13-8-610

GARDNER DENVER@ 3rd Edition

January, 1994

ELECTRA-SCREW@ STATIONARY

BASE-MOUNTED COMPRESSORS

MODELS
EDEQHF - 40 HP
EDEQJF - 50 HP

60 HZ

OPERATING AND
SERVICE MANUAL
 MAfNTAfN COMPRESSOR RELIABILITYAND PERFORMANCE WfTH
GENUINE GARDNER DENVER AND JOY COMPRESSOR
PARTS AND SUPPORT SERVICES

Gardner Denver and Joy Compressor genuine parts,
engineered to original tolerances, are designed for op-
timum dependability --- specifically for Gardner-Denver
and Joy compressor systems. Design and material in-
novations are the result of years of experience with
hundreds of different compressor applications.
Reliability in materials and quality assurance are incor-
porated in our genuine replacement parts.
1. Trained parts specialists to assist you in selecting
the correct replacement parts.
2. Factory warranted new and remanufactured rotary
screw air ends. Most popular model remanufac-
tured air ends are maintained in stock at MDC for
purchase on an exchange basic with liberal core
credit available for the replacement unit.

Your authorized Gardner Denver and Joy Compres-
sor distributor offers all the backup you’ll need. A
worldwide network of authorized distributors provides
the finest product support in the air compressor industry.
Your local authorized distributor maintains a large inven-
tory of genuine parts and he is backed up for emergency
parts by direct access to the Gardner Denver Machinery
Inc. Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
Denver or Joy air compressor with these services:
3. A full line of factory tested AEON ‘M compressor
lubricants specifically formulated for use in Gardner
Denver and Joy compressors.
4. Repair and maintenance kits designed with the
necessary parts to simplify servicing Your compres-
sor.
Authorized distributor service technicians are fac-
tory-trained and skilled in compressor maintenance
and repair. They are ready to respond and assist you
by providing fast, expett maintenance and repair
services.

For the location of your local authorized Gardner-Denver and Joy Air Compressor distributor refer to the yellow
pages of your phone directory or contact:

Distribution Center: Factory:

Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: (217) 222-5400
Phone: (901) 363-6100 Fax: (217) 223-5897
Fax: (901) 363-1095

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL NUM-
BER (see nameplate on unit). Serial Number is also
stamped on top of the cylinder flange to the right of the
inlet housing.
All orders for Parts should be placed with the nearest
authorized distributor.
Where NOT specified, quantity of parts required per
compressor or unit is one (l); where more than one is
required per unit, quantity is indicated in parenthesis.
SPECIFY EXACTLY THE NUMBER OF PARTS RE-
QUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left Hand side of a
compressor, stand at the motor end and look toward the
compressor. Right Hand and Left Hand are indicated in
parenthesis following the part name, i.e. (RH) & (LH).

AIR ENDS

NOTE: Factory warranted new and rebuilt air ends are available from your authorized Gardner Denver and Joy
Compressor Distributor.
 FOREWARD

Gardner Denver Electra-Screw@ compressors are the result of advanced engineering and skilled manufacturing. To
be assured of receiving maximum service from this machine the owner must exercise care in its operation and
maintenance. This book is written to give the operator and maintenance department essential information for
day-to-day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical
operation and minimum downtime.

~DANGER

I
I
Danger is used to indicate the presence of a hazard which will cause severe personal
injury, death, or substantial propery damage if the warning is ignored.
I
I

~WARNING

I
Warning is used to indicate the presence of a hazard which can cause severe personal
injury, death, or substantial propery damage if the warning is ignored.
I

~ CAUTION

Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or propery damage if the warning is ignored.

NOTICE

I Notice is used to notify people of installation, operation or maintenance

which is important but not hazard-related.
information
I

This book covers the following models:

HP PSIG Air Cooled Parts List

40 100, 125, 150, 175 EDEQHF 13-8-510
50 100, 125, 150, 175 EDEQJF 13-8-510

TABLE OF CONTENTS
GENERAL INFORMATION ............................................................................................................................. SECTION 1

INSTALLATION ............................................................................................................................................... SECTION 2

STARTING AND OPERATING PROCEDURES ............................................................................................. SECTION 3

CONTROLS AND INSTRUMENTS ................................................................................................................. SECTION 4

LUBRICATION, OIL COOLER, OIL FILTER AND SEPARATOR ................................................................... SECTION 5

AIR FILTERS ................................................................................................................................................... SECTION 6

BELT DRIVE ................................................................................................................................................... SECTION 7

MAINTENANCE SCHEDULE ......................................................................................................................... SECTION 8

TROUBLE SHOOTING ................................................................................................................................... SECTION 9

13-8-610 Page i
 INDEX
NOTE: Numbers preceding dash are Section Numbers -- Numbers following
Addition of Oil Between Changes ...............................5-2
Air Control Components .............................................4-2
Air Cooled Unit installation ..........................................2.l
Air Filter Element, Heavy Duty ....................................6-1
Air Filter Element, Standard Duty ................................6-2
Air Filter Element Life, Heavy Duty ..............................6-l
Air Filter Element Life, Standard Duty .........................6-2
Air Filter Element Servicing Instructions ............. 6-1, 6-2
AIR FILTER (SECTION 6) .. . .......................................6-1
Air Flow in the Compressor System ...........................l-l
Air Receiver, Auxiliay ..................................................2.3
AUTO-LAG Button with LED ........................................4-3
AUTO-LEAD Button with LED .....................................4-3
Auto Sentry S -Auto Lag Button .................................4-3
Auto Sentry S -Auto Lead Button ...............................4-3
Auto Sentry S - Constant Run Button .........................4-3
Auto Sentry S - Control Pad Diagram .........................4-8
Auto Sentry S - Controller with Keypad ......................4-3
Auto Sentry S - Emergency Stop Pushbutton ............4-3
Auto Sentry S - Hourmeter ..........................................4.3
Auto Sentry S - Lead-Lag operation ...........................4-6
Auto Sentry S - Programming and Set-Up
instructions ..........................................................4.4
Auto Sentry S - Stop/Reset Button .............................4-3
Auxiliay Air Receiver ...................................................2.3
Basic information .........................................................l.l
BELT DRIVE (SECTION 7) ..........................................7-1
Belt Tension, ChecMng ................................................7.l
Blowdown Valve ..........................................................4.2
Blowdown Valve Piping ...............................................2.4
CHANGE AIR FILTER LED ..........................................4-4
CHANGE SEPARATOR LED .......................................4-4
Check, Daily .................................................................3.2
Check, Pre-Start-Up ....................................................3.l
Cold Ambient Operation ..............................................5-2
Cold Weather Operation ..............................................2.2
Compression Principal ................................................l.l
Compressor Oil Cooler ................................................5.5
Compressor Oil Filter ..................................................5.4
Compressor Oil System ..............................................5-1
Compressor System, Air Flow ....................................l-l
CONSTANT RUN Button with LED .............................4-3
Control Piping ..............................................................2.3
CONTROLS AND INSTRUMENTS (SECTION 4) .......4-1
Control System Operation ...........................................4.3
AUTO LAG Button with LED ................................4-3
13-8-610
dash are Page Numbers
AUTO LEAD Button with LED .............................4-3
CHANGE AIR FILTER LED ..................................4-4
CHANGE SEPARATOR LED ...............................4-4
CONSTANT RUN Button with LED .....................4-3
HIGH AIR TEMPERATURE LED .........................4-3
MOTOR OVERLOAD LED ...................................4-4
Pressure and Temperature Digital Readouts .....4-4
STOP/RESET Button with LED ...........................4-3
Cooler, Compressor Oil ..............................................5.5
Cooling, Lubrication and Sealing ...............................1-1
Daily Check ..................................................................3-2
Decals ...................................................................l.7. 1-8
Definitions of Error Messages .....................................4.4
Discharge Service tine ...............................................2.3
Drain, Oil Resewoir .....................................................2.2
Draining and Cleaning The Oil System ......................5-3
Electrical Wiring ...........................................................2.4
Element, Air Filter .................................................6.l. 6-2
Emergency Stop Pushbutton .....................................4-3
Enclosure ....................................................................2.2
Error Messages - Definitions .......................................4.4
Extreme Cold Weather Operation, Installation ...........2-3
Filling Oil Reservoir ....................................................5.3
Filter, Nr ................................................................6.l. 6-2
Filter, Compressor Oil .................................................5.4
Filter Element ........................................................6.l. 6-2
Filter Element tife .................................................6.l. 6-2
Foundation .................................................................2.l
Gauge, Oil Sight ...................................................4.2. 5-3
GENERAL INFORMATION (SECTION 1) ..................1-1
Grease Recommendations, Electric Motor ................2-4
Grounding ....................................................................2.4
Heavy Duty Air Filter....................................................6.l
HIGH AIR TEMPERATURE LED ..................................4-3
High Discharge Temperature Shutdown ....................4-l
High Temperature Operation .....................................5-1
Hourmeter ....................................................................4.3
Inlet Line ....................................................................2.3
Inlet Line Lengths ........................................................2.3
Inlet Tube, Air Filter .....................................................6.l
Inlet Valve ...................................................................4.2
INSTALLATION (SECTION 2) ....................................2-1
Page ii
 INDEX (Continued)
NOTE: Numbers preceding dash are Section Numbers -- Numbers following
installation, Air Cooled Unit .........................................2-l
installation for Cold Weather Operation. ....................2-2
instruments ..................................................................4.2
Lead-Lag Operation of TWO Compressors .................4-6
LED - Change Air Filter ................................................4.4
LED - Change Separator .............................................4.4
LED - High Air Temperature ........................................4.3
LED - Motor Overload ..................................................4.3
Lifting Unit ...................................................................2.1
Load-Unload Pressure Setpoints, Programming .......4-4
Location .......................................................................2.l
Lubricant, Addition of Oil Between Changes ..............5-2
Lubricant, Changing Type of Oil .. ............................5-1
Lubricant, Draining and Cleaning System ..................5-3
Lubricant, Oil Specifications .......................................5-1
Lubricant, Recommended.. .........................................5-1
Lubricant Change lntewal ...........................................5.3
Lubricant Change Procedure ......................................5-1
Lubrication, Cooling and Sealing ................................l-l
Lubrication, Motor .......................................................2.4
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5).. ...............................5-1
MAINTENANCE SCHEDULE (SECTION 8) ...............8-1
Minimum Pressure/Check Valve ................................4-3
Moisture in the Oil System .........................................5-3
Moisture Separator/Trap .............................................2-3
Motor Grease Recommendations ...............................2.4
Motor Lubrication .......................................................2.4
MOTOR OVERLOAD LED ...........................................4-4
Motor Regressing lntewal ...........................................2.5
Motor Protection Devices ...........................................4-1
Oil Change lntewal ......................................................5.3
Oil Cooler, Compressor ...............................................5.5
Oil FiIter ........................................................................5.4
Oil Level Gauge ..........................................................5.3
Oil Pressure Differential Gauging, Oil Cooler .............5-6
Oil Resewoir .................................................................5.5
Oil Reservoir Drain .......................................................2.2
Oil Reservoir, Filling.....................................................5.3
Oil Separator ................................................................5.5
Oil Separator - Inspection ...........................................5-6
Oil Separator - Pressure Differential Gauging ............5-5
Oil Separator- Removal ..............................................5.6
Oil Sight Gauge .................................................... 4-2, 5-3
13-8-610
dash are Page Numbers
Oil Specifications .........................................................5.l
Oil System Check ...................................................... 5-6
Air and Oil Discharge Temperature ....................5-6
Compressor Oil Inlet Temperature .....................5-6
Oil Cooler Oil Pressure Differential
(Air-Cooled Radiator) .....................................5-6
Oil Cooler Temperature Differential
(Air-Cooled Radiator) .....................................5-6
Oil Inlet Pressure .................................................5.6
Oil System, Compressor .............................................5.l
Oil System, Draining & Cleaning ................................5-3
Operating Alr Pressure Adjustment ............................4-7
Operation
Cold Weather ......................................................2.2
Extreme Cold Weather ........................................2-3
High Temperature ...............................................5-l
Optional Motor Protective Devices
Wye Delta Stafler ................................................4.l
Ordering Instructions, Repair Parts ............................... ii
Outline Drawings ...........................................l.2. 1-3, 1-4
Piping, Blowdown Valve ..............................................2.4
Piping, Control .............................................................2.3
Precautions, Safety ..............................................l.5. 1-6
Pressure and Temperature Digital Readouts .............4-4
Pressure Differential, Oil Cooler Oil ............................5-6
Pressure, Oil inlet ........................................................5.6
Pressure, Separator Differential ..................................4-l
Prestart-Up Instructions ..............................................3-1
Prestarting Check
Air Filter ...............................................................3.l
Compressor Oil ...................................................3.l
Electrical ..............................................................3.l
Enclosure ............................................................3.2
Grounding ...........................................................3.l
Operating Mode ..................................................3.2
Piping.. .................................................................3.l
Rotation ...............................................................3.l
System Pressure .................................................3.l
Programming Load-Unload Pressure Setpoints ........4-4
Protective Devices .......................................................4.l
Protective Devices
Blowdown Valve ..................................................4.2
Motor Protective Devices ....................................4-l
Relief Valve ..........................................................4.l
Receiver. Auxiliay Mr ..................................................2.3
Recommended Lubricant ...........................................5-1
Page iii
 INDEX (Continued)
NOTE: Numbers preceding dash are Section Numbers -- Numbers following dash are Page Numbers
Regressing Interval, Electric Motor .............................2-5
Relief Valve ...................................................................4-l
Reservoir, Oil................................................................5.5
Safety Precautions .............................................. 1-5, 1-6
Sealing, Lubrication and Cooling ................................l-l
Separator Differential Pressure Shutdown .................4-1
Separator/Trap, Moisture ............................................2-3
Service Check tist .......................................................8.l
Air Filter ................................................................8.l
Every Year ...........................................................8-1
Motor Lubrication ................................................8.l
Oil Separator ........................................................8.l
8 Hours Operation ...............................................8-l
125 Hours Operation ...........................................8-1
1000 Hours Operation .........................................8-1
4000 Hours Operation .........................................8-1
6000 Hours Operation .........................................8-1
Service Line, Discharge ...............................................2.3
Shutdowns
High Discharge Temperature ..............................4.l
Separator Differential Pressure ...........................4-l
Specifications, Oil ........................................................5.l
Starter/Control Box (Components) .............................4-3
AUTO IAG Button with LED ................................4-3
AUTO LEAD Button with LED .............................4-3
Auto Sentry “S”Controller with Keypad ..............4-3
CHANGE AIR FILTER LED ..................................4-4
CHANGE SEPARATOR LED ...............................4-4
CONSTANT RUN Button with LED .....................4-3
Emergency Stop Pushbutton ..............................4.3
HIGH AIR TEMPERATURE LED ..........................4-3
13-8-610
Hourmeter ...........................................................4.3
MOTOR OVERLOAD LED ...................................4-4
Pressure and Temperature Digital Readouts .....4-4
STOP/RESET Button with LED ...........................4-3
Starter, Wye-Delta (Optional) .....................................4-l
STARTING & OPERATING PROCEDURES
(SECTION 3) ..........................................................3.l
Starting The Unit, Cold ................................................3.2
Starting The Unit, Hot ..................................................3.2
Stop, Emergency (Pushbutton) ..................................4-3
STOP/RESET Button with LED ...................................4-3
Stopping The Unit ......................................................3-2
Subtractive Pilot ..........................................................4.7
Temperature Differential, Oil Cooler ...........................5-6
Temperature, Air& Oil Discharge ...............................5-6
Temperature, Compressor Oil inlet ............................5-6
Thermostatic Mixing Valve .........................................5-5
TROUBLE SHOOTING (SECTION 9) ........................9-1
Tube, Inlet ....................................................................6.l
Unload-Load Pressure Setpoints, Programming .......4-4
Valve, Blowdown .........................................................4.2
Valve, Inlet ...................................................................4.2
Valve, Minimum Pressure/Check ................................4-3
Valve, Relief .................................................................4.l
Wiring Diagram ............................................................4.9
Wiring, Electrical ..........................................................2.4
Wye.Delta Statier ........................................................4.l
Page iv
 ILLUSTRATIONS

No. Description Page

1-1 Compression Cycle ................................................................................................................................. 1-1

1-2 Package - Minimum Pressure/Check Valve, Mixing Valve & Oil Filter .................................................. 1-2

1-3 Package - Oil Level Gauge, Separator &Air Filter................................................................................. 1-3

1-4 Package - Controller& Starter Box ........................................................................................................ 1-4

2-1 Typical Compressor Room ..................................................................................................................... 2-1

2-2 Minimum Air Flow Chafl .........................................................................................................................2.l

2-3 Cold Weather installation ........................................................................................................................2.2

4-1 Control Schematic .................................................................................................................................. 4-1

4-2 Inlet Valve ................................................................................................................................................4.2

4-3 Minimum Pressure/Check Valve .............................................................................................................4.2

4-4 Definitions of Error Messages ................................................................................................................4.4

4-5 Pressure Chati ........................................................................................................................................ 4-6

4-6 Subtractive Pilot (Closed) .......................................................................................................................4.6

4-7 Subtractive Pilot (Opened) .....................................................................................................................4.6

4-8 Maximum Setpoints for Auto-Sentry S Controller, PSIG .......................................................................4.8

4-9 Auto-Sentry S Solid State Control Touch Pad .......................................................................................4.8

4-1o Wiring Diagram ....................................................................................................................................... 4-9

5-1 Flow Diagram -Air-Oil System ............................................................................................................... 5-1

5-2 Approximate Oil System Capacities .......................................................................................................5.2

5-3 Thermostatic Mixing Valve ...................................................................................................................... 5-3

5-4 Dew Point Temperature vs. Ambient Temperature Chati ..................................................................... 5-5

5-5 Oil Separator ........................................................................................................................................... 5-5

6-1 Standard Air Filter ................................................................................................................................... 6-1

6-2 Heavy Duty Air Filter (Optional) .............................................................................................................. 6-1

7-1 Belt Tension 5VX Belts ............................................................................................................................ 7-1

13-8-610 Page v
SECTION 1
GENERAL INFORMATION
FIGURE 1-1 - COMPRESSION CYCLE
COMPRESSOR - The Gardner Denver@ compressor
is a single stage, positive displacement rotary machine
using meshing helical rotors to effect compression. Both
rotors are supported between high capacity roller bear-
ings located outside the compression chamber. Single
width cylindrical roller bearings are used at the inlet end
of the rotors to carry part of the radial loads. Tapered
roller bearings at the discharge end locate each rotor
axially and carry all thrust loads and the remainder of the
radial loads.
COMPRESSION PRINCIPLE (Figure 1-1) - Compres-
sion is accomplished by the main and secondary rotors
synchronously meshing in a one-piece c Iinder. The
main rotor has four (4) helical lobes 90 apart. The
secondary rotor has six (6) matching helical grooves 60°
apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor
cylinder near the drive shaft end. The discharge port is
near the bottom at the opposite end of the compressor
cylinder. Figure 1-1 is an inverted view to show inlet and
discharge ports. The compression cycle begins as the
rotors unmesh at the inlet port and air is drawn into the
cavity between the main rotor lobes and the secondary
rotor grooves (A). When the rotors pass the inlet port
cutoff, air is trapped in the interlobe cavity and flows
axially with the meshing rotors (B). As meshing con-
tinues, more of the main rotor lobe enters the secondary
rotor grove, normal volume is reduced and pressure
increases.
13-8-610 Section 1
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume
reduction and pressure increase continues until the
air/oil mixture trapped in the interlobe cavity by the
rotors passes the discharge port and is released to the
oil reservoir (C). Each rotor cavity follows the same
“fill-compress-discharge” cycle in rapid succession to
produce a discharge airflow that is continuous, smooth
and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure
5-1, page 1, Section 5) - Air enters the air filter and passes
through the inlet unloader valve and on into the com-
pression chamber where oil is injected into the air. After
compression, the air/oil mixture passes into the oil reser-
voir where most of the entrained oil is removed by
velocity change and impingement and drops back into
the reservoir. The air and remaining oil then passes
through piping and the air/oil separator. The air then
passes through the minimum pressure/check valve, the
aftercooler and the moisture separator and into the plant
air lines.
LUBRICATION, COOLING AND SEALING - Oil is
forced by air pressure from the oil reservoir through the
oil cooler, thermostatic mixing valve, and oil filter and
discharged into the compressor main oil gallery. A por-
tion of the oil is directed through internal passages to
the bearings, gears and shaft oil seal. The balance of the
oil is injected directly into the compression chamber to
remove heat of compression, seal internal clearances
and lubricate the rotors.
Page 1
 PRESSURE
RELIEFVALVE MOISTURE
SEPERATOR
MINIMUM
PRESSUREICHECK
VALVE
\ T 1

A Uu “’’’’’’’’’11111
III II;F’T’F’RI
MA=
‘r A -- IIIIl“i’l”l-i’~pflLF!
1111111111
1111111111

o I IIIL c o 0 LER

I ,,, ,,, , !!, ,,, ,,

OIL RESERVOIR By_pAss pipING

OIL FILTER1 [ THERMAL CONTROL
(MIXING)VALVE

FIGURE 1-2- PACKAGE- MINIMUMPRESSURE/CHECK

VALVE,MIXINGVALVE&OIL FILTER

13-8-610 Section 1 Page 2

 AIR/OIL SEPERATOR
AIR FILTER

OIL FILLER PLUG

1
\

—
OIL LEVEL FLOAT GAUGE

RESERVOIR OIL DRAIN

FIGURE 1-3 - PACKAGE- OIL LEVEL GAUGE, SEPARATOR& AIR FILTER

13-8-610 Section 1 Page 3

STARTER/CONTROL BOX= HOURMETER

- EMERGENCY STOP BUTTON

CONTROL PANEL

FIGURE 1-4- PACXAGE- CONTROLLER &STARTER BOX

13-8-610 Sectionl Page4

 SAFETY PRECAUTIONS

Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances
cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for
safety hazards and be cautious. Some general safety precautions are given below:

DANGER

Failure to observe these notices could result in injury to or death of personnel.

. KeeP finGers and clothinG awav from revolving fan, drive coupling, etc.

● Do not use the air discharae from this unit for breathing - not suitable for
human consumption.

● Do not loosen or remove the oil filler plug, drain plugs, covers, the thermo-
static mixing valve or break any connections, etc. in the compressor air or
oil system until the unit is shut down and the air pressure has been relieved.

● Electrical shock can and may be fatal.

● coMPresso r unit must be arounded in accordance with the National Electri-

cal Code. Aground jumper equal in size to the equipment ground conductor
must be used to connect the compressor motor base to the unit base.

. Fan motors and must remain arounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.

. OPen main disconnect switch, tag and lockout before working on the control.

● Disconnect the compressor unit from its power source, tag and lockout
before working on the unit-this machine is automatically controlled and may
start at anytime.

13-8-610 Section 1 Page 5

 WARNING

Failure to observe these notices could result in damage to equipment.

● StoP the unit if any repairs or adjustments on or around the compressor are
required.

. Disconnect the compressor unit from its power source, tag and lockout before
working on the unit - this machine is automatically controlled and may start at
any time.

. An Excess Flow Valve should be on all compressed air supply hoses exceed-
ing 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)

. Do not exceed the rated maximum Pressure values shown on the nameplate.

● Do not ope rate unit if safety devices we not operating properly. Check
periodically. Never bypass safety devices.

13-8-610 Section 1 Page 6

 DECALS

DISCHARGE AIR USED FOR

BREATHING WILL CAUSE AIR AND OIL UNOER PRESSURE
SEVERE INJURY OR DEATH. WILL CAUSE SEVERE PERSONAL
CONSULT FILTRATION NJURY OR DEATH.
SPECIALI ST FOR HUTDOWN COMPRESSOR ANO
ADDITIONAL FILTRATION ELIEVE SYSTEM OF ALL
AND TREATMENT EQUIPMENT PRESSURE BEFORE REMOVING
TO MEET HEALTH AND VALVES, CAPS. PLUGS,
SAFETY REGULATIONS. FITTINGS. BOLTS ANO FILTERS.
-

206 EAQ077 212EAQ077

HIGH vOLTAGE.
ROTATING MACHINERY.
AIR ANo OIL
UNDER PRESSURE,
DO NOTMODIFY
IMPROPER MODIFICATION
OF EQUIPMENT WILL
UNITWITHOLIT
CAUSE SEVERE PERSONAL WRITTEN PERMISSION
INJURY OR DEATH. FROMMANUFACTURER.
—

218EAQ077

UNIT CAN AUTOMATICALLY

ROTATING MACHINERY CAH RESTART.
CAUSE 1NJUR% OR DEATH. CAN CAUSR PIRSONAL INJUR
KEEP ALL GUAROS AND OR OEATH.
SAFETY DEVICES IN KNOW MODS OF 0PERATION
PLACE. BEFORE WORKING ON OR
NSAR THE MACHINE.
a- -

211 EAQ077 207 EAQ077

13-8-610 Section 1 Page 7

 DECALS

ELECTRICAL SHOCK FROM

IMPROPER GROUNDING CAN
CAUSE INJURY OR DEATH.

GROUND UNIT AND RELATED

EQUIPMINT ACCORDING TO
NATIONAL ELECTRIC COOE
AND LOCAL REGULATIONS.

216 EAQ077

ELECTRICAL SHOCK CAN

CAUSE INJURY OR DEATH.
AIR AND OIL UNDER
DISCONNECT ALL CIRCUITS
PRESSURE. BEFORE WORKING ON THIS
CANCAUSESEVERE CONTROL.
PERSONAL INJURY SEE WIRING DIAGRAM.

OR DEATH.
INSPECTOIL RESERVOIR
FORCRACKS AT LEAST
ANNUALLY. 222 EAQ077
-

217EAQ077

@
ELECTRICAL ARCING CAN
CAUSE A FIRE WHEN UNIT IS
MOUNTEO ON A cOMBUSTIBLE
SURFACE RESULTING IN
PiRSONAl INJURY OR
PRoPERTY OAMAGE. MACHINE DAMAGE OR INJURY
UNIT MUST BE MOUNTID ON CAN OCCUR DUE TO IMPROPER
A FLOOR PLATE EXTENDING LIFTING.
ON ALL SIOES. 00 NOT LIFT MACH INF. WITH
SEE INSTALLATION THE MO1OR LYEBOLT.
DRAWING FoR PROPER
DIMENSIONS.
- I —1

221 EAQ077 208 EAQ077

13-8-610 Section 1 Page 8

SECTION 2
INSTALLATION
GENERAL - On receipt of unit, check for any damage
that may have been incurred during transit. RepoRtany
damage or missing parts as soon as possible.
~CAUTION
Do not electric weld on the compressor
or base; bearings can be damaged by
passage of current.
obstruction on the starter end and control box end of the
unit. Allow two (2) feet to the nearest obstruction above
and on other sides of unit. For continuous efficiency, oil
cooler cores must be periodically cleaned with either
vacuum or compressed air. If wet cleaning is required,
shield motor and spray on a mild soap solution and flush
with clean water. - -
~WARNING

For aluminum oil coolers, do not use

LIFTING UNIT - Proper lifting and/or transporting any cleaning solution that is not com-
methods must be used to prevent damage. patible with aluminum. Use of improper
solution may result in damage to
cooler.
~CAUTION

Lift compressor unit by base only. Do

FOUNDATION - The Electra-Screw@ comPressor re-
not use other places such as enclosure,
quires no special foundation, but should be mounted on
motor, compressor oil discharge a smooth, solid surface. Whenever possible install the
manifold and piping as lifting points. unit near level. Temporary installation may be made at a
maximum 10° angle lengthwise or 10° sidewise.
Mounting bolts are not normally required. However, in-
~DANGER
I stallation conditions such as piping rigidity, angle of tilt,

The eyebolts or lugs provided on the

motor are for lifting the motor only and LOUVERED
ExHAUST FAN
LO UVEREO
should not be used to lift any additional
weight. All eyebolts must be securely
tightened. When lifting the motor the
lifting angle must not exceed 15
degrees. Failure to observe this warn-
ing may result in damage to equipment
or personal injury.

Lifting slots are provided in the base for towmotor use.

Unit may also be moved into location by rolling on bars.
LOCATION - The compressor should be installed where A75119
it is protected from rain, snow and freezing tempera-
tures, in a clean, well-lighted, well-ventilated area with
FIGURE 2-1 - TYPICAL COMPRESSOR ROOM
ample space all around for maintenance. Select a loca-
tion that provides a cool, clean, dry source of air. In some
cases it may be necessary to install the air filter at some
distance from the compressor to obtain proper air supp-
ly. I Minimum Air Flow* For Compressor
And CoolinG (Cubic Feet/Minute)

AIR-COOLED UNIT - A combination oil/aftercooler is I I Air Cooled

supplied as standard equipment on all air-cooled units.
The air-cooled unit with the standard enclosure requires
sufficient flow, Figure 2-2, for the compressor oil/after- I All Models
I 6500 cfm

cooling system and electric motor cooling. Air is drawn

into the unit at the motor side of the enclosure and is * 80”F inlet air
exhausted at the oil cooler side. Do not block the airflow
to and from the unit. Allow three (3) feet to the nearest FIGURE 2-2

13-8-610 Section 2 Page 1

 MOTOR
T r COMPRESSOR

8 FT. PLYWOOD FENCE’”

FT. PLYWOOO “FENCE”
/’”- 8

WELL MAN RADIANT 2-ELEMENT

HEATER (OR EOUAL)
f RH400 WITH (21 RH4502
ELEMENTS - 2 REQD.
5,200 WATTS EACH
4 FT.
7

VP ‘._ //
/
—OIL RESERVOIR
\’ ● /

\ /

WELLMANRADIANT 2-ELEMENT
AWAY FROM PREVAILING WINDS
HEATER (oR EOUA) ELEVATION VIEW
RH7000 WI TH (2) RH7502
ELEMENTS - 2 REOD
6.200 WATTS EACH

FIGURE 2-3- COLD WEATHER INSTALLATION

or danger of shifting from outside vibration or moving Any of the enclosure doors maybe removed by opening
vehicles may require the use of mounting bolts and the door and lifting it up slightiyto disengage the hinges.
shims to provide uniform support for the base. Belt
alignment and tension should be checked after installa-
tion. (For information on belt alignment and tension see
Section 7, page 1.)
I ~DANGER

OIL RESERVOIR DRAIN -The oil drain is piped from the Do not operate compressor with fan
botTom of the reservoir to the side of the frame. This drain and belt guard removed. Exposed fan
is approximately 2 inches above the floor level. If this is and belts may cause injury to person-
‘;
not sufficient to conveniently drain the oil some other nel.
methods of providing drain are:
1. Elevate the comPressor unit on a suitable structure
to obtain the deSired drain height, The motor inspection/air filter service panel is held by
two latches and lifts away from the enclosure. The air
outlet panel is attached by screws to the enclosure and
~CAUTION is not readily removable.

If the compressor unit base is raised INSTALLATION FOR COLD WEATHER OPERATION
above floor level, the space between - It is recommended that the unit be installed inside a
the floor and the base bottom must be shelter that will be heated to temperatures above freez-
closed with solid material all around to ing (32”F, O“C). This will eliminate many of the problems
prevent recirculation of hot air from the associated with operating units in cold climates, such as
oil cooler end and over temperature freezing in control lines and downstream of the cooler.
operation. Refer to Engineering Data Sheet 13-9-411 for the ad-
vantages of using the heat recovered from rotary com-
pressors. This heat recovery could easily pay for an
2. Construct an oil sump or trough below the floor adequate shelter for the unit.
level and pump or bail the drained oil.
When an outside installation must be made, the precau-
3. Pump oil from the reservoir filler opening or drain tions required will depend on how severe the environ-
to a container. ment. The following are general guidelines for outside
installations:
ENCLOSURE - The compressor, electric motor, oil
Cold Weather (Down To + 10”F)
cooler and afTercooler are mounted inside the enclosure.
1. Be sure all drains, traps and control lines including
Service doors are provided for maintenance access. Be pressure transducer lines are heated to avoid freez-
sure to allow enough space around the unit for the doors ing of condensate. Heat tape with thermostat con-
to open completely. trol is generally satisfactory for this purpose and

13-8-610 Section 2 Page 2

 can be obtained at various local plumbing or
hardware outlets at nominal cost.
2. If an air-cooled aftercooler is to be used, provisions
to bypass the aftercooler must be made. Since cold
air contains very little moisture, successful opera-
tion can be achieved without the aftercooler.
3. Provide at least some simple shelter such as a
plywood windbreak to protect against drifting
snow.
4. Use only Gardner-Denver@ AEON ‘M 9000
lubricant.
5. Monitor unit carefully during start-up and operation
to be sure it is functioning normally.
6. Specify NEMA 4 enclosure for electrical devices.
Extreme Cold Weather Operation (Down To -40”F)
In addition to the above, the following should be
provided:
1. It will be necessary to provide shutters or to block
off part of the cooler in some manner since the
cooler is greatly oversized for operation inthese low
temperatures. Since shutters are not provided as
a factory option, blocking off a portion of the cooler
with plywood should be satisfactory.
2. In extreme environments, run the unit in “Constant
Speed” only.
3. Some means of ProvidinG heat during shutdown
should be provided. TherE are various-methods to
accomplish this, but since openings are not
provided for sump heaters, the use of radiant
heaters is recommended. The heaters should be
sized to provide at least a + 10°F environment for
coolers, motor and sump. Figure 3-2 shows how
these might be located in a typical installation and
sizes required.
Remember unsheltered (outside) installations should be
avoided where possible. Installation next to a heated
building where enough heat can be used to keep the
compressor room above freezing will save many com-
plications in the operation and installation of the unit.
Refer to Engineering Data Sheet 13-9-411, available from
an authorized Gardner Denver distributor, for the ad-
vantages of using the heat recovered from rotary com-
pressors. This heat recovery could easily pay for an
adequate shelter for the unit.
AUXILIARY AIR RECEIVER - An auxiliary air receiver is
not required if the piping system is large and provides
INLET LINE LENGTHS
Length of Inlet Line
Oto 10 Feet .......................................................................................................... Same as Compressor Inlet Opening
10to 17 Feet .......................................................................................................... One Size Larger Than Inlet Opening
17t038 Feet ........................................................................................................ Two Sizes Larger Than Inlet Opening
13-8-610
sufficient storage capacity to prevent rapid cycling.
When used, an air receiver should be of adequate size,
provided with a relief valve of proper setting, a pressure
gauge and a means of draining condensate.
MOISTURE SEPARATOR/TRAP - Since unit is
equipped with a built-in aftercooler, a combination mois-
ture separator and trap is furnished with the unit.
CONTROL PIPING - Control piping is not necessary
since the Electra-Screw@ unit is factory wired and piped
for the control system specified.
SP
INLET LINE - Where an inlet line is used between the air
filter and the compressor, it must be thoroughly cleaned
on the inside to prevent dirt or scale from entering the
compressor. If welded construction is used, the line
must be shot blasted and cleaned to remove welding
scale. In either case, the inlet line must be coated
internally by galvanizing or painting with a moisture and
oil-proof sealing lacquer. Up to ten (1O) feet in length,
the inlet line should be the full size of the inlet opening
on the compressor. If an extra-long line is necessary,
the pipe size should be increased according to Inlet Line
Chart below.
Accessibility for inlet air filter servicing must be con-
sidered when relocating the filters from the unit to a
remote location.
DISCHARGE SERVICE LINE - The discharge service
line connection is made at the upper right hand corner
of the cooler, viewed from the oil cooler side. A hand
operated valve, (air service valve) must be installed be-
tween the unit and the customer’s air system. When
manifolding two or more Electra-Screw” units on the
same line, each unit is isolated by the check valve in the
unit discharge line. If an Electra-Screw@ unit is
manifolded to another compressor, be sure the other
compressor has a check valve in the line between the
machine and the manifold. If an Electra-Screw” and a
reciprocating compressor are manifolded together, an
air receiver Rust be located between the two units.
DANGER
Discharge air used for breathing will
cause severe injury or death.
Consult filtration specialists for addi-
tional filtration and treatment equip-
ment to meet health and safety
standards.
Diameter of Pipe Size
Section 2 Page 3
BLOWDOWN VALVE PIPING - The blowdown valve is
fitted with a muffler for operation indoors. if the installa-
tion requires, the muffler may be removed and the blow-
down valve piped to the outside with a pipe size the same
as the blowdown valve outlet connection.
ELECTRICAL WIRING - Standard Units - The Electra-
Screw@ compressor is factory wired for all starter to
motor and control connections for the voltage specified
on the order. It is necessary only to connect the unit
starter to the correct power supply. The standard unit is
supplied with an open drip-proof motor, a NEMA 12
starter and control enclosure. See “Location” paragraph
fordistanceto nearest obstruction on statterand control
box sides of the unit.
MOTOR LUBRICATION - Long time satisfactory oper-
ation of an electric motor depends in large measure on
proper lubrication of the bearings. The following charts
show recommended grease qualities and regressing
intervals for ball bearing motors. For additional informa-
tion refer to the motor manufacturer’s instructions.
The following procedure should be used in regressing:
1. Stop the unit.
2. Disconnect, tag and lockout the unit from the
power supply.

The overload heaters are to be selected according to 3. Remove the relief plug and free hole of hardened
starter manufacturer’s tables, which are attached to the grease.
inside of the control box, based on motor nameplate full
load amperage. 4. Wipe lubrication fitting clean and add grease with
a hand-operated grease gun.

wARNING 5. Leave the relief plug temporarily off. Reconnect

unit and run for about 20 minutes to expell the
Electrical shock can cause injury or excess grease.
death. Open main disconnect switch,
tag and lockout before working on 6. Stop the unit. Replace the relief plug.
starter/control box.
7. Restart the unit.

GROUNDING - Equipment must be grounded in accor-

dance with Section 250 of the National Electrical Code.

wARNiNG
WARNING
Rotating machinery can cause injury or
Failure to properly ground the com- death. Open main disconnect, tag and
pressor package could result in con- lockout before working on electric
troller malfunction. motor.

ELECTRIC MOTOR GREASE RECOMMENDATIONS

Standard High
Service Temperature

Worked Penetration ....................................................................................... 265-296 220-240

Grease Viscosity, SSU At 100°F ..................................................................... 400-550 475-525

Soap Type ...................................................................................................... Lithium Lithium

N-H Bomb, Minimum Hours For20 PSI Drop at 21O”F. ................................ 750 1000
Bleeding, Maximum Weight % In 500 Hours 212°F. ..................................... 10 3

Rust inhibiting .................................................................................................. Yes Yes

13-8-610 Section 2 Page 4

 ELECTRIC MOTOR REGRESSING INTERVAL

Type of Service Typical Examples Rating Relubrication Interval

Standard One- or Two-Shift Operation 150 HP& Below 18 Months

Severe Continuous Operation 150 HP & Below 9 Months

Very Severe Dirty Locations, High 150 HP& Below 4 Months

Ambient Temperature

13-8-610 Section 2 Page 5

SECTION 3
STARTING & OPERATING PROCEDURES
PRESTART-UP INSTRUCTIONS - A new unit as
received from the factory has been prepared for ship-
ping only. Do not attempt to operate the unit until
checked and serviced as follows:
1. ComPressor Oil - Check oil level in the reservoir.
Add Oil only if the oil level gauge reads in the red
“ADD OIL” range. Do not mix different type oils.
Unit is shipped filled with Gardner Denver”
AEON ‘“ 4000 Lubricating Coolant which is suitable
for the first 4000 hours under normal operating
conditions. AEON ‘M 4000 is generally suitable for
use up to 6000 hours service life, provided the
lubricant is monitored by periodic analysis.
REPLACE OIL FILTER EVERY 1000 HOURS.
Initial fill, or filling after a complete draining of the
system, may show the oil level above the FULL
mark (the center of the gauge). After start-up, the
oil level will drop and fluctuate as the machine runs.
To check for proper oil level, shut off the machine
and allow the foam to settle out. if necessary, add
oil to bring the level to the FULL mark. See Figure
1-3, page 3, Section 1,
NOTICE
Regular maintenance and replacement
at required intervals of the oil filter, air
filter and air-oil separator is necessary
to achieve maximum service and ex-
tended drain intervals of AEONTM 4000
petroleum base lubricant. Use only
genuine Gardner Denver filters
designed and specified for this com-
pressor.
DANGER
Before removing oil filler plug, always
stop the unit and release air pressure,
disconnect, tag and lockout the power
supply to the starter. Failure to release
pressure or properly disconnect the
power may result in personal injury or
death.
During unloaded operation and after shutdown, the
system will partially drain back into the oil reservoir
and the oil level may read higher than when operat-
ing on load. DO NOT DRAIN OIL TO CORRECT;
on the next loaded cycle or start, oil will again fill
the system and the gauge will indicate the operat-
ing level.
13-8-610 Section 3
2. Air Filter - Inspect the air filter to be sure it is clean
and tightly assembled. Refer to Section 6, “Air
Filter,”for complete servicing instructions. Be sure
the inlet line, if used, is tight and clean.
3. Piping - Refer to Section 2, “installation,”and make
sure piping meets all recommendations.
4. Electrical - Check the wiring diagrams furnished
with the unit to be sure it is properly wired. See
Section 4, ‘[Controls and instruments,” page 9, for
general wiring diagrams and Section 2 for installa-
tion instructions.
5. Grounding - Unit must be properly grounded ac-
cording to Section 250 of the National ELectrica
Code.
WARNING
Failure to properly ground the com-
pressor package could result in con-
troller malfunction.
6. Rotation - Check for correct motor rotation using
“JOG MODE.” ComPressor drive shaft rotation
must be clockwise standing facing the compressor
sheave. See Section 4, page 5, STep8.
wARNING
Operation with incorrect motor rotation
can damage equipment and cause oil
eruption from the compressor inlet.
When checking motor rotation, induce
minimum rotation (less than oNe
revolution if possible). Never allow
motor to reach full speed.
7. System Pressure - Set the controls to the desired
load pressure. DO NOT EXCEED MAXIMUM
OPERATING PRESSURE ON COMPRESSOR
NAMEPLATE. See Section 4, pages 4 through 7,
“Controls and Instruments,” for procedure.
I WARNING
I
Operation at excessive discharge air
pressure can cause personal injury or
damage to equipment. Do not adjust
the full discharge air pressure above
the maximum stamped on the unit
nameplate.
Page 1
8. Operating Mode - Refer to Section 4 for detailed
information on the control system.
9. Enclosure - Check for damaged panels or doors.
Check all screws and latches for tightness. Be sure
doors are closed and latched.
STARTING THE UNIT - Observe the following starting
procedures.
Unit Cold:
1. Close the air service valve (customer furnished)
between the main air system and the check valve
on the package.
2. If the unit is water-cooled, open any manual water
inlet valves wide open.
3. Start the unit by pushing either the “CONSTANT
RUN” or one of the “AUTO” buttons.
4. Run for approximately five minutes or until the
temperature stabilizes and then open the air ser-
vice valve.
The unit is equipped with a minimum (65 psig) pres-
sure/check valve, no special procedure to maintain the
unit reservoir pressure is required.
Unit Hot (No warm-up period is required):
1. Close the air service valve (customer furnished)
between the main air system and the check valve
on the package.
13-8-610 Section 3
2. If the unit is water-cooled, open any manual water
inlet valves wide open.
3. Start the unit by pushing either the “CONSTANT
RUN” or one of the “AUTO” buttons.
4. Run for approximately one minute and then open
the air service valve.
The unit is equipped with a minimum (65 psig) pres-
sure/check valve, no special procedure to maintain the
unit reservoir pressure is required.
DAILY CHECK - Refer to Section 8, “Maintenance
Schedule.”
STOPPING THE UNIT:
1. Close the air service valve (customer furnished)
between the main air system and the check valve
on the package.
2. Allow the unit to build up to full unloaded pressure
and run unloaded for 1 to 2 minutes.
3. Wait a short period for the reservoir to blow down.
4. Press “STOP-RESET’ button.
Stopping the unit at a pressure below full unloaded may
cause oil carry-over and can damage the air/oil separa-
tor element. The oil reservoir will automatically blow
down as the motor stops. Open the air service valve.
Page 2
SECTION 4
CONTROLS & INSTRUMENTATION
GENERAL -The Gardner Denver@ “EDE” Electra-Screw@
compressor is supplied with a factory mounted starter
and complete controls as standard equipment. The
standard control system consists of constant run
load/unioad operation, or auto start/timed stop opera-
tion. Lead/Lag operation of two EDE compressors is also
possible without additional equipment. Inlet valve
modulation is standard.
PROTECTIVE DEVICES - All compressors incorporate
the following protective devices:
Motor Protection Devices - Overload heaters are fur-
nished for the starter in the voltage range specified.
There are three (3) overloads in the starter of proper size
for the starter and its enclosure. An overload trip is
indicated by the “MOTOR OVERLOAD” LED located on
the control keYpad.
Optional Motor Protective Devices - Wye-Delta Starter
- Overload heaters are furnished for the starter in the
voltage range specified. There are three (3) overloads in
the starter of proper size for the starter and its enclosure.
Note that motor namePlate cu rrent must be muLTIPLied
.577 for wye-delta starters. Proper starter coil and contact
action is also monitored to ensure proper operation.
Separator Differential Pressure - The Separator dif-
ferential pressure is continually monitored by the
microprocessor controller. At a differential of ap-
proximately 8 PSI, the “CHANGE SEPARATOR” LED lo-
cated on the control keypad flashes indicating required
IIt
...
Swlrcn
FIGURE 4-1 - CONTROL SCHEMATIC
13-8-610
maintenance. If the warning is ignored, and the separator
differential continues to increase, the microprocessor
controller will stop the unit and the LED will remain on
steady. See “Control System Operation” in this section for
further information on operation of the microprocessor
controller.
High Discharge Temperature - The compressor is
protected from high discharge temperature by two inde-
pendent thermistor probes. One probe is located in the
compressor discharge housing to sense compressor
discharge air-oil mixture temperature. The second probe
is located at the separator discharge and senses the
temperature of the air at the oil separator.
The microprocessor controller will shut the compressor
down if the temperature sensed at either location ex-
ceeds 225 F. See “High Air Temperature LED,” page 4,
Section 4.
I CAUTION
bv Machine damage will occur if repeated-
ly restarted after high temperature
stops operation. Find and correct the
malfunction before resuming opera-
tion.
Relief Valve - A pressure relief valve(s) is (are) installed
PlnG, ,,0
— Wlrlci
Section 4 Page 1
 AIR FILTER
VACWN WITCH
BLOVWII
FACU
lNLEF VALVE
(OPEN F.)5ITIou)
BLOUWHN
VALVE
PLUG
FIGURE 4-2- INLET VALVE
in the final discharge line and set at the factory to
approximately 120%. of the unit’s full load operating
pressure for protection against overpressure. Periodic
checks should be made to insure its proper operation.
The relief valve should be tested for proper operation at
least once every year. To test relief valve, raise system
operating pressure to 75% of the relief valve set pressure
and manually open the valve with the hand lever. Hold
valve open for a few seconds and allow it to snap shut.
I wARNING
When relief valve opens, a stream of
high velocity air is released, resulting
in a high noise level and possible dis-
charge of accumulated dirt or other
debris. Always wear eye and ear pro-
tection and stand clear of the dis-
charge port when testing the relief
valve to prevent injury.
cAuTION
Never paint, lubricate or alter a relief
valve. Do not plug vent or restrict dis-
charge.
1
wARNING
Operation of unit with improper relief
valve setting can result in severe per-
sonal injury or machine damage.
Insure properly set valves are installed
and maintained.
13-8-610
ORIFICE
IN
OUT
FIGURE 4-3- MINIMUM PRESSURE/CHECK VALVE
Blowdown Valve (Figure 4-1, page 1, this section) - The
blowdown valve releases pressure from the oil reservoir.
See description under’’Air Control Components,” below,
for construction and operation information.
INSTRUMENTS - All units incorporate the following
instruments and indicators:
Oil Level Gauge (Figure 1-3, page 3, Section 1) - The
oil level gauge is located on the side of the reservoir.
See Section 5, “Lubrication, Oil Cooler, Oil Filter and
Separator”, for information on how to correctly read the
I
gauge. All other instruments are part of the programma-
ble controller.
AIR CONTROL COMPONENTS - All units incorporate
the following air control components. See Figure 1-4 for
schematic tubing diagram.
Inlet Valve (Figure 4-2, above) - The inlet valve is a
pilot-actuated valve that restricts the inlet to control
capacity and closes to unload the compressor. At shut-
down the inlet valve closes to function as a check valve
and prevent backflow of air.
As control pressure is increased the valve will begin to
close, restricting the inlet and reducing compressor
capacity. Approximately 18 psig of control pressure is
required to close the inlet valve completely. When
closed, the inlet valve prevents the flow of air in either
direction. With optional modulating control feature:
when the control pressure is less than 18 psig, the inlet
valve will modulate to match compressor capacity to
_ system demand.
Blowdown Valve (Figure 1-2, page 2, Section 1) - The
blowdown valve is atwo-way solenoid valve that is piped
into the oil separator outlet, but ahead of the check valve.
When the solenoid is de-energized, the blowdown valve
opens, and the oil system is blown down. When the
solenoid is energized, the blowdown valve closes, and
allows the oil system to pressurize.
Section 4 Page 2
Minimum Pressure/Check Valve (Figure 4-3, pre-
vious page) - An internal spring-loaded minimum pres-
sure valve is used in the final discharge line to provide a
positive pressure on the oil system even when the air
service valve is fully open. The valve senses upstream
pressure. if demand for air exceeds the compressor
capacity, the valve throttles the flow to maintain a mini-
mum pressure on the upstream (oil reservoir) side of the
valve. When the pressure rises above the minimum pres-
sure (standard setting 60 to 65 PSIG) the valve reaches
the full open position.
A check valve incorporated in the minimum pressure
valve prevents backflow of air from the shop air line
when the unit stops, unloads or is shut down.
The valve does not require maintenance or adjustment.
If the valve fails to function, it must be replaced because
it is not field adjustable or field repairable.
DANGER
Air and oil under pressure will cause
severe personal injury or death. Shut
down compressor and relieve system
of all pressure, disconnect, tag and
lockout the power supply to the starter
before removing valves, caps, plugs,
fittings, bolts, and filters.
STARTER/CONTROL BOX (Figure 1-3, page 3, Section
1) - The following control components are located on the
combination starter/control box.
Hourmeter -A continuous reading (nonreset) type hour-
meter displays the accumulated operating time of the
unit and provides a convenient means for scheduling
changes of oil and servicing of filters, separators and
other devices.
Auto-Sentry S Controller With Keypad - Monitors and
controls compressor operation.
Emergency Stop Pushbutton - Removes power from
the microprocessor controller outputs to provide a posi-
tive means of stopping the unit in an emergency situa-
tion.
CONTROL SYSTEM OPERATION - See Figure 4-9,
page 8, this section. The following are operations of the
Auto-Sentry S Controller.
“STOP/RESET’ Button With LED - This button is used
to stop the compressor under ordinary conditions. It is
also used to extinguish any fault LED’s that are il-
luminated. in addition, it is used in the procedure to
adjust the operating pressure. See “Adjusting the
Operating Pressure.” The LED is illuminated whenever
the unit is stopped for any reason EXCEPT a normal
shutdown in one of the “AUTO” modes. A flashing LED
indicates that a reset is required.
13-8-610
Machine damage will occur if repeated-
ly restarted after any one of the shut-
down modes stops operation of the
unit. Find and correct the malfunction
before resuming operation.
“CONSTANT RUN” Button With LED - This button is
used to operate the unit in the constant run mode. In this
mode, the compressor runs continuously, loading and
unloading in response to air demand. It will continue to
run until stopped, either manually or by a protective
shutdown. The LED is illuminated at all times while run-
ning in this mode.
“AUTO LEAD” Button With LED - This button is used to
operate the unit in the “Auto-Start-Timed-Stop” mode,
either by itself, or as the lead compressor in a Lead/Lag
arrangement. Loading and unloading occurs as in the
“CONSTANT RUN” mode, however, if the compressor
runs unloaded for a period of 10 minutes, the unit is
stopped. At this point, the compressor remains in the
“AUTO LEAD” mode and will restart when the system
pressure reaches the ‘load’ setpoint programmed into
the controller. The LED will remain illuminated
throughout the cycle.
I wARNING
Unit can automatically restart causing
personal injury.
Disconnect, tag and lockout the power
supply to the starter.
“AUTO LAG” Button With LED - This button is used to
select the ‘lag’ unit in a lead-lag arrangement. Operation
is identical to “AUTO LEAD” except that the start-load and
unload setpoints are automatically 5 PSI lower than
programmed.
NOTICE
Any mode may be selected at anytime
without stopping the compressor.
“HIGH AIR TEMPERATURE’ LED - This LED is used to
indicate an over temperature condition at either the
compressor or oil separator discharge. At the time of a
high temperature shutdown, the LED is illuminated and
the temperature digital readout is locked on to the of-
fending temperature. Illumination of the decimal point in
the lower right hand corner of the digital readout indi-
Section 4 Page 3
cates that the temperature displayed is at the oil sepa-
rator. A non-illuminated decimal point indicates com-
pressor discharge. Pressing “STOP/RESET” will
extinguish the LED (if the temperature has lowered
below 225”F) and revert the digital readout to displaying
actual discharge temperature.
“MOTOR OVERLOAD’ LED - This LED indicates that
the motor overload relay has tripped. The overload relay
itself must be reset before pressing “STOP/RESET” will
extinguish the LED.
“CHANGE SEPARATOR” LED - This LED flashes when
the differential pressure across the oil separator reaches
approximately 8 PSI. At this point, schedule the separa-
tor element for service at the earliest opportunity. (See
Section 5, pages 4 & 5, for separator maintenance.)
Should the condition be ignored and allowed to further
deteriorate, the compressor will be shutdown and the
LED illuminated steadily when the differential pressure
reaches 15 PSI.
I CAUTION
Machine damage will occur if repeat-
edly restarted after any one of the shut-
down modes stops operation of the
unit. Find and correct the malfunction
before resuming operation.
“CHANGE AIR FILTER” LED -This LED is used to signal
when the air filter requires servicing or changing. It is a
reminder only and will not stop or impede the operation
of the unit. Operating the compressor with the LED
illuminated risks collapse of the filter and ingestion into
the compressor.
I CAUTION
Machine damage can occur with ex-
tended operation after “Change Air Fil-
ter” LED illuminates. Service air filter
as soon as possible.
Pressure Readout
Error # Meaning
EO1 Failure of final discharge pressure sensor
E02 Failure of oil sump pressure sensor
E03 Failure of both pressure sensors
E04 EMERGENCY STOP
FIGURE 4-4- DEFINITIONS OF ERROR MESSAGES
13-8-610
Pressure And Temperature Digital Readouts - These
readouts normally indicate pressure at the minimum
pressure check valve and temperature at the air end
discharge. See “High AIr Temperature LED,” page 3, this
section, for a description of readout action during a high
temperature condition. Alternate y, these readouts can
be selected to display oil reservoir pressure and sepa-
rator air temperature. To obtain such display while the
compressor is running, simply press the operating mode
button that corresponds to the current operating mode
of the unit. (For Example: If the unit is operating in
“AUTO LEAD” mode, press the “AUTO LEAD” button.)
This will cause the readout to display the alternate pa-
rameters. This alternate display mode is indicated by
illuminated decimal points in the lower right hand corner
of each display. After releasing the button, the display
will revert to its normal mode in 5 seconds.
The digital readouts are also used to display error mes-
sages. These error messages correspond to various
indications concerning condition of the pressure and
temperature sensors and EMERGENCY STOP condi-
I tion.
DEFINITIONS OF ERROR MESSAGES - Refer to chart
in Figure 4-4 below for definitions.
An error message will stop the compressor, if running,
and prevent it from restarting. The failed sensor must be
replaced to clear the error.
Any condition requiring the control panel to be reset will
be indicated by a flashing “STOP/RESET” LED. If all
readouts and LED’s are flashing, a power interruption
has occurred, requiring the control panel to be reset.
I Programming The Load-Unload Pressure Setpoints
- Programming of the Load and Unload Pressure
setpoints can only be accomplished with the unit not
running.
SteP I: StoP the comPressor and disconnect, tag and
lockout the power supply to the starter -
Temperature Readout
Error # Meaning
EO1 Failure of compressor temperature sensor
E02 Failure of separator temperature sensor
E03 Failure of both temperature sensors
section 4 Page 4

AWARNING
Electrical shock can cause injury or
death. Open main disconnect, tag and
lockout power supply to the starter and
any other circuits before working in-
side control box.
SteP 2: Turn the “SetuP”switch located on the control-
ler circuit boaRd(inner side of control box door)
to the”+” position. Close control box door and
restore po”wer.
NOTICE
This switch is provided to prevent un-
authorized programming of the
setpoints. If this level of security is not
required, the “Setup” switch can be left
in the”+” position, eliminating Steps 1
and 2.
Step 3: With the unit already in the STOP/RESET con-
dition, press the “STOP/RESET” button a sec-
ond time. This Puts the controller in the
program mode. The displays will read as fol-
Iows:
Pressure: the current unload setpoint (ad-
justable 58-175 psig)
I II
Temperature: I_I _indicating that
pressure value is the
“unload” value.
Step 4: Press the “AUTO LEAD” button to raise the
unload setPoint. Press “AUTO LAG” to lower
the unload’ setpoint. See Figure 4-9, page 8,
this section.
wARNING
Operation at excessive discharge air
pressure can cause personal injury or
damage to equipment. Do not set un-
load pressure above the maximum
stamped on the unit nameplate.
Step 5: When the desired unload setpoint is displayed
in the pressure readout, press the
“STOP/RESET’ button. This will enter the de-
sired unload setpoint and advance the pro-
gramming function to the load setpoint. The
displays will now read:
13-8-610
Pressure: the current load setpoint (adjust-
able 50-167 psig)
Temperature: indicating that the
pressure value is the
“load” value.
SteP 6: Raise or lower the load setPoint in the same
manner as the unload setpo’int in Step 4.
NOTICE I
The load setpoint cannot be set within
8 PSI of the unload setpoint. See Figure
8-4, Section 4, page 7.
Step 7: When the desired load setpoint is displayed in
the pressure readout, press the “STOP/RESET’
button, entering the new load setpoint and
completing the programming.
Step 8: The display now indicates: l_l
At this time, compressor rotation may be
checked by pressing any of the three operating
mode buttons. The starter will be momentarily
energized giving a slight rotation that is short
enough in duration to prevent reverse oil flow
in the event that rotation is reversed. Press
“Stop/Reset” to exit jog mode.
Step 9: The displays will now read:
the Pressure r
Temperature: 1-11:1 or _ _
If this compressor is equipped with the expan-
sion board for the remote control option this
must be set to “yes”. The standard setting is
“no”. This value is toggled by pressing any
mode switch. Press the “Stop/Reset” button to
continue to the next step.
Step 10: The display now indicates either
lrl Iz r
F gl r
or
I_ Iz r
i_l 13 1- 1-
Pressing any mode key will toggle the display
from one set of units to the other. PSI/F causes
the controller to display pressures in pounds
per square inch and temperatures in degrees
Fahrenheit. bar/”C causes the controller to dis-
play parameters in bars and degrees Centi-
grade. Press “Stop/Reset” when the desired
units are visible in the display to continue.
Section 4 Page 5
Step 11: When display shows dashes (---- ----):
a) Press “Stop-Reset” - the pressure display now w
a
shows the current “zero” pressure for the final 3
discharge transducer in the left window, and m
0
“PI” in the right window. w
a!
R
b) Press “Stop-Reset” again - this will zero the
circuit board on the final discharge pressure
transducer and move the display to the next
step. The left window will read the current 1-
“zero” pressure for the oil reservoir transducer in
n
and the right window will now read “P2.” 3

c) Press “Stop-Reset” again - this will zero the

circuit board on the oil reservoir pressure
transducer and move display program back to
the normal setup mode. The display should
read “O”pressure in the left window, and ----
current sump temperature in the right window.
Step 12: Stop the compressor and disconnect, tag and
lockout the power supply to the starter.
Step 13: Move the circuit board slide switch back to the
“set” position (right). You may now proceed
with normal start up procedure.
NOTICE
A. To readjust, the slide switch must
be in the”+” position.
B. If procedure is repeated, the
transducer zero operation may
be bypassed by not pressing
“STOP-RESET” while the dashes
( ---- ----) are displayed.
C. To zero the transducer, discon-
nect the control lines to the trans-
ducers and press “STOP/RESET”
while the dashes are displayed .
DOWNSTREAM PRESSURE
FIGURE 4-5
LEAD-LAG OPERATION OF TWO COMPRESSORS -
The Auto-Sentry S controller provides the capability of
true lead-lag operation without the need to purchase any
additional equipment and without complicated intercon-
necting wiring.
Follow these steps to operate two compressors in a
lead-lag arrangement:
Step 1: Program load and unload pressure setpoint
on both units to the same value. For example:
ComPressor “A’ load at 92 PSI: unload at 100
PSI. ComPressor “B”load at 92 PSI: unload at
100 PSI. $ee page 6, this section, for complete
information on programming the setpoints.
WARNING
Operation at excessive discharge air
pressure can cause personal injury or
damage to equipment. Do not set un-
load pressure above the maximum
stamped on the unit nameplate.

, VENT ADJUSTING
ADJUSTING SCREW
SCREW ‘d

SPRING

DIAP UPSTREAM DIAPHRAGM

LINE UPSTREAM
LINE

VALVE
REAM LINE OPEN
I 1- DOWNSTREAM LINE

FIGURE 4-6- SUBTRACTIVE PILOT (CLOSED) FIGURE 4-7- SUBTRACTIVE PILOT (OPENED)

13-8-610 Section 4 Page 6

Step 2: Operate one compressor in the “Auto Lead”
mode. This compressor will now be the “Lead”
or “Base Load” compressor.
Step 3: Operate the second compressor in the “Auto
Lag” mode. This compressor will now be the
“lag” or “trim”compressor. It will automatically
be brought on line, if required, by a large air
demand. After the demand is satisfied, the lag
unit will unload, time out and stop, ready to
start again when needed.
Step 4: Periodically reverse the roles of the units by
changing each unit’s mode of operation from
“Auto Lead” to “Auto Lag” and vice versa. By
using the hourmeters on the control panel to
schedule the mode changes, the operating
hours can be kept as close as possible, equal-
izing machine wear and minimizing mainte-
nance costs.
WARNING
Unit can automatically restart causing
personal injury.
Disconnect, tag and lockout the power
supply to the starter.
Subtractive Pilot (Modulating Feature) - The subtrac-
tive pilot is an adjustable, Spring-loaded diaphragm
valve that controls pressure in relation to the upstream
(discharge) pressure.
The downstream pressure is maintained equal to the
upstream pressure minus a constant which is adjusta-
ble. In the example shown in Figure 4-5, previous page,
the downstream pressure equals the upstream pressure
minus 95 psi. When the upstream pressure rises to 100
psig, the downstream pressure rises to 5 psig. This 1
to 1 psi rise is constant above the set point.
Below the set point, the valve seat is closed and the
downstream pressure is vented. In the example of Fig-
ure 4-5, previous page, downstream pressure is vented
below 95 psig.
Figure 6-4, previous page, shows a schematic cross
section of the subtractive pilot with the valve seat closed
and downstream line vented. Figure 7-4, previous page,
shows the pilot with valve seat open, holding a down-
stream pressure which is adjustable with the screw. In
this position it is normal for the valve to continually bleed
13-8-610 Section 4
air through the small vent hole in the bowl.
Moisture, oil and dirt in the control system lines and
components can cause the set point of the subtractive
pilot to shift or be erratic. The subtractive pilot can be
disassembled and the diaphragm and ports cleaned
when necessary.
Operating Air Pressure Adjustment - The Auto-Sen-
try S controller load and unload pressure setpoints
should already be programmed. See page 6 and Figure
4-8, page 8, this section.
WARNING
Operation at excessive discharge air
pressure can cause personal injury or
damage to equipment. Do not set un-
load pressure above the maximum
stamped on the unit nameplate.
To adjust the subtractive pilot:
1. With the unit off, loosen the locknut and back out
the adjusting screw several turns so the subtractive
pilot will fully unload the compressor before the
unload pressure setpoint of the microprocessor
controller is reached.
2. Close the air service valve and start the unit in the
“CONSTANT RUN” mode. Allow unit to reach the
pressure at which the subtractive pilot fully unloads
the compressor,
3. Turn-in the adjusting screw until the unload pres-
sure setpoint is reached and the microprocessor
controller allows the unit to blow down.
4. Turn-in the adjusting screw an additional one-
eighth (1/8) turn and tighten the locknut. As a result,
the subtractive pilot will not fully unload the com-
pressor before the microprocessor controller’s un-
load pressure setpoint is reached.
5. Using the air setvice valve, cycle the unit between
load and unload several times to be certain that the
unit will reach the microprocessor controller’s un-
load pressure setpoint and blow down.
Page 7
 NAMEPLATE MODULATING
FULL LOAD CONTROL SYSTEM
OPERATING
PRESSURE LOAD UNLOAD
100 100 108
125
I 125
I 133
150 150 158
I I
175
I 167 I 175
I 1

NOTE
Load setpoint cannot be set within 8 psi of the unload setpoint.
Minimum operating pressure is 60-65 PSIG.

FIGURE 4-8- MAXIMUM SETPOINTS FOR AUTO-SENTRY S CONTROLLER, PSIG

FIGURE 4-9- AUTO SENTRY “S”SOLID STATE CONTROL TOUCH PAD

13-8-610 Section 4 Page 8

13-8-610 Section 4 Page 9
SECTION 5
LUBRICATION
OIL COOLER, OIL FILTER & SEPARATOR
rlw
D,sc-
FIGURE 5-1 - FLOW DIAGRAM - AIR-OIL SYSTEM
COMPRESSOR OIL SYSTEM (Figures 5-1) cools the
compressor, lubricates moving parts and seals internal
clearances in the compression chamber.
The oil inlet line is connected at the top of the oil reservoir.
Air pressure in the oil reservoir forces oil through the oil
cooler, thermostatic mixing valve, oil filter and into the
compressor main oil gallery.
The oil passes through internal passages for lubrication,
cooling and sealing. The air-oil mixture is then dis-
charged to the oil reservoir where a large part of the
entrained oil drops out of the air stream; the air then
passes through the final oil separator where most of the
remaining oil is removed. The separated oil is returned
to the compressor and the air passes to the final dis-
charge line.
RECOMMENDED LUBRICANT - Gardner Denver com-
pressors are factory filled with AEON ‘Mlubricants. These
Iubricantsareformulated to the highest quality standards
and are factory authorized, tested and approved for use
in rotary screw compressors. AEON ‘M lubricants are
available through your authorized Gardner-Denver com-
pressor distributor.
OIL SPECIFICATIONS - The recommended compres-
sor lubricant is Gardner Denver AEON ‘“ 4000 Lubricat-
ing Coolant which can be used for year-round operation
except as noted in the “High Temperature Operation”
paragraph below, or low temperature, see “installation
for Cold Weather,” Section 2, page 2. AEONTM 4000
Lubricating Coolant is a superior petroleum base
13-8-610
lubricant formulated and containing additives for use in
Gardner Denver compressors.
I CAUTION I
Specific AEON lubricants are recom-
mended for use in this equipment.
Other lubricants may cause excessive
carryover or compressor damage. Do
not mix different types of lubricants.
HIGH TEMPERATURE OPERATION - If the discharge
temperature is sustained between 200-21 O°Ffor a period
of more than four (4) hours due to continuing high
ambient air temperature, use Gardner Denver” AEON
9000 SP Lubricating Coolant which is a superior syn-
thetic lubricant. Short periods of up to four (4) hours of
sustained discharge temperatures up to 21 O°F do not
require a change from the recommended year-round
lubricant AEON ‘M4000.
LUBRICANT CHANGE PROCEDURE - Upgrading to a
longer life lubricant is essentially a very worthwhile prac-
tice. Following are the primary steps to be completed
when upgrading or changing the type of lubricant.
1. Thoroughly drain system:
- Drain oil from air end and cooler while hot.
- Break low point connections and drain oil from
pipe runs.
Section 5 Page 1
 - Dump Oil from filter and reinstall used filter.

2. Fill system with a 50 percent charge of the new

lubricant:
WARNING I
High temperature operation can cause
damage to equipment or personal in-
- Start machine and stay there to observe.
jury. Do not repeatedly restart after high
- Allow machine to run about five minutes at
temperature, or until temperature stabilizes, temperature stops operation. Find and
then shut down. correct the malfunction before resum-
ing operation.
3. Thoroughly drain machine.

4. Change to new filter and separator. AWARNING

All materials used in Gardner Denver

5. Fill system with full charge of the new lubricant. compressor units are compatible with
AEON ‘M 9000 SP Lubricating Coolant.
6. Machine should then be run normallv. however. Use caution when selecting down-
total run time after the initial changeoUt should be stream components such as air line
50 percent of normal anticipated service life of the lubricating bowls, gaskets and valve
new lubricant. trim.

- Drain all lubricant from system, change filter AEON ‘M9000 SP Synthetic Lubricant is
and separator, and replace with full charge of not compatible with low nitrile Buna N
the new lubricant. or acrylic paints. AEON ‘M 9000 SP is
compatible with most air system down
stream components.
cAuTION

improper equipment maintenance with Material Safety Data Sheets (MSDS) are available for all
AEON lubricants from your authorized Gardner Denver
use of synthetic lubricants will damage
distributor or by calling 217-222-5400.
equipment. Oil filter and oil separator
change intervals remain the same as COLD AMBlENT OPERATION - See “installation for
for AEON ‘M 4000 -- See maintenance Cold Weather Operation,” Section 2, page 2.
schedule, Section 8. ADDITION OF OIL BETWEEN CHANGES must be
made when the oil level is at the bottom of the red range
on the gauge as read while the unit is running.
To add oil, follow these steps:
DANGER
1. Be sure the unit is completely off and that no air
Oil under pressure will cause severe pressure is in the oil reservoir.
personal injury or death. Shut down
compressor and relieve system of all 2. Disconnect, tag and Iockput the power supply to
the starter.
pressure, disconnect, tag and lockout
pOWer supply to the starter before 3. Wipe away all dirt around the oil filler plug.
removing valves, caps, plugs, fittings,
bolts and filters. 4. Remove the oil filler plug and add oil as reuuired to
return the oil level to thE center of the green range.

40& 50 HP

Refill Capacity For Normal Oil Change .............................................................................................5.5 U.S. Gallons

Red To Yellow Range ......................................................................................................................l.25 U.S. Gallons

FIGURE 5-2- APPROXIMATE OIL SYSTEM CAPACITIES

13-8-610 Section 5 Page 2

DO NOT OVERFILL. The quantity required to raise the
oil level from the red range to the center of the green
range is shown in Figure 5-2, below. Repeated addition
of oil between oil changes may indicate excessive oil
carry-over and should be investigated.
DANGER
Air/oil under pressure will cause severe
personal injury or death. Shut down
compressor and relieve system of all
pressure, disconnect, tag and lockout
the power supply to the starter before
removing valves, caps, plugs, fittings,
bolts, and filters.
CAUTION
Excessive oil carryover can damage
equipment. Never fill oil reservoir
above “FULL” marker.
OIL LEVEL SIGHT GAUGES (Figure 1-3, page 3, Sec-
tion 1) indicate the amount of oil in the oil reservoir. Read
oil level only when unit is on. In operation the oil level will
fluctuate as the compressor loads and unloads. Add oil
only when the oil is at the bottom of the red range on the
gauge as read when the compressor is on. Drain oil only
when the oil level is above the center of the green range
on the gauge as read when the compressor is on.
MOISTURE IN THE OIL SYSTEM -In normal humidity
and with normal operating temperatures and pressures,
the thermal mixing valve controls the oil temperature and
prevents moisture contamination of the oil. Unusual
cooling of the oil reservoir, short loaded cycle in high
humidity or malfunctions of the thermal valve may result
in moisture in the oil system which is detrimental to
compressor lubrication and could cause oil carryover. If
moisture is observed in the oil reservoir, drain the mois-
ture and correct the condition causing the accumulation.
See “Compressor Oil System Check’ and “Thermal Con-
trol (Thermostatic Mixing) Valve” in this section.
OIL CHANGE INTERVAL - Recommended oil change
intervals are based on oil temperature.
Discharge AEON 4000 AEON 9000 SP
Temperature Change interval Change Interval
up to 180”F 6000 hrs. 8000 hrs.
180 to 190°F 45OO hrs. 6000 hrs.
190 to 200”F 3000 hrs. 4000 hrs.
200 + 1500 hrs. 2000 hrs.
13-8-610
When operating conditions are severe (very dusty, high
humidity) it will be necessary to change the oil more
frequently. Operating conditions and the appearance of
the drained oil must be surveyed and the oil change
intervals planned accordingly by the user. A lubricant
analysis program can DrOVide maximum service lIfe and
assist in plaNning the change interval.
DRAINING AND CLEANING OIL SYSTEM -
DANGER
Air/oil under pressure will cause severe
personal injury or death. Shut down
compressor and relieve system of all
pressure, disconnect, tag and lockout
the power supply to the starter before
removing valves, caps, plugs, fittings,
bolts, and filters.
Always drain the complete system. Draining when the
oil is hot will help to prevent varnish deposits and carry
away impurities. To drain the system, use one of the
following methods:
If the unit is not elevated high enough to use the oil
reservoir drain line to drain oil, a small hand, electric or
air operated pump should be used to drain reservoir
through the oil filler opening or from the drain valve.
If the unit is elevated so that the oil reservoir drain can
be used, empty the oil reservoir through the drain valve
to a suitable container or sump.
if the drained oil and/or the oil filter element are con-
taminated with dirt, flush the entire system: reservoir, oil
cooler, mixing valve and lines. Inspect the oil separator
elements for dirt accumulation; replace if necessary. If
a varnish deposit exists, contact the factory for recom-
mendations for removal of the deposit and prevention of
varnish.
FILLING OIL RESERVOIR -
I DANGER
Air/oil under pressure will cause severe
personal injury or death. Shut down
compressor and relieve system of all
pressure, disconnect, tag and lockout
the power supply to the starter before
removing valves, caps, plugs, fittings,
bolts, and filters.
1. Be sure the unit is completely off and that no air
pressure is in the oil reservoir.
Section 5 Page 3
 OIL IN
0-
C A CAUTION

FROM COOLER Excessive oil carryover can damage

equipment. Never fill oil reservoir
above “FULL” marker.

D
COMPRESSOR OIL FILTER (Figure 1-2, Section 1,
OIL lN-
page 2) - This replaceable element filter is a vital part in
BYPASS maintaining a trouble-free compressor, since it removes
FROM dirt and abrasives from the circulated oil. The filter is
RESERVOIR eqUiPPed with a relief valve that oPens in the event the
element becomes dirty enough to-block the flow of oil.

I CAUTION

Improper oil filter maintenance will

cause damage to equipment. Replace
filter element every 1000 hours of op-
OIL ‘OUT eration. More frequent replacement
\\ * %8407 could be required depending on oper-
A ation conditions. Filter element left in
SERVICE Toolong may damage equipMENT
.
FIGURE S-3 - THERMOSTATIC MIXING VALVE

2. Disconnect, tag and lockout the power supply to Use only the replacement element shown on the filter
the starter. tag or refer to the parts list for the part number. Use the
following procedure to replace the filter element. Do
3. Wipe away all dirt arount the oil filler plug. not disturb the piping,
4. Remove the oil filler plug and add oil as required to
return the oil level to the center of the green range

5.
on the gauge.

Operate unit for about a minute allowing oil to fill all

I DANGER

areas of the system. Air/oil under pressure will cause se-

6. Shut down unit, allowing the oil to settle, and be
certain all pressure is relieved.
7. Add oil, if necessary, to bring level to the center of
the green range on the gauge.
On unloaded operation and after shutdown some oil will
drain back into the oil reservoir and the oil level will read
over “FULL”. DO NOT DRAIN OIL TO CORRECT. On
the nexT stafF, oil will again fill the system and the gauge
will indicate operating at the proper level. DO NOT
OVERFILL as oil carryover will result. The quantity of oil
required to raise the oil level from “ADD” to “FULL” is
shown in Figure 5-2, page 2, this section. Repeated
addition of oil between oil changes may indicate exces-
sive oil carryover and should be investigated.
Use only CLEAN containers and funnels so no dirt enters
the reservoir. Provide for clean storage of oils. Chang-
ing the oil will be of little benefit if done in a slipshod
manner.
vere personaI injury or death. Shut
down compressor and relieve system
of all pressure, disconnect, tag and
lockout the power supply to the starter
before removing valves, caps, plugs,
fittings, bolts, and filters.
1. Stop unit and be sure no air pressure is in the oil
reservoir.
2. Remove the spin-on element.
3. Clean the gasket face of the filter body.
4. Coat the new element gasket with clean lubricant
used in the unit.
5. Screw new element on filter body and tighten by
hand. DO NOT OVERTIGHTEN ELEMENT.
6. Run the unit and check for leaks.

13-8-610 Section 5 Page 4

 24[ OIL SE
COVER
220

20(

180
..
160
:
E 140 OIL SEPA
~ HOUSING
0 ~ PLEATED SEPARATOR
&
●
120
:
100

80
OIL RETURN LINE
60
/
40
20 40 60 80 100 120
AMBIENT TEMP. . “F

FIGURE 5-4- DEW POINT TEMPERATURE VS. AMBIENT FIGURE 5-5- OIL SEPARATOR
TEMPERATURE (100% RELATIVE HUMIDITY)

COMPRESSOR OIL COOLER - (Figure 5-1, page 1,
this section) - The cooler fan is mounted on the com-
pressor motor shaft; air is exhausted through the oil
cooler and away from the unit. Do not obstruct airflow
to and from the oil cooler. Allow a minimum of two (2)
feet clearance around the cooler. Keep both faces of the
cooler core clean for efficient cooling of the compressor
oil.
THERMAL CONTROL (THERMOSTATIC MIXING)
VALVE (Figure 5-3, previous page) is installed in system
as shown in Figure 1-5, page 1, this section. This valve
is used to control temperature of the oil both air-cooled
radiator and water-cooled heat exchanger type oil
cooler systems. On start-up with unit cold, element is
open to bypass, allowing oil to pass directly from the
reservoir to compressor during warm-up. As oil warms,
element gradually closes to the bypass allowing more of
the oil from the cooler to mix with oil from the bypass.
After the unit is warmed up, mixing valve maintains oil
injection temperature into the compressor at a minimum
of 160”F. This system provides proper compressor
warm-up and prevents moisture contamination of the oil.
To check element, heat in oil -it should be fully extended
at 160° F. If unit shuts down due to high air discharge
temperature, the cause may be that the element is stuck
open to the bypass, in which case bypass lines (Figure
1-5, page 1, this section) will be hot to touch and lines
out of mixing valve much cooler. When flushing the oil
system, remove mixing valve and clean all parts thor-
oughly.
OIL RESERVOIR -The oil reservoir-separator combines
multiple functions into one vessel. The lower half is the
oil reservoir, providing oil storage capacity for the sys-
tem and the top portion, a primary oil separation means.
The reservoir also provides limited air storage for control
and gauge actuation.
COMPRESSOR (G-D ELIMINATOR) OIL SEPARA-
TOR located in a separate housing, consists of a renew-
able cartridge-type separator element and provides the
final removal of oil from the air stream (Figure 5-5).
Oil impinging on the inside of the separator element
drains directly back into the oil reservoir by gravity. Oil
collected outside the element is returned through tubing
to the compressor cylinder.
Oil carry-over through the service lines may be caused
by a faulty oil separator, overfilling of the oil reservoir, oil
that foams, oil return line malfunction, or water conden-
sate in the oil. If oil carryover occurs, inspect the sepa-
rator only after it is determined that the oil level is not too
high, the oil is not foaming excessively, the oil return tube
from the bottom of the separator to the compressor
cylinder is not clogged or pinched off, the check valve
in the oil return is functioning properly, and there is not
water or an oil/water emulsion in the oil.
Oil carry-over malfunctions of the oil separator are usu-
ally due to using elements too long, heavy dirt or varnish
deposits caused by inadequate air filter service, use of
improper oil or using oil too long for existing conditions.
Excessive tilt angle of the unit will also hamper separa-
tion and cause oil carry-over.
Oil separator element life cannot be predicted; it will vary
greatly depending on the conditions of operation, the
quality of the oil used and the maintenance of the oil and
air filters. The condition of the separator can be deter-
mined by pressure differential or by inspection.
Pressure Differential Gauging - The “CHANGE SEPA-
RATOR” message will flash when the pressure differen-
tial across the oil separator reaches approximately 8
PSI. Replace the oil separator element at this time. If
ignored, the unit will shut down and the display will
indicate shutdown and the change separator LED will be
on when the pressure differential reaches 15 PSI.

13-8-610 Section 5 Page 5

To measure the pressure differential, see “Pressure and
Temperature Digital Readouts” in Section 4, page 4.
Simply subtract the downstream reading from the up-
stream reading.
CAUTION
Using an oil separator element at ex-
cessive pressure differential can cause
damage to equipment. Replace sepa-
rator when “Change Separator” mes-
sage flashes.
NOTICE
A sudden drop to zero pressure differ-
ential or sudden heavy oil carryover
may indicate a ruptured element.
Inspection - After removal of separator element, shine
a light inside the element to reveal areas of heavy dirt or
varnish deposits or breaks (ruptures) in element media.
Removal Of Oil Separator For Inspection Or Replace-
ment:
~\\DANGER
Air/oil under pressure will cause se-
vere personal injury or death. Shut
down compressor and relieve system
of all pressure, disconnect, tag and
lockout the power supply to the starter
before removing valves, caps, plugs,
fittings, bolts, and filters.
1. Be certain unit is completely off and that no air
pressure is in the oil reservoir.
2. Disconnect, tag and lockout the power supply to
the starter.
3. Remove screws holding the top plate to the sepa-
rator housing. Lift the top plate from the separator
housing.
13-8-610 Section 5
4. Lift the separator from the separator housing.
5. Inspect and/or replace the separator as necessary.
Be sure the o-ring is not damaged. Before installing
(or re-installing) any separator, apply grease to the
o-ring. Oil will be wiped off by the chamfer and the
ring could be damaged.
6. Remove any gasket material adhering to the top
plate or separator housing, and install the new
gasket.
7. Lower the separator into the housing and center
the separator on the chamfer. Press the separator
down into the housing. Do not use excessive force
as separator damage can occur.
8. Place the spacer on the indent in the separator.
Seat the top plate to the separator, spacer and
separator housing. Install and tighten all cap
screws.
9. Run the unit and check for leaks.
COMPRESSOR OIL SYSTEM CHECK - The following
readings are based on ambient temperature of 80°F with
the system in good condition. Compressor should be
at operating temperature at the time of checks. One-half
hour of loaded operation is usually sufficient to reach
level-out operating temperatures.
Air and Oil Discharge Temperature -170° to 200° F -
Read at gauge on the instrument panel or check with a
thermometer at the discharge housing.
Compressor Oil Inlet Temperature -165 to 175° F -
Install tee at oil filter outlet and check with thermometer.
Oil Inlet Pressure - Check at the fitting in the line near
the compressor oil inlet. With air receiver pressure at
100 psi, oil inlet pressure should be 65-75 psig.
Oil Cooler Oil Pressure Differential (Air-Cooled Ra-
diator) - Check differential across oil system by measur-
ing oil inlet pressure as described above.
Oil Cooler Temperature Differential (Air-Cooled Ra-
diator) - The oil temperature differential depends on the
temperature of the air at the oil cooler fan and cleanliness
of the core faces. As ambient temperatures and core
restrictions increase, the oil cooler outlet temperature
will increase. The oil inlet temperature is approximately
the same as the air discharge temperature - see the
gauge on the instrument panel. The outlet oil tempera-
ture may be checked by installing a tee at the oil filter
outlet.
Page 6
SECTION 6
AIR FILTER
AIR INTLET
AIR OUTLET + pleated media; replace the element if any are found.
AUTOMATIC UNLOADER F 5.
FIGURE 6-1 - HEAVV DUTY AIR FILTER
GENERAL - The air filter must receive proper main-
tenance if maximum service is to be obtained from the
unit. Establishing adequate and timely filter service is
MOST IMPORTANT. A wide range of operating hours is
possible. With wide variation of dust conditions en-
countered, only experience can determine the proper
time interval for servicing filters.
HEAVY-DUTY AIR FILTER (Figure 6-1) furnished as
standard equipment on units with an enclosure is a
heavy-duty washable element dry type air filter. The air
filter must receive proper maintenance if maximum ser-
vice is to be obtained from the unit. Establishing ade-
quate and timely filter service is MOST IMPORTANT.
Improperly maintained air filter can cause a loss of com-
pressor air delivery.
Filter Element - Service the air filter element when the
“CHANGE AIR FILTER” LED is illuminated. Clean every
50 to 150 operating hours depending on dust condi-
tions.
NOTICE
Use only genuine Gardner Denver air
filter elements on Gardner Denver com-
pressor units. Genuine parts are avail-
able through your authorized Gardner
Denver distributor.
To service:
1. Remove wingnut and pull out filter element.
2. Visually inspect the element. If cleaning is not
necessary, reinstall the filter element. If the element
requires cleaning, go through steps 3, 4 and 5.
13-8-610
3. Wash the element by soaking about 15 minutes in
warm water with a mild nonsudsing detergent.
Rinse the element thoroughly with clean water; a
hose may be used if the water pressure does not
exceed 40 psig.
4. Inspect the element for ruptures or cracks in the
Inspect the gasket on the bottom (outlet end) of the
element; replace the entire element if the gasket is
damaged, a spare element will keep down time to
a minimum.
Allow the element to air dry COMPLETELY. Do not
expose the element to heat over 150° F. Install the
element in the filter body and fasten securely with
the wing nut.
WARNING
Do not oil this element. Do not wash in
inflammable cleaning fluids. Do not use
solvents other than water. Improper
cleaning may damage element.
CAUTlON
Never operate the unit without the ele-
ment. Never use elements that are
damaged, ruptured or wet. Never use
gaskets that won’t seal. Keep spare ele-
ments and gaskets on hand to reduce
downtime. Store elements in a
protected area free from damage, dirt
and moisture. Handle all parts with
care.
Filter Element Life - The element should be replaced
after six (6) cleanings or if:
1. Visual inspection indicates a rupture, crack or pin
hole in the pleated media. Inspection should be
done by placing a bright light inside the element.
2. Pressure drop through a filter with a freshly cleaned
element is below three (3) inches of water with
compressor running at full load - this would indicate
a rupture or crack.
Inlet Tube - Inspect the inlet screen and tube for dirt
accumulation each time the filter is serviced. Clean the
tube when required by ramming a clean dry cloth
Section 6 Page 1
 Elements contaminated with oil or greasy dirt
deposits:
n
(a) Mix a sufficient amount of the followin clean-
0000000000 ing solution to allow the element to i e fully
@ooooo oo*oooooooQ4
40000*0*00000000001 submerged. To one gallon of lukewarm water
#oooooo oooooo”oooos add four tablespoons of mild household deter-
0000000*000*0000000 gent and one-half teaspoon of trisodium phos-
0000000000000000000 phate. Mix well.
0*0000000*00000000*
L I
(b) Place element into cleaning solution and allow
to soak for five minutes. Agitate in solution and
I allow to soak for five minutes. Agitate in solu-
tion for two minutes and remove.
(c) Discard dirty solution and mix a new batch of
FIGURE 6-2- STANDARD DUTY AIR FILTER (OPTIONAL) cleaning solution as above.
(d) Place element in clean solution and agitate for
five minutes.
through the tube. Wipe the inside of the filter body to
remove any dirt falling from the inlet tube before reinstall- 4. Remove from solution, drain, and flush with clear
ing the element. water from the inside out by using hose. Use a
gentle water stream and do not point directly at
Causes of short element life include: severe dust condi-
element
tions, infrequent servicing, improper cleaning, or con-
tamination by oil or chemical fumes. 5. Inspect for rupture by placing a bright light inside
the element. The slightest rupture requires replace-
ment of the element
STANDARD DUTY AIR FILTER (OPTIONAL) - (Figure
6-2) - Service and replacement instructions are given in 6. Allow element to dry before reinstalling. A wet ele-
the following sections: Filter Element and Filter Element ment may collapse during operation.
Life.
Filter Element - The element should be serviced when Filter Element Life - The element should be replaced
inspection indicates an accumulation of dirt on the out- after eight cleanings or if visual inspection indicates a
rupture, crack or pin hole in the pleated media. Inspec-
side of the element. Clean every 100 to 500 operating
hours depending on dust conditions. Inspect every few
tion should be done by placing a bright light inside the
element.
days until experience determines the proper time interval
for servicing.
To Service:

1. Remove element from filter housing.

I wARNiNG

Do not oil this element. Do not wash in

2. Blow off excess dirt with air nozzle. Direct air blast other cleaning fluids. Never operate
parallel to element pleats at a slight upward angle.
unit without element. Never use ele-
Do not point air blast directly at element.
ments that are damaged or ruptured.
3. Elements contaminated with dry dirt only: Never use elements that won’t seal.
Keep spare elements on hand to
(a) Mix a sufficient amount of warm water and reduce downtime. Store elements in a
household detergent to allow the element to be
fully submerged. protected area free from damage, dirt
and moisture. Handle filter parts with
(b) Place element into cleaning solution and allow
to soak for five minutes. Agitate in solution for care.
two more minutes.

13-8-610 Section 6 Page 2

SECTION 7
BELT DRIVE
Proper drive belt tension and alignment are provided at
the factory, however, good practice dictates checking CAUTION
the drive alignment and tension after shipment and
before initial start-up. Sheaves should align straight Interference between the fan and the
across the front with a straight edge. The best tension is orifice can damage equipment. Be cer-
just enough tension to keep belts from “squealing” on tain the orifice has even clearance
start-up. around the fan before starting the unit.

CHECKING BELT TENSION - Using a spring scale,

CAUTION
Excessive belt tension can damage the
equipment. Tension the belts as shown
in Table 7-1.
Belts can be changed when necessary by first removing.
the wire guard. ThEn loosen, but do not remove, the four
motor foot nuts. Next, use the adjusting screws in the
motor base to loosen belt tension. Remove the belts over
the fan.
apply a perpendicular force to each belt at the midpoint
of the span and measure the deflection. Correct deflec-
tion force and deflection are shown in Table 1-7. To
tighten belts, merely increase the center distance.
I NOTICE I
When a new set of belts is installed on
a drive, the initial deflection force
should be 1/3 greater than shown in
Table 7-1. Recheck tension frequently
during the first 24 hours of operation.

DEFLECTION FORCE (LBS)

I DEFLECTION (INCHES)
----- _
I
----- ---
+

I
I

No. Deflection Deflection

Motor of Force Pounds In
H.P. Belts (per belt) Inches

40 4 6-8.5 3/8

50 4 7-1o 3/8

TABLE 7-1 - BELT TENSION 5VX BELTS

13-8-610 Section 7 Page 1

SECTION 8
MAINTENANCE SCHEDULE
SERVICE CHECK LIST - Every 125 Hours Operation
Air Filter - Operating conditions determine frequency of 1. Check for dirt accumulation on oil/aftercooler core
service. The “CHANGE AIR FILTER” display will flash to faces and the cooling fan. If cleaning is required,
signal that the air filter requires servicing or changing. clean the exterior fin surfaces of the cores by blow-
See “Air Filter,” Section 6. ing compressed air carrying a nonflammable safety
solvent in a direction opposite that of the cooling
Oil Separator - Operating conditions determine the fre-
fan air flow. This cleaning operation will keep the
quency of service. The “CHANGE SEPARATOR” display
exterior cooling surfaces clean and ensure effective
will flash to signal that oil separator element requires
heat dissipation.
changing. See “Compressor Oil Separator,” Section 5,
page 5. Every 1000 Hours Operation
Motor Lubrication - Refer to Section 2, page 4 and 1. Change oil filter element.
Maintenance Schedule Chart below.
Every 4000 Hours Operation
Every 8 Hours Operation 1. Inspect oil separator element. See Section 5.
1. Check the reservoir oil level -add oil if required. See Every 6000 Hours Operation
Section 5. If oil consumption is high, refer to “Ex-
cessive Oil Consumption” in Section 9, page 2. 1. Change the compressor lubricant. UNDER AD-
VERSE CONDITIONS, CHANGE MORE
2. Observe if the unit loads and unloads properly. FREQUENTLY (refer to “Oil Change interval” in
3. Check discharge pressure and temperature. Section 5). Flush system if required.

4. Drain the moisture trap in the control system. See Every Year
Section 4.
1. Check the relief valve for proper operation. See
5. Check Panel LED for advisories. Section 4.

MAINTENANCE SCHEDULE (See detail notes above)

Maintenance Action If
Panel Every Every Every Every Every Every
LED is 8 125 1000 4000 6000 Year
Lit Hours Hours Hours Hours Hours

Change Air Filter ●

Change Oil Separator ●

Check Reservoir Oil Level @

Check For Proper Load/Unload ●

Check Discharge Pressure/Temp. ●

Check Dirt Accumulation on Cooler ●

Change Oil Filter Element ●

Inspect Oil Separator Element

Change Compressor Lubricant (AEON 4000)’ ●

Check Relief Valve

* See Oil Change Interval Chart, Section 5, page 3, for specific lubricant life.

13-8-610 Section 8 Page 1

SECTION 9
TROUBLE SHOOTING

Symptom Possible Cause Remedy

Compressor fails to start. 1. Wrong lead connections. 1. Change leads.

2. Blown fuses in control 2. Replace fuse,

box.

3. Motor starter overload 3. Reset and investigate

heaters tripped. cause of overload.

4. Pressure in reservoir. 4. Inspect blowdown valve

and muffler.

5. Read error messaae on 5. Replace switch.

control panel. See-Section 4.

Compressor starts but 1. High discharge temperature. 1. See “High Discharge

stops after a short time. Air Temperature,” page 2,
this section.

2. High discharge 2. Replace switch.

temperature switch
malfunction.

3. Blown fuse in starter/ 3. Replace fuse

control box. (investigate if fuses
continue to blow).

4. Motor starter overload 4. Reset and investigate

heaters trip. cause of overload.

Compressor does not 1. Improperly adjusted 1. Refer to Section 4, pages 4-6,

unload (or load). control. and adjust control.

2. Air leak in control 2. Determine source of

lines. leak and correct.

3. Restricted control line. 3. Clean control lines.

4. Subtractive pilot or blow- 4. Repair, clean or re-

down valve malfunction. place valve.

13-8-610 Section 9 Page 1

 Symptom Possible Cause Remedy

Compressor cycles from 1. Insufficient receiver capacity. 1. Increase receiver size.

load to unload excessively.

2. Restriction in control 2. Inspect and clean

tubing. control tubing.

3, Subtractive pilot setting too high. 3. Adjust valve. See Section 4.

Compressor is low on 1. Restricted air filter. 1. Clean or replace filter.

delivery and pressure.

2. Sticking inlet valve, 2. Inspect and clean

inlet valve.

3. Subtractive pilot or uload 3. Adjust valve or unload

pressure adjusted too low. pressure. See Section 4,
page 7.

4. Minimum pressure valve 4. Replace valve,

stuck closed.

High discharge air 1. Thermostatic mixing 1. Repair or replace valve,

temperature. valve stuck open.

2. Dirty or clogged cooler face. 2. Clean cooler.

3. insufficient cooling 3. Provide unrestricted

air flow. supply of cooling air.

4. Clogged oil filter 4. Replace filter or

or cooler (interior). clean cooler.

5. Low Compressor oil. 5. Add oil to proper level.

Excessive Oil Consumption 1. Oil carryover through lines. 1. See “Oil Carryover,” page 3,
this section.

2. Oil leaks at all fittings 2. Tighten or replace

and gaskets. fittings or gasket.

13-8-610 Section 9 Page 2

 Symptom Possible Cause Remedy

Oil Carry-Over 1. Overfilling the reservoir. 1. Drain excess oil

from system.

,~, DANGER

Air/oil under pressure will cause severe personal injury or death. Shut down com-
pressor and relieve system of all pressure, disconnect, tag and lockout the power
supply to the starter before removing valves, caps, plugs, fittings, bolts, and filters.

2. Clogged, broken or loose 2. Tighten or replace

oil return lines faulty lines.

3. Ruptured oil separator 3. Replace element.

element.

4. Loose assembly. 4. Tighten all fittings

and gaskets.

5. Foam caused by use of 5. Use Gardner Denver”

incorrect oil. AEON 4000 or 9000 SP
Lubricating Coolant.

6. Inoperative minimum 6. Replace valve.

pressure valve.

7. Operation at elevated 7. Reduce temperature. See

discharge temperatures. High Discharge Air Temp-
erature - in this section.

8. Scavenge line check 8. Replace check valve.

valve failure.

9. Water condensate in oil. 9. Check oil reservoir temp and

if low change thermal mixing
valve element to higher temp.

13-8-610 Section 9 Page 3

 Symptom Possible Cause Remedy

“CHANGE SEPARATOR” light 1. Separator differential is 1. Change Separator.

(FLASHING OR ON Steadily) greater than 8 psid (.5 Bars).

2. Bad Transducer. 2. Verify readings with mechan-

ical gauges. If defective,
replace with 88H1 98.

3. Misadjusted minimum 3. Set minimum pressure valve at

pressure valve. 65 psig (4.5 Bars).

4. Sticky minimum pressure 4. Disassemble and clean.

valve.

5. Defective minimum 5. Rebuild or replace.

pressure valve.
[Won’t set at 65 psig (4.5 Bars)]

CHANGE SEPARATOR” light 1. Separator differential is 1. Change Separator.

WHILE RUNNING) greater than 8 psid (.5 Bars).

2. Electrical noise creating 2. Make sure transducer wires

false readings. are kept to a minimum length
and are twisted.

3. Oil reservoir is overfilling. 3. Fill to proper level (center of

the green range).

4. Unit is rapidly cycling. 4. Adjust subtractive pilot.

See Service Memo #248.
(Add subtractive pilot if
unit does not have one.)

5. Defective transducer. 5. Verify readings with mechan-

ical gauges. If defective,
replace with 88H1 98.

6. Plugged aftercooler, due 6. Clean or replace aftercooler.

to freezing or varnishing.

“MOTOR OVERLOAD” 1. Running compressor at a 1. Lower pressure to nameplate.

shutdown. pressure over nameplate
pressure.

2. Incoming voltage low or 2. Consult your power company.

high.

3. Imbalance voltage 3. If imbalance exceeds 5%,

(check phase to phase). check incoming power.

13-8-610 Section 9 Page 4

 Symptom
“MOTOR OVERLOAD”
shutdown. (cont.)
“CHANGE AIR FILTER” light on.
“CHANGE AIR FILTER” light on,
and WILL NOT RESET.
“MOTOR OVERLOAD”
shutdown.
(RELAY NOT TRIPPED)
“E04”, Emergency Stop
will not clear.
Possible Cause
4. Imbalance amps.
5. Incorrect motor overload
setting.
1. Dirty air filter.
1. Faulty vacuum switch.
2. Control board fault.
1. Loose connections.
2. Control board fault.
1. Loose connections or
faulty switch.
2. Control board fault.
3. Contact block not
properly installed.
13-8-610 Section 9
Remedy
4. Rotate 3 phase power leads.
If the high reading stays on
the same leg, the problem is
with the motor.
If the high reading moves
with the lead, the problem
is with the incoming power.
5. Set overload to motor name-
plate amps.
1. Clean or replace.
1. Measure the AC voltage
between wire number 7 and
connector #6 at board.
If the reading is zero,
replace the vacuum switch.
2. Measure the AC voltage
between wire number 7 and
connector #6 at board.
If the reading is 24 volts,
replace the control board.
1. Measure the AC voltage
between wire number 5 and
connector #6 at board.
If the reading is zero,
tighten the connections.
2. Measure the AC voltage
between wire number 5 and
connector #6 at board.
If the reading is 24 volts,
replace the control board.
1. Tighten connection or
repair or replace switch.
2. Measure the AC voltage
between wire number 3 and
connector #6 at board.
If.the reading is 24 volts,
replace the control board.
3. Ensure contact block is fully
snapped into left or right (not
center) slot of switch operator.
Page 5
 Symptom
Erroneous Pressure Readings
[135 -150 psig constantly].
(9.3 -10.3 Bars)
Oil leak at the bottom of
the seal housing.
Fuse on board blows.
Gardner-Denver factory remanufactured replacement compressor air end units are
available from your authorized distributor, on an exchange basis, for all rotary screw
compressor units.
Possible Cause
1. Electrical noise creating
false readings.
2. Loose connector.
3. Bad transducer.
1. Gasket leaking.
2. Capscrew leaking.
3. Shaft seal leaking.
1. Bad board.
2. Shorted coils on hour
meter, starter coil,
or blowdown valve.
NOTICE
13-8-610 Section 9 Page 6
Remedy
1. Make sure transducer wires
are kept to a minimum length
and are twisted.
2. Measure the DC voltage
between the white and black
wires of the corresponding
transducer at the control
board with zero pressure on
the transducer. If .460 to
.540 volts, replace the plug-
gable connector that connects
transducers to the board.
3. Measure the DC voltage
between the white and black
wires of the corresponding
transducer at the control
board with zero pressure on
the transducer. If 3.10 to
3.60 volts, replace the
transducer.
1. Tighten capscrew; if leak
continues, replace the
gasket.
2. Tighten cap screw.
3. Change seal.
1. Remove all power from the
unit by opening the main
disconnect, replace fuse,
energize main power. If fuse
blows - replace board.
2. If fuse does not blow, check
for shorted coils.

GENERAL PROVISIONS AND LIMITATIONS
Gardner Denver Machinery Inc. (the “Company”)
to each original retail purchaser (“Purchaser”) of its new
products from the Company or its authorized distributor that
such products are, at the time of delivery to the Purchaser,
made with good material and workmanship. No warranty
is made with respect to:
1. Any product which has been repaired or altered in
such a way, in the Company’s judgment, as to affect
the product adversely.
2. Any product which has, in the Company’s judgment,
been subject to negligence, accident, improper
storage, or improper installation or application.
3. Any product which has not been operated or
maintained in accordance with the recommendations
of the Company.
4. Components or accessories manufactured, warranted
and serviced by others.
5. Any reconditioned or prior owned product.
Claims for items described in (4) above should be submitted
directly to the manufacturer.
WARRANTY PERIOD
The Company’s obligation under this warranty is limited
to repairing or, at its option, replacing, during normal
business hours at an authorized service facility of the
Company, any part which in its judgment proved not to
be as warranted within the applicable Warranty Period as
follows.
COMPRESSOR AIR ENDS
Compressor air ends, consisting of all parts within and
including the compressor cylinder and gear housing, are
warranted for24 months from date of initial use or27 months
from date of shipment to the first purchaser, whichever
occurs first.
Any disassembly or partial disassembly of the air end, or
failure to return the “unopened” air end per Company
instructions, will be cause for denial of warranty.
OTHER COMPONENTS
All other components are warranted for 12 months from
date of initial use or 15 months from date of shipment to
first purchaser, whichever occurs first.
LABORTRANSPORTATIONAND INSPECTION
The Company will provide labor, by Company representative
or authorized service personnel, for repair or replacement
of any product or part thereof which in the Company’s
judgment is proved not to be as warranted. Labor shall
be limited to the amount specified in the Company’s labor
rate schedule.
AU-20 R 1/94
WARRANTY
ROTARY SCREW COMPRESSORS
OIL INJECTED ● OIL FREE
Labor costs in excess of the Company rate schedules
caused by, but not limited to, location or inaccessibility of
warrants
the equipment, or labor provided by unauthorized service
personnel is not provided by this warranty.
All costs of transportation of product or parts claimed not
to be as warranted and, of repaired or replacement parts
to or from such service facility shall be borne by the
Purchaser. The Company may require the return of any
part claimed not to be as warranted to one of its facilities
as designated by Company, transportation prepaid by
Purchaser, to establish a claim under this warranty.
Replacement parts provided under the terms of this warranty
are warranted for the remainder of the Warranty Period
of the product upon which installed to the same extent as
if such parts were original components.
WARRANTY REGISTRATION VALIDATION
A warranty registration form is provided with each machine.
The form must be completed by the Purchaser and mailed
within ten days after machine start-up to validate the
warranty.
DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT
IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE,
THE COMPANY MAKES NO OTHER WARRANTIES,
EXPRESSED, IMPLIED OR STATUTORY, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY.
THE REMEDY PROVIDED UNDER THIS WARRANTY
SHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDY
AVAILABLE TO THE PURCHASER AND IN NO CASE
SHALL THE COMPANY BE SUBJECT TO ANY OTHER
OBLIGATIONS OR LIABILITIES. UNDER NO
CIRCUMSTANCES SHALL THE COMPANY BE LIABLE
FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES OR
DELAYS HOWSOEVER CAUSED.
No statement, representation, agreement or understanding,
oral or written, made by any agent, distributor,
representative, or employee of the Company which is not
contained in this Warranty will be binding upon the Company
unless made in writing and executed by an officer of the
Company.
This warranty shall not be effective as to any claim which
is not presented within 30 days after the date upon which
the product is claimed not to have been as warranted. Any
action for breach of this warranty must be commenced within
one year after the date upon which the cause of action
occurred.
Any adjustment made pursuant to this warranty shall not
be construed as an admission by the Company that any
product was not as warranted.
For addkional information, contact Gardner Denver Machinery Inc., 13C-1-94
1800 Gardner Expreaaway, Quincy, Illinois 62301
Telephone (217) Z4-&300. Fax (217) 224-7814

Specifications subject to change without notice.

COPYRIGHT 1994 Gardner Denver Machinery Inc. Ltiho in USA