Gardner Denver ELECTRA-SCREW EBE DD Series Service manual

GARDNER-DENVER” 13-8-609
1st Edition
ELECTRA-SCREW@ STATIONARY
BASE-MOUNTED &TANK-MOUNTED
COMPRESSORS
MODELS
EBE_DD -15 HP
EBE_ED -20 HP
EBE-_FD -25 HP
EBE_GD -30 HP
OPERATING AND
SERVICE MANUAL
●
COOPER
Gardner-Denver
Industrial Machinery

MAINllUN COMPRESSORRELiABILllY AND PERFORMANCE M/Ill-l
GENUINE GARDNER-DENVER AND JOY COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner-Denver and Joy Compressor genuine
parts, engineered to original tolerances, are de-
signed for optimum dependability --- specifically
for Gardner-Denver and Joy 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 are incorporated in our
genuine replacement parts.
Your authorized Gardner-Denver and Joy Com-
pressor distributor offers all the backup you’ll
need. Aworldwide network of authorized distribu-
tors provides the finest product support in the air
compressor industry.
Your local authorized distributor maintains alarge
inventory of genuine parts and he is backed up for
emergency parts by direct access to the Gardner-
Denver Industrial Machinery Master Distribution
Center (MDC) in Memphis, Tennessee.
Your authorized distributor can support your
Gardner-Denver or Joy air compressor with these
services:
1. Trained parts specialiststo assist you inselect-
ing the correct replacement parts.
2. Factory warranted new and remanufactured
rotary screw air ends. Most popular model
remanufactured air ends are maintained in
stock at MDC for purchase on an exchange
basic with liberal core credit available for the
replacement unit.
3. Afull line of factory tested AEON mcompres-
sor lubricants specifically formulated for use in
Gardner-Denver and Joy compressors.
4. Repair and maintenance kitsdesigned with the
necessary parts to simplify servicing your
compressor.
Authorized distributor service technicians are
factory-trained and skilled in compressor main-
tenance and repair. They are ready to respond
and assist you by providing fast, expert main-
tenance and repair services.
For the location of your local authorized Gardner-Denver and Joy Air Compressor distributor refer
to the yellow pages of your phone directory or contact:
Distribution Center: Factory:
Gardner-Denver Gardner-Denver
Industrial Machinery Division Industrial Machinery Division
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38115 Phone: [phone]
Phone: [phone] Fax: [phone]
Fax: [phone]

FOREWARD
Gardner-Denver Electra-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
Failure to observe aDANGER notice could result in injury to, or death of personnel.
1I
11
WARNING
Failure to observe aWARNING notice could result in damage to equipment.
CAUTION
CAUTION notices set forth general reminders of good safety practice, or direct
attention to unsafe practices.
NOTE
Information furnished in aNOTE will include general information or the highlights of
aprocedure.
This book covers the following models:
HP PSIG Air Cooled
15 100, 125 EBE_DD
20 100, 125, 150 EBE_ED
25 100, 125, 150, 175 EBE_FD
30 100, 125, 150, 175 EBE_GD
TABLE OF CONTENTS
GENERAL lNFORMATION ............................................................................................................................. SECTION 1
lNSTALMTION ............................................................................................................................................... SECTION 2
STARTING AND OPERATING PROCEDURES ............................................................................................. SECTION 3
CONTROLS AND INSTRUMENTS ................................................................................................................. SECTION 4
LUBRICATION, OIL COOLER, OIL FILTER AND SEPARATOR ................................................................... SECTION 5
AIR FILTERS .................................................................................................................................................. SECTION 6
BELT DRIVE .................................................................................................................................................... SECTION 7
MAINTENANCE SCHEDULE ....................................................... ................................................................. SECTION 8
TROUBLE SHOOTING ................................................................................................................................... SECTION 9
13-6-609 Page i

INDEX
NOTE: Numbers preceding dash are Section Numbers –Numbers following dash are Page Numbers
Air Control Components ..........................................4-2
Air Cooled Unit installation .......................................2.l
Air Filter Element Liie................................................6.2
Air Filter Element Servicing instructions ..................6-l
AIR FILTER (SECTION 6) .........................................6-1
Air Flow Quantity. .....................................................2-l
Air/Oil Flow Diagram .................................................5.l
Auto Sentry S-Auto Lag Button ..............................4-3
Auto Sentry S-Auto Lead Button ............................4-3
Auto Sentry S-Constant Run Button ......................4-3
Auto Sentry S-Control Pad Diagram ......................4-8
Auto Sentry S-Hourmeter .......................................4.3
Auto Sentry S-Keypad ............................................4-3
Auto Sentry S-Lead-Lag operation ........................4-6
Auto Sentry S-Programming and Set-Up
Instructions ..........................................................4.4
Auto Sentry S-Stop/Reset Button ..........................4-3
Basic information ......................................................l.l
BELT DRIVE (SECTION 7) .......................................7-1
Blowdown Valve Control ..........................................4.2
Blowdown Valve Piping ............................................2.3
Cold Weather Operation ...........................................2.2
CONTROLS AND INSTRUMENTS (SECTION 4) ....4-1
Decals .......................................................................l.5
Discharge Service tine .............................................2.3
Electrical Wring ........................................................2.4
Enclosure .................................................................2.2
Error Messages -Definitions ....................................4-4
Filling Oil Resetvoir ..................................................5.3
Foundation ...............................................................2.l
GENERAL INFORMATION (SECTION 1) ................1-1
High Temperature Operation ..................................5-1
High Temperature Shutdown ...................................4.l
Inlet Line ..................................................................2.3
Inlet Valve Control ....................................................4.2
INSTALLATION (SECTION 2) .................................2-1
instruments ...............................................................4.2
LED -Change Air Filter .............................................4.4
LED -Change Separator ..........................................4.4
LED -High NrTemperature .....................................4.3
LED -Motor Overload ...............................................4.3
Lifting Unit ................................................................2-1
Location ...................................................................2.l
Lubricant, Addition of Oil Between Changes ..........5-2
Lubricant, Changing Type of Oil..............................5-1
Lubricant, Draining and Cleaning System ...............5-3
Lubricant, Oil Specifications ....................................5-1
Lubricant Change Interval ........................................5-3
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5) .................................5-1
MAINTENANCE SCHEDULE (SECTION 8) ............8-1
Minimum Pressure/Check Valve .............................4-2
Moisture in the Oil System ......................................5-3
Motor Lubrication ....................................................24
Motor Protection Devices .......................................4-1
Oil Cooler -Radiator Type .......................................5-4
Oil Filter.....................................................................5.4
Oil Level Gauge .......................................................5.3
Oil Reservoir .............................................................5.4
Oil Reservoir Drain ...................................................2-2
Oil Separator ............................................................5.5
Oil Separator -Pressure Differential Gauging .........5-5
Oil Separator -Removal ...........................................5-5
Oil System Check ................................................... 5-6
Operating Air Pressure Adjustment .........................4-6
Outline Drawings ...................................................... 1-2
Pressure and Temperature Digital Readouts ..........4-4
Prestart-Up instructions .................................?.........3-1
Protective Devices and Shutdown ..........................4-1
Regressing Interval ..................................................2.5
Relief Valve ...............................................................4.l
Safety Precautions .................................................. 1-4
Separator Differential Pressure Shutdown ..............4-1
STARTING &OPERATING PROCEDURES
(SECTION 3) .......................................................3.l
Starting The Unit, Cold .............................................3-2
Starting The Unit, Hot ...............................................3-2
Stopping The Unit ...................................................3.2
Subtractive Pilot .......................................................4.6
Thermostatic Mixing Valve ......................................5-4
TROUBLE SHOOTING (SECTION 9) .....................9-1
Wiring Diagram .........................................................4.9
13-8-609 Page ii

SECTION 1
GENERAL INFORMATION
FIGURE 1-1 -COMPRESSION CYCLE
COMPRESSOR -The Gardner-Denver@ comtxessor
is asingle stage, positive displacement rotary machine
using meshing helical rotors to effect compression. Both
rotors are supported between high capacity roller bear-
ings 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. Tapered
roller bearings at the discharge end locate each rotor
axially and carry allthrust loads and the remainder of the
radial loads.
COMPRESSION PRINCIPLE (Figure 1-1) -Compres-
sion is accomplished by the main and secondary rotors
synchronously meshing in aone-piece c~linder. The
main rotor has four (4) helical lobes 90 apart. The
secondary rotor has six (6) matching helical grooves 60°
apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor
cylinder near the drive shafl end. The discharge port is
near the bottom at the opposite end of the compressor
cy!inder. Figure 1-1 is an inverted view to show inlet and
discharge ports. The compression cycle begins as the
rotors unmesh at the inlet port and air is drawn into the
cavity between the main rotor lobes and the secondary
rotor grooves (A). When the rotors pass the inlet port
cutoff, air is trapped in the interiobe cavity and flows
axially with the meshing rotors (B). As meshing contin-
ues, more of the main rotor lobe enters the secondary
rotor grove, normal volume is reduced and pressure
increases.
v
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-
duction and pressure increase continues until the air/oil
mixture trapped in the interlobe cavity by the rotors
passes the discharge port and is released to the oil
reservoir (C). Each rotor cavity follows the same “fill-
compressdischarge’i cycle in rapid succession to pro-
duce adischarge airflow that iscontinuous, smooth and
shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure
1-5) -Air enters the air filter and passes through the inlet
unloader valve and on into the compression chamber
where oil is injected into the air. After compression, the
air/oil mixture passes into the oil reservoir where most
of the entrained oil is removed by velocity change and
impingement and drops back into the reservoir. The air
and remaining oil then passes through piping and the
air/oil separator. The air then passes through the mini-
mum pressure/check valve, the aftercooler and the
moisture separator and into the plant air lines.
LUBRICATION, COOLING AND SEALING -Oil is
forced by air pressure from the oil reservoir through the
oil cooler, thermostatic mixing valve, and oil filter and
discharge intothe compressor main oilgallery. Apottion
of the oil is directed through internal passages to the
bearings, gears and shaft oil seal. The balance of the oil
is injected directly into the compression chamber to
remove heat of compression, seal internal clearances
and lubricate the rotors.
13-8-W9 Section 1Page 1

OIL SEPARATOR
OIL RESERVOIRFILLER
bE:~:E::”vE ST(RE-,
ERATOR
~TH[RM~ CONTROL
\‘+
(MIXING) VALVE
OIL FILTER
BY-PASSPIPING
OIL RESERVOIR
FIGURE 2-1
13-8-609 Section 1Page 2

OIL LEVEL SIGHT GAUGES
n“R “LTER~
STARTER/CONTROL
::::;;= \
RESERVOIR OIL DRAIN
FIGURE 3-1
13-8-609 Sectionl Page3

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 wst experience, watch out for
safety hazards and be cautious. Some general safety precautions are given below -
WARNING
Failure to observe these notices could result in damage to equipment.
●stoD the unit if any repairs or adjustments on or around the compressor are
required.
●Disconnect the comtxesso runit from its power source 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 1518.302)
●J)o not excee dthe rated maximum nressure value Sshown on the nameplate.
oDo not otI crate unit if safety devices are not operating properly. Check
periodically. Never bypass safety devices.
DANGER
Failure to observe these notices could result in injury to or death of personnel.
o~ee~ finaers and cIothina awa yfrom revolving fan, drive coupling, etc.
.Do not usethe air discharae from this unit for breathing -not suitable for
human consumption.
.Do not loosen or remove the oil filler plug, drain plugs, covers, the thermo-
static mixing valve or break any connections, etc. in the compressor air or
oil system until the unit is shutdown and the air pressure has been relieved.
.Electrical shock can and may be fatal.
●co mmesso runit must be arounded in accordance with the National Electri-
cal Code. Aground jumper equal in size to the equipment ground conductor
must be used to connect the compressor motor base to the unit base.
●Fan motors must remain arounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.
●g~e nmain disco nnects witc tI before working on the control.
●Disco nnect the comm’esso runit from its power source before working on
the unit -this machine is automatically controlled and may start at any time.
13-8-609 Section 1Page 4

DECALS
OIscHARGE AIR USED foR
BREATHING WILL CAUSE
StVERf INJARY OR DEATH.
coNsuLT rILTRAr ION
SPECIALIST FOR
AOGiIIONAl flLTRATl@!l
AND TREATMENT [OUIPMINT
TO MtXT HIALIN ANO
SAfETY RIGIKAIIONS. mum
AIR ANO OIL UNDER PRCSSURf
WILL CAUS[ SEVERE PERSONAL
INJURY OR DEATH.
SHUTDOWN COMPRESSOR ANO
RELIEVE SYSTEM OF ALL
PR[SSURE BEFORC REMCVING
VALVCS. CAPS. PLUGS.
FIT TINGS.BOLTS ANO FILTERS.
,—
r
ADAINi@m
HIGH VOLTAGE.
ROTATING MACHINERY.
AIR ANO OIL
UNOEil PRESSURE.
IMPROPER MODIFICATION DO NOT MODIFY
OF COUIPMCNT WILL UNIT WITHOUT
CAUSE SEV[RE PERSONAL WRITTEN PERMISSION
INJURY OR DEATH. FROM MANUFACTURER.
—1
@i!!!!i!!!!
Q3iii
o
ROTATING MACHINERY CAN
CAUSE INJURY OR OEATH.
KCEP ALL GUAROS ANO
SAFETY OIVICES IN
PLACE.
UNIT CAN AUTOMATICALLY
RESTART.
CAN CAUSS PERSONAL IN.ARY
OR CtATIL
KNOW MODE Of OIW?ATION
SZfORE WORKING ON OR
NEAR THE MACHINt. —
13-8-609 Sectionl Page5

fLECTRICAL SHOCK FROM kwm!wm
‘MpROpER‘ROuNO’NGCAN-o
CAUSE INJURY OR DEATH.
GROUND UNIT AND llfLATCD
EQUIPMENT ACCORDING TO
NATl OHAL [LfCTRIC CODE
ANO LOCAL REGULATIONS.
a
—IuI
AIR AND OIL UNDER
PRfSSURE.
CAN CAUSE SEVERE
PERSONAL INJURY
OR DEATH.
INSPECT OIL RESCRVOIFI
FOR CRACKS AT LEAST
ANNUALLY. —El
CLICTRICAL ARCING CAN
CAUSE AFIRE WHfN UNIT IS
MOUNTED ON ACOMBUSTIBLE
SURfACC RESULTING IN
PERSONAL INJURY OR
PROPERTY DAMAGE.
UNIT MUST 6[ MOUNTED ON
AFLOOR PLAT[ EXTfNOING
ON ALL SIOCS.
SfE INSTALLATION
DRAWING fOR PROPER
DIMENSIONS. —
[LICTRICA1 SHOCK CAM
CAUSE INJURY OR OEATN.
OIS:ONNECT ALL CIRCUITS
SEfORS WORI(IN6 OK THIS
COISTROL.
StE WIRIN6 DIAGRAM.
!!wwimm
IACHINE DAMAGE OR INJURY
:AN OCCUR OLK TO IMPROPER
IF TING.
IO NOT LIFT MACHINE WITH
“HE MOTOR EYf80LT.
—
13-8-609 Sectionl Page6