Gardner Denver INTEGRA EFC99A, Operating And Service Manual

Page 1: ...GARDNER DENVER 13 8 621 Version 05 October 14 2004 INTEGRA BASE MOUNTED COMPRESSORS MODELS EFC99A EFC99F 20 25 30 HP OPERATING AND SERVICE MANUAL...

Page 2: ...ner 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 Shelby Drive Memphis...

Page 3: ...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 a hazard which can cause severe perso...

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: ...ended 24 Upgrade Procedure 28 Lubrication Motor 12 Lubrication Cooling And Sealing 1 Lubrication Oil Cooler Oil Filter Separator Section 5 24 Maintenance Schedule Section 8 39 Moisture Separator Trap...

Page 6: ...Every 4000 Hours Operation 39 Every 8 Hours Operation 39 Every Year 39 Motor Lubrication 39 Starting Operating Procedures Section 3 14 Starting The Unit 16 Unit Cold 16 Unit Hot 16 Stopping The Unit 1...

Page 7: ...er Installation 9 Figure 4 1 Control Schematic 17 Figure 4 2 Key Pad 18 Figure 4 3 Wiring Diagram 22 Figure 5 1 Flow Diagram 24 Figure 5 2 Approximate Oil System Capacities 26 Figure 5 3 Oil Change In...

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 8 621 Page 2 Figure 1 2 COMPRESSOR ILLUSTRATION 302EFC797 A Ref Drawing...

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 8 621 Page 5 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 13: ...13 8 621 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 panels to be removed Any of the enclosure panels may be removed by opening the latch and liftin...

Page 17: ...unsheltered outside installations 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 compl...

Page 18: ...ed by the check valve in the unit discharge line If a rotary screw unit is manifolded to another compressor be sure the other compressor has a check valve in the line between the machine and the manif...

Page 19: ...The following charts show recommended grease qualities and regreasing intervals for ball bearing motors For additional information refer to the motor manufacturer s instructions The following procedur...

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: ...air filter and air oil separator is necessary to achieve maximum service and extended drain intervals of AEON 4000 lubricant Use only genuine Gardner Denver filters designed and specified for this com...

Page 22: ...t the controls to the desired load pressure DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE See Operating Adjustments in Controller Operating and Service Manual WARNING Operat...

Page 23: ...To start press STOP RESET then press RUN 3 Run for approximately five minutes or until the temperature stabilizes The unit is equipped with a minimum 45 psig pressure check valve No special procedure...

Page 24: ...r keypad Prior to starting the STOP RESET key must be pressed to place the controller into its READY state as indicated on the display Compressor operation may then be started by pressing the RUN key...

Page 25: ...to approximately 120 125 of the unit s full load operating pressure for protection against overpressure Periodic checks should be made to ensure its operation The relief valve should be tested for pr...

Page 26: ...et valve cylinder to unload the compressor When the solenoid valve is energized reservoir pressure is supplied to the top of the cylinder to load the compressor Check Valve Figure 4 1 page 17 This val...

Page 27: ...provides connections for all 110 120 volt devices not contained within the enclosure Main Starter This starter is used to provide control and overload protection for the main drive motor Standard full...

Page 28: ...ge 21 7 Re assemble valve including the snap ring 8 Tighten the cover down to the separator housing 9 Loosen the nut on top of the minimum pressure check valve 05 to 08 inches 10 Run the unit and chec...

Page 29: ...13 8 621 Page 22 4 3 WIRING DIAGRAM 300EFC546 B Ref Drawing Page 1 of 2...

Page 30: ...13 8 621 Page 23 300EFC546 B Ref Drawing Page 2 of 2...

Page 31: ...oil return line through an orifice and back into the compressor RECOMMENDED LUBRICANT Gardner Denver compressors are factory filled with AEON lubricants These lubricants are formulated to the highest...

Page 32: ...the oil air mixture has separated The oil should be visible between the min and max range shown in Figure 5 4 page 30 If the oil level is above the max range the oil must be drained If the oil level...

Page 33: ...Change 2 00 U S Gallons 8 5 Liters Bottom of Site Glass to Top of Site Glass 2 U S Quart 2 Liters Figure 5 2 APPROXIMATE OIL SYSTEM CAPACITIES OIL CHANGE INTERVAL Recommended oil change intervals are...

Page 34: ...he air oil reservoir 5 Close the drain valve If the drained oil and or the oil filter element are contaminated with dirt flush the entire system the reservoir oil cooler and lines Inspect the air oil...

Page 35: ...rage of oils Changing the oil will be of little benefit if done in a careless manner CAUTION Excessive oil carryover can damage equipment Never fill oil reservoir above the top of the site glass LUBRI...

Page 36: ...filter and reinstall used filter 4 Fill system with a 50 percent charge of the new lubricant Start the machine and stay there to observe Allow the machine to run about five minutes at temperature or u...

Page 37: ...ental 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 Compressor Oil Syst...

Page 38: ...and after operation 1 Stop unit and be sure no air pressure is in the oil reservoir 2 Disconnect tag and lock out the power supply to the starter 3 Remove the spin on element 4 Clean the gasket face...

Page 39: ...val of oil from the air stream Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity Oil collected outside the element is returned through tubing...

Page 40: ...ir service valve located after the compressor package discharge 3 Disconnect lockout and tagout the power supply to the starter 4 Remove the minimum pressure check valve see Item 1 Figure 5 6 page 34...

Page 41: ...ometer 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 should be 80 to 90 psig 5 5 to 6 2 Bar Oil Coo...

Page 42: ...an accumulation of dirt on the outside of the element Inspect every few days until experience determines the proper time interval for servicing To Service 1 Be certain the unit is off and that no air...

Page 43: ...dia Inspection should be done by placing a bright light inside the element WARNING Do not oil this element Never operate unit without element Never use elements that are damaged or ruptured Never use...

Page 44: ...ting screws jack the motor base up to loosen the belt tension Remove the belts 4 Install new belts tighten belts using the adjust screws Check for correct belt tension 5 Check sheave alignment 6 Assem...

Page 45: ...deflection are shown in Figure 7 1 To tighten belts merely increase the center distance NOTICE When a new set of belts is installed on a drive the initial deflection force should be 1 3 greater than s...

Page 46: ...ing is required 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 ope...

Page 47: ...oir Oil Level Check for Proper Load Unload Check Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Strainer Change Compressor Lubricant AEON 4000 Check Relief Valve Check Conditio...

Page 48: ...otor 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 control 2 Air leak...

Page 49: ...he compressed air system 7 Check for leaks fix any leaks found 8 V Belts broken 8 Replace 9 V Belts slipping 9 Test belt tensioning 10 Pressure limits incorrectly set 10 Check correct pressure limits...

Page 50: ...ubricating coolant 6 Inoperative minimum pressure valve 6 Replace seals in valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See High Discharge Air Temperature this section 8 S...

Page 51: ...ration with lower voltages will reduce motor life and load capacity As voltages get further below the design range other symptoms may show up Low voltages may lead to high motor currents The overload...

Page 52: ...initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized ser...

Page 53: ...epresentative or Gardner Denver Compressor and Pump Division 1800 Gardner Expressway Quincy Illinois 62301 Customer Service Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all...