Gardner Denver EDF-KB, Operating And Service Manual

Page 1: ...GARDNER DENVER ELECTRA SCREW STATIONARY BASE MOUNTED COMPRESSORS MODELS EDF_KB 60 HP EDF_LB 75 HP EDH_MB 100 HP OPERATING AND SERVICE MANUAL 13 8 606 3rd Edition March 1997...

Page 2: ...nver Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Machinery Inc Gardner Denver Machinery Inc Master Distribution C...

Page 3: ...ce of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severe person...

Page 4: ...FOR ORDERING REPAIR PARTS When ordering parts specify Compressor MODEL Method of Cooling HORSEPOWER and SERIAL NUMBER see nameplate on unit The Serial Number is also stamped on top of the cylinder fl...

Page 5: ...ANT RUN Button with LED 20 Control Piping 11 Control System Operation 19 AUTO LAG Button with LED 20 AUTO LEAD Button with LED 20 Change Air Filter LED 20 Change Separator LED 20 CONSTANT RUN Button w...

Page 6: ...or Grease Recommendations 14 Motor Lubrication 13 Motor Overload LED 20 Motor Protection Devices 17 Motor Regreasing Interval 14 Oil Change Interval 33 Oil Cooler Compressor 35 Oil Filter Compressor 3...

Page 7: ...r Trap Moisture 10 SERVICE CHECK LIST AIR FILTER 43 Service Check List 43 Every 1000 Hours Operation 43 Every 125 Hours Operation 43 Every 6000 Hours Operation 43 Every 8 Hours Operation 43 Every Year...

Page 8: ...3 Minimum Pressure Check Valve 19 Figure 4 4 Definition of Error Messages 21 Figure 4 5 Pressure Chart 24 Figure 4 6 Subtractive Pilot Closed 24 Figure 4 7 Subtractive Pilot Opened 24 Figure 4 8 Maxi...

Page 9: ...rs B As meshing continues more of the main rotor lobe enters the sec ondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compress...

Page 10: ...13 8 606 Page 2 FIGURE 1 2 STARTER BOX FIGURE 1 3 PACKAGE CONTROLLER STARTERS FIGURE 1 4 PACKAGE DRIVE MOTOR AIR FILTER...

Page 11: ...13 8 606 Page 3 FIGURE 1 5 PACKAGE OIL FILTER OIL LEVEL GAUGE MIXING VALVE MINIMUM PRESSURE VALVE CHECK VALVE FIGURE 1 6 PACKAGE AIR OIL FLOW DIAGRAM 203EDF797 Ref Drawing...

Page 12: ...g drain plugs covers the thermostat ic mixing valve or break any connections etc in the compressor air or oil sys tem until the unit is shut down and the air pressure has been relieved D Electrical sh...

Page 13: ...be fore working on the unit this machine is automatically controlled and may start at any time D An Excess Flow Valve should be on all compressed air supply hoses ex ceeding 1 2 inch inside diameter...

Page 14: ...13 8 606 Page 6 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 15: ...13 8 606 Page 7 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 16: ...with ample space all around for mainte nance Select a location that provides a cool clean dry source of air In some cases it may be necessary to install the air filter at some distance from the compr...

Page 17: ...g drain are 1 Elevate the compressor unit on a suitable struc ture to obtain the desired drain height If the compressor unit base is raised above floor level the space between the floor and the base b...

Page 18: ...ler with plywood should be satisfactory 2 Auto operation should not be used in extreme en vironments 3 Some means of providing heat during shutdown should be provided There are various methods to acco...

Page 19: ...hould be the full size of the inlet opening on the compressor If an extra long line is necessary the pipe size should be in creased according to Inlet Line Length Chart FIGURE 2 4 HEAT EXCHANGER Appro...

Page 20: ...e piped to the outside with a pipe size the same as the blowdown valve outlet connection WATER PIPING Water Cooled Heat Exchanger Models Only On machines equipped with water cooled heat exchangers the...

Page 21: ...voltage non reversing type in NEMA CEMA enclosure suitable for the environment with two 2 rejection type control circuit fuses size accord ing to motor starter manufacturer s standard a 200 208 volt c...

Page 22: ...C 750 1000 Bleeding Maximum Weight In 500 Hours 212_F 100_C 10 3 Rust Inhibiting Yes Yes ELECTRIC MOTOR REGREASING INTERVAL Relubrication Type of Service Typical Examples Rating Interval 150 HP 112 KW...

Page 23: ...ure tag and lockout the power supply to the starter Failure to release pressure or properly dis connect the power may result in personal injury or death During unloaded operation and after shutdown th...

Page 24: ...air ser vice valve The unit is equipped with a minimum 65 psig 4 5 Bars pressure check valve no special procedure to main tain the unit reservoir pressure is required Unit Hot No warm up period is req...

Page 25: ...cified There are three 3 over loads in the starter of proper size for the starter and its enclosure Note that motor nameplate current must be multiplied by 577 for wye delta starters Proper starter co...

Page 26: ...riodic checks should be made to insure that it is operating properly The relief valve should be tested for proper operation at least once every year To test the relief valve raise the system operating...

Page 27: ...alve closes and allows the oil system to pressurize Minimum Pressure Check Valve FIGURE 4 3 An internal spring loaded minimum pressure valve is used in the final discharge line to provide a positive p...

Page 28: ...tart load and unload setpoints are automatically 5 PSI 3 Bar lower than programmed Any mode may be selected at any time without stopping the compressor HIGH AIR TEMPERATURE LED This LED is used to ind...

Page 29: ...starting The failed sensor must be re placed to clear the error Any condition requiring the control panel to be reset will be indicated by a flashing STOP RESET LED If all readouts and LED s are flash...

Page 30: ...e momentarily energized giving a slight rotation that is short enough in duration to prevent reverse oil flow in the event that rotation is reversed Press Stop Reset to exit jog mode Step 9 The displa...

Page 31: ...essor will now be the lag or trim compressor It will automatical ly be brought on line if required by a large air demand After the demand is satisfied the lag unit will unload time out and stop ready...

Page 32: ...tive pilot will fully unload the compressor before the unload pressure setpoint of the microproces sor controller is reached 2 Close the air service valve and start the unit in the CONSTANT RUN mode A...

Page 33: ...o 65 PSIG 4 1 to 4 5 Bars NAMEPLATE CONTROL SYSTEM PRESSURE FULL LOAD OPERATING PRESSURE LOAD UNLOAD 100 PSI 6 9 Bars 100 PSI 6 9 Bars 108 PSI 7 5 Bars 125 PSI 8 6 Bars 125 PSI 8 6 Bars 133 PSI 9 2 Ba...

Page 34: ...13 8 606 Page 26 FIGURE 4 10 WIRING DIAGRAM FULL VOLTAGE DUAL CONTROL 208EDF546 Ref Drawing...

Page 35: ...below or low temperature see Installation for Cold Weather page 9 AEONt 4000 Lubricating Coolant is a superior petro leum base lubricant formulated and containing addi tives for use in Gardner Denver...

Page 36: ...13 8 606 Page 28 FIGURE 5 1 FLOW DIAGRAM 204EDF797 Ref Drawing...

Page 37: ...13 8 606 Page 29 201EAP797 Ref Drawing FIGURE 5 2 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED 218ECM797 Ref Drawing...

Page 38: ...should be firm ly supported to avoid strain on the cooler manifold and connections Flexible connections should be installed in all interconnecting piping adjacent to the cooler to avoid transmitting...

Page 39: ...atmosphere This will shut the oil stop valve and prevent excessive oil from running into the reservoir Failure to install these parts could result in high oil car ryover and cause the machine to shutd...

Page 40: ...it after high temperature stops operation Find and correct the mal function before resuming operation All materials used in Gardner DenverR compressor units are compatible with AEONt 9000 SP Lubricati...

Page 41: ...revent varnish deposits and carry away impurities To drain the system use one of the following methods 1 If the unit is not elevated high enough to use the oil reservoir drain line to drain oil a smal...

Page 42: ...d 7 Add oil if necessary to bring level to the center of the green range on the gauge On unloaded operation and after shutdown some oil will drain back into the oil reservoir and the oil level gauge w...

Page 43: ...FIGURE 1 5 page 3 The oil cooler motor and fan is mounted on the oil cooler module air is exhausted through the oil cooler and away from the unit Do not obstruct air flow to and from the oil cooler A...

Page 44: ...d in the return bonnet opposite end to the water pipe connections of heat ex changers to provide internal water system corrosion protection These anodes should be inspected periodi cally and replaced...

Page 45: ...idge type separator element and pro vides the final removal of oil from the air stream FIGURE 5 11 Oil impinging on the inside of the separator element drains directly back into the oil reservoir by g...

Page 46: ...ator from the separator housing 5 Inspect and or replace the separator as neces sary Be sure the o ring is not damaged Before installing or reinstalling any separator apply grease to the o ring Oil wi...

Page 47: ...stalling a tee at the oil filter outlet Oil Cooler Temperature Differential Water Cooled Heat Exchanger The oil temperature differential de pends on the inlet water temperature and the water flow rate...

Page 48: ...ally inspect the element If cleaning is not necessary reinstall the filter element If the ele ment requires cleaning go through steps 3 4 and 5 3 Wash the element by soaking about 15 minutes in warm w...

Page 49: ...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...

Page 50: ...sure the collar is installed on the shaft behind one coupling body 2 Assemble the motor to the compressor 3 Working through the coupling guard opening cen ter the coupling over the gap between the sh...

Page 51: ...k 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...

Page 52: ...rature switch malfunction 3 Blown fuse in starter 3 Replace fuse control box investigate if fuses continue to blow 4 Motor starter overload 4 Reset and investigate heaters trip cause of overload Compr...

Page 53: ...mpressor oil 5 Add oil to proper level Excessive Oil Consumption 1 Oil carryover through lines 1 See Oil Carryover in this section 2 Oil leaks at all fittings 2 Tighten or replace fittings and gaskets...

Page 54: ...65 psig 4 5 Bars 4 Sticky minimum pressure 4 Disassemble and clean valve 5 Defective minimum 5 Rebuild or replace pressure valve Won t set at 65 psig 4 5 Bars CHANGE SEPARATOR light 1 Separator differ...

Page 55: ...7 and wire number 6 at board If the reading is zero replace the vacuum switch 2 Control board fault 2 Measure the AC voltage between wire number 7 and wire number 6 at board If the reading is 24 volts...

Page 56: ...corresponding transducer at the control board with zero pressure on the transducer If 3 10 to 3 60 volts replace the transducer Oil leak at the bottom of 1 Gasket leaking 1 Replace the gasket the sea...

Page 57: ...gment 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...

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