Related Manuals for Gardner Denver INTEGRA EFC99F
Summarization of Contents
Genuine Gardner Denver Compressor Parts and Support
Authorized Distributor Support Services
Services provided by authorized distributors, including parts, expertise, and emergency support.
Remanufactured Airends Program
Details on factory remanufactured airends, their availability, quality assurance, and warranty.
Section 1: General Information
Compressor Operation and Principles
Explains the rotary screw compressor, compression principle, and air flow system.
Lubrication, Cooling, and Sealing
Describes how oil is used for lubrication, cooling, and sealing within the compressor.
General Safety Precautions
DANGER Safety Warnings
Critical warnings indicating hazards that can cause severe injury, death, or property damage.
WARNING Safety Alerts
Alerts for potential severe injury, death, or equipment damage if warnings are ignored.
CAUTION Safety Advisories
Notices for minor injury or property damage risks if cautions are not observed.
Section 2: Installation
General Installation Procedures
Guidelines for unit receipt, inspection, and initial setup requirements.
Lifting and Unit Placement
Proper techniques for lifting and positioning the compressor unit safely.
Location and Environmental Considerations
Selecting optimal installation sites and accounting for environmental factors.
Cold Weather Installation
Cold Weather Operational Guidelines
Precautions and guidelines for installing units in cold environments to prevent freezing.
Piping and Air Receiver Requirements
Guidelines for inlet/discharge piping and the use of auxiliary air receivers.
Motor Lubrication and Grounding
Grounding Requirements
Procedures for grounding the compressor package according to electrical codes.
Electric Motor Lubrication Procedures
Recommended procedures and intervals for greasing electric motor bearings.
Section 3: Starting & Operating Procedures
Pre-Start Up Instructions
Essential checks and servicing required before operating a new compressor unit.
Air Filter and Piping Checks
Instructions for inspecting the air filter and ensuring proper piping connections.
Electrical and Grounding Checks
Verifying correct electrical wiring and proper grounding of the unit.
Starting and Stopping the Unit
Cold and Hot Unit Start-Up Procedures
Step-by-step guide for starting the compressor in both cold and hot conditions.
Daily Checks and Stopping Procedures
Routine checks to perform daily and the correct method for stopping the compressor.
Section 4: Controls & Instrumentation
General Description of Controls
Overview of the compressor's pre-wired controls, motor, and starter system.
AutoSentry® Operation Modes
Explanation of the AutoSentry controller and its different operating modes.
Control Devices Overview
Controller and Keypad Functions
Details on the AutoSentry controller, its functions, and the keypad interface.
Relief Valve Operation and Testing
Information on the pressure relief valve, its purpose, setting, and testing procedures.
Compressor System Monitoring Components
Oil Level and Pressure Monitoring
How to read the oil level gauge and understand minimum discharge pressure/check valve.
Inlet, Unloader, and Blowdown Valves
Descriptions of the inlet, magnetic unloader, and blowdown solenoid valves.
Pressure and Temperature Sensors
Function of system and reservoir pressure transducers and discharge temperature probes.
Control System Components Details
Reservoir Thermistor and Emergency Stop
Role of reservoir thermistor and proper use of the emergency stop pushbutton.
Control Transformer and Terminal Strip
Function of the control transformer and terminal strip for voltage conversion and connections.
Main Starter and Seal Replacement
Details on the main starter for motor protection and procedure for changing valve seals.
Section 5: Lubrication, Oil Cooler, Filter & Separator
Compressor Oil System Overview
Explanation of the oil system's function in cooling, lubricating, and sealing the compressor.
Recommended Lubricants and Specifications
Guidance on Gardner Denver AEON lubricants, their compatibility, and specifications.
Oil Change Intervals and Capacities
Approximate Oil System Capacities
Table showing oil refill capacities for different HP models.
Oil Change Interval Guidelines
Recommended oil change intervals based on discharge temperature and lubricant type.
Draining and Filling the Oil System
Draining and Cleaning the Oil System
Step-by-step instructions for safely draining and cleaning the compressor oil system.
Filling the Oil Reservoir
Procedures for adding oil to the reservoir, including cautions against overfilling.
Section 7: Belt Drive
Belt Tension and Alignment
Importance of proper belt tension and alignment for optimal drive performance.
Replacing Compressor Belts and Sheaves
Procedures for replacing drive belts and compressor sheaves.
Checking Belt Tension
Method for measuring and setting correct belt tension using a spring scale.
Section 8: Maintenance Schedule
Service Check List Overview
Summary of maintenance actions based on operating hours and controller indications.
Interval-Based Maintenance Tasks
Specific maintenance actions required at 8, 125, 1000, 4000 hours, and annually.
Section 9: Troubleshooting
Compressor Start-Up Issues
Common causes and remedies for compressors failing to start or starting slowly.
Operation and Cycling Problems
Troubleshooting issues like stopping after a short time, incorrect loading/unloading, and excessive cycling.
Troubleshooting Performance Issues
Low Delivery and High Temperature Issues
Diagnosing and resolving problems related to low air delivery and high discharge temperatures.
Excessive Oil Consumption
Troubleshooting causes and remedies for high oil consumption in the compressor.
Troubleshooting Oil Carryover
Causes of Oil Carryover
Identifying common reasons for oil carryover, such as reservoir overfilling or separator issues.
Troubleshooting Voltage Problems
Impact of High and Low Voltages
Explains how voltage variations affect compressor operation, motor life, and component stress.
Wiring and Connection Issues
Identifying potential problems with wiring adequacy, connections, and contactors.
Warranty Information
General Provisions and Limitations
Outlines general terms, limitations, and what is excluded from the product warranty.
Warranty Period by Component
Specifies the warranty duration for different parts like airends, motors, and other components.
Labor, Transportation, and Disclaimer
Details regarding labor costs, transportation, and the disclaimer of other warranties.
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