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Gardner Denver INTEGRA EFD99E User Manual

Gardner Denver INTEGRA EFD99E
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13-20-604
Version: 01
August 20, 2009
INTEGRA
BASE-MOUNTED
COMPRESSORS
AIRSMART CONTROL
MODELS – EFD99E
40 - 50 HP
OPERATING AND
SERVICE MANUAL
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Gardner Denver INTEGRA EFD99E Specifications

General IconGeneral
BrandGardner Denver
ModelINTEGRA EFD99E
CategoryAir Compressor
LanguageEnglish

Summary

General Information

Compressor Operation

Rotary screw compressor description.

Air Flow System

Path of air through the compressor.

Lubrication, Cooling, Sealing

Role of oil in the system.

Installation Guidelines

General Installation

Unit checks and damage reporting.

Lifting and Location

Proper lifting and site selection.

Air-Cooled Unit Requirements

Air flow and clearance needs.

Cold Weather Installation

Cold Weather Operation

Guidelines for cold climate operation.

Inlet Line Specifications

Requirements for compressor inlet lines.

Electrical and Motor Maintenance

Grounding Requirements

Electrical grounding procedures.

Motor Lubrication

Motor bearing regreasing procedure.

Starting and Operating Procedures

Prestart-Up Checks

Essential steps before operating a new unit.

Compressor Oil Checks

Procedures for checking oil levels.

Air Filter Service

Inspection and servicing of the air filter.

Unit Control and Operation

Rotation Check

Verifying correct motor and compressor rotation.

System Pressure Settings

Adjusting and monitoring system pressure.

Unit Cold Start

Steps for starting the compressor from a cold state.

Stopping the Unit

Procedures for safely shutting down the compressor.

Quick Start Guide

Setting Target Pressure

How to adjust the compressor's target pressure.

Setting Unload/Load Pressure

Adjusting unload and load pressure settings.

Controls and Instrumentation

AirSmart Control Operation

Detailed operation of the AirSmart controller.

Relief Valve Operation

Testing and maintenance of the pressure relief valve.

System Components

Emergency Stop

Use and location of the emergency stop button.

Main Starter

Role and wiring of the main motor starter.

Maintenance Procedures

Changing Valve Seals

Procedure to replace seals in the minimum pressure/check valve.

Compressor Oil System

Overview of the oil system and its functions.

Recommended Lubricant

Guidance on selecting appropriate compressor lubricants.

Oil System Management

High Temperature Operation

Lubricant recommendations for high temperatures.

Checking Oil Level

Steps for accurately checking the oil level.

Oil Change Intervals

Schedule for changing compressor oil based on temp.

Oil System Maintenance

Draining and Cleaning

Procedures for draining and cleaning the oil system.

Filling the Oil Reservoir

Steps for adding oil to the reservoir.

Filter and Separator Service

Compressor Oil Filter

Importance and maintenance of the oil filter.

Replacing Filter Element

Step-by-step guide for replacing the oil filter.

Separator Replacement and System Check

Separator Removal

Procedure for removing and inspecting the oil separator.

Oil System Check

Key readings for checking the compressor oil system.

Air Filter Service

Standard Duty Air Filter

Replacement instructions for the air filter.

Filter Element Life

Guidelines for filter element replacement.

Belt Drive Maintenance

Replacing Compressor Belts

Steps for removing and installing drive belts.

Sheave Alignment

Procedures for aligning motor and airend sheaves.

Belt Tensioning

Checking Belt Tension

Method for checking and adjusting belt tension.

Maintenance Schedule

Service Check List

Summary of maintenance actions and frequencies.

8-Hour Operations

Maintenance tasks required every 8 operating hours.

125-Hour Operations

Maintenance tasks required every 125 operating hours.

1000-Hour Operations

Maintenance tasks required every 1000 operating hours.

4000-Hour Operations

Maintenance tasks required every 4000 operating hours.

Annual Maintenance

Maintenance tasks required annually.

Troubleshooting

Failure to Start

Common causes and remedies for startup failures.

Stops After Short Time

Causes and solutions for premature unit shutdown.

Low Delivery and Pressure

Troubleshooting low air output and pressure.

High Discharge Temperature

Diagnosing and resolving high discharge air temps.

Excessive Oil Consumption

Causes and remedies for high oil usage.

Troubleshooting Voltage Problems

Voltage Impact on Operation

How voltage affects operation and troubleshooting steps.

Warranty Information

General Provisions and Limitations

Overall warranty terms and exclusions.

Warranty Period

Specific warranty durations for unit components.

Disclaimer

Legal disclaimers and limitations of liability.

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