Powerex SED1007 User manual

Brand: Powerex

Model: SED1007

Category: Air compressors

Type: User manual

Scroll Enclosure Air Compressor

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.

Powerex • 150 Production Drive • Harrison, OH 45030 • USA

1-888-769-7979

IN558804AV 6/12

Speciﬁ cations

Product SED, SET, SEQ, SEH and SEO Series

Performance

Speciﬁ cations

See Page 2

Lubrication Grease-ﬁ lled Bearings / Dry Scroll

Operating Voltages 3Ø 208-230/460 Volts, 60 Hz

Compression Cycle Scroll

Motor Overload

Protection

IEC Motor Overload Relay

Pressure Settings

Working Pressure

Cut-In: 94 psig Cut-Out: 116 psig

Cut-In: 116 psig Cut-Out: 145 psig

(High Pressure Unit)

Overpressure

Protection

Safety Valve Factory Set and Sealed

Outlet Air

Connections

See Page 2

Minimum

Recommended Tank

Sizes

See Page 5, Chart 2

Unit Isolation Standard All Units

Drive 3V Belt

Control Panel UL508A Listed for medical units

Description

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 Oilless Rotary Scroll Air Compressor has

advanced scroll compressor technology through the

development of a completely oilless 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 ﬁ ltration,

or inlet valves are required on the Powerex Scroll unit. The

compressor is virtually maintenance free.

The Powerex Oilless 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, ﬂ at 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 ﬁ xed 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 ﬁ xed scroll so no valves are needed.

Scroll Enclosure Air Compressors

Performance Speciﬁ cations

Model SED1007 SED1007HP SET1507 SET1507HP SEQ2007 SEQ2007HP SEH3007 SEH3007HP SEO4007 SEO4007HP

Installed Motor

HP 10 10 15 15 20 20 30 30 40 40

Maximum

Pressure PSIG 116 145 116 145 116 145 116 145 116 145

Performance

SCFM @

100 PSIG

30.4 25.6 45.6 38.4 60.8 51.2 91.2 76.8 121.6 102.4

FLA*

208 / 230 / 460

30.6 / 27.6 /

13.8

30.6 / 27.6 /

13.8

45.9 / 41.4 /

20.7

45.9 / 41.4 /

20.7

61.2 / 55.2 /

27.6

61.2 / 55.2 /

27.6

91.8 / 82.8 /

41.4

91.8 / 82.8 /

41.4

122.4 /

100.4 / 55.2

122.4 /

100.4 / 55.2

Noise Level dB(A) 53 53 56 56 58 58 59 59 60 60

Discharge

Connection 3/4 inch 3/4 inch 3/4 inch 3/4 inch 1 inch 1 inch 1-1/2 inch 1-1/2 inch 1-1/2 inch 1-1/2 inch

Dimensions

in Inches

(L x W x H)

38 x 26 x 47 38 x 26 x 47 38 x 26 x 47 38 x 26 x 47 38 x 26 x 61 38 x 26 x 61 58 x 45 x 65 58 x 45 x 65 58 x 45 x 65 58 x 45 x 65

Weight (lbs) 620 620 800 800 1030 1030 1945 1945 2320 2320

Discharge Air

Temp. °F

< Intake

temp.

+49°F

< Intake

temp.

+49°F

< Intake

temp.

+52°F

< Intake

temp.

+52°F

< Intake

temp.

+63°F

< Intake

temp.

+63°F

< Intake

temp.

+63°F

< Intake

temp.

+63°F

< Intake

temp.

+63°F

< Intake

temp.

+63°F

* Full System Amps

Safety Guidelines

This manual contains information that is very important

to know and understand. This information is provided for

SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help

recognize this information, observe the following symbols.

Danger indicates an imminently

hazardous situation which, if

not avoided, will result in death or serious injury.

Warning indicates a potentially

hazardous situation which, if

not avoided, could result in death or serious injury.

Caution indicates a potentially

hazardous situation which, if

not avoided, MAY result in minor or moderate injury.

Notice indicates important

information, that if not

followed, may cause damage to equipment.

Unpacking

After unpacking the unit, inspect carefully for any damage

that may have occurred during transit. Make sure to tighten

ﬁ ttings, bolts, etc., before putting unit into service.

Do not operate unit if damaged

during shipping, handling

or use. Damage may result in bursting and cause injury or

property damage.

The compressor nameplate should be checked to see if the

unit is the correct model and voltage as ordered.

PRECAUTIONS DURING TRANSPORTATION AND MOVEMENT

TRANSPORTATION BY FORKLIFT

Use openings for forklift under both sides of the unit.

Avoid damaging the panel with

tips of the forklift.

TRANSPORTATION BY CRANE

Use openings at the bottom of the unit to lift up by cable,

lifting straps and etc. Make sure all lifting devices are rated

for the maximum load.

Be sure to use pads in order to

protect panels.

Figure 1

Figure 2

Scroll Enclosure Air Compressors

General Safety Information

The operator of this compressor must take the necessary

precautions to prevent the level of danger indicated by these

symbols. The operator is also required to read and understand

this instruction manual and all safety warnings, labels, etc.

Any employer allowing the use of this compressor in their

ﬁ eld of work must distribute this instruction manual to

all users. The employer must also ensure all users read,

understand and follow the instructions as described in the

manual, safety warnings, labels, etc.

1. Read and understand all safety warnings and

instructions before operating this compressor.

Failure to read and follow all safety warnings

may result in serious personal injury or death.

Property damage and/or compressor damage

may also occur if all warnings are not followed.

2. Air used for breathing or food processing must

meet O.S.H.A. 29 C.F.R. 1910.134 or C.F.R. 178.3570

regulations.

Motors, electrical

equipment and

controls can cause electrical arcs that will ignite a

ﬂ ammable gas or vapor. Never operate or repair in

or near a ﬂ ammable gas or vapor. Never store

ﬂ ammable liquids or gases in the vicinity of the compressor.

3. Safety Valves or Relief Valves used on this compressor

must be in accordance with ANSI/ASME B19 safety

standards. Improperly sized Safety Valves will result in

serious personal injury or death.

Do not remove the

panel or try to

service the air compressor while the compressor is

running or while the air receiver is under pressure.

Serious personal injury or death will occur.

4. Never use rubber hoses, plastic piping or soldered joints

in any part of the compressed air or gas system. The

compressor and system piping must be compatible.

5. The compressor will shutoff when the pressure reaches a

predetermined maximum pressure. Care should be used

since the compressor may suddenly restart automatically

when the pressure drops to the predetermined minimum

pressure. Never assume the compressor is ready for

service just because the unit is stopped.

Release all pressure

from the system

before attempting to install, service, relocate or

perform any maintenance.

6. Keep clear of all moving parts especially if the compressor

is operating with the door panel removed for inspection

or repair.

Do not touch HOT

parts of the

compressor such as the air end, discharge pipe,

aftercooler, motor, etc.

7. Keep ﬂ ammable gases away from the compressor. Parts

of the compressor become very hot during operation and

the vapors from ﬂ ammable gases may cause the unit to

explode.

8. Never use ﬂ ammable or toxic solvents to clean the

compressor or any of the unit’s parts.

9. Do not remove or tamper with any safety devices,

guards, panels or insulation parts while compressor is in

operation. All guards or panels must be in place before

starting or operating the compressor.

Install a properly

sized Safety Relief

Valve in the discharge piping ahead of or before

a shut-off valve, heat exchanger, oriﬁ ce, etc. The

compressor or part of the system could rupture or

explode if a Safety Relief Valve is not installed.

10. Do not change the pressure setting of the Safety Relief

Valve. Do not replace the Safety Relief Valve with a plug

or restrict the Safety Relief Valve. The system or the

compressor may be over-pressurized if the Safety Relief

Valve is tampered with in any way.

11. Do not service the compressor or any compressor part

while the unit is in operation.

12. Do not remove, disconnect or tamper with the High

Temperature Shutdown Switch. The High Temperature

Shutdown Switch must be installed on the compressor

to protect against high temperatures damaging the

compressor.

13. All electrical connections should be made by a qualiﬁ ed

electrician.

Disconnect all

power supplies to

the compressor before opening the electrical box

or before servicing the unit. High voltage may be

present.

14. Never remove or alter any safety warning labels, tags,

etc. located on or provided with compressor.

MANUAL

Breathable Air Warning

This compressor / pump is not equipped and should

not be used “as is” to supply breathing quality air. For

any application of air for human consumption, you

must ﬁ t the air compressor / pump with suitable in-line

safety and alarm equipment. This additional equipment

is necessary to properly ﬁ lter and purify the air to

meet minimal speciﬁ cations for Grade D breathing as

described in Compressed Gas Association Commodity

Speciﬁ cation G 7.1 - 1966, OSHA 29 CFR 1910. 134,

and / or Canadian Standards Associations (CSA).

DISCLAIMER OF WARRANTIES

IN THE EVENT THE COMPRESSOR IS USED FOR THE

PURPOSE OF BREATHING AIR APPLICATION AND PROPER

IN-LINE SAFETY AND ALARM EQUIPMENT IS NOT

SIMULTANEOUSLY USED, EXISTING WARRANTIES ARE

VOIDED, AND POWEREX DISCLAIMS ANY LIABILITY

WHATSOEVER FOR ANY LOSS, PERSONAL INJURY OR

DAMAGE.

Scroll Enclosure Air Compressors

General Safety Information

(Continued)

15. Always provide a clean air source for your compressor.

Keep all piping direct and short when using an outside

air source.

16. Locate compressor inlet system away from possible

ingestion of ﬂ ammable or toxic vapors, water, dirty air or

air temperatures exceeding 104°F.

17. Never set the pressure to a higher setting than the one

provided from the factory.

18. Check all gauges daily to be sure the compressor is

operating correctly.

19 Follow all directions for maintenance. Check all safety

devices according to instructions.

20. Never attempt to lift or move the compressor except

when using the proper lifting procedures.

21. Make sure all electrical components follow the National

Electric code and all state and local codes when installing

the compressor.

22 Do not operate the compressor if unusual noise or

vibration occurs.

23. Keep all panels in place at all times.

24. Standard motors are not appropriate for dirty, wet or

explosive areas.

25. All service should be performed by trained and qualiﬁ ed

people only.

26. The Drive Belt tension should be checked often during

initial operation of the compressor.

27. Never substitute oil bath or oil wetted ﬁ lters for the inlet

ﬁ lters provided with the compressor.

Installation

INSTALLATION SITE

1. The scroll compressor must be located in a clean, well lit

and well ventilated area. A contaminated area can clog

the intake ﬁ lter and / or intake metal mesh.

2. The area should be free of excessive dust, toxic or

ﬂ ammable gases, moisture and direct sunlight.

3. Never install the compressor where the ambient

temperature is higher than 104°F or lower than 32°F

or where humidity is high. High humidity will cause

electrical short circuit and rusting of components.

4. Clearance must allow for safe, effective inspection and

maintenance. 24 inch of clearance for sides, 40 inch

clearance from the top is recommended.

5. If necessary, use metal shims or leveling pads to level the

compressor. Never use wood to shim the compressor.

VENTILATION

1. If the scroll compressor is located in a totally enclosed

room, an exhaust fan with access to outside air must be

installed.

2. Never restrict the cooling fan exhaust air.

3. Vent the exhaust air outside to prevent the compressor

from operating at high temperatures and shutting down.

4. Never locate the compressor where hot exhaust air from

other heat generating units may be pulled into the unit.

SUGGESTED VENTILATION SYSTEM

1) The following ventilation capacity is designed to keep

the temperature rise inside the room to be max. 10°F.

Since the calculation is based on zero static pressure,

the actual ventilation capacity should be larger than the

capacity value listed in Chart 1.

FRESH

AIR IN

EXHAUST

AIR OUT

FRESH

AIR IN

EXHAUST

AIR OUT 8 inches to

12 inches

Clearance

Setup A Setup B

Figure 3

Model - Setup B 10 HP 15 HP 20 HP 30 HP 40 HP

Ventilation

Capacity (cfm) 885 1415 1770 2830 3535

Model - Setup A 10 HP 15 HP 20 HP 30 HP 40 HP

Ventilation

Capacity (cfm) 2650 3885 5300 7770 10595

Chart 1

Scroll Enclosure Air Compressors

Installation (Continued)

2) Install the exhaust duct in order to minimize the

pressure lost of the ducting. Keep the distance between

the inlet duct and the compressor exhaust to be at least

12 inches for ease of maintenance. Intake section of the

duct should be larger than the dimension of compressor

exhaust shown below:

WIRING

All electrical hook-ups must be performed by a qualiﬁ ed

electrician. Installations must be in accordance with local and

national electrical codes.

1. Use solderless terminals to connect the electric power

source.

2. Remove front panel.

3. Remove the rectangle electrical box cover located

beneath air inlet ﬁ lter on the right front of the unit.

4. Connect the power inlet cable to the inlet power

junction block located on the inlet side of all starter

connections.

Consult your NEC and local codes for wire size

PIPING

These units do not include air receivers. An air receiver can

be purchased separately. Please consult our distributors. Use

Chart 2 as a guideline for sizing the air receiver.

1. Make sure the piping is lined up without being strained

or twisted when assembling the piping for the scroll

compressor.

2. Appropriate expansion loops or bends should be installed

at the compressor to avoid stresses caused by changes in

hot and cold conditions.

3. Piping supports should be anchored separately from the

compressor to reduce noise and vibration.

4. Never use any piping smaller than the compressor

connection.

5. Use ﬂ exible hose to connect the outlet of the compressor

to the piping so that the vibration of the compressor

does not transfer to the piping.

SAFETY VALVES

The ﬂ ow capacity of a safety valve should be equal to or

greater than the capacity of the compressor.

1. The pressure setting of the safety valve must not be

greater than the maximum working pressure of the air

receiver.

2. Safety valves should be placed ahead of any possible

blockage point in the system, i.e. shutoff valve.

3. Avoid connecting the safety valve with any tubing or

piping.

4. Manually operate the safety valve every six months to

avoid sticking or freezing.

Model 10 HP 15 HP 20 HP 30 HP 40 HP

Air Receiver Minimum

Capacity (gallons) 30 60 60 110 160

Chart 2

Scroll Enclosure Air Compressors

Operation

BEFORE START UP

1. Make sure all safety warnings, labels and instructions

have been read and understood before continuing.

2. Remove any shipping materials, brackets, etc.

3. Conﬁ rm that the electric power source and ground have

been ﬁ rmly connected.

4. Check the belts for tightness.

5. Be sure all pressure connections are tight.

6. Check to be certain all safety relief valves, etc., are

correctly installed.

7. Securely mount all panels and guards.

8. Check that all fuses, circuit breakers, etc., are the proper

size.

9. Make sure the inlet ﬁ lter is properly installed.

10. Conﬁ rm that the drain valve is closed.

11. Visually check the rotation of the compressor pumps.

The rotation should be counterclockwise if viewing the

compressor from the pulley or belt side of the motor or

the air end. If the rotation is incorrect, have a qualiﬁ ed

electrician correct the incomming T1 and T2 connections.

START-UP AND OPERATION

1. Follow all the procedures under “Before start-up” before

attempting operation of the compressor.

2. Switch on the electric source breaker.

3. Make sure electric source lamp lights up and that the

caution code or alarm code does not show up on the

display.

Note: The alarm lamp light will come on if a temperature

sensor is not connected. If the sensor is not connected, have a

qualiﬁ ed service person reconnect the sensor.

4. Open the discharge valve completely.

5. Push ON button and check that the compressor operates

without excessive vibration, unusual noises or leaks.

6. Close the discharge valve completely.

7. If the pressure does not rise on a three phase unit,

turn the unit off, the unit is running backwards.

Have a qualiﬁ ed electrician switch the breaker OFF

and exchange two out of three phases of electric

source.

8. Check the discharge pressure. Also make sure the air

pressure rises to the designated pressure setting by

checking the discharge pressure gauge.

CONTROL LOGIC SEQUENCING ORDER

Since the compressors are designed using multiple air-ends,

they are using multiplex controller. The controller will start

and stop each air-end according to the pressure and air

consumption.

1) Alternating Control:

The controller will equalize the operating hours on

each air-end. It will alternate between the air end with

the most running time and the air end with the lowest

running time.

2) Prevention of long term operation:

When an air-end has been operating longer than the set-

time, the controller will alternate to the air-end with the

lowest running time. This will prevent one air end from

running continuously for too long and will equalize the

running time between the available air ends.

SHUT-DOWN

1. Stop the compressor by pushing the OFF button.

NOTE: If the compressor rotates in reverse for more than ﬁ ve

seconds, the check valve needs to be cleaned or replaced.

2. Switch the breaker OFF if the compressor is not to be

used for a long period of time.

STOPPING THE COMPRESSOR DURING NORMAL

OPERATION

1. Close the discharge valve.

2. Allow the air pressure to build and the compressor to

stop.

3. Turn the compressor off by pushing the OFF button.

STOPPING THE COMPRESSOR DURING EMERGENCY

OPERATION

Stop the compressor by pushing the OFF button or by turning

the power off at the main disconnect panel.

SED SET

SEQ

SEH

(6)3

(4)

(5)2

SEO

(8)

1 (5)

2 (6)

3 (7)

Figure 4 - Control Logic Sequencing Order

Scroll Enclosure Air Compressors

Multi-Stage Control

As this compressor uses plural air ends, it employs multi-stage control. It can start and stop each air end according to pressure

and air consumption, automatically select the number of air ends in accordance with air consumption and achieve optimum and

uniform operation at all times as well as energy-saving and labor-saving operation.

1. Multi-stage control

Among air ends which are operating under group control, it stops the air end which has been operating for a longer

time and restarts the air end whose operating time has been shorter, thus resulting in equalization of operating time

of each air end and operation with a min. quantity of air ends in accordance with air consumption and energy-saving

operation by eliminating waste of electricity.

2. Prevention of long-term operation

When operating time of an air end exceeds the initial setting time, it changes operation from that air end to the one

which has stopped, prevents long-term operation of one air end, lengthens the lifetime of air ends and equalizes the

operating time of air ends.

No 1

No 8

No 7

No 6

No 5

No 4

No 3

No 2

Compressor

Multi-stage control

OFF ON

100%

Max

pressure

Min

pressure

Pressure

Ratio of

air consumption

Ration of Load

Scroll Enclosure Air Compressors

Operation Mode

Caution Mode

Service Mode

Set Mode

ON OFF

Compressor

Run

Mode Item

Reset

Display

Mode Display Light

Indicates selected

display mode

Reset Switch

Performs various

resettings

Compressor

Operating Lamp

Indicates selected

display mode

ON Switch

Starts the unit

OFF Switch

Stops the unit

ITEM button

Selects the informa-

tion to be displayed

MODE button

Selects the mode

to be displayed

Figure 5 - Operating Panel (SED, SET, and SEQ)

Operation Mode

Time Mode

Set Mode

ON OFF

Compressor

Run

Mode Item

Reset

Display

Mode Display Light

Indicates selected

display mode

Reset Switch

Performs various

resettings

Compressor

Operating Lamp

Indicates selected

display mode

ON Switch

Starts the unit

OFF Switch

Stops the unit

ITEM button

Selects the informa-

tion to be displayed

MODE button

Selects the mode

to be displayed

Unit Display

Indicates selected unit

UNIT 1 UNIT 2

Figure 6 - Operating Panel (SEO and SEH)

Operating Panel

DISPLAY MODE

There are ﬁ ve modes of display: Operation, Caution, Service,

Set, and Time.

1. Operation Mode (Default Mode) - To toggle between

display, push item button. You can obtain operating

information (pressure, hours, operating conditions)

which are useful for daily maintenance and inspection.

It functions whether compressor operates or stops. (See

Charts 3 and 4).

2. Caution Mode - In order to select Caution Mode, push

Mode button so that Caution Mode light is illuminated.

By Item button, you can determine causes and conditions

when problems occur as indicated in Charts 5 and 6. It

functions only when compressor stops (2.5 second delay

before each pump starts).

3. Service Mode - In order to select Service Mode, push

Mode Selector Switch so that Service Mode light is

illuminated. By Item Selector Switch, you can determine

causes and conditions when problems occur, as indicated

in Charts 5 and 7. It functions only when compressor

stops.

4. Set Mode - Push Mode button so that Set Mode light

is illuminated. Item button can show each of the set

contents as shown in Chart 8. It functions only when

compressor stops.

5. Time Mode (Only STO and SEH) - In order to select the

Time Mode, push Mode Button so that Time Mode light

is illuminated. By utilizing Item Button, you can scroll the

display shown in the chart below. Compressor must be

turned off before selecting the Time Mode.

The Early Caution maintenance alarm becomes effective

by installing a Early Caution maintenance connector. By

doing so, the maintenance alarm will be activated at

7800 hours (2000 hours earlier than maintenance

alarm 1).

CHANGING MINIMUM AND MAXIMUM PRESSURE

SETTING

1. Change to Set Mode by utilizing Mode button.

2. Display maximum pressure or minimum pressure by

utilizing Item button.

3. You can decrease set pressure by pushing OFF button and

Item button at the same time.

4. You can increase set pressure by pushing Off button and

Mode button at the same time.

5. Cut off circuit breaker and switch on breaker again.

Restrictions:

• Maximum pressure does not exceed ﬁ gure initially set at

our plant.

• Pressure difference between maximum and minimum

pressure is 14.5 psig or over.

• Minimum pressure is 29 psig.

• The display will round all pressure increments to the

nearest psi.

RESETTING OF MAINTENANCE COUNTERS

1. Change to “Set Mode” by utilizing Mode button.

2. Display “Maintenance Time 1” by utilizing Item Switch.

3. Press Reset Switch.

4. Cut off circuit breaker and switch on breaker again.

Scroll Enclosure Air Compressors

Items Display Explanation

Pressure Displays compressor outlet pressure in psig

(Display on the left means 68 psig.)

Operating

Time

Displays operating time in hours x10.

(Display on the left means 230 hours.)

* Number of Hours that any pump is running x load factor

(between 0 to 1 depending on how many pumps are running)

Operating

conditions

Displays operating condition of of air ends No. 1-4

Displays operating condition of air ends No. 1,2,3 and 4 from left to right of the display

(The air end that are located on the bottom of the Unit is designated as No 1)

In the above example, No. 1 and No. 3 air ends are in operation, No.2 air end is in an

emergency stop and No. 4 air end is off.

If the unit has no air end to display, the indicator will always display “underline”.

Operating

condition of

Unit No. 1

(SEO and

SEH series)

Displays operating condition of present Unit No. 1 (left side) which consists of air ends

no. 1~4.

Display contents are the same as illustrated above.

Operating

condition of

Unit No. 2

(SEO and

SEH series)

Displays operating condition of present Unit No. 2 (right side) which consists of air ends

no. 1~4.

Display contents are the same as illustrated above.

Chart 3 - Operation Mode

●

means speciﬁ c air

end in operation

Compressor is off when

“underline” lights up

Indicates emergency stop

when “hyphen” lights up.

Operating Panel (Continued)

Operation Mode Operating Situation

dX10 Initial stage of stop

dX11 Normal stop

dX12 Dryer preliminary start-up

dX20 Initial stage of start

dX21 Start 1

dX22 Start 2

dX30 Initial stage of load

dX31 Normal load

Chart 4 - Detail of Operating Mode X: Air end No.

Scroll Enclosure Air Compressors

Caution Mode Description

CX 5 Failure of dryer (only available for unit

with dryer option)

CX21 High Temperature of air end

CX22 Failure of temperature sensor

CX42 Caution of low pressure (option)

C 91 Maintenance time 1: Intermediate

inspection and maintenance.

Refer to page 9.

C 92 Maintenance time 2: Intermediate

inspection and maintenance.

Refer to page 9. Only SEH and SEO series.

Chart 6 - Caution Code X: Air end No.

Items Display Explanation

Emergency

Code Number

Shows causes for emergency code numbers.

(Refer to Chart 7 regarding details.)

Pressure Shows Pressure in psig when emergency stops occur.

(Display means 78 psig.)

Temperature

Shows Temperature of air end in °C when emergency stops occur. (This display means 58°C.)

When air end temperature is less than 15°C or other failure like cut of temperature sensor

occurs, displays.

Operating

Time

Shows Operating Time in x 10 hours when emergency stops occur. (This display means

230 hours.)

Operating

Mode

Shows Operating Mode in number when emergency stops occur. (Refer to Chart 9 for

Operating Mode.)

Chart 5 - Caution and Service Mode

Operating Panel (Continued)

Service Code Description

EX21 Sudden temperature rise of air end

EX22 High temperature of air end

EX32 High current

EX41 Abnormally high pressure (Only SEH and

SEO series)

EX60

EX61

EX63

Communication failure (Only SEH and SEO

series)

E91 Maintenance time 1: Intermediate

inspection and maintenance.

Refer to page 9.

E92 Maintenance time 2: Intermediate

inspection and maintenance.

Refer to page 9. (Only SEH and SEO series)

Chart 7 - Service Code Number X: Air end No.

Scroll Enclosure Air Compressors

Items Display Explanation

Maximum

Pressure

Shows Max. Set Pressure in psig.

(This display means 116 psig.)*

Minimum

Pressure

Shows Min. Set Pressure in psig.

(This display means 93 psig.)

Time to

change

Operating Air

End

Shows Time to Change Operating Air End and prevents the same air end from operating

for a long time. 1 on display means 15 minutes. (This display means 2 x 15 minutes - 30

minutes.)

External

Operation

means that external operation is set.

means that external operation is canceled.

(When either displays, it can be changed by pushing reset switch.)

External

Output

Shows set situation of external output.

displays when emergency stop occurs.

displays when emergency stop or caution occurs.

(When either displays, it can be changed by pushing reset switch.)

Maintenance

Time 1

Shows remaining time until intermediate maintenance and inspection in terms of 10

hours. The ﬁ rst ﬁ gure is 980 (480 for high pressure models) and decreases as operating

time becomes longer.

Group

Control

Shows set situation of Group Control.

means that Group Control mode OFF is set.

means that Group Control mode ON is set.

* If Group control mode ON is set, ON/ OFF button does not work.

(When either displays, it can be changed by pushing reset switch.)

Chart 8 - Set Mode

Operating Panel (Continued)

Items Display Explanation

Maintenance

time 1

Shows remaining time until next maintenance and inspection in x10 hrs. (calculated in

the same fashion with operating time).

It will start at 980 (9800 hrs.) and continue to decrease as the unit is being operated.

Maintenance

time 2

Standard unit does not have this function.

Becomes effective when Early Caution maintenance connector is used (see page 10).

Shows remaining time until scheduled maintenance and inspection.

Running time Running time records the number of hours during which any or the pump on the system

is running (This display means 860 operating hours).

Chart 9 - Time Mode

Scroll Enclosure Air Compressors

Operating Panel (Continued)

POWER OUTAGE RESET CONNECTOR (SEH AND SEO

SERIES ONLY)

(Shipped with compressor as an accessory)

You can install the power outage reset connector (auto restart

connector) to this compressor. When you install this connector,

the compressor will automatically start again, after the power

to the control panel is restored (without this connector, you

have to manually push the start button to activate the unit).

When power outage reset

connector is installed on

the system, be sure to push stop switch before doing the

maintenance to stop compressor and turn off main electric

source. Otherwise the system can start automatically after

main electric source is energized.

INSTALLATION PROCEDURE

• Remove printed circuit board (PCB) cover (PCB is installed

at the backside of operating panel) by removing 4 screws

around this cover (see Figure 7).

• Insert the power outage reset connector into CN11 on

circuit board (see Figure 8).

• Replace the cover of to the PCB case

EARLY CAUTION MAINTENANCE CONNECTOR (SEH AND

SEO SERIES ONLY)

(Shipped with compressor as an accessory)

Early Caution maintenance will provide an early alarm for

maintenance schedule. By installing this connector, the

caution alarm for maintenance of one unit will be activated

2,000 hours earlier than the standard maintenance schedule.

This will allow you to spread the cost of maintenance over

period of times. Another alarm will activated at 9,800 hours.

INSTALLATION PROCEDURE

In the same way as stated in the above to install power

outage reset connector, insert attached the Early Caution

maintenance connector into CN26 on circuit board.

Caution Troubleshooting Guide

When caution occurs, caution number ﬂ ashes on the display

section of operating panel and on each Unit operating panel

(compressor does not stop). When the cause of caution goes

away, the light will stop ﬂ ashing. You can check caution

information by going to Caution Display Mode.

When caution occurs, cut off circuit breaker, solve problem

and then turn on electric source again. Caution display will be

reset.

CX21: Temperature of air end is high - When the

temperature of air end becomes high, CX 21 will be

displayed. See Chart 10.

CX22: Failure on temperature sensor - See Chart 11.

C 91 &

C 92: Intermediate Maintenance and Inspection - It

shows that maintenance time (remaining time to

intermediate maintenance and inspection) is 0.

Refer to Set Mode on page 8 for details. It is time

for grease up, replacement of tip seal, etc. Contact

our distributor and ask them to do intermediate

maintenance and inspection.

Main print

board

Front side

board

case

Relay

board

Transformer

Rubber bush

Print board

cover

Figure 7 - Circuit Board

Figure 8 - Circuit Board

Main print board

CN26

CN11

Early Caution

maintenance

connector

Power outage

reset

connector

Scroll Enclosure Air Compressors

Item Causes

Sensor 1. Temperature sensor cords are not

properly connected

2. Temperature sensor cords are cut

3. Defective temperature sensor

Ambient

Temperature

When it is less than about 32°F

Chart 11 - Troubleshooting Guide: CX22 X: Air end No.

Item Causes

Ambient

temperature

Ambient temperature is high

Failure of

cooling

1. Air inlet is clogged

2. Air outlet is clogged.

3. Dirty aftercooler ﬁ ns.

4. Failure of ventilation fan, damaged intake

hose.

5. High exhaust pressure.

Chart 12 - Troubleshooting Guide: EX21

and EX22 X: Air end No.

Item Causes

Electric source Open phase of R or T phases, low voltage

Air end Failure

Electric motor Failure

Chart 13 - Troubleshooting Guide: EX31

and EX32 X: Air end No.

Emergency Troubleshooting

Guide

In case of emergency stop, emergency (alarm) code shown

in Chart 7 ﬂ ashes on display section and the associated

compressor (air end) will stop. The normal air end with no

problem continues to operate. You can check the emergency

information by going to Emergency Display Mode.

In case of Emergency Stop, study the information, ﬁ nd the

cause and take necessary measures. Then push Reset Switch

on operating panel to cancel ﬂ ashing emergency number.

If you cannot ﬁ nd a reason or remedy, consult with our

technical service team or our service centers.

EX21: Sudden temperature rise of air end

EX22: Temperature rise of air end; If the temperature rises

more than set temperature, compressor (air end)

stops. See Chart 12.

EX32: Rise of current; If current becomes very high, EX32

displays and compressor stops. See Chart 13.

EX41: Emergency stop by high pressure; When pressure is

higher than cut-out pressure by 15 psig, E41 displays

and compressor stops. (Only SEH and SEO series)

EX60,

EX61, &

EX63: Communications failure between the main panel

circuit board and circuit board on each Unit. See

Chart 14. (Only SEH and SEO series)

E 91 &

E 92: Intermediate maintenance and inspection is over -

If you do not conduct intermediate maintenance

when your compressor reaches its time and continue

operation for a further 200 hours with C 91 and

C 92 not canceled, and stop operation; E 91 and

E 92 will display when you switch on circuit breaker

again.

When E 91 and/or E 92 displays, contact our

distributor and ask them to do the intermediate

maintenance and cancel E 91 and/or E 92.

As a temporary measure, you can continue operation

by pushing reset switch, but the manufacturer is not

responsible for any failure or problem after E 91 and

E 92 displays.

When E 91 or E 92 displays,

contact our distributor and do

the intermediate maintenance and inspection soon.

Item Causes

Ambient

temperature

Ambient temperature is high

Failure of

cooling

1. Unit intake wire screen is clogged

2. Exhaust outlet is clogged.

3. Dirty aftercooler ﬁ ns.

4. Ventilation fan fails or intake hose is

damaged.

5. Cooling passage of compressor is clogged

6. High exhaust pressure.

Chart 10 - Troubleshooting Guide: CX21 X: Air end No.

Item Causes

Wiring Failure of connections

Circuit Board Failure

Chart 14 - Troubleshooting Guide: EX60,

EX61, and EX63 X: Air end No.

Scroll Enclosure Air Compressors

Troubleshooting Guide

Items marked by ▲ are difﬁ cult for you to remedy. Please contact our distributor.

Problems Possible Cause(s) Corrective Action

Compressor does not operate

No display on the

operating panel

• Electric source is not turned on

• Fuse on the circuit board was blown

• Electric source is not correctly connected

• Failure of circuit board

• Turn on electric source

• Replace

• Connect correctly

• Inspect, repair or replace ▲

It does not operate

despite displays

• Failure or wiring failure of magnetic starter

• Circuit board failure

• Motor failure

• Low voltage

• Inspect, repair or replace ▲

• Check electric source capacity and the size of

electric source cable and change to proper one

E60, E61 or E63 are

displayed

• Communication failure of circuit board

between operating panel and each Unit

operating panel

• Inspect wiring around communications circuit

board

• Replace circuit board

E91 or E92 are

displayed • Scheduled maintenance time has elapsed • After maintenance, push reset switch to cancel ▲

Err is displayed • Failure of circuit board • Disengage and reengage the circuit breaker

• Replace circuit board*

It starts but then stops

E21 or E22 are

displayed

• High ambient temperature or bad

ventilation

• Clogging of aftercooler ﬁ ns or intake wire

screen

• Failure of ventilating fan

• Damage to intake hose

• Cooling passage of air end clogs

• High exhaust pressure

• Improve installation environment and ventilation

• Clean

• Replace

• Inspect

E32 is displayed

• Low voltage

• Motor failure

• Air end failure

• Loosened wiring screw

• High exhaust pressure

• Failure of thermal overload

• Check electric source capacity, size of electric source

cable and change to proper on

• Inspect, repair or replace ▲

• Tighten

• Readjust

• Replace ▲

E41 is displayed • High exhaust pressure

• Failure of pressure sensor

• Check pressure

• Replace pressure sensor

Exhaust pressure does

not increase.

• Air leaks from exhaust piping

• Air-end rotates backward

• Wrong pressure setting

• Clogged intake ﬁ lter

• Inspect, repair

• Change phases

• Readjust ▲

• clean or replace

Safety valve activates. • Failure of safety valve

• Failure of pressure setting

• Replace ▲

• Readjust ▲

Abnormal sound

• Air-end rotates backward

• Air end failure

• Belt slips

• Motor failure

• Cooling fan contacted

• Loosened bolts

• Change phases

• Inspect, repair or replace ▲

• Check tension and readjust

• Inspect, repair or replace ▲

• Inspect and repair

• Inspect and tighten

Scroll Enclosure Air Compressors

(A) Load Speciﬁ cations

Panel Part

Number

Motor

Size (HP)

(A) Power

(V/PH)

(A) motor Load

Each (FLA)

Panel Load

Total (FLA)

SED100720E

SED100720EHP

SED100730E

SED100730EHP

SED100740E

SED100740EHP

208V/3

230V/3

460V/3

16.7

15.2

7.6

SET150720E

SET150720EHP

SET150730E

SET150730EHP

SET150740E

SET150740EHP

208V/3

230V/3

460V/3

16.7

15.2

7.6

SEQ200720E

SEQ200720EHP

SEQ200730E

SEQ200730EHP

SEQ200740E

SEQ200740EHP

208V/3

230V/3

460V/3

16.7

15.2

7.6

SEH300720B

SEH300720BHP

SEH300730B

SEH300730BHP

SEH300740B

SEH300740BHP

208V/3

230V/3

460V/3

16.7

15.2

7.6

100

SEO400720B

SEO400720BHP

SEO400730B

SEO400730BHP

SEO400740B

SEO400740BHP

208V/3

230V/3

460V/3

16.7

15.2

7.6

134

121

Branch Circuit Protection Table

(B) Branch circuit protection -

provided by installer

Non-time

Delay Fuse

Time Delay

Fuse

Inverse Time

Circuit Breaker

70A

60A

30A

45A

20A

60A

50A

30A

90A

75A

40A

60A

30A

80A

70A

35A

100A

90A

45A

80A

70A

40A

100A

90A

45A

135A

125A

60A

120A

110A

55A

125A

60A

175A

80A

150A

70A

175A

80A

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 front panel of the unit.

2. Remove the air inlet housing, the wing nut and the inlet

ﬁ lter element.

3. Clean the inlet ﬁ lter element with compressed air or

replace with a new element.

NOTE: Never clean ﬁ lter element with solvents or water.

VENTILATION SCREEN

1. Remove the ventilation screen located at the rear of the unit.

2. Clean with compressed air or soap and water, if necessary.

INSPECT V-BELT TENSION

1. Check V-Belt tension with tension gauge.

2. Adjust to the speciﬁ cations listed in Chart 15.

GREASE COMPRESSOR BEARINGS

1. Remove the plastic dust cap from the airend.

2. Move the compressor pulley until the grease ﬁ tting is

visible through the dust cap hole.

3. Use a grease gun extension adapter to engage the

grease ﬁ tting and supply the proper volume of grease as

indicated on the grease delivery chart. See Chart 16.

GREASE PIN CRANK BEARING (FIGURE 10)

1. Remove the fan duct (2) (Key #6).

2. Remove the nuts and bolts and then the ﬁ xed scroll from

the air end.

3. Grease all three pin crank bearings as indicated on the

grease delivery Chart 14 above.

Use only Powerex genuine

grease (Part # IP600000AV), or

equivalent. Pump grease gun before feeding to eliminate air

from grease passage of the needle adapter.

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.

The grease ﬁ tting, located in

the center of the pin crank

bearing, feeds only the orbit scroll side bearing. Use a needle

adapter to supply grease to the housing side bearing. Pump

grease gun before feeding to eliminate air from grease passage

of the needle adapter. Hold grease gun for 5 - 10 seconds after

feeding to prevent grease blowback from the grease ﬁ tting.

New Belt Load ± Deﬂ ection

Kg/ 10mm

Existing Belt Load ± Deﬂ ection

Kg/ 10mm

6 ± 0.5 5.5 ± 0.5

Chart 15

Model 1st Time 2nd Time

O.S. Bearing 7 times 6 times

Pin Crank Bearing

O.S. Side 7 times 7 times

Chart 16 - Grease Delivery

Figure 10 - Airend: to locate the grease ﬁ tting on the coun-

ter weight, place the key way on the crankshaft as shown.

Key Way

Counter

Weight

Extension

Adapter

Grease Gun

Plastic Dust Cap

Grease Fitting

52°

Grease ﬁ ttings for

pin crank bearings

Figure 9

Scroll Enclosure Air Compressors

Scheduled Maintenance

(Continued)

REPLACE TIP SEAL

1. Remove intake hose

2. Remove the discharge hose.

3. Remove nuts and bolts that secure ﬁ xed scroll.

4. Remove the ﬁ xed scroll housing.

5. Take out the old tip seal from the orbiting scroll housing

and ﬁ xed scroll housing, see Figure 11.

6. Remove the old dust seals from ﬁ xed scroll, see Figure 12.

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 angels (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 12.

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 11 and 12).

2. Insert so that new LP tip seal will contact closely with HP

tip seal inside Scroll Groove.

Insert approxi-mately half of

the LP tip seal and remove the

tip seal to conﬁ rm 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 backup tube located

on outermost side FS set.

4. Insert new backup tube in the FS Scroll in the 6 o’ clock

position (See Figure 13).

Figure 11

Lip Direction Enter

Side

Lip Surface

(Inside)

Lip Side

(Grooved bottom)

Figure 12

Model Size Torque

Pulley bolt M8 175

Housing Nut

(See Figure 1) M10 265

Chart 17 - Bolt Torque (In. - lbs.)

Machined to avoid

movement during

installation

Figure 13

Facing Left Facing Right

Lip

(Bottom Side)

Lip

(Inside)

Fixed Scroll Orbit Scroll

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 ﬁ gure on the right.

Scroll Enclosure Air Compressors

Scheduled Maintenance

(Continued)

5. Insert new dust seal on the backup tube (See Figure 14).

6. After replacing tip seal set, reassemble Fixed Scroll set to

the Orbit Scroll. Tighten nuts and bolts temporarily and

conﬁ rm if pump pulley rotates smoothly by hand and

tighten them ﬁ rmly. Tightening torques are:

NOTE: Assemble so that dust seal and tip seal will not drop

between Orbit Scroll set and Fixed Scroll set.

Dust

Seal

Back-up

Tube

Figure 14

Bolt Torque

First Second

17 in lb. 265 in lb.

Scroll Enclosure Air Compressors

Operating Hours

Item Action Needed 500 2500 5000 10,000 20,000 Remarks

Intake Filter Clean, replace ●▲ Every 500 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 5000 hours or less

Compressor Grease ▲▲

(pump)

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

Temperature Sensor ●Conﬁ rm operation

Pressure Sensor Conﬁ rm operation ●

Magnetic Starter Inspect ●Replace if contact points deteriorated

Check valve Inspect ●▲

Conﬁ rm operation by watching pump shut

off

Safety Valve Conﬁ rm operation Every 500 hours or less

Ventilation Fan Inspect ●Replace if malfunctions

Pulley Inspect groove ●Repair if abnormal wear is detected

Motor Inspect ●●

Replace if abnormal noise is detected

Intake hose Replace ▲

Air Hose Inspect, replace ●▲

After Cooler Clean outside ●Every 5000 hours or less

O-ring Replace ▲

Operating Panel Inspect monitor

display Daily

Piping Inspect for leakage ●

● Inspect

▲ Replace

NOTES:

1. Inspect and perform maintenance periodically according to maintenance schedule.

2. The maintenance schedule relates to the normal operation 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.

Chart 18

Maintenance Schedule

Scroll Enclosure Air Compressors

Electrical Diagram - External Operation and External Output

REMOTE ON / OFF SWITCH INSTRUCTIONS

1. Turn the compressor off and lockout the power to the

compressor per OSHA standards.

2. Remove the top panel from the scroll cabinet to access

the operating panel. Remove the plastic cover from the

backside of the operating panel. Lift the expansion PCB

from the operating panel.

3. Connect an external AC power source of 200 V between

terminals 1 and 2 on the expansion PCB. A switch rated

at least 200 V AC should be used. It is possible to use the

200 V AC source from the transformer on the bottom of

the cabinet.

4. The power wires should run through the right hand side

grommet when facing the front of the control panel. The

left side grommet is reserved for low voltage wires (to

reduce interference).

5. Replace the plastic cover of the operating panel. Replace

the top cover of the scroll compressor.

6. Return the power to the compressor.

7. Set the mode on the display to show external operation

mode (“ECon”).

8. The compressor should now start when external switch is

ON, and turn off when the external switch is OFF.

9. Both the external switch and the control panel controls

will now turn the compressor on and off.

GENERAL FAULT DRY CONTACT CONNECTIONS

1. Turn the compressor off and lockout the power to the

compressor per OSHA standards.

2. Remove the top panel from the scroll cabinet to access

the operating panel. Remove the plastic cover from the

backside of the operating panel. Lift the expansion PCB

from the operating panel.

3. Output wires should be connected between terminals 3

and 4. The dry contacts are normally open; when there

is a fault, the contacts close. The contact rating is as

follows: 200 V AC, 1A, maximum.

4. For larger load devices such as a horn or emergency light,

a relay should be used.

5. The signal wires should run through the right hand side

grommet when facing the front of the control panel. The

left side grommet is reserved for low voltage wires (to

reduce interference).

6. Replace the plastic cover of the operating panel. Replace

the top cover of the scroll compressor.

7. Return the power to the compressor.

8. The external output will now operate when there is

either a caution or emergency. This is the default setting

for the control panel. The external output of the control

panel can be changed to only operate in case of an

emergency.

9. Reasons for Caution and Emergency stop are needed to

conﬁ rm on the control panel display.

Self-holding

switch

AC200V

Electric source

External operation circuit

*See "ECon" in manual

External output circuit

for General Fault

Dry contact

(Normally open)

CN7

CN6

CN3

CN26

CN27

CN5

CN4

TB1

CN29

CN32

CN28

EXB

Expansion circuit board

Crimping terminal sizeR1.25-3

CR 1

CN2

CN22

CN31

CN26

CN25

CN24

CN23

CN21

CN20

CN11

CN10

CN1

CN27CN30

CN13

Display circuit board

CN1

Main circuit board

Modular plug for

setting and communication

TRANS

CN12

Figure 15

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Powerex SED1007 User manual

Brand: Powerex

Model: SED1007

Category: Air compressors

Type: User manual

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Powerex SED1007 User manual

Powerex SED1007 User manual

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