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Gardner Denver INTEGRA EFA99F Operating And Service Manual

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13-8-639
GARDNER DENVER
®
Version: 00
June 8, 2004
INTEGRA
BASE-MOUNTED
COMPRESSORS
MODELS
EFA99F
5, 7-1/2 & 10 HP
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver INTEGRA EFA99F

  • Page 1 13-8-639 GARDNER DENVER ® Version: 00 June 8, 2004  INTEGRA BASE-MOUNTED COMPRESSORS MODELS EFA99F 5, 7-1/2 & 10 HP OPERATING AND SERVICE MANUAL...

  • Page 2: Remanufactured Airends

    Authorized distributor service technicians 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 or contact:...

  • Page 3: Foreword

    FOREWORD 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: Table Of Contents

    TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ..............2 Remanufactured Airends ..........................2 Foreword ............................... 3 Index................................5 List Of Illustrations............................7 Section 1, General Information ........................8 Section 2, Installation ..........................14 Section 3, Starting &...

  • Page 5: Index

    INDEX Air Cooled Unit ..........16 Foundation ............16 Air Filter Element ............57 General Information Element Life..........57 Section 1 ............8 Section 6............57 Grounding ............19 Standard Duty..........57 Air Flow In Compressor System ......8 Inlet Line ............18 Air Receiver Installation Auxiliary ............18 Section 2 ............
  • Page 6 Oil Cooler Oil Pressure Differential ....56 Air/Oil............54 Oil Cooler Temperature Differential....56 Service Check List ........... 63 Oil Inlet Pressure ..........56 Air Filter ............63 Operating Principles...........9 Every 1000 Hours Operation......63 Every 125 Hours Operation......63 Piping Every 1500 Hours Operation......63 Control ............18 Every 4000 Hours Operation......

  • Page 7: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compressor Cycle ........................8 Figure 1-2 – Compressor Package Components ..................9 Figure 2-1- Preferred Lifting Method......................14 Figure 2-2 – Outline, Unit Package......................15 Figure 2-3 – Air Flow Chart ......................... 16 Figure 2-4 – Cold Weather Installation ....................... 17 Figure 4-1 –...

  • Page 8: 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 9: Figure 1-2 - Compressor Package Components

    OPERATING PRINCIPLES MAIN COMPONENTS The Gardner Denver screw compressor is a single stage screw compressor with oil cooler. The pressurized air is produced with a screw compressor unit driven by an electric motor. Oil is separated from the compressed air in an oil separation receiver. The pressurized air and the oil are cooled with separate coolers.
  • Page 10 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: DANGER Failure to observe these notices could result in injury to or death of personnel.
  • Page 11 SAFETY PRECAUTIONS WARNING 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, lockout and tagout before working on the unit –...
  • Page 12 DECALS DANGER WARNING WARNING Unit can automatically restart and cause personal injury or Discharge air used for breathing will cause severe injury Rotating machinery can cause personal injury or death. death. or death. Consult filtration specialist for additional Keep all guards and safety devices in place. Know mode of operation before working on or near the filtration and treatment equipment to meet health and ADVERTENCIA...
  • Page 13 DECALS CONTROLLER LEGEND WARNING WARNING (Refer to instruction manual for detailed procedure before starting unit) Load indicator light (not on when machine Display Scrolling is running unloaded) Pressure indicator light Start Electrical shock can cause injury or death. Disconnect all Unit can automatically restart causing personal injury Temperature indicator light circuits before working on control.

  • Page 14: 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. CAUTION Do not electric weld on the compressor or base; bearings can be damaged by passing of current.

  • Page 15: Figure 2-2 - Outline, Unit Package

    300EFA804-A (Ref. Drawing) Figure 2-2 – OUTLINE, UNIT PACKAGE...

  • Page 16: Figure 2-3 - Air Flow Chart

    AIR-COOLED UNIT - A combination oil/aftercooler is supplied as standard equipment on all air-cooled units. The air-cooled unit with the standard enclosure requires sufficient flow for the compressor oil/aftercooling system and electric motor cooling (Figure 2-3 below). Air is drawn into the unit above the motor and discharged through the cooler.

  • Page 17: Figure 2-4 - Cold Weather Installation

    DANGER Do not operate the compressor with the fan, belts or sheaves exposed. Exposed fan, belts and sheaves may cause injury to personnel. CAUTION The enclosure doors are connected to a shutdown switch that will not allow the compressor to operate without the complete enclosure in place. Figure 2-4 –...
  • Page 18 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 19 WARNING 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.
  • Page 20 WARNING Failure to properly ground the compressor package could result in injury or death. Install ground wiring in accordance with the National Electrical Code and any applicable local codes. MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings.
  • Page 21 ELECTRIC MOTOR REGREASING INTERVAL Type of Service Typical Rating Relubrication Interval Standard One or Two Shift Operation 5 to 50 HP 3200 Hours Dirty Locations, High Ambient Temperature Very Severe 5 to 50 HP 500 hours (104° F, 40° C) 13-8-639 Page 21...

  • Page 22: Section 3, Starting & Operating Procedures

    For instructions on checking the oil and the proper oil level, refer to Section 5, page 45. 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 23 WARNING The motor is held up to prevent belt damage during shipment. Remove the shipping hardware to lower the motor to its operating position prior to starting the package. Loosen locking nut and unthread the long set screw the majority of the way (this lowers the motor) and tighten the locking nut.
  • Page 24 DANGER 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. CAUTION The enclosure doors are connected to a shutdown switch that will not allow the compressor to operate without the complete enclosure in place.

  • Page 25: Section 4, Controls & Instrumentation

    SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The rotary screw compressor package 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 the shop air line. A standard compressor package consists of the compressor, air/oil reservoir, oil cooling system and filter, motor, starter/control box and control components.
  • Page 26 Compressor blowdown time before restart. (The air/oil separator must be blowndown before starting). Control System Operation - The purpose of the control system is to adjust the production of compressed air according to the demands of the system and to lower power consumption. Compressor Running Fully Loaded - When the compressor runs loaded, the inlet valve is open and the compressor produces compressed air.
  • Page 27 The electronic controller has a built-in automatic restart for restarting the compressor package after a power failure. This function is switched off in the factory settings. See USER MENU, "Automatic start after power failure", page 31, The version identification of the electronic controller is on a label behind the controller and on the display when the controller is powered up.

  • Page 28: Figure 4-2 - Starter/Control Box And Instrument Panel

    Figure 4-2 – STARTER/CONTROL BOX AND INSTRUMENT PANEL INSTRUMENT PANEL (Figure 4-2) – The following is a description of the various displays, buttons and indicator lights on the AirPilot Electronic controller: 1. Scrolling 2. Start 3. Stop 4. Change Setting (up) 5.

  • Page 29: Figure 4-3 - Airpilot Electronic Controller

    306EAU1255-A (Ref. Drawing) Figure 4-3 – AIRPILOT ELECTRONIC CONTROLLER PROGRAMMING AND SETUP INSTRUCTIONS FOR THE AIRPILOT ELECTRONIC CONTROLLER The AIRPILOT ELECTRONIC CONTROLLER has five menus, three of which can be accessed by the operator. The other menus contains the factory settings of the compressor. Access to the factory settings menu requires a special code.
  • Page 30 NOTICE The basic display can be entered from all menus by depressing the reset key. The basic display will also return after one minute, if the panel is not used. The following are the compressor running modes: DISPLAY RUNNING MODE Off illuminated Compressor switched off Off flashing slowly...
  • Page 31 The unload pressure set at the factory is equal to the compressor’s maximum pressure which cannot be exceeded. Setting the discharge pressure: The pressure indicator light and the lower left segment of the display illuminate when the discharge pressure is in the programming mode. NOTICE Changing the discharge pressure will cause the pressure difference to change.
  • Page 32 After replacing the oil, filters or separators, the service interval must be reset in the controller. MULTIPILOT MENU - Contact Gardner Denver Customer Service. To enter the MultiPilot Menu from the basic display when the compressor is stopped, simultaneously push the up arrow and the down arrow keys and hold for 5 seconds, until all the indicator lights on the display start flashing, then select code 03.
  • Page 33 Use the scroll key ( ) to select the desired option for programming. The numerical values can be changed with the up arrow or the down arrow keys. The value flashes on the display to indicate change. When the flashing stops, the value becomes the new setting. The following can be programmed through the MULTIPILOT MENU.
  • Page 34 Parameter Setting Range Factory Setting Unload pressure 45 psig to compressor maximum Maximum pressure rating for pressure (see nameplate) the package as built at the factory Load pressure 45 psig to compressor maximum Differential pressure = 10 psi pressure (see nameplate) Automatic timer 1-20 minutes 3 or 5 minutes...
  • Page 35 See the Parts List for a listing of the kits available for rebuilding or replacing the valve. Repair kits are available from your local authorized Gardner Denver distributor. Changing Minimum Pressure/Check Valve Seals Be sure the unit is completely off and that no air pressure is in the oil reservoir.
  • Page 36 DANGER 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. Inlet Valve – The inlet valve opens and closes to control delivery and closes to unload the compressor. At shutdown, the inlet valve closes to prevent the back flow of air.

  • Page 37: Figure 4-4 - Compressor Running Loaded

    Figure 4-4 – COMPRESSOR RUNNING LOADED Ref. Component Function Solenoid Valve (Blowdown) Exhausts the oil separator during unloaded running Solenoid Valve (Inlet Valve) Opens and closed the intake valve Pressure Transducer Transmits the discharge pressure signal Allows the pressure of the oil separator or the compressed-air Shuttle system (the higher one) to close the intake valve Check Valve...
  • Page 38 Pressure Transducer (Figure 4-4, page 37) – This transducer is connected after the minimum pressure/check valve. It converts the pressure in the plant air system into an electrical signal for use by the controller. ALARMS Indication on the control panel Cause Overpressure alarm causing compressor to shutdown or Pressure light flashing...
  • Page 39 WIRING DIAGRAMS – 3 PHASE...
  • Page 40 WIRING DIAGRAMS – 3 PHASE...
  • Page 41 WIRING DIAGRAMS – 3 PHASE...
  • Page 42 WIRING DIAGRAMS – 1 PHASE...
  • Page 43 WIRING DIAGRAM – 1 PHASE...
  • Page 44 WIRING DIAGRAM – 1 PHASE...

  • Page 45: Figure 5-1 - Flow Diagram

    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 46 CAUTION 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 47: 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 48 DRAINING AND CLEANING OIL SYSTEM DANGER 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 49 4. Remove the oil filler plug and add oil as required to return the oil level to the max. range on the oil gauge. 5. Install the oil filler plug and operate the unit for about a minute allowing oil to fill all areas of the system.
  • Page 50 WARNING 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. AEON 9000SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints.

  • Page 51: Figure 5-4 - Oil Level Gauge, Oil Fill And Oil Drain

    306EBA797-A (Ref. Drawing) Figure 5-4 – OIL LEVEL GAUGE, OIL FILL AND OIL DRAIN MOISTURE IN THE OIL SYSTEM – In environments with normal operating temperatures and pressures and low relative humidity, the thermal mixing valve controls the oil temperature and prevents moisture accumulation in the oil.

  • Page 52: Figure 5-5 - Dew Point Chart °F

    Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 100 psig 125 psig 150 psig 175 psig Ambient Temp. F Figure 5-5 – DEW POINT CHART °F Dew -Point Tem perature vs. Am bient Tem perature (100% Relative Hum idity) 6.9 bar 8.6 bar 10.4 bar 12.1 bar...
  • Page 53 COMPRESSOR OIL FILTER (Figure 5-1, page 45and Figure 5-7, page 54) This replaceable element filter is a vital part in maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. CAUTION Improper oil filter maintenance will cause damage to equipment. Replace filter element every 1000 hours of operation.

  • Page 54: Figure 5-7 - Oil Filter

    Figure 5-7 – OIL FILTER 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.
  • Page 55 Pressure Differential Gauging Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, lockout and tagout the power supply to the starter. Install accurate pressure gauges upstream and downstream of the air/oil separator. If the differential pressure is greater than 8 psi (.6 bar), change the air/oil separator, see "Removal of Oil Separator for Inspection or Replacement", page 55.
  • Page 56 5. Lift out the air/oil separator elements. 6. Inspect and/or replace the separator as necessary. 7. Clean the sealing surfaces on the air/oil separator and the minimum pressure/check valve. 8. Clean the orifice, in the oil return line, the strainer in oil return line, and if necessary, the air/oil separator housing.

  • Page 57: Section 6, Air Filter

    SECTION 6 AIR FILTER Figure 6-1 – AIR FILTER STANDARD DUTY AIR FILTER - Service and replacement instructions are given in the following sections: Filter Element and Filter Element Life. Filter Element - The element should be serviced when inspection indicates an accumulation of dirt on the outside of the element.

  • Page 58: 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 59: Figure 7-2 - Removing The Motor Sheave

    REPLACING THE COMPRESSOR BELTS 1. Disconnect, tagout and lockout the power supply to the starter. 2. Open the top enclosure door and remove the enclosure around the motor. 3. Raise the motor, until the locking pin (2) can be inserted through the slot (3) and into the hole (4) in the bracket.

  • Page 60: Figure 7-3 - Installing Bushing In Drive Sheave

    23 Ft-Lbs (31 Nm) 12. Fill the holes in the bushing/sheave with grease to protect them from dirt and debris. 13. Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver belts. 13-8-639 Page 60...

  • Page 61: Figure 7-5 - Drive Sheave

    8. Note, the wear sleeve will come off with the sheave. 9. Always replace both the wear sleeve and the shaft seal. The sleeve is removed by tapping it off with Gardner Denver tool EFC03476918, or by tapping it off with a drift, through the three holes in the sheave.
  • Page 62 Gardner Denver tool EFC03476918 and tighten the left handed bolt to 60 ft-lbs (80 Nm). 15. Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver belts. 16. Remove the locking pin (Item 2 in Figure 7-1, page 58) and lower the motor. The weight of the motor keeps the belts properly tensioned.

  • Page 63: 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 57. Motor Lubrication - Refer to SECTION 2, page 20. Every 8 Hours Operation Check the reservoir oil level - add oil if required. See Section 5, page 45. If oil consumption is high, refer to “Excessive Oil Consumption,”...
  • Page 64 MAINTENANCE SCHEDULE (See Detail Notes above) Maintenance Action Every Every Every Every Every Every 8 1000 4000 Year Hours Hours Hours Hours Hours Check/Change Air Filter ** ..........• Change Oil Separator *** ..........• • Check Reservoir Oil Level **** ........... •...

  • Page 65: 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. Plant pressure higher than Wait for plant pressure to pressure setting in drop below load pressure. controller. Main motor overloaded Test motor thermistors.
  • Page 66 Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Wrong oil type Use Gardner Denver 2000, 4000 or 9000SP Lubricating Coolant. Compressor is low on Restricted air filter. Clean or replace filter.
  • Page 67 SYMPTOM POSSIBLE CAUSE REMEDY High discharge air Dirty or clogged cooler Clean cooler. temperature face. Insufficient cooling air Provide unrestricted flow. supply of cooling air. Clogged oil filter or cooler Replace filter or clean (interior). cooler. Low compressor oil. Add oil to proper level. Faulty temperature Replace sensor.
  • Page 68 SYMPTOM POSSIBLE CAUSE REMEDY Oil Carry-Over continued Foam caused by use of Use Gardner Denver incorrect oil. 2000, 4000 or 9000SP Lubricating Coolant. Inoperative minimum Replace seals in valve. pressure valve. Operation at elevated Reduce temperature. See discharge temperatures. “High Discharge Air Temperature”, this...
  • Page 69 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 70 GENERAL PROVISIONS AND LIMITATIONS Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty is made with respect to: Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.
  • Page 71 For additional information contact your local representative 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 major cities. Specifications subject to change without notice.

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