Gardner Denver ESM 30 Original User Manual

Original User Manual
Screw Air Compressor

ESM 30-ESM 50
●
GB ●
CDN ●
USA Id. no. ZS1064358 / 00 - January 2010
Downloaded from www.dlmanuals.com

General Information
These compressors are for compressing atmospheric air and are not suitable for compressing any other gas. They are
designed and manufactured to give optimum performance with long life and reliability.
This manual gives the user all the information required to install and operate the compressors and carry out the regular
schedules for servicing and maintenance, which will ensure the maximum satisfactory service life.
Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of Gardner
Denver Companies and Distributors. If replacement parts are needed, the user should, in the first instance, contact the
local Gardner Denver Company or Distributor.
The information given in this manual was correct at the time of printing, however, as part of continuous development,
modifications to parts and procedures may be made without notice which could affect the servicing requirements of the
compressors. Before any servicing or maintenance work is undertaken the user is advised to contact the local Gardner
Denver Company or Distributor who is supplied with revised and up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL NUMBER and where
possible the YEAR of MANUFACTURE.
All pressure data given in this manual refer to overpressures (pressure gauge pressures) unless specified otherwise.
Maintenance
To ensure the continued trouble-free operation of the compressor unit it is important that periodic maintenance and
servicing is carried out in accordance with the information given in the ‘Maintenance’ section of this manual. To assist in
this matter your local Gardner Denver Company or Distributor can provide a number of optional maintenance agreements
to suit your requirements. These agreements provide the user with the expertise of our factory trained technicians and
the guarantee that only Genuine Gardner Denver parts will be used.
Warranty
The conditions of the Gardner Denver Warranty are set out in the Company’s standard Conditions of Sale available from
the Gardner Denver Company or Distributor supplying the machine.
USE ONLY GARDNER DENVER GENUINE PARTS. YOUR

WARRANTY COULD BE AFFECTED IF A SERVICE OR
REPAIR IS CARRIED OUT USING NON-GENUINE PARTS.
Deutsche Basis-BA: ZS1064357 / 00 3

Data sheet for users
Fig. 1
The values on the type plate are maximum values.
Your Gardner Denver distributor
Name:
Address: ______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
Telephone: Fax:
Contact: Spare Parts:
Service:

1. Foreword
1 For ew or d
1.1 Notes on the compressor 1.3 Maintenance

Gardner Denver screw compressors are the result of Carefully performed maintenance is imperative, this
many years of research and development. These ensures that your screw compressor can meet all the
prerequisites combined with high quality standards requirements placed upon it. It is therefore imperative to
guarantee the manufacture of screw compressors adhere to the specified maintenance intervals and to
providing a long service life, high reliability and cost- carry out the maintenance work with particular care,
effective operation. It stands to reason that all especially when the unit is utilized under harsh
requirements concerning environmental protection are operating conditions.
met.
Servicing
Please contact your authorized Gardner Denver dealer

1.2 Intended use in the case of malfunctions or when spare parts are
required. In the case of damage, our fully trained
The machine/unit has been constructed in accordance
personnel will ensure that a quick and proper repair is
with state-of-the-art technology and the recognized
carried out using genuine Gardner Denver spare parts.
safety regulations. Nevertheless, its use may constitute
Genuine Gardner Denver spare parts are manufactured
a risk to life and limb of the user or third persons or
utilizing state-of-the-art technology, thus guaranteeing
cause damage to the machine or to other material
the further reliable operation of the unit.
property, if
• it is not used as intended,
In case of queries
• it is operated by unqualified personnel,
• it is improperly modified or changed, Please enter the data on the nameplate of your
• the safety regulations are not observed. compressor into the nameplate shown in fig. 1 on
page 4. In the case of queries or spare parts orders,
Therefore, any person entrusted with the operation, please refer to the compressor type indicated on the
maintenance or repair of the machine must read and nameplate, the identification no. and the year of
follow the safety regulations. If required, this has to be construction. With this information at hand it can be
acknowledged by signature. guaranteed that you will receive the right information or
In addition, required spare parts.
• relevant accident prevention regulations,

• generally recognized safety regulations and
• national regulations 1.4 Notes
have to be observed. General
The machine/unit must only be used in technically These operating instructions are intended to familiarize
perfect condition and in accordance with its intended the user with the machine/unit and its intended use. The
use and the instructions set out in the operating instructions contain important notes on how to operate
manual, and only by safety-conscious persons who are the compressor safely, properly and cost-effectively.
fully aware of the risks involved in operating the Observing these instructions helps to avoid risks, to
machine/unit! Any functional defects, especially those reduce repair costs and downtimes and to increase the
affecting safety, have to be rectified immediately (or reliability and service life of the machine/unit.
rectified by others)!
The operating instructions have to be supplemented by
The machine/unit is designed exclusively for the the respective national rules and regulations regarding
generation of compressed air to power air-driven the prevention of accidents and environmental
devices. Using the machine/unit for purposes other than protection. They must always be available at the
those mentioned above is considered contrary to its location of the machine/unit. The operating instructions
intended use. The manufacturer/supplier cannot be held must be read and followed by any person carrying out
responsible for damage resulting from such use. The work in connection with the machine/unit, e.g.
risk of such misuse lies solely with the user. operation, including setting up, trouble-shooting in the
operation cycles, disposal of production waste, care,
Operating the machine within the limits of its intended service, and disposal of waste fuels and consumables,
use also involves observing the instructions set out in upkeep (maintenance, inspection, repair), transport.
the operating manual and complying with the inspection
and maintenance directives.

1. Foreword
Besides the operating instructions and the binding

regulations for the prevention of accidents, which are
valid in the country and place of operation of the
machine/unit, the generally recognized technical
regulations for safe and proper working have also to be
observed.
Guarantee
Operate this compressor only if you have an exact

knowledge of the machine taking into respect these
instructions.
Gardner Denver cannot be held responsible for the safe

operation of the machine/unit if it is used in a manner
which does not correspond to the intended use, or for
other applications which are not mentioned in these
instructions.
Warranty claims will not be accepted in the case of
• Operating errors
• Incorrect maintenance
• Wrong auxiliary materials
• Use of spare parts other than Gardner Denver
genuine spare parts
• Modifications and changes to the installation
The warranty and liability conditions of the general

terms and conditions of Gardner Denver will not be
extended by the notes above.
Any unauthorized change to the compressor unit/

station, or the installation of components not accepted
by the manufacturer (e.g. fine separator) will result in
the withdrawal of the CE mark. As a consequence, any
liability and warranty claims will not be accepted by the
manufacturer.
Safety regulations
Danger
The safety regulations in chapter 3 of the operating

instructions have to be strictly observed.
Technical changes
In the course of technical development we reserve the
right to modify the units without further notice.

2. Table of contents
2 Tab le of co nte nt s
1 Foreword ...............................................................................................................................................................................5
1.1 Notes on the compressor .............................................................................................................................................5
1.2 Intended use..................................................................................................................................................................5
1.3 Maintenance..................................................................................................................................................................5
1.4 Notes .............................................................................................................................................................................5
2 Table of contents .................................................................................................................................................................7
3 Safety regulations ...............................................................................................................................................................9
3.1 Identification of safety guidelines .................................................................................................................................9
3.2 General safety instructions...........................................................................................................................................9
3.3 Changes and modifications to the machine ..............................................................................................................10
3.4 Installation and normal operation...............................................................................................................................10
3.5 Special work/maintenance .........................................................................................................................................12
3.6 Warning of special dangers........................................................................................................................................14
3.7 Storage of compressors .............................................................................................................................................15
3.8 Symbols and explanations .........................................................................................................................................16
4 Design and functioning ....................................................................................................................................................20
4.1 Design of the unit ........................................................................................................................................................20
4.2 Schematic diagram .....................................................................................................................................................21
4.2.1 Schematic diagram ESM 30 ...........................................................................................................................21
4.2.2 Schematic diagram ESM 37-ESM 50 ............................................................................................................22
4.3 Oil circuit......................................................................................................................................................................23
4.4 Air circuit......................................................................................................................................................................23
4.5 System control ............................................................................................................................................................23
4.5.1 System control ESM 30 (Fig. 3 a) ..................................................................................................................23
4.5.2 System control ESM 37-ESM 50 (Fig. 3 b)....................................................................................................24
4.5.3 Manner of operation of the suction regulator ESM 45-ESM 50 ....................................................................26
5 Transport and installation ................................................................................................................................................27
5.1 Transport .....................................................................................................................................................................27
5.2 Installation ...................................................................................................................................................................28
6 Preparations for commissioning ....................................................................................................................................29
6.1 Cooling air volume/minimum cross ............................................................................................................................29
6.2 Compressed air connection........................................................................................................................................30
6.3 Electrical connection...................................................................................................................................................30
6.3.1 Electrical connection (EUROPE-Version only)..............................................................................................30
6.3.2 Electrical connection (USA/CANADA-Version only) .....................................................................................33
6.4 Oil level check .............................................................................................................................................................35
6.5 Sound pressure level ..................................................................................................................................................35
7 Commissioning ..................................................................................................................................................................36
7.1 First commissioning ....................................................................................................................................................36
7.2 Routine commissioning ..............................................................................................................................................38
7.3 Commissioning after malfunction...............................................................................................................................38
8 Service and maintenance.................................................................................................................................................39
8.1 Maintenance recommendations.................................................................................................................................39
8.2 Maintenance electric motor ........................................................................................................................................39
8.3 Maintenance schedule................................................................................................................................................40
8.4 Oil change ...................................................................................................................................................................41
8.5 Change of oil filter cartridge .......................................................................................................................................42
8.6 Change of the fine separator cartridge ......................................................................................................................42
8.7 Change of air intake filter............................................................................................................................................43
8.8 Safety valve.................................................................................................................................................................44
8.9 Connecting terminals in the switch cabinet/control transformer setting...................................................................45
8.10 Fittings .........................................................................................................................................................................45
8.11 General maintenance and cleaning ...........................................................................................................................45
8.12 Clean / change filter mat with cooling air inlet and control cabinet inlet ..................................................................45
8.13 Maintenance information and lubricant recommendations for stationary compressors..........................................46
9 Trouble-shooting ...............................................................................................................................................................47

2. Table of contents
10 Annex...................................................................................................................................................................................49
10.1 Technical Data ............................................................................................................................................................49
10.1.1 EUROPE version ESM 30-ESM 37................................................................................................................49
10.1.2 EUROPE version ESM 45-ESM 50................................................................................................................50
10.1.3 North America version ESM 30-ESM 37 .......................................................................................................51
10.1.4 North America version ESM 45-ESM 50 .......................................................................................................52
10.2 Layout plan..................................................................................................................................................................53
10.3 Declaration of conformity............................................................................................................................................55

3. Safety regulations
3 Safet y r eg ula tio ns
3.1 Identification of safety guidelines 3.2 General safety instructions

Gardner Denver is not liable for any damage or injury Organizational measures
resulting from the non-observance of these safety
The operating instructions must always be at hand at
instructions or negligence of the usual care and
the place of operation of the machine/unit!
attention required during handling, operation,
maintenance or repair, even if this is not explicitly In addition to the operating instructions, all other
mentioned in these operating instructions. generally applicable legal and other mandatory
regulations relevant to accident prevention and
If any of the regulations contained in these instructions
environmental protection must be adhered to and
-especially with regard to safety - does not correspond
passed on to others! These compulsory regulations
to the local legal provisions, the stricter of both shall
may also deal with the handling of hazardous materials
prevail.
or the issuing/wearing of personal protective equipment,
These safety regulations are general and valid for or traffic regulations.
various types of machines and equipment. It is
Instructions, including supervisory responsibility and
therefore possible that some references do not apply to
duty of notification for taking into account in-plant
the unit(s) described in these instructions.
factors, for example regarding work organization,
Danger sequences of operations, personnel assigned to certain
tasks, are to be added to the operating manual.
Passages marked with this sign indicate a possible
The personnel entrusted with working on the machine
danger to persons.
must have read the operating instructions and in
Important particular the chapter on safety regulations before
starting work. Reading the instructions after work has
Passages marked with this sign indicate a possible begun is too late. This applies especially to persons
danger to machines or part of machines. working only occasionally on the machine, e.g. for
setting up or maintenance.
Note
Check on a regular basis that the personnel are
Passages marked with this sign provide technical carrying out the work in compliance with the operating
information on an optimal cost-effective use of the instructions and that they are paying attention to the
machine. safety requirements!
For safety reasons, long hair must be tied back or
otherwise secured, garments must be close-fitting and
no jewellery - such as rings - may be worn. Injury may
result from being caught up in the machinery or from
rings catching on moving parts! As necessary or as
required by regulations, personal protective equipment
should be used.
Observe all safety and warning notices attached to the

machine/unit!
See to it that safety instructions and warnings attached
to the machine are always complete and perfectly
legible.
In the case of safety-relevant changes to the machine/

unit or its operating behaviour, stop the machine/unit
immediately and report the fault to the responsible
department/person!
Spare parts have to comply with the technical

requirements specified by the manufacturer. This can
always be ensured by using original spare parts.
Hydraulic hoses have to be changed within stipulated
and periodic intervals, even if no safety-relevant faults
have been detected!
Adhere to prescribed intervals or those specified in the
operating instructions for routine checks and
inspections!

For the execution of maintenance work, tools and The manufacturer is not liable for damage resulting
workshop equipment adapted to the task on hand are from the use of non-original parts or special
absolutely indispensable. accessories. This applies also to the installation and
setting of safety equipment and valves as well as to
The personnel must be made familiar with the location welding on structural or pressurized parts.
and operation instructions of fire extinguishers !
Observe all fire-warning and fire-fighting procedures!
Limit values (pressures, time settings, etc.) have to be 3.4 Installation and normal operation
permanently identified!
Installation
Selection and qualification of personnel; In addition to the general technical operation in
basic responsibilities accordance with the stipulations of the local authorities,
we would like to refer in particular to the following
Work on/with the machine/unit must be carried out by
regulations.
reliable personnel only. Statutory minimum age limits
must be observed! For the lifting of a compressor, a suitable lifting
mechanism is to be used, which meets the local safety
Employ only trained or instructed personnel and clearly
regulations. All loose or slew able parts must be safely
set out the individual responsibilities of the personnel
fixed before the machine can be lifted. It is strictly
for operation, set-up, maintenance and repair!
prohibited to stay in the danger zone of a lifted load.
Ensure that only authorized personnel work on or with
The correct method of lifting (according to the operating
the machine!
instructions of the load suspension device) has to be
Define the machine operator's responsibilities giving the ensured.
operator the authority to refuse instructions by third
All blind flanges, plugs, caps and bags with drying
persons that are contrary to safety regulations. agent have to be removed prior to the installation of the
Do not allow persons to be trained or instructed or pipes. Distributing pipes and pipe connections have to
persons taking part in a general training course to work be of the proper size and suitable for the relevant
on or with the machine/unit without being permanently operating pressure.
supervised by an experienced person!
The system must be set up on a level surface with full
Work on the electrical equipment of the machine/unit contact between its base frame and the supporting
must be carried out only by a skilled electrician in surface.
accordance with electrical engineering rules and
The system has to be installed in such a way that it is
regulations. adequately accessible and the required cooling is
Work on system elements such as hoses may only be guaranteed. Never block the air intake. Make sure that
carried out by personnel with special knowledge and the ingress of humidity via the intake air is kept to a
experience of hydraulics! minimum.
The air intake is to be located so that no hazardous

constituent (solvent vapour, etc., but also dusts and
3.3 Changes and modifications to the other hazardous material) can be sucked in. This
machine applies also to flying sparks.
The air intake is to be positioned so that no loose
Do not make any changes, modifications or
clothing of persons can be sucked in. Make sure that
attachments to the machine/unit, which could affect
the pressure line from the compressor to the after
safety, without the supplier's prior permission!
cooler or the air circuit can expand under heat and does
Unauthorized changes to the machine are not permitted not come into contact with inflammable material.
for safety reasons.
The pressure line connected to the air outlet of the
Original parts were especially designed for this system must be fitted stress-free. When connecting the
machine. We would like to point out that we have not compressor on the mains side to the compressed air
released and will not release parts and special system available at the customer‘s end, check the
accessories which have not been supplied by us. The operating temperatures and operating pressures
installation and/or use of such products can therefore required and examine the required connecting flange or
affect the active and/or passive safety. the connection thread for proper functioning.
In the case of connections by means of connecting

hoses, take appropriate measures to prevent whipping
of the loose end in the event that the hose connection
tears off.
10

If a remote control is used, the system must carry a If the room temperature can fall below zero, the
clearly visible sign with the following note: Attention! condensation drain system must be protected from
This installation is operated by remote control and can freezing, e.g. by means of a steam heater.
start up without prior warning!
If it is possible that the intake temperature of the air will
As an additional safety measure, persons, who start exceed, from time to time, the admissible maximum
remotely controlled systems, have to take sufficient specified in the operating instructions, a precooler with
safety precautions in order to ensure that nobody is condensate drain is to be installed before the dryer.
checking the system or working on it. For this, a label
with a corresponding warning notice has to be attached Tests or repair work on the coolant circuit may only be
to the remote control equipment. carried out in a well vented room. Never breath in
coolant vapour; if necessary, wear a breathing mask.
Compressed air and cooling water lines have to be Always wear protective goggles and gloves. If skin
clearly marked in line with the local regulations. comes into contact with coolants, rinse well with water.
Never take off or tear up clothes but rinse them well
If a system comprises several compressors, hand with water until the coolant is washed off; then see a
operated isolator valves have to be installed in order to doctor.
be able to shut off each machine individually. When
operating pressure systems, do not rely on the
effectiveness of start valves alone to isolate these Condensate drain
systems.
The drain hose for condensate discharge is to be
Safety equipment, protective covers or insulation must connected to the drains or to a collecting reservoir, if
not be removed or modified. Any pressure reservoir, local regulations prohibit direct discharge to the drains.
which is located outside the system, the permissible In connection with this, it must be taken into account
operating pressure of which is higher than the that the condensate from compressors with oil-
atmospheric pressure and which is fitted with two or lubricated pressure chambers can contain oil.
more pressure supply lines, has to be equipped with
additional safety equipment, which will automatically
prevent the admissible operating pressure from rising Normal operation
by more than 10%. Take the necessary precautions to ensure that the
The installed unit-specific safety valves only assume machine is used only when in a safe and reliable state!
the pressure safeguarding function of the compressor Operate the machine only when all protective
unit provided in currently valid standards and equipment, emergency shut-off equipment, sound-
regulations. proofing elements and extraction devices are in place
and fully functional!
For pressure components/systems mounted to the
connecting flange on the pressure side, a pressure Check regularly that
safety device (safety valve or similar) has to be installed • all means of protection are correctly fitted and fixed,
taking into account the weakest pressurized
component. • all hoses and/or pipes within the system are in good
condition, firmly fixed and do not chafe,
The min. and max. temperatures of +1 °C/33.8 °F and
+45 °C/113°F are also valid for the intake air. Pipes • there are no leakages (fuel, oil or coolant),
and/or other parts with a surface temperature higher
• all fittings are firmly tightened,
than 70 °C/158 °F have to be suitably identified and
shielded against touching. • all wires are connected correctly and are in good
condition,
Electrical connections must meet the local regulations.
Power units must be connected to earth and protected • all safety valves and other pressure relief
from short-circuits by means of fuses. mechanisms are in good order and not blocked by
e.g. dirt or paint,
Cold dryer • the safety mechanisms are fully functional.
Wherever possible, the cold dryer should be installed in If compressed air hoses are used, they must be of the
a place where the ambient air is as clean as possible proper size and suitable for the relevant operating
and where the temperatures never rise above or fall pressure. Do not use chafed, damaged or poor-quality
below the respective limit values as indicated in the hoses.
operating instructions. If required, the cooling air is to
be taken from a cleaner, cooler or warmer area via an Only use hose couplings and fittings of the right type
intake channel; depending on the size of the machine, and the correct size.
an additional fan could turn out to be necessary.
11

Before blowing through a hose or an air pipe ensure Brief the operating personnel prior to starting special
that the open end is positively held. A free end whips operations or maintenance work! Appoint a person to
and can cause injuries. supervise the activities!
Before decoupling a hose ensure that it is pressureless. Maintenance and repair work may only be carried out
under the supervision of a person who is qualified for
Refrain from any working method which is doubtful in this work.
terms of safety.
Oil losses result in a slippery floor. Therefore, always
Never play around with compressed air! clean the floor and the outside of the machine prior to
Never aim compressed air at your skin or at other starting the maintenance work.
persons! Checks, maintenance and repair work may only be
Never use compressed air to clean your clothing. carried out with the screw compressor being at rest and
depressurized. Protective equipment to be removed for
When using compressed air to clean equipment take this work, has to be refitted after completion of these
the utmost care and always wear protective goggles. activities. Operation of the machine without protective
equipment is not permitted. When working on a running
The compressed air generated by these compressors
screw compressor system, working clothes have to be
must never be used for breathing unless it has been
close-fitting.
conditioned for those applications in line with the “safety
requirements for respiratory air”. If the machine/unit is completely shut down for
maintenance and repair work, it must be secured
Never use the machine in an environment where
against inadvertent restarting:
inflammable or poisonous vapour can be sucked in.
• Lock the main command elements and remove the
Never operate the system at pressures and
key and/or
temperatures below or above the values indicated in the
technical data sheet. • attach a warning sign to the main switch.
The access panels, etc. have to be closed during Always use the correct tools for maintenance and repair
operation. work.
Persons in an environment or areas in which the sound Never use inflammable solvents or carbon tetrachloride
pressure is 85 dB(A) or higher have to wear ear to clean parts. Take precautions against poisonous
protectors. vapours from cleaning agents.
Check the machine/unit at least once per shift for visible In any work concerning the operation, conversion or
damage and faults! Report any changes (including adjustment of the machine and its safety-oriented
changes in the machine’s operating behaviour) to the devices or any work related to maintenance, inspection
responsible department/person immediately. If and repair, always observe the start-up and shutdown
necessary, stop and lock the machine immediately! procedures set out in the operating instructions and the
information on maintenance work.
In the case of malfunction, stop the machine/unit
immediately and lock it! Have any defects rectified Ensure that the maintenance area is adequately
immediately! secured.
Observe the start-up and stopping procedures and the To lower the risk of accidents, individual parts and large
control displays according to the operating instructions. assemblies being moved for replacement purposes
Before starting up or setting the machine in motion, should be carefully attached to lifting tackle and
ensure that nobody is at risk. secured. Use only suitable and technically correct lifting
gear and only utilize suspension systems with adequate
Do not cut off or remove extraction or venting facilities
lifting capacity. Never work or stand under suspended
while the machine is running.
loads!
During maintenance and when carrying out repair work,
cleanliness is very important. Avoid the ingress of dirt
3.5 Special work/maintenance
by covering parts and free openings with a clean cloth,
Carefulness paper or adhesive tape.
Observe the adjusting, maintenance and inspection After the completion of each repair, check that tooling or
activities and intervals set out in the operating loose parts have not been left in the or on top of the
instructions, including information on the replacement of machine, drive motor or drive equipment and ensure
parts and equipment. These activities may be carried that no cloth has been left inside these units.
out by skilled personnel only. Be careful when the screw compressor system is in
operation.
12

Maintenance/rectification of faults Avoid damage to the safety valves and other pressure
reducing components. Check in particular for clogging
The employer has to inform the employee of the caused by paint, oil carbon or the accumulation of dust,
dangers possibly arising during the repair and which could deteriorate the effectiveness of these
maintenance of the machine/unit as well as on how to components.
avoid them; the employee has to observe all measures
for safety at work. Safety equipment for the prevention Insulation or protective shielding, the temperature of
or elimination of danger has to be maintained regularly which may exceed 70 °C/158 °F and which could be
and functionally checked at least once a year. Faults erroneously touched by the personnel, must not be
observed have to be immediately rectified and/or removed before these parts have cooled down to room
reported to the responsible person. temperature.
Use only original spare parts. Check the accuracy of pressure and temperature
indicators at regular intervals. If the admissible
Only carry out maintenance and repair work when the tolerance limits have been exceeded, these devices
system is not in operation and the power supply have to be replaced.
disconnected. Ensure that the power unit cannot be
switched on inadvertently. Before removing or overhauling a compressor, a motor
or another machine, ensure that all moveable parts of a
Before removing or opening pressurized components, mass of more than 15 kg cannot move or roll away.
positively isolate any source of pressure and
depressurize the entire system. After completion of repair work, always verify that no
tools, loose parts or cloths have been left in or on the
Never weld near oil systems or carry out any other work machine, drive motor or drive equipment. Machines
requiring heat. Pressure reservoirs or components and performing a back and forward main movement have to
pipes containing oil have to be drained completely and be cycled at least once, rotating machines have to be
cleaned, for example by means of a steam jet, before cycled several times in order to ensure that there are no
beginning such work. mechanical faults in the machine or the drive member.
Never weld any pressure reservoir or change it in any Check the direction of rotation of the electric motors
way. during first commissioning and after each modification
of the electrical connections in order to prevent the
If work which produces heat, flames or sparks has to be compressor from being damaged.
carried out on a machine, the adjacent components
have to be protected by means of non inflammable The fastening of loads and the instructing of crane
material. operators should be entrusted to experienced persons
only. The person giving the instructions must be within
Before releasing the power unit for operation after sight or voice contact with the operator.
maintenance or overhaul, check that the operating
pressures, temperatures and time settings are correct For carrying out overhead assembly work always use
and that the regulating and shut-down equipment specially designed or otherwise safety-orientated
function properly. ladders and working platforms. Never use machine
parts as a climbing aid. Wear a safety harness when
Motor, air filter, electrical components and regulating carrying out maintenance work at greater heights.
equipment have to protected from the ingress of
humidity, e.g. when cleaning the system by means of a Keep all steps, handles, handrails, platforms, landings
steam jet. and ladders free from dirt, snow and ice! Clean the
machine, especially connections and threaded unions,
Under no circumstance must the sound-proofing of any traces of oil, fuel or preservatives before carrying
material be removed or modified. out maintenance or repair work! Never use aggressive
detergents! Use lint-free cleaning rags!
Never use etching solvents which could attack the
materials used. Before cleaning the machine with water or steam jet
(high pressure cleaner) or other cleaning agents,
If indicated or if there is any suspicion that an internal
cover/mask all openings which have to be protected
part of the machine has run hot, the machine has to be
from the ingress of water, steam or detergents for
shut down.
safety and/or functional reasons, in particular electric
In order to avoid an increase in the operating motors and switch cabinets.
temperature, check and clean the heat transfer surfaces
After cleaning, remove the covers/masking completely !
(cooling fins, intermediate cooler, water cooling jackets,
etc.) at regular intervals. Prepare a plan of the most Check all hydraulic oil lines for leakage, loose fittings,
favourable cleaning intervals for each machine. abrasion and damage after cleaning. Any defect must
be rectified immediately!
Always re-tighten screwed connections which have

been loosened for maintenance and repair work.
13

If the set-up, maintenance or repair require the Observe any existing national regulations if work is to
demounting of safety equipment, this equipment has to be carried out in small rooms.
be remounted and checked immediately after these
activities. Always check a correct power supply to the compressor
before commissioning. The voltage supply has to fulfill
Ensure that consumables and replacement parts are the requirements of EN60204-1/IEC60204-1 for such
disposed of in a safe and environmentally friendly kind of industrial equipment. Insufficient power quality
manner. could have a strong effect on health & safety and may
constitute a risk to life and limb of the user or third
persons or cause damage to the machine or also the
environment around.
3.6 Warning of special dangers
Electric energy Hydraulics, pneumatics
Use only original fuses with the specified current rating. Work on hydraulic equipment may only be carried out
Switch off the machine/unit immediately if trouble by persons with special knowledge and experience of
occurs in the electric system. hydraulics.
Work on the electrical system or equipment may only Check all lines, hoses and screwed connections
be carried out by a skilled electrician or by specially regularly for leaks and obvious damage. Repair
instructed personnel under the control and supervision damage immediately. High pressure jets of oil may
of such an electrician and in line with the relevant cause injury and fire.
electrical engineering rules.
Depressurize all system sections and pressure pipes
If regulations require, the power supply to parts of (hydraulic system, compressed-air system) which are to
machines and plants on which inspection, maintenance be removed in accordance with the specific instructions
and repair work is to be carried out must be cut off. for the assemblies concerned before carrying out any
Before starting any work, check the deenergized parts repair work.
for the presence of power and ground or short-circuit
them in addition to insulating adjacent live parts and Hydraulic and compressed-air lines must be laid and
elements. fitted properly. Ensure that no connections are
exchanged. The fittings, lengths and quality of the
The electrical equipment of the machines/units is to be hoses must comply with the technical requirements.
inspected and checked at regular intervals. Defects
such as loose connections or scorched cables must be
rectified immediately. Noise
Necessary work on live parts and elements must be Sound-proofing elements on the machine/unit have to
carried out in the presence of a second person who can be active during operation (i.e. sound-proofing panels
cut off the power supply in case of danger by operating closed, etc.).
the emergency shutdown or main power switch. Secure
Where necessary, wear the personal hearing protection
the working area with a red-and-white safety chain and
prescribed.
a warning sign. Use insulated tools only.
Noise, even at a low level, can cause nervousness and
Before starting work on high-voltage assemblies and
annoyance; over a longer period of time, our nervous
after having cut out the power supply, the feeder cable
system can suffer serious damage. We therefore
must be grounded, and components, such as
recommend a separate machine room in order to keep
capacitors, short-circuited with a grounding rod.
the noise of the machine away from the workshop.
• In order to consider all noise-relevant parameters
Gas, dust, steam and smoke
and to adequately protect the health of the operator,
Carry out welding, flame-cutting and grinding work on the European Regulation 2003/10/EC must be
the machine/unit only if this has been expressly satisfied completely by the user.
authorized, as there may be a risk of explosion and fire.
• In states outside the European Community, the
Before carrying out welding, flame-cutting and grinding respective noise protection directives must be taken
operations, clean the machine/unit and its surroundings into consideration.
from dust and other inflammable substances and make
Take care that the noise transmission through walls and
sure that the premises are adequately ventilated (risk of
frames does not result in too high a noise level in the
explosion)!
surrounding areas.
Adhere to the regulations valid for the place of
operation!
14

Oils, greases and other chemical substances
When handling oils, greases and other chemical

substances, observe the safety regulations for this
product! Be careful when handling hot fuels and
consumables (danger of burning or scalding)!
Rooms subject to explosion hazards
Danger
Compressor units must never be operated in areas

subject to explosion hazards!
(Exception: Special units with the corresponding
technical modifications)
3.7 Storage of compressors

All compressors are protected against corrosion at the
factory for transport and for brief storage before
commissioning.
If the compressors are to be stored for period

exceeding six months, additional precautions must be
taken.
Compressors which are to be shut down for a lengthy

period must also be protected from corrosion.
Since corrosion occurs more quickly in damp

atmospheres than in dry conditions, it is not possible to
specify a maximum permissible standstill time which will
apply in all cases.
Note
The following aspects must be taken into account for
storage of storing compressors.
The compressor should be stored in a dry building
which should be heated if possible.
This is particularly true during the months of winter.
If there is a risk that the temperature will fall or rise
above the limits of -10 °C/14 °F to +65 °C/149 °F , the
electrical controller must be removed and stored in
ambient temperatures of +5 °C/41 °F to +30 °C/86 °F.
Before commissioning the compressor all the electrical
and electronic components and units should be
checked for the ingress of water or condensation.
15

3.8 Symbols and explanations
Carefully read the operating manual before

commissioning or servicing this compressor.
Never breathe in compressed air from this system.
Never operate the unit with open doors or loose access

panels.
16

Warning: Hot surface
Warning: Pressurized part or system
Warning: This system can start up by means of a

remote control or automatically after a power
failure.
17

Warning: The system continues to run for 30 seconds

after pressing the O-key
Warning: Danger of electric shock
Attention: Lifting point
18

Attention: Check and, if required, re-tighten

connection terminals. For further details,
see the operating instructions.
Attention: Opening pressure safety valve = xx bar

(value "xx" see sticker on compressor)
19

4. Design and functioning
4 Desig n a n d f un cti oni ng
4.1 Design of the unit
Fig. 2
1 Intake filter 16 Oil temperature regulator 29 Fan protection panel

2 Intake regulator 17 Cooling air ventilator 30 Pressure relief for cooler
3 Electric motor 18 Cooling air inlet filter mat 31 Filter mat, cooling-air inlet, dryer
4 Screw compressor 19 Compressed air outlet (option)
5 Pressure reservoir 20 Base frame 32 Condensate connection (only for
6 Oil fine separator 21 Control keypad dryer option or for integrated
7 Oil filling port 22 EMERGENCY OFF push-button water-separator option)
8 Oil drain 23 Control cabinet 33 Heat-recovery connection (option)
9 Oil level indicator 24 Supply cable gland 34 Integrated refrigeration dryer
10 Oil filter 25 Final compression temperature (option)
11 Oil cooler sensor 35 Safety valve for optional
12 Safety valve 26 Network pressure sensor refrigeration dryer
13 Pressure holding and check valve 27 Final compression pressure 36 Condensate drain for optional
14 Air cooler sensor refrigeration dryer
15 Oil fine separator extractor 28 Opening for lifting gear
20

4.2 Schematic diagram
4.2.1 Schematic diagram ESM 30
Fig. 3 a
1 Intake filter 9 Safety valve 23 Oil level indicator

2 Intake regulator 10 Oil filter monitor (S5) 24 Intake filter monitor (S7)
2.1 Actuator 11 Oil filter 25 Fine separator monitor (S6)
2.2 Pressure control valve 12 Oil cooler 26 Cooling air ventilator
2.3 Controller block 13 Throttle 27 Intake monitor, visual
3 Electric motor 14 Check valve 28 Network pressure sensor (B1)
4 Compressor block 15 Pressure holding and check 29 Motor temperature (R1)
5 Final compression valve 30 3/2-way solenoid valve
temperature sensor (R2) 16 Compressed air after-cooler (control valve) (Y1)
6 Pressure reservoir 18 Final compression pressure 31 Blow-off valve
7 Fine separator sensor (B2) 32 Minimum pressure valve
8 Oil drain ball valve 22 Oil temperature regulator
21

4.2.2 Schematic diagram ESM 37-ESM 50
reacting pressure 50 mbar reacting pressure 50 mbar
operating pressure: 4,5 bar
reacting pressure: 1,2 bar

residual pressure: ca. 1.5 bar
throttle diameter: 1,1 mm
operating temperature: 55 °C [70 °C]
Fig. 3 b
1 Intake filter 8 Oil drain ball valve 20 Control/blow-off valve(Y4)
2 Intake regulator 9 Safety valve 21 Blow-off valve
2.1 Actuator 10 Oil filter monitor (S5) 22 Oil temperature regulator
2.2 Pressure control valve 11 Oil filter 23 Oil level indicator
2.3 Check valve 12 Oil cooler 24 Intake filter monitor (S7)
2.4 Controller block 13 Throttle 25 Fine separator monitor (S6)
3 Electric motor 14 Check valve 26 Cooling air ventilator
4 Compressor block 15 Pressure holding and check valve 27 Intake monitor, visual
5 Final compression temperature 16 Compressed air after-cooler 28 Network pressure sensor (B1)
sensor (R2) 18 Final compression pressure 29 Motor temperature (R1)
6 Pressure reservoir sensor (B2)
7 Fine separator 19 Control valve (Y1)
22

4.3 Oil circuit 4.5 System control

The oil flows from the pressure reservoir (- 6 - Fig. 3) 4.5.1 System control ESM 30 (Fig. 3 a)
into the oil thermostat (- 22 - Fig. 3). With oil tempera-
tures < 55 °C/131 °F the oil flows via the by-pass of the (See also operating instructions for the compressor
oil cooler directly into the oil filter (- 11 - Fig. 3) and is control GD Pilot MK)
then injected into the screw compressor (- 4 - Fig. 3).
With oil temperatures of between 55 °C/131 °F and Standstill of the system
70 °C/ 158 °F the oil flow is divided and fed into the oil
• If the plant is shut down, the suction controller (-2-)
cooler (- 12 - Fig. 3) and the by-pass.
is closed by a pressure spring in the adjusting
With oil temperatures above 70 °C/158 °F the entire oil cylinder.
flow is directed via the oil cooler through the oil filter into • The solenoid valve (- 30 - (Y1)) is deenergised.
the screw compressor.
• The oil separator vessel (-6-) is released via valve
The oil separated by the oil separator element (-21-) to atmospheric pressure.
(- 7 - Fig. 3) is fed through an oil scavage line to the
screw compressor.
Starting the system
The entire oil circulation is based on a differential
pressure in the system. Considering the pressure • The motor starts up in the Y-mode.
difference of approx. 2 bar/29 PSI within the oil circuit,
the oil is then injected into the screw compressor with • The intake regulator is closed.
approx. 8 bar/116 PSI at a reservoir pressure of e.g. • The compressor aspires a certain amount of air
10 bar/145 PSI. through a bypass valve. Pressure builds up in the
When the screw compressor is in the off-load mode, a reservoir.
sufficiently high pressure differential and thus the • The oil supply of the screw compressor takes place
required oil injection quantity is achieved owing to the through a drop in pressure between the oil separator
fact that when the intake regulator (- 2 - Fig. 3) is vessel and the injection spot in the screw
closed, a vacuum pressure occurs in the intake compressor.
connection and at the place of injection, and an
overpressure of approx. 15. bar/22 PSI (residual • If the drive motor is switched over to Δ operation,
pressure) in the reservoir. the magnetic valve switches over (-30-(Y1) since it
is supplied with current.
• The air circulated in the system streams over the

solenoid valve (-30- (Y1)) in the upper control area
of the operating cylinder (-2.1-). Valves (-31-) and
4.4 Air circuit (-32-) are closed and the lower control space of the
adjusting cylinder is ventilated.
The intake air passes through the intake filter (-1- Fig.
3) and the intake regulator (- 2 - Fig. 3) into the screw • The pressure control valve (- 2.2 -) in the intake
compressor (- 4 - Fig. 3). During the compression regulator (- 2 -) opens.
process, the intake air is cooled via the injected oil, and
the developed air/oil mixture flows tangentially into the • At a reservoir pressure of approx. 4.5 bar/65 PSI the
pressure reservoir (oil reservoir) (- 6 - Fig. 3). After pre- pressure holding and check valve (- 15 -) opens.
separation and subsequent fine separation by the • Compressed air is now delivered into the consumer
separator element (- 7 - Fig. 3), the compressed air with network.
a low oil content is fed via the minimum pressure valve
(- 15 - Fig. 3) and the air cooler (- 16 - Fig. 3) into the • The system is now in load running mode.
consumer network.
Stopping the system
• To de-energise the solenoid valve (- 30 - (Y1) and
press the OFF push-button on the keypad of the
compressor control GD Pilot MK.
• The pressure valve (-2.2-) in the suction controller
(-2-) closes and the tank is relieved to atmospheric
pressure via the minimum pressure valve (-32-).
• After 30 seconds, the drive motor (- 3 -) and the
cooling air ventilator motor (- 26 -) are shut down.
23

Automatic operation (open-close operation) 4.5.2 System control ESM 37-ESM 50

• When the pressure reaches the upper switching (Fig. 3 b)
point set on the network pressure sensor (-28 - (See also operating instructions for the compressor
(B1)), solenoid valve (- 30 - (Y1)) is deenergised.
control GD Pilot MK)
• The pressure valve (-2.2-) closes because the lower
control space of the adjusting cylinder (-2.1.-) is Danger
relieved by the deenergised valve (-30-(Y1)) the
The lower control area of the operating cylinder
upper control space is impinged with pressure via
(2.1) is generally pressurised (even when the
the valve (-32-).
system is at a standstill). Before working on the
• The oil separator tank is relieved to no-load suction regulator this must be bled by carefully
pressure (residual pressure) via the two valves (-31- unscrewing the return valve (2.3).
and -32-).
• The screw compressor is now running in the offload
mode. Standstill of the system
• The cooling air ventilator (- 26 -) is switched on or • During plant standstill the suction regulator (-2)
off in dependence upon the final compression should be closed via pressurisation in the lower
temperature. control area of the operating cylinder (-2.1-).
• When the pressure at the network pressure sensor • Solenoid valves (- 19 - (Y1) and - 20 - (Y4)) are
(- 28 - (B1)) does not fall to the set lower switching deenergised.
point within the set motor run-on time (e.g. 120 • The oil separator vessel (-6-) is released via the
seconds), the drive motor (- 3 -) and the cooling air relief valve (-21-) to atmospheric pressure.
ventilator motor (- 26 -) are shut down and the
system is depressurised to atmospheric pressure.
Starting the system
• The system is now in the “stand-by” mode and can
restart at any time when the network pressure falls • The motor starts up in the Y-mode.
to the lower switching point (see section “Starting of
• The intake regulator is closed.
the system”).
• The compressor aspires a certain amount of air
• When the pressure at the network pressure sensor
through a bypass valve. Pressure builds up in the
(- 28 - (B1) falls to the preset lower switching point
reservoir.
before the set motor run-on time has elapsed,
solenoid valve (- 30 - (Y1)) is energised again. • The oil supply of the screw compressor takes place
through a drop in pressure between the oil separator
• The unit now changes over to on-load operation.
vessel and the injection spot in the screw
compressor.
• When switching the drive motor over to Δ-mode,

switch the solenoid valves (-19-(Y1) and 20 (Y4) as
these are supplied with power.
• The air circulated in the system streams over the

solenoid valve (-20- (Y4)) in the upper control area
of the operating cylinder (-2.1-). The relief valve
(-21-) is closed.
• The lower control area of the operating cylinder
(-2.1-) is blocked and bled by the solenoid valve
(-19- (Y1)) from the oil separator vessel.
• The pressure control valve (- 2.2 -) in the intake
regulator (- 2 -) opens.
• At a reservoir pressure of approx. 4.5 bar/65 PSI the
pressure holding and check valve (- 15 -) opens.
• Compressed air is now delivered into the consumer

network.
• The system is now in load running mode.
24

Stopping the system
• To de-energise the solenoid valves (- 19 - (Y1) and

- 20 - (Y4)) press the OFF push-button on the
keypad of the compressor control GD Pilot MK.
• The pressure control valve (- 2.2 -) in the intake
regulator (- 2 -) closes and the pressure reservoir is
unloaded to atmospheric pressure.
• After 30 seconds, the drive motor (- 3 -) and the
cooling air ventilator motor (- 26 -) are shut down.
Automatic operation (open-close operation)
• When the pressure reaches the upper switching

point set on the network pressure sensor (-28 -
(B1)), solenoid valves (- 19 -(Y1) and - 20 - (Y4))
are deenergised.
• The pressure control valve (- 2.2 -) closes.
• This occurs because the lower control area of the

operating cylinder (-2.1-) is charged with pressure
by the current-free switched valve (-19- Y1), and the
upper control area is bled via the solenoid valve
(-20- Y4).
• The oil separator vessel (-6-) is released to the idle

pressure (residual pressure).
• The screw compressor is now running in the offload
mode.
• The cooling air ventilator (- 26 -) is switched on or

off in dependence upon the final compression
temperature.
(- 28 - (B1)) does not fall to the set lower switching
point within the set motor run-on time (e.g. 120
seconds), the drive motor (- 3 -) and the cooling air
ventilator motor (- 26 -) are shut down and the
system is depressurised to atmospheric pressure.
• The system is now in the “stand-by” mode and can
restart at any time when the network pressure falls
to the lower switching point (see section “Starting of
the system”).
(- 28 - (B1) falls to the preset lower switching point
before the set motor run-on time has elapsed,
solenoid valves (- 19 - (Y1) and - 20 - (Y4) ) are
again energised.
• The unit now changes over to on-load operation.
25

4.5.3 Manner of operation of the suction regulator ESM 45-ESM 50

Load running mode
When switching over to delta connection the two upper control area of the operating cylinder. The suction
solenoid valves are supplied with power (7 (Y1) and regulator valve opens, the lower control area is bled
9 (Y4)). The relief spool (11) is closed. At the same through the pipe (22) by the solenoid valve (7 (Y1).
time compressed air flows through the pipe (20) into the
Oil separator
vessel
Fig. 4
Idling mode
As soon as mains pressure has been attained, both opens and relieves the oil separator vessel via the
solenoid valves (7 (Y1) and 9 (Y4)) are switched without pipes (16) and (23). A small amount of air is sucked in
current. The operating cylinder is closed via the pipes through the bypass valve (15).
(21) and (22). At the same time the relief spool (11)
Oil separator
vessel
Fig. 5
26

5. Transport and installation
5 Tr ans por t an d i ns tall ati on
The proper lifting of the load (according to the

5.1 Transport
operating instructions of the load suspension
device) has to be ensured.
Important
Never lift or lash the compressor and its hood via

the enclosure. The screw compressor is lifted with
the help of a fork lift truck (Fig. 6). The separation
of the forks and their length must be taken into
account for transportation.
Only use the identified lifting points. Do not slide
the unit when it is standing on the floor.
Weights
The values listed below are approximate values, they
refer to a screw compressor unit including oil fill:
Fig. 6
ESM 30 923 kg / 2061 lbs
ESM 37 966 kg / 2157 lbs
ESM 45 988 kg / 2206 lbs
ESM 50 1055 kg / 2356 lbs
with optional dryer:
ESM 30 1023 kg / 2255 lbs

ESM 37 1071 kg / 2361 lbs
ESM 45 1093 kg / 2410 lbs
ESM 50 1160 kg / 2557 lbs
Fig. 7
1 Wire pin
2 Hinge pin
Note
The wire pins (-1- Fig. 7) and the doors must be

removed prior to transportation.
Danger
The compressor must be lifted using a suitable

forklift truck which complies with the local safety
regulations.
The length of the forks must correspond at least to
the width of the unit (see Chapter 10.2).
Before lifting, all loose or slewable parts of the
machine have to be firmly secured.
It is strictly prohibited to work or stand in the
danger zone of a lifted load.
27

5. Transport and installation
5.2 Installation
A = 1m/39,4“
B = 1m/39,4 “
Fig. 8
Danger
• The weight carrying capacity of the foundation
has to be taken into account when installing the
compressor.
• Provide for a solid and plane base.
• The system may not be operated on the transport
pallet.
• The intakes are to be located so that no
hazardous constituent (solvent vapour, etc., but
also dusts and other hazardous material) can be
sucked in. This applies also to flying sparks.
• Pipes and/or other parts with a surface
temperature higher than 70 °C/158 °F have to be
suitably identified and secured against
touching.
See also the safety regulations in chapter 3 of the
operating instructions.
Important
The operator has to provide adequate ventilation
for the compressor station.
The screw compressor unit has to be levelled. A
minimum distance from walls, other machines, etc.
should be maintained so that there is sufficient
clearance for maintenance and repair work (Fig. 8).
During operation of the screw compressor unit, heat is
generated by the electric motor and the compression
process. The screw compressor radiates a part of this
heat into the surroundings.
Proper ventilation has a considerable effect on the
service life and the performance of a compressor.
Once the compressor has been installed, the wire pins
(-1- Fig. 7) can be removed from the hinge pins (-2- Fig.
7). The wire pins (-1- Fig. 7) prevent the doors from
falling off in the case of transportation from the
manufacturer's site.
28

6. Preparations for commissioning
6 Pr epar ati on s f or com m iss io nin g
6.1 Cooling air volume/minimum cross Note

In order to ensure a good heat dissipation, auxiliary
fans should be rated to process approximately 15 to
20% more air volume than the total cooling air
quantity required by the compressors installed in the
compressed air station.
The figures below show the recommended ventilation

sections arrangement:
Air channel
Air
intake
Fig. 9
1 Cooling air intake

2 Cooling air outlet
3 Cooling-air inlet for optional refrigeration dryer
4 Cooling-air outlet for optional refrigeration dryer
The cooling air volume required by these screw

compressors is as follows:
ESM 30 65 m3/min Ventilator

ESM 37 78 m3/min
ESM 37RS 78 m3/min
ESM 45 87 m3/min
ESM 50 87 m3/min
ESM 45RS 87 m3/min Air
intake
The required cooling-air flow is increased by 33 m³/min.
if a dryer is installed.
Under unfavourable local conditions, we recommend

the installation of venting ducts. However, the velocity
of the cooling air should not exceed 5 m/s/ 17 ft/sec.
We recommend a minimum duct cross-section of
approx. 0.55 m 2/6 ft2. Fig. 9b
Important
The stated minimum cross-section refers to a

maximum duct length of 5 m/16.4 ft and a maximum
of one bend. In the event of differing values (over
5 m/16.4 ft, more than one bend, filter cartridges,
screens, etc.), please contact your technical
adviser.
Gardner Denver screw compressors are rated for

ambient temperatures and cooling temperatures of
+1°C/ 33.8°F to +45°C/113°F. In the case of
temperatures other than the above limiting values,
please consult your technical adviser.
29

6.2 Compressed air connection In the case of connections by means of connecting

hoses, take appropriate measures to prevent
whipping of the loose end in the event that the
hose connection tears off.
6.3 Electrical connection
6.3.1 Electrical connection (EUROPE-

Version only)
Compressor units are finished in the factory according
to standard EN60204 (industrial machinery). Please
observe the following important notes:
Danger
The power supply to the compressor side has to be

fitted for industrial equipment and fulfilling the
requirements of EN60204-1/IEC60204-1. To avoid
strong damages and fire on the power electric
components, any kind of operation outside of the
Fig. 10 stated limits of EN60204-1/IEC60204-1 is
inadmissible.
The customer has to connect a main switch in the
incoming line of the compressor unit (unless
factory-mounted as special accessories)
(DIN EN 1012 - 1).
If this switch does not provide short-circuit and
overload protection for the system, suitable
back-up fuses have to be installed according to
EN 60269-1 (low voltage directive ) (see table).
The main switch must meet the requirements of the
safety standard EN 60 204-1 (electrical equipment
of machinery) as well as of EN 60947-2 (low-
voltage switchgear and control gear (circuit-
breakers)).
The electrical connection and protective measures
have to be installed in accordance with VDE, BS or
Fig. 11 local regulations. As a rule, additional instructions
of the relevant power supplier have also to be
1 Compressed air connection
adhered to.
2 Thread identification compressed air connection
The compressed air line system is connected at the The electrical connections must be made by an
compressed air supply of the screw compressor authorized specialist.
( - 1 - Fig. 10).
Attention: Interference voltage!
For this you should use a flexible connection
(e.g. compressed air hose, compensator). If external electric circuits, which cannot be cut out
via the main switch, are connected to the control,
Europe-Version: DIN 2999 R 1 1/2" these have to be identified according to EN60204.
USA/CANADA-Version: NPT 1 1/2“ - 11-1/2 Warning signs have to be fixed near the main
switch and near these electric circuits. In addition,
Danger these conductors have to be laid separately and/or
identified by colors. Work on control cabinets may
When connecting the compressor on the mains side
only be carried out by electrotechnical specialists.
to the compressed air system available at the
If the installation conditions of the system differ
customer‘s end, check the operating temperatures
from the conditions described in EN60204, please
and operating pressures required and examine the
contact your technical adviser.
required connecting flange or the connection thread
for proper type, size and functioning. (see fig. 11).
30

To establish an electrical connection, proceed as Danger

follows:
When carrying out adjustment work on the control
Route the supply cable through the cable gland power transformer, the unit must be electrically
(-1 - Fig. 12) on the control cabinet and tighten screws. isolated and locked off.
Connect the supply line to the connecting terminals as Work on the control cabinet may only be carried
shown in the circuit diagram. out by electrotechnical specialist personnel.
Important
A wrong setting of the control-power transformer

jeopardizes the trouble-free operation of compres-
sor units and can result in malfunction or damage.
The verification of the control-power transformer

setting is a must during commissioning and
periodic inspection/maintenance, as the voltage
supply conditions may vary.
The correct setting should be checked during

under load operation of the unit by measuring the
control power transformer output voltages.
Danger
In the case of an ungrounded 3-phase power supply

Fig. 12 (IT- Net), please note the relevant instructions in the
documentation supplied with the drive.
Checking the setting of the control-power If a Residual Current Detector (RCD) is used as a
transformer system ground fault monitor, only Type B (value
and delay adjustable) devices should be used to
The control-power transformer is factory-preset to the avoid nuisance tripping.
rated voltage. However, practice has shown that the
actual supply voltage often differs from this value. In
order to adjust the unit to the local conditions, the setting
of the control-power transformer must be checked by
measuring the control-power transformer output voltages
during under load operation and, if required, re-set.
Several tapping points are provided for this purpose (see
circuit diagram). Fig. 13 illustrates an example.
Fig. 13
31

Recommended supply cable cross-sections and fuses
Installed nominal Fuse protection Line cross section

Compressor type Supply voltage
motor power (slow-blow fuse) at 30°C
[V]
[kW] [AgL] [mm2]
50-Hz-Compressors
220V 160 3x70PE35
ESM 30 380V 30 100 4G35
400V 80 4G25
220V 200 3x95PE50
ESM 37 380V 37 100 4G35
400V 100 4G35
220V 200 3x95PE50
ESM 45 - ESM 50 380V 45 125 4G50
400V 125 4G50
60-Hz-Compressors
230V 160 3x70PE35
ESM 30 380V 30 100 4G35
460V 80 4G25
230V 160 3x70PE35
ESM 37 380V 37 100 4G35
460V 100 4G35
230V 200 3x95PE50
ESM 45 - ESM 50 380V 45 125 4G50
460V 100 4G35
Notes on the table: Important

We do not know the cable type used by you, its length If local regulations are stricter than the values
and the installation conditions (temperatures, grouping). specified above, observe the stricter regulations.
The table above can therefore only be regarded as a
guideline.
The supply cable cross-sections given in the table

comply with VDE 0298, part 4 - table 13, column 7.
(Rubber hose line at 30 °C/86 °F and max. line length of
50 m). In the case of differing conditions (line length,
temperature and grouping), establish the cross sections
in accordance with DIN VDE 0298, part 4 or BS7671
taking into account the cable type.
32

6.3.2 Electrical connection

(USA/CANADA-Version only)
Danger
The power supply to the compressor side has to be

fitted for industrial equipment and fulfilling the
requirements of EN60204-1/IEC60204-1. To avoid
strong damages and fire on the power electric
components, any kind of operation outside of the
stated limits of EN60204-1/IEC60204-1 is
inadmissible.
To establish an electrical connection, proceed as

follows:
Route the supply cable through the cable gland
(- 1 - Fig. 12) on the control cabinet and tighten screws. Fig. 13
Connect the supply line to the connecting terminals as Danger

shown in the circuit diagram.
When carrying out adjustment work on the control-
power transformer, the unit must be electrically
isolated and locked off.
Work on the control cabinet may only be carried
out by electrotechnical specialist personnel.
Important
A wrong setting of the control-power transformer

jeopardizes the trouble-free operation of compres-
sor units and can result in malfunction or damage.
The verification of the control-power transformer

setting is a must during commissioning and
periodic inspection/maintenance, as the voltage
supply conditions may vary.
The correct setting should be checked during

under load operation of the unit by measuring the
Fig. 12 control power transformer output voltages.
Danger
Checking the setting of the control-power
transformer In the case of an ungrounded 3-phase power supply
(IT- Net), please note the relevant instructions in the
The control-power transformer is factory-preset to the
documentation supplied with the drive.
rated voltage. However, practice has shown that the
actual supply voltage often differs from this value. In If a Residual Current Detector (RCD) is used as a
order to adjust the unit to the local conditions, the system ground fault monitor, only Type B (value
setting of the control-power transformer must be and delay adjustable) devices should be used to
checked by measuring the control-power transformer avoid nuisance tripping.
output voltages during under load operation and, if
required, re-set. Several tapping points are provided for
this purpose (see circuit diagram).
33

Recommended supply cable cross-sections and fuses for multi-wire cables or three current-carrying
conductors in raceway based on 86 °F ambient temperature
Compressor type Supply Installed Fuse(s) Line cross section

voltage nominal motor protection conductor rated
power (slow-blow
fuse) class J 140°F 167°F 194°F
[V] [hp] [A]
60-Hz-compressors
200V 175 AWG4/0 AWG3/0 AWG2/0
230V 150 AWG3/0 AWG2/0 AWG1/0
ESM 30 40
460V 70 AWG3 AWG4 AWG4
200V 200 MCM250 AWG4/0 AWG3/0
230V 175 AWG4/0 AWG3/0 AWG2/0
ESM 37 50
200V 250 MCM350 MCM300 AWG4/0
230V 200 MCM300 AWG4/0 AWG3/0
ESM 45, ESM 50 60
460V 100 AWG1/0 AWG2 AWG2
An adequate electrical power supply of the correct Caution

voltage must be provided. All control enclosure wiring
has been completed at the factory. IN ALL CASES, THE LOCAL, STATE, AND
NATIONAL ELECTRICAL CODES MUST BE
The electrical supply should be equipped with a fused STRICTLY FOLLOWED.
line disconnect switch or circuit breaker so that
electrical power may be disconnected while the unit is
being serviced.
The fuse line disconnect should be located and moun-
ted in accordance with all state, local, and national
regulations.
The unit must be properly grounded to provide adequa-

te ground fault protection. As a guide, it is suggested
that the ground wire be equal in size to one of the
conductors which feeds the compressor motor circuit.
Make certain the ground wire connections are clean
and tight.
The wire used to feed the compressor circuit should be

selected and sized based on the following conditions:
1. Motor full load amperage plus service factor.
2. Ambient temperature in the area where the wire is
located.
3. Length of wire
4. Insulation type
This information may be found in the latest edition of
the National Electrical Code.
When installing a unit in a "Hazardous Location"; that is

in a location where fire or explosion is a definite hazard,
refer to the appropriate section of the National Electrical
Code for further information.
34

6.4 Oil level check 6.5 Sound pressure level
Danger Sound pressure level measured in dB(A) according to

ISO 2151 under full load at a distance of 1 m (tolerance:
Only check the oil level when the screw ± 3 dB(A)):
compressor unit is out of operation and
depressurized! 50 Hz compressors dB(A)
The pressure reservoir can be under pressure and ESM 30 67

the oil hot. Warning: Danger of scalding! ESM 37 68
Do not spill oil! Check for leakage! ESM 45 69
ESM 50 67
60 Hz compressors dB(A)
ESM 30 69
ESM 37 70
ESM 45 71
1 ESM 50 69
Subject to technical revision.

3
Fig. 14
1 Oil filler cap R1"

2 Oil-level indicator
3 Maximum oil level
4 Minimum oil level
Important
Do not mix oils of different specifications.

Machines which are delivered without oil must first
be filled to the max. mark in the pressure reservoir
sight glass (see also chapters 8.4 and 8.13)
Check the oil level as follows:
• Stop the compressor, with the stop button.

• Wait at least 5 minutes for the oil to settle and for
the air to disperse
• The oil level is checked with the help of the
transparent plastic tube at the pressure reservoir
(- 2 - Fig. 14) after every stop and at regular
intervals. If required, top up oil
Also see chapter 8 “Service and maintenance”
35

7. Commissioning
7 Com m issio ni ng
7.1 First commissioning • After the power supply was switched on, all LEDs
on the compressor control GD Pilot MK light up for
a display test. The fault shown on the display
Danger
[FAULT POWER LOSS] must be acknowledged
Make sure before commissioning that nobody is in before the unit can be started. To this end, press the
the danger zone of the screw compressor. acknowledgement pushbutton [Θ] (- 4 - Fig. 16).
Only operate the screw compressor with closed • After the acknowledgement, the message [READY
access panels. TO START] appears on the display unless another
fault is present.
Important
• The factory setting of the setpoint value for the
Although every Gardner Denver screw compressor network pressure (upper and lower switching point)
has been subjected to a test run at the factory and is saved in the compressor control GD Pilot MK and
has again been thoroughly inspected before depends on the relevant pressure variant of the
shipment, damage during shipment cannot be compressor (see nameplate 0, stage pressures =
excluded. For this reason, every screw compressor maximum operating pressure). These settings can
should be checked once again for damage before be checked or changed in the [CONTROL MENU] of
being commissioned. In addition, it should be the compressor control GD Pilot MK (see operating
observed during the first operating hours. instructions, chapter 1 of the compressor control
GD Pilot MK).
If the screw compressor is newly connected to a
power supply, check the direction of rotation of the • Temporarily remove the panel in order to check the
drive motor! direction of rotation; for the prescribed direction of
rotation, see (- 1 - Fig. 15 a) for the direction of
The screw compressor unit is completely factory- rotation of the drive motor of the geared compressor
assembled. It can be directly connected to the com- and (- 1 - Fig. 15 b) for the direction of rotation of the
pressed air mains by means of a flexible connection. drive motor with direct drive. For the prescribed
direction of rotation of the fan, see direction of
rotation arrow on the fan (- 3 - Fig. 15 c). The proper
First commissioning is carried out as follows:
rotation direction of the fan motor can also be
• Remove transport guards, if fitted. checked on the basis of the cooled airflow direction
(- 1 - , - 2 - Fig. 15 c).
• Fill oil in the pressure vessel up to “maximum oil
level” mark. (This applies to compressor systems Important
which are delivered without having been filled with
oil). (Refer to Chapter 8.4 and 8.13 for information With a wrong direction of rotation, shut down the
on filling oil). unit immediately by pressing the emergency STOP
button (-1- Fig. 16) (not the [O]), otherwise the
• Check the oil level in the pressure reservoir
compressor may be seriously damaged, even
(see also chapter 6.4). (Fig. 14)
during short periods of operation.
• Check the setting of the control-power transformer
(see also chapter 6.3). The access panels may temporarily be opened for
checking the direction of rotation (wear ear
• Check and re-tighten all connecting terminals of the protectors).
electrical control.
Danger
• Open isolator valves between the screw compres-
sor, reservoir and pipe. Beware of rotating parts! Rotating parts can lead to
injuries. Stay at a safe distance away from rotating
• Operate main power supply switch. machine parts!
Press the START button [ I ] (- 2 - Fig. 16) and
check the direction of rotation. With a wrong direction
of rotation, press the emergency STOP button
(- 1 - Fig. 16) immediately and correct the direction of
rotation.
36

7. Commissioning
Fig. 15
1 Drive motor‘s direction of rotation for geared

compressor
Fig. 15 c
1 Cooling air intake

2 Cooling air outlet
3 Arrow “direction of rotation for compressor“
(direction of rotation may deviate from this
representation)
1
Note
Fig. 15 b For switching the compressor off “normally”, use only

the stop push-button (- 3 - Fig. 16), but not the
1 Drive motor‘s direction of rotation in the case of EMERGENCY STOP push-button (- 1 - Fig. 16).
direct drive After shutdown the compressor has a run on time of
30-50 seconds (soft-stop).
Temperature start-up protection
The screw compressor unit will not start up if the

ambient temperature is lower than + 1 °C/33.8 °F.
37

7. Commissioning
Display of the compressor control GD Pilot MK • To switch off the compressor in the usual way use
the STOP button (- 3 - Fig. 16) and not the
1 5 6 7 emergency STOP button (- 1 - Fig. 16). After
shutdown the compressor has a run on time of
30-50 seconds (soft-stop).
2
3 Start-up protection of the electric motor
4 The screw compressor unit will not start up if the final

compression pressure is more than 0.8 bar / 11, 6 PSI.
Temperature start-up protection

Fig. 16
The screw compressor unit will not start up if the ambi-
1. EMERGENCY STOP pushbutton ent temperature is lower than + 1 °C/33.8 °F.
2. Start push-button [ I ]
3. Stop push-button [ O ]
4. Acknowledgement push-button [ Θ ]
5. Final compression temperature
7.3 Commissioning after malfunction
6. Final compression pressure
Important
7. Network pressure
The final compression temperature (- 5 - Fig. 16), Do not switch the screw compressor on repeatedly
the final compression pressure (- 6 - Fig. 16) and the without having rectified the malfunction, since this
network pressure (- 7 - Fig. 16) are shown on the may cause considerable damage to the machine.
keypad of the compressor control GD Pilot MK. Re-start after an automatic shutdown due to a
malfunction as follows:
• Faults are shown on the display of the compressor

control GD Pilot MK in the form of text.
7.2 Routine commissioning
• Turn master switch off.
Danger
• Eliminate fault.
Make sure before commissioning that nobody is in
the danger zone of the motor/screw compressor. • Turn master switch on.
After completion of work: Verify that all safety • Press acknowledgement push-button [Θ]
devices have been refitted and that all tools have (- 4 - Fig. 16)
been removed.
• After the acknowledgement, the message [READY
Only operate the screw compressor unit with TO START] appears on the display, unless another
closed access panels.
fault is present.
For routine commissioning, proceed as follows: • Press START button [ I ] (- 2 - Fig. 16).
• Check oil level in the pressure reservoir (see also

chapter 6.4).
• Open shut-off valves between the screw
compressor, reservoir and pipe.
• Switch on the power supply master switch.

• After the power supply was switched on, all LEDs
on the compressor control GD Pilot MK light up for a
display test. The fault shown on the display [FAULT
POWER LOSS] must be acknowledged before the
unit can be started. To this end, press the
acknowledgement push-button [Θ] (- 4 - Fig. 16).
• After the acknowledgement, the message [READY
TO START] appears on the display, unless another
fault is present.
• Press START button [ I ] (- 2 - Fig. 16).
38

8. Service and maintenance
8 Ser vice an d m ai nte na nce
8.1 Maintenance recommendations
Note
The screw compressor unit can only operate to your
complete satisfaction when the maintenance work is
carefully carried out at the specified intervals.
In order to facilitate this task, the scope of supply of the
screw compressor unit comprises the “Maintenance and
inspection manual for Gardner Denver compressors”, in
which you can list your performed maintenance work at
the specified intervals.
You can also have this maintenance work performed by
our trained technicians. Please ask your Gardner
Denver distributor for a maintenance contract.
8.2 Maintenance electric motor

The maintenance of the electric motor is to be
performed in line with the motor operating instructions.
The electric motor is permanently lubricated.
39

8.3 Maintenance schedule • The screw compressor unit must therefore be

depressorized prior to any maintenance work by
Danger slowly opening the lock (oil filler cap) with
integral vents
When performing control, adjusting and mainte-
nance work, be careful with hot surfaces of • The customer-installed main switch is set to "O"
machine parts. (OFF) and locked off
Checks and maintenance work may only be carried • Warning:

Electrical voltage: Only work on the screw
out when the following points are observed:
compressor unit when it is disconnected.
• Press the STOP button on the control panel and
Intervals are valid for normal industrial environments
wait until the screw compressor unit has come
to rest and the screw compressor unit is and operating conditions. When in doubt, check the oil
depressurized change intervals by carrying out an oil analysis.
• The pressure display does no longer indicate If necessary, reduce the oil change intervals and
pressures < 0.3 bar/4.4 PSI. cleaning intervals in the event of heavy soiling.
• Shortly after switching the screw compressor For order numbers see the spare parts list.
off, the system can contain a low residual
pressure.
3,000 h
6,000 h
9,000 h
12,000 h
15,000 h
18,000 h
Commissioning
Due at x service hours
12 M
24 M
36 M
48 M
60 M
72 M
At the latest after x months
Package A Oil filter cartridge, air filter cartridge      

Package B Oil separator element   
Package C Wearing parts 
Maintenance every 3000 h, although at least each year
Replacement of air filter cartridge      
Replacement of oil filter cartridge      
Cleaning/replacement of cooling air inlet filter      
Oil change when using AEON 3000 or AEON 6000      
Safety valve / functional test at least once a year      
ESM30-50 with dryer only: Cleaning/replacement of dryer cooling air inlet filter      
Maintenance every 6000 h, although at least every 2nd year
Checking/tightening of connecting terminals in the switch cabinet/ and checking of the
“control transformer” setting    
Checking/tightening screw connections    

General maintenance/cleaning   
Oil change when using AEON 9000   
Oil analysis when using AEON 9000   
Replacement of oil fine separator cartridge   
Replacement of lubrication cartridges   
 These maintenance intervals must be observed!

x For your own benefit, put a cross on the servicing schedule against maintenance work when performed.

40

8.4 Oil change intake air from a normal environment without a high
content of foreign matter (dusts, vapours, gases).
When changing the oil, the waste oil is to be drained
completely, since used oil reduces the service life of the
new oil fill considerably.
Do not mix lubricating oils of different makes. When
changing over to a new oil type, the oil in the oil circuit
must be drained completely.
For the oil change intervals, see maintenance schedule.
When changing the oil, proceed as follows:
• Switch the screw compressor unit off and ensure

that it is depressurized, electrically isolate and
locked off.
• Slowly open the oil filler cap (- 2 - Fig. 17), to
depressurize the screw compressor by releasing
any residual pressure in the unit
Fig. 17
• Remove the oil filler cap
1 Oil reservoir • Open the oil drain (- 6 - Fig. 17) for the pressure
2 Oil filler cap R1" reservoir and the oil cooler
3 Oil-level indicator
4 Max. oil level • Drain oil at operating temperature through the drain
5 Min. oil level hose (- 7 - Fig. 17)
6 Oil drain R1/2" • Close the oil drain
7 Drain hose
• Fill in oil up to the marking “maximum oil level”
Danger (ca. 15 litres/ca. 4 US-Gal.)
• Close the oil filler cap
Only change the oil when the screw compressor
unit is not in operation and is depressurized! • Let the screw compressor unit run for approx.
2 minutes
Be careful when draining hot oil:
Danger of scalding! • Check for leakages
• Switch the screw compressor unit off
Important
Remove oil residues and other deposits from unit the air to disperse
parts and from the coolers of compressors, which
are exposed to hot compressed air, according to • Check oil level (see chapter 6.4)
the operating instructions. • The oil level must be between the maximum level
(- 4 - Fig. 17) and minimum level (- 5 - Fig. 17)
Note marked on the oil reservoir.
Collect the waste oil, do not allow it to seep into the • If required, top up oil
ground!
Disposal in accordance with the regulations! Do not spill Changing intervals for lubricants
oil! Check for leakage!
The operating conditions (e.g. coolant temperatures),
With these compressors, the oil change intervals the operating modes and the quality of the intake air
strongly depend on the degree of contamination of the (e.g. content of dust, content of gaseous foreign matter
circulating oil. It must therefore be taken care that no such as SO2, solvent vapours) have a strong influence
oil-deteriorating matter (dusts, vapours, gases) are
on the oil change intervals.
transported through the air intake filter into the oil circuit
of the compressor unit. Also a high content of humidity In this case the oil must be analyzed to check the
in the intake air and the formation of condensate within permissible length of time that the oil can be used (see
the machine affect the service life of the lubricant oil so also chapter 8.13). Under no circumstances should the
that a reduction in the oil change intervals may become oil be used beyond its design life.
necessary. The specified oil change intervals refer to an
41

8.5 Change of oil filter cartridge • Check oil level (see chapter 6.4)
• If required, top up oil.
Changing intervals for oil filter cartridge

the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours, etc.) have a strong
influence on the service life of the filters (air filters, oil
filters, fine separators).
Where such conditions exist the filter element may

require changing more frequently.
8.6 Change of the fine separator

cartridge
Fig. 18
5
1 Oil filter cartridge
6 4
Danger
8 3
Only replace the oil filter cartridge when the screw
compressor unit is out of operation and 9 2
depressurized!
Be careful with hot oil: Danger of scalding! Do not 7
spill oil!
1
Note
Dispose of the oil filter cartridge in line with the
regulations - special waste ! Check for leakage!
Fig. 19 a
For the changing intervals, see the maintenance
schedule. 1 Oil fine separator
2 Oil extraction plastic tube
3 Control air plastic tube
4 Oil extractor
Change the oil filter cartridge as follows:
5 Victaulic connection to the cooler
• Switch the screw compressor unit off and ensure 6 Victaulic connection to the pressure holding valve
that it is depressurized, electrically isolate and 7 Hexagon screw
locked off. 8 Cheese heads screw for lifting the reservoir cover
9 Reservoir cover
the air to disperse. Danger
• Unscrew the oil filter cartridge ( - 1 - Fig. 18) using The pressure reservoir is under pressure! Only
an appropriate tool work on the screw compressor unit when it is out
of operation and depressurized!
• Dispose of the oil filter cartridge according to the
regulations Be careful with hot oil: Danger of scalding!
Do not spill oil!
• Oil the gasket of the new oil filter cartridge slightly
Note
• Screw on the new oil filter cartridge and tighten
manually (take notice of the instructions on the oil Dispose of the fine separator cartridge in line with the
filter cartridge) regulations - special waste! Check for leakage!
• Check for leakage For the changing intervals, see the maintenance
schedule.
42

If the oil fine separator is monitored (option), too high a • Turn cheese head screw (- 8 - Fig. 19 a)
differential pressure is indicated on the keypad of the counterclockwise until the reservoir cover is loosely
compressor control GD Pilot MK. When the lying on the pressure reservoir flange
corresponding warning lights up, change the oil fine
• Screw down all hexagonal head screws, with
separator.
exception of the two screws lying in the swivel area
of the pressure control valve and tighten crosswise.
• Swivel the pressure control valve back to its starting
position and assemble with the appropriate screws.
Then assemble the remaining hexagonal head
screws in the lid of the vessel and tighten.
• Tighten (clockwise) cheese head screw for lifting the
reservoir cover (- 8 - Fig. 19 a) to protect it against
unwanted turning
• Reassemble all dismantled pipes to the pressure
vessel and assemble oil suction again.
Changing intervals for oil fine separator cartridge

filters, fine separators).
Fig. 19 b
Where such conditions exist the filter element may
require changing more frequently.
Change the oil fine separator as follows:
• Switch the screw compressor unit off and make sure
that it is depressurised and no voltage is supplied. 8.7 Change of air intake filter
For this, while the system is switched off carefully
open the ballcock (- 1 - Fig. 19 b) on the
downstream cooler until the system has been bled,
then close the stopcock again.
• Loosen the plastic tube of the oil extractor
(- 2 - Fig. 19 a).
• Loosen the plastic tube of the control air line
(- 3 - Fig. 19 a).
• Loosen all hexagonal head screws from the
pressure control valve.
• Loosen the two screws in the swivel direction of the
pressure control valve and remove, then the valve
can be swivelled inwards.
• Remove all hexagon screws (- 7 - Fig. 19 a) on the
circumference of the pressure reservoir’s cover.
• The cheese head screw for lifting the reservoir cover
(- 8 - Fig. 19 a) must be screwed in clockwise until
the cover is lifted off by some mm.
• Swivel the reservoir cover with pressure holding
valve by 180° (- 1 - Fig. 19 a).
• Remove used oil fine separator (- 1 - Fig. 19 a). Fig. 20
• Clean sealing faces and, if required, remove and 1 Air intake filter
clean O-rings. 2 Intake filter monitor (visual)
• Install new oil fine separator.
• Swivel reservoir cover back to the initial position
43

Danger 8.8 Safety valve

Only perform checks and carry out work on the
screw compressor when the unit is out of operation
and depressurized! 2
Important
1
Never operate the screw compressor unit without
the air filter (even a short operating time without
this filter can result in considerable damage to the
machine)!
As a standard, the air filter is provided with a visual in-

take filter monitor (- 2 - Fig. 20), which indicates clog-
ging of the air filter cartridge.
When the red service field of the intake filter monitor is

Fig. 21 a
visible and remains clicked into position while the screw
compressor is out of operation, replace the air filter
cartridge.
However, the air filter cartridge should be replaced at

the latest as specified in chapter 8.3, maintenance item
W1 “Change of air filter cartridge“. Check air filter at
least once a week or, if required, daily for the accu-
mulator of dust. When carrying out maintenance work,
make sure that no dirt gets to the clean air side of the
air filter.
Changing intervals for air filter cartridge

filters, fine separators). Fig. 21 b (only for dryer option)
Where such conditions exist the filter element may 1 Safety valve
require changing more frequently. 2 Valve cap
3 Safety-valve for optional refrigeration dryer
Change the air filter as follows:

Testing the safety valve
• Pull snap latch outward and remove housing base.
The valve should be tested on a separate compressed
• Detach air filter cartridge while slightly turning it. air line in accordance with local legislation.
• Carefully insert new air filter cartridge in the Operate the safety valve (- 1 - Fig. 21), depending on
housing. the type of valve:
• Close air filter with housing base. The snap latches • Slightly turn the valve cap (-2- Fig. 21) (1-2 turns),
must click into position. and then re-close it.
• Actuation of the bleeding lever/pulling ring
Danger
Never operate a screw compressor system with a

defective safety valve or without safety valve!
44

8.9 Connecting terminals in the switch 8.12 Clean / change filter mat with cooling
cabinet/control transformer setting air inlet and control cabinet inlet
Danger
In the case of electric voltage:

• Actuate STOP button at the operating panel
• Set the customer-fitted main power switch to
"O" (OFF).
The connecting terminals in the switch cabinet have to
be checked and, if required, re-tightened during first
commissioning and later on in line with the maintenance
schedule.
The setting of the control transformer must be checked

according to chapter 6.3 “Electrical connection”.
8.10 Fittings
The fittings of the air and oil circuits have to be checked
and, if required, re-tightened according to the Fig. 22
maintenance schedule.
1 Filter mat cooling air inlet
Check the hose and piping for unsealed areas. 2 Mounting bolts
3 Sound-proofing element
4 Cover plate (only for dryer option)
5 Fixing screws (only for dryer option)
6 Dryer filter mat (only for dryer option)
8.11 General maintenance and cleaning
Danger
Important
Only perform filter mat change after the
Remove oil residues and other deposits from unit compressor system has been shut down and
parts and from the coolers of compressors, which depressurized!
are exposed to hot compressed air, according to
the operating instructions.
Perform filter mat change as follows:
Blow off the screw compressor unit with
compressed air at the specified intervals (never a) Filter mat, cooling-air inlet
direct compressed air towards persons) paying • Remove fixing screws (- 2 - Fig. 22).
particular attention to:
• Remove filter mat (- 1 - Fig. 22) and clean,
• Regulating elements exchange if damaged.
• Fittings
• Compressor block • Re-insert filter mat in sound insulating panel
• Cooler (- 3 - Fig. 22).
• Electric motor
• Secure filter mat by means of fixing screws.
b) Filter mat, dryer (option)
• Remove fixing screws (-5- Fig. 22) and then

remove the cover plate (-4- Fig. 22).
• Remove dryer filter mat (-6- Fig. 22) and clean it,
replace if damaged.
• Install cleaned or new filter mat.
• Fix the cover plate using the screws

(-5- Fig. 22).
45

Cleaning:
Clean the filter mat by brushing or washing.
Important
Never install the filter mat in a wet or moist state!
Changing times for the filter mat

The operating modes and the quality of the suctioned
air (e.g. dust content) has a strong influence on the filter
service life.
The filter should be checked on a weekly basis,
eventually daily basis, for dust build-up.
In these operational cases, shorter change intervals are

possible.
8.13 Maintenance information and

lubricant recommendations for
stationary compressors
Lubricant recommendations
Please note that proper lubrication will considerably
increase the service life of your compressor unit.
According to regulations relating to the prevention of
accidents, use lubricants the properties of which meet
the requirements of the operating conditions on site.
Do not mix lubricating oils of different makes. When
changing over to a new oil type, drain the old oil
completely from the system.
If final compression temperatures of more than 90 °C/

195 °F occur continually, the oil change intervals given
in section 8.3 (maintenance schedule) are halved.
The oil change intervals should be calculated more

accurately in accordance with the actual operating
conditions by analyzing the oil.
Use the following oil type:
AEON 3000, AEON 6000 or AEON 9000.
46

9. Trouble-shooting
9 Tr ou ble -s ho oti ng
In the case of faults or warnings that are detected by the compressor control GD Pilot MK, please refer to the
chapter “Fault/warning table” in the operating instructions of the GD Pilot MK.
Malfunction Possible cause Remedy
Unit cannot be started 1. No operating or control voltage 1. Check fuses, main switch and supply line
2. Malfunction not acknowledged 2. Acknowledge fault message
3. Pressure reservoir not depressurized 3. Wait until depressurized. Screw

compressor does not start up, when
reservoir pressure is > 0.8 bar/11.6 PSI
4. Electric motor defective 4. Check connections, winding, etc.
5. Compressor defective 5. Turn the compressor manually;

if required, replace
6. Ambient temperature less than 6. Make sure that the ambient temperature
+1 °C/ 33.8 °F is not less than +1 °C/ 33.8 °F; install an
auxiliary heater, if required
7. Remote control/timer has been 7. Deactivate remote control/timer

activated via terminal strip
8. Mains pressure is above the lower switch 8. Wait until the mains pressure has fallen
set point below the lower switch set poin
Unit stops during the 1. Intake regulator only closes partly, 1. Fix intake regulator or, if required,
start-up phase pressure builds up too quickly in the replace; check solenoid valves
pressure reservoir
2. Short-circuit in the unit 2. Determine and eliminate cause; replace

defective fuses
3. Connecting terminals in the switch 3. Check and re-tighten

cabinet are loose
4. Oil too viscous 4. Select the type of oil according to the

ambient conditions or install an auxiliary
heater
5. Maximum motor switching cycles 5. Avoid frequent manual on and off-

exceeded due to too frequent manual switching, let electric motor cool down
on and off-switching
Unit does not reach the 1. Mains pressure sensor set too low 1. Check, re-set
set mains pressure
2. Intake regulator opens only partly 2. Fix intake regulator or, if required,
replace; check solenoid valves
3. Excessive air consumption 3. Reduce consumption or cut in a further

compressor
4. Fine separator clogged 4. Replace fine separator cartridge
5. Air filter clogged 5. Replace air filter cartridge
6. Heavy leakage in the compressor 6. Check unit

system
47

9. Trouble-shooting
Malfunction Possible cause Remedy
Unit switches off 1. Ambient temperature too high 1. Ventilate compressor room
2. Electric motor defective 2. Check electric motor and thermistor
3. Fan defective 3. Check/replace fan
4. Sensor, connections or lines defective 4. Check sensors, connections and lines
5. Cross section of the electric supply 5. Measure power requirement,

lines too small if necessary, replace lines
6. Power requirement too high 6. Oil fine separator clogged,

replace, if necessary
7. Oil level too low 7. Top up oil in the pressure reservoir
8. Oil injection pressure too low 8. Replace oil filter cartridge,

clean oil system
9. Excessive oil temperature 9. Check oil cooler and fan/

Check oil thermostat
Excessive idling 1. Intake regulator does not close correctly 1. Check intake regulator
pressure Check solenoid valves
2. System not unloaded 2. Check solenoid valves
Oil in the compressed air 1. Oil fine separator defective 1. Replace oil fine separator cartridge
2. Oil foams 2. Change oil

3. Oil level too high 3. Drain off oil
4. Minimum pressure valve defective 4. Check minimum pressure valve
5. Orifice of oil extractor clogged 5. Remove and clean orifice
(-13- Fig. 3)
Oil in the air filter 1. Intake regulator setback function 1. Check intake regulator
defective
2. Intake regulator does not close correctly 2. Check intake regulator
Check solenoid valves
3. Frequent emergency shutdown 3. The emergency shutdown may only be
activated in the case of safety-relevant
functional problems
Safety valve opens 1. Safety valve defective 1. Replace
2. Oil fine separator clogged and final 2. Replace oil fine separator cartridge and
compression pressure sensor defective change final compression pressure
sensor
3. Intake regulator closes too slowly 3. Check intake regulator and solenoid
valves
4. Mains pressure sensor defective 4. Replace mains pressure sensor
5. Electronics defective 5. Replace electronics
Danger
Never operate the screw compressor with defective safety valve!
48

10. Annex
10 Ann ex
10.1 Technical Data
10.1.1 EUROPE version ESM 30-ESM 37

ESM 30 ESM 37
Technical Data 50Hz
7.5 10 13 7.5 10 13
Maximum operating pressure bar 7.5 10 13 7.5 10 13
Minimum operating pressure bar 5
Ambient temperature °C 1...45°C
Flow m3/min 5.75 5.11 4.36 7.1 6.17 5.3
After-cooler outlet temperature above ambient temp. °C 7 6 6 7 6 6
Sound pressure level (to ISO 2151) dB(A) 67 68
Nominal motor rating kW 30 37
Full-load current max. IP55 (220V, 380V, 400V) A 130 / 75 / 71 154 / 89 / 85
Motor protection type - IP55, EFF1, ECA
Nominal speed rpm 3000
Nominal fan motor power kW 0.85 (IP-54)
Recommended cable cross-section (220V / 380V / 400V) mm2 3*70PE35 / 4G35 / 4G25 3*95PE50 / 4G35 / 4G35
Recommended fuse size (220V / 380V / 400V) (type gG) A 160 / 100 / 80 200 / 100 / 100
Cooling air flow through ventilator m3/min 65 78
Cooling air outlet temperature above ambient temp. °C 28
Max. allowable pressure drop in duct at ambient 35°C / 45°C Pa 120 / 90 100 / 80
Total oil volume l 23
Compressed air delivery connections (male screwed thread) - EN 10226 R 1 1/2" (DIN 2999-R 1 1/2)
Weight kg 923 966
Dimensions L x W x H mm 1722 x 920 x 1659
ESM 30 ESM 37
Technical Data 60Hz
7.5 9 13 7.5 9 13
Maximum operating pressure bar 7.5 9 13 7.5 9 13
Flow m3/min 5.77 5.31 4.37 6.84 6.41 5.27
After-cooler outlet temperature above ambient temp. °C 7 6 6 7 6 6
Nominal motor rating kW 30 37
Full-load current max. IP55 (230V, 380V, 460V) A 130 / 76 / 63 148 / 90 / 75
Nominal fan motor power kW 0.86 (IP-54)
Recommended cable cross-section (230V / 380V / 460V) mm2 3*70PE35 / 4G35 / 4G25 3*70PE35 / 4G35 / 4G35
Recommended fuse size (230V / 380V / 460V) (type gG) A 160 / 100 / 80 160 / 100 / 100
Cooling air flow through ventilator m3/min 65 78
Max. allowable pressure drop in duct at ambient 35°C / 45°C Pa 120 / 90 100 / 80
Weight kg 923 966
Dimensions L x W x H mm 1722 x 920 x 1659
49

10. Annex
10.1.2 EUROPE version ESM 45-ESM 50

ESM 45 ESM 50
Technical Data 50Hz
7.5 10 13 7.5 10
Maximum operating pressure bar 7.5 10 13 7.5 10
3
Flow m / min 8 7 6.11 8.67 7.55
After-cooler outlet temperature above ambient temp. °C 7 6 6 7 6
Nominal motor rating kW 45
Full-load current max. IP55 (220V, 380V, 400V) A 188 / 109 / 102
Nominal fan motor power kW 1.4 (IP54)
Recommended cable cross-section (220V / 380V / 400V) mm2 3x95PE50 / 4G50 / 4G50
Recommended fuse size (220V / 380V / 400V) (type gG) A 200 / 125 / 125
3
Cooling air flow through ventilator m / min 87
Max. allowable pressure drop in duct at ambient 35°C / 45°C Pa 130 / 90
Weight kg 988 1055
Dimensions L x W x H mm 1722 x 920 x1659
ESM 45 ESM 50
Technical Data 60Hz
7.5 9 13 7.5 9
Maximum operating pressure bar 7.5 9 13 7.5 9
Flow m3 / min 7.89 7.39 6.07 8.63 7.92
After-cooler outlet temperature above ambient temp. °C 7 6 6 7 6
Nominal motor rating kW 45
Full-load current max. IP55 (230V / 380V / 460V) A 180 / 109 / 90
Nominal fan motor power kW 1.5 (IP54)
Recommended cable cross-section (230V / 380V / 460V) mm2 3x95PE50 / 4G50 / 4G35
Recommended fuse size (230V / 380V / 460V) (type gG) A 200 / 125 / 100
Cooling air flow through ventilator m3 / min 87
Max. allowable pressure drop in duct at ambient 35°C / 45°C Pa 130 / 90
Weight kg 988 1055
Dimensions L x W x H mm 1722 x 920 x1659
50

10. Annex
10.1.3 North America version ESM 30-ESM 37

Technical Data 60Hz North America ESM 30 ESM 37
Nominal pressure psi g 100 125 190 100 125 190
Maximum working pressure psi g 110 130 190 110 130 190
Minimum working pressure psi g 75
Ambient temperature - min / max °F 34...113
FAD at nominal pressure cfm 203.7 187.5 154.3 241.7 226.3 186.0
Discharge temperature of air above ambient °F 13 11 11 13 11 11
Free field noise level (ISO 2151) dB(A) 69 70
Nominal motor rating hp (kW) 40 (30) 50 (37)
Full load current max. IP55 (200V, 230V, 460V, 575V) Amps 143 / 124 / 63 / 50 170 / 148 / 75 /59
Standard drive motor detail - TEFC IP55, EPACT
Drive motor speed rpm 3600
Fan motor rating hp (kW) 1.2 (0.86) (IP-54)
AWG3/0 AWG4/0
AWG2/0 AWG3/0
Suggested cable size (200V, 230V, 460V, 575V)@167°F
AWG4 AWG3
AWG6 AWG4
Suggested fuse rating @ (200V, 230V, 460V, 575V)

Amps 175 / 150 / 70 / 60 200 / 175 / 90 / 70
(slow-blow fuse, class J)
Ventilating fan capacity cfm
Cooling air temp above ambient approx. °F 50 50
Max. allowable pressure drop in duct at ambient 95°F / 113°F Pa 120 / 90 100 / 80
Compressor oil capacity gal (l) 6 (23)
Compressed air delivery connection (male screwed thread) - 1 1/2-11 1/2 NPT
Weight lbs/kg 2035 (923) 2130 (966)
Package dimension L x W x H in/mm 67.8 x 36.2 x 65.3 (1722 x 920 x 1659)
51

10. Annex
10.1.4 North America version ESM 45-ESM 50

Technical Data 60Hz North America ESM 45 ESM 50
Nominal pressure psi g 100 125 190 100 125
Maximum working pressure psi g 110 130 190 110 130
Minimum working pressure psi g 75
Ambient temperature - min / max °F 34...113
FAD at nominal pressure cfm 278.7 160.8 214.5 304.7 279.7
Discharge temperature of air above ambient °F 13 11 11 13 11

Free field noise level (ISO 2151) dB(A) 71 69
Nominal motor rating hp (kW) 60 (45)
Full load current max. IP55 (200V, 230V, 460V, 575V) Amps 207 / 180 / 90 / 73
Standard drive motor detail - TEFC IP55, EPACT
Drive motor speed rpm 3600
Fan motor rating hp (kW) 2.0 (1.5) (IP-54)
MCM300
AWG4/0
Suggested cable size (200V, 230V, 460V, 575V)@167°F
AWG2
AWG3
Suggested fuse rating @ (200V, 230V, 460V, 575V),

Amps 250 / 200 / 100 / 80
(slow-blow fuse, class J)
Ventilating fan capacity cfm 3072
Cooling air temp above ambient approx. °F 50
Max. allowable pressure drop in duct at ambient 95°F / 113°F Pa 130 / 90
Compressor oil capacity gal ( l ) 6 (23)
Compressed air delivery connection (male screwed thread) - 1 1/2-11 1/2 NPT
Weight lbs/kg 2178 (988) 2326 (1055)
Package dimension L x W x H in / mm 67.8 x 36.2 x 65.3 (1722 x 920 x 1659)
52

10. Annex
10.2 Layout plan
Fig. 23 (all dimensions in mm)

A Compressed air connection
Europe version: male screwed thread DIN 2999 - R 1 1/2
Canada USA version: male screwed thread NPT 1 1/2 - 11 ½
B Condensate connection
(only for dryer option or for integrated water-separator option)
outer-∅ 10 for polyamide pipe PA11/12
C Water inlet (cold) (only for integrated heat-recovery option)
D Water outlet (hot) (only for integrated heat-recovery option)
E Cooling air inlet
F Cooling-air outlet
G Cooling-air inlet, dryer (option)
H Cooling-air outlet, dryer (option)
J Electrical connection
K Center of gravity
53

10. Annex
Fig. 24 (all dimensions in mm)
54

10. Annex
10.3 Declaration of conformity
1. EC Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A
2. We, hereby declare Gardner Denver Deutschland GmbH

Argenthaler Str.11
D-55469 Simmern
that the product: Kompressor
type:
trade mark:
manufacturer no.:
in the form as shipped by us complies with the following relevant provisions:
2009/ 105/EG 97/ 23/EG 2004/ 108/EG

2006/ 42/EG
3. If the machine is modified in a way not agreed upon with us, this statement will be void.
4. Harmonised standards applied, particularly
EN 1012-1 EN ISO 12100-1+2 EN 60034 EN 61000-6-4

EN 14121-1 EN 29001 EN 60204-1 EN 61000-6-2
5. National engineering standards and specifications applied
VDE 0298 DIN 3230 AD-S1/2000 BetrSichV
6. Recording agency: Gardner Denver Deutschland GmbH

|QM | 11.96 | Nr. 221 | ÄZ 00 | 01 | 02 | 03 | 04 |
Technische Abnahme: Hans-Otto-Christ
Simmern,
Signature
Date
(Christ, Leiter techn. Abnahme)
55

Gardner Denver Compressor Division,
1800 Gardner Expressway, Quincy, Illinois 62305
Telephone: (800) 682-9868

Fax: (217) 224-7814
Gardner Denver Deutschland GmbH

Argenthaler Str. 11
55469 Simmern
Deutschland
Tel. ++49 (0)6761 832-0

Fax ++49 (0)6761 832-409

Gardner Denver ESM 30 Original User Manual

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Original User Manual

Screw Air Compressor

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USE ONLY GARDNER DENVER GENUINE PARTS. YOUR

Deutsche Basis-BA: ZS1064357 / 00 3

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The values on the type plate are maximum values.

Your Gardner Denver distributor

Contact: Spare Parts:

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1.1 Notes on the compressor 1.3 Maintenance

Please contact your authorized Gardner Denver dealer

• relevant accident prevention regulations,

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Besides the operating instructions and the binding

Operate this compressor only if you have an exact

Gardner Denver cannot be held responsible for the safe

Warranty claims will not be accepted in the case of

The warranty and liability conditions of the general

Any unauthorized change to the compressor unit/

The safety regulations in chapter 3 of the operating

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3 Safet y r eg ula tio ns

3.1 Identification of safety guidelines 3.2 General safety instructions

Observe all safety and warning notices attached to the

In the case of safety-relevant changes to the machine/

Spare parts have to comply with the technical

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The air intake is to be located so that no hazardous

In the case of connections by means of connecting

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Downloaded from www.dlmanuals.com

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Always re-tighten screwed connections which have

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Oils, greases and other chemical substances

When handling oils, greases and other chemical

Rooms subject to explosion hazards

Compressor units must never be operated in areas

3.7 Storage of compressors

If the compressors are to be stored for period

Compressors which are to be shut down for a lengthy

Since corrosion occurs more quickly in damp

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3.8 Symbols and explanations

Carefully read the operating manual before

Never breathe in compressed air from this system.

Never operate the unit with open doors or loose access

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Warning: Hot surface

Warning: Pressurized part or system

Warning: This system can start up by means of a

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Warning: The system continues to run for 30 seconds

Warning: Danger of electric shock

Attention: Lifting point

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Attention: Check and, if required, re-tighten

Attention: Opening pressure safety valve = xx bar

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