Remanufacturing Center in Indianapolis, IN., for purchase on an exchange basis with liberal core credit available for the replacement unit. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.
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.
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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.
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 could result in injury to or death of personnel.
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ..............1 Instructions For Ordering Repair Parts/Remanufactured Airends ..............1 Warning – Prohibition – Mandatory Label Information.................. 1 Safety Precautions ............................3 Index................................5 List Of Illustrations............................
INDEX Air Filter, Section 7...........54 Oil System Air Flow In The Compressor System ....7 Addition Of Oil Between Changes....43 Air-Cooled Units, Location .......13 Compressor..........42 Auxiliary Air Receiver ........15 Draining And Cleaning ......... 44 Moisture............43 Cold Weather Installation .........14 Oil Change Interval ........
GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR – Your Gardner Denver Rotary Screw package is fitted with one (1) single stage, positive displacement rotary compressor using meshing helical rotors to effect compression. Each pair of rotors is supported between high capacity anti-friction bearings located outside the compression chamber. Single cylindrical roller bearings are used at each end of the rotors to carry the radial loads.
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 passage of current.
(e.g., hot cooling air entering the fresh air inlet). The package is designed to operate at ambient temperatures ranging from 40°F to 113°F (at up to 1000 meter elevation). Contact Gardner Denver for package operation at conditions exceeding the stipulated values.
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Do not block flow of air entering or exiting the enclosure - allow minimum of 3-1/2 feet (1.1 m) clearance to the nearest obstruction all around and on top. FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface and as near level as possible. Temporary installation may be made at a maximum 10°...
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DISCHARGE SERVICE LINE - The discharge service line connection on the air-cooled units is located at the upper right-hand area of the intake grill side of the enclosure. Gardner Denver compressor packages are inherently isolated from the service line by their own minimum pressure/check valves. Installer or end user must ensure that other compressors that are piped into a common pipe manifold with the Gardner Denver compressor package are each provided with an isolation check valve.
(VFD) to control compressor motor. The indicated Gardner Denver guidelines for proper wiring, grounding, and feed power conditioning must be followed in order to protect the VFD electronics. Failure to do so will void your warranty.
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GROUNDING – Equipment must be properly grounded in accordance with the National Electrical Code and/or applicable local codes. 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.
Do not mix different type oils. When the unit is shipped, it is filled with Gardner Denver AEON™ 9000SP lubricating coolant, suitable for the first 8000 hours under normal operating conditions.
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Make sure to check the wiring of the optional compressed air dryer, as it is serviced by an independent electrical power feed. 6. Grounding - Equipment must be properly grounded according to Gardner Denver Guidelines for proper wiring, grounding and feed power conditioning.
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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 is reconnected to the power supply.
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Next, press the Enter button to access the Adjustment Menu tree ADJUSTMENT MENU OPERATION ADJUSTMENT (SELECT SUB MENU) Since the Target Pressure setting is under the Operation Adjustment menu, press Enter again to access that sub-menu OPERATION ADJUSTMENT LANGUAGE-LANGUAGE ENGLISH (US) (SELECT PARAMETER) The Target Pressure is the second item in the Operation Adjustment sub-menu so press the Down...
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• Setting the Unload and Load Pressure After setting the Target Pressure, set the Unload and Load Pressures values in a similar fashion. The Unload pressure is the third item in the Operation Adjustment sub-menu so press the Down button to navigate to the Unload Pressure setting. The Unload Pressure will control at which pressure the compressor unload and stops.
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Unit Hot - Start-up instructions are the same as that of a cold start. Compressed Air Dryer (Optional) – The dryer module is supplied electrical power from a separate (off- package), disconnect provided by the end user – the disconnect must be engaged prior to dryer operation.
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Operation of the unit with improper pressure relief valve setting can result in severe personal injury or machine damage. Ensure properly set valves are installed and maintained. 13-18-604 Page 24...
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver rotary screw compressor package is pre-wired with all electrical components suitable for the voltage and horsepower at time of order. It is necessary only to connect the compressor unit to the correct power supply and to the shop air supply network - and to the appropriate water supply if using the water-cooled variant.
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ASSEMBLED CONTROL BOX WITH EMC FILTER ASSEMBLED CONTROL BOX WITHOUT EMC FILTER AIRSMART CONTROLLER DRIVE GROUP SPLITTER CABLE SCREW TERMINAL PLUG CONTROL BOX EXHAUST FILTER OPERATOR CONTACT BLOCK POWER SUPPLY POWER DISTRIBUTION BLOCK TERMINAL LUG (not shown) FUSE HOLDER FUSE FUSE BLOCK FUSE RELAY...
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Heat Exchanger Fan/Motor and Starter - The combination axial fan/motor provides cooling air for the heat exchangers and electronics box. The starter provides control for the fan motor only, as the latter includes its own thermally-resettable, internal overload protection. This device is designed to operate with 3 ph-60 Hz-460 vac electrical power –...
Blow Down Valve (P) - This (two-way solenoid) device vents compressed air from the air/oil sump. During compressor operation (e.g., compressor is running or has temporarily stopped due to line pressure reaching unload pressure); the blow down valve remains energized (closed) and the air/oil reservoir remains pressurized.
AEON 9000SP lubricant is available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000SP lubricating coolant for all-year-round operation. This is a polyalphaolefin (PAO) synthetic lubricant specially formulated for rotary screw compressor service.
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Use of improper lubricants will cause damage to equipment. Do not mix different types of lubricants or use inferior lubricants. All materials used in Gardner Denver compressor units are compatible with AEON 9000SP Synthetic Lubricating Coolant. Use caution when selecting downstream components such as lubricating bowls, gaskets and valve trim.
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(e.g., very dusty, high humidity, etc.), may require more frequent oil changes. Gardner Denver offers a free oil analysis program with our AEON 9000SP lubricant. The first sample from a new unit should be sent in between 40-100 hours of operation.
If the drained oil and/or the oil filter element are contaminated with dirt, flush the entire system, reservoir, oil cooler, mixing valve and lines. Inspect the oil separator element for dirt accumulation; replace if necessary. If a varnish deposit exists, contact the factory for recommendations for removal of the deposit and prevention of varnish.
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. The filter media is contained within an easily replaced, spin-on cartridge. Use the following procedure to replace the filter.
Normal Package Operation - The AirSmart controller includes an algorithm that determines, in real time, and on the basis of the intake temperature and the programmed target discharge pressure, the minimum discharge temperature the compressor must attain in order to keep water vapor from condensing in the oil system.
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OIL SEPARATION RESERVOIR / COALESCING ELEMENT - This device serves multiple functions in the compressor package: • Air/oil centrifugal separation - The bulk of the liquid oil is separated, by change of direction, impingement and additional centrifugal effects, away from the compressed air and aerosol streams, and is then gravity-collected at the bottom of the sump.
Figure 5-5 – CHANGING OIL COALESCING ELEMENT Oil Coalescing Element Service – Use the following procedures to replace or inspect the element: Be sure the unit is completely off and that oil sump is depressurized. Disconnect, lockout and tagout power supply to the compressor package. Remove cap screws and body of MPV/sump cover (1).
SECTION 6 HEAT EXCHANGERS (OIL, AIR) Compressor, air/oil reservoir, separator chamber 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 tagout package from power supply.
2100 Figure 6-1 – AIR FLOW CHART 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: Air-cooled heat exchanger cores are fabricated from aluminum.
5. Inspect core area. If blocked with debris, use a moderate (e.g., 100psi) source of compressed air and/or water while directing nozzle (pointed through core to inside) to dislodge debris and clean. Vacuum (applied from inside) can also be employed to clean the heat exchanger cores. Remove all loose debris and water from cooler box after cleaning process is complete.
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The separator (4) removes the liquid water from the compressed air stream by inertial effects and collected in a lower bowl (3). The collected water is evacuated by a float-type drain valve (1). The device prevents the loss of compressed air by only allowing the discharge of liquid water during its opening phase.
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.
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Never operate the unit without the air filter element. Never use elements that are damaged, ruptured or wet. Keep spare elements 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 Replacement: 1.
SECTION 8 SHAFT COUPLING Figure 8-1 – COUPLING COMPONENTS Rotating machinery can cause personal injury or death. Turn the unit completely off, open the main disconnect, lockout and tagout before servicing the coupling. SHAFT COUPLING – Main motors drive their companion compressors by means of curved jaw-type couplings.
• After engaging each hub on the matching recesses of the coupling element, check that the gap between the hub flats (see dimension “E” on Figure 8-2) is within 0.79/.85 in (20.0/21.5 mm). A smaller gap will produce abnormal wear of the element by friction and excessive thermal expansion –...
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Coupling Hub Installation: • Have coupling installation tool part number CC1021458 available – contact Gardner Denver for sourcing details. • Mount coupling hub onto tool via provided magnets.
Coupling Hub Removal: • Have removal tool part number 90500152 available – contact Gardner Denver for sourcing details. Before removing an interference-fitted hub, note and record the position of the hub with respect to the end of the companion shaft. This is particularly critical if an installation tool is not available.
The valve does not require maintenance or adjustment. If the valve fails to function, check the valve stem O-ring for sealing, valve orifices for restriction, or valve and valve seat for burrs and dirt. Repair kits are available from your local authorized Gardner Denver distributor. Before servicing the minimum pressure valve, always stop the unit, release air pressure, lockout and tagout the power supply to the compressor package.
7. Re-assemble internal assembly (1-4, 6-11, 15) into MPV frame (5) in reverse order. 8. Clean o-ring sealing surfaces between sump and bottom of MPV frame (5). Inspect, clean and or replace o-ring prior to re-installation. 9. Re-install MPV unto sump with provided bolts. 10.
SECTION 10 INLET CONTROL VALVE INLET CONTROL VALVE – This device is located at the intake flange of the compressor, and allows the compressor to remain pressurized and ready for quick response to air demand when the latter is not running.
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5. Remove four bolts (9) securing valve body to compressor body and remove valve. 6. Inspect poppet seal (o-ring) (5) for wear and tear. Replace, if necessary. 7. In case of noted malfunction (e.g., valve will not open/close properly with good air signal), proceed to dismantle internal blow-off valve.
SECTION 11 PRESSURE RELIEF VALVE Pressure Relief Valve - This device protects the pressure-containing components of the compressor package against pressures exceeding 188.5 psig. It is installed on the dry-side of the oil sump. Before inspecting the pressure relief valve, release air pressure, lockout and tagout the power supply to the compressor package.
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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.
SECTION 12 VENTILATION FILTERS (ELECTRICAL ENCLOSURE) Ventilation Filters - The electronics housed in the standard IP54 enclosure box are ventilated by a combination of an intake air filter and pressurized air provided by the heat exchanger cooling fans. Filter Inspection - In order to ensure the electronics operate at peak efficiency and free from troublesome temperature-related stoppages, it is imperative that the filter elements be kept clean: 1.
SECTION 13 MOTOR LUBRICATION Rotating machinery can cause injury or death. Open main disconnect, lockout and tagout power supply to compressor package before working on the electric motor. Motor Lubrication - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings.
SECTION 14 MAINTENANCE SCHEDULE SERVICE CHECK LIST Daily Checks: • Air Filter (Compressor) - Replace when controller displays “CHANGE AIR FILTER” message. Refer to Section 7 for air filter details. • Oil Separator Element - Replace when controller displays “CHANGE OIL SEPARATOR ELEMENT”. Refer to Section 5, page 43 for oil separator element details.
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Yearly Checks: • Heat Exchangers (Air and Water-Cooled) – Check cooling performance of air and oil cores – see Section 6 of this manual for details on typical performance expectations as well as recommended cleaning procedures. • Pressure Relief Valve – Check operation of device – see Section 11 for test procedure. •...
SECTION 15 TROUBLESHOOTING 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 compressor package before removing valves, caps, plugs, fittings, bolts and filters. SYMPTOM POSSIBLE CAUSE REMEDY...
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Restriction in service piping Inspect and clean service piping. Restriction in control tubing Inspect and clean control tubing. Compressor Acceleration time in VFD set too Contact your Gardner Denver distributor. starts too long slowly Minimum Pressure/Check Valve Repair or replace.
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SYMPTOM POSSIBLE CAUSE REMEDY Excessive oil Oil separation malfunction See “Oil Carryover” in this section. consumption Oil leaks at fittings and gaskets Detect and correct oil leaks. Shaft seal leaking Inspect or replace shaft seal. High discharge Oil mixing valve stuck on bypass Check 24Vdc power feed to servo.
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Ruptured oil separator Replace element. element. Loose assembly Tighten all fittings and gaskets. Foam caused by use of Use Gardner Denver AEON 9000SP incorrect oil oil only. Minimum pressure valve Repair or replace. Inspect, adjust or malfunction – discharge replace regulator.
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