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Gardner Denver INTEGRA AIRSMART EFC99J Operating And Service Manual

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13-20-600
Version: 04
August 11, 2009
INTEGRA™
BASE-MOUNTED
COMPRESSORS
AIRSMART™ CONTROL
MODELS – EFC99J
20, 25, 30 HP
60 HZ
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver INTEGRA AIRSMART EFC99J

  • Page 1 13-20-600 Version: 04 August 11, 2009 INTEGRA™ BASE-MOUNTED COMPRESSORS AIRSMART™ CONTROL MODELS – EFC99J 20, 25, 30 HP 60 HZ OPERATING AND SERVICE MANUAL...

  • Page 2: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support 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...

  • 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 ......................1 Warning – Prohibition – Mandatory Label Information.................. 2 Safety Precautions ............................4 Index................................6 List Of Illustrations............................8 Section 1, General Information ........................

  • Page 7: Index

    INDEX Air Cooled Unit ..........11 Upgrade Procedure........55 Air Filter Lubrication Element............62 Motor ............16 Element Life..........63 Lubrication, Cooling And Sealing....... 9 Section 6............62 Lubrication, Oil Cooler, Oil Filter & Separator Standard Duty..........62 Section 5 ............51 Air Flow In Compressor System ......9 Air Receiver Maintenance Schedule Auxiliary ............14...
  • Page 8 Safety Precautions ..........4 Unit Cold............20 Sealing, Lubrication And Cleaning.....9 Unit Hot ............21 Separators Stopping The Unit ..........21 Air/Oil ............59 Service Check List ...........67 Trouble Shooting Air Filter ............67 Section 9 ............69 Every 1000 Hours Operation......67 Troubleshooting Voltage Problems....72 Every 125 Hours Operation......67 Every 4000 Hours Operation......67 Valve...

  • 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

    302EFC797-B (Ref. Drawing) Figure 1-2 – COMPRESSOR ILLUSTRATION...

  • 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 continuous efficiency, oil cooler cores must be periodically cleaned with either vacuum or compressed air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with clean water. For aluminum oil coolers, do not use any cleaning solution that is not compatible with aluminum.

  • 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° 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 Above 150 HP (112 KW)

  • 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 51. 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. 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 Adjust Menu” in Controller Operating and Service Manual.
  • Page 21 Enclosure - Check for damaged panels or doors. Check all screws and latches for tightness. Be sure doors are closed and latched. 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.
  • 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 (45 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

    SECTION 4, 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 Main Starter - This starter is used to provide control and overload protection for the main drive motor. Wiring diagrams for typical full voltage applications are illustrated on pages 29 thru 49. For Wye Delta and less starter applications, refer to the wiring diagram included in each control box enclosure. Overload protection is provided for each motor on full voltage and Wye Delta applications.

  • Page 30: Figure 4-3 - Wiring Diagram - Wye Delta 20, 25 & 30 Hp (200 & 460 Volt)

    307EBE546-D (Ref. Drawing) Figure 4-3 – WIRING DIAGRAM – WYE DELTA 20, 25 & 30 HP (200 & 460 VOLT) Page 1 of 2...
  • Page 31 307EBE546-D (Ref. Drawing) Page 2 of 2...

  • Page 32: Figure 4-4 - Wiring Diagram - Wye Delta 20, 25 & 30 Hp (230 Volt)

    315EBE546-A (Ref. Drawing) Page 1 of 2 Figure 4-4 – WIRING DIAGRAM – WYE DELTA 20, 25 & 30 HP (230 VOLT)
  • Page 33 315EBE546-A (Ref. Drawing) Page 2 of 2...

  • Page 34: Figure 4-5 - Wiring Diagram - Full Voltage 20, 25 & 30 Hp (460 Volt)

    308EBE546-D (Ref. Drawing) Page 1 of 2 Figure 4-5 – WIRING DIAGRAM – FULL VOLTAGE 20, 25 & 30 HP (460 VOLT)
  • Page 35 308EBE546-D (Ref. Drawing) Page 2 of 2...

  • Page 36: Figure 4-6 - Wiring Diagram - Full Voltage 20, 25 & 30 Hp (200 Volt)

    313EBE546-C (Ref. Drawing) Page 1 of 2 Figure 4-6 – WIRING DIAGRAM – FULL VOLTAGE 20, 25 & 30 HP (200 VOLT)
  • Page 37 313EBE546-C (Ref. Drawing) Page 2 of 2...

  • Page 38: Figure 4-7 - Wiring Diagram - Full Volt - 20 Hp (230 Volt)

    314EBE546-A (Ref. Drawing) Page 1 of 2 Figure 4-7 – WIRING DIAGRAM – FULL VOLT - 20 HP (230 VOLT)
  • Page 39 314EBE546-A (Ref. Drawing) Page 2 of 2...

  • Page 40: Figure 4-8 - Wiring Diagram - Full Voltage 25 & 30 Hp (230 Volt)

    317EBE546-A (Ref. Drawing) Page 1 of 2 Figure 4-8 – WIRING DIAGRAM - FULL VOLTAGE 25 & 30 HP (230 VOLT)
  • Page 41 317EBE546-A (Ref. Drawing) Page 2 of 2...

  • Page 42: Figure 4-9 - Wiring Diagram - Less Starter (200 & 460 Volt)

    309EBE546-D (Ref. Drawing) Figure 4-9 – WIRING DIAGRAM – LESS STARTER (200 & 460 VOLT) Page 1 of 2...
  • Page 43 309EBE546-D (Ref. Drawing) Page 2 of 2...

  • Page 44: Figure 4-10 - Wiring Diagram - Less Starter (230 Volt)

    316EBE546-A (Ref. Drawing) Page 1 of 2 Figure 4-10 – WIRING DIAGRAM – LESS STARTER (230 VOLT)
  • Page 45 316EBE546-A (Ref. Drawing) Page 2 of 2...

  • Page 46: Figure 4-11 - Wiring Diagram - Wye Delta (575 Volt)

    310EBE546-C (Ref. Drawing) Page 1 of 2 Figure 4-11 – WIRING DIAGRAM – WYE DELTA (575 VOLT)
  • Page 47 310EBE546-C (Ref. Drawing) Page 2 of 2...

  • Page 48: Figure 4-12 - Wiring Diagram - Full Voltage (575 Volt)

    311EBE546-C (Ref. Drawing) Page 1 of 2 Figure 4-12 – WIRING DIAGRAM – FULL VOLTAGE (575 VOLT)
  • Page 49 311EBE546-C (Ref. Drawing) Page 2 of 2...

  • Page 50: Figure 4-13 - Wiring Diagram - Less Starter (575 Volt)

    312EBE546-C (Ref. Drawing) Page 1 of 2 Figure 4-13 – WIRING DIAGRAM – LESS STARTER (575 VOLT)
  • Page 51 312EBE546-C (Ref. Drawing) Page 2 of 2...

  • Page 52: 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 53 HIGH TEMPERATURE OPERATION - If the discharge temperature is sustained between 200-210° F. for a period of more than four (4) hours due to continuing high ambient air temperature, use Gardner Denver AEON 9000SP Lubricating Coolant which is a superior synthetic lubricant. Short periods of up to four (4) hours of sustained discharge temperatures up to 210°...

  • Page 54: 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 55 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 56 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 57 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 58: Figure 5-4 - Oil Level Gauge, Oil Fill And Oil Drain

    OIL LEVEL GAUGE (Figure 5-4, page 57) - 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 below the min. range on the site glass. Drain oil only when the oil level is above the max.

  • Page 59: Figure 5-5 - Oil Filter

    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. Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation.
  • Page 60 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 61 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 62: Figure 5 6 - Oil Separator

    10. Replace the O-Ring, Item 5, Figure 5 6, page 61, 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, Item 6, Figure 5-1, page 61, and the cover of the valve. See “Changing Minimum Pressure/Check Valve Seals,”...

  • Page 63: 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 64 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. Do not oil this element.

  • Page 65: 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 66 of the sheave on the motor shaft to get proper alignment. 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 67: Figure 7-1 - Belt Tension - J Section Micro-V Belts

    Deflection Motor H.P. No. of Belts Force Pounds Deflection In Inches 6 – 8.5 6 – 8.5 6 – 8.5 Figure 7-1 – BELT TENSION – J SECTION MICRO-V BELTS 13-20-600 Page 66...

  • Page 68: 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 62. 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 51. If oil consumption is high, refer to “Excessive Oil Consumption,”...
  • Page 69 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 70: 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 relay tripped . cause of overload. Pressure in reservoir. Inspect blowdown valve. Emergency stop Release button.
  • Page 71 SYMPTOM POSSIBLE CAUSE REMEDY 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.
  • Page 72 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 73 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 75 For additional information contact your local representative or Gardner Denver Compressor 1800 Gardner Expressway, Quincy, Illinois 62305 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 224-7814 Specifications subject to change without notice. Copyright © 2009 Gardner Denver, Inc. Litho in U.S.A. Visit our Web Site: www.gardnerdenver.com...

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