Related Manuals for Gardner Denver EDF-KB
Summary of Contents for Gardner Denver EDF-KB
- Page 1 13–8–606 GARDNER DENVER 3rd Edition March, 1997 ELECTRA–SCREW STATIONARY BASE–MOUNTED COMPRESSORS MODELS EDF_KB – 60 HP EDF_LB – 75 HP EDH_MB – 100 HP OPERATING AND SERVICE MANUAL...
- Page 2 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: Factory: Gardner Denver Machinery Inc.
- Page 3 FOREWORD Gardner Denver Electra–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–...
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Page 4: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability and Performance with Genuine Gardner Denver Compressor Parts and Support Services ................ -
Page 5: Section 1, General Information
INDEX Addition of Oil Between Changes ....Change Air Filter LED ..... Air Control Components . -
Page 6: Section 6, Air Filter
INDEX Grounding ........Oil Change Interval . -
Page 7: Remanufactured Air Ends
INDEX System Pressure ......Motor Lubrication ......Programming Load–Unload Pressure Setpoints Oil Separator . -
Page 8: Section 2, Installation
LIST OF ILLUSTRATIONS Figure 1–1 Compressor Cycle ..............Figure 1–2 Starter Box . -
Page 9: Lubrication, Cooling And Sealing
SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSOR CYCLE COMPRESSOR – The Gardner Denver compres- Oil is injected into the cylinder to remove the heat of sor is a single stage, positive displacement rotary ma- compression and seal internal clearances. Volume re-... - Page 10 FIGURE 1–2 – STARTER BOX FIGURE 1–3 – PACKAGE – CONTROLLER & STARTERS FIGURE 1–4 – PACKAGE – DRIVE MOTOR & AIR FILTER 13–8–606 Page 2...
- Page 11 FIGURE 1–5 – PACKAGE – OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE, MINIMUM PRESSURE VALVE & CHECK VALVE 203EDF797 (Ref. Drawing) FIGURE 1–6 – PACKAGE – AIR/OIL FLOW DIAGRAM 13–8–606 Page 3...
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Page 12: 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 13 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, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
- Page 14 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–8–606 Page 6...
- Page 15 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–8–606 Page 7...
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Page 16: Installation, Section 2
SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- LOCATION – The compressor should be installed, age that may have been incurred during transit. Report whenever possible, in a clean, well–lighted, well–venti- any damage or missing parts as soon as possible. lated area with ample space all around for mainte- nance. -
Page 17: Installation For Cold Weather Operation
Minimum Air Flow* For Compression And Cooling – Cubic Feet/Minute (Cubic Meters/Minute) If the compressor unit base is raised HP (KW) Air Cooled Water Cooled above floor level, the space between the floor and the base bottom must be 60 – 100 HP 12,500 1,700 closed with solid material all around... -
Page 18: Moisture Separator/Trap
Refer to Engineering Data Sheet 13–9–411, available Use only Gardner Denver AEON 9000 SP lu- from an authorized Gardner Denver distributor, for the bricant. advantages of using the heat recovered from rotary Monitor the unit carefully during start–up and op- compressors. -
Page 19: Inlet Line
Length of Inlet Line Diameter of Pipe Size 0 to 10 Feet (0 to 3 Meters) ........Same as Compressor Inlet Opening 10 to 17 Feet (3 to 5 Meters) . -
Page 20: Line, Discharge Service
* (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY. FIGURE 2–7 – SERIES PIPING FIGURE 2–8 – PARALLEL PIPING Accessibility for inlet air filter servicing must be consid- blowdown valve piped to the outside with a pipe size the ered when relocating the filters from the unit to a remote same as the blowdown valve outlet connection. -
Page 21: Grounding
PARALLEL PIPING (FIGURE 2–8, page 12) – A sepa- GROUNDING – Equipment must be grounded in ac- rate water control valve is required to control the dis- cordance with Table 250–95 of the National Electrical charge air temperature. If a remote (externally Code. -
Page 22: Motor Grease Recommendations
ELECTRIC MOTOR GREASE RECOMMENDATIONS Standard High Service Temperature Worked Penetration ......... . . 265–296 220–240 Grease Viscosity, SSU At 100 F (38 C) -
Page 23: Prestart-Up Instructions
“ADD OIL” range. Do not mix different type Air Filter – Inspect the air filter to be sure it is clean oils. The unit is shipped filled with Gardner Denver and tightly assembled. Refer to Section 6, “Air Fil-... -
Page 24: Enclosure
System Pressure – Set the controls to the de- Run for approximately five minutes or until the sired load pressure. DO NOT EXCEED THE temperature stabilizes and then open the air ser- MAXIMUM OPERATING PRESSURE ON THE vice valve. COMPRESSOR NAMEPLATE. See Section 4, The unit is equipped with a minimum (65 psig, 4.5 Bars) pages 21 and 23, “Programming the Load–Unload pressure/check valve;... -
Page 25: High Discharge Temperature
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL – The Gardner Denver Electra–Screw enclosure. Note that motor nameplate current must be compressor is supplied with a factory mounted starter multiplied by .577 for wye–delta starters. Proper starter and complete controls as standard equipment. The... -
Page 26: Relief Valve
210EDF797 (Ref. Drawing) FIGURE 4–2 – INLET VALVE probe is located at the separator discharge and senses the temperature of the air at the oil separator. The microprocessor controller will shut the compressor When the relief valve opens, a stream down if the temperature sensed at either location ex- of high velocity air is released, result- ceeds 225 F (107 C). -
Page 27: Hourmeter
When the solenoid is energized, the blowdown valve closes, and allows the oil system to pressurize. Minimum Pressure/Check Valve (FIGURE 4–3) – An internal spring–loaded minimum pressure valve is used in the final discharge line to provide a positive pressure on the oil system even when the air service valve is fully open. -
Page 28: High Air Temperature Led
It is also used to extinguish any fault LED’s that are illu- minated. In addition, it is used in the procedure to adjust operating pressure. See “Programming the Load–Un- load Pressure Setpoints,” page 21. The LED is illumi- Any mode may be selected at any time nated whenever the unit is stopped for any reason EX- without stopping the compressor. -
Page 29: Pressure And Temperature Digital Readouts
readouts and LED’s are flashing, a power interruption has occurred, requiring the control panel to be reset. Programming The Load–Unload Pressure Set- Machine damage can occur with ex- points – Programming of the Load and Unload Pres- sure setpoints can only be accomplished with the unit tended operation after the “Change not running. - Page 30 Pressure: the current unload setpoint (adj. checked by pressing any of the three operat- 58–175 psig, 4.0 to 12.1 Bar) ing mode buttons. The correct rotation is clockwise. The starter will be momentarily energized giving a slight rotation that is short Temperature: indicates that the enough in duration to prevent reverse oil flow...
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Page 31: Lead-Lag Operation Of Two Compressors
back to the normal setup mode. The display Step 2: Operate one compressor in the “Auto Lead” should read “0” pressure in the left window, mode. This compressor will now be the and –––– current sump temperature in the “Lead” or “Base Load” compressor. right window. - Page 32 Operation at excessive discharge air pressure can cause personal injury or damage to equipment. Do not set un- load pressure above the maximum stamped on the unit nameplate. To adjust the subtractive pilot: With the unit off, loosen the locknut and back out the adjusting screw several turns so the subtrac- tive pilot will fully unload the compressor before the unload pressure setpoint of the microproces-...
- Page 33 NAMEPLATE CONTROL SYSTEM PRESSURE FULL LOAD OPERATING PRESSURE LOAD UNLOAD 100 PSI (6.9 Bars) 100 PSI (6.9 Bars) 108 PSI (7.5 Bars) 125 PSI (8.6 Bars) 125 PSI (8.6 Bars) 133 PSI (9.2 Bars) Load setpoint cannot be set within 8 psi (.6 Bar) of the unload setpoint.
- Page 34 208EDF546 (Ref. Drawing) FIGURE 4–10 – WIRING DIAGRAM – FULL VOLTAGE – DUAL CONTROL...
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Page 35: High Temperature Operation
OIL SPECIFICATIONS – The recommended com- AEON 4000. pressor lubricant is Gardner Denver AEON 4000 Lubri- cating Coolant which can be used for year–round op- eration except as noted in the “High Temperature Operation” paragraph below, or low temperature, see “Installation for Cold Weather,”... - Page 36 204EDF797 (Ref. Drawing) FIGURE 5–1 – FLOW DIAGRAM...
- Page 37 201EAP797 (Ref. Drawing) 218ECM797 (Ref. Drawing) FIGURE 5–2 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED 13–8–606 Page 29...
- Page 38 All materials used in Gardner Denver compressor units are compatible with AEON 9000 SP Lubricating Coolant. Use caution when selecting down- stream components such as air line lubricating bowls, gaskets and valve trim. AEON 9000 SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints.
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Page 39: Lubricant Change Procedure
age, the thermal mixing valve (H) remains on the pack- ADDITION OF OIL BETWEEN CHANGES must be age. Control group part number 200ECM4002 will be made when the oil level is in the red range on the gauge mounted on package at the factory. This group controls as read while the unit is on. -
Page 40: Moisture In The Oil System
Change to a new filter and separator. Fill the system with a full charge of the new lubri- cant, then reinstall drain plug. All materials used in Gardner Denver Machine should then be run normally, however, compressor units are compatible with... -
Page 41: Oil Change Interval
Operating conditions and the appear- ance 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 sam- ple be sent in at 100 hours on a new unit. -
Page 42: Oil Filter, Compressor
60, 75 & 100 HP 40 & 50 HP (45, 55 & 75 KW) Refill Capacity For Normal Oil Change ..5.5 U.S. Gallons 8.5 U.S. Gallons (32 Liters) Red to Yellow Range . -
Page 43: Oil Cooler, Compressor
Improper oil filter maintenance will cause damage to equipment. Replace filter element every 1000 hours of op- eration. More frequent replacement could be required depending on oper- ating conditions. A filter element left in service too long may damage equipment. Use only the replacement element shown on the filter tag or refer to the parts list for the part number. - Page 44 and/or salt in the cooling water supply. However, chemical treatment methods may be necessary in cer- tain instances to inhibit corrosion and/or remove dis- solved solids, to alter the water’s tendency to form scale deposits, or prevent the growth of microorgan- isms.
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Page 45: Oil Reservoir
FIGURE 5–10 – DEW POINT TEMPERATURE VS. AMBIENT TEMPERATURE (100% RELATIVE HUMIDITY) material or scale is likely, the use of a strainer in the in- let water line is recommended. WATER SHUTOFF VALVE – WATER–COOLED HEAT EXCHANGER (Optional Equipment) (FIGURE 5–1, page 28) – A magnetic solenoid–oper- ated water shutoff valve rated at 150 psig (10.3 Bars) water pressure should be mounted in the water outlet line after the oil cooler. -
Page 46: Inspection
Oil separator element life cannot be predicted; it will Be certain unit is completely off and that no air vary greatly depending on the conditions of operation, pressure is in the oil reservoir. the quality of the oil used and the maintenance of the Disconnect, tag and lockout power supply to the oil and air filters. -
Page 47: Oil Cooler Temperature Differential
Check that oil inlet pressure is correct or measure the Heat Exchanger) – The oil temperature differential de- differential between drains on the oil cooler shell. pends on the inlet water temperature and the water flow rate permitted by the water flow control valve setting. Oil Cooler Temperature Differential (Air–Cooled The oil inlet temperature is approximately the same as Radiator) –... - Page 48 Never use gaskets that won’t seal. Keep spare elements and gaskets on hand to re- Use only genuine Gardner Denver air duce downtime. Store elements in a filter elements on Gardner Denver protected area free from damage, dirt compressor units.
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Page 49: Inlet Tube
done by placing a bright light inside the element. tube when required by ramming a clean dry cloth through the tube. Wipe the inside of the filter body to Pressure drop through a filter with a freshly remove any dirt falling from the inlet tube before rein- cleaned element is below three (3) inches (76 stalling the element. - Page 50 SECTION 7 COUPLING (17 N–M) (37 N–M) (1.6 mm to 3.2 mm) FIGURE 7–1 – INSTALLATION OF COUPLING CUSHIONS Working through the coupling guard opening, cen- ter the coupling over the gap between the shafts, maintaining the gap as shown in FIGURE 7–1 be- tween the ends of the jaws on one coupling body Rotating machinery...
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Page 51: Maintenance Schedule, Section 8
SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. The “CHANGE AIR FILTER” display will Check for dirt accumulation on oil/aftercooler core flash to signal that the air filter requires servicing or faces and the cooling fan. -
Page 52: Trouble Shooting, Section 9
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. cause of overload. 4. -
Page 53: Trouble Shooting, Oil Carry-Over
3. Ruptured oil separator 3. Replace element. element. 4. Loose assembly. 4. Tighten all fittings and gaskets. 5. Foam caused by use of 5. Use Gardner Denver incorrect oil. AEON 4000 or 9000 SP Lubricating Coolant. 6. Inoperative minimum 6. Replace valve. - Page 54 SYMPTOM POSSIBLE CAUSE REMEDY Oil Carry–Over (Continued) 7. Operation at elevated 7. Reduce temperature. See discharge temperatures. High Discharge Air Temperature, page 45, this section. 8. Scavenge line check 8. Replace check valve. valve failure. 9. Water condensate in oil. 9.
- Page 55 SYMPTOM POSSIBLE CAUSE REMEDY “MOTOR OVERLOAD” 1. Running compressor at a 1. Lower pressure to nameplate. shutdown. pressure over nameplate pressure. 2. Incoming voltage low or 2. Consult your power company. high. 3. Imbalanced voltage 3. If imbalance exceeds 5%, (check phase to phase).
- Page 56 1. If fuse does not blow, check meter, starter coil, for shorted coils. or blowdown valve. Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13–8–606...
- Page 57 Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.