Gardner Denver EFD-25 HP Operating And Service Manual
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Gardner Denver EFD-25 HP Operating And Service Manual

Gardner Denver EFD-25 HP Operating And Service Manual

Electra-screw stationary base-mounted compressors
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R
13- -8- -625
GARDNER DENVER
1st Edition
March 24, 2000
ELECTRA- -SCREW
STATIONARY BASE- -MOUNTED
COMPRESSORS
MODELS
EFD - - 25, 30, 40 & 50 HP
PARTS LIST,
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver EFD-25 HP

  • Page 1 13- -8- -625 GARDNER DENVER 1st Edition March 24, 2000 ELECTRA- -SCREW STATIONARY BASE- -MOUNTED COMPRESSORS MODELS EFD - - 25, 30, 40 & 50 HP PARTS LIST, OPERATING AND SERVICE MANUAL...

  • Page 2: Remanufactured Airends

    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 Rotary screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of re- ceiving 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 PAGE Total Product Support -- Gardner Denver’s Continuing Commitment To Your Air Compressor Performance ..Remanufactured Airends ................

  • 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:...

  • Page 6: Index

    INDEX Addition of Oil Between Changes ....Inlet Valve ......Air Cooled Unit .
  • Page 7 INDEX Installation for Cold Weather Operation ..Oil Cooler Temperature Differential ..Instrument Panel ......Oil Inlet Pressure .
  • Page 8 INDEX Remanufactured Air Ends ..... . STARTING & OPERATING PROCEDURES, SECTION 3 ......Remote Control Operation .
  • Page 9 LIST OF ILLUSTRATIONS Figure 1--1 Compressor Cycle ............. . . Figure 1--2 Compressor Package Components .

  • Page 10: Section 1, General Information

    SECTION 1 GENERAL INFORMATION FIGURE 1- - 1 - - COMPRESSOR CYCLE COMPRESSOR -- The rotary screw compressor is Oil is injected into the cylinder to remove the heat of a single stage, positive displacement rotary machine compression and seal internal clearances. Volume re- using meshing helical rotors to effect compression.

  • Page 11: Figure 1--2 Compressor Package Components

    FIGURE 1- - 2 - - COMPRESSOR PACKAGE COMPONENTS Component Purpose Electric motor Powers compressor unit Belts Power transmission Compressor unit Generates pressurized air Inlet valve Air output control Inlet filter Cleans inlet air Air/oil reservoir Separates oil from air Minimum pressure/check valve Maintains min.
  • Page 12 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 13 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13- -8- -616 Page 4...
  • Page 14 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13- -8- -616 Page 5...

  • Page 15: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL -- On receipt of the unit, check for any dam- age that may have been incurred during transit. Report any damage or missing parts as soon as possible. The eyebolts or lugs provided on the motor are for lifting the motor only and should not be used to lift any Do not electric weld on the compres- additional weight.

  • Page 16: Figure 2--3 Typical Compressor Room

    AIR- -COOLED UNIT -- A combination oil/aftercooler is FOUNDATION -- The rotary screw compressor re- supplied as standard equipment on all air--cooled units. quires no special foundation, but should be mounted on The air--cooled unit with the standard enclosure re- a smooth, solid surface.

  • Page 17: Figure 2--5 Cold Weather Installation

    This heat recovery could easily pay for an ad- equate shelter for the unit. Use only Gardner Denver AEON 9000SP lubri- cant. When an outside installation must be made, the pre- cautions required will depend on the severity of the en- Monitor unit carefully during start--up and opera- vironment.
  • Page 18 OPTIONAL MOISTURE SEPARATOR/TRAP -- The unit is equipped with a built--in aftercooler, a combina- tion moisture separator and trap is furnished as an op- tion to the unit. This should be piped into the system Discharge air used for breathing will down stream of the aftercooler.
  • Page 19 instructions. The following procedure should be used Stop the unit. Replace the relief plug. in regreasing: Restart the unit. Stop the unit. Disconnect, tag and lockout the unit from the power supply. Remove the relief plug and free hole of hardened grease.

  • Page 20: Section 3, Starting & Operating Procedures

    Section 5, page 28. 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 Failure to properly ground the com- under normal operating conditions.
  • Page 21 System Pressure -- The discharge pressure of the unit is set at the factory. To change the dis- charge pressure, set the controls to the desired load pressure. DO NOT EXCEED THE MAXI- After an emergency stop, be sure that MUM OPERATING PRESSURE ON THE COM- the pressure in the air/oil reservoir is PRESSOR NAMEPLATE.

  • Page 22: Section 4, Controls & Instrumentation

    SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION -- The rotary screw com- compressor’s operation: pressor package is prewired with all controls, motor Discharge pressure regulating method: blow- and starter for the voltage and horsepower at the time down/stopping automatics, start/stop operation. of ordering.It is necessary only to connect the com- pressor unit to the correct power supply and the shop Unload pressure: the pressure at which the com-...
  • Page 23 air according to the demands of the system and to The AIRPILOT ELECTRONIC CONTROLLER has a lower power consumption. 7--digit LED display for showing information. The nor- mal display shows operating pressure and tempera- Compressor Running Fully Loaded (FIGURE 4--1, ture.

  • Page 24: Figure 4--2 Starter / Control Box And Instrument Panel

    To restart the compressor, wait one (1) minute, Display indicator light then turn the Emergency Stop button clockwise to Emergency stop release it. Then, start the compressor per the Remote control selecting switch above instructions. In case of alarm, press the Reset button before restarting.

  • Page 25: Figure 4--3 Air Pilot Electronic Controller

    306EAU1255- -A (Ref. Drawing) FIGURE 4- - 3 - - AIR PILOT ELECTRONIC CONTROLLER keys. The value on the display starts flashing to indi- when unloading). If the motor is stopped, the display cate it is being changed. shows the compressor’s running mode. The following are the compressor running modes: The flashing stops when the value is changed.
  • Page 26 Use the scroll key ( ) to get the following information: DISPLAY RUNNING MODE Changing the discharge pressure Pressure light on Discharge pressure will cause the pressure difference to Temperature light on Compressor temperature change. Operating hours light Operating hours Compressor automatic timer: Operating hours Loaded hours flashing...
  • Page 27 Condensate removal, close time: The settings in this menu are used when the compres- sor is connected to the optional Multipilot control Condensate removal close time is in seconds. through an RS 485 communication line. This is time between condensate removal. Use the scroll key ( ) to select the desired option for The oil separator light illuminates when this can...
  • Page 28 COMPRESSOR SETTINGS CHANGEABLE BY THE USER: Parameter Setting range Factory setting Unload pressure 45 psig to compressor maximum Maximum pressure rating for the pressure (see nameplate) package as built at the factory* Discharge pressure 45 psig to compressor maximum differential pressure = 10 psi pressure (see nameplate) Automatic timer 1--20 minutes...
  • Page 29 Repair kits are available from the unit’s inlet and the back side of the inlet valve piston. your local authorized Gardner Denver distributor. A partial vacuum is formed in the suction line, causing the inlet valve to crack open and the compressor to Changing Minimum Pressure/Check Valve Seals start producing compressed air.

  • Page 30: Figure 4--4 Compressor Running Fully Loaded

    13- -8- -625 Page 21...
  • Page 31 REFERENCE NUMBER DISCRIPTION FOR FIGURE 4- - 4 Ref. Ref. Component Component PRESSURE TRANSDUCER ELBOW SOLENOID VALVE -- 3 WAY, TUBE TEE INLET VALVE CONTROL TUBE INLET VALVE SCREW--SOCKET AIR FILTER HOUSING TUBE AIR FILTER COVER CLAMP AIR FILTER ELEMENT THERMISTOR AIR FILTER CLAMP PIPE BUSHING...

  • Page 32: Figure 4--5 Wiring Diagram

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  • Page 33: Figure 4--6 Wiring Diagram

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  • Page 34: Figure 4--7 Wiring Diagram

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  • Page 35: Figure 4--8 Wiring Diagram

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  • Page 36: Figure 5--1 Flow Diagram

    OIL SPECIFICATIONS -- The recommended com- cates moving parts and seals internal clearances in the pressor lubricant is Gardner Denver AEON 4000 Lubri- compression chamber. cating Coolant which can be used for year--round op- Air pressure in the oil reservoir forces oil through the oil eration except as noted in the “High Temperature...

  • Page 37: Figure 5--2 Approximate Oil System Capacities

    (3) quarts. Repeated addition of oil between oil for a period of more than four (4) hours due to continu- changes may indicate excessive oil carry--over and ing high ambient air temperature, use Gardner Denver- should be investigated. AEON 9000SP Lubricating Coolant which is a superior Use only CLEAN containers and funnels so no dirt en- synthetic lubricant.

  • Page 38: Figure 5--3 Oil Change Interval

    humidity, etc.), it will be necessary to change the oil spect the oil separator elements for dirt accumula- more frequently. Operating conditions and the appear- tion; replace if necessary. If a varnish deposit ex- ance of the drained oil must be surveyed and the oil ists, contact the factory for recommendations for change intervals planned accordingly by the user.
  • Page 39 Shut down unit, allowing the oil to settle, and be Change to a new filter and separator. certain all pressure is relieved. Fill system with a full charge of the new lubricant. Add oil, if necessary, to bring level to the top of the white section of the oil level gauge, FIGURE 5--4, Machine should then be run normally;...

  • Page 40: Figure 5--4 Oil Level Gauge, Oil Fill And Oil Drain

    FIGURE 5- - 4 - - OIL LEVEL GAUGE, OIL FILL AND OIL DRAIN circulated oil. Improper oil filter maintenance will All materials used in Gardner Denver cause damage to equipment. Replace compressor units are compatible with filter element every 1000 hours of op- AEON 9000SP Lubricating Coolant.

  • Page 41: Figure 5--5 Oil Filter

    FIGURE 5- - 5 - - OIL FILTER mounted on the compressor motor shaft; air is ex- hausted 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 Compressor, air/oil reservoir, separa- cooler.
  • Page 42 the oil system, remove the mixing valve and clean all parts thoroughly. OIL RESERVOIR -- The oil reservoir--separator com- Using an oil separator element at ex- bines multiple functions into one vessel. The lower half is the oil reservoir, providing oil storage capacity for the cessive pressure differential can system and the top portion, a primary oil separation cause damage to equipment.
  • Page 43 3. Disconnect, tag and lockout the power supply to COMPRESSOR OIL SYSTEM CHECK -- The follow- the starter. ing readings are based on ambient temperature of 80_F (27_C) with the system in good condition. The 4. Remove the minimum pressure/check valve (air/ compressor should be at operating temperature at the oil separator housing) cover.

  • Page 44: Section 6, Air Filter

    SECTION 6 AIR FILTER FIGURE 6- - 1 - - AIR FILTER STANDARD DUTY AIR FILTER (FIGURE 6--1) -- Re- Remove the air filter cover (FIGURE 6--1) and re- placement instructions are given in the following sec- move the old filter elements. tions: Filter Element and Filter Element Life.

  • Page 45: Section 7, Belt Drive

    SECTION 7 BELT DRIVE DRIVE BELT TENSIONING -- This compressor pack- age has an automatic drive belt tensioning system. The belts are kept at the correct tension by the spring (figure 7--1). In the upper end of the spring, the position of the pin indicates the correct tension on the belts.

  • Page 46: Figure 7--2 Removing Drive Sheave

    moved a little. This can affect the alignment of the sheaves. 9. Tighten the screws evenly. 10. Tap the bushing lightly with a drift, and retighten the screws. REPEAT THIS PROCEDURE SEV- ERAL TIMES TO MAKE SURE THE BUSHING AND SHEAVE ASSEMBLY IS TIGHT ON THE SHAFT.

  • Page 47: Figure 7--5 Belt Tension -- 5 V Section V--Belts

    Deflection Deflection Motor Force Pounds H.P. Belts (per belt) Inches 25/30 6 -- 8.5 (1.3 -- 1.9) 3/8 (9.5) 40/50 7 -- 10 (1.5 -- 2.2) 3/8 (9.5) FIGURE 7- - 5 - - BELT TENSION - - 5 V SECTION V- - BELTS 13- -8- -625 Page 38...

  • Page 48: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST -- Air Filter -- Operating conditions determine frequency cleaning operation will keep the exterior cooling sur- of service. See “Air Filter,” Section 6, page 35. faces clean and ensure effective heat dissipation. Every 150 Hours Operation Motor Lubrication -- Refer to Section 2, page 9, and Maintenance Schedule Chart below.

  • Page 49: 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 (if appliable). cause of overload.
  • Page 50 SYMPTOM POSSIBLE CAUSE REMEDY Compressor starts too slowly 1. Wye Delta switch time set 1. Contact your Gardner Denver too long. distributor. 2. Minimum Pressure/Check 2. Repair or replace. Valve is faulty. 3. Supply voltage is too low. 3. Check the supply voltage.
  • Page 51 4. Oil separator clogged. 4. Replace element. 5. Loose assembly. 5. Tighten all fittings and gaskets. 6. Foam caused by use of 6. Use Gardner Denver AEON incorrect oil. 2000, 4000 or 9000SP Lubricating Coolant. 13- -8- -625 Page 42...
  • Page 52 SYMPTOM POSSIBLE CAUSE REMEDY Oil Carry--Over (Continued) 7. Inoperative minimum 7. Replace seals in valve. pressure valve. 8. Operation at elevated 8. Reduce temperature. See discharge temperatures. High Discharge Air Temperature, page 41, this section. 9. Water condensate in oil. 9.

  • Page 53: Section 10, Parts List

    SECTION 10 PARTS LIST BARE COMPRESSOR Ref. Name of Part CYLINDER MAIN ROTOR SECONDARY ROTOR DISCHARGE BEARING HOUSING DRIVE SHAFT SEAL DISCHARGE END PLATE For Replacement Airend order Part Number 306EFD6013. See page 75. For Periodic Overhaul Kit order Part Number 307EFD6013. See page 75. 13- -8- -625 Page 44...

  • Page 54: Airend Group

    AIREND GROUP 13- -8- -625 Page 45...
  • Page 55 Order by Part Number and Description. Reference Numbers are for your convenience only. AIREND GROUP Ref. Name of Part Qty. Part No. STUD,AIR/OIL SEPARATOR ........EFC30899728 MINIMUM PRESSURE/CHECK VALVE ASSEMBLY .

  • Page 56: Inlet Valve Repair Parts

    Order by Part Number and Description. Reference Numbers are for your convenience only. INLET VALVE REPAIR PARTS 13- -8- -625 Page 47...
  • Page 57 Order by Part Number and Description. Reference Numbers are for your convenience only. INLET VALVE REPAIR PARTS Ref. Name of Part Qty. Part No. INLET VALVE ASSEMBLY ........EFC22330248 INLET VALVE SEAL KIT (ITEMS 1--6, 18, 19) .

  • Page 58: Minimum Pressure/Check Valve

    Order by Part Number and Description. Reference Numbers are for your convenience only. MINIMUM PRESSURE/CHECK VALVE 13- -8- -625 Page 49...
  • Page 59 Order by Part Number and Description. Reference Numbers are for your convenience only. MINIMUM PRESSURE/CHECK VALVE Ref. Name of Part Qty. Part No. MIN PRESS/CHECK VALVE HOUSING ......EFC03979868 MIN PRESS/CHECK VALVE ASSY KIT (ITEMS 2--20) .
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  • Page 76: Water Separator Assembly

    Order by Part Number and Description. Reference Numbers are for your convenience only. WATER SEPARATOR ASSEMBLY Ref. Name of Part Qty. Part No. MOISTURE SEPARATOR ........EFC81708999 HOSE FITTING .
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  • Page 80: Enclosure Group

    ENCLOSURE GROUP 13- -8- -625 Page 71...
  • Page 81 Order by Part Number and Description. Reference Numbers are for your convenience only. ENCLOSURE GROUP Ref. Name of Part Qty. Part No. ENCLOSURE GROUP ......... . . 300EFD4023 BASE, ENCLOSURE .

  • Page 82: Quiet Enclosure

    Order by Part Number and Description. Reference Numbers are for your convenience only. QUIET ENCLOSURE Ref. Name of Part Qty. Part No. QUIET ENCLOSURE ASSEMBLY ....... . . EFC03812103 QUIET ENCLOSURE SIDE ADD ON .

  • Page 83: Main Motor

    MAIN MOTOR MOTOR -- 25 HP, 230/460 VOLT (ABB) EFC89618809 MOTOR -- 30 HP, 230/460 VOLT (ABB) EFC89618929 MOTOR -- 40 HP, 230/460 VOLT (ABB) EFC89562189 MOTOR -- 50 HP, 230/460 VOLT (ABB) EFC89562469 13- -8- -625 Page 74...

  • Page 84: Repair Kits

    REPAIR KITS Name of Part Qty. Part No. ROUTINE MAINTENANCE KIT ........300EFD6013 ELEMENT, AIR FILTER .
  • Page 85 REPAIR KITS (Continued) Name of Part Qty. Part No. PNEUMATIC CONTROLS AND GAUGES ......308EFD6013 BLOW DOWN VALVE .

  • Page 86: Warranty

    LABOR TRANSPORTATION AND INSPECTION The Company will provide labor, by Company representative or Gardner Denver (the “Company”) warrants to each original retail authorized service personnel, for repair or replacement of any product purchaser (“Purchaser”) of its new products from the Company or its or part thereof which in the Company’s judgment is proved not to be as...
  • Page 87 1800 Gardner Expressway, Quincy, Illinois 62301 Telephone: (800) 682- -9868 FAX: (217) 224- -7814 Sales and Service in all major cities. For parts information, contact Gardner Denver, Master Distribution Center, Memphis, TN Telephone: (800) 245- -4946 FAX: (901) 542- -6159 Specifications subject to change without notice.

This manual is also suitable for:

Efd-30 hpEfd-40 hpEfd-50 hp

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