Gardner Denver INTEGRA EFB99A, Operating And Service Manual

Page 1: ...GARDNER DENVER 13 8 619 Version 09 May 2 2006 INTEGRA BASE MOUNTED COMPRESSORS MODELS EFB99A EFB99F 7 5 10 15 HP OPERATING AND SERVICE MANUAL...

Page 2: ...ocal authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Master Distribution Center 5585 East S...

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

Page 4: ...ed Airends i Foreword ii Index iv List Of Illustrations vi Section 1 General Information 1 Section 2 Installation 7 Section 3 Starting Operating Procedures 14 Section 4 Controls Instrumentation 17 Sec...

Page 5: ...ubrication Motor 12 Lubrication Oil Cooler Oil Filter Separator 24 Section 5 24 Lubrication Cooling And Sealing 1 Maintenance Schedule Section 8 38 Minimum Pressure Check Valve 18 Changing Seals 19 Mo...

Page 6: ...nment 36 Sheave And Shaft Seal Replacing 36 Solenoid Valve 18 Starter Control Box 19 Hourmeter 19 Starting Operating Procedures Section 3 14 Starting The Unit 15 Unit Cold 15 Unit Hot 15 Stopping The...

Page 7: ...rol Schematic 18 Figure 4 2 Maximum Setpoint For Nema 4 Pressure Switch 21 Figure 4 3 Wiring Diagram 23 Figure 5 1 Approximate Oil System Capacities 25 Figure 5 2 Oil Change Interval 26 Figure 5 3 Oil...

Page 8: ...B As meshing continues more of the main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression...

Page 9: ...13 8 619 Page 2 300EFB797 A Ref Drawing Figure 1 2 COMPRESSOR ILLUSTRATION...

Page 10: ...ing not suitable for human consumption Do not loosen or remove the oil filler plug drain plugs covers the thermostatic mixing valve or break any connections etc in the compressor air or oil system unt...

Page 11: ...d tagout 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 diame...

Page 12: ...13 8 619 Page 5 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 13: ...13 8 619 Page 6 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 14: ...hould be installed where it is protected from rain snow and freezing temperatures in a clean well lighted well ventilated area with ample space all around for maintenance Select a location that provid...

Page 15: ...possible install the unit near level Temporary installation may be made at a maximum 5 angle lengthwise or 5 sidewise Mounting bolts are not normally required However installation conditions such as...

Page 16: ...Service panels are provided for maintenance access Be sure to allow enough space around the unit for the doors to be removed Any of the enclosure panels may be removed by opening the latch and liftin...

Page 17: ...allations should be avoided where possible Installation next to a heated building where enough heat can be used to keep the compressor room above freezing will save many complications in the operation...

Page 18: ...lded together an air receiver must be located between the two units DANGER Discharge air used for breathing will cause severe injury or death Consult filtration specialists for additional filtration a...

Page 19: ...asing intervals for ball bearing motors For additional information refer to the motor manufacturer s instructions The following procedure should be used in regreasing 1 Stop the unit 2 Disconnect lock...

Page 20: ...GREASING INTERVAL Type of Service Typical Rating Relubrication Interval Up to 150 HP 112 KW 18 Months Standard One or Two Shift Operation Above 150 HP 112 KW 12 Months Up to 150 HP 112 KW 9 Months Sev...

Page 21: ...ain intervals of AEON 4000 lubricant Use only genuine Gardner Denver filters designed and specified for this compressor DANGER Always stop the unit and release air pressure before removing oil filler...

Page 22: ...r doors Check all screws and latches for tightness Be sure doors are closed and latched STARTING THE UNIT Observe the following starting procedures Unit Cold 1 Open the air service valve customer furn...

Page 23: ...Refer to Maintenance Schedule SECTION 8 page 38 STOPPING THE UNIT 1 To stop compressor operation place the switch in the OFF position The oil reservoir will automatically blow down as the motor stops...

Page 24: ...ere is no demand the motor stops after a time delay is completed The compressor drive motor and wiring are protected from overload by a thermal overload relay inside of the control box The control sys...

Page 25: ...he operating conditions Solenoid Valve Figure 4 1 The solenoid valve is operated by the controller When energized the valve closes the inlet valve opens and the package starts compressing air When the...

Page 26: ...control components are located on the combination starter control box Hourmeter A continuous reading nonreset type hourmeter displays the accumulated operating time of the unit and provides a conveni...

Page 27: ...rator temperature fault indicator 3 Yellow High low temperature warning 4 Green Automatic mode indicator 5 Green Power on indicator CAUTION Machine damage will occur if compressor is repeatedly restar...

Page 28: ...SYSTEM PRESSURE PSI LOAD UNLOAD 100 85 100 125 110 125 150 135 150 175 160 175 Figure 4 2 MAXIMUM SETPOINT FOR NEMA 4 PRESSURE SWITCH WARNING Electrical shock can cause injury or death Open main disc...

Page 29: ...jumper on the pair of pins furthest from the edge of the controller The shutdown will occur prior to the compressor reaching its normal operating temperature Disconnect power remove the jumper and cl...

Page 30: ...13 8 619 Page 23 300EFB542 C Ref Drawing Figure 4 3 WIRING DIAGRAM...

Page 31: ...n the High Temperature Operation this section or low temperature see Installation for Cold Weather Section 2 page 10 AEON 4000 Lubricating Coolant is a superior petroleum base lubricant formulated and...

Page 32: ...a careless manner 7 1 2 to 15 HP 5 6 to 11 2 KW Refill Capacity For Normal Oil Change 1 0 U S Gallon 3 8 Liters Bottom of Site Glass to Top of Site Glass 1 0 U S Quart 9 Liter Figure 5 1 APPROXIMATE O...

Page 33: ...l is hot will help to prevent varnish deposits and carry away impurities To drain the system use one of the following methods 1 Be sure the unit is completely off and that no air pressure is in the oi...

Page 34: ...arryover and should be investigated Use only CLEAN containers and funnels so no dirt enters the reservoir Provide for clean storage of oils Changing the oil will be of little benefit if done in a care...

Page 35: ...l pressure disconnect lockout and tagout power supply to the starter before removing valves caps plugs fittings bolts and filters WARNING High temperature operation can cause damage to equipment or pe...

Page 36: ...m which is detrimental to compressor lubrication and could cause oil carryover If moisture is observed in the oil reservoir drain the moisture and correct the condition causing the accumulation See Co...

Page 37: ...lement 3 Clean the gasket face of the filter body 4 Coat the new element gasket with clean lubricant used in the unit 5 Screw new element on filter body and tighten by hand DO NOT OVERTIGHTEN ELEMENT...

Page 38: ...essor cylinder Oil carry over through the service lines may be caused by a faulty oil separator overfilling of the oil reservoir oil that foams oil return line malfunction or water condensate in the o...

Page 39: ...r 2 Disconnect lockout and tagout the power supply to the starter 3 Remove the minimum pressure check valve air oil separator housing cover 4 Lift out the air oil separator element 5 Inspect and or re...

Page 40: ...e oil filter outlet and check with a thermometer Oil Inlet Pressure Check at the fitting in the line near the compressor oil inlet With air receiver pressure at 100 psi 6 9 bar oil inlet pressure shou...

Page 41: ...with air nozzle Direct air blast parallel to element pleats at a slight upward angle Do not point air blast directly at element 3 Inspect for rupture by placing a bright light inside the element The s...

Page 42: ...nsion the belts as shown in Figure 7 2 Page 37 REPLACING THE COMPRESSOR BELTS 1 Disconnect lockout and tagout the power supply to the starter 2 Remove the belt guards 3 Using adjusting screws jack the...

Page 43: ...otted platform for the Tempest units To achieve proper sheave alignment the sheaves must be adjusted for both parallel and angular alignment The alignment between the motor and air end sheaves should...

Page 44: ...d not be over tightened To check belt tension use a Gardner Denver Belt Tension Gauge Part Number 00543217 V belt tension will drop after the first 8 24 hrs of unit run time Failure to check and re te...

Page 45: ...equired clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow This cleaning operation w...

Page 46: ...heck Reservoir Oil Level Check for Proper Load Unload Check Fault Indicator Lights Check Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Strainer Change Compressor Lubricant AEO...

Page 47: ...tinue to blow 4 Motor starter overload heaters trip 4 Reset and investigate cause of overload Compressor does not unload or load 1 Improperly adjusted control 1 Refer to SECTION 4 page 17 and adjust c...

Page 48: ...eturn lines 2 Tighten or replace faulty lines 3 Ruptured oil separator element 3 Replace element 4 Loose assembly 4 Tighten all fittings and gaskets 5 Foam caused by use of incorrect oil 5 Use Gardner...

Page 49: ...imply indicates the operating state of the controller When it is off the compressor operation is stopped If the switch is in the OFF position switch it to ON to start the compressor If the light is of...

Page 50: ...high voltage Disconnect power Refer to the transformer connection information in the installation instructions and connect the transformer properly Check that the motor is properly connected for the a...

Page 51: ...re power If overload problems persist contact a qualified electrician or motor shop Measure all incoming voltages with the motor off and at full load Measure amps while running full load Correct wirin...

Page 52: ...y representative or authorized service personnel for repair or replacement of any product or part thereof which in the Company s judgment is proved not to be as warranted Labor shall be limited to the...

Page 53: ...e Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all major cities For parts information contact Gardner Denver Master Distribution Center Memphis TN Telephone 800 245 4946 FAX...