Gardner Denver INTEGRA AIRSMART EFC99J Operating And Service Manual Download Page 1

Page: 1 / 75

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

Summary of Contents for 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: ...ly formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor Authorized distributor service technicians are...

Page 3: ...mical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriate...

Page 4: ...low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Li...

Page 5: ...r oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any...

Page 6: ...rations 8 Section 1 General Information 9 Section 2 Installation 11 Section 3 Starting Operating Procedures 18 Section 4 Controls Instrumentation 24 Section 5 Lubrication Oil Cooler Oil Filter Separat...

Page 7: ...bricant Recommended 51 Upgrade Procedure 55 Lubrication Motor 16 Lubrication Cooling And Sealing 9 Lubrication Oil Cooler Oil Filter Separator Section 5 51 Maintenance Schedule Section 8 67 Moisture S...

Page 8: ...000 Hours Operation 67 Every 8 Hours Operation 67 Every Year 67 Motor Lubrication 67 Sheave Alignment 64 Starting Operating Procedures Section 3 18 Starting The Unit 20 Unit Cold 20 Unit Hot 21 Stoppi...

Page 9: ...ge 20 25 30 HP 200 Volt 35 Figure 4 7 Wiring Diagram Full Volt 20 HP 230 Volt 37 Figure 4 8 Wiring Diagram Full Voltage 25 30 HP 230 Volt 39 Figure 4 9 Wiring Diagram Less Starter 200 460 Volt 41 Figu...

Page 10: ...B As meshing continues more of the main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression...

Page 11: ...13 20 600 Page 10 Figure 1 2 COMPRESSOR ILLUSTRATION 302EFC797 B Ref Drawing...

Page 12: ...ir oil reservoir separator chamber and all piping and tubing may be at high temperature during and after operation LOCATION Figure 2 1 page 12 The compressor should be installed where it is protected...

Page 13: ...ON The rotary screw compressor requires no special foundation but should be mounted on a smooth solid surface Whenever possible install the unit near level Temporary installation may be made at a maxi...

Page 14: ...sure Service panels are provided for maintenance access Be sure to allow enough space around the unit for the panels to be removed Any of the enclosure panels may be removed by opening the latch and l...

Page 15: ...r unsheltered outside installations should be avoided where possible Installation next to a heated building where enough heat can be used to keep the compressor room above freezing will save many comp...

Page 16: ...ischarge line If a rotary screw unit is manifolded to another compressor be sure the other compressor has a check valve in the line between the machine and the manifold If a rotary screw and a recipro...

Page 17: ...following charts show recommended grease qualities and regreasing intervals for ball bearing motors For additional information refer to the motor manufacturer s instructions The following procedure sh...

Page 18: ...EGREASING 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 12 Months Up to 150 HP 112 KW 9 Months Se...

Page 19: ...t required intervals of the oil filter air filter and air oil separator is necessary to achieve maximum service and extended drain intervals of AEON 4000 lubricant Use only genuine Gardner Denver filt...

Page 20: ...tation less than one revolution if possible Never allow motor to reach full speed The compressor unit s direction of rotation must be check every time the compressor is reconnected to the power supply...

Page 21: ...Wait one minute or more before restarting The controller has an automatic start stop sequence built in You do NOT need to close the air service valve Closing the air service valve on start up or prio...

Page 22: ...nute The unit is equipped with a minimum 45 psig pressure check valve no special procedure to maintain the unit reservoir pressure is required DAILY CHECK Refer to Maintenance Schedule SECTION 8 page...

Page 23: ...n of the compressor the machine must be stopped and in the Ready mode Stop the compressor by pressing the Stop Reset button The front panel display should read READY on line 3 Next press the Enter but...

Page 24: ...at were made press the Enter button If the Stop Reset button is pressed the parameter changes will be lost the next time the compressor power is turned off Setting The Unload and Load Pressure After s...

Page 25: ...troller keypad Prior to starting the STOP RESET key must be pressed to place the controller into its READY state as indicated on the display Compressor operation may then be started by pressing the RU...

Page 26: ...ler Operating and Service Manual Figure 4 2 KEY PAD Relief Valve A pressure relief valve is installed in the final discharge line and set to approximately 120 125 of the unit s full load operating pre...

Page 27: ...ir pressure in its piston cylinder which is controlled by the AirSmart through the magnetic unloader solenoid valve When the top of the cylinder is pressurized the inlet opens for full air delivery Wh...

Page 28: ...dless of controller status It is located on the middle section of the control box door below the keypad This should be used for emergency purposes only use the keypad STOP RESET for normal controlled...

Page 29: ...imum Pressure Check Valve Seals 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 starte...

Page 30: ...13 20 600 Page 29 Figure 4 3 WIRING DIAGRAM WYE DELTA 20 25 30 HP 200 460 VOLT 307EBE546 D Ref Drawing Page 1 of 2...

Page 31: ...13 20 600 Page 30 307EBE546 D Ref Drawing Page 2 of 2...

Page 32: ...13 20 600 Page 31 Figure 4 4 WIRING DIAGRAM WYE DELTA 20 25 30 HP 230 VOLT 315EBE546 A Ref Drawing Page 1 of 2...

Page 33: ...13 20 600 Page 32 315EBE546 A Ref Drawing Page 2 of 2...

Page 34: ...13 20 600 Page 33 Figure 4 5 WIRING DIAGRAM FULL VOLTAGE 20 25 30 HP 460 VOLT 308EBE546 D Ref Drawing Page 1 of 2...

Page 35: ...13 20 600 Page 34 308EBE546 D Ref Drawing Page 2 of 2...

Page 36: ...13 20 600 Page 35 Figure 4 6 WIRING DIAGRAM FULL VOLTAGE 20 25 30 HP 200 VOLT 313EBE546 C Ref Drawing Page 1 of 2...

Page 37: ...13 20 600 Page 36 313EBE546 C Ref Drawing Page 2 of 2...

Page 38: ...13 20 600 Page 37 Figure 4 7 WIRING DIAGRAM FULL VOLT 20 HP 230 VOLT 314EBE546 A Ref Drawing Page 1 of 2...

Page 39: ...13 20 600 Page 38 314EBE546 A Ref Drawing Page 2 of 2...

Page 40: ...13 20 600 Page 39 Figure 4 8 WIRING DIAGRAM FULL VOLTAGE 25 30 HP 230 VOLT 317EBE546 A Ref Drawing Page 1 of 2...

Page 41: ...13 20 600 Page 40 317EBE546 A Ref Drawing Page 2 of 2...

Page 42: ...13 20 600 Page 41 Figure 4 9 WIRING DIAGRAM LESS STARTER 200 460 VOLT 309EBE546 D Ref Drawing Page 1 of 2...

Page 43: ...13 20 600 Page 42 309EBE546 D Ref Drawing Page 2 of 2...

Page 44: ...13 20 600 Page 43 Figure 4 10 WIRING DIAGRAM LESS STARTER 230 VOLT 316EBE546 A Ref Drawing Page 1 of 2...

Page 45: ...13 20 600 Page 44 316EBE546 A Ref Drawing Page 2 of 2...

Page 46: ...13 20 600 Page 45 Figure 4 11 WIRING DIAGRAM WYE DELTA 575 VOLT 310EBE546 C Ref Drawing Page 1 of 2...

Page 47: ...13 20 600 Page 46 310EBE546 C Ref Drawing Page 2 of 2...

Page 48: ...13 20 600 Page 47 Figure 4 12 WIRING DIAGRAM FULL VOLTAGE 575 VOLT 311EBE546 C Ref Drawing Page 1 of 2...

Page 49: ...13 20 600 Page 48 311EBE546 C Ref Drawing Page 2 of 2...

Page 50: ...13 20 600 Page 49 Figure 4 13 WIRING DIAGRAM LESS STARTER 575 VOLT 312EBE546 C Ref Drawing Page 1 of 2...

Page 51: ...13 20 600 Page 50 312EBE546 C Ref Drawing Page 2 of 2...

Page 52: ...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...

Page 53: ...FOR CHECKING OIL LEVEL Figure 5 4 page 57 Check the oil level when the compressor is shutdown and the oil air mixture has separated The oil should be visible between the min and max range shown in Fi...

Page 54: ...benefit if done in a careless manner 20 to 30 HP 15 22 kW Refill Capacity For Normal Oil Change 2 00 U S Gallons 8 5 Liters Bottom of Site Glass to Top of Site Glass 2 U S Quart 2 Liters Figure 5 2 A...

Page 55: ...rter 3 Stick the end of the drain tube into a suitable container such as a 5 gallon pail 4 Open the drain valve and allow oil to drain out of the air oil reservoir 5 Close the drain valve If the drain...

Page 56: ...OT OVERFILL as oil carryover will result The quantity of oil required to raise the oil level from the min range to the max range on the site glass is shown in Figure 5 2 page 53 Repeated addition of o...

Page 57: ...ir oil reservoir 2 Disconnect tag and lock out the power supply to the starter 3 Thoroughly drain system Drain oil from airend and cooler while hot Break low point connections and drain oil from pipe...

Page 58: ...trimental to compressor lubrication and could cause oil carryover If moisture is observed in the oil reservoir drain the moisture and correct the condition causing the accumulation See Compressor Oil...

Page 59: ...ter operation 1 Stop unit and be sure no air pressure is in the oil reservoir 2 Disconnect tag and lock out the power supply to the starter 3 Remove the spin on element 4 Clean the gasket face of the...

Page 60: ...removal of oil from the air stream Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity Oil collected outside the element is returned through tu...

Page 61: ...operation 1 Be certain the unit is off and that no air pressure is in the oil reservoir The compressor package will automatically blowdown in about 2 minutes 2 Close the air service valve located afte...

Page 62: ...80 F 71 C to 82 C Check with a thermometer at the discharge housing Compressor Oil Inlet Temperature 150 F to 165 F 66 C to 74 C Install a tee at the oil filter outlet and check with a thermometer Oil...

Page 63: ...umulation of dirt on the outside of the element Inspect every few days until experience determines the proper time interval for servicing To Service 1 Be certain the unit is off and that no air pressu...

Page 64: ...ed media Inspection should be done by placing a bright light inside the element Do not oil this element Never operate unit without element Never use elements that are damaged or ruptured Never use ele...

Page 65: ...e properly aligned the straight edge should touch the two outer edges of each sheave for a total of four points of contact Gaps between the outer edges of either of the sheaves and the straight edge i...

Page 66: ...ppage and premature belt failure Please see Figure 7 1 page 66 for proper belt tension Interference between the fan and the orifice can damage equipment Be certain the orifice has even clearance aroun...

Page 67: ...13 20 600 Page 66 Motor H P No of Belts Deflection Force Pounds Deflection In Inches 20 4 6 8 5 3 8 25 4 6 8 5 3 8 30 4 6 8 5 3 8 Figure 7 1 BELT TENSION J SECTION MICRO V BELTS...

Page 68: ...and the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling f...

Page 69: ...oir Oil Level Check for Proper Load Unload Check Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Strainer Change Compressor Lubricant AEON 4000 Check Relief Valve Check Conditio...

Page 70: ...starter overload relay tripped 4 Reset and investigate cause of overload Compressor does not unload or load 1 Improperly adjusted control 1 Refer to Control Manual 13 17 600 and adjust control 2 Air...

Page 71: ...id valve is faulty 6 Replace 7 Leaks in the compressed air system 7 Check for leaks fix any leaks found 8 V Belts broken 8 Replace 9 V Belts slipping 9 Test belt tensioning 10 Pressure limits incorrec...

Page 72: ...se Gardner Denver AEON 2000 4000 or 9000SP lubricating coolant 6 Inoperative minimum pressure valve 6 Replace seals in valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See Hig...

Page 73: ...tage Operation with lower voltages will reduce motor life and load capacity As voltages get further below the design range other symptoms may show up Low voltages may lead to high motor currents The o...

Page 74: ......

Page 75: ...Denver Compressor 1800 Gardner Expressway Quincy Illinois 62305 Customer Service Department Telephone 800 682 9868 FAX 217 224 7814 Visit our Web Site www gardnerdenver com Specifications subject to...

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