly high water level prevails.
Water Solenoid Valves (aa, rr, tt) - The fill (tt) and drain (aa) valves respond to the signal from the
water level switches to fill or drain, respectively, water from the main reservoir. The dump (rr) valve
responds to signals from the PLC to dump the water charge stored in the water treatment reservoir when
the compressor unit is not operating.
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PLC (RO timer function) – This device governs the frequency and duration of the water-fill cycles. It
shares use of the fill water solenoid valve with the AUTO SENTRY W controller and governs the dump
water solenoid valve. It is located in the starter enclosure. Refer to the RO Filtration System, SECTION
8, for details on its operation and adjustments.
Emergency Stop/Push Button - This is a maintained push-button, and removes power from the
controller outputs regardless of controller status. It is located 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 controlled stopping.
WARNING
Automatic restarting or electrical shock can cause injury or death. Open, tag
and lockout main disconnect and any other circuits before servicing the unit.
Control Transformer - This changes the incoming power voltage to 110-120 volts for use by all unit
control devices. Two primary and one secondary fuse are provided. Refer to adjacent labeling for
replacement information.
Terminal Strip - This provides connections for all 110-120 volt devices not contained within the
enclosure.
Fan Starter - The starter is used to provide control and overload protection for the fans. Overload
heaters should be selected and adjusted based on the motor nameplate amps and the instructions
located inside the cover of the electrical enclosure.
Main Starter - This starter is used to provide control and overload protection for the main drive motor.
Full voltage starters employ a single contactor. Overload heaters should be selected and adjusted based
on the motor nameplate amps and the instructions located inside the cover of the enclosure. Wye-Delta
starters employ three contactors which are controlled sequentially to provide low current starting. For
Wye-Delta starters, the motor nameplate amps must be first multiplied by 0.577 before using the heater
table.
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305EWC546-B
(Ref. Drawing)
Page 1 of 2
Figure 4-4 – WIRING DIAGRAM – FULL VOLTAGE
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305EWC546-B
(Ref. Drawing)
Page 2 of 2
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306EWC546-B
(Ref. Drawing)
Page 1 of 2
Figure 4-5 – WIRING DIAGRAM – FULL VOLTAGE LESS STARTER
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Page 35
306EWC546-B
(Ref. Drawing)
Page 2 of 2
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SECTION 5
LUBRICATION
COMPRESSOR OIL SYSTEM - The airend oil reservoir is filled with oil and the inlet bearing lubrication
fittings are greased at the factory before shipment. A tag on the reservoir fill cap indicates the type of oil
in the reservoir as it left the factory.
RECOMMENDED LUBRICANT - Gardner Denver compressors are factory filled with AEON™
lubricants. These lubricants are formulated to the highest quality standards and are factory authorized,
tested and approved for use in rotary screw compressors.
AEON lubricants are available through your authorized Gardner Denver compressor distributor.
OIL SPECIFICATIONS - The airend reservoir is factory filled with AEON 800 lubricant. A lubricant
analysis program for a periodic check of lubricant quality and remaining life can maximize the change
interval.
For grease specifications, refer to “Electric Motor Grease Specifications,” page 11.
Material Safety Data Sheets (MSDS) are available for all AEON lubricants from your authorized Gardner
Denver distributor or by calling 217-222-5400.
CAUTION
Use of improper lubricants will cause damage to equipment. Do not mix
different types of lubricants or use inferior lubricants.
CAUTION
Improper equipment maintenance with use of synthetic lubricants will damage
equipment. Oil change intervals must be adhered to for maximum compressor
protection and efficiency. See “Maintenance Schedule”, page 50
WARNING
High temperature operation can cause damage to equipment or personal injury.
Do not repeatedly restart the unit after high temperature stops the operation.
Find and correct the malfunction before resuming operation.
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LUBRICANT MAINTENANCE INTERVAL - The oil reservoir at the discharge end of the airend has a
capacity of approximately 32 oz. (.8 liters). The oil bath type lubrication utilized does not require an oil
filter or dedicated circulation hardware. As such, discharge end lubricant change intervals of 2000 hours
are recommended as the only maintenance requirement in lieu of filter changes and circulation system
maintenance.
NOTICE
IF OIL IS ANALYZED at the end of a maintenance interval (2000 hr. max.), and is
found in good condition, it may be used for the next 2000 hour interval – GD
provides free oil analysis services. OTHERWISE, IF OIL IS NOT ANALYZED at
the end of any interval, it must be changed.
The drive end bearings of the airend should be lubricated with the prescribed grease every 2000 hours of
operation until a small amount comes lightly out of the relief holes on the lower sides of the compressor
inlet end or on the inlet end cover.
During initial start-up and after regreasing, a small amount of grease may be ejected from the relief holes.
Wipe off any excess lubricant.
Severe operating conditions may require shorter regreasing intervals.
OIL LEVEL SIGHT GLASS -Figure 1-2, page 2) indicates the amount of oil in the airend oil reservoir.
Read the oil level when the unit is off. In operation the oil level may fluctuate.
Add oil only when the oil level drops into the lower half of the glass. Drain oil only when the compressor
is off.
Figure 5-1 – OIL LEVEL SIGHT GLASS
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SECTION 6
AIR FILTER
Figure 6-1 – HEAVY DUTY AIR FILTER (STANDARD)
HEAVY-DUTY AIR FILTER (Figure 6-1) furnished as standard equipment on units with an enclosure is a
heavy-duty washable element dry type air filter. The air filter must receive proper maintenance if
maximum service is to be obtained from the unit. Establishing adequate and timely filter service is MOST
IMPORTANT. Improperly maintained air filter can cause a loss of compressor air delivery.
Filter Element - Service the air filter element when the “CHANGE AIR FILTER” message appears on
the display accompanied by a yellow indicator in the status area of the keypad. Clean every 50 to 150
operating hours depending on dust conditions.
NOTICE
Use only genuine Gardner Denver air filter elements on Gardner Denver
compressor units. Genuine parts are available through your authorized
Gardner Denver distributor.
To service:
1.
Remove the wing nut and pull out the filter element.
2.
Visually inspect the element. If cleaning is not necessary, reinstall the filter element. If the
element requires cleaning, go through Steps 3, 4 and 5.
3.
Wash the element by soaking about 15 minutes in warm water with a mild non-sudsing 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).
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4.
Inspect the element for ruptures or cracks in the pleated media; replace the element if any are
found. Inspect the gasket on the bottom (outlet end) of the element; replace the entire element if
the gasket is damaged. A spare element will keep down time to a minimum.
5.
Allow the element to air dry COMPLETELY. Do not expose the element to heat over 150° F
(66° C). Install the element in the filter body and fasten securely with the wing nut.
WARNING
Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use
solvents other than water. Improper cleaning may damage the element.
NOTICE
Never operate the unit without the element. Never use elements that are
damaged, ruptured or wet. Never use gaskets that won’t seal. Keep spare
elements and gaskets on hand to reduce downtime. Store elements in a
protected area free from damage, dirt and moisture. Handle all parts with care.
Filter Element Life - The element should be replaced after six (6) cleanings or if:
1.
Visual inspection indicates a rupture, crack or pin hole in the pleated media. Inspection should be
done by placing a bright light inside the element.
2.
Pressure drop across a filter with a freshly cleaned element is below three (3) inches (76 mm) of
water with the compressor running at full load - this would indicate a rupture or crack.
Inlet Tube - Inspect 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 remove any dirt falling from the inlet tube before reinstalling the element.
Causes of short element life include: severe dust conditions, infrequent servicing, improper cleaning, or
contamination by oil or chemical fumes.
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SECTION 7
BELT DRIVE
Proper drive belt tension and alignment are provided at the factory; however, good practice dictates
checking the drive alignment and tension after shipment and before initial start-up.
Sheaves should align straight across the front with a straight edge. The best tension is just enough
tension to keep belts from “squealing” on start-up.
CAUTION
Excessive belt tension can damage the equipment. Tension the belts as shown
in Figure 7-1, page 42.
Belts can be changed when necessary by the following instructions: Disconnect, tag and lockout power
to the starter, remove the belt guard, and loosen, but do not remove, the four motor foot nuts.
Next, use the adjusting screws in the motor base to loosen belt tension. Remove the belts, and replace
with new belts. Check for correct belt tension and sheave alignment, tighten the motor foots bolts, and
re-attach the wire guard.
CHECKING BELT TENSION - Using a spring scale, apply a perpendicular force to each belt at the
midpoint of the span and measure the deflection. Correct deflection force and deflection are shown in
Figure 7-1, page 42. To tighten belts, merely increase the center distance between the sheaves.
NOTICE
When a new set of belts is installed on a drive the initial deflection force should
be 1/3 times greater than shown in Figure 7-1, page 42. Recheck tension
frequently during the first 24 hours of operation.
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Deflection Force (Lbs.) (N)
Deflection (Inches) (mm)
No. of Belts
Deflection
Force Pounds (Newtons)
(per belt)
Deflection
In
Inches (mm)
20 (15 kW)
4
6 to 7 (1.3 to 1.5)
5/16 (8)
25 (19 kW)
4
6 to 8.5 (1.3 to 1.9)
5/16 (8)
30 (22 kW)
4
6 to 7 (1.3 to 1.5)
5/16 (8)
Motor
H.P. (Kw)
Figure 7-1 – BELT TENSION 3VX BELTS
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SECTION 8
RO WATER FILTRATION SYSTEM
General Information:
The water mass utilized by the water-flooded screw compressor typically contains solids in dissolved and
suspended forms. These solids, of organic and inorganic nature, are present in the local water supply or
are deposited by the air stream pumped through the compressor, and usually contain corrosive and
fouling agents. Under conditions which promote the precipitation of dissolved solids, the latter may
deposit on adjacent surfaces and disrupt the transfer of heat in cooler cores, impede the motion of
mechanical components (e.g., the inlet throttling valve, solenoid valves, etc.), or abrade the surface of
shaft sealing elements. The concentration of solids residing in the close-loop water mass also increases
with time. As the water evaporates by interacting with atmospheric air, and as the solubility of hardnesscausing agents decreases with heat, solids precipitate and increase their amount in the water.
The RO (reverse osmosis) filtration system integrated into your compressor package overcomes
the above-mentioned problems as follows:
•
It provides a source of clean water, thus limiting the amount of fouling agents that may
appear in the close-loop water mass.
•
It provides regular, repeatable, and programmable exercising of the treatment filters, thus
keeping their elements working at peak efficiency and prolonging their service life.
•
It provides regular, repeatable, and programmable means to drain water from the close-loop
system, thus flushing away any suspended solids.
•
It operates the filtration system independent of compressor running state.
Principles of Operation:
The system layout is shown in the Figure 1-3, page 3, and the operation of its main components will be
described as follows:
The sediment filter (hh) is the 1st stage of filtration provided. Its 5-micron element traps sediments such
as silt, sand, grit, and sludge from the raw feed water.
The carbon filter (ii) follows the sediment filter. Its 10-micron element absorbs, among various
compounds, chlorine, which is harmful to the RO membrane.
The back-pressure regulator (jj) controls the feed of water to the RO system. As the holding tank (nn) fills
and water pressure builds up, the regulator stops water flow once the latter reaches 65% of the feed
water pressure. Pressure gauge (xx) indicates the water pressure in the holding tank.
The RO filter (kk) is the last and finest filtration step of the system. Its semi-permeable membrane
separates organic and inorganic impurities from the water, at the molecular level, when a pressure
differential greater than the osmotic pressure of said impurities in the water is present. It fills the holding
tank with 3.0 gal of filtered water in 2.2 hrs, when fed 14.4 gal of raw water at 90 psig, 70° F, and 150
TDS. The membrane requires a minimum raw feed water pressure of 50 psig to sustain the cleansing
process. The quality and volume of treated water is proportional to both the pressure and the
temperature of the raw feed water.
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The capillary tube (mm) controls the flow of wash water used to flush away the contaminants captured by
the RO membrane. The flushing process, active whenever the membrane is filtering water, requires 3.5
gpm of treated water for every 1 gpm of treated water delivered. The fast-flush valve (ll) is provided to
intensify the flushing process during periodic maintenance.
The 3.2 gal holding tank (nn) stores the filtered water output from the RO membrane for use in timed
batch cycles. An internal flexible membrane, pressurized with 10 psig air (tank without water), helps
evacuate the water from the holding tank.
The electronic timer module, included in the supplied programmable logic controller (PLC), and powered
by 120 VAC, determines the frequency (off time) and duration (on time) of the RO system water
dispensing cycles:
•
The GD designed program is downloaded to the PLC via an RS485 port and is stored in a
non-volatile EEPROM memory to end battery failure worries.
•
The “off” cycles are adjustable in 1, 2, 3, 5 and 7day intervals, and the “on” cycles are
adjustable to a 3 or 5 minute. intervals, but are typically set to 3 days “off”/3 minute. “on”
cycles.
•
A short test mode, 10 seconds “off”/5 seconds “on”, is provided to check the timer
operation.
•
Two additional cycles are provided to initially fill the reservoir with water in the field: 4 hour
and 8 hour “on” cycles. These cycles allow the field user to fill the reservoir unattended –
at the end of the “on” period, the cycle freezes in time until the mode switch is toggled off/on
again.
•
The setting of the cycles is accomplished via wire jumpers between PLC terminals 4, 5,
6, 7, and 9 – See Figure 8-1, page 46, for details.
•
An external switch is provided to execute the program in memory (run mode) or to halt and/or
allow the loading of programming (stop mode).
•
The external switch, when toggled from “stop” to “run”, resets the time counter to 0 and
initiates the “on” cycle first. This is particularly helpful when using one of the two fill cycles
during initial package commissioning.
•
At power-up, the timing sequence starts with the “off” cycle first. If the program execution is
halted via the external “run/stop” mode switch, the cycle under operation is “frozen” in time
until the switch is set back to “run”.
•
During the “on” cycle, whenever the compressor is running, the “fill” relay and the water fill
solenoid valve are energized and the water stored in the holding tank is admitted into the
package water system via the compressor intake.
•
During the “on” cycle, whenever the compressor is stopped, the dump solenoid valve is
energized and the water stored in the holding tank is evacuated via the package drain tubeworks.
•
When the water level in the package receiver reaches a high level, the package high level
float switch triggers the package ES controller to dump the excess water mass via the
package drain valve.
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CAUTION
Ensure that the PLC “run/stop” mode selection switch remains in the “run” position at all times
– except during reprogramming. Failure to do so will halt the timed operation of the RO Filter
System and will damage its membrane by fouling.
RO System Specifications :
Clean water flow capacity: 73 gpd (192ml/min) at 50 psig, 70° F, 150 TDS raw feed water.
94 gpd (247ml/min) at 90 psig, 70° F, 150 TDS raw feed water.
Effect of water temperature of on clean water production: 1.8% flow change for every degree of temperature change
above (+) or below (-) 70° F rating.
Effect of water pressure on clean water production: 1.7% flow change for every psig of pressure change above (+)
or below (-) a known (e.g., 90 psi or 50 psi) rating.
Raw water-to-clean water flow ration: System utilized 3.5 gal of raw water to discharge 1 gal of treated water.
Working pressure:
40 to 100 psig.
Working temperature:
40° F to 104° F.
Holding tank capacity:
(5 gal model) holds 3.0 gal @ 10 psig membrane air pressure, 90 psig feed.
(5 gal model) holds 2.5 gal @ 10 psig membrane air pressure, 50 psig feed.
(7 gal model) holds 7.0 gal @ 10 psig membrane air pressure, 90 psig feed.
(7 gal model) holds 6.0 gal @ 10 psig membrane air pressure, 50 psig feed.
Holding tank evacuation time:
RO membrane design:
3.5 minutes when filled with 90 psig feed.
2.5 minutes when filled with 50 psig feed.
spiral wound TFA
Sediment prefilter:
5-micron element, spun PPE w/o end caps, typical 4 psid loss clean at full flow.
Carbon prefilter:
10-micron charcoal element, PPE wrap/netting, w/end caps, typical 1 psid loss clean at full flow.
Rejection levels of various water-soluble compounds:
Calcium
Copper
Hardness
Manganese
Iron
Lead
Silica
Sodium
Sulfate
96-98%
98-99%
95-98%
98-99%
95-98%
96-98%
85-90%
87-98%
98-99%
Incoming raw water allowable contaminant concentrations:
Total Dissolved Solids (TDS):
Iron
Hardness (non-carbonate)
Hydrogen Sulfide
Manganese
Silica
Turbidity
pH
1800 ppm
0.4 ppm
293 ppm
.05 ppm
.1 ppm
100 ppm
20 FTU
6.5 to 8.5
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Page 45
Initial Set-Up and Operation:
The RO system is fully assembled and integrated into the compressor package.
As delivered, the new RO membrane contains a FDA approved preservative solution to prevent
microbiological growth and freezing. This preservative will be flushed during the initial hours of operation.
Adjusting the cycle timer.
The frequency of fill-up cycles ultimately depends on the quality of the water within the main reservoir.
Cycle times of 3 days “off” and 3 minutes “on” typically yield acceptable results – injection water TDS level
is held below 60ppm and no suspended solids form. To conserve water, longer “off” time cycles may be
used if the resulting injection water quality does not exceed 60 ppm and no suspended solids form.
Adjustment of the timer for 3 days “off” and 3 minutes “on” cycles is accomplished by interconnecting PLC
terminal 4, 6, 7, and 9 with jumper wires. Refer to Fig 8-1 for PLC connections and cycle-time
combinations available.
Reverse Osmosis Cycle Time Table
Connect Wire # 9 to PLC Input
Terminals (shown by “X”)
4
5
6
7
Time On
Time Off
3 Min.
1 Day
3 Min.
2 Days
X
3 Min.
3 Days
X
3 Min.
5 Days
X
3 Min.
7 Days
X
X
Fill 4 Hr.
X
X
X
5 Min.
1 Day
X
5 Min.
2 Days
X
X
5 Min.
3 Days
X
X
5 Min.
5 Days
X
X
5 Min.
7 Days
X
X
X
X
X
X
X
X
Fill 8 Hr.
Test 5 Sec.
Test 10 Sec.
Figure 8-1 – PLC CONNECTIONS AND CYCLE TIME COMBINATIONS
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Page 46
X
X
X
X
X
Maintenance:
Monitoring the water quality.
The performance of the RO system is directly related to the quality of the incoming raw water. It is critical
that an on-site water-sampling schedule be originated to monitor the performance of the RO system.
By comparing specified rejection rates to those experimentally observed, the performance of the RO
system is determined. For example, if the raw water feed and RO clean water total hardness are
measured at 200 ppm and 5 ppm respectively, this is indicative that the system is performing adequately,
as the normal rejection level for this compound is [200 ppm x 95% = 10 ppm].
Three (3) water test drains (gg, qq, and uu) have been provided to retrieve samples of the raw, clean, and
injection water flows – make sure to run the test valve for a few seconds to get a fresh water sample. It is
recommended that the following devices be available to check the water quality:
•
Test strips. Hach (1-800-227-4224) supplies a vial with 50 strips which monitor 5 different
water parameters (total chlorine, free chlorine, total hardness, total alkalinity, and pH) in a
single paper strip (Cat. No. 27552-50). One other vial with 25 strips, monitors total iron (Cat.
No. 27453-25), a very common contaminant (rust) in water pipes. A test only involves
inserting the test strip in a water sample and comparing the resulting color changes to a
chart printed on the vial. The results indicate gross water quality for trending purposes and
serves as an early warning of upsets conditions that may require a formal laboratory
analysis.
•
TDS analyzer. Hach (1-800-227-4224) has available a pocket unit, Cat. No. 44400-00, which
measures the total dissolved solids in water samples.
CAUTION
It is recommended that the quality of the water be checked weekly after the
package is commissioned or after major repairs (e.g., airend exchange) take
place. If consistent results are obtained, the testing interval can be extended to
longer testing periods, but these should not exceed 4 weeks.
CAUTION
The use of make-up water exceeding the quality limits outlined in the “RO Water
Filter”, SECTION 8, may result in damage to critical compressor components by
corrosion and/or scaling action of impurities in the water.
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Monitoring the water flow
In addition to the water quality, it is important that the filtered water flow be checked monthly:
•
Turn off the isolation valve (pp) on the water tank (nn).
•
If the compressor is not running, just open the filtered water test point (qq), let it run for a few
seconds to depressurize the line, and then time-collect a sample of the steady stream.
Expect to collect between 192 to 247 ml/min of filtered water, depending on the raw feed
water pressure.
•
If the compressor is running, make sure that the fill solenoid valve (tt) does not open during
the collection time, otherwise an erroneously low volume can result.
Filter cartridges.
The operational lives of the sediment and carbon filters elements vary with the quality of the raw feed
water. As a general rule, they should be replaced yearly or whenever the reverse osmosis membrane is
exchanged. Typical signs that these devices are plugging up are a decrease of clean water flow and/or
an increase of chlorine in the clean water (carbon filter upset).
Replacing filter cartridges:
•
Turn off the valve (ff) feeding raw water to the RO system.
•
Open the raw and RO water test drains (gg, qq) to depressurize the water charge from the
reservoir (nn) and lines.
•
Unscrew the filter housing sumps by hand or with the provided spanner wrench – note that
the o-ring may lift out of the housing and stick to the cap.
•
Remove the used cartridges and discard. If signs of fouling are visible, rinse out the
housings and fill 1/3 with water, then add 2-3 tablespoons of bleach, scrub clean with brush
or sponge, and rinse thoroughly with water.
•
Remove o-rings from the housings and wipe groove and o-ring clean. Lubricate o-rings with
a coating of clean petroleum jelly. Place o-rings back into grooves and press with fingers to
seat. If anyone o-ring appears damaged or crimped, replace immediately.
•
Install the new cartridges into sumps making sure that it slips down over the sump
standpipes.
•
Turn the sump into the cap and hand-tighten – do not over-tighten.
•
Close the raw water test point.
•
Open the raw water shutoff valve. After a minute or so, a trickle of water should be coming
from the open RO water test drain, indicating the system is again producing water. Close
now the RO water test drain.
•
The water reservoir, at a minimum raw water pressure of 50 psig, will fill up in about 2 hours.
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RO membrane
The operational live of the RO membrane also varies with the quality of the raw feed water. As a general
rule, it should be replaced every 1-2 years. Typical signs that the device is plugging up are a decrease of
clean water flow and a decrease of rejection of levels of compounds found in the site water. If rejection of
any compound falls below a 70% level consistently, the membrane should be replaced and so should the
sedimentation and carbon cartridges.
Whenever the rejection levels start decreasing below their minimum acceptable value, a fast-flush valve
(ll) is provided to temporarily increase the internal cleansing of the membrane and hopefully restore
membrane performance. If the fast-flushing procedure does not restore the rejection performance, than
the membrane must be replaced.
Replacing the RO membrane:
•
Turn off the valve (ff) feeding raw water to the RO system.
•
Open the raw and RO water test drains (gg, qq) to depressurize the water charge from the
reservoir (nn) and lines.
•
Disconnect the processed water line from the RO housing end cap via the quick disconnect
fitting.
•
Unscrew the end cap from the housing – reasonable force may have to be used.
•
Remove the used membrane and discard.
•
Lubricate two end o-rings with a coating of clean petroleum jelly.
•
Install the new membrane into housing with two o-rings end first.
•
Lubricate o-rings on membrane housing with a coating of clean petroleum jelly.
•
Thread the cap back on hand-tighten firmly.
•
Close the raw water test point.
•
Open the raw water shutoff valve. After a minute or so, a trickle of water should be coming
from the open RO water test drain, indicating the system is again producing water. Close
now the RO water test drain.
•
The water reservoir, at a minimum raw water pressure of 50 psig, will fill up in about 2 hours.
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SECTION 9
MAINTENANCE SCHEDULE
SERVICE CHECK LIST
Air Filter - Operating conditions determine frequency of service. When the air pressure differential
across the filter reaches 25” H2O, the “CHANGE AIR FILTER” message appears on the display
accompanied by a yellow indicator in the status area of the keypad signaling that the air filter requires
servicing or changing. See “Air Filter,” Section 6, page 39.
Water Filter - Operating conditions and water quality determine the frequency of service. When the
water pressure differential across the filter reaches 30 psi, the “CHANGE H2O FILTER” message appears
on the display accompanied by a yellow indicator in the status area of the keypad, signaling that the water
filter requires changing.
To change the filter:
1.
Be sure the unit is completely off and that no air pressure is in the system.
2.
Disconnect, tag and lockout the power supply to the starter.
3.
Drain the water from the filter housing by either turning the petcock or removing the plug on the
bottom of the filter assembly.
4.
Remove the nut at the top of the filter assembly, while holding the filter housing to keep it from
dropping. When the nut is removed, change the filter and reassemble.
5.
Repeat Steps 3 and 4 on the makeup water filter.
6.
Reconnect the power supply to the starter, start the machine and check for leaks.
RO Water Filtration System - Operating conditions and water quality determine the frequency of
service. Refer to Section 8 for detailed maintenance instructions.
Motor Lubrication - Refer to Section 2, page 11.
Every 8 Hours Operation
1.
Observe if the unit loads and unloads properly.
2.
Check discharge pressure and temperature.
3.
Check Panel Status indicators and message line for advisories.
4.
Check that there is condensate flow in the plastic connected between the aftercooler liquids
separator drain and the inlet valve.
5.
Check that there is no accumulation of condensate in the bowl of the control air filter.
6.
Check setting of buffer air pressure regulator – normal pressure is 5 psig to 7 psig.
7.
Check setting of buffer water pressure regulator – normal pressure is 2 psig to 3 psig.
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Every 125 Hours Operation
1.
Check for dirt accumulation on oil/aftercooler core faces and the cooling fan. If cleaning is required,
clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable
safety solvent in a direction opposite that of the cooling fan air flow. This cleaning operation will
keep the exterior cooling surfaces clean and ensure effective heat dissipation.
2.
Check the airend reservoir oil level - add oil if required. Loss of oil will be because of seal failure or
leaks in the system and should be fixed immediately.
3.
Check the level of condensate in the control air filter bowl. Use the manual pet cock to evacuate any
accumulation and check the operation of the automatic float valve. Cleanse the automatic float valve
as needed.
4.
Check the quality of the raw (incoming), RO (treated) and injection (reservoir) water. Refer to
Section 8, for recommendations to check the water quality.
Every 500 Hours Operation
1.
Check the delivery of filtered water from the reverse osmosis system.
Refer to the RO Filtration System, SECTION 8, “Monitoring the Water Flow”, for the recommended
procure.
Every 2000 Hours Operation
1.
Change the airend lubricant. UNDER ADVERSE CONDITIONS, CHANGE MORE FREQUENTLY
(refer to “Oil Change Interval” in Section 5). Flush reservoir if required. DO NOT MIX
LUBRICANTS.
2.
Grease the fittings on the inlet end of the airend (refer to “Lubrication Maintenance Interval”, page
38).
Every Year
1.
Check the relief valve for proper operation. See Section 4, page 29.
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Page 51
MAINTENANCE SCHEDULE (See Detail Notes)
As
indicated
by AUTO
SENTRY
W
Maintenance Action
Change Air Filter
•
Change Water Filter
•
Every
8
Hours
Check for Proper Load/Unload
•
Check Discharge Pressure/Temp
•
Every
125
Hours
Check Dirt Accumulation on Cooler
•
Check Reservoir Oil Level
•
Change Compressor Lubricant (AEON 800)
Every
500
Hours
Every
2000 *
Hours
•
•
Every
Year
•
Check Relief Valve
•
Check the Check Valve Seals
•
•
Add Grease to Inlet End Bearings
•
Check Water Quality **
•
Check Water Flow (RO Filter Discharge)
Check Condensate Flow at Aftercooler Separator
Drain
•
Check Condensate Level in Control Air Filter Bowl
•
Check Setting of Buffer Air Pressure Regulator
•
Check Setting of Buffer Water Pressure Regulator
•
*
IF OIL IS ANALYZED at the end of a maintenance interval (2000 hr. max.), and is found in
good condition, it may be used for the next 2000 hour interval – GD provides free oil analysis
services. OTHERWISE, IF OIL IS NOT ANALYZED at the end of any interval, it must be
changed.
**
Depends on water quality – longer periods may be used when the quality of water meets or
exceeds our standards consistently.
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SECTION 10
TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSE
REMEDY
Compressor fails to start
1.
2.
3.
1.
2.
3.
6.
Wrong lead connections.
Blown fuses in control box.
Motor starter overload
heaters tripped.
Pressure in reservoir.
Read error message on
control panel.
Remote Contact is open.
1.
High discharge temperature.
1.
2.
High discharge temperature
switch malfunction.
Blown fuse in starter/control
box.
Motor starter overload
heaters trip.
2.
1.
Improperly adjusted control.
1.
2.
Air leak in control lines.
2.
3.
4.
Restricted control line.
Blowdown valve malfunction.
3.
4.
Compressor shuts down or
falters while unloading
1.
Purge air pressure reaching
airend is excessive.
1.
Adjust auxiliary blowdown
pressure switch to the
proper level. See Section 4
for adjustment details.
Replace if defective.
Compressor cycles from load to
unload excessively
1.
Insufficient receiver capacity.
1.
Increase receiver size.
2.
Restriction in control tubing.
2.
Inspect and clean control
tubing.
4.
5.
Compressor starts but stops
after a short time
3.
4.
Compressor does not unload
(or load)
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Page 53
4.
5.
6.
3.
4.
Change leads.
Replace fuse.
Reset and investigate
cause of overload
Inspect blowdown valve.
Take appropriate action.
See Section 4.
Replace switch or jumper
(terminals 6 & 9).
See “High discharge air
temperature”, this Section.
Replace switch.
Replace fuse (investigate if
fuses continue to blow).
Reset and investigate
cause of overload.
Refer to Section 4 and
adjust control.
Determine source of leak
and correct.
Clean control lines.
Repair, clean or replace
valve.
SYMPTOM
POSSIBLE CAUSE
REMEDY
Compressor is low on delivery
and pressure
1.
Restricted air filter.
1.
Clean or replace filter.
2.
Sticking inlet valve.
2.
3.
3.
5.
Unload pressure adjusted too
low.
Discharge check valve
stuck closed.
Subtractive valve is active.
Inspect and clean inlet
valve.
Adjust the unload pressure.
See Section 4.
Disassemble and clean
valve.
Adjust subtractive valve to
start operating at 1 psi
above the desired full load
operating pressure. Clean
or replace if output is not
linear - 2.3 psi output per 1
psi input.
1.
2.
Dirty or clogged cooler face.
Insufficient cooling air flow
1.
2.
3.
3.
4.
Clogged water injection filter
or cooler (interior).
Reservoir water level low
1.
Drain valve leaking
1.
2.
RO producing none to low
water.
Condensate return strainer
and/or orifice plugged.
2.
3.
Inspect and clean or
replace.
See RO Troubleshooting
details.
Inspect and clean.
Condensate return strainer
and/or orifice plugged.
1.
Inspect and clean.
4.
High discharge air temperature
Reservoir water level low
3.
Abnormal water volume found
in package discharge air
1.
4.
5.
4.
Clean cooler.
Provide unrestricted supply
of cooling air.
Replace filter or clean
cooler.
See “Reservoir water level
low” details.
NOTICE
Gardner Denver factory remanufactured replacement compressor airend units
are available from your authorized distributor, on an exchange basis, for all
rotary screw compressor units.
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Page 54
SECTION 11
TROUBLESHOOTING AUTO SENTRY W CONTROLLER W
DISPLAY MODES
A green power on light is located in the lower right corner of the keypad. It lights whenever the controls
are energized. A steady light indicates that automatic restarting is not enabled, the compressor must be
restarted manually following a power failure. A blinking green light indicates that the control will
automatically resume its selected mode following an interruption in power.
The normal display indicates the package service pressure, the airend discharge temperature, the total
running hours, and one of the following operating modes. The green run light will be on for any operating
mode, whether the compressor is running or not.
READY
The compressor has been stopped by pressing the [STOP/RESET] key
CON
The compressor is operating in the Constant Run mode
LDM
The compressor is operating in the Low Demand mode
AUTO
The compressor is operating in the Automatic mode
SEQ n
The compressor is operating in the Sequence mode
The following alternate displays may be called by pressing the [ ? ] or a cursor [<] or [>] key. The [?] key
always displays DIF PRES on the first press; the cursor keys will redisplay the last alternate display. Any
will scroll through the list with additional presses.
DIF PRES
The pressure drop across the water filter
RES PRES
The pressure in the water reservoir
INJ PRES
The pressure between the filter and injectors
SYS PRES
The pressure at the service connection
DIS TMP
The temperature at the airend discharge
TOT HRS
The total hours of compressor running
LOAD HRS
The hours of compressor delivery
BD TMR
The time remaining before a blowdown will be allowed
AUTO TMR
The time remaining of unloaded motor operation
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Page 55
ADVISORY TROUBLESHOOTING GUIDE
All advisories are indicated on the keypad by a yellow indicator in the Status area, and one of the
following messages alternating with the normal lower line display. Perform service or maintenance as
indicated, the clear the advisory as instructed in Section 4.
Message
Action Needed
CHNG AIR FILTER
Excessive vacuum has been detected after the air filter, indicating it has
become full. Change the air filter to ensure maximum air delivery.
CHNG H2O FILTER
The differential pressure across the water filter has risen to over 30 psid.
Change the filter to ensure an adequate flow of coolant.
RELUBE
The unit has been operated for the programmed number of hours since the
last lubricant change or addition. Change or add lubricant as indicated in the
lubrication instructions to ensure lubricant quality.
HIGH DISCH TEMP
The temperature was greater than 180° F (82° C) at the airend discharge.
Ensure that the compressor receives adequate cooling air or water, and that
the coolers are not plugged.
LOW AMB TEMP
The temperature was less than 40° F (4° C) at the airend discharge. Ensure
that the compressor is located in a room kept above freezing.
SHUTDOWN TROUBLESHOOTING GUIDE
All shutdowns are indicated on the keypad by the word “SHUTDOWN” on the top line of the display, and
one of the following messages on the lower line of the display. The red indicator in the Status area will be
steadily lit while the conditions exist, and will flash after the condition has been corrected. Perform
service as indicated. Press the [STOP/RESET] key to clear the shutdown.
Message
Action Needed
BAD FLOAT
SWITCH
120 volts is present at both terminal 6 and 7 of the terminal strip. This
indicates a likely wiring error to the float switch; check and correct. It may also
indicate a short within the switch itself.
CHECK CN7
All inputs at connector 7 of the controller are off. The most common cause for
this is that the connector plug has been pulled out. Plug the connector back in
firmly.
CHECK CN5
120 volts has been removed from ALL inputs to connector 5 of the controller.
The most common cause for this 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 psid.
Change the filter to ensure an adequate flow of coolant.
EMERGENCY STOP
The Emergency Stop button has been pressed. Pull it back out to its normal
position. If the button has not been pressed, check that the contact block is
firmly mounted in the right or left (not center) position of the operator. Check
for loose connections which would remove 120 volts from connector 5-8 of the
controller.
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Page 56
Message
Action Needed
EXTERNAL DEVICE
120 volts has been removed from J1-4 of the expansion board. This is
normally jumpered directly to terminal 9, but the jumper may be removed to
add a field installed shutdown switch. Reset the external switch.
HIGH DIS TEMP R
This indicates that the controller has detected a rapid temperature rise in the
airend discharge. This normally would indicate a loss of coolant injection into
the airend. Completely check all water piping, the filter, and flow controls for
blockage or freezing. This may also be caused by a loose connection at
connector 7 of the controller. Monitor the temperature carefully during restarts
after servicing.
HIGH DISCH TEMP
This indicates that the controller has detected temperature in excess of the
programmed high temperature limit at the airend discharge. The most
common cause for this is inadequate package cooling. Ensure proper air flow
for air-cooled units, or adequate cooling water for water cooled units. Monitor
the temperature carefully during restarts after servicing.
HIGH INJ PRESS
Pressure in excess of the programmed high pressure limit has been detected.
This shutdown will occur if a loss of pneumatic controls occurs. Check the inlet
valve, all control piping, solenoid valves, and all other control devices to find
the cause for the inlet valve not closing. Other possible causes are loose
connections to the transducer, electrical noise and transients, or improper
setting of the high pressure limit.
HIGH RESVR
PRESS
Pressure in excess of the programmed high pressure limit has been detected.
This shutdown will occur if a loss of pneumatic controls occurs. Check the inlet
valve, all control piping, solenoid valves, and all other control devices to find
the cause for the inlet valve not closing. Other possible causes are loose
connections to the transducer, electrical noise and transients, or improper
setting of the high pressure limit.
HIGH SYSTEM
PRESS
Pressure in excess of the programmed high pressure limit has been detected.
The most likely cause is other, higher pressure compressors on the same air
system; separate these from this compressor unit. Other possible causes are
loose connections to the transducer, electrical noise and transients, or
improper setting of the high pressure limit.
HIGH VIBRATION
120 volts has been removed from J1-4 of the expansion board. This is
normally jumpered directly to terminal 9, but the jumper may be removed to
add a field installed shutdown switch. Reset the external switch.
HIGH WATER
LEVEL
120 volts has been removed from terminal 5 of the terminal strip. This
normally indicates that a high water level in the reservoir has opened switch
LS3 of the float switch assembly. Check that the drain is clear and that the
drain solenoid valve is functioning properly. This may also indicate a loose
connection along wire 5.
LOW DISCH TEMP
The temperature, as measured at the airend discharge, has fallen below
freezing. Repair room heating to prevent further damage to the unit.
13-11-607
Page 57
Message
Action Needed
LV RELAY
120 volts has been removed from J1-4 of the expansion board. This is
normally jumpered directly to terminal 9, but the jumper may be removed to
add a field installed shutdown switch. Reset the external switch.
MOTOR CONTACT
The controller has attempted to turn off the compressor, but is still receiving a
return signal from the starters’ auxiliary contacts. Check that the starter
operates freely and that the contact blocks are properly installed on the starter.
MOTOR OVERLOAD
One of the motor overload relays within the electrical control box has tripped,
indicating high motor shaft load, low voltage, or excessive imbalance in the
incoming power. Disconnect and lock out power, open the box, and press the
reset buttons one at a time - the tripped one will click when reset. Measure
motor amps, and take corrective actions to get all currents within the motor
nameplate rating. If overloads had not tripped, check for the cause that 120
volts was removed from connector 5-3 of the controller.
MOTOR STARTER
The controller has attempted to start the compressor, 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 6 of the controller is plugged in
firmly, and check the starter coil. If the starter does pick up, but this message
appears, check that the auxiliary contact block is properly installed on the
starter and wired to connector 1, terminal 4.
OPEN
THERMISTOR
The controller has detected an open connection to the airend discharge
thermistor. This normally indicates a loose or broken connection at the
controller connector 7; check and correct the connection. This could also be
indicating a broken wire or thermistor probe.
OPEN XDUCER
Signal voltage has fallen too low at transducer: (A) Final discharge, (B) Water
Injection, or (C) Reservoir. This usually indicates a loose connection of the red
wire to the transducer or a defective transducer. Check connections, or
replace transducer if necessary.
PHASE RELAY
120 volts has been removed from J1-4 of the expansion board. This is
normally jumpered directly to terminal 9, but the jumper may be removed to
add a field installed shutdown switch. Reset the external switch.
POWER FAILURE
The power to the compressor unit has been turned off and back on. Press
[STOP/RESET] and select an operating mode.
SHORTED
THERMSTR
The controller has detected a shorted connection to the airend discharge
thermistor. This normally indicates a faulty connection (e.g. wire strands
touching) at the controller connector 7; check and correct the connection. This
could also be indicating a damaged wire or thermistor probe.
SHORTED XDUCER
Signal voltage has exceeded approximately 4.6 volts at transducer: (A) Final
discharge, (B) Water Injection, or (C) Reservoir. This may indicate a loose
connection of the black wire to the transducer or a defective transducer.
Check connections, or replace transducer if necessary.
13-11-607
Page 58
Message
Action Needed
WATER PRESS
120 volts has been removed from J1-4 of the expansion board. This is
normally jumpered directly to terminal 9, but the jumper may be removed to
add a field installed shutdown switch. Reset the external switch.
ZERO XDUCER
Signal voltage has fallen too low at transducer: (A) Final discharge, (B) Water
Injection, or (C) Reservoir. This error is usually the result of the transducers
being improperly zeroed. Disconnect the air lines to the transducers and follow
the procedure indicated in the adjustment instructions.
CONTROLS TROUBLESHOOTING GUIDE
The following are recommended service actions. Observe all instructions noted elsewhere in this manual.
All electrical service is to be performed only by a qualified electrician.
Message
Action Needed
No display,
compressor stopped
Check incoming power to the compressor unit. Ensure that the disconnect is
on and that fuses have not blown (or circuit beaker tripped). If power is being
properly supplied to the control box, check the fuses located at the fan starter,
the control transformer fuses, and the fuse located on the AUTO SENTRY W
keypad chassis.
Compressor will not
start
To operate, the controller must be placed into an operating mode (e.g.
AUTO); press the [STOP/RESET] key to put the control into the READY
state, then start by pressing the [START] key. In AUTOMATIC and
SEQUENCE modes, compressors will not start until the pressure drops below
the load pressures.
Display indicates
“NOT BLOWN DOWN”
The controller prevents attempts to start the main motor if the reservoir
pressure is over 5 psig. Pressure continues to be relieved from the reservoir
while this message is on, and the compressor will start automatically after the
pressure has dropped. If this message remains with NO pressure in the
reservoir, follow the transducer zeroing procedure found in the controls
adjustment section.
Display indicates
“REMOTE STOP”
The controller is provided with an input for user-furnished remote controls.
This display indicates that 120 volt is removed from terminal 23 of the
terminal strip. Check all connections of the expansion board, or the
customer-provided controls, if applicable
Display indicates
“SHUTDOWN”
If the display indicates “SHUTDOWN”, refer to the shutdown troubleshooting
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.
13-11-607
Page 59
Message
Action Needed
Compressor runs, but
does not load
In the CONSTANT RUN and LOW DEMAND modes, the compressor will not
load until the pressure drops below load pressure. Refer to the operating
instructions for further information. If pressure is below the load pressure,
check that the inlet valve operates freely. Check that the unloader valve is
wired and operating properly.
Compressor runs,
unloads at low
pressure
Compressor does not
unload
If the inlet valve closes at low pressure, check the wiring to the blowdown
valve and the piping and check valves in its discharge line.
Compressor cycles
rapidly between load
and unload
The external air receiver should be sized appropriately to prevent rapid cycles
The rapid response time in the CONSTANT RUN mode will operate with
small receivers, but any plant air system will operate more efficiently with
adequately sized storage. Refer to the operating instructions for further
information.
Display is illegible.
The LCD contrast is adjustable from all black to all green. To adjust, find the
small adjustment screw located on the larger circuit board behind the keypad.
Using a small screwdriver, adjust for the most pleasing display.
Erratic pressures in
SEQUENCE only
The sequencing system transmits low-level signal between units to
communicate pressures. Units must be properly grounded to a good ground
system. The communications cable should use only appropriate quality
cable, and the cable should be run in its own conduit.
Compressor cycles
rapidly in SEQUENCE
mode only
In the sequence mode, the operating system requires all compressors be
piped directly to receiver, such that all transducers sense the same pressure.
Check valves or restrictions between compressors and the storage will cause
system instability. Run units in AUTOMATIC mode until the system is
corrected.
Pressure display error.
Accuracy of the pressure display and controls requires that the controller and
transducers be calibrated together. This MUST be done with no pressure at
the transducer, or errors will occur. This is easiest to check with all pressure
removed. All pressure displays should indicate 0 psi (0 bar) +1 psi. If the
display indicates greater pressures, recalibrate the system as instructed in the
configuration adjustments. Note: reservoir pressure may drop below zero
psig when the compressor is stopped, but will return slowly to zero as the
vacuum is relieved.
The W controller operates the inlet valve to maintain pressure near the unload
pressure, matching delivery to demand. If the pressure continues to rise
above unload pressure, check that the inlet valve operates freely, and that
control air is supplied to the unloader solenoid valve. If normal unload control
does not close the valve, it will be closed during a blowdown as pressure
approaches the high pressure limit.
13-11-607
Page 60
SECTION 12
TROUBLESHOOTING THE RO FILTRATION SYSTEM
Problem: None or low water production
Reasons:
Solutions:
Raw water feed (gg) turned off. ...........................
Open raw feed water valve.
Pre-filters (ll, hh) fouled or plugged. .....................
Replace cartridges.
Raw water feed pressure below 50psig................
Improve pressure condition.
Back pressure regulator (jj) plugged. ...................
Cleanse or replace.
Membrane fouled or plugged. .............................
Fast-flush or replace.
Storage tank (nn) under pressurized....................
Adjust membrane air pressure (15-20 psi).
Storage tank membrane ruptured. .......................
Replace storage tank.
Isolation valve (pp) turned off. .............................
Open isolation valve.
Fill valve (tt) leaking or stuck open.......................
Cleanse or replace
Problem: High TDS product water
Reasons:
Solutions:
Membrane fouled. ..............................................
Fast-flush or replace.
TDS increased in raw water feed.........................
Check that TDS < 1800 ppm.
Membrane fouled. ..............................................
Fast-flush or replace.
Prefilter housings not flushed. .............................
Repeat housing cleansing and flushing.
Problem: Cloudy water
Reasons:
Solutions:
Dissolved oxygen in feed water is concentrated
In product water.................................................
Oxygen dissolves from water over time
13-11-607
Page 61
INDEX
Air Filter, Section 6 ............................................................ 39
Air Flow In The Compressor System.................................... 1
Auto Sentry W Controller
Alarm Relay ................................................................... 29
Automatic Sequence Change........................................ 27
Auxiliary Shutdown........................................................ 29
Configuration Adjustments ............................................ 23
Connection Of Expansion Board And External Control
Circuits...................................................................... 27
Control Display .............................................................. 16
Installation...................................................................... 25
Main Adjustments Menu ................................................ 21
Maintenance Adjustments ............................................. 22
Operation Adjustments .................................................. 21
Other Control Devices ................................................... 29
Other Control Features.................................................. 24
Other Features .............................................................. 27
Programming And Setup ............................................... 21
Remote On/Off.............................................................. 28
Sequence Adjustments ................................................. 22
Sequencing Compressor ............................................... 24
Unit Setup Adjustments ................................................. 23
Auto Sentry W Operation................................................... 15
Automatic Mode............................................................. 16
Constant Run Mode....................................................... 15
Low Demand Mode........................................................ 16
Sequence Mode ............................................................ 16
Belt Drive, Section 7 .......................................................... 41
Control Devices, Other ...................................................... 29
Air Filter Vacuum Switch............................................... 31
Air Pressure Regulator.................................................. 31
Aux. Blowdown Vavle.................................................... 30
Aux. Pressure Switch.................................................... 30
Blowdown Valve............................................................ 30
Check Valve.................................................................. 30
Control Transformer ...................................................... 32
Discharge Termistor...................................................... 31
Emergency Stop/Push Button ....................................... 32
Fan Starter .................................................................... 32
Injection Pressure Transducer....................................... 31
Inlet Valve...................................................................... 30
Main Starter................................................................... 32
Plc.................................................................................. 32
Pressure Gauge............................................................ 31
Relief Valve................................................................... 29
Reservoir Pressure Transducer..................................... 31
Shuttle Valve................................................................. 31
Subtractive Valve.......................................................... 30
System Pressure Transducer ........................................ 31
Terminal Strip ................................................................ 32
Water Level Switches.................................................... 31
Water Pressure Regulator............................................. 31
Water Pressure Relief Valve......................................... 31
Water Solenoid Valves .................................................. 31
Controls & Instrumentation, Section 4................................ 15
Coolers & Water Systems, Section 2................................... 5
Compression Injection Water System Check................... 9
Compressor Water Specifications ................................... 7
Water System.................................................................. 1
General Information, Section 1 ............................................ 1
Installation, Section 2........................................................... 5
Air/Water Reservoir With Integral Moisture Separator..... 9
Air-Cooled Units .............................................................. 5
Auxiliary Air Receiver ...................................................... 8
Compressor Injection Water System Check.................... 9
Compressor Water Specification..................................... 7
Discharge Service Line.................................................... 9
13-11-607
Electrical Wiring............................................................. 10
Enclosure ........................................................................ 7
Foundation....................................................................... 7
General............................................................................ 5
Grounding...................................................................... 10
Inlet Line .......................................................................... 8
Lifting Unit........................................................................ 5
Location........................................................................... 5
Moisture Separator/Orifice.............................................. 8
Motor Lubrication........................................................... 11
Oil Reservoir Drain.......................................................... 7
Unit Water Drain .............................................................. 9
Lubrication, Section 5 ........................................................ 37
Compressor Oil System................................................. 37
Electric Motor Grease Recommendations ..................... 11
Electric Motor Regreasing Interval................................. 11
Maintenance Interval ..................................................... 38
Motor ............................................................................. 11
Oil Level Sight Glass ..................................................... 38
Oil Specifications........................................................... 37
Recommended .............................................................. 37
Maintenance Schedule, Section 9 ..................................... 50
Prestart-Up Instructions ..................................................... 12
Air Filter......................................................................... 12
Compressor Oil.............................................................. 12
Electrical........................................................................ 12
Enclosure ...................................................................... 13
Grounding...................................................................... 13
Initial Water Fill/Adjusting Ro Timer.............................. 14
Operating Mode............................................................. 13
Piping............................................................................. 12
Rotation ......................................................................... 13
System Pressure........................................................... 13
RO Water Filtration, Section 8 ........................................... 43
General Information....................................................... 43
Initial Set-Up And Operation.......................................... 46
Maintenance.................................................................. 47
Principles Of Operation ................................................. 43
RO Membrane............................................................... 49
RO System Specifications ............................................. 45
Safety Precautions .............................................................. 4
Service Advisories ............................................................. 18
Service Check List............................................................. 50
Shutdowns
Emergency Stop............................................................ 19
External Device............................................................. 19
High Pressure ............................................................... 19
High Temperature.......................................................... 18
High Water Level........................................................... 19
Motor Protective Devices .............................................. 18
Other ............................................................................. 19
Power Failure ................................................................ 19
Water Filter Differential Pressure .................................. 19
Starting & Operating Procedures, Section 3...................... 12
Starting The Unit............................................................ 14
Stopping The Unit .......................................................... 14
Troubleshooting
Auto Sentry W Controller, Section 11............................ 55
Advisory Troubleshooting Guide............................... 56
Controls Troubleshooting Guide ............................... 59
Display Modes .......................................................... 55
Shutdown Troubleshooting Guide............................. 56
General, Section 10....................................................... 53
Ro Filtration System, Section 12 ................................... 61
Page 62
WARRANTY
ROTARY SCREW COMPRESSORS AND VACUUM PACKAGES
OIL INJECTED – OIL FREE
GENERAL PROVISIONS AND LIMITATIONS
Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized
distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty is made with
respect to:
1.
Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.
2.
Any product which has, in the Company’s judgment been subject to negligence, accident, improper storage, or improper installation or
application.
3.
Any product which has not been operated or maintained in accordance with the recommendations of the Company.
4.
Components or accessories manufactured, warranted and/or serviced by others.
5.
Any reconditioned or prior owned product.
Claims for items described in (4) above should be submitted directly to the manufacturer.
WARRANTY PERIOD
The Company’s obligation under this warranty is limited to repairing or, at its option, replacing, during normal business hours at an authorized service
facility of the Company, and part which in its judgment proved not to be as warranted within the applicable Warranty Period as follows.
AIRENDS
Airends, consisting of all parts within and including the cylinder and gear housing, are warranted for 24 months from date of initial use or 27 months
from date of shipment to the purchaser, whichever occurs first.
Any disassembly or partial disassembly of the airend, or failure to return the “unopened” airend per Company instructions, will be cause for denial of
warranty.
MAJOR PACKAGE COMPONENTS
Air or water cooled coolers and the AutoSentry Controllers are warranted for 24 months from date of initial use or 27 months from date of shipment to
the first purchaser, whichever occurs first, as provided in, and subject to the terms of the original component manufacturer’s warranty.
DRIVE AND FAN MOTOR
The drive and fan motor (if applicable) are warranted for 60 months from start-up or 63 months from shipment, whichever occurs first. The warranty is
applicable only to Toshiba low voltage motors (600 Volts or less). High voltage motors and other manufacturer motors furnished due to customer
request or special requirements carry the motor manufacturer’s warranty.
OTHER COMPONENTS
All other components are warranted for 12 months from date of initial use or 15 months from date of shipment to first purchaser, whichever occurs first.
LABOR TRANSPORTATION AND INSPECTION
The Company will provide labor, by Company representative or authorized service personnel, for repair or replacement of any product or part thereof
which in the Company’s judgment 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 by unauthorized service personnel is not provided for by this warranty.
All costs of transportation of product, labor or parts claimed not to be as warranted and, of repaired or replacement parts to or from such service
facilities shall be borne by the Purchaser. The Company may require the return of any part claimed not to be as warranted to one of its facilities as
designated by Company, transportation prepaid by Purchaser, to establish a claim under this warranty.
Replacement parts provided under the terms of the warranty are warranted for the remainder of the Warranty Period of the product upon which
installed to the same extent as if such parts were original components.
DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE COMPANY MAKES NO
OTHER WARRANTIES AND HEREBY EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION, EXPRESSED,
IMPLIED OR STATUTORY WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
USE.
THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE TO PURCHASER
AND IN NO CASE SHALL THE COMPANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES. UNDER NO CIRCUMSTANCES
SHALL THE COMPANY BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES OR
DELAYS HOWSOEVER CAUSED.
NO STATEMENT, REPRESENTATION, AGREEMENT, OR UNDERSTANDING, ORAL OR WRITTEN, MADE BY ANY AGENT, DISTRIBUTOR,
REPRESENTATIVE, OR EMPLOYEE OF THE COMPANY WHICH IS NOT CONTAINED IN THIS WARRANTY WILL BE BINDING UPON THE
COMPANY UNLESS MADE IN WRITING AND EXECUTED BY AN OFFICER OF THE COMPANY.
THIS WARRANTY SHALL NOT BE EFFECTIVE AS TO ANY CLAIM WHICH IS NOT PRESENTED WITHIN 30 DAYS AFTER THE DATE UPON
WHICH THE PRODUCT IS CLAIMED NOT TO HAVE BEEN AS WARRANTED. ANY ACTION FOR BREACH OF THIS WARRANTY MUST BE
COMMENCED WITHIN ONE YEAR AFTER THE DATE UPON WHICH THE CAUSE OF ACTION OCCURRED.
ANY ADJUSTMENT MADE PURSUANT TO THIS WARRANTY SHALL NOT BE CONSTRUED AS AN ADMISSION BY THE COMPANY THAT
ANY PRODUCT WAS NOT AS WARRANTED.
AU-20 R 10/02
COPYRIGHT  2002 Gardner Denver, Inc.
For additional information contact your local representative or
Gardner Denver Compressor and Pump Division,
1800 Gardner Expressway, Quincy, Illinois 62301
Customer Service Department Telephone:
(800) 682-9868 FAX: (217) 224-7814
Specifications subject to change without notice.
Copyright © 1999 Gardner Denver, Inc.
http://www.gardnerdenver.com
Sales and Service in all major cities.
Litho in U.S.A.
[email protected]
For parts information, contact Gardner Denver,
Master Distribution Center, Memphis, TN
Telephone: (800) 245-4946 FAX: (901) 542-6159
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