Gardner Denver L Series Operating And Service Manual

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13-25-617
Version: 02
February 21, 2018
L-SERIES
SINGLE STAGE
BASE- MOUNTED and TANK MOUNTED
COMPRESSORS
GD PILOT Controller
MODELS L7-11B (Fixed Speed)
MODELS LRS7-11B (Variable Speed)
10 and 15 HP
60HZ
OPERATING AND
SERVICE MANUAL
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER&reg; COMPRESSOR PARTS AND SUPPORT SERVICES
Gardner Denver&reg; Compressor genuine parts, manufactured to design tolerances, are developed for optimum
dependability – specifically for Gardner Denver compressor systems. Design and material innovations are the result
of years of experience with hundreds of different compressor applications. Reliability in materials and quality
assurance is incorporated in our genuine replacement parts.
Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. An AirSmart™ network of
authorized distributors provides the finest product support in the air compressor industry.
Your authorized distributor can support your Gardner Denver air compressor with these services:
1.
Trained parts specialists to assist you in selecting the correct replacement parts.
2.
Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured
airends are maintained in stock at the factory, for purchase on an exchange basis with liberal core credit
available for the replacement unit.
3.
A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver
compressors.
4.
Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.
Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They
are ready to respond and assist you by providing fast, expert maintenance and repair services.
To Contact Gardner Denver or locate your local distributor:
Visit: www.contactgd.com/compressors
Or
Call: (800) 682-9868
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, Method of Cooling, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). The Airend Serial Number is also stamped on top of the discharge bearing carrier casting.
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 (1); where more than one is required
per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED.
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) and (LH),
when appropriate.
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WARNING – PROHIBITION – MANDATORY LABEL INFORMATION
Gardner Denver Rotary 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.
Boxed text formats are used, within this manual, to alert users of the following
conditions:
Safety Labels are used, within this manual and affixed to the appropriate areas of the
compressor package, to alert users of the following conditions:
Indicates a hazard with a high level of risk, which if not avoided, WILL result in death or serious
injury.
Equipment Starts Automatically
Health Hazard – Explosive Release of Pressure
Cutting of Finger or Hand Hazard – Rotating
Impeller Blade
High Voltage – Hazard of Shock, Burn, or Death
Present until Electrical Power is Removed
Cutting of Finger or Hand Hazard – Rotating Fan
Blade
Entanglement of Fingers or Hand/Rotating Shaft
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Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or
serious injury.
Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air
Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or
moderate injury.
Burn Hazard – Hot surface
PROHIBITION/MANDATORY ACTION REQUIREMENTS
Do not Operate Compressor with Guard Removed
Lockout Electrical Equipment in De-Energized
State
Do Not Lift Equipment with Hook – No Lift Point
Loud Noise Hazard – Wear Ear Protection
Handle Package at Forklift Points Only
Read the Operator’s Manual Before Proceeding
with Task
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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:
Failure to observe these notices will result in injury to or death of personnel.
&middot;
Keep fingers and clothing away from rotating fan, drive coupling, etc.
&middot;
Disconnect the compressor unit from its power source, lockout and tagout before working on the
unit – this machine is automatically controlled and may start at any time.
&middot;
Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostatic mixing valve or
break any connections, etc., in the compressor air or oil system until the unit is shut down and
the air pressure has been relieved.
&middot;
Electrical shock can and may be fatal.
&middot;
Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.
Open main disconnect switch, lockout and tagout and check for voltage before working on the
control.
Failure to observe these notices could result in damage to equipment.
&middot;
Stop the unit if any repairs or adjustments on or around the compressor are required.
&middot;
Do not use the air discharge from this unit for breathing – not suitable for human consumption.
&middot;
An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).
&middot;
Do not exceed the rated maximum pressure values shown on the nameplate.
&middot;
Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.
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TABLE OF CONTENTS
Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And
Support Services ..................................................................................................................................... 1
Instructions For Ordering Repair Parts ..................................................................................................... 1
Warning – Prohibition – Mandatory Label Information .............................................................................. 2
Safety Precautions .................................................................................................................................. 4
Index ....................................................................................................................................................... 6
Section 1, General Information ................................................................................................................ 8
Section 2, Installation............................................................................................................................. 12
Section 3, Starting &amp; Operating Procedures ........................................................................................... 18
Section 4, Controls &amp; Instrumentation .................................................................................................... 23
Section 5, Lubrication. Oil Cooler, Oil Filter &amp; Separator ........................................................................ 49
Section 6, Heat Exchangers (Oil/Air) ...................................................................................................... 57
Section 7, Air Filters .............................................................................................................................. 60
Section 8, Belt Drive System.................................................................................................................. 62
Section 9, Servicing Of Miscellaneous Devices ...................................................................................... 65
Section 10, Tank Mounted Compressor - Total System .......................................................................... 59
Section 11, Maintenance Schedule ........................................................................................................ 74
Section 12, Troubleshooting .................................................................................................................. 76
This book covers the following models:
HP
PSIG
Air Cooled
Parts List
Controller Manual
10, 15
110, 130, 190
L7-11B
13-25-530
ZS1054347
10, 15
110, 130, 190
LRS7-11B
13-25-530
ZS1054347
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INDEX
Air Cooled Unit ...............................................12
Air Filters
Section 7.....................................................52
Air Flow in Compressor System ....................... 8
Air Receiver
Auxiliary ......................................................15
BELT DRIVE SYSTEM
SECTION 8.................................................54
Cold Weather
Installation ..................................................15
Compression Principle ..................................... 8
Compressor ..................................................... 8
Controls &amp; Instrumentation
AirSmart G2 Controller Operation................23
General Description ....................................23
Section 4.....................................................23
Cooling, Sealing and Lubrication...................... 8
Daily Check ....................................................22
Discharge Service Line ...................................15
ELECTRICAL WIRING ...................................16
ELECTRICAL WIRING Sizing .........................16
Enclosure .......................................................14
Foundation .....................................................13
GENERAL INFORMATION
SECTION 1.................................................. 8
Grounding ......................................................17
HEAT EXCHANGERS (OIL/AIR)
Section 6.....................................................49
Inlet Line ........................................................15
Installation
Cold Weather ..............................................15
General .......................................................12
Section 2.....................................................12
Lifting Unit ......................................................12
Location .........................................................12
Lubrication, Cooling and Sealing...................... 8
LUBRICATION, OIL COOLER, OIL FILTER &amp;
SEPARATOR
SECTION 5.................................................41
MAINTENANCE SCHEDULE
SECTION 10 ...............................................63
SECTION 11 ...............................................64
Miscellaneous Control Devices .......................38
Moisture Separator/Trap
Standard .................................................... 15
Motor Lubrication ........................................... 17
Oil Reservoir
Drain .......................................................... 13
Piping
Control ....................................................... 15
Prestart-Up Instructions.................................. 18
Air Filter...................................................... 18
Compressor Oil .......................................... 18
Electrical .................................................... 18
Enclosure ................................................... 21
Grounding .................................................. 18
Inlet Filter ................................................... 18
Operating Mode.......................................... 21
Piping ......................................................... 18
Rotation...................................................... 19
V-Belt System............................................. 19
SAFETY PRECAUTIONS ................................ 4
Sealing, Lubrication and Cleaning .................... 8
Service Check List ......................................... 64
Every 1000 Hours Operation....................... 64
Every 125 Hours Operation ........................ 64
Every 4000 Hours Operation....................... 64
Every 8 Hours Operation ............................ 64
Every Year ................................................. 64
Motor Lubrication........................................ 64
SERVICING OF MISCELLANEOUS DEVICES
SECTION 9 ................................................ 57
STARTING &amp; OPERATING PROCEDURES
SECTION 3 ................................................ 18
Starting the Unit ............................................. 22
Unit Cold .................................................... 22
Stopping the Unit ........................................... 22
TROUBLE SHOOTING
SECTION 11 .............................................. 66
SECTION 12 .............................................. 66
TROUBLESHOOTING VOLTAGE PROBLEMS
................................................................... 69
WARNING – PROHIBITION – MANDATORY
LABEL INFORMATION ................................ 2
Wiring
Electrical .................................................... 16
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LIST OF ILLUSTRATIONS
Figure 1-1 - Compressor Cycle .................................................................................................8
Figure 1-2 – Compressor Illustration - External Details ..............................................................9
Figure 1-3 – Compressor Illustration - Internal Details ............................................................. 10
Figure 1-4 – Compressor Illustration - Total System ................................................................ 11
Figure 2-1 – Typical Compressor Room .................................................................................. 13
Figure 2-2 – Air Flow Chart ..................................................................................................... 13
Figure 2-3 – Cold Weather Installation .................................................................................... 14
Figure 2-4 – Electrical Wiring Sizing Data ............................................................................... 16
Figure 4-1 – Controller Layout And Main Screen ..................................................................... 23
Figure 4-2 – Wiring Diagram – (200-230/460 V) ...................................................................... 25
Figure 4-3 – Wiring Diagram – (380 V).................................................................................... 26
Figure 4-4 – Wiring Diagram – (575 V).................................................................................... 31
Figure 4-5 -- Wiring Diagram -- (230V, 1 Phase) .................................................................... 34
Figure 4-6 -- Piping and Instrumentation Illustration ................................................................ 40
Figure 5-1 – Oil Level Sight Glass........................................................................................... 49
Figure 5-2 – Oil Change Interval ............................................................................................. 44
Figure 5-3 – Dew Point Chart &deg;F ............................................................................................. 48
Figure 5-4 -- Dew Point Chart &deg;C ............................................................................................ 48
Figure 6-1 – Air Flow Chart ..................................................................................................... 57
Figure 6-2 – Cooler Access .................................................................................................... 59
Figure 7-1 – Compressor Air Filter .......................................................................................... 61
Figure 7-2 – Pre-Filter Cover, Pre-Filter and Fan Grill ............................................................. 61
Figure 8-1 – Motor Jacking Assembly ..................................................................................... 62
Figure 8-2 – V-Belt Drive Components.................................................................................... 62
Figure 8-3 - Measuring Angular Misalignment ......................................................................... 63
Figure 9-1 – Inlet Valve Assembly .......................................................................................... 65
Figure 9-2 - Pressure Relief Valve .......................................................................................... 68
Figure 9-3 - Minimum Pressure Valve and Seat ...................................................................... 69
Figure 9-4 – Thermostatic Mixing Valve .................................................................................. 70
Figure 9-6 – Electrical Box Cooling Hardware ......................................................................... 63
Figure 9-7 – VFD Fan Removal .............................................................................................. 64
Figure 9-8 – VFD Fan Disconnect ........................................................................................... 64
Figure 9-9 – VFD Fan Reconnect ........................................................................................... 64
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SECTION 1
GENERAL INFORMATION
Figure 1-1 - COMPRESSOR CYCLE
COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine
using meshing helical rotors to effect compression. Both rotors are supported between high capacity antifriction bearings located outside the compression chamber. Roller bearings are used at the inlet end of
the rotors to carry part of the radial loads. Angular contact ball and 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) - Compression is accomplished by the main and secondary
rotors synchronously meshing in a one-piece cylinder. The main rotor has five (5) helical lobes 90&deg; apart.
The secondary rotor has six (6) matching helical grooves 72&deg; 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 continues, more of the main rotor lobe enters the secondary rotor grove, normal volume is
reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of compression 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 air flow that is
continuous, smooth and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 1-3) - Air enters the air filter and passes through
the inlet unloader valve and on into the compression chamber where oil is injected into the air. After
compression, the air/oil mixture passes into the oil reservoir 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 the air/oil separator. The air then passes through the minimum pressure/check valve, the
after cooler 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 discharge into the compressor main oil gallery.
A portion of the oil is directed through internal passages to the bearings 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.
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302ECA797 - 00
(Ref. Drawing)
Page 1 of 2
Figure 1-2 – COMPRESSOR ILLUSTRATION - EXTERNAL DETAILS
(L7-11 model shown with controller set for “front” display)
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Figure 1-3 – COMPRESSOR ILLUSTRATION - INTERNAL DETAILS
(L7-11 model shown with controller set for “top” display)
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Figure 1-4 – COMPRESSOR ILLUSTRATION – TOTAL SYSTEM
(L7-11 base model with 120g receiver and RNC dryer shown)
301ECA804-A
(Ref. Drawing)
Page 1 of 1
SECTION 2
INSTALLATION
GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit.
Report any damage or missing parts as soon as possible.
Do not electric weld on the compressor or base; bearings can be damaged by
passing of current.
LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Unit may
be moved into location by lift truck.
Lift compressor unit under base only. Do not use other places such as motor,
compressor or discharge manifold piping as lifting points.
The eyebolts or lugs provided on the motor are for lifting the motor only and should
not be used to lift any additional weight. All eyebolts must be securely tightened.
When lifting the motor the lifting angle must not exceed 15 degrees. Failure to observe
this warning may result in damage to equipment or personal injury.
Compressor, air/oil reservoir, separator chamber and all piping and tubing may be at
high temperature during and after operation.
LOCATION (Figure 2-1) - The compressor must be installed where it is protected from rain, snow and
freezing temperatures, in a clean, well-lighted, well-ventilated area with ample space all around for
maintenance. Select a location 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 supply, see
“Inlet Line, page 15.
AIR-COOLED UNIT - A combination oil/air cooler is supplied as standard equipment on all air-cooled
units. A shaft driven axial fan supplies the ventilation needs for the oil/air cooler and electric motor
cooling (Figure 1-2). Air is drawn into the unit through the left side panel, over the motor and discharged
through the cooler cores. Do not block the air flow to and from the unit. Allow three and one half (3-1/2)
feet to the nearest obstruction on the control box end of the unit. Allow two (2) feet to the nearest
obstruction above and on other sides of unit.
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For continuous efficiency, the 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.
NOTICE
Coolers are aluminum; do not use any cleaning solution that is not compatible with
aluminum. Use of improper solution may result in damage to the cooler.
Figure 2-1 – TYPICAL COMPRESSOR ROOM
Minimum Air Flow* For Compressor
And Cooling (Cubic Feet/Minute)
Air Cooled
All Models
1368 CFM
* 80&deg;F Inlet Air
Figure 2-2 – AIR FLOW CHART
FOUNDATION - The rotary screw compressor requires no special foundation, but should be mounted on
a smooth, solid surface. Whenever possible install the unit near level. Mounting bolts are not normally
required. However, installation conditions such as piping rigidity, angle of tilt, or danger of shifting from
outside vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform
support for the base. Belt alignment and tension should be checked after installation. (For information on
belt alignment and tension, Section 8.
OIL SUMP / OIL COOLER DRAIN – Sump oil and oil cooler charge are drained from a single plugged
connection on the lower, left-hand side of the core – see Figure 1-3.
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ENCLOSURE - The compressor, electric motor, oil cooler and after cooler are mounted inside the
enclosure.
Service panels are provided for maintenance access. Be sure to allow enough space around the unit for
the panels to be removed. Any of the enclosure panels may be removed by opening the latch and lifting it
up slightly.
Do not operate the compressor with the fan and belt guard removed. Exposed fan and
belts may cause injury to personnel.
The enclosure doors and panels must be closed and latched while the compressor is
operating. Failure to close and latch the doors and panels will cause high temperature
shutdowns.
Figure 2-3 – COLD WEATHER INSTALLATION - TYPICAL
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INSTALLATION FOR COLD WEATHER OPERATION (
Figure 2-3) - It is recommended that the unit be installed inside a shelter that will be heated to
temperatures above freezing (32oF, 0oC). This will eliminate many of the problems associated with
operating units in cold climates, such as freezing in control lines and downstream of the cooler.
Refer to Engineering Data Sheet 13-9-411 for the advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for an adequate shelter for the unit.
When the unit must be installed in an outdoors installation and/or exposed to ambient temperatures below
freezing (32ᴼ F, 0ᴼ C), contact Gardner Denver for recommendations.
When using a Total System with a compressed air dryer option, refer to Section 10 for details.
Remember unsheltered (outside) installations should be avoided whenever possible. Installation next to
a heated building, where enough heat can be used to keep the compressor room above freezing, will
save many complications in the operation and installation of the unit.
AUXILIARY AIR RECEIVER – When using the base compressor package, an auxiliary air receiver is not
required if the piping system is large and provides 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
STANDARD MOISTURE SEPARATOR/TRAP - The unit is provided with a stand-alone combination
moisture separator and trap that is field-installed downstream of the after cooler.
CONTROL PIPING - Control piping is not necessary since the rotary screw unit is factory wired and piped
for the control system specified.
INLET LINE - The filter is close-coupled to the compressor intake flange, thus no inlet line is used or
recommended.
DISCHARGE SERVICE LINE – For a stand-alone compressor unit, the discharge service line connection
is provided at the outlet of the field installed water separator, which in turn is located at the lower right
hand side of the after cooler core.
For a compressor unit integrated into the Total System, the discharge service line connection is provided
at the outlet of the dryer bypass loop (when dryer options is furnished) or at the outlet of the receiver
vessel.
A hand operated valve, (air service valve) and a separate (swing-type) check valve must be installed
between the unit and the customer’s air system. If a fast operating valve such as a ball valve is used, it
must be closed slowly to give the intake valve time to shut and keep the discharge pressure from spiking.
The controller has an automatic start/stop sequence built in. You do NOT need to
close the air service valve. Closing the air service valve on start-up or prior to
shutdown will cause rapid cycling, and could cause a high pressure shutdown.
When piping two or more rotary screw units on a common discharge line, each unit shall be isolated by
the check valve in the unit discharge line.
If a rotary screw and a reciprocating compressor are piped to a common discharge line, an air receiver
must be located between the two units.
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Discharge air used for breathing will cause severe injury or death.
Consult filtration specialists for additional filtration and treatment equipment to meet
health and safety standards.
ELECTRICAL WIRING - Standard Units – The stand alone compressor package is factory wired for all
connections from the starter to the motor, for the horsepower and voltage specified on the order. The
standard unit is supplied with totally enclosed motors and a UL Type 1 (NEMA 1) starter and controls
enclosure. See “Location” paragraph in Section 2, for distance to the nearest obstruction on the control
box side of the package.
The overload settings are to be selected based on motor nameplate full load amperage.
Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable local
electrical codes. Wiring must be performed only by qualified electricians.
Electrical shock can cause injury or death. Open main disconnect switch, lockout and
tag out before working on control box.
When the compressor unit is integrated into a Total System and the optional compressed air dryer is
furnished, the latter shall be provided with a separate source of electrical power.
Electrical Wire Sizing - A certified electrician familiar with National Electric Codes and applicable local
codes shall size the electrical power wires serving the compressor package. Refer to Figure 2-4 for a
summary of maximum package current draw values.
Package Power
Voltage
15 / 10
&quot;
“
&quot;
“
575
460
380
230
208
Max Current Draw - amps
Full Speed – Var. Speed
18.1 / 18.4 – 13.6 / 13.2
22.6 / 23.0 – 17.0 / 16.5
27.3 / 27.8 – 20.5 / 20.0
45.2 / 46.0 – 33.9 / 33.0
50.0 / NA – 37.5 / NA
Figure 2-4 – Electrical Wiring Sizing Data
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GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical
Code.
Failure to properly ground the compressor package could result in injury or death.
Install ground wiring in accordance with the National Electrical Code and any
applicable local codes.
MOTOR LUBRICATION - The Hebei type H112-2 motors used with this compressor package have
sealed bearings which have been greased at the factory and require no re-greasing during their
operational life. These motors do not have injection or drain ports for re-greasing.
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SECTION 3
STARTING &amp; OPERATING PROCEDURES
PRESTART-UP INSTRUCTIONS - A new unit received from the factory has been prepared for shipping
only. Do not attempt to operate the unit until checked and serviced as follows:
1.
Compressor Oil - The oil level must be checked before starting the unit and every 8 hours of
operation. For instructions on checking the oil and the proper oil level, refer to “Oil level gauge”,
Section 5.
Do not mix different type oils. Standard Unit is shipped filled with Gardner Denver AEON 4000
lubricant which is suitable for the first 4000 hours under normal operating conditions. Other AEON
lubricants are available. Check the decal on the reservoir to be sure which lubricant is in the
machine.
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 extended drain intervals
of AEON 4000 lubricant. Use only genuine Gardner Denver filters designed and
specified for this compressor.
Always stop the unit and release air pressure before removing oil filler plug. Failure to
release pressure may result in personal injury or death.
Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to SECTION 7 for
complete servicing instructions. Be sure the inlet line, if used, is tight and clean.
2.
Package Inlet Filter (Figure 1-2) Inspect the Pre-Filter to be sure it is clean. Refer to Section 7 for
complete servicing instructions
3.
Piping – Refer to Section 2, “Discharge Service Line” and make sure all piping meets all
recommendations.
4.
Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See
Figures 4-2 to 4-5 for general wiring diagrams and Section 2 for “Electrical Wiring”.
5.
Grounding - Unit must be properly grounded according to Section 250 of the National Electrical
Code.
6.
When using a Total System with a compressed air dryer option, refer to Section 10 for details.
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Page 18
Failure to properly ground the compressor package could result in controller
malfunction.
7.
V-Belt System - Refer to Section 8 for detailed instruction to unpack and check the alignment of the
belt system.
The motor jacking hardware must be re-configured, the main motor carrier bracket
removed, and belts engaged and the belt sheaves alignment checked prior to
compressor operation. Failure to do so will prevent compressor operation and/or
component damage.
8.
Rotation - Check for correct motor rotation by, in quick succession, starting and stopping the
compressor system. Note that the controller can also detect reverse motor rotation by sensing a
vacuum pressure, but this may damage the compressor by prolonged operation under reverse
rotation. If motor reverse rotation is confirmed, follow the appropriate “lockout/tagout” procedure to
isolate the package from the electrical grid, reverse any two motor leads connected to the package
or motor, restore electrical power to the package, and re-check rotation.
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.
The compressor unit’s direction of rotation must be checked every time the
compressor package or its main motor is reconnected to the power supply.
Electrical shock can cause injury or death. Open main disconnect switch, lockout and
tagout before working on control box.
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Page 19
9.
For your convenience, the following excerpt from the Controller manual is presented to assist in
programming the basic operating parameters. However, we strongly recommend you read the
Controller manual before attempting operating the compressor package.
Figure 3-1 – GD Pilot Controller Layout and Main Screen
&middot;
Controller Hardware layout.
o
See Fig 3-1 for the layout of the main screen and input devices.
o
The ( I ) key switches unit on.
o
The (O) key switches unit off.
o
The (Ө) key enters a selection and clears a fault.
o
The (↑↓) keys, hit simultaneously, call up or exit a menu/submenu.
o
The (↑) key navigates to a previous submenu/menu or increases a parameter value.
o
The (↓) key navigates to a next submenu/menu or decreases a parameter value.
o
Display info (1st row): AE discharge temp and press, MPV discharge press (permanent).
o
Display info (2nd row): Menus. Total Running Hrs. default menu.
o
Display info (3rd row): Status, Fault and Warning messages. Load status default menu.
&middot;
Setting the Cut-out Pressure
o
Navigate to the [Control Menu] by pressing simultaneously the (↑↓) keys.
o
Navigate to the [Cut out] submenu with the (↓) key. Adjust the pressure to a value between 1
to 6 psig above the desired operating pressure by using the (↑↓) keys.
&middot;
Setting the Cut-in Pressure
o
Navigate to the [Cut in] submenu with the (↓) key. Adjust the pressure to a value at least 1 to
6 psig below that of the desired operating pressure by using the (↑↓) keys.
o
For variable speed models which use a variable frequency drive, the “Cut-in” submenu is
replaced with a “Target” submenu. In this case, adjust the pressure to a value equal to the
desired operating pressure.
&middot;
Selecting the operating mode
o
Navigate to the [Automatic Operation] submenu with the (↓) key – this is the recommended
mode to use until you become familiar with the Controller manual and other operating modes
available.
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Operation at excessive discharge air pressure can cause personal injury or damage to
equipment. Do not adjust the operating discharge air pressure above the maximum
stamped on the unit nameplate.
10. Enclosure - Check for damaged panels or doors. Check all screws and latches for tightness. Be
sure doors are closed and latched.
The compressor starts and stops automatically. Automatic restarting can cause injury
or death. Open, lockout and tagout main disconnect and any other circuits before
servicing the unit.
The enclosure doors must be closed and latched to keep the compressor package
from overheating when the compressor is running.
After an emergency stop, be sure that the pressure in the air/oil reservoir is less than 5
psig. Wait one minute or more before restarting.
The controller has an automatic start/stop sequence built in. You do NOT need to
close the air service valve. Closing the air service valve on start-up or prior to
shutdown will cause rapid cycling, and could cause a high pressure shutdown.
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STARTING THE UNIT - Observe the following starting procedures:
Unit Cold or Hot:
1. When using a Total System with a compressed air dryer option, refer to Section 10 for operating
details.
2. Open the air service valve (customer furnished) between the main air system and the check valve
on the package.
3. Turn on power to the compressor package. Press the (Ө) key to clear faults (if present), then
press the ( I ) key to start the unit.
4. Run for approximately several minutes until the temperature stabilizes.
5. The unit is equipped with a minimum (70psig) pressure/check valve. No special procedure is
required to maintain the unit reservoir pressure.
DAILY CHECK - Refer to “Maintenance Schedule”, Section 11.
STOPPING THE UNIT:
1.
To stop compressor operation, press the (O) key.
2.
Wait approximately one minute to allow the compressor to stop. The oil reservoir will automatically
blow down as the motor stops.
3.
When using a Total System with a compressed air dryer option, refer to Section 10 for operating
details.
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SECTION 4
CONTROLS &amp; INSTRUMENTATION
GENERAL DESCRIPTION
The Gardner Denver rotary screw compressor is pre-wired with all controls, motor, and starter for the
voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the
correct power supply and to the shop airline. A standard package unit consists of the GD1 compressor,
oil separation module, air/oil cooling and filtration system, TEFC electric main motor, full-voltage magnetic
starter (variable speed drive option available) housed in an UL Type 1 (NEMA 1) enclosure / control box,
and control components as described below.
ELECTRONIC CONTROLLER AND STARTER ASSEMBLY HARDWARE - See to the Wiring
Diagrams listed [by voltage] at the end of this section, for more details on the location of the
referred hardware.
GD Pilot Controller - The compressor package features the GD Pilot controller, which integrates all the
control functions under microprocessor control - see Figure 4-1 for general detail of the controller keypad
and display. Controller functions include safety and shutdown, compressor regulation, operator control
and advisory/maintenance indicators. The keypad and display provides a logical and easily operated
control of the compressor and indication of its condition. The controller is factory adjusted for the
compressor package, but allows tuning for specific applications.
FIGURE 4- 1 – GD Pilot Controller Layout and Main Screen
Emergency Stop Pushbutton - This is a maintained pushbutton, and removes power from the controller
outputs regardless of controller status. It is located on the electrical panel door, below the controller
keypad. This should be used for emergency purposes only - use the (O) key for normal controlled
stopping.
Control Transformer – A control transformer is provided to supply 230 and 24 VAC control power
supply.
Fuse Blocks – Fuse blocks provide input and output side protection for the control transformer.
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Terminal Strip - This device provides an interconnection between the GD Pilot controller and the low
voltage hardware such as sensors and switches within the enclosure.
Main Starter - For Fixed Speed variant models, a full-voltage starter provides control and overload
protection for the main drive motor. The overloads are adjustable and are factory set based on the motor
nameplate amps and the instructions located inside the control box door. For Variable Speed variant
models, a variable speed drive provides the overload protection for the main drive motor as well as
compressor speed modulation.
Wiring diagrams for typical full voltage applications are illustrated in the following pages of this section.
NOTICE
Read the Operator’s Manual before operating the compressor. It is critical that the
detailed instructions for the controller, found in the controller manual
are read and
understood. Once the appropriate parameters have been selected into the controller,
compressor operation may commence. For convenience, a “Quick Start” excerpt from
the controller manual is shown in Section 3
FIELD CONVERSION OF MULTI-VOLTAGE ELECTRICAL SYSTEM - To convert the
compressor package from its as-built voltage configuration to one of its optional ones, contact Gardner
Denver and request “Instructions – Tri-Voltage Conversion”, document TED000579.
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303ECB546-B
(Ref. Drawing)
Page 1 of 3
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Page 25
FIGURE 4- 2 – WIRING DIAGRAM, FIXED SPEED – 380v 60Hz
303ECB546-B
(Ref. Drawing)
Page 2 of 3
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Page 26
FIGURE 4- 3 – WIRING DIAGRAM, FIXED SPEED – 380v 60Hz
303ECB546-B
(Ref. Drawing)
Page 3 of 3
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Page 27
FIGURE 4- 4 – WIRING DIAGRAM, FIXED SPEED – 380v 60Hz
305ECB546-A
(Ref. Drawing)
Page 1 of 3
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Page 28
FIGURE 4- 5 – WIRING DIAGRAM, FIXED SPEED 575V-60Hz
305ECB546-A
(Ref. Drawing)
Page 2 of 3
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Page 29
FIGURE 4- 6 – WIRING DIAGRAM, FIXED SPEED 575V-60Hz
305ECB546-A
(Ref. Drawing)
Page 3 of 3
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Page 30
FIGURE 4- 7 – WIRING DIAGRAM, FIXED SPEED 575V-60Hz
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Page 31
307ECB546-A
(Ref. Drawing)
Page 1 of 3
FIGURE 4- 8 – WIRING DIAGRAM, FIXED SPEED – 208-230/460v-60Hz
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FIGURE 4- 9 – WIRING DIAGRAM, FIXED SPEED – 208-230/460v-60Hz
307ECB546 - A
(Ref. Drawing)
Page 2 of 3
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Page 33
307ECB546 - A
(Ref. Drawing)
Page 3 of 3
FIGURE 4- 10 – WIRING DIAGRAM, FIXED SPEED – 208-230/460v-60Hz
300EJB546-D
(Ref. Drawing)
Page 1 of 4
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Page 34
Figure 4-5 – WIRING DIAGRAM, VARIABLE SPEED – 230v-60Hz
300EJB546-D
(Ref. Drawing)
Page 2 of 4
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Page 35
Figure 4-5 – WIRING DIAGRAM, VARIABLE SPEED – 230v-60Hz
300EJB546-D
(Ref. Drawing)
Page 3 of 4
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Page 36
Figure 4-5 – WIRING DIAGRAM, VARIABLE SPEED – 230v-60Hz
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Page 37
300EJB546-D
(Ref. Drawing)
Page 4 of 4
Figure 4-5 – WIRING DIAGRAM, VARIABLE SPEED – 230v-60Hz
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Page 38
301EJB546-D
(Ref. Drawing)
Page 1 of 4
Figure 4-6 – WIRING DIAGRAM, VARIABLE SPEED – 380/460v-60Hz
301EJB546-D
(Ref. Drawing)
Page 2 of 4
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Page 39
Figure 4-6 – WIRING DIAGRAM, VARIABLE SPEED – 380/460v-60Hz
301EJB546-D
(Ref. Drawing)
Page 3 of 4
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Page 40
Figure 4-6 – WIRING DIAGRAM, VARIABLE SPEED – 380/460v-60Hz
301EJB546-D
(Ref. Drawing)
Page 4 of 4
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Page 41
Figure 4-6 – WIRING DIAGRAM, VARIABLE SPEED – 380/460v-60Hz
302EJB546-C
(Ref. Drawing)
Page 1 of 4
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Page 42
Figure 4-7 – WIRING DIAGRAM, VARIABLE SPEED – 575v -60Hz
302EJB546-C
(Ref. Drawing)
Page 2 of 4
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Page 43
Figure 4-7 – WIRING DIAGRAM, VARIABLE SPEED – 575v -60Hz
302EJB546-C
(Ref. Drawing)
Page 3 of 4
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Page 44
Figure 4-7 – WIRING DIAGRAM, VARIABLE SPEED – 575v -60Hz
302EJB546-C
(Ref. Drawing)
Page 4 of 4
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Page 45
Figure 4-7 – WIRING DIAGRAM, VARIABLE SPEED – 575v -60Hz
MISCELLANEOUS CONTROL DEVICES - Refer to Figure 4-8 for the schematic diagram of the control system.
Intake [Air] Filter (1) - Captures solid impurities in the air stream entering compressor inlet. It also attenuates
noise emitted by the compressor inlet.
Inlet-Valve Assembly (2) - This device controls the intake of atmospheric air entering the compressor during the
Load/Unload phases of operation.
&middot;
During the loaded state: The inlet poppet (2.2) remains open and allows atmospheric air to enter the
compressor inlet.
&middot;
During the unloaded state: The 2-way solenoid valve (Y1) feeds pressurized air underneath the piston
(2.1), forcing it and the inlet poppet (2.2) upward and blocking-off the compressor intake. Excess gas is
vented to atmosphere via orifice 18. A small purge orifice (2.3) allows a stream of air to reach (e.g., purge)
the rotors and keep them from unstable, noisy operation and producing sufficient pressure to maintain
cooling / lubricating oil flow. See Section 9, page 65, for maintenance information.
Electric Motor (3) – Drives the compressor (4) via a belt drive assembly (5), and drives the package
ventilation fan from a secondary rear shaft. It is energized by the full voltage-type starter (variable frequency drive
in variable speed models), which in turn is controlled by the GD Pilot controller.
Oil Sump (6) –.Separates by inertial effects the bulk of the compressed air and injection oil streams and serves
as a sump for the latter.
Air/oil separator (7) - Intercepts and coalesces the aerosol oil stream in the compressed air exiting the inertial
separation process within the oil sump.
Oil Filler Cap (8) – Oil fill port on the oil sump.
Oil drain (9) – Ball valve drains the oil from the sump and the oil trapped in the oil cooler and associated hoses.
Oil Level Indicator (10) - This gauge is located on the oil sump and indicates the oil level. See “Oil Level Gauge”
on Section 5 for more details.
Oil Filter (11) - Captures solid impurities in the oil entering the compressor injection port.
Oil Cooler (12) – The air-cooled heat exchanger removes heat from the oil stream prior to injection.
Pressure Relief Valve (13) – This device protects the pressure containing components of the compressor
package against high pressure exceeding 217 psig. See Section 9, for maintenance information.
Minimum Discharge Pressure/Check Valve (14) - This device maintains minimum pressure (70psig) within the
air/oil sump, thus ensuring adequate lubricating oil injection flow to the compressor even when no air delivery into
the system is taking place. It also functions as a check valve to prevent reversed air flow from the system line
during compressor stoppage. See Section 9 for maintenance information.
Air cooler (15) – The air-cooled heat exchanger removes heat from the air stream prior to exit from the package.
Scavenge line orifice and orifice (16) – This annular orifice, built into the air/oil separator element adaptor pipe,
controls the amount of oil and compressed air that is returned from the air/oil separator back into the compressor.
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Solenoid Valve (Y1) - This 2-way valve controls the position of the inlet valve in response to signals from the GD
Pilot Controller.
Pressure Sensor - Sump Dry Side (B1) - This device is connected after the minimum pressure valve. It
converts the pressure in the plant air system into an electrical signal for use by the GD Pilot controller for
monitoring and control load/unload operation.
Pressure Sensor - Sump Wet Side (B2) - This device is connected to the oil sump. It converts the pressure in
the oil sump into an electrical signal for use by the GD Pilot controller for monitoring and control. Its signal, when
compared to that of sensor (B1), indicates the pressure loss across the air/oil separator element and it can also
trigger a shutdown event in case an exceedingly high pressure is detected.
Temperature Sensor - Sump Wet Side (R1) - This device is connected to the oil sump. It converts the
temperature in the oil sump into an electrical signal for use by the GD Pilot controller for monitoring and control.
Its signal is used to monitor compressor temperature and also trigger a shutdown event in case an exceedingly
high is detected.
(The following items are provided with the Total System variant:)
Receiver (21) - Provides storage of compressed air and serves as a support for the compressor unit and optional
dryer.
Refrigerated dryer (22) - The [optional] electric refrigerated dryer cools and lowers the dew point of the
compressed air stream delivered by the compressor unit by removing the condensed water vapor entrained.
Dryer bypass valve (23) – These 2-way valves allow the isolation of the refrigerated dryer (from the compressed
air line) for trouble shooting or maintenance purposes.
Drain isolation valve (24) - This valves isolate the condensate drain device from the compressed air lines, thus
allowing for maintenance and/or temporary condensate drainage functions.
Condensate drain valve (25) - This device provides automatic condensate drainage from the receiver. It, along
with the receiver, replaces the water 1separator shipped loose with the basic package.
Pressure relief valve (26) - This device protects the pressure containing components included with the received
against high pressure exceeding 195.5 psig. Section 9 for maintenance information.
Pressure gauge (27) - This device monitors the compressed air pressure within the receiver.
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Figure 4-8 – PIPING AND INSTRUMENTATION ILLUSTRATION
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300ECB797-00
(Ref. Drawing)
Page 1 of 1
SECTION 5
LUBRICATION
OIL COOLER, OIL FILTER &amp; SEPARATOR
COMPRESSOR OIL SYSTEM - Lubricating oil is employed to absorb the heat of compression, lubricate
moving parts and seal internal clearances between the rotor and the air cylinder. Pressure differential
between the air/oil sump and the final injection point into the compressor is used to move the oil mass
through the various oil system components. Refer to Figure 4-8 for the arrangement of the oil system
components - they are highlighted in blue for identification ease.
Oil exits the air/oil sump and is delivered to the heat exchange and thermal mixing valve, where cold (oil
cooler branch) and hot (oil bypass branch) are mixed to the desired compressor injection temperature.
The tempered oil is cleansed via the oil filter before injection into the compressor casing.
RECOMMENDED LUBRICANT - Gardner Denver compressors is factory filled with one of several
Gardner Denver AEON lubricants. These lubricants are formulated to the highest quality standards and
are factory authorized, tested and approved for use in rotary screw compressors. AEON lubricants are
available through your authorized Gardner Denver compressor distributor.
OIL SPECIFICATIONS - The standard factory fill compressor lubricant is Gardner Denver AEON 4000, a
superior semi-synthetic blend of petroleum stock and various protective additives, suitable for year-round
operation. For exceedingly high or low operating temperatures, see lubricant recommendations in this and
in Section 2.
OIL LEVEL INDICATOR (GAUGE) indicates the amount of oil in the oil reservoir - See Fig 5-1 for details.
Read oil level when unit is shut off and the foam has settled out. In operation the oil level will fluctuate as
the compressor loads and unloads. Adequate oil level falls between the MAX and MIN limits of the sight
glass:
&middot; The approximate oil system total capacity is 1.0 Gals (5 L)
&middot; The differential between &quot;MAX&quot; and &quot;MIN&quot; levels on sight glass is 0.7 Gal (2.8 L).
Figure 5-1 – Oil Level Sight Glass
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Page 49
Before draining, adding, or changing the lubricant oil in the compressor, be aware of the
following hazards associated with these tasks:
Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout power
supply to the starter before removing valves, caps, plugs, fittings, bolts and filters.
Compressor, air/oil reservoir, separator chamber and all piping and tubing may be at
high temperature during and after operation.
Use of improper lubricants will cause damage to equipment. Do not mix different types
of lubricants or use inferior lubricants.
Improper equipment maintenance with use of synthetic lubricants will damage
equipment. Oil filter and oil separator change intervals remain the same as for AEON
4000 – See “Maintenance Schedule”, page 74.
High temperature operation can cause damage to equipment or personal injury. Do not
repeatedly restart the unit after high temperature stops operation. Find and correct the
malfunction before resuming operation.
Read the oil level when the unit is shut off for an accurate measurement.
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All materials used in Gardner Denver compressor units are compatible with AEON
9000SP Lubricant. Use caution when selecting downstream components such as air
line lubricating bowls, gaskets and valve trim.
AEON 9000SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic
paints. AEON 9000SP is compatible with most air system downstream components.
Safety Sheets (SDS) are available for all AEON lubricants at web address.
www.gardnerdenverproducts.com/downloads.aspx
LUBRICANT CHANGE PROCEDURE - If upgrading to a different lubricant type (e.g., longer life, higher
temperature, food grade, etc.), following the proceeding steps - see Figure 1-3 for hardware details:
1. Be sure the 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. Thoroughly drain oil system while hot:
&middot; Remove the plug and open the drain valve at the lower left hand side of the oil core tank. Once the
oil has been drained, close the drain valve and reinstall the plug.
&middot; Remove and drain oil from the oil filter. Reinstall the used filter.
4. Fill the system with a 50 percent charge of the new lubricant:
&middot; Start the machine and monitor its operation.
&middot; Allow the machine to reach a stable discharge temperature (5-7min), then shut down.
5. Thoroughly drain oil system.
6. Replace used oil filter and air/oil separator element with new ones.
7. Fill the system with a full charge of the new lubricant.
8. Machine should then be run normally; however, total run time after the initial change-out should be 50
percent of normal anticipated service life of the new lubricant.
&middot; Drain all lubricant from the system, change the filter and separator, and replace with a full charge
of the new lubricant.
9
Subsequent lubricant change-outs should be at normal intervals. See “Oil Change Interval” in this
Section for details.
COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation”, Section 2 and
Figure 2-3.
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ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is below the minimum level of
the sight glass as read while the unit is completely off and blown down, and the foam has settled out.
1.
Be sure the unit is completely off and that no air pressure is in the oil reservoir.
2.
Disconnect, lockout and tagout the power supply to the starter.
3.
Wipe away all dirt around the oil filler plug located on top of the oil sump.
4.
Remove the oil filler plug and add oil as required to return the oil level to the middle of the sight
gauge.
5.
Install oil filler plug, run and check for leaks.
DO NOT OVERFILL (you should see oil slightly above the full line after running fully loaded and then
shutting down the machine and allowing the foam to settle out). The quantity required to raise the oil level
from “ADD” to “FULL” is shown on Figure 5-1. Repeated addition of oil between oil changes may indicate
excessive oil carry-over and should be investigated.
Excessive oil carry-over can damage equipment. Never fill oil reservoir above the
“FULL” marker.
OIL CHANGE INTERVAL - Recommended oil change intervals are based on oil temperature - see Figure
5-2 for typical trends for the standard lubricant (AEON 4000) and a synthetic lubricant (AEON 9000SP).
Consult GD for additional lubricant types available for your compressor.
When operating conditions are severe (very dusty, high humidity, etc.), it will be necessary to change the
oil more frequently. Operating conditions and the appearance of the drained oil must be surveyed and the
oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis program
with the AEON lubricants, and we recommend a sample be sent in at 100 hours on a new unit.
Discharge
Temperature
AEON 4000
Change Interval
AEON 9000SP
Change Interval
Up to 180&deg; F (82&deg; C)
4000 hrs.
8000 hrs.
180&deg; to 190&deg; F (82&deg; C to 88&deg; C)
3000 hrs.
6000 hrs.
190&deg; to 200&deg; F (88&deg; C to 93&deg; C)
2000 hrs.
4000 hrs.
200&deg; F+ (93&deg; C)
1000 hrs.
2000 hrs.
Figure 5-2 – Oil Change Interval
DRAINING AND REFILLING THE OIL SYSTEM - Always drain the complete system. Draining when the
oil is hot will help to prevent varnish deposits and carry away impurities – see Figure 1-3 for hardware
details.
1. Be sure the unit is completely off and that no air pressure is in the oil reservoir.
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2. Disconnect, lockout and tagout the power supply to the starter.
3. Thoroughly drain oil system while system is hot:
&middot;
Remove the plug and open the drain valve at the lower left hand side of the oil core tank. Once
the oil has been drained, close the drain valve and reinstall the plug. Make sure to provide a
suitable pan to catch the 1.3 gal. (5 l) oil charge.
&middot;
If the drained oil and/or oil filter element is contaminated, discontinue this procedure and follow
instead the &quot;Lubricant Change Procedure&quot; in this Section.
4. Replace both used oil filter and air/oil separator element with new ones.
&middot; Remove each spin-on element.
&middot; Clean each gasket face of the filter body.
&middot; Coat each new element gasket with clean lubricant used in the unit
&middot; Screw each new element on the filter body and tighten by hand. Tighten 1/2 turn more after
gasket makes contact. DO NOT OVERTIGHTEN ELEMENT.
5. Wipe away all dirt around the oil filler plug.
6. Remove the oil filler plug and add oil as required to return the oil level to the full marker on the gauge.
7. Install the oil filler plug and operate the unit for about a minute allowing oil to fill all areas of the
system. Check for leaks.
8. Shut down unit, allowing the oil to settle, and be certain all pressure is relieved.
9. Add oil, if necessary, to bring level to “FULL.”
Use only CLEAN containers and funnels so no dirt enters the reservoir. Provide for clean storage of oils.
Changing the oil will be of little benefit if done in a careless manner.
Use only the replacement element shown on the filter tag or refer to the parts list for
the part number.
Excessive oil carry-over can damage equipment. Never fill oil reservoir above the
“FULL” marker.
Improper oil filter maintenance will cause damage to equipment. Replace filter element
every 1000 hours of operation. More frequent replacement could be required
depending on operating conditions. A filter element left in service too long may
damage equipment
MOISTURE IN THE OIL SYSTEM – During periods of low ambient temperatures, light duty cycles, high
humidity, or in the event of thermal mixing valve malfunction, the oil charge residing in the sump may not
reach a high enough temperature to keep water vapor from condensing as liquid water, a condition that
contaminates the oil charge, may cause excessive oil carryover, or result in compressor failure.
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To help the end user determine if the compressor package is operating under potential water condensing
conditions, the charts in Fig 5-3 and 5-4 have been provided. To use, find the prevailing ambient
temperature along the horizontal scale of the chart, move vertically from this point until intercepting the
slanted line corresponding to the operating discharge pressure; and finally, move horizontally from this
point to read the corresponding water vapor dew point on the vertical scale. The compressor discharge
temperature must be maintained at a minimum of 10&deg; F (5.5&deg; C) above this dew-point temperature to
prevent condensation accumulation in the lubricant reservoir. Note that the charts conservatively assume
100% relative humidity for the ambient air.
The presence of water in the oil may be identified by one of the following means:
&middot; Oil drawn from the oil sampling valve attached to the sump (see Fig 1-3).
&middot; Oil volume drained during an oil exchange.
&middot; Periodic (e.g., every 2000hrs) oil sample analyzed by a reputable laboratory.
If water is found in the oil, drain sufficient volume of oil until no visible water is found - the heavier water
will collect at the low elevations of the oil system, thus it will likely be expelled first. If this condition
persists, consider the following solutions to avoid water condensation in the compressor oil:
&middot; Make sure that the correct setting for the thermostatic mixing valve element is used - value is
stamped on valve body.
&middot; If the standard thermostatic element (55&ordm;C/131&deg;F) does not prevent water condensation, consult
your application with Gardner Denver. The standard thermostatic element may be replaced with
a high temperature one (70&ordm;C/158&deg;F) and the oil charge changed (see &quot;Lubricant Change
Procedure in this section) with a high temperature one (AEON 9000TH). Depending on the
prevailing ambient temperature, the controller setting for the high discharge temperature
shutdown may have to be reset to 240&ordm;F also.
THERMOSTATIC MIXING VALVE. This device, housed within the compressor body, mixes hot and
cooled oil and delivers a tempered mixture to the oil filter and finally the compressor injection port - see
Fig 1-3 for its location.
Its thermostatic element expands with heat – it will stroke from just opening to fully open state within a
27&deg;F (15&deg;C) temperature change. Within these two temperature limits the valve gradually mixes hot
separator oil with cooled heat exchanger oil to maintain a nearly constant oil injection temperature.
Above this range of oil temperature, the valve blocks all hot oil and only cooled oil is delivered.
The valve’s nominal setting is stamped on the valve body. It may be verified by immersing the valve
assembly into an open container with lubricating oil, raising its temperature to its nominal setting and
checking that the element strokes fully from closed to open.
&middot;
Standard valve opening temp = 131&deg;F (55&deg;C), fully open temp = 158&deg;F (70&deg;C)
&middot;
Optional valve opening temp = 158&deg;F (70&deg;C), fully open temp = 185&deg;F (85&deg;C)
Optional Element. If the compressor is used in a predominantly cold (&lt;32&ordm;F, 0&ordm;C) and/or humid
environment, proper oil viscosity and avoidance of water vapor condensation in the oil system may be
achieved by using a higher setting (185&ordm;F, 85&ordm;C) thermostatic element. Consult Gardner Denver for
details.
OIL SUMP (RESERVOIR) - This device provides the inertial separation of air and oil streams discharged
by the compressor - the bulk (98%) of the air/oil separation is done at this step. It also serves as a
holding and degassing volume for the major portion of the oil charge. It provides limited air storage for
control and gauge actuation.
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AIR / OIL SEPARATOR - This device provides the final (2%) of the air/oil separation - typically 2ppm oil
content at the final discharge of the compressor package. It is housed in a removable spin-on cartridge.
Its high level of performance may be affected by the following conditions:
&middot;
Compromised media (e.g., ruptured).
&middot;
Contaminated media (e.g., vanish, moisture, inadequate oil type).
&middot;
High oil level in oil sump.
&middot;
Blockage of oil return orifice.
&middot;
Abnormally frequent or fast depressurization cycles.
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 determined by pressure differential or by inspection.
Separator Pressure Differential - The pressure drop across the separator is equivalent to the difference
between the two (2) pressure sensors in use. Use the measured pressure difference to forewarn of a
potentially contaminated air-oil separator element:
&middot;
The pressure differential value may be calculated by subtracting the system pressure value from
the compressor discharge pressure value.
&middot;
A pressure differential of 8psi may indicate a moderately dirty element.
&middot;
A pressure differential of 15psi may indicate a severely dirty element – replace ASAP.
Using an oil separator element at excessive pressure differential can cause damage to
equipment. Replace the separator when the pressure differential has reached 15psi.
OIL FILTER, AIR/OIL SEPARATOR ELEMENT INSPECTION PROCEDURE
1. Remove the spin-on element.
2. Clean the gasket seating surface of the head.
3. Inspect the element internals by shinning a light unto the media surface. If signs of contamination
(dirt, rust, varnish, etc.) or damage is evident, replace the element.
4. Before reassembly, coat the element gasket with the same lubricant used in the unit.
5. Screw on until gasket makes contact. Hand tighten 1/3 to 1/2 turn extra.
6. Run the unit and check for leaks.
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Discharge PDP - oF
Pressure Dew Point Trend (100% r.h.)
260
250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90
80
100psig
125psig
150psig
175psig
30
40
50
60
70
80
90
Am bient Temp - oF
100
110
120
130
Figure 5-3 – Dew Point Chart &deg;F
Discharge PDP - oC
Pressure Dew Point Trend (100% r.h.)
130
125
120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
6.9bar
8.6bar
10.3bar
12.1bar
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
Ambient Temp - oC
Figure 5-4 – Dew Point Chart &deg;C
13-25-617
Page 56
40.0
45.0
50.0
SECTION 6
HEAT EXCHANGERS (OIL/AIR)
OIL/AIR HEAT EXCHANGERS – The heat of compression absorbed by the oil injected into the
compressors (for cooling and lubrication) is ultimately rejected in a convenient medium such as air - for
these air-cooled cores. Proper operation of the heat exchangers is essential for the following processes:
&middot;
The (L11) oil core maintains a compressor injection temperature 54&deg;F above the ambient temperature
while rejecting 9.7kW of heat from the 5.6gpm oil injection stream and operating at 110psig discharge
pressure. The standard (AEON4000) lubricating and cooling oil must be kept at a normal operating
temperature below 225&deg;F in order to preserve its longevity.
&middot;
The (L11) air core maintains a package discharge temperature 27&deg;F above ambient temperature
while rejecting 1.3kW of heat from the 61cfm air stream and operating at 110 psig discharge pressure
Be aware that this temperature differential (aka approach) may increase several degrees due to
environmental conditions such high air temperature and ambient humidity.
VENTILATION CONFIGURATION – Air-cooled cores (radiator-type) are provided as standard feature.
One (1) axial fan, located behind the fresh air inlet grille, delivers an air stream to: a) cool the exterior of
the main electric motor and b) meet the cooling demands of the air/oil combination heat exchanger on its
way out the package confines. The fan is mounted on a rear shaft of the main motor. In addition, an
open-weave, non-metallic mesh media is held in place over the fresh air inlet grill to pre clean the cooling
air stream.
Refer to Figure 6-1 for estimates of ventilation requirements. Please note that the air-cooled package
requires the combined total of the heat exchanger plus the enclosure ventilation flow rates (which include
motor ventilation and compressor intake). Furthermore, when package location makes it necessary to
duct fresh cooling air in/out, these ducts must be sized with a maximum (total) pressure loss of 0.1 inch
water gauge to avoid impacting the heat exchanger cooling air system. An external ventilation fan may
be required to properly evacuate hot air from the compressor room.
Minimum Cooling Air Flow Requirements
Model HP size
CFM
10, 15
1368
FIGURE 6-1 – Air Flow Chart
HEAT EXCHANGER MAINTENANCE - All the required hardware, mechanical and electrical connections
have been made at the Gardner Denver factory, thus the only regular maintenance required is to keep the
exterior core fins free from dirt and other airborne debris per the following procedure:
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Compressor, air/oil sump and all piping and tubing may be at high temperature during
and after operation.
Do not attempt inspection or cleaning of air-cooled heat exchangers until cooling fan
has stopped rotating. Disconnect lockout and tag out package from power supply.
Air-cooled heat exchanger cores are fabricated from aluminum. Do not use caustic
liquids to cleanse core or permanent damage will take place.
1. Be sure the unit is completely off and that oil reservoir is depressurized.
2. Open and/or remove enclosure door panel adjacent the cooler assembly – See Figure 6-2 for details.
3. Inspect core area. If blocked with debris, use a moderate (e.g., 100psi) source of compressed air
while directing nozzle (pointed to outer core finned surface) to dislodge debris and clean. Vacuum
(applied from inner finned core surface) can also be employed to clean the surfaces.
4.
Remove all loose debris from inner surfaces of the enclosure, including the main cooling fan area
and its pre-filter, after cleaning process is complete.
5. Re-install the removed enclosure door panels.
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The ventilation system for the air-cooled package relies on positive back pressure to
cool the heat exchanger. Make sure that the enclosure panels that surround the heat
exchanger area are closed during compressor operation, or the compressor discharge
temperature will reach shutdown levels quickly.
FIGURE 6-2 – Cooler Access
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Page 59
SECTION 7
AIR FILTERS
COMPRESSOR AIR FILTER - This device cleans the air stream entering the compressor inlet and is
furnished as standard equipment on the compressor package. It is a single stage, high efficiency,
cellulose media element housed in a non-corrosive housing.
Efficient compressor package operation depends on the unrestricted, clean supply of fresh air delivered
by the air filter. In turn, the longevity of the filter element depends on the cleanliness of the local
environment.
NOTICE
Use only genuine Gardner Denver air filter elements on Gardner Denver compressor
units. Genuine parts are available through your authorized Gardner Denver distributor.
Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use
solvents other than water. Improper cleaning may damage the element.
Never operate the unit without the element. Never use elements that are damaged,
ruptured or wet. Never use gaskets that won't seal. Keep spare elements 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 INSPECTION AND/OR REPLACEMENT
1.
Loosen and remove the fastening band (2) and remove the filter element (1) - see Figure 7-1 for
details
2.
Visually inspect the filter element (1). Replace it if:
&middot;
Flaws (tears in media, damage to sealing surfaces) are evident.
&middot;
Contamination (dirt, grease, etc.) is evident.
&middot;
Recommended replacement period has been achieved – see Figure 11-1 for details.
3.
Install the air filter element (1) and the fastening band (2) in the reverse order.
13-25-617 Page 60
PACKAGE PRE-FILTER MAINTENANCE
1. Remove the central screw and washer securing the pre-filter to the grill assembly and remove the
pre-filter media (17). See Figure 7-2 for component details. Note: do not remove the fan grill.
2. Cleanse the pre-filter media with compressed air or with water to remove debris trapped in its
fibers.
3. Replace the pre-filter media and central screw and washer in the reverse order.
Figure 7-1 – Compressor Air Filter
Figure 7-2 – Pre-Filter Cover, Pre-Filter and Fan Grill
13-25-617 Page 61
SECTION 8
BELT DRIVE SYSTEM
The motor power is transmitted to the compressor with a system comprised of heavy-duty v-belts,
sheaves, and bushings. Belt tension is provided by the motor weight with the help of a free-pivoting
bracket -see Figure 8-1 for details.
Figure 8-1 – Motor Jacking Assembly
Figure 8-2 – V-Belt Drive Components
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UNPACKING THE V-BELT SYSTEM
To protect the belts from shock and strain during transportation, the free-swinging side of the motor frame
is locked in place by means of a carrier bracket assembly. Proceed to prepare the belt system for
operation as follows - refer to Figure 8-2 for component description:
1. Unlatch and remove the door panel opposite to the main cooling fan panel to gain access to the
v-belt system.
2. Lift motor from carrier bracket (1) by loosening jam-nut (2) and screwing in adjusting bolt (6).
3. Loosen and remove fastening screws (3) and (4) as well as carrier bracket (1). Keep this
hardware for future use – such as relocating compressor package.
4. Check alignment of the sheave set and make sure that v-belts are properly seated in sheave
grooves.
5. Screw out adjusting bolt (6) and secure with jam-nut (2) to allow motor weight to rest on v-belts.
SHEAVE SET ALIGNMENT
1. Use a straight edge for alignment checks.
2. Check parallel alignment. It should be simple to control by moving one of the sheave/bushing
pairs along the shaft to match the other.
3. Check angular alignment. The misalignment A = ArcTan * ((X2-X1)/D), where calculated A is in
degrees and measured X1, X2 and D are in inches or mm.
4. The allowable total misalignment is 0.5 degrees for best belt longevity. As reference, 0.5 degrees
represents a gap (e.g., X1-X2) of 0.05&quot; (1.33mm) over a 6&quot; diameter sheave.
Figure 8-3 - Measuring Angular Misalignment
Check sheave misalignment prior to start compressor operation. Failure to do so may
shorten the operational live of the belts.
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REPLACING THE COMPRESSOR BELTS
When signs damage (e.g., wear, tear, breakage, etc.) appear on any belt, replace the complete set of
three (3) v-belts as follows:
1.
Disconnect, lockout and tagout the power supply to the starter
2.
Unlatch and remove the door panel opposite to the main cooling fan panel to gain access to the
v-belt system – see Figure 1-3 for details.
3.
Remove the compressor shaft belt guard.
4.
Raise the motor to remove the belt set. This is accomplished by turning the jacking screw
clockwise (after loosening the jam nut) and raising the motor body until the v-belts can be
dismounted from the motor sheave.
5.
Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver
belts.
6.
Check the sheave alignment.
7.
Turn the jacking screw counter-clockwise to lower motor and transfer its weight unto the belt
set. Make sure that the belts remain aligned into each corresponding groove. Keep turning
jacking screw until it clears base frame surface by at least one inch and jam in with provided
nut.
REPLACING THE SHEAVES
1.
Follow steps 1 through 4 given above to replace the compressor belts.
2.
Remove the belts.
3.
Carefully sketch or photograph the orientation of each sheave/bushing pair as they sit on their
respective shaft. You'll need this information to re-install each pair.
4.
Loosen and remove the mounting screws securing the sheave to companion bushing. Install
the removed screws in the jack holes provided on the sheave and turn each in to pry the
bushing loose from the sheave. Remove the sheave and bushing from the shaft.
5.
When installing a new sheave / bushing pair, remove all protective grease their surfaces.
6.
Insert the mounting screws in the sheave / bushing pair and lightly tighten them.
7.
Clean the shaft and mount the sheave / bushing pair. Align the motor sheave to the air end
sheave. When mounting the sheave / bushing pair, the bushing clamps to the shaft first, the
sheave can still be moved a little. This can affect the alignment of the sheaves.
8.
Tighten the mounting screws evenly.
9.
Tap the bushing lightly with a drift, and retighten the screws. REPEAT THIS PROCEDURE
SEVERAL TIMES TO MAKE SURE THE BUSHING AND SHEAVE ASSEMBLY IS TIGHT ON
THE SHAFT.
10.
Fill the holes in the bushing/sheave with grease to protect them from dirt and debris.
11.
Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver
belts.
12. Check the sheave alignment - Refer to Sheave Set Alignment Figure 8-3.
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SECTION 9
SERVICING OF MISCELLANEOUS DEVICES
This section will cover basic maintenance of various control devices used with the compressor
package. Refer to Fig 9-1 for pictorial with general locations of these devices.
INLET CONTROL VALVE ASSEMBLY
Inlet-Valve Assembly - This device is located within and below the intake flange of the compressor - see
Figure 9-1 for internal details and Figure 4-6 for schematic details.
During the loaded state, the inlet poppet (2.2) remains open and enables atmospheric air to enter the
compressor inlet - this is done by venting to atmosphere the gas trapped underside of the piston via
check valve (19). During the unloaded state, a two-way solenoid valve feeds pressurized air underneath
the piston (2.1), forcing it and the inlet poppet (2.2) upward and blocking-off the compressor intake. A
small purge check valve, located in the poppet, allows a stream of air to reach (e.g., purge) the rotors and
keep them from unstable, noisy operation and producing sufficient pressure to maintain cooling /
lubricating oil flow.
Figure 9-1 – Inlet Valve Assembly
Air/oil pressure will cause severe personal injury or death. Shut down compressor,
relieve system of all pressure, disconnect, lockout and tagout power supply to the
starter before removing valves, caps, plugs, fittings, bolts and filters.
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Inlet Valve (Body) Inspection - The valve does not require maintenance or lubrication. If air/oil leaks
develop across the valve disc during pressurized conditions (e.g., machine stopped), valve seals should
be inspected for wear and tear signs:
1. Be sure the unit is completely off and oil sump is depressurized.
2. Disconnect, lockout and tag out power supply to the compressor package.
3. Close (when provided) valve isolating compressor package from air system.
Refer to
4. Figure 9-1 for hardware details.
5. Loosen and remove the air filter element.
6. Remove four bolts securing inlet flange to the compressor body and remove the flange.
7. Remove the poppet assembly and the poppet return spring.
8. Unscrew the valve body from the compressor housing using the hex pattern provided on the
valve body – see Figure 9-2 for details.
9. Inspect poppet seals (O-rings) for wear and tear.
10. In case of noted malfunction (e.g., valve will not open/close properly with good air signal), unless
a damaged or worn component can be identified and/or repaired, replace the complete inlet valve
assembly.
&middot; Remove retainer ring to release piston assembly free.
&middot; Inspect the piston seal and piston return spring. If any component if found worn of damaged,
replace the complete valve.
&middot; Re-assembly the piston assembly in reverse order.
11. Reinstall inlet valve in reverse order.
Figure 9-2 – Inlet Valve Body Hex
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Figure 9-3 –Exploded View of EK76 Compressor
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PRESSURE RELIEF VALVE
Pressure Relief Valve - This device protects the pressure-containing components of the compressor
package against pressures exceeding 218 psig. It is installed on the wet-side of the oil sump.
Figure 9-4 - Pressure Relief Valve
Before inspecting the pressure relief valve, release air pressure, lockout and tagout the
power supply to the compressor package. Failure to release pressure or properly
disconnect the power may result in personal injury or death.
Never paint, lubricate or alter a relief valve. Do not plug vent or restrict.
Operation of the unit with improper relief valve setting can result in severe personal
injury or machine damage. Ensure properly set valves are installed and maintained.
Pressure Relief Valve Check During Operation - The pressure relief valve has no user-serviceable or
repairable components. However, it should be tested for proper operation at least once every year. To
test the pressure relief valve:
&middot;
Raise the system operating pressure to its normal level
&middot;
Pull the stem ring to open valve and let it vent for a few seconds.
&middot;
Release the stem ring to close the valve.
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MINIMUM PRESSURE VALVE
Minimum Pressure Valve (MPV) Inspection – This device has no user-serviceable or repairable
components. If it fails to maintain adequate minimum pressure (70psig) or fails to check the backflow of
system compressed air after compressor stoppage, replace it as follows:
Figure 9-5 - Minimum Pressure Valve and Seat
Air/oil pressure will cause severe personal injury or death. Shut down compressor,
relieve system of all pressure, disconnect, lockout and tagout power supply to the
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 and in the air cooled
after cooler. Close the service valve.
2. Disconnect lockout and tagout the power supply to the starter.
3. Unscrew the minimum pressure valve assembly from compressor housing and remove.
4. Inspect the valve seat surface screwed into the compressor housing. Cleanse or replace – use
14mm hex wrench to unscrew. Note that fitting an O-ring on the hex wrench body helps hold the seat
in position during installation.
5. Assemble the MPV assembly into the host manifold.
6. Run the unit and check for leaks.
7. If a new MPV has been fitted, its proper setting must be adjusted:
a. Make sure the site pipe system has a means to vent the compressor air to atmosphere with a
valve. If this is not available, temporarily fit a &frac12;” to &frac34;” ball valve to achieve so.
b. Start the compressor and monitor the wet (B1) and dry (B2) sump pressure sensors at the
GD Pilot controller display.
c. Open the site vent valve to limit the dry sump pressure to about 40psig (2.8bar)
d. Loosen the jam nut on the TMV adjusting stem and screw it in until the wet sump reaches
70psig (4.8bar).
e. Tighten the jam nut on the TMV adjusting stem.
f. Close the site vent valve.
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THERMOSTATIC MIXING VALVE
Thermostatic Mixing Valve (TMV) Inspection – This device has no user-serviceable or repairable
components. Refer to Section 5, for further details on this device. If it fails to maintain adequate
compressor discharge temperature, replace it as follows:
Figure 9-6 – Thermostatic Mixing Valve
1.
Be sure the unit is completely off and that no air pressure is in the oil reservoir and in the air cooled
after cooler. Close the service valve.
2.
Disconnect lockout and tagout the power supply to the starter.
3.
Unscrew the hex cap holding the TMV assembly within the manifold block. Retrieve the TMV body
and its spring from the compressor housing.
4.
Inspect the valve seat surfaces for damage or foreign matter. Note its setting temperature – it is
stamped on the valve seat area.
5.
Immerse the valve body in a bath of compressor oil; heat the oil slowly and note the temperatures at
which seat first starts moving and at it finally stops moving. Replace the device if one of the
following conditions is present:
a. The stamped setting on the valve seat is not correct. The standard compressor package should
be fitted with the 158&ordm;F (70&ordm;C) (opening temperature) element, unless by consultation with
Gardner Denver, it has been approved to use the 181&ordm;F (98&ordm;C) (opening temperature) element
instead.
b. The seat fails to stroke fully at the correct temperature.
6.
Assemble the TMV assembly into the housing in the reverse order.
7.
Run the unit and check for leaks.
INPUT SHAFT SEAL ASSEMBLY
Input Shaft Seal Maintenance – This device has no user-serviceable or repairable components. If oil
leaks past its seal and unto the external portion of the shaft, contact Gardner Denver to have it inspected
and/or repaired by a trained mechanic.
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ELECTRICAL BOX COOLING SYSTEM MAINTENANCE (Variable Speed Variant only)
In order to maintain the VFD module, supplied with 1-phase variants, in good working order, its external
filters, internal ventilation fans and heat sink must be inspected for debris and cleansed one per year.
Follow the following guidelines to achieve this simple task.
Figure 9-7 – Figure 9-7Electrical Box Cooling Hardware
Cooling System Inspection
1.
2.
3.
4.
5.
6.
7.
8.
De-energize, lockout and tagout incoming electrical power to the compressor package.
Remove VFD exhaust air duct 47 in Figure 9-6.
Inspect external cooling fan/filter assembly 45, 46 in Figure 9-6.
Remove dust and debris from fan with a vacuum cleaner or replace if not operational. Contact
Gardner Denver for a replacement cooling fan assembly.
Shake off debris and gently wash foam filter medial under tap water and dry off completely.
Replace if damaged.
Remove VFD internal cooling fans to access the outlet segment of the heat sink duct – refer to
the following section “VFD Cooling Fan Removal and Replacement” for removal instructions.
Inspect the heatsink surfaces from the inlet segment of the heat sink duct – be aware that its
surfaces may be hot. Remove debris and dust from its surfaces with a vacuum cleaner placed on
the outlet segment of the heat sink duct.
Reinstall the VFD internal cooling fans, VFD module, exterior filters and exhaust air duct in the
reverse order.
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VFD Cooling Fan Removal and Replacement
1. Make sure that steps 1 and 2 of “Cooling System Inspection” have been completed.
2. Depress the right and left sides of the fan cover tabs and pull upward. Remove the fan cover
from the top of the drive per Figure 9.8 – one (1) fan assembly shown, but the same procedure
applies to two (2) fan assembly.
3. Remove the cooling fan module. Disconnect the individual plug connector and remove fan(s)
per Figure 9.9.
4. Install the replacement fan(s) – make sure to properly align individual plug prior to connection –
per Figure 9.10
Figure 9-8 – VFD Fan Removal
Figure 9-9 – VFD Fan Disconnect
Figure 9-10 – VFD Fan Reconnect
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SECTION 10
TANK MOUNTED COMPRESSOR - TOTAL SYSTEM
DESCRIPTION - The basic compressor can be furnished mounted on an optional compressed air
receiver (80, 120 and 240 gallon sizes) and paired to an optional RNC [refrigerated non-cycling]
compressed air dryer, as shown on Figure 1-4.
&middot;
&middot;
&middot;
Refer to Figure 1-4 for dimensioned outline drawing.
Refer to Figure 4-6 for the instrument and piping schematic and to Section 4 for the description of
the main components that comprise the Total System.
Refer to vendor-supplied instruction manual included with the refrigerated dryer for full details on
the installation, operation and maintenance of this optional device when supplied.
It is critical to refer to the vendor-supplied instruction manual, included with the refrigerated dryer, for full
details on the installation, operation and maintenance of this optional device. When the dryer is part of
the Total System, the following are some of the critical items to keep in mind:
&middot;
Dryer models corresponding to compressor package models:
L unit nominal HP
RNC dryer model
10
RNC50
15
RNC75
&middot;
Installation - Package must installed in a location with an ambient temperature range of 40&ordm;F to
110&ordm;F (3&ordm;C to 43&ordm;C). Consult Gardner Denver for operation outside this range.
&middot;
Discharge service pipe - The discharge service line connection is provided at the outlet of the
bypass valve assembly. A hand operated valve, (air service valve) and a separate (swing-type)
check valve must be installed between the unit and the customer’s air system. If a fast operating
valve such as a ball valve is used, it must be closed slowly to give the intake valve time to shut
and keep the discharge pressure from spiking.
&middot;
Electrical power connections - Provide a grounded 1ph-60Hz-115vac receptacle to plug in the
dryer power cord. Refer to the dryer serial number tag for the proper ampacity.
&middot;
Starting and stopping the dryer o Energize the receptacle - green power light will illuminate in the control panel.
o Toggle ON/OFF switch to the ON position to start dryer operation. It is recommended
that the dryer be started 15min before the compressed air flow begins.
o Do not stop or de-energize the dryer during the normal operational shift (e.g., 8 hrs) of
compressed air system.
o The RNC dryer runs continuously when turned on. This is normal operation.
o Toggle ON/OFF switch to the OFF position to stop dryer operation.
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SECTION 11
MAINTENANCE SCHEDULE
SERVICE CHECK LIST –
Air Filter and Pre-Filter - Operating conditions determine frequency of service. See “Air Filter,”
SECTION 7.
Motor Lubrication - Refer to Section 2.
Every 8 Hours Operation
1.
Check the reservoir oil level - add oil if required. See Section 5..
2.
Observe if the unit loads and unloads properly.
3.
Check discharge pressure and temperature.
4.
Check control panel display for advisory text messages.
Every 125 Hours Operation
1.
Check for dirt accumulation on oil, air core finned faces and the cooling fan. If cleaning is required,
clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable
safety solvent in a direction opposite that of the cooling fan air flow. This cleaning operation will
keep the exterior cooling surfaces clean and ensure effective heat dissipation.
Every 2000 Hours Operation
1.
Change oil filter element.
Every 4000 Hours Operation
1.
Change the compressor lubricant. Under adverse conditions, change more frequently (refer to “Oil
Change Interval”, Figure 5-2. Flush system if required.
Every Year
1.
Check the pressure relief valve for proper operation. See Section 9.
2.
Change oil separator. See “Removal of Oil Separator for Inspection or Replacement”, Section 5, for
further details.
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MAINTENANCE SCHEDULE (See Detail Notes above)
Maintenance Action
As Indicated
by GD Pilot
Controller
Every
8
Hours
Every
50
Hours
Every
125
Hours
Every
2000
Hours
Every
4000
Hours
&middot;
Check/Change Air Filter..............................................
&middot;
Check/Change Package Inlet Filters ...........................
Change Oil Separator ................................................
&middot;
&middot;
Check Reservoir Oil Level ** .......................................
&middot;
Check for Proper Load/Unload ....................................
&middot;
&middot;
Check Dirt Accumulation on Cooler .............................
&middot;
Change Oil Filter Element &amp; Clean Oil Return Orifice...
Change Compressor Lubricant (AEON 4000) * ............
&middot;
&middot;
Check Relief Valve .....................................................
&middot;
Check Condition of Hoses ..........................................
&middot;
Check Operation of Condensate Removal Drain Valve
Figure 11-1 – Maintenance Schedule
* See “Oil Change Interval Chart”, Figure 5-2, for specific lubricant life.
**
Every
Year
Must be checked when the compressor is stopped and the air/oil mixture is separated.
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SECTION 12
TROUBLESHOOTING
SYMPTOM
Compressor fails to start
POSSIBLE CAUSE
1.
No electrical power.
1.
2.
Motor starter overload
relay tripped.
Pressure in reservoir.
Wrong lead connections
2.
3.
4.
Check main disconnect, fuses
and supply line.
Reset and investigate cause of
overload.
Inspect unload valve.
Change leads.
Emergency stop
depressed.
Unacknowledged fault
5.
Release button.
4.
Clear fault at controller
1.
High separator/ high
compressor temperature
shutdown event
1.
See “High Discharge Air
Temperature,” this section.
2.
Blown fuse in starter/
control box.
Motor starter overload
relay tripped.
Fast pressure buildup due
to open inlet valve
2.
5.
High oil viscosity
5.
Replace fuse (investigate if
fuses continue to blow).
Reset and investigate cause of
overload.
Inspect inlet valve and
unloader valve operation.
Replace if faulty.
Review oil type for ambient
temperature or provide site
heating.
1.
Improperly adjusted
control.
Faulty inlet valve or
unloaded valve solenoid.
1.
1.
Insufficient receiver
capacity.
1.
Increase receiver size.
2.
Restriction in service
piping.
Pressure range too
narrow.
2.
3.
Inspect and clean service
piping.
Extend pressure range.
1.
Minimum Pressure Valve
is faulty.
1.
Inspect and/or replace.
2.
Supply voltage is too low.
2.
Check the supply voltage.
1.
Restricted air filter.
1.
Clean or replace filter.
2.
Partially open inlet valve.
2.
Inspect, clean or replace inlet
valve.
3.
4.
5.
6.
Compressor starts but
stops after a short time
3.
4.
Compressor does not
unload (or load)
2.
Compressor cycles from
load to unload
excessively
3.
Compressor starts too
slowly
Compressor does not
reach load pressure
REMEDY
13-25-617
Page 76
3.
4.
4
Refer to Control Manual
ZS1054347 and adjust control.
Inspect and/or replace faulty
component.
SYMPTOM
3.
REMEDY
Replace valve.
4.
Replace.
Condensate drain
solenoid valve is faulty.
Leaks in the compressed
air system.
V-Belts broken.
V-Belts slipping.
5.
Inspect and replace.
6.
Pressure limits incorrectly
set.
Aftercooler is frozen
9
Check for leaks, fix any leaks
found.
Replace complete set.
Inspect and clean belt.
Check that motor pivots freely
on bracket shaft.
Check/correct pressure limits
in the GD Pilot Controller.
Thaw out. This machine
cannot operate in temperatures
below 32&deg; F (0&deg; C).
1.
Dirty or clogged cooler
core or fins.
1.
Clean cooler.
2.
Insufficient cooling air
flow.
Clogged oil filter or cooler
(interior).
Low compressor oil level.
Faulty temperature
sensor.
Thermostatic mixing valve
stuck open.
Oil carryover through
lines.
Oil leaks at all fittings and
gaskets.
Shaft seal leaking.
2.
3.
Provide unrestricted supply of
cooling air.
Replace filter or clean cooler.
4.
5.
Add oil to proper level.
Replace sensor.
6.
Inspect and/or replace valve.
1.
See “Oil Carryover”, in this
section.
Tighten or replace fittings or
gaskets.
Inspect scavenge orifice
3.
4.
5.
6.
7.
8.
9
10
High discharge air
temperature
3.
4.
5.
6.
Excessive oil
consumption
1.
2.
3.
POSSIBLE CAUSE
Minimum pressure valve
stuck closed.
Oil separator clogged.
13-25-617
Page 77
7.
8.a
8.b
10.
2.
3.a
SYMPTOM
Oil carryover
POSSIBLE CAUSE
1.
Overfilling the reservoir.
1.
2.
3.
Clogged scavenge orifice
Ruptured oil separator
element.
Loose assembly.
2.
3.
Foaming caused by use of
incorrect oil.
Inoperative minimum
pressure valve.
Operation at elevated
discharge temperatures.
5.
8.
Water condensate in oil.
8.
1.
Water separator drain
(basic unit or total system
receiver and/or dryer)
malfunction.
1.
2.
Dryer not energized
2.
3.
Dryer bypass valve is in
bypass position
Dryer malfunction
3.
4.
5.
6.
7.
Excessive water in air
delivery line
REMEDY
4.
4.
6.
7.
4.
Drain excess oil from
system.
Inspect and cleanse.
Replace element.
Tighten all fittings and
gaskets.
Use Gardner Denver
AEON lubricating coolant.
Inspect and/or replace.
Reduce temperature. See
“High Discharge Air
Temperature”, this
section.
Check oil reservoir
temperature and if low,
change thermal mixing
valve element to one with
higher temperature
setting.
Inspect and cleanse or
replace drain float valve
Check that dryer is
plugged and turned on.
Inspect and cleanse.
Refer to dryer manual for
further details.
Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout power
supply to the starter before removing valves, caps, plugs, fittings, bolts and filters
13-25-617
Page 78
TROUBLESHOOTING VOLTAGE PROBLEMS
The compressor package has been designed, built, and tested to operate within one of the following
standard ranges:
200-208 Volts, 60 Hertz (Fixed Speed models only)
230-240 Volts, 60 Hertz
380-400 Volts, 60 Hertz
460-480 Volts, 60 Hertz
575-600 Volts, 60 Hertz
Connection to higher voltages will reduce the life of electrical devices within the compressor package. As
voltages get further above the design range, other symptoms may show up.
High voltages may lead to high motor currents. The overload relay will sense these and shut down the
compressor to protect the motor.
If the power supply and/or control transformer primary fuses blow, check that the devices are properly
connected for the incoming line voltage.
Operation with lower voltages will reduce motor life and load capacity. As voltages get further below the
design range, other symptoms may show up.
Low voltages may lead to high motor currents. The overload relay will sense these and shut down the
compressor to protect the motor. If voltage is low while the compressor is off, locate and correct the
cause. If the voltage drops low only while the compressor is running, look for poor connections or
undersized wiring.
If any of the starters or contactors within the box chatters, or if the electronic controller drops out while
attempting to start, it is a clear indication that the wiring is inadequate for the compressor. Look for poor
connections or undersized wiring.
NOTICE
Gardner Denver factory remanufactured replacement compressor airend units are
available from your authorized distributor, on an exchange basis, for all rotary screw
compressor units.
13-25-617
Page 79
Standard Warranty
Oil-Lubricated Rotary Screw / Rotary Vane Compressor Packages
APEX, APEX VS, Electra Screw, Integra, Electra Saver II, Electra Saver, L, LRS, VS, VST, V, HV, HV
RS, and HR Series
STANDARD WARRANTY
Gardner Denver (the “Company”) warrants 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, free of defects in material and workmanship. This Standard Warranty statement applies
to compressors shipped after April 1st, 2015.
STANDARD 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. Regular maintenance in
accordance with the service manual is required. Use of genuine Gardner Denver OEM parts and
lubricants are highly recommended. If a component failure is deemed a result of using non-genuine
Gardner Denver parts and lubricants, warranty will not be allowed.
COMPONENT
STANDARD WARRANTY COVERAGE
Package
12 months from startup or 15 months from date of
shipment to first purchaser, whichever occurs first
All components within the package, excluding normal wear items
Airend
24 months from startup or 27 months from date of
shipment to first purchaser, whichever occurs first
Normal wearing items, such as shaft seals and inlet valve components,
along with the servicing of these items is not covered under the warranty
unless deemed as material or workmanship defects. Any disassembly or
partial disassembly of the airend, or failure to return the “unopened” airend
per Company instructions, will be cause for denial of warranty
Electric Motors
12 months from startup or 15 months from date of
shipment to first purchaser, whichever occurs first
Includes both drive motor and cooling fan motor. For nonstandard motors,
the original manufacturer’s warranty will take precedence.
Major Package
Components
24 months from startup or 27 months from date of
shipment to first purchaser, whichever occurs first
Includes package controller, variable frequency drive if applicable, air/oil
reservoir, air/oil cooler, and precision mixing valve (VS Series)
Service will be provided by Company representative or authorized service
personnel, for repair or replacement of any product or part which in the
Company’s sole judgment is proved not to be as warranted. Labor shall be
limited to the amount specified in the Company’s labor rate schedule. All
costs of transportation of product, parts, and repaired or replacement parts
claimed not to be as warranted to and from such service facilities 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 the warranty
are warranted for the remainder of the Warranty Period.
Package / Electric Motors: 12 months from
startup or 15 months from date of shipment to first
purchaser, whichever occurs first
Labor
Airend / Major Package Components: 24 months
from startup or 27 months from date of shipment to
first purchaser, whichever occurs first
DETAILS
NO WARRANTY IS MADE WITH RESPECT TO:
1.
2.
3.
4.
ANY PRODUCT WHICH HAS BEEN REPAIRED OR ALTERED IN SUCH A WAY, IN THE COMPANY’S
JUDGMENT, AS TO AFFECT THE PRODUCT ADVERSELY
ANY PRODUCT WHICH HAS, IN THE COMPANY’S JUDGMENT BEEN SUBJECT TO NEGLIGENCE,
ACCIDENT, IMPROPER STORAGE, OR IMPROPER INSTALLATION OR APPLICATION
ANY PRODUCT WHICH HAS NOT BEEN OPERATED OR MAINTAINED IN ACCORDANCE WITH THE
RECOMMENDATIONS OF THE COMPANY
ANY RECONDITIONED OR PRIOR OWNED PRODUCT
STANDARD WARRANTY DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE COMPANY MAKES NO OTHER
WARRANTIES AND HEREBY EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION, EXPRESSED, IMPLIED
OR STATUTORY WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE. THE
REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE TO 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 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. WARRANTY IS NOT
TRANSFERRABLE
Form No. BT-28
Copyright &copy; 2015 Gardner Denver, Inc
NOTES:
For additional information, contact your local representative or visit:
www.contactgd.com/compressors
&copy;2018 Gardner Denver, Inc.
Printed in U.S.A.
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