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Summary of Contents for Gardner Denver INTEGRA EFB99A
- Page 1 13-8-619 ® GARDNER DENVER Version: 09 May 2, 2006 ™ INTEGRA BASE-MOUNTED COMPRESSORS MODELS – EFB99A & EFB99F 7.5, 10 & 15 HP OPERATING AND SERVICE MANUAL...
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Page 2: Remanufactured Airends
Your local authorized distributor maintains a large inventory of genuine parts and he is backed up for emergency parts by direct access to the Gardner Denver Master Distribution Center (MDC) in Memphis, Tennessee. -
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 ..............i Remanufactured Airends ..........................i Foreword ............................... ii Index................................iv List Of Illustrations............................vi Section 1, General Information ........................1 Section 2, Installation ............................ 7 Section 3, Starting &... -
Page 5: Index
INDEX Air Control Components........18 Lubrication Changing Minimum Pressure/Check Valve Motor ............12 Seals ............19 Lubrication Oil Cooler, Oil Filter & Separator .. 24 Inlet Valve .............18 Section 5 ............24 Minimum Pressure/Check Valve ....18 Lubrication, Cooling And Sealing....... 1 Solenoid Valve..........18 Air Cooled Unit ...........7 Maintenance Schedule Air Filter... - Page 6 Piping............14 Starting & Operating Procedures Rotation ............14 Section 3 ............14 System Pressure ..........15 Starting The Unit ..........15 Unit Cold............15 Relief Valve ............17 Unit Hot ............15 Stopping The Unit ..........16 Sealing, Lubrication And Cleaning.....1 Separator Thermal Control (Thermostatic Mixing) Valve . 31 Compressor Oil..........31 Troubleshooting Separator/Trap...
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Page 7: List Of Illustrations
LIST OF ILLUSTRATIONS Figure 1-1 – Compressor Cycle ........................1 Figure 1-2 – Compressor Illustration......................2 Figure 2-1 – Typical Compressor Room ....................... 8 Figure 2-2 – Air Flow Chart ........................... 8 Figure 2-3 – Cold Weather Installation ......................9 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 Illustration
300EFB797-A (Ref. Drawing) Figure 1-2 – COMPRESSOR ILLUSTRATION... - 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 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 212EAQ077 206EAQ077 218EAQ077 211EAQ077 207EAQ077 13-8-619 Page 5...
- Page 13 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13-8-619 Page 6...
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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 2-1 - Typical Compressor Room
WARNING 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 3000 cfm... -
Page 16: Figure 2-3 - Cold Weather Installation
CAUTION 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 17 Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000 SP lubricant. Monitor unit carefully during start-up and operation to be sure it is functioning normally.
- Page 18 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 right hand corner of the package when viewed from the control box end, viewed from the oil cooler side.
- Page 19 GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical Code. 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.
- Page 20 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)
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Page 21: Section 3, Starting & Operating Procedures
For instructions on checking the oil and the proper oil level, refer to “Compressor Oil Filter”, SECTION 5, page 29. 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 9000 SP is also available. - Page 22 WARNING Operation with incorrect motor rotation can damage equipment and cause oil eruption from the compressor inlet. When checking motor rotation, induce minimum rotation (less than one revolution if possible). Never allow motor to reach full speed. System Pressure - The discharge pressure of the unit is set at the factory. To change the discharge pressure, set the controls to the desired load pressure.
- Page 23 DAILY CHECK - Refer to “Maintenance Schedule,” SECTION 8 page 38. STOPPING THE UNIT: To stop compressor operation, place the switch in the OFF position. The oil reservoir will automatically blow down as the motor stops. Close the air service valve. 13-8-619 Page 16...
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Page 24: Section 4, Controls & Instrumentation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL - The electrical controls on the compressor package are prewired and require only connection to the building wiring. The standard package has all of the necessary controls for protection and fully automatic operation. OPERATION - The switch on the control box has an OFF position and an ON position. For normal operation, leave the power connected to the compressor continuously, and use this selector switch. -
Page 25: Figure 4-1 - Control Schematic
WARNING 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. 302EBA797-C (Ref. Drawing) Figure 4-1 – CONTROL SCHEMATIC AIR CONTROL COMPONENTS - All units incorporate the following air control components. See Figure 4-1 for schematic tubing diagram. - Page 26 Changing Minimum Pressure/Check Valve Seals 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. Tighten the nut down on the minimum pressure/check valve cover. Remove the 6 bolts holding the cover onto the separator housing.
- Page 27 The pressure switch starts and stops the compressor while in the automatic mode. The pressure input to this switch is the plant pressure, measured within the package. The switch is wired to an input of the electronic controller. Thermistors are located in the air system directly after the compressor and after the separator. These sense the temperature at these two locations, and are wired back to the electronic controller.
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Page 28: Figure 4-2 - Maximum Setpoint For Nema 4 Pressure Switch
The first adjustment, the load pressure, controls the pressure at which the compressor will start, see Figure 4-2). This is often referred to as the cut-in or reset pressure, and will be the minimum pressure while in automatic operation. For the most economical operation, set this as low as tolerable for the equipment operating from the compressed air. - Page 29 Install a jumper on the center pair of pins when it is necessary to have the compressor automatically restart after a power interruption. There will be a brief delay, then the controller will resume operation if the selector switch is in its ON position. This feature should only be enabled when the owner determines that it is safe to do so.
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Page 30: Figure 4-3 - Wiring Diagram
300EFB542-C (Ref. Drawing) Figure 4-3 – WIRING DIAGRAM... -
Page 31: Section 5, Lubrication, Oil Cooler, Oil Filter & Separator
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 9000 SP Lubricating Coolant which is a superior synthetic lubricant. Short periods of up to four (4) hours of sustained discharge temperatures up to 210°... -
Page 32: Figure 5-1 - Approximate Oil System Capacities
To add oil, follow these steps: 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. Wipe away all dirt around the oil filler plug. It is located by the oil filter. See Figure 1-2, page 2. Remove the oil filler plug and add oil as required to return the oil level to the top of the site glass. -
Page 33: Figure 5-2 - Oil Change Interval
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. Discharge AEON 4000 AEON 9000SP... - Page 34 DANGER Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. Wipe away all dirt around the oil filler plug. Remove the oil filler plug and add oil as required to return the oil level to the top of the site glass. Install the oil filler plug and operate the unit for about a minute allowing oil to fill all areas of the system.
- Page 35 WARNING All materials used in Gardner Denver compressor units are compatible with AEON 9000 SP Lubricating Coolant. Use caution when selecting downstream components such as air line lubricating bowls, gaskets and valve trim.
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Page 36: Figure 5-3 - Oil Level Gauge
306EBA797-A (Ref. Drawing) Figure 5-3 – OIL LEVEL GAUGE OIL LEVEL GAUGE (Figure 5-3) - The oil level gauge indicates the amount of oil in the oil reservoir. Read oil level only when unit is shut down and the air/oil mixture has separated. Add oil only when the oil level is at the bottom of the site glass. -
Page 37: Figure 5-4 - Air Flow Through The Reservoir, Air/Oil Separator & Minimum Pressure Check Valve
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. DANGER Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. - Page 38 THERMAL CONTROL (THERMOSTATIC MIXING) VALVE is installed in the system. This valve is used to control the temperature of the oil. On start-up with unit cold, the element is open to bypass, allowing oil to pass directly from the reservoir to the compressor during warm-up. As oil warms, the element gradually closes to the bypass allowing more of the oil from the cooler to mix with oil from the bypass.
- Page 39 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: DANGER Air/oil under pressure will cause severe personal injury or death.
- Page 40 COMPRESSOR OIL SYSTEM CHECK - The following readings are based on ambient temperature of 80° F (27° C) with the system in good condition. The compressor should be at operating temperature at the time of the checks. One-half hour of loaded operation is usually sufficient to reach level-out operating temperatures.
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Page 41: Section 6, Air Filter
SECTION 6 AIR FILTER Figure 6-1 – STANDARD DUTY AIR FILTER STANDARD DUTY AIR FILTER (Figure 6-1) - 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 42: 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 43 REPLACING THE COMPRESSOR SHEAVE AND SHAFT SEAL (Figure 7-1, page 35) Disconnect, lockout and tagout the power supply to the starter. Remove the guards. Using the adjusting screws, jack the motor base up to loosen the belt tension, Remove the belts. The mounting bolt of the sheave has a left hand thread.
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Page 44: Figure 7-2 - Belt Tension - J Section Micro-V Belts
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 45: 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 34. Motor Lubrication - Refer to SECTION 2, page 12. Every 8 Hours Operation Check the reservoir oil level - add oil if required. See SECTION 5, page 24. If oil consumption is high, refer to “Excessive Oil Consumption,”... - Page 46 MAINTENANCE SCHEDULE (See Detail Notes above) Maintenance Action Every 8 Every Every Every Every Every Hours 1000 4000* Year Hours Hours Hours Hours • Check/Change Air Filter ** • Change Oil Separator *** • Check Reservoir Oil Level • Check for Proper Load/Unload •...
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Page 47: 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. Compressor starts but High discharge See “High Discharge Air... - Page 48 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 9000 SP lubricating coolant. Inoperative minimum Replace seals in valve. pressure valve.
- Page 49 TROUBLESHOOTING AUTOSENTRY T ELECTRONIC CONTROLLER The electronic controller provides all of the control functions necessary to operate the compressor package. Five indicator lights on the electronic controller provide information on its operating status. Whenever unexpected operation occurs, carefully note which indicators are lit. GREEN POWER-ON INDICATOR This light indicates that power is supplied to the controller.
- Page 50 RED COMPRESSOR TEMPERATURE FAULT INDICATOR These indicators light only if shutdown conditions exist with thermistors used to sense temperatures. The shutdown conditions are (1) high temperature, (2) shorted thermistor or wiring, (3) open thermistor or wiring or (4) extreme low temperature. The indicator will be lit steadily while the condition exists, and flash after the condition is cleared.
- Page 51 If the pressure rises, but the Auto light stays lit steadily, check the adjustment and connections of the pressure switch. 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 52 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 53 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 224-7814 Sales and Service in all major cities. Specifications subject to change without notice. For parts information, contact Gardner Denver, Copyright © 2005 Gardner Denver, Inc. Litho in U.S.A. Master Distribution Center, Memphis, TN Telephone: (800) 245-4946 FAX: (901) 542-6159 http://www.gardnerdenver.com...