Gardner Denver INTEGRA EFD99E, Operating And Service Manual

Page 1: ...13 20 604 Version 01 August 20 2009 INTEGRA BASE MOUNTED COMPRESSORS AIRSMART CONTROL MODELS EFD99E 40 50 HP OPERATING AND SERVICE MANUAL ...

Page 2: ...hnicians are factory trained and skilled in compressor maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory check the Gardner Denver Web Site at www gardnerdenver com or contact Gardner Denver 1800 ...

Page 3: ...omical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriate areas of the compressor package to alert users of the following conditions Indicates a hazard with a high level of risk which if not avoided WILL result in death or serious injury Equipment starts au...

Page 4: ... low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Lift Equipment with Hook No Lift Point Handle Package at Forklift Points Only Lockout Electrical Equipment in De Energized State Loud Noise Hazard Wear Ear Protection Read the Operator s Manual Before ...

Page 5: ...or oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any applicable local electrical codes Wiring and electrical service must be performed only by qualified electricians Open main disconnect switch lockout and tagout before working on the control wait 10 ...

Page 6: ... 6 List Of Illustrations 8 Section 1 General Information 9 Section 2 Installation 11 Section 3 Starting Operating Procedures 18 Section 4 Controls Instrumentation 24 Section 5 Lubrication Oil Cooler Oil Filter Separator 35 Section 6 Air Filter 47 Section 7 Belt Drive 49 Section 8 Maintenance Schedule 52 Section 9 Troubleshooting 54 This book covers the following models HP PSI Model Parts List Cont...

Page 7: ...commended 35 Upgrade Procedure 39 Lubrication Motor 16 Lubrication Cooling And Sealing 9 Lubrication Oil Cooler Oil Filter Separator Section 5 35 Maintenance Schedule Section 8 52 Moisture Separator Trap Optional 14 Motor Lubrication 16 Oil Change Interval 37 Oil Cooler Compressor 44 Oil Filter 42 Oil Level Gauge 42 Procedure For Checking 36 Oil Reservoir 44 Drain 12 Filling 38 Oil Separator Inspe...

Page 8: ...y 8 Hours Operation 52 Every Year 52 Motor Lubrication 52 Sheave Alignment 49 Starting Operating Procedures Section 3 18 Starting The Unit 20 Unit Cold 20 Unit Hot 21 Stopping The Unit 21 Trouble Shooting Section 9 54 Troubleshooting Voltage Problems 57 Valve Thermal Control Thermostatic Mixing 44 Warning Prohibition Mandatory Label Information 2 Wiring Electrical 15 ...

Page 9: ...e 4 1 Control Schematic 24 Figure 4 2 Key Pad 25 Figure 4 3 Wiring Diagram Full Voltage 29 Figure 4 4 Wiring Diagram Wye Delta 31 Figure 4 5 Wiring Diagram Less Starter 33 Figure 5 1 Flow Diagram 35 Figure 5 2 Approximate Oil System Capacities 37 Figure 5 3 Oil Change Interval 37 Figure 5 4 Oil Level Gauge Oil Fill and Oil Drain 42 Figure 5 5 Oil Filter 43 Figure 6 1 Air Filter 47 Figure 7 1 Belt ...

Page 10: ...s 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 and seal internal clearances Volume reduction and pressure increase continues until the air oil mixture trapped in the interlobe cavity by the rotors passes the discharge port and is released to the...

Page 11: ...13 20 604 Page 10 Figure 1 2 COMPRESSOR ILLUSTRATION 300EFD797 B Ref Drawing ...

Page 12: ...emperatures in a clean well lighted well ventilated area with ample space all around including above for maintenance If a low ceiling is encountered the hot discharge air may need to be ducted out to avoid recirculation 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 compressor to obtain proper air...

Page 13: ...face Whenever 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 piping rigidity angle of tilt or danger of shifting from outside vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform support for the base Belt ...

Page 14: ...osure 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 lifting it up slightly Do not operate the compressor with the fan and belt guard removed Exposed fan and belts may cause injury to personnel The enclosure doors and panels must be closed and latched w...

Page 15: ...er 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 complications in the operation and installation of the unit AUXILIARY AIR RECEIVER An auxiliary air receiver is not required if the piping system is large and provides sufficient storage capacity to prev...

Page 16: ...ted 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 manifold If a rotary screw and a reciprocating compressor are manifolded together an air receiver must be located between the two units Discharge air used for breathing will cause severe injury or death C...

Page 17: ... 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 procedure should be used in regreasing 1 Stop the unit 2 Disconnect lockout and tagout the unit from the power supply 3 Remove the relief plug and free hole of hardened grease 4 Wipe lubrication fitting clean an...

Page 18: ... REGREASING 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 Severe Continuous Operation Above 150 HP 112 KW 6 Months Up to 150 HP 112 KW 4 Months Very Severe Dirty Locations High Ambient Temperature Above 150 HP 112 KW 2 Months ...

Page 19: ...d replacement at required intervals of the oil filter 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 compressor Always stop the unit and release air pressure before removing oil filler plug Failure to release pressure may result in personal injury or...

Page 20: ...ection of rotation must be check every time the compressor is reconnected to the power supply 7 System Pressure The discharge pressure of the unit is set at the factory To change the discharge pressure set the controls to the desired load pressure DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE See Operation Adjustments in the Controller Operating and Service Manual Operat...

Page 21: ...ait one minute or more before restarting The controller has an automatic start stop sequence built in You do NOT need to close the air service valve Closing the air service valve on start up or prior to shutdown will cause rapid cycling and could cause a high pressure shutdown Unit Cold 1 Open the air service valve customer furnished between the main air system and the check valve on the package 2...

Page 22: ...inute The unit is equipped with a minimum 70 psig pressure check valve no special procedure to maintain the unit reservoir pressure is required DAILY CHECK Refer to Maintenance Schedule SECTION 8 page 52 STOPPING THE UNIT 1 To stop compressor operation press STOP RESET 2 Wait approximately one minute to allow the compressor to stop The oil reservoir will automatically blow down as the motor stops ...

Page 23: ...on of the compressor the machine must be stopped and in the Ready mode Stop the compressor by pressing the Stop Reset button The front panel display should read READY on line 3 Next press the Enter button to access the Adjustment Menu tree Since the Target Pressure setting is under the Operation Adjustment menu press Enter again to access that sub menu The Target Pressure is the second item in the...

Page 24: ...hat were made press the Enter button If the Stop Reset button is pressed the parameter changes will be lost the next time the compressor power is turned off Setting The Unload and Load Pressure After setting the Target Pressure set the Unload and Load Pressures values in a similar fashion The Unload pressure is the third item in the Operation Adjustment sub menu so press the Down button to navigat...

Page 25: ...er 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 While in any operating mode the display will indicate the mode and the operating light will be on Press the STOP RESET key at any time to stop the compressor under normal conditions AUTOMATIC is the ...

Page 26: ...ller Operating and Service Manual Figure 4 2 KEY PAD Relief Valve A pressure relief valve is installed in the final discharge line and set 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 proper operation at least once every year To test the relief val...

Page 27: ...pressure is relieved from the cylinder the inlet valve closes to restrict air flow and compressor delivery Magnetic Unloader Solenoid Valve Figure 4 1 page 24 This valve controls the position of the inlet valve in response to signals from the AirSmart Control When de energized pressure is relieved from the top of the inlet valve cylinder to unload the compressor When the solenoid valve is energize...

Page 28: ...ly use the keypad STOP RESET for normal controlled stopping Automatic restarting or electrical shock can cause injury or death Open and lock main disconnect and any other circuits before servicing unit Power Supply This device changes the incoming AC supply voltage to 24 volts DC for use by all unit control devices For 575 volt AC units only a control transformer is provided to supply 230 240 volt...

Page 29: ...voir Close the service valve 2 Disconnect lockout and tagout the power supply to the starter 3 Tighten the nut down on the minimum pressure check valve cover 4 Remove the four 4 bolts holding the cover onto the separator housing 5 Remove the snap ring in the cover 6 Remove the internal parts see Parts List Book and replace the seals in the minimum pressure check valve 7 Re assemble valve including...

Page 30: ...13 20 604 Page 29 Figure 4 3 WIRING DIAGRAM FULL VOLTAGE 308EDE46 A Ref Drawing Page 1 of 2 ...

Page 31: ...13 20 604 Page 30 308EDE46 A Ref Drawing Page 2 of 2 ...

Page 32: ...13 20 604 Page 31 Figure 4 4 WIRING DIAGRAM WYE DELTA 309EDE546 A Ref Drawing Page 1 of 2 ...

Page 33: ...13 20 604 Page 32 309EDE546 A Ref Drawing Page 2 of 2 ...

Page 34: ...13 20 604 Page 33 Figure 4 5 WIRING DIAGRAM LESS STARTER 310EDE546 A Ref Drawing Page 1 of 2 ...

Page 35: ...13 20 604 Page 34 310EDE546 A Ref Drawing Page 2 of 2 ...

Page 36: ...via an 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 quality standards and are factory authorized tested and approved for use in rotary screw compressors AEON lubricants are available through your authorized Gardner Denver compressor distributor ...

Page 37: ... page 42 Check the oil level when the compressor is shutdown and the oil air mixture has separated The oil should be visible in the white range a flashlight must be used of the gauge If there is only red showing on the gauge the oil level is too high and must be drained If the oil level is in the red range below the white range the oil level is too low and oil must be added ADDITION OF OIL BETWEEN...

Page 38: ...t if done in a careless manner 40 to 50 HP 30 to 37 KW Refill Capacity For Normal Oil Change 3 U S Gallons 11 Liters Bottom of Site Glass to Top of Site Glass 3 U S Quart 3 Liters Figure 5 2 APPROXIMATE OIL SYSTEM CAPACITIES OIL CHANGE INTERVAL Recommended oil change intervals are based on oil temperature Figure 5 3 shows how the change interval is affected by temperature When operating conditions...

Page 39: ...arter 3 Stick the end of the drain tube into a suitable container such as a 5 gallon pail 4 Open the drain valve and allow oil to drain out of the 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 separator element for dirt accumulation replace if neces...

Page 40: ... NOT OVERFILL as oil carryover will result The quantity of oil required to raise the oil level from the red range to the white range on the site glass is shown in Figure 5 2 page 37 Repeated addition of oil between oil changes may indicate excessive oil carryover and should be investigated Use only CLEAN containers and funnels so no dirt enters the reservoir Provide for clean storage of oils Chang...

Page 41: ...g bowls gaskets and valve trim AEON 9000SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints AEON 9000SP is compatible with most air system downstream components 1 Be sure the unit is completely off and that no air pressure is in the air oil reservoir 2 Disconnect tag and lock out the power supply to the starter 3 Thoroughly drain system Drain oil from air end and coo...

Page 42: ...w lubricant Drain all lubricant from system change filter and separator and replace with full charge of the new lubricant 9 Subsequent lubricant change outs should be at normal intervals See Oil Change Interval Figure 5 3 page 37 Material Safety Data Sheets MSDS are available for all AEON lubricants from your authorized Gardner Denver distributor or by calling 217 222 5400 ...

Page 43: ...nusual cooling of the oil reservoir short loaded cycle in high humidity or malfunctions of the thermal valve may result in moisture in the oil system 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 Compressor Oil System Check page 46 and Thermal Contro...

Page 44: ...ervoir separation chamber and all piping and tubing may be at high temperature during and after operation 1 Stop unit and be sure no air pressure is in the oil reservoir 2 Disconnect lockout and tagout the power supply to the starter 3 Remove the spin on element 4 Clean the gasket face of the filter body 5 Coat the new element gasket with clean lubricant used in the unit 6 Screw new element on fil...

Page 45: ...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 to the compressor cylinder Oil carryover 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 i...

Page 46: ...ation chamber and all piping and tubing may be at high temperature during and after operation 1 Be certain the unit is off and that no air pressure is in the oil reservoir The compressor package will automatically blowdown in about 2 minutes 2 Close the air service valve located after the compressor package discharge 3 Disconnect lockout and tagout the power supply to the starter 4 Remove the mini...

Page 47: ...ecks One half hour of loaded operation is usually sufficient to reach level out operating temperatures Air and Oil Discharge Temperature 160 F to 180 F 71 C to 82 C Check with a thermometer at the discharge housing Compressor Oil Inlet Temperature 150 F to 165 F 66 C to 74 C Install a tee at the oil filter outlet and check with a thermometer Oil Inlet Pressure Check at the fitting in the line near...

Page 48: ...inspection indicates 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 pressure is in the air oil reservoir The compressor package will automatically blow down in about 2 minutes 2 Close the air service valve located after the compressor package disc...

Page 49: ...or a rupture crack or pin holes in the pleated media Inspection should be done by placing a bright light inside the element Do not oil this element Never operate unit without element Never use elements that are damaged or ruptured Never use elements that won t seal Keep spare elements on hand to reduce downtime Store elements in a protected area free from damage dirt and moisture Handle filter par...

Page 50: ...ght edge should touch the two outer edges of each sheave for a total of four points of contact Gaps between the outer edges of either of the sheaves and the straight edge indicate sheave misalignment The airend sheave is set in the parallel and angular direction by mounting it on the air end shaft that is part of the Tempest unit that is bolted to the platform The platform has been set in the para...

Page 51: ...ilure Please see Figure 7 1 page 51 for proper belt tension Interference between the fan and the orifice can damage equipment Be certain the orifice has even clearance around the fan before starting the unit REPLACING THE COMPRESSOR SHEAVE 1 Disconnect lockout and tagout the power supply to the starter 2 Remove the guards 3 Using the adjusting screws jack the motor base up to loosen the belt tensi...

Page 52: ...13 20 604 Page 51 Motor H P No of Belts Deflection Force Pounds Deflection In Inches 40 6 6 8 5 3 8 50 6 6 8 5 3 8 Figure 7 1 BELT TENSION 3VX BELTS ...

Page 53: ...ning 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 operation will keep the exterior cooling surfaces clean and ensure effective heat dissipation Every 1000 Hours Operation 1 Change oil filter element Every 4000 Hours Operation 1 Change the compressor lu...

Page 54: ... Oil Separator Check Reservoir 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 Condition of Hoses Change Inlet Valve Seals See Oil Change Interval Chart Figure 5 3 page 37 for specific lubricant life Must be checked when the compressor is stopped and the air o...

Page 55: ... 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 24 and adjust control 2 Air leak in control lines 2 Determine source of leak and correct 3 Restricted control line 3 Clean control lines 4 Faulty inlet valve solenoid 4 Replace solenoid valve Compressor cycles from load to unload ...

Page 56: ...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 in the Air Pilot Controller 11 Aftercooler is frozen 11 Thaw out This machine cannot operate in temperatures below 32 F 0 C High discharge air temperature 1 Dirty or clogged cooler face 1 Clean cooler 2 Insufficien...

Page 57: ... 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 Scavenge line check valve failure 8 Replace check valve 9 Water condensate in oil 9 Check oil reservoir temperature and if low change thermal mixing valve element to higher temperature Air oil under pressure wil...

Page 58: ...eration 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 relay will sense these and shut down the compressor to protect the motor If voltage is low while the compressor is off locate and correct the cause If the voltage drops low only while the compressor ...

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Page 60: ...r Denver Compressor 1800 Gardner Expressway Quincy Illinois 62305 Customer Service Department Telephone 800 682 9868 FAX 217 224 7814 Visit our Web Site www gardnerdenver com Specifications subject to change without notice Copyright 2009 Gardner Denver Inc Litho in U S A ...