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Gardner Denver EBB BB-7.5 HP Operating And Service Manual

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GARDNER DENVER
ELECTRA–SCREW STATIONARY
INTEGRATED DRYER and
TANK– MOUNTED COMPRESSORS
BASE–MOUNTED,
BASE–MOUNTED with
MODELS
EBB_BB – 7.5 HP (ES–7.5)
EBB_CB – 10 HP (ES–10.0)
EBB_DB – 15 HP (ESS–15.0)
PARTS LIST &
OPERATING AND
SERVICE MANUAL
Manual Brought to You By:IndustrialAirPower.com
13–8–612
2nd Edition
March, 1997

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Summary of Contents for Gardner Denver EBB BB-7.5 HP

  • Page 1 13–8–612 GARDNER DENVER 2nd Edition March, 1997 ELECTRA–SCREW STATIONARY BASE–MOUNTED, BASE–MOUNTED with INTEGRATED DRYER and TANK– MOUNTED COMPRESSORS MODELS EBB_BB – 7.5 HP (ES–7.5) EBB_CB – 10 HP (ES–10.0) EBB_DB – 15 HP (ESS–15.0) PARTS LIST & OPERATING AND SERVICE MANUAL...

  • Page 2: Remanufactured Air Ends

    TOTAL PRODUCT SUPPORT – GARDNER DENVER’S CONTINUING COMMITMENT TO YOUR AIR COMPRESSOR PERFORMANCE Commitment to total product support continues long after the purchase of your quality Gardner Denver rotary screw compressor. Gardner Denver original parts incorporate years of experience and improvements in design, materials and quality assurance.

  • Page 3: Foreword

    FOREWORD Gardner Denver Electra–Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day–to–...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PAGE Total Product Support – Gardner Denver’s Continuing Commitment To Your Air Compressor Performance ..Remanufactured Air Ends ................

  • Page 5: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor

    They are ready to respond and assist you by pro- Denver air compressor with these services: viding 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 or contact: Distribution Center: Factory: Gardner Denver Machinery Inc.

  • Page 6: Index

    INDEX Adding/Checking Oil Level and Changing Oil ..AUTO LEAD Button with LED ....Air Control Components ..... . . Change Air Filter LED .
  • Page 7 INDEX High Discharge Temperature ....Mounting Group ......High Temperature Operation .
  • Page 8 INDEX Inlet Valve ....... Repair Parts ....... . . Intake Valve Controller .
  • Page 9 LIST OF ILLUSTRATIONS Figure 1–1 Compressor Cycle ..............Figure 1–2 Compressor/Motor Side –...

  • Page 10: Model Ebb - 7.5, 10 & 15 Hp Electra-Screw Compressors Matrix/Menu

    MODEL EBB – 7.5, 10 & 15 HP ELECTRA–SCREW COMPRESSORS MATRIX/MENU NOTICE TO CUSTOMER – To find the construction options for your compressor unit, FILL IN THE BALANCE OF LET- TERS OR NUMBERS FROM YOUR UNIT NAMEPLATE. __ __ __ __ __ __ __ __ __ __ __ __ __ ..........

  • Page 11: Section 1, General Information

    SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSOR CYCLE COMPRESSOR – The Gardner Denver compres- Oil is injected into the cylinder to remove the heat of sor is a single stage, positive displacement rotary ma- compression and seal internal clearances. Volume re-...

  • Page 12: Figure 1-2 Compressor/Motor Side - Package

    FIGURE 1–2 – PACKAGE – COMPRESSOR / MOTOR SIDE FIGURE 1–3 – PACKAGE – BELT GUARD SIDE 13–8–612 Page 2...

  • Page 13: Figure 1-4 Controller End - Package

    FIGURE 1–4 – PACKAGE – CONTROLLER END 13–8–612 Page 3...
  • Page 14 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
  • Page 15 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
  • Page 16 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–8–612 Page 6...
  • Page 17 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–8–612 Page 7...

  • Page 18: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- AIR–COOLED UNIT – A combination oil/aftercooler is age that may have been incurred during transit. Report supplied as standard equipment on all air–cooled units. any damage or missing parts as soon as possible. The air–cooled unit with the standard enclosure re- quires sufficient flow for the compressor oil/aftercooling system and electric motor cooling (FIGURE 2–2, page...

  • Page 19: Figure 2-2 Air Flow Chart

    Elevate the compressor unit on a suitable struc- Minimum Air Flow* For Compressor ture to obtain the desired drain height. And Cooling (Cubic Feet/Minute) Air Cooled All Models 3000 cfm If the compressor unit base is raised * 80 F Inlet Air above floor level, the space between the floor and the base bottom must be FIGURE 2–2...
  • Page 20 Exposed fan and belts may cause Refer to Engineering Data Sheet 13–9–411, available injury to personnel. from an authorized Gardner Denver distributor, for the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit.
  • Page 21 tween the unit and the customer’s air system. If a fast operating valve, such as a ball valve, is used, it must be closed slowly to give the intake valve time to shut and keep the discharge pressure from spiking. When Electrical shock can cause injury or manifolding two or more Electra–Screw units on the...
  • Page 22 ELECTRIC MOTOR GREASE RECOMMENDATIONS Standard High Service Temperature Worked Penetration ......... . . 265–296 220–240 Grease Viscosity, SSU At 100 F...

  • Page 23: Section 3, Starting & Operating Procedures

    See Section 4, page 20, AEON 2000 lubricant. Use only gen- Step 8. uine Gardner Denver filters designed and specified for this compressor. Operation with incorrect motor rota- tion can damage equipment and cause oil eruption from the compres- Always stop the unit and release air sor inlet.
  • Page 24 The unit is equipped with a minimum (65 psig) pres- sure/check valve, no special procedure to maintain the unit reservoir pressure is required. Operation at excessive discharge air Unit Hot (No warm–up period is required): pressure can cause personal injury or If the unit has the optional integrated dryer, start damage to equipment.

  • Page 25: Section 4, Controls & Instrumentation

    SECTION 4 CONTROLS & INSTRUMENTATION GENERAL – The Gardner Denver Electra–Screw mately 8 PSI, the “CHANGE SEPARATOR” LED compressor is supplied with a factory mounted starter located on the control keypad flashes indicating re- and complete controls as standard equipment. The quired maintenance.

  • Page 26: Figure 4-3 Minimum Pressure/Check Valve

    FIGURE 4–2 – INLET VALVE FIGURE 4–3 – MINIMUM PRESSURE/CHECK VALVE Operation of the unit with improper Damage will occur to the machine if it relief valve setting can result in se- is repeatedly restarted after high tem- vere personal injury or machine dam- perature stops operation.

  • Page 27: Figure 4-4 Intake Controller

    FIGURE 4–4 – INTAKE CONTROLLER To readjust the minimum pressure: the inlet valve cylinder, so inlet valve opening pressure required to overcome the spring force can be built up Remove the locknut, located below the air/oil in the cylinder above the piston. This pressure is fully separator.
  • Page 28 operating pressure. See “Programming the Load–Un- load Pressure Setpoints,” page 19. The LED is illumi- nated whenever the unit is stopped for any reason EX- CEPT a normal stop in one of the “AUTO” modes. A Any mode may be selected at any time flashing LED indicates that a reset is required.

  • Page 29: Figure 4-5 Definition Of Error Messages

    has occurred, requiring the control panel to be reset. Programming The Load–Unload Pressure Set- points – Programming of the Load and Unload Pres- sure setpoints can only be accomplished with the unit Machine damage can occur with ex- not running. tended operation after “Change Air Step 1: Stop the compressor and remove all power...
  • Page 30 ing mode buttons. The correct rotation is counterclockwise. The starter will be mo- Temperature: indicates that the mentarily energized giving a slight rotation pressure value is the “un– that is short enough in duration to prevent re- load” value. verse oil flow in the event that rotation is re- versed.

  • Page 31: Figure 4-6 Maximum Setpoints For Auto-Sentry S Controller, Psig

    should read “0” pressure in the left window, purchase any additional equipment and without compli- and –––– current sump temperature in the cated interconnecting wiring. right window. Follow these steps to operate two compressors in a lead–lag arrangement: Step 12: Move the circuit board slide switch back to the “set”...

  • Page 32: Figure 4-7 Auto-Sentry S Solid State Control Touch Pad

    FIGURE 4–7 – AUTO SENTRY “S” SOLID STATE CONTROL TOUCH PAD 13–8–612 Page 22...

  • Page 33: Figure 4-8 Wiring Diagram

    200EBB546 (Ref. Drawing) FIGURE 4–8 – WIRING DIAGRAM...

  • Page 34: Section 5, Lubrication, Oil Cooler, Oil Filter & Separator

    (see FIGURE 5–1, above). The oil tives for use in Gardner Denver compressors. filler plug is provided with a lateral safety hole, from which oil or air will appear if the oil reservoir has not been completely blown down.

  • Page 35: Figure 5-2 Approximate Oil System Capacities

    Fill system with a 50 percent charge of the new lu- bricant: – Start the machine and stay there to observe. Air/oil under pressure will cause – Allow the machine to run about five minutes at severe personal injury or death. Shut temperature, or until temperature stabilizes, then shut down.

  • Page 36: Figure 5-3 Oil Change Interval

    Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis pro- All materials used in Gardner Denver gram with the AEON lubricants and we recommend a sample be sent in at 100 hours on a new unit.

  • Page 37: Figure 5-4 Thermostatic Mixing Valve

    Changing the oil will be of little benefit if done in a care- less manner. COMPRESSOR OIL FILTER (FIGURE 1–2, Section 1, page 2) – This replaceable element filter is a vital part in maintaining a trouble–free compressor, since it re- moves dirt and abrasives from the circulated oil.
  • Page 38 pressor cylinder is not clogged or pinched off, the check Removal Of Oil Separator For Inspection Or Re- valve in the oil return is functioning properly, and there placement: is not water or an oil/water emulsion in the oil. Oil carry–over malfunctions of the oil separator are usually due to using elements too long, heavy dirt or varnish deposits caused by inadequate air filter ser- vice, use of improper oil, or using oil too long for existing...
  • Page 39 Oil Inlet Pressure – Check at the fitting in the line near Radiator) – The oil temperature differential depends the compressor oil inlet. With air receiver pressure at on the temperature of the air at the oil cooler fan and 100 psi, oil inlet pressure should be 65–75 psig.

  • Page 40: Section 6, Air Filter

    SECTION 6 AIR FILTER FIGURE 6–1 – STANDARD DUTY AIR FILTER STANDARD DUTY AIR FILTER (FIGURE 6–1) – Ser- Filter Element Life – The element should be replaced vice and replacement instructions are given in the fol- after eight cleanings or if visual inspection indicates a lowing sections: Filter Element and Filter Element Life.

  • Page 41: Section 7, Belt Drive

    SECTION 7 BELT DRIVE Proper drive belt tension and alignment are provided at the factory, however, good practice dictates checking the drive alignment and tension after shipment and be- fore initial start–up. Interference between the fan and the orifice can damage equipment. Be Sheaves should align straight across the front with a certain the orifice has even clearance straight edge.

  • Page 42: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. The “CHANGE AIR FILTER” display will Check for dirt accumulation on oil/aftercooler core flash to signal that the air filter requires servicing or faces and the cooling fan.

  • Page 43: Section 9, Trouble Shooting

    SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
  • Page 44 3. Ruptured oil separator 3. Replace element. element. 4. Loose assembly. 4. Tighten all fittings and gaskets. 5. Foam caused by use of 5. Use Gardner Denver incorrect oil. AEON 2000, 4000 or 9000 SP Lubricating Coolant. 6. Inoperative minimum 6. Replace valve.
  • Page 45 SYMPTOM POSSIBLE CAUSE REMEDY Oil Carry–Over (Continued) 7. Operation at elevated 7. Reduce temperature. See discharge temperatures. High Discharge Air Temperature, page 34, this section. 8. Scavenge line check 8. Replace check valve. valve failure. 9. Water condensate in oil. 9.
  • Page 46 SYMPTOM POSSIBLE CAUSE REMEDY “MOTOR OVERLOAD” (Continued) 4. Imbalanced amps. 4. Rotate 3 phase power leads. If the high reading stays on the same leg, the problem is with the motor. If the high reading moves with the lead, the problem is with the incoming power.
  • Page 47 1. If fuse does not blow, check meter, starter coil, for shorted coils. or blowdown valve. Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13–8–612...

  • Page 48: Section 10, Parts List

    SECTION 10 PARTS LIST Ref. Name of Part Qty. Part No. SEPARATOR – AIR/OIL ......Refer to page 42 UNION (Separator To Housing) .

  • Page 49: Figure 4-2 Inlet Valve

    INLET VALVE 208EBB810 (Ref. Drawing) Ref. Name of Part Qty. Part No. SNAP RING ..........2117021 DISK (CHECK VALVE) .
  • Page 50 AIR FILTER 209EBB810 (Ref. Drawing) Ref. Name of Part Qty. Part No. WING NUT ..........2117034 CLOSE NIPPLE .
  • Page 51 INTAKE VALVE CONTROLLER 210EBB810–A (Ref. Drawing) Ref. Name of Part Qty. Part No. GASKET ........... . HOUSING .
  • Page 52 MINIMUM PRESSURE/CHECK VALVE 211EBB810 (Ref. Drawing) Ref. Name of Part Qty. Part No. NUT (Lock) ..........2117006 SCREW–SET .
  • Page 53 PIPING AND MOUNTING GROUP 213EBB810–B (Ref. Drawing)
  • Page 54 PIPING AND MOUNTING GROUP Ref. Ref. Name of Part Qty. Part No. Name of Part Qty. Part No. SCREW–FLANGED ..75LM51 SCREW–FLANGED ..75K48 NUT–FLANGED .
  • Page 55 MOUNTING GROUP 212EBB810–A (Ref. Drawing) Ref. Name of Part Qty. Part No. BASE ............200EBB285 PANEL .
  • Page 56 QUIET ENCLOSURE 202EBB810–B (Ref. Drawing) Ref. Part No. Name of Part Qty. 203EBB4017 BAFFLE ........... . . 202EBB840 SCREW–FLANGED .
  • Page 57 AIR RECEIVER WITHOUT CONDENSATE DRAIN 214EBB810 (Ref. Drawing) Ref. Name of Part Qty. 80 Gallon 120 Gallon RECEIVER–AIR ....... . . 200EBB645 201EBB645 DECAL...
  • Page 58 AIR RECEIVER WITH CONDENSATE DRAIN 215EBB810 (Ref. Drawing) Ref. Name of Part Qty. 80 Gallon 120 Gallon RECEIVER–AIR ....... . . 200EBB645 201EBB645 DECAL...
  • Page 59 DRIVE GROUP 204EBB810–B (Ref. Drawing) REF. NAME OF PART QTY. 100 PSI 125 PSI 150 PSI 175 PSI 7.5 HP DRIVE GROUP ..209EBB4004 200EBB4004 201EBB4004 202EBB4004 VALVE–PRESSURE RELIEF . . . 90AR661 90AR662 90AR663 90AR657...
  • Page 60 CONTROL TUBING 203EBB810–C (Ref. Drawing) Ref. Name of Part Qty. Part No. TRANSDUCER–PRESSURE ........88H242 SWITCH–VACUUM .
  • Page 61 ELECTRICAL GROUP 205EBB810–A (Ref. Drawing) For Parts List, Refer to Pages 52 thru 54. 13–8–612 Page 51...
  • Page 62 ELECTRICAL GROUP – 7.5 HP (Refer to Illustration, Page 51, This Section) Ref. 200 Volt 230 Volt 460 Volt 575 Volt Name of Part Qty. Part No. Part No. Part No. Part No. ELECTRICAL GROUP ..200EBB4007 201EBB4007 202EBB4007 203EBB4007...
  • Page 63 ELECTRICAL GROUP – 10 HP (Refer to Illustration, Page 51, This Section) Ref. 200 Volt 230 Volt 460 Volt 575 Volt Name of Part Qty. Part No. Part No. Part No. Part No. ELECTRICAL GROUP ..204EBB4007 205EBB4007 206EBB4007 207EBB4007...
  • Page 64 ELECTRICAL GROUP – 15 HP (Refer to Illustration, Page 51, This Section) Ref. 200 Volt 230 Volt 460 Volt 575 Volt Name of Part Qty. Part No. Part No. Part No. Part No. ELECTRICAL GROUP ..208EBB4007 209EBB4007 210EBB4007 211EBB4007...
  • Page 65 CONTROLLER ASSEMBLY Name of Part Part No. Part No. ASSEMBLED PANEL – NEMA 1 ......202EBB466 203EBB466 BOX–CONTROL...
  • Page 66 MOTOR GROUP (MAIN DRIVE MOTORS) (F1 CONDUIT BOX MOUNTING) (60 HZ – ODP) 7.5 HP 10 HP 15 HP DESCRIPTION PART # PART # PART NO. (1800 RPM) (3600 RPM) (3600 RPM) MOTOR, 200V 24AW6 MOTOR, 230/460V 24AW22 MOTOR, 575V 24AW41 MOTOR, 200V 24CA674...
  • Page 67 OVERLOAD RELAY HEATER CONVERSION LISTING Refer to Motor Nameplate “Amperage” and Decal in Control Panel for Selection of Overload Relay Heater Packs. CUTLER–HAMMER GARDNER DENVER PART NUMBER PART NUMBER H2002B ........... .
  • Page 68 ......201EJB077 DECAL, NOTICE – USE GARDNER DENVER PARTS ....
  • Page 69 REPAIR PARTS Your Gardner Denver rotary screw compressor is designed and manufactured for many years of reliable opera- tion. All components are engineered to exacting specifications, which will function together as a system to provide maximum efficiency. To insure the continuing integrity of compressor operation, use only original quality genuine Gardner Denver replacement parts and accessories.

  • Page 70: Section 11, Optional Integrated Dryer, Service Instructions And Parts List

    SECTION 11 OPTIONAL INTEGRATED DRYER SERVICE INSTRUCTIONS AND PARTS LIST INSTALLATION – There should be at least 12 inches The refrigerant suction pressure gauge reading after (305 mm) clearance on all sides of the dryer. The con- start–up and while operating under rated load will be densor fins and surfaces should be regularly cleaned (R–22) 57–65 psig.

  • Page 71: Figure 11-2 Temperature-Pressure Chart (R-22)

    TEMPERATURE–PRESSURE CHART (R–22) Temperature Pressure Temperature Pressure psig psig 52.4 111.2 54.9 121.4 57.5 132.2 60.1 143.6 62.8 155.7 65.6 168.4 68.5 181.8 76.0 195.9 84.0 210.8 92.6 226.4 101.6 FIGURE 11–2 – TEMPERATURE–PRESSURE CHART (R–22) button, “MOTOR RUN” indicator and an “ALARM” indi- should indicate 65 psig for R–22.

  • Page 72: Figure 11-4 Refrigerated Dryer

    FIGURE 11–4 – REFRIGERATED DRYER FIGURE 11–5 – SUCTION PRESSURE GAUGE, DRYER INLET AND OUTLET 13–8–612 Page 62...

  • Page 73: Figure 11-6 Condenser, Heat Exchanger, Hot Gas Bypass

    FIGURE 11–6 – CONDENSER, HEAT EXCHANGER, HOT GAS BYPASS FIGURE 11–7 – COMPRESSOR (REFRIGERATED DRYER) 13–8–612 Page 63...
  • Page 74 TROUBLE SHOOTING GUIDE FOR OPTIONAL INTEGRATED DRYER SYMPTOM POSSIBLE CAUSE REMEDY Dryer not running 1. Low voltage to the dryer. 1. Verify proper line voltage to unit Motor Run light is on 2. Contactor not pulling in. 2. Check all safeties, verify con– trol voltage, check coil continuity.
  • Page 75 SYMPTOM POSSIBLE CAUSE REMEDY High suction pressure 1. Excessive air load exceeding 1. Verify proper flow and load at dryer (62 to 72 psig normal) the capacity of the dryer. inlet. 2. Hot gas by–pass valve setting 2. Follow instructions in manual too high.
  • Page 76 SYMPTOM POSSIBLE CAUSE REMEDY Alarm light on 1. Air inlet temperature too high. 1. Verify proper load and temperature (Refrigerant at dryer inlet. compressor OFF) 2. Refrigerant shortage. 2. Check for leaks using soap bubbles or electronic leak detector. If leaks are detected repair immediately using industry approved standards.
  • Page 77 INTEGRATED DRYER ASSEMBLY AND PIPING 301EBB810–A (Ref. Drawing)
  • Page 78 INTEGRATED DRYER ASSEMBLY AND PIPING Ref. Name of Part Qty. Part No. NIPPLE–PIPE ............63G3G SEPARATOR–MOISTURE .
  • Page 79 INTEGRATED DRYER MOUNTING GROUP 300EBB810 (Ref. Drawing) Ref. Name of Part Qty. Part No. BASE ............200EBB285 PANEL .
  • Page 80 STARTER CONTROL BOX FULL VOLTAGE – NEMA 1 – 120 VOLT Ref. Name of Part Qty. Part No. CONTROL BOX ..........300EBB179 BLOCK .
  • Page 81 REFRIGERATION COMPONENTS Ref. Name of Part Qty. Part No. COMPRESSOR ..........7000510 FAN BLADE .
  • Page 82 300EBB541–B (Ref. Drawing)

  • Page 83: Warranty

    Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.

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