Gardner Denver INTEGRA EFD99E Operating And Service Manual
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Gardner Denver INTEGRA EFD99E Operating And Service Manual

Gardner Denver INTEGRA EFD99E Operating And Service Manual

Base-mounted compressors airsmart control 40 - 50 hp
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13-20-604
Version: 01
August 20, 2009
™
INTEGRA
BASE-MOUNTED
COMPRESSORS
AIRSMART CONTROL
MODELS – EFD99E
40 - 50 HP
OPERATING AND
SERVICE MANUAL

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  • 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: Maintain Compressor Reliability And Performance With

    Remanufacturing Center in Indianapolis, IN., for purchase on an exchange basis with liberal core credit available for the replacement unit. 3. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.

  • Page 3: Warning - Prohibition - Mandatory Label Information

    WARNING – PROHIBITION – MANDATORY LABEL INFORMATION Gardner Denver Rotary 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-day operation, maintenance and adjustment.
  • Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.

  • Page 5: Safety Precautions

    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 6: Table Of Contents

    TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services............1 Instructions For Ordering Repair Parts/Remanufactured Airends ..............1 Warning – Prohibition – Mandatory Label Information.................. 2 Safety Precautions ............................4 Index................................6 List Of Illustrations............................

  • Page 7: Index

    INDEX Air Cooled Unit ..........11 Lubrication Air Filter Motor ............16 Element............47 Lubrication, Cooling And Sealing....... 9 Element Life..........48 Lubrication, Oil Cooler, Oil Filter & Separator Section 6............47 Section 5 ............35 Standard Duty..........47 Air Flow In Compressor System ......9 Maintenance Schedule Air Receiver Section 8 ............
  • Page 8 Separators Unit Hot ............21 Air/Oil ............44 Stopping The Unit ..........21 Service Check List ...........52 Air Filter ............52 Trouble Shooting Every 1000 Hours Operation......52 Section 9 ............54 Every 125 Hours Operation......52 Troubleshooting Voltage Problems....57 Every 4000 Hours Operation......52 Every 8 Hours Operation ......52 Valve Every Year............52...

  • Page 9: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compressor Cycle ........................9 Figure 1-2 – Compressor Illustration......................10 Figure 2-1 – Typical Compressor Room ..................... 12 Figure 2-2 – Air Flow Chart ......................... 12 Figure 2-3 – Cold Weather Installation ....................... 13 Figure 4-1 –...

  • Page 10: Section 1, General Information

    SECTION 1 GENERAL INFORMATION Figure 1-1 – COMPRESSOR CYCLE COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads.

  • Page 11: Figure 1-2 - Compressor Illustration

    Figure 1-2 – COMPRESSOR ILLUSTRATION 300EFD797-B (Ref. Drawing)

  • Page 12: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passing of current.

  • Page 13: Figure 2-1 - Typical Compressor Room

    For aluminum oil coolers, do not use any cleaning solution that is not compatible with aluminum. Use of improper solution may result in damage to the cooler. Figure 2-1 – TYPICAL COMPRESSOR ROOM Minimum Air Flow* For Compressor And Cooling (cubic Feet/Minute) Air Cooled All Models 4800 cfm...

  • Page 14: Figure 2-3 - Cold Weather Installation

    If the compressor unit base is raised above floor level, the space between the floor and the base bottom must be closed with solid material all around to prevent recirculation of hot air from the oil cooler end and over temperature operation.
  • Page 15 Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000SP lubricant. Monitor unit carefully during start-up and operation to be sure it is functioning normally.
  • Page 16 INLET LINE LENGTHS Length of Inlet Line Diameter of Pipe Size 0 to 10 Feet ..........Same as Compressor Inlet Opening 10 to 17 Feet ........... One Size Larger Than Inlet Opening 17 to 38 Feet ........... Two Sizes Larger Than Inlet Opening DISCHARGE SERVICE LINE - The discharge service line connection is made at the left hand corner of the package when viewed from the control box end.
  • Page 17 Electrical shock can cause injury or death. Open main disconnect switch, lockout and tagout before working on control box. GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical Code. Failure to properly ground the compressor package could result in injury or death.
  • Page 18 ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30° C to 50° C) MANUFACTURER TRADE NAME CHEVRON SRI #2 SHELL DOLIUM R EXXON UNIREX #2 EXXON POLYREX ELECTRIC MOTOR REGREASING INTERVAL Type of Service Typical Rating Relubrication Interval Up to 150 HP (112 KW) 18 Months Standard One or Two Shift Operation...

  • Page 19: Section 3, Starting & Operating Procedures

    For instructions on checking the oil and the proper oil level, refer to “Compressor Oil Filter”, Section 5, page 35. Do not mix different type oils. Unit is shipped filled with Gardner Denver AEON 4000 Lubricating Coolant which is suitable for the first 4000 hours under normal operating conditions. AEON 9000SP is also available.
  • Page 20 Failure to properly ground the compressor package could result in controller malfunction. Rotation - Check for correct motor rotation by jogging the motor. See “Unit Setup Adjustments” in the Controller Operating and Service Manual. Compressor drive shaft rotation must be clockwise, standing facing the compressor sheave.
  • Page 21 The compressor starts and stops automatically. Automatic restarting can cause injury or death. Open, lockout and tagout main disconnect and any other circuits before servicing the unit. The enclosure doors must be in place and fastened down to keep the compressor package from overheating when the compressor is running.
  • Page 22 Unit Hot (No warm-up period is required): Open the air service valve (customer furnished) between the main air system and the check valve on the package. Run for approximately one minute. The unit is equipped with a minimum (70 psig) pressure/check valve, no special procedure to maintain the unit reservoir pressure is required.
  • Page 23 Quick Start Guide Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run button to start the compressor, no other settings are required. The Target Pressure comes preset to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure setting is desired, the following steps can be used as a guide.
  • Page 24 To change the Target Pressure, press the Enter button to edit the value. OPERATION ADJUSTMENT TARGET PRESSURE 100 PSI (EDIT PARAMETER) A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the Plus and Minus buttons to change its value.

  • Page 25: Section 4, Controls & Instrumentation

    CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION The Gardner Denver rotary screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop air line.

  • Page 26: Figure 4-2 - Key Pad

    CONTROL DEVICES Controller - This compressor unit features the "AirSmart" controller, which integrates all the control functions under microprocessor control. Its functions include safety and shutdown, compressor regulation, operator control, and advisory/maintenance indicators. The keypad and display provide the operator with a logical and easily operated control of the compressor and indication of its condition. The controller is factory adjusted for the compressor package, but allows tuning for specific applications.
  • Page 27 Never paint, lubricate or alter a relief valve. Do not plug vent or restrict discharge. Operation of the unit with improper relief valve setting can result in severe personal injury or machine damage. Ensure properly set valves are installed and maintained. Oil Level Gauge - This gauge is located on the oil reservoir and indicates the oil level.
  • Page 28 Reservoir Pressure Transducer (Figure 4-1, page 24) - This transducer is connected to the coolant system. Its signal is used to prevent loaded starts, monitor oil pressure, and to monitor the condition of the separator. Air Filter Vacuum Switch (Figure 4-1, page 24) - This switch is used to monitor air filter condition and alert the user if the filter requires service or replacement.
  • Page 29 Changing Minimum Pressure/Check Valve Seals Air/oil pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Be sure the unit is completely off and that no air pressure is in the oil reservoir.

  • Page 30: Figure 4-3 - Wiring Diagram - Full Voltage

    308EDE46-A (Ref. Drawing) Page 1 of 2 Figure 4-3 – WIRING DIAGRAM – FULL VOLTAGE...
  • Page 31 308EDE46-A (Ref. Drawing) Page 2 of 2...

  • Page 32: Figure 4-4 - Wiring Diagram - Wye Delta

    309EDE546-A (Ref. Drawing) Page 1 of 2 Figure 4-4 – WIRING DIAGRAM – WYE DELTA...
  • Page 33 309EDE546-A (Ref. Drawing Page 2 of 2...

  • Page 34: Figure 4-5 - Wiring Diagram - Less Starter

    310EDE546-A (Ref. Drawing) Page 1 of 2 Figure 4-5 – WIRING DIAGRAM – LESS STARTER...
  • Page 35 310EDE546-A (Ref. Drawing) Page 2 of 2...

  • Page 36: Section 5, Lubrication, Oil Cooler, Oil Filter & Separator

    Oil separated at the air/oil separator is sent 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.
  • Page 37 Specific AEON™ lubricants are recommended for use in this equipment. Other lubricants may cause excessive carryover or compressor damage. Do not mix different types of lubricants or use inferior lubricants. Check the decal on the oil reservoir for lubricating coolant specification. HIGH TEMPERATURE OPERATION - If the discharge temperature is sustained between 200°...

  • Page 38: Figure 5-2 - Approximate Oil System Capacities

    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 program with the AEON lubricants and we recommend a sample be sent in at 100 hours on a new unit.
  • Page 39 DRAINING AND CLEANING OIL SYSTEM Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Always drain the complete system.
  • Page 40 Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. 1. Be sure the unit is completely off and that no air pressure is in the oil reservoir. 2. Disconnect, lockout and tagout the power supply to the starter. 3.
  • Page 41 Do not repeatedly restart the unit after high temperature stops operation. Find and correct the malfunction before resuming operation. All materials used in Gardner Denver compressor units are compatible with AEON 9000SP Lubricating Coolant. Use caution when selecting downstream components such as air line lubricating bowls, gaskets and valve trim.
  • Page 42 Machine should then be run normally; however, total run time after the initial change outs should be 50 percent of normal anticipated service life of the new lubricant. • Drain all lubricant from system, change filter and separator, and replace with full charge of the new lubricant.

  • Page 43: Figure 5-4 - Oil Level Gauge, Oil Fill And Oil Drain

    OIL LEVEL GAUGE (Figure 5-4, page 42) - The oil level gauge indicates the amount of oil in the air/oil reservoir. Read oil level only when the unit is shut down and the air/oil mixture has separated. Add oil only when the oil level is in the bottom red range, below the white range on the gauge (you must use a flashlight).

  • Page 44: Figure 5-5 - Oil Filter

    Use only the replacement element shown on the filter tag or refer to the parts list for the part number. Use the following procedure to replace the filter element. Do not disturb the piping. Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters.
  • Page 45 COMPRESSOR OIL COOLER - The cooler fan is mounted on the compressor motor shaft; air is exhausted through the oil cooler and away from the unit. Do not obstruct air flow to and from the oil cooler. Allow a minimum of two (2) feet (.6M) clearance around the cooler. Keep both faces of the cooler core clean for efficient cooling of compressor oil.
  • Page 46 NOTICE A sudden drop of zero pressure differential or sudden heavy oil carryover may indicate a ruptured element. Inspection - After removal of separator element, shine a light inside the element to reveal areas of heavy dirt or varnish deposits or breaks (ruptures) in element media. Removal of Oil Separator For Inspection or Replacement: Air/oil under pressure will cause severe personal injury or death.
  • Page 47 9. Grease the O-Ring on the separator element and install the separator into the housing. 10. Replace the O-Ring between the minimum pressure/check valve and the air/oil separator housing. 11. Replace the sealing kit in the minimum pressure/check valve. After the assembling of the valve, leave about .08 inch gap between the nut and the cover of the valve.

  • Page 48: Section 6, Air Filter

    SECTION 6 AIR FILTER Figure 6-1 – AIR FILTER STANDARD DUTY AIR FILTER (Figure 6-1) - Replacement instructions are given in the following sections: Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. The air filter element can not be cleaned or reused.
  • Page 49 Install new air filter element and the air filter cover. Open the air service valve. Filter Element Life - The element should be replaced if visual inspection indicates an accumulation of dirt, or a rupture, crack or pin holes in the pleated media. Inspection should be done by placing a bright light inside the element.

  • Page 50: 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 before initial start-up. Sheaves should align straight across the front with a straight edge. The best tension is just enough tension to keep belts from “squealing”...
  • Page 51 Once proper alignment has been obtained, lock the sheave in place on the motor shaft; then the jack bolt lock nuts must be tightened. One set of nuts is tightened down against the base to lock the jack bolts in place.

  • Page 52: Figure 7-1 - Belt Tension - 3Vx Belts

    Deflection Motor H.P. No. of Belts Force Pounds Deflection In Inches 6 – 8.5 6 – 8.5 Figure 7-1 – BELT TENSION – 3VX BELTS 13-20-604 Page 51...

  • Page 53: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter - Operating conditions determine frequency of service. See “Air Filter,” SECTION 6, page 47. Motor Lubrication - Refer to SECTION 2, page 16. Every 8 Hours Operation Check the reservoir oil level - add oil if required. See Section 5, page 35. If oil consumption is high, refer to “Excessive Oil Consumption,”...
  • Page 54 MAINTENANCE SCHEDULE (See Detail Notes above) Maintenance Action As Indicated by Every Every Every Every AirSmart Every 8 1000 4000 Year Controller Hours Hours Hours Hours • Check/Change Air Filter ............. • • Change Oil Separator ............• Check Reservoir Oil Level **..........•...

  • Page 55: Section 9, Troubleshooting

    SECTION 9 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate heaters tripped . cause of overload. Pressure in reservoir. Inspect blowdown valve. Emergency stop Release button.
  • Page 56 Compressor starts too Wye Delta switch time set Contact your Gardner slowly too long. Denver distributor. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Compressor is low on Restricted air filter. Clean or replace filter.
  • Page 57 Ruptured oil separator Replace element. element. Loose assembly. Tighten all fittings and gaskets. Foam caused by use of Use Gardner Denver incorrect oil. AEON 2000, 4000 or 9000SP lubricating coolant. Inoperative minimum Replace seals in valve. pressure valve. Operation at elevated Reduce temperature.
  • Page 58 Look for poor connections or undersized wiring. NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units.
  • Page 60 For additional information contact your local representative or Gardner Denver Compressor 1800 Gardner Expressway, Quincy, Illinois 62305 Specifications subject to change without notice. Customer Service Department Telephone: Copyright © 2009 Gardner Denver, Inc. Litho in U.S.A. (800) 682-9868 FAX: (217) 224-7814 Visit our Web Site: www.gardnerdenver.com...

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