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Gardner Denver INTEGRA EFA99F, Operating And Service Manual

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Gardner Denver INTEGRA EFA99F Operating And Service Manual Download Page 1

GARDNER DENVER

®

13-8-639

Version:  00

June 8, 2004

INTEGRA

BASE-MOUNTED

COMPRESSORS

MODELS

EFA99F

5, 7-1/2 & 10 HP

OPERATING AND

SERVICE MANUAL

Summary of Contents for INTEGRA EFA99F

Page 1: ...GARDNER DENVER 13 8 639 Version 00 June 8 2004 INTEGRA BASE MOUNTED COMPRESSORS MODELS EFA99F 5 7 1 2 10 HP OPERATING AND SERVICE MANUAL ...

Page 2: ...uthorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Master Distribution Center 5585 East Shelby Drive Memphis TN 38141 Gardner Denver 1800 Gardner Expressway Quincy IL 62301 Phone 901 542 6100 800 245 4946 Phone 217 222 5400 Fax 901 542 6159 Fax 217 224 7814 REMANUFACTURED AIRENDS Whenever an ai...

Page 3: ...ndicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Warning is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION Caution is used to indicate the presence of a hazard which will or can cause minor personal i...

Page 4: ...red Airends 2 Foreword 3 Index 5 List Of Illustrations 7 Section 1 General Information 8 Section 2 Installation 14 Section 3 Starting Operating Procedures 22 Section 4 Controls Instrumentation 25 Section 5 Lubrication Oil Cooler Oil Filter Separator 45 Section 6 Air Filter 57 Section 7 Belt Drive 58 Section 8 Maintenance Schedule 63 Section 9 Troubleshooting 65 ...

Page 5: ...ox 26 Cooling Sealing And Lubrication 8 Daily Check 24 Decals 12 Discharge Service Line 18 Electric Motor Grease Recommendations 20 Regreasing Interval 21 Electrical Wiring 19 Emergency Stop 24 Enclosure 16 Foundation 16 General Information Section 1 8 Grounding 19 Inlet Line 18 Installation Section 2 14 Instrument Panel 28 Lifting Unit 14 Lubricant Recommended 45 Upgrade Procedure 49 Lubrication ...

Page 6: ...ructions For The Airpilot Electronic Controller 29 Remote Control Operation 33 Safety Precautions 10 11 Sealing Lubrication And Cooling 8 Separators Air Oil 54 Service Check List 63 Air Filter 63 Every 1000 Hours Operation 63 Every 125 Hours Operation 63 Every 1500 Hours Operation 63 Every 4000 Hours Operation 63 Every 8 Hours Operation 63 Every Year 63 Motor Lubrication 63 Service Menu 32 Startin...

Page 7: ...ilot Electronic Controller 29 Figure 4 4 Compressor Running Loaded 37 Figure 5 1 Flow Diagram 45 Figure 5 2 Approximate Oil System Capacities 47 Figure 5 3 Oil Change Interval 47 Figure 5 4 Oil Level Gauge Oil Fill And Oil Drain 51 Figure 5 5 Dew Point Chart F 52 Figure 5 6 Dew Point Chart C 52 Figure 5 7 Oil Filter 54 Figure 6 1 Air Filter 57 Figure 7 1 Belt Drive Tensioner 58 Figure 7 2 Removing...

Page 8: ...otors B As meshing continues more of the main rotor lobe enters the secondary rotor groove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volume reduction and pressure increase continues until the air oil mixture trapped in the interlobe cavity by the rotors passes the discharge port and is released t...

Page 9: ...pression 4 Inlet Valve Output control 5 Inlet Filter Filtering inlet air 6 Oil Separator Oil separation 7 Minimum Pressure Check Valve Check valve maintaining minimum pressure for oil flow to bearings 8 Pressure Relief Valve Protection against too high pressures 9 Oil Cooler Cooling of oil 10 Aftercooler Cooling of compressed air 11 Fan Cooling 12 Oil Filter Oil filtering 13 Instrument Panel Compr...

Page 10: ...thing not suitable for human consumption Do not loosen or remove the oil filler plug drain plugs covers the thermostatic mixing valve or break any connections etc in the compressor air or oil system until the unit is shut down and the air pressure has been relieved Electric shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any applicable loca...

Page 11: ... lockout and tagout before working on the unit this machine is automatically controlled and may start at any time An Excess Flow Valve should be on all compressed air supply hoses exceeding 1 2 inch inside diameter OSHA Regulation Section 1926 302 or local regulations Do not exceed the rated maximum pressure values shown on the nameplate Do not operate unit if safety devices are not operating prop...

Page 12: ... air et l huile sous pression entraîneront des blessures graves ou la mort Arrêter le compresseur verrouiller et étiqueter l alimentation et purger toute la pression du système avant de déposer les soupapes les capuchons les prises les raccords les boulons et les filtres El aire y el aceite bajo presión pueden ocasionar lesiones personales graves o la muerte Apague el compresor bloquee y rotule la...

Page 13: ...roper dimensions High voltage Electrical shock can cause personal injury or death Open main disconnect switch and disconnect all circuits before working on this control See wiring diagram Improper modification of equipment will cause severe personal injury or death Do not modify unit without written permission from manufacturer DANGER Las descargas eléctricas pueden ocasionar lesiones o la muerte ...

Page 14: ...nsporting methods must be used to prevent damage CAUTION Lift compressor unit by base only Do not use other places such as motor compressor or discharge manifold piping as lifting points DANGER The eyebolts or lugs provided on the motor are for lifting the motor only and should not be used to lift any additional weight All eyebolts must be securely tightened When lifting the motor the lifting angl...

Page 15: ...13 8 639 Page 15 Figure 2 2 OUTLINE UNIT PACKAGE 300EFA804 A Ref Drawing ...

Page 16: ...er possible install the unit near level Temporary installation may be made at a maximum 5 angle lengthwise or 5 sidewise Mounting bolts are not normally required However installation conditions such as piping rigidity angle of tilt or danger of shifting from outside vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform support for the base Belt alignment a...

Page 17: ...he unit be installed inside a shelter that will be heated to temperatures above freezing 32o F 0o C This will eliminate many of the problems associated with operating units in cold climates such as freezing in control lines and downstream of the cooler Refer to Engineering Data Sheet 13 9 411 for the advantages of using the heat recovered from rotary compressors This heat recovery could easily pay...

Page 18: ...mbination moisture separator and trap piped into the system down stream of the aftercooler CONTROL PIPING Control piping is not necessary since the rotary screw unit is factory wired and piped for the control system specified INLET LINE Where an inlet line is used between the air filter and the compressor it must be thoroughly cleaned on the inside to prevent dirt or scale from entering the compre...

Page 19: ...rds ELECTRICAL WIRING All of the electrical connections and controls are factory wired for the voltage specified on the order Verify that the available voltage source matches that shown on the compressor package nameplate before installing the compressor package It is necessary only to connect the package to the supply and ground of the branch circuit The connections to the compressor package are ...

Page 20: ...agout the unit from the power supply 3 Remove the relief plug and free hole of hardened grease 4 Wipe lubrication fitting clean and add grease with a hand operated grease gun 5 Leave the relief plug temporarily off Reconnect unit and run for about 20 minutes to expel the excess grease 6 Stop the unit Replace the relief plug 7 Restart the unit WARNING Rotating machinery can cause injury or death Op...

Page 21: ...IC MOTOR REGREASING INTERVAL Type of Service Typical Rating Relubrication Interval Standard One or Two Shift Operation 5 to 50 HP 3200 Hours Very Severe Dirty Locations High Ambient Temperature 104 F 40 C 5 to 50 HP 500 hours ...

Page 22: ...lubricant Use only genuine Gardner Denver filters designed and specified for this compressor DANGER Always stop the unit and release air pressure before removing oil filler plug Failure to release pressure may result in personal injury or death 2 Air Filter Inspect the air filter to be sure it is clean and tightly assembled Refer to SECTION 6 page 57 for complete servicing instructions Be sure the...

Page 23: ...than one revolution if possible Never allow motor to reach full speed WARNING The compressor unit s direction of rotation must be check every time the compressor is reconnected to the power supply 7 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 DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON T...

Page 24: ...ic start stop sequence built in You do NOT need to close the air service valve Closing the air service valve on start up or prior to shutdown will cause rapid cycling and could cause a high pressure shutdown 1 Turn the customer supplied main switch on 2 Push the Start button DAILY CHECK Refer to Maintenance Schedule Section 8 page 63 STOPPING THE UNIT 1 Push the Stop button 2 Wait approximately on...

Page 25: ...splay provide the operator with a logical and easily operated control of the compressor package and indication of its condition Figure 4 1 CONTROL SCHEMATIC AIRPILOT ELECTRONIC CONTROLLER The controller controls all the functions connected to the regulation of the compressor The unit adjusts the following parameters of the compressor s operation Discharge pressure regulating method Blowdown stoppi...

Page 26: ...ed into the controller the inlet control solenoid valve Item 1 Figure 4 1 page 25 closes the connection to the upper side of the inlet piston and the air oil reservoir and the inlet valve spring closes the inlet valve plate At the same time the blowdown valve Item 2 Figure 4 1 page 25 opens and the air oil reservoir is blown down The purge valve Item 2 Figure 4 1 page 25 is used for bleeding a sma...

Page 27: ...RNING 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 CAUTION The enclosure doors are connected to a shutdown switch that will not allow the compressor to operate without the complete enclosure in place Starting the compressor package 1 Turn the customer supplied main switch on 2 Push the start button Stopping...

Page 28: ...sic display 7 Display 8 Left upper segment of display 9 Left lower segment of display 10 Pressure indicator light 11 Temperature indicator light running temp dew point 12 Operating hour indicator light total hours loaded hours 13 Change oil light 14 Air filter indicator light 15 Air oil separator indicator light 16 Oil filter indicator light 17 Motor indicator light 18 Power indicator light 19 Loa...

Page 29: ... 4 2 page 28 The programming menus are accessed by simultaneously depressing the up arrow and the down arrow keys and holding for 5 seconds All indicator lights will light up and the display will start flashing The 3 different menus can then be chosen using the up arrow key The up arrow key and the down arrow key will increase or decrease displayed numeric values step through the top level menus o...

Page 30: ...ge oil Air filter light on 5 Replace air filter Oil separator light on 6 Replace air oil separator Oil filter light on 7 Replace oil filter No lights on Compressor running mode on display USER MENU To enter the User Menu from the basic display when the compressor is stopped simultaneously push the up arrow and the down arrow keys and hold for 5 seconds until all the indicator lights on the display...

Page 31: ...mmable This timer is factory set at 5 minutes Automatic start after power failure This mode is disabled by setting the value to 0 Other values define the starting delay of the compressor when power is restored recommend one 1 minute or longer The operating light flashes when automatic starting is programmable DANGER Automatic restarting can cause injury or death Open lockout and tagout main discon...

Page 32: ... set The factory recommends using Figure 5 3 page 47 as a guide Air filter interval The air filter light illuminates when the new service interval can be set for the air filter See Section 6 page 57 for change intervals Air oil separator interval The air oil separator light illuminates when the new service interval can be set for the air oil separator The factory recommends this be set at 4000 hou...

Page 33: ...entification number can be changed The number flashes quickly as its value is being changed Selecting the pressure control point The compressor s pressure control point can be changed here The text LOCAL indicates control by the compressor while the text PILOT means control by the MultiPilot system REMOTE CONTROL OPERATION Remote control operation is selected by turning the selector switch on the ...

Page 34: ...NTROLLER See AirPilot Electronic Controller page 25 for description Relief Valve A pressure relief valve s is are installed in the final discharge line and set to approximately 120 125 of the unit s full load operating pressure for protection against over pressure Periodic checks should be made to ensure its their operation The relief valve should be tested for proper operation at least once every...

Page 35: ...he unit stops unloads or is shutdown The valve incorporates a spring loaded piston which maintains approximately 65 psig in the air oil reservoir When the air pressure on the upstream air oil reservoir side of the valve rises above 45 psig the spring is overridden and the valve opens to full porting The valve does not require adjustment If the valve fails to function check the valve for dirt or bu...

Page 36: ...nvironment and the operating conditions Repair kits are available from your local authorized Gardner Denver distributor Inlet Valve Solenoid Figure 4 4 page 37 This valve controls the position of the inlet valve in response to signals from the controller When the inlet solenoid valve is energized after a delay of 2 seconds it allows the pressure to escape from below the inlet valve piston A partia...

Page 37: ...g unloaded running 2 Solenoid Valve Inlet Valve Opens and closed the intake valve 3 Pressure Transducer Transmits the discharge pressure signal 4 Shuttle Allows the pressure of the oil separator or the compressed air system the higher one to close the intake valve 5 Check Valve Unloading noise reduction by leading blow out air into intake ...

Page 38: ...n or pressure sensor fault Temperature light flashing Temperature alarm Temperature light flashing fast Temperature alarm causing shutdown Service light flashing Oil change service alarm Air filter light flashing Air filter replacement required Air filter light flashing fast Air filter indicator switch triggered Air oil separator light flashing Air oil separator replacement required Oil filter lig...

Page 39: ...13 8 639 Page 39 WIRING DIAGRAMS 3 PHASE ...

Page 40: ...13 8 639 Page 40 WIRING DIAGRAMS 3 PHASE ...

Page 41: ...13 8 639 Page 41 WIRING DIAGRAMS 3 PHASE ...

Page 42: ...13 8 639 Page 42 WIRING DIAGRAMS 1 PHASE ...

Page 43: ...13 8 639 Page 43 WIRING DIAGRAM 1 PHASE ...

Page 44: ...13 8 639 Page 44 WIRING DIAGRAM 1 PHASE ...

Page 45: ...or 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 AEON lubricants are available through your authorized Gardner Denver compressor d...

Page 46: ...CHECKING OIL LEVEL Figure 5 4 Page 51 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 Figure 5 4 page 51 If the oil level is above the max range the oil must be drained If the oil level is below the min range oil must be added ADDITION OF OIL BETWEEN CHANGES Oil must be added when the oil lev...

Page 47: ... 2 APPROXIMATE OIL SYSTEM CAPACITIES OIL CHANGE INTERVAL Recommended oil change intervals are based on oil temperature Figure 5 3 shows how the change interval is affected by temperature When operating conditions are severe very dusty high humidity etc it will be necessary to change the oil more frequently Operating conditions and the appearance of the drained oil must be surveyed and the oil chan...

Page 48: ...e drained oil and or the oil filter element are contaminated with dirt flush the entire system the reservoir oil cooler and lines Inspect the air oil separator element for dirt accumulation replace if necessary If a varnish deposit exists contact the factory for recommendations for removal of the deposit and prevention of varnish FILLING OIL RESERVOIR DANGER Air oil under pressure will cause sever...

Page 49: ...ll be of little benefit if done in a careless manner CAUTION Excessive oil carryover can damage equipment Never fill oil reservoir above the top of the site glass LUBRICANT UPGRADE PROCEDURE Upgrading to a longer life lubricant is essentially a very worthwhile practice The following are the primary steps to be completed when upgrading or changing the type of lubricant CAUTION Improper equipment ma...

Page 50: ...n about five minutes at temperature or until temperature stabilizes then shut down 5 Thoroughly drain machine 6 Change to a new filter and separator 7 Fill system with a full charge of the new lubricant 8 Machine should then be run normally however total run time after the initial changeouts should be 50 percent of normal anticipated service life of the new lubricant Drain all lubricant from syste...

Page 51: ...e moisture formation and compressor damage The compressor must be observed to ensure that it is operating properly The best method for detecting moisture is a disciplined lubricant sampling analysis program every 2 000 hours of operation If moisture is observed in the oil reservoir drain the moisture and correct the operating conditions to reduce moisture See Thermal Control Thermostatic Mixing Va...

Page 52: ...e along the bottom axis of the chart and then reading the appropriate pressure curve to determine the corresponding dew point temperature on the left axis of the chart The compressor discharge temperature must be maintained at a minimum of 10 F above this dew point temperature to prevent condensation accumulation in the lubricant reservoir These charts assume 100 relative humidity Dew Point Temper...

Page 53: ...ng 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 1 Stop unit and be...

Page 54: ...nd the top portion a primary oil separation means The reservoir also provides limited air storage for control and gauge actuation COMPRESSOR AIR OIL SEPARATOR Figure 5 1 page 45 Located in a separate housing consists of a renewable cartridge type separator element and provides the final removal of oil from the air stream Oil impinging on the inside of the separator element drains directly back int...

Page 55: ...ment 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 Shut down compressor relieve system of all pressure disconnect lockout and tagout power supply to the ...

Page 56: ...s 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 Air and Oil Discharge Temperature 170 F to 200 F 77 C to 93 C Check with a thermometer at the discharge housing Compressor Oil Inlet Temperature...

Page 57: ...zzle Direct air blast parallel to element pleats at a slight upward angle Do not point air blast directly at element 3 Inspect for rupture by placing a bright light inside the element The slightest rupture requires replacement of the element Filter Element Life The element should be replaced after eight cleanings or if visual inspection indicates a rupture crack or pin hole in the pleated media In...

Page 58: ...s held up to prevent belt damage during shipment Remove the shipping hardware to lower the motor to its operating position prior to starting the package Loosen locking nut and unthread the long set screw the majority of the way this lowers the motor and tighten the locking nut Then remove the screws clamping the vibration isolators on the airend sub base CAUTION Excessive belt tension can damage t...

Page 59: ...alignment 8 Replace the enclosure and close the top enclosure door CAUTION Interference between the fan and the orifice can damage equipment Be certain the orifice has even clearance around the fan before starting the unit REPLACING THE MOTOR SHEAVE 1 Disconnect tagout and lockout the power supply to the starter 2 Open the top enclosure door and remove the enclosure around the motor 3 Raise the mo...

Page 60: ... SHEAVE ON COMPRESSOR OR MOTOR 9 Clean the shaft and mount the sheave assembly Figure 7 4 When mounting the sheave assembly the bushing clamps to the shaft first the sheave can still be moved a little This can affect the alignment of the sheaves 10 Tighten the screws evenly 11 Tap the bushing lightly with a drift and retighten the screws REPEAT THIS PROCEDURE SEVERAL TIMES TO MAKE SURE THE BUSHING...

Page 61: ...nting bolt of the compressor sheave has a left hand thread The bolt can be loosened by giving the handle of the handle of the hex socket key a sharp blow with a hammer while holding the sheave in place using Gardner Denver tool EFC03476918 Remove the screw only about 7 Pull the sheave off of the rotor with a gear puller 8 Note the wear sleeve will come off with the sheave 9 Always replace both the...

Page 62: ... place with Gardner Denver tool EFC03476918 and tighten the left handed bolt to 60 ft lbs 80 Nm 15 Replace the old belts with new ones For proper belt life use only genuine Gardner Denver belts 16 Remove the locking pin Item 2 in Figure 7 1 page 58 and lower the motor The weight of the motor keeps the belts properly tensioned 17 Check the sheave alignment 18 Replace the enclosure and close the top...

Page 63: ...xterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow This cleaning operation will keep the exterior cooling surfaces clean and ensure effective heat dissipation Every 150 Hours Operation 1 Check change the air filter Every 1000 Hours Operation 1 Change oil filter element Every 4000 Hours Operatio...

Page 64: ...eck Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Strainer Orifices Change Compressor Lubricant AEON 4000 Check Relief Valve Check Condition of Hoses Check Operation of Condensate Removal Solenoid Valve Change Inlet Valve Seals See Oil Change Interval Chart Figure 5 3 page 47 for specific lubricant life Check change more often in dirty environments Also change when 8 psi P...

Page 65: ... Compressor starts but stops after a short time 1 High discharge temperature 1 See High Discharge Air Temperature this section 2 High separator high compressor temperature light flashing 2 See page 38 Controller Alarms 3 Blown fuse in starter control box 3 Replace fuse investigate if fuses continue to blow 4 Motor starter overload heaters or thermistor in motor tripped 4 Reset and investigate caus...

Page 66: ...rdner Denver distributor 2 Minimum Pressure Check Valve is faulty 2 Repair or replace 3 Supply voltage is too low 3 Check the supply voltage 4 Wrong oil type 4 Use Gardner Denver 2000 4000 or 9000SP Lubricating Coolant Compressor is low on delivery and pressure 1 Restricted air filter 1 Clean or replace filter 2 Sticking inlet valve 2 Inspect and clean inlet valve 3 Minimum pressure valve stuck cl...

Page 67: ...lve solenoid valve faulty 1 Replace solenoid valve 2 Air service valve closed 2 Open air service valve 3 Inlet valve plate seal is leaking 3 Replace 4 Aftercooler is frozen 4 Thaw out This machine cannot operate in temperature below 32 F 0 C 5 Faulty blowdown valve piston 5 Replace piston Excessive oil consumption 1 Oil carryover through lines 1 See Oil Carryover in this section 2 Oil leaks at all...

Page 68: ... this section 9 Water condensate in oil 9 Check oil reservoir temperature and if low change thermal mixing valve element to higher temperature Inlet Valve leaks oil after emergency stop 1 Inlet valve seal leaking 1 Replace seals in valve 2 Control line check valve failed 2 Replace check valve DANGER Air oil under pressure will cause severe personal injury or death Shut down compressor relieve syst...

Page 69: ...eration 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 overload relay will sense these and shut down the compressor to protect the motor If voltage is low while the compressor is off locate and correct the cause If the voltage drops low only while the compressor ...

Page 70: ... initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized service personnel for repair or replacement of any product or part thereof which in the Company s judgment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s...

Page 71: ...ervice Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all major cities For parts information contact Gardner Denver Master Distribution Center Memphis TN Telephone 800 245 4946 FAX 901 542 6159 Specifications subject to change without notice Copyright 1999 Gardner Denver Inc Litho in U S A http www gardnerdenver com mktg gardnerdenver com ...

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