Gardner Denver 50 HP Operating And Service Manual
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Gardner Denver 50 HP Operating And Service Manual

Gardner Denver 50 HP Operating And Service Manual

Base-mounted compressors
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13-8-638
®
GARDNER DENVER
Version: 01
May 2, 2006
™
INTEGRA
BASE-MOUNTED
COMPRESSORS
MODELS – EFD99B
40 & 50 HP
OPERATING AND
SERVICE MANUAL

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  • Page 1 13-8-638 ® GARDNER DENVER Version: 01 May 2, 2006 ™ INTEGRA BASE-MOUNTED COMPRESSORS MODELS – EFD99B 40 & 50 HP OPERATING AND SERVICE MANUAL...

  • Page 2: Remanufactured Airends

    Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They are ready to respond and assist you by providing 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:...

  • 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 ..............ii Remanufactured Airends ..........................ii Foreword ...............................iii Index................................v List Of Illustrations............................vii Section 1, General Information ........................1 Section 2, Installation ............................ 7 Section 3, Starting &...

  • Page 5: Index

    INDEX Air Cooled Unit ...........7 Upgrade Procedure........28 Air Filter Lubrication Element............35 Motor ............12 Element Life..........36 Lubrication, Cooling And Sealing....... 1 Section 6............35 Lubrication, Oil Cooler, Oil Filter & Separator Standard Duty..........35 Section 5 ............24 Air Flow In Compressor System ......1 Air Receiver Maintenance Schedule Auxiliary ............10...
  • Page 6 Air/Oil ............32 Unit Cold............16 Service Check List ...........40 Unit Hot ............16 Air Filter ............40 Stopping The Unit ..........16 Every 1000 Hours Operation......40 Every 125 Hours Operation......40 Trouble Shooting Every 4000 Hours Operation......40 Section 9 ............42 Every 8 Hours Operation ......40 Troubleshooting Voltage Problems....

  • 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

    Figure 1-2 – COMPRESSOR ILLUSTRATION 300EFD797-A (Ref. Drawing)
  • 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 13-8-638 Page 5...
  • Page 13 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13-8-638 Page 6...

  • 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 4800 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 9000SP 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 left hand corner of the package when viewed from the control box end.
  • Page 19 WARNING 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. WARNING Failure to properly ground the compressor package could result in injury or death.
  • Page 20 ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30° C 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...

  • 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 24. 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 22 Rotation - Check for correct motor rotation by jogging the motor. See “Unit Setup Adjustments” in the Controller Operating and Service Manual. Compressor drive shaft rotation must be clockwise, standing facing the compressor sheave. WARNING Operation with incorrect motor rotation can damage equipment and cause oil eruption from the compressor inlet.
  • Page 23 STARTING THE UNIT - Observe the following starting procedures: WARNING After an emergency stop, be sure that the pressure in the air/oil reservoir is less than 5 psig. Wait one minute or more before restarting. WARNING The controller has an automatic start/stop sequence built in. You do NOT need to close the air service valve.

  • Page 24: Section 4, Controls & Instrumentation

    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 25: Figure 4-2 - Key Pad

    CONTROL DEVICES ® Controller - This compressor unit features the "AUTOSENTRY " 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.
  • Page 26 Oil Level Gauge - This gauge is located on the oil reservoir and indicates the oil level. See “Oil Level Gauge”, Figure 5-4, page 30, for how to read oil level. Minimum Discharge Pressure/Check Valve - An internal spring-loaded minimum pressure valve is used in the final discharge line to provide a positive pressure on the coolant system of the compressor even if the air service valve is fully open to atmospheric pressure.
  • Page 27 Discharge Thermistor (Figure 4-1, page 17) - This sensor is located directly in the compressor discharge. Its signal is used to monitor compressor temperature and shut down the compressor if a coolant problem is detected. Reservoir Thermistor (Figure 4-1, page 17) - This sensor is located in the reservoir/separator housing and is used to monitor temperature and shut down the compressor if temperature problems occur at the separator.
  • Page 28 Changing Minimum Pressure/Check Valve Seals DANGER Air/oil 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. Be sure the unit is completely off and that no air pressure is in the oil reservoir.

  • Page 29: Figure 4-3 - Wiring Diagram - Full Voltage

    303EFD546-D (Ref. Drawing) Page 1 of 2 Figure 4-3 – WIRING DIAGRAM – FULL VOLTAGE...

  • Page 30: Figure 4-4 - Wiring Diagram - Full Voltage

    303EFD546-D (Ref. Drawing) Page 2 of 2 Figure 4-4 – WIRING DIAGRAM – FULL VOLTAGE...

  • Page 31: 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 32 CAUTION Specific AEON™ lubricants are recommended for use in this equipment. Other lubricants may cause excessive carryover or compressor damage. Do not mix different types of lubricants or use inferior lubricants. Check the decal on the oil reservoir for lubricating coolant specification. HIGH TEMPERATURE OPERATION - If the discharge temperature is sustained between 200°...

  • Page 33: 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 34 DRAINING AND CLEANING OIL SYSTEM 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.
  • Page 35 3. Wipe away all dirt around the oil filler plug. 4. Remove the oil filler plug and add oil as required to return the oil level to the white range on the oil gauge. 5. Install the oil filler plug and operate the unit for about a minute allowing oil to fill all areas of the system.
  • Page 36 WARNING 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. AEON 9000SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints.

  • Page 37: Figure 5-4 - Oil Level Gauge, Oil Fill And Oil Drain

    OIL LEVEL GAUGE (Figure 5-4, page 30) - 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 in the bottom red range, below the white range on the gauge (you must use a flashlight).

  • Page 38: Figure 5-5 - Oil Filter

    Use only the replacement element shown on the filter tag or refer to the parts list for the part number. Use the following procedure to replace the filter element. Do not disturb the piping. 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.
  • Page 39 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 40 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 41 13. Open the air service valve. 14. Run the unit and check for leaks. 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.

  • Page 42: 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: DANGER Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. WARNING The air filter element can not be cleaned or reused.
  • Page 43 Install new air filter element and the air filter cover. Open the air service valve. 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.

  • Page 44: 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 45 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 46: Figure 7-1 - Belt Tension - 3Vx Belts

    Deflection Motor H.P. No. of Belts Force Pounds Deflection In Inches 6 – 8.5 6 – 8.5 Figure 7-1 – BELT TENSION – 3VX BELTS 13-8-638 Page 39...

  • Page 47: 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 35. 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 48 MAINTENANCE SCHEDULE (See Detail Notes above) Maintenance Action As Indicated by Every Every Every Every AutoSentry Every 8 1000 4000 Year Controller Hours Hours Hours Hours • Check/Change Air Filter ............. • • Change Oil Separator ............• Check Reservoir Oil Level **..........•...

  • Page 49: 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. Emergency stop Release button.
  • Page 50 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 51 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 52 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 53 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 54 For additional information contact your local representative or Gardner Denver Compressor and Pump Division, 1800 Gardner Expressway, Quincy, Illinois 62301 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 224-7814 Sales and Service in all major cities. Specifications subject to change without notice.

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