Powerex SED1007E User manual
DESCRIPTION
GENERAL
Powerex Scroll Enclosure Air Compressors are designed to
supply continuous oil-free air by using the most advanced
scroll technology. These turn-key packages are extremely quiet
and offer electronic control that will reduce electrical power
consumption.
The Powerex Oil-less Rotary Scroll Air Compressor has
advanced scroll compressor technology through the
development of a completely oil-less unit. The Powerex Scroll
Compressor offers a dynamically balanced air end which
insures vibration-free operation. The rotary design permits a
continuous 100% duty cycle. No oil separation, oil filtration,
or inlet valves are required on the Powerex Scroll unit. The
compressor is virtually maintenance free.
The Powerex Oil-less Rotary Scroll Air Compressor is based
on the theory of scroll compression. A scroll is a free standing,
intricate spiral bounded on one side by a solid, flat plane or
base. A scroll set, the basic compression element of a scroll
compressor, is made up of two identical spirals which form
right and left hand parts. One of these scroll components is
indexed or phased 180° with respect to the other so the scrolls
can mesh. Crescent-shaped gas pockets are formed and
bounded by the spirals and the base plate of both scrolls. As
the moving scroll is orbited around the fixed scroll, the pockets
formed by the meshed scrolls follow the spiral toward the
center and diminish in size. The moving scroll is prevented
from rotating during this process so the 180° phase
relationship of the scrolls is maintained. The compressor’s
inlet is at the outer boundary of the scrolls. The entering gas is
trapped in two completely opposite gas pockets and
compressed as the pockets move toward the center. The
compressed gas is discharged through the outlet at the center
of the fixed scroll so no valves are needed.
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
IN563601AV
SPECIFICATIONS
Powerex - 150 Production Drive - Harrison, Ohio 45030 - USA
1-888-769-7979 - www.powerexinc.com
10 HP to 20 HP Scroll Enclosure Air Compressors
Product SE Series Enclosed Scroll Air
Compressor
Lubrication Grease-filled Bearing
Operating
Voltages 3Ø - 208-230/460/575 Volts, 60 Hz
Compression
Cycle Scroll
Motor Overload
Protection Motor Protector/Circuit Breaker
Pressure Settings Cut in: 90 psig Cut out: 116 psig
Cut in: 119 psig Cut out: 145 psig
(High Pressure Units)
Overpressure
Protection Safety Valve Factory Set and Sealed
Drive 3V Belt
Agency Approvals UL/CSA Certified
Pg 1
09/12
10HP - 20HP Scroll Enclosure Air Compressors
Pg 2
TROUBLESHOOTING GUIDE
Problem Possible Cause Corrective Action
Compressor does not operate
No Display on the
Operating Panel 1. The electric source is not turned on
2. Transformer primary or secondary fuse open
3. Electric source is not correctly connected
4. Failure of display or PLC
1. Turn on electric source
2. Replace
3. Connect correctly
4. Inspect, repair or replace
It does not operate
despite displays 1. Failure or wiring failure of magnetic starter
2. Motor failure
3. Low voltage
1. Inspect, repair or replace
2. Inspect, repair or replace
3. Check electric source capacity and the size of
electric source cable and change to proper one
Alarm Screen
Active 1. High temperature condition
2. Motor Overload condition
3. High temperature indicated but unit is cool,
has never been hot
1.Allow to cool and reset, determine cause
2. Reset motor overload, reset alarm and
determine root cause of overload
3. A temperature switch may be disconnected or
defective, check wiring
Compressor starts but then stops
Alarm Screen
High Temperature 1. High ambient temperature or bad ventilation
2. Clogging of aftercooler fins or intake wire
screen
3. Failure of ventilating fan
4. Damage to intake hose
5. Cooling passage of air end clogged
6. High exhaust pressure
1.Improve installation environment & ventilation
2. Clean
3. Replace
4. Replace
5. Inspect and clean
6. Inspect– control malfunction likely
Alarm Screen
Motor Overload 1. Low voltage
2. Motor Failure
3. Air end failure
4. Loosened wiring screw
5. High exhaust pressure
6. Failure of thermal overload
1. Check electric source capacity, size of electric
source cable and change to proper one
2. Inspect, repair or replace
3. Inspect, repair or replace
4. Tighten
5. Inspect - control failure likely
6. Replace
Exhaust pressure
does not increase 1. Air leaks from exhaust piping
2. Air-end rotates backward
3. Wrong pressure setting
4. Clogged intake filter
1. Inspect, repair
2. Change phases
3. Readjust
4. Clean or replace
Safety valve
activates 1. Failure of safety valve
2. Failure of pressure setting 1. Replace
2. Inspect - control failure likely
Abnormal sound 1. Air-end rotates backward
2. Air end failure
3. Belt slips
4. Motor failure
5. Cooling fan contacting frame
6. Loosened bolts
1. Change phases
2. Inspect, repair or replace
3. Check tension and readjust
4. Inspect, repair or replace
5. Inspect and repair
6. Inspect and tighten
10HP - 20HP Scroll Enclosure Air Compressors
Pg 3
MAINTANANCE SCHEDULE
Item Action Needed Operating Hours
500 2500 5000 10,000 20,000 Remarks
Intake Filter Replace Every 2500 hours or less
Ventilation Screen Clean Every 500 hours or less
Air End/Blower Fan Clean Every 5000 hours or less
Fan Duct Clean Every 5000 hours or less
Compressor Fins Clean Every 2500 hours or less
Compressor Grease Use genuine Powerex grease
(every 5000 hours for High
Pressure Models)
Tip Seal Replace (every 5000 hours for High
Pressure Models)
Dust Seal Inspect, Replace (every 5000 hours for High
Pressure Models)
V-belt Inspect, Replace * *Readjust
Pressure Sensor Confirm
Operation Check touchscreen for pressure rise
and fall
Magnetic Starter Inspect Replace if contact points are
deteriorated/excessive arching
Check Valve Inspect Confirm operation by watching pump
and motor shut off and stop turning
Safety Valve Confirm
Operation Every 500 hours or less. Pull ring to
make sure not stuck or plugged.
Ventilation Fan Inspect Confirm ventilation air is exiting
Motor Pulley Inspect Groove/
Make sure tight
on shaft
Replace if abnormal wear is detected
Motor Inspect Replace if abnormal noise is
detected./ Make sure electrical
connections are secure.
Intake Hose Inspect Replace if damaged or deteriorating
Braided Hose Inspect, Replace Make sure there are no leaks
Aftercooler Clean outside Every 5000 hours or less
Operating Panel Inspect monitor
daily Verify pressure/Check for alarm
notification
Piping Inspect for leaks Every 2500 hours or less
NOTES:
1. Inspect and perform maintenance periodically according to the maintenance schedule.
2. The maintenance schedule relates to the normal operating conditions. If the circumstances and load condition are adverse,
shorten the cycle time and perform maintenance accordingly.
3. *Marked “Readjust” means the tension of the V-belt should be adjusted during the initial stage and inspected every 2,500
hours afterwards.
Inspect
Replace
Replace Pump
Pg 4
10HP - 20HP Scroll Enclosure Air Compressors
SCHEDULED MAINTENANCE
Per OSHA regulations, lockout
compressor system from all power sources BEFORE
performing any maintenance.
INTAKE FILTER
1. Remove the small rear access panel.
2. Remove the wingnut on the filter housing and drop the
cover down. Remove the element without removing the cover
from the enclosure cavity.
3. Clean the inlet filter element with compressed air or
replace with a new element.
NOTE: Never clean filter element with solvents or water.
VENTILATION SCREEN
1. Remove the ventilation screen located at rear of the unit.
2. Clean with compressed air or soap and water if necessary.
INSPECT V-BELT TENSION
1. See page 9 of Operation Manual, IN562802AV.
GREASE COMPRESSOR BEARINGS (Figure 7)
1. Remove the plastic dust cap from the airend.
2. Move the compressor pulley until the grease fitting is
visible through the dust cap hole.
3. Use a grease gun extension adapter to engage the grease
fitting and supply the proper volume of grease as indicated on
the grease delivery chart. See chart below.
Model 1st Time 2nd Time
O.S. Bearing 7 times 6 times
Pin Crank Bearing O.S. Side 7 times 7 times
GREASE PIN CRANK BEARING (Figure 6)
1. Remove fan duct (2) (Key #5)
2. Remove the nuts and bolts and then the fixed scroll from
the air end.
3. Grease all three pin crank bearings as indicated on the
grease delivery chart above.
Use only Powerex genuine
grease. Pump grease gun before
feeding to eliminate air from grease passage of the needle
adaptor.
NOTE: Each pump of the grease gun equals 0.65g of grease.
The volume of grease is less after the 2nd pump since some
of the grease supply will remain in the grease passage.
MAINTENANCE INDICATORS
The PUMP MAINT indicator will activate when the running
hours of any pump accumulates to a required maintenance
interval. The system is designed for multiple pumps to accu-
mulate hours evenly and for maintenance intervals to be ap-
proached simultaneously. To prevent nuisance PUMP
MAINT indications, all applicable maintenance counters
should be reset after the required maintenance actions are
performed.
Pg 5
10HP - 20HP Scroll Enclosure Air Compressors
SCHEDULED MAINTENANCE (Cont’d)
REPLACE TIP SEAL
1. Remove intake hose
2. Remove the discharge hose.
3. Remove nuts and bolts that secure fixed scroll.
4. Remove the fixed scroll housing.
5. Take out the old tip seal from the orbiting scroll housing
and fixed scroll housing, see Figure 8.
6. Remove the old dust seals from fixed scroll, see Figure 9.
Install the new tip seals and dust seals in the stationary and
orbiting scroll housings in the following manner:
NOTE: Tips seals for Fixed Scroll and Orbit Scroll have
opposing seal cut angles (See NOTE and explanatory
diagram below).
Insert tip seal so that the lip of tip seal is on the bottom of seal
groove and inner side of involute and the direction of lip
faces the center of involute (curving spiral). See Figure 9.
This is to be done for both FS and OS sets.
Use caution not to tear or distort lip.
1. Insert new HP tip seal from the center section for OS or
Orbit Scroll so that there will be no clearance at the tip (start)
section (See Figure 8 and 9).
2. Insert so that new LP tip seal will contact closely with HP
tip seal inside Scroll Groove.
Insert approximately half of
the LP tip seal and remove the tip seal to confirm that a
notch in the tip seal has been created. This will prevent
movement during installation (See Figure 8).
3. Repeat the same procedure for FS or Fixed Scroll tip seal
set, remove both the dust seal and the backup tube located on
outermost side FS set.
4. Insert new backup tube in FS in the 6 o’clock position (See
figure 10).
NOTE: In order to distinguish between the tip seal for Fixed Scroll and the tip seal for Orbit Scroll place the tip seal as shown
below then view from the arrow direction and refer to the figure on the right.
Pg 6
10HP - 20HP Scroll Enclosure Air Compressors
SCHEDULED MAINTENANCE (Cont’d)
5. Insert new dust seal on the backup tube (See Figure 11).
6. After replacing tip seal set, reassemble Fixed Scroll set to
the Orbit Scroll. Tighten nuts and bolts temporarily and
confirm if pump pulley rotates smoothly by hand and tighten
them firmly. Tightening torques are in the chart below:
First Second
175 in lbs. 265 in lbs.
Bolt Torque
NOTE: Assemble so that dust seal and tip seal will not drop
between Orbit Scroll set and Fixed Scroll set.
10HP - 20HP Scroll Enclosure Air Compressors
PARTS DIAGRAM
1 Air End
2 Motor
3 Motor
Pulley
4.1 PLC
4.2 HMI
Touch Screen
5 V Belt
6 Intake
Filter
Element
7 Temp Switch
8 Pressure Sensor
9 Check Valve
10 Safety Valve
11.1 Magnetic
Contactor
11.2 Motor
Protector
12.1 Distribution Block
12.2 Distribution Block Cover
13 Inlet Plate
16 Inlet Gasket
14 Exhaust Fan
15 Control Transformer
19 Fuses
17 Braided Hose
18 Aftercooler
Pg 7
10HP - 20HP Scroll Enclosure Air Compressors
Ref.
No. 10HP 15 HP 20 HP Qty.
Description SED1007E SED1007EHP SET1507E SET1507EHP SEQ2007E SEQ2007EHP
1 Air End SL016502AJ SL016511AJ SL016502AJ SL016511AJ SL016502AJ SL016511AJ 2,3,4
2.1 Motor
208-230/460V
MC303305AV
2,3,4
2.2 Motor
575V
MC303307AV
2,34
3 Motor Pulley PU009754AV 2,3,4
4.1 PLC PE000420AV 1
4.2 Touch Screen
HMI panel PE000417AV 1
5 3VX-belt BT012900AV 4,6,8
6 Intake filter
element ST073907AV 1
7 Temp Switch AM003011AV AM003012AV AM003011AV AM003012AV AM003011AV AM003012AV 2,3,4
8 Pressure Sensor PE000450AV 1
9 Check Valve IP087700AV 2,3,4
10 Safety Valve V-215400AV V-215401AV V-215400AV V-215401AV V-215400AV V-215401AV 1
REPLACEMENT PARTS LIST
Pg 8
10HP - 20HP Scroll Enclosure Air Compressors
REPLACEMENT PARTS LIST (CONT.)
Pg 9
Ref.
No. 10HP 15 HP 20 HP Qty.
Description SED1007E SED1007EHP SET1507E SET1507EHP SEQ2007E SEQ2007EHP
11.1 Magnetic
Contactor PE000102AV 2,3,4
11.2 Motor Protector
208-230V PE000307AV 2,3,4
Motor Protector
460V/575V PE000305AV 2,3,4
12.1 Distribution
Block PE000622AV 1
12.2 Distribution
Block Cover PE000640AV 1
13 Inlet Plate IP088400AV 2,3,4
14 Exhaust fan SM001301AV 2,3,4
15.1 Control
Transformer
208-230/460V
PS005850AV 1
15.2 Control
Transformer
575V
PS005839AV 1
16 Inlet Gasket IP088200AV 2,3,4
17 Braided Hose SM001501AV 2,3,4
18 Aftercooler SL300100AV 2,3,4
19.1 Primary Fuses
208V JP007710AV 2
19.2 Primary Fuses
230/460V JP007714AV 2
19.3 Primary Fuses
575V JP007709AV 2
19.4 Secondary Fuse
208-575V JP007715AV 1
10HP - 20HP Scroll Enclosure Air Compressors
Pg 10
Ref.
No. Description SLAE05E SLAE05EHP Qty.
1 Air End Pulley 02549110 1
2 Key IP600600AV 1
3 Centrifugal Fan IP601300AV 1
4 Fan Duct (1) IP601400AV 1
5 Fan Duct (2) 02519042 1
6 Fan Cover IP601700AV 1
7 Fan Dust Gasket (1) IP601900AV 1
8 Heat Insulation Pipe IP602000AV 1
9 Fan Duct Gasket (2) IP602400AV 1
10 Long Nipple 96647011 1
11 Dust Cap IP603500AV 1
12 Tip Seal Set 92832070 92832080 1
* Grease Gun Kit IP616201AJ
* Grease Gun IP616101AJ
* Grease IP600000AV * NOT SHOWN
PARTS DIAGRAM & LIST
This manual suits for next models
5
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