Gardner Denver ELECTRA-SAVER EAY99G Operating And Service Manual
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Gardner Denver ELECTRA-SAVER EAY99G Operating And Service Manual

Gardner Denver ELECTRA-SAVER EAY99G Operating And Service Manual

Stationary base-mounted compressor
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13-10-617
Version: 00
July 28, 2011
ELECTRA-SAVER
STATIONARY BASE-MOUNTED
COMPRESSOR
™
AirSmart
Controller
EAY99G
350, 400, 500 HP
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver ELECTRA-SAVER EAY99G

  • Page 1 13-10-617 Version: 00 July 28, 2011 ELECTRA-SAVER STATIONARY BASE-MOUNTED COMPRESSOR ™ AirSmart Controller EAY99G 350, 400, 500 HP OPERATING AND SERVICE MANUAL...

  • Page 3: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services

    Remanufacturing Center in Indianapolis, IN., 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.

  • Page 4: Warning - Prohibition - Mandatory Label Information

    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.
  • Page 5 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.

  • Page 6: Safety Precautions

    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.

  • Page 7: Table Of Contents

    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.................. 2 Safety Precautions ............................4 Index................................6 List Of Illustrations............................

  • Page 8: Index

    INDEX Addition Of Oil Between Changes ....52 Inlet Valve ............33 Aftercooler Piping..........50 Installation For Cold Weather Operation ..17 Installation, Section 2........14 Air Filter ............65 Air Filter Vacuum Switch ........35 Air Filter, Section 6...........65 Lifting Unit ............14 Air Flow In The Compressor System ....9 Location ............
  • Page 9 Parallel Piping ..........20 Service Check List Piping Air Filter ............70 Series............21 Shuttle Valve............ 34 Power Supply ...........36 Solenoid Valves Ivc And Ivo ......34 Pressure Differential Gauging ......62 Solenoid Valves Tvc And Tvo......35 Pressure Regulator ..........34 Starting & Operating Procedures, Section 3..24 Prestart-Up Instructions ........24 Starting The Unit ..........

  • Page 10: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ........................9 Figure 1-2 – Control Box ..........................10 Figure 1-3 – View Of Water Cooled Unit With Aftercooler (Less Enclosure) Compressor – Reservoir End....................11 Figure 1-4 – View Of Water Cooled Unit With Aftercooler (Less Enclosure) Reservoir Side..... 11 Figure 1-5 –...

  • Page 11: Section 1 General Information

    GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR - The Gardner Denver 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 roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads.

  • Page 12: Figure 1-2 - Control Box

    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 discharges into the compressor main oil gallery. A portion of the oil is directed through internal passages to the bearings, gears and shaft oil seal. The balance of the oil is injected directly into the compression chamber to remove heat of compression, seal internal clearances and lubricate the rotors.

  • Page 13: Figure 1-3 - View Of Water Cooled Unit With Aftercooler (Less Enclosure) Compressor - Reservoir End

    Figure 1-3 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – RESERVOIR END Figure 1-4 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) RESERVOIR SIDE 13-10-617 Page 11...

  • Page 14: Figure 1-5 - View Of Water Cooled Unit With Aftercooler (Less Enclosure) Compressor - Motor Side

    Figure 1-5 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – MOTOR SIDE Figure 1-6 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) – MOTOR END 13-10-617 Page 12...

  • Page 15: Figure 1-7 - Air/Oil Flow Diagram

    219ECM797-A (Ref. Drawing) Figure 1-7 – AIR/OIL FLOW DIAGRAM 13-10-617 Page 13...

  • Page 16: Section 2 Installation

    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.

  • Page 17: Figure 2-1 - Typical Compressor Room

    Both the air-cooled and water-cooled units require cooling air as well as air to the compressor inlet. Proper ventilation MUST be provided; hot air must be exhausted from the compressor operating area. A typical inlet-outlet air flow arrangement is shown in (Figure 2-1) Figure 2-1 –...
  • Page 18 Allow three (3) feet (.9 m) to the nearest obstruction above and on other sides of the unit. FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be made at a maximum 10°...

  • Page 19: Figure 2-3 - Cold Weather Installation

    Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 4000 lubricant. Monitor the unit carefully during start-up and operation to be sure it is functioning normally.

  • Page 20: Figure 2-4 - Inlet Line Lengths

    Refer to Engineering Data Sheet 13-9-411, available from an authorized Gardner Denver distributor, for the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit.

  • Page 21: Figure 2-5 - Heat Exchanger (Oil Cooler) Approximate Water Flow

    DISCHARGE SERVICE LINE - The discharge service line connection on both water-cooled and air- cooled units is made at the center of left end of the unit, viewed from the control panel side. When manifolding two or more rotary screw units on the same line, each unit is isolated by the check valve in the unit discharge line.

  • Page 22: Figure 2-7 - Parallel Piping (Standard Package)

    WATER PIPING (Water-Cooled Heat Exchanger Models Only) - On machines equipped with water- cooled heat exchangers, the water inlet and outlet connections are located in the unit base flange on the left side of the unit. It is mandatory that any water cooled unit be installed in a shelter heated to temperatures above freezing (32°...

  • Page 23: Figure 2-8 - Series Piping (Customer Piped, Optional)

    Figure 2-8 – SERIES PIPING (CUSTOMER PIPED, OPTIONAL) SERIES PIPING ( ) - Water flow must be through aftercooler first for effective cooling of Figure 2-8 discharge air and is so piped on the standard water-cooled unit. The water control valve is to be adjusted to maintain oil out of the heat exchanger within the 140° F to 150°...
  • Page 24 ELECTRICAL WIRING - Standard Units – The 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 open drip proof motors and a UL Type 4 control box. Totally enclosed motors are available as factory options.
  • Page 25 MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The following charts show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions.

  • Page 26: Section 3 Starting & Operating Procedures

    Compressor Oil - Check the oil level in the reservoir. Add oil only if the oil level gauge reads in the red “ADD OIL” range. Do not mix different type oils. The unit is shipped filled with Gardner Denver AEON 4000 Lubricating Coolant which is suitable for the first 4000 hours under normal operating conditions.
  • Page 27 Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See (FIGURE 4-11, page 41) and (FIGURE 4-12, page 43) for general wiring diagrams and Section 2, for installation instructions. Grounding - Equipment must be properly grounded according to Section 250 of the National Electrical Code.
  • Page 28 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. STARTING THE UNIT - Observe the following starting procedures. Unit Cold - If the unit is a water-cooled heat exchanger model, open any manual water inlet valves wide open.

  • Page 29: Operation Adjustment

    Quick Start Guide Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run button to start the compressor, no other settings are required. The Target Pressure comes preset to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure setting is desired, the following steps can be used as a guide.
  • Page 30 To change the Target Pressure, press the Enter button to edit the value. OPERATION ADJUSTMENT TARGET PRESSURE 100 PSI (EDIT PARAMETER) A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the Plus and Minus buttons to change its value.

  • Page 31: Section 4 Controls & Instrumentation

    SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver Rotary Screw compressor is prewired with all controls, and motor for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply, starter and to the shop air line (and to the appropriate water supply if water-cooled).

  • Page 32: Figure 4-1 - Key Pad

    Figure 4-1 – KEY PAD Relief Valve - A pressure relief valve(s) is (are) installed in the final discharge line and set to approximately 120-125% of the unit’s full load operating pressure for protection against over pressure. Periodic checks should be made to ensure its (their) operation. The relief valve should be tested for proper operation at least once every year.

  • Page 33: Figure 4-2 - Schematic Tubing Diagram

    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. 202EAY797-B Figure 4-2 – SCHEMATIC TUBING DIAGRAM (Ref. Drawing) 13-10-617 Page 31...

  • Page 34: Figure 4-3 - Blowdown Valve

    Figure 4-3 – BLOWDOWN VALVE Blowdown Valve (Figure 4-3) - This valve normally is used for control functions, but also serves to relieve reservoir pressure following a shutdown. The blowdown valve is a two-way solenoid valve which is piped into the oil reservoir outlet ahead of the minimum pressure valve. When the solenoid is de- energized, the valve opens and the coolant system is blown down.

  • Page 35: Figure 4-5 - Inlet Valve

    To service the valve, make sure all pressure is relieved, disconnect the unit from the power supply, lockout and tagout, then unscrew the valve cap from the body. The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor. 203EAY797-B (Ref.

  • Page 36: Figure 4-6 - Shuttle Valve

    Solenoid Valves IVC and IVO - These valves control position of the inlet valve in response to signals from the “AirSmart” Controller. With both valves de-energized, the normally open IVC valve allows control pressure to the inlet piston to close the valve. If IVC only is energized, the inlet valve is held in its current position.

  • Page 37: Figure 4-7 - Turn Valve

    213ECM797-A (Ref. Drawing) Figure 4-7 – TURN VALVE Turn Valve (Figure 4-7) - The turn valve is a helical valve which, when rotated, opens and closes a series of ports cast into the compressor cylinder. When these ports are open, they direct some of the air which would otherwise be compressed back to the inlet, reducing both capacity and power consumption.
  • Page 38 Discharge Thermistor - This sensor is located directly in the compressor discharge. Its signal is used to monitor compressor temperature and shut down the compressor if a coolant problem is detected. Reservoir Thermistor - This sensor is located near the separator and is used to monitor temperature and shut down the compressor if high temperatures are detected.
  • Page 39 COMPRESSOR CAPACITY CONTROL - TURN VALVE The capacity of the compressor is controlled by the action of the turn valve and the compressor inlet valve. The turn valve controls compressor delivery to match demands of 40% to 100% of the compressor’s maximum capacity.

  • Page 40: Figure 4-8 - Control Schematic - Compressor At Full Load

    204EAY797-E (Ref. Drawing) Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD...

  • Page 41: Figure 4-9 - Control Schematic - Compressor Fully Unloaded - Constant Speed Mode

    205EAY797-E (Ref. Drawing) Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – CONSTANT SPEED MODE...

  • Page 42: Figure 4-10 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode

    206EAY797-E (Ref. Drawing) Figure 4-10 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE...

  • Page 43: Figure 4-11 - Wiring Diagram - Less Starter (Air-Cooled / Water-Cooled) - 200, 230, 380, 460 Volt

    316EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-11 – WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 380, 460 VOLT...
  • Page 44 316EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 380, 460 VOLT...

  • Page 45: Figure 4-12 - Wiring Diagram - Less Starter (Air-Cooled / Water-Cooled) - 575 Volt

    317EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-12 – WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT...
  • Page 46 317EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT...

  • Page 47: Section 5 Lubrication Oil Cooler, Oil Filter & Separator

    AEON lubricants are available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 4000 lubricating coolant which can be used for year-round operation. AEON 4000 is a semi - synthetic, extended life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based lubricant.
  • Page 48 HIGH TEMPERATURE OPERATION - Gardner Denver AEON 4000 lubricating coolant will operate at a sustained discharge temperature up to 210° F (99° C). When unusually high ambient air temperature is encountered, it will shorten the lubricant life; see ( , page 53).

  • Page 49: Figure 5-1 - Dew Point Chart °F

    Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 100 psig 125 psig 150 psig 175 psig Ambient Temp. F Figure 5-1 – DEW POINT CHART °F Dew-Point Temperature vs. Ambi ent Tem perature (100% Relative Humidity) 6.9 bar 8.6 bar 10.4 bar 12.1 bar -1 0...

  • Page 50: Figure 5-3 - Flow Diagram - Air/Oil System

    207EAY797-D (Ref. Drawing) Figure 5-3 – FLOW DIAGRAM – AIR/OIL SYSTEM...

  • Page 51: Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted Cooler

    218ECM797-A (Ref. Drawing) Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED COOLER REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be disconnected after test and the vent fan motor connected in its place.

  • Page 52: Figure 5-5 - Cooler Drain Detail

    Figure 5-5 – COOLER DRAIN DETAIL AFTERCOOLER PIPING - At shutdown of the system, all units should be drained completely of condensate if there is any possibility of freezing or corrosion damage. To help remove the condensate, the cooler may be tapped per ( ), and a drain cock installed.
  • Page 53 NOTICE When removing the cooling module from the package for remote operation, do not use the flexible coupling (when supplied) between the air/oil separator housing and the minimum pressure/check valve. The discharge piping from the air/oil separator housing should be piped into the minimum pressure/check valve, then into piping to the cooler, with a flexible connection between the minimum pressure/check valve and aftercooler to keep the weight of the piping off of the cooler.
  • Page 54 Failure to install these parts or installations with pipe lengths and/or vertical runs outside the recommended limits could result in high oil carryover and cause the machine to shut down on high discharge temperature. COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation,” Section 2. ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is in the red range on the gauge as read while the unit is on.

  • Page 55: Figure 5-6 - Oil Change Interval

    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.
  • Page 56 DRAINING AND CLEANING OIL SYSTEM 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, separation chamber and all piping and tubing may be at high temperature during and after operation.

  • Page 57: Filling Oil Reservoir

    FILLING OIL RESERVOIR 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. Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, lockout and tagout the power supply to the starter.
  • Page 58 COMPRESSOR BEARING OIL FILTER (Figure 1-6, Page12) - This screw on oil filter is a vital part in maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is located in the oil filter head. The relief valve opens in the event the element becomes dirty enough to block the flow of oil.

  • Page 59: Figure 5-8 - Compressor Main Oil Filter

    Figure 5-8 – COMPRESSOR MAIN OIL FILTER COMPRESSOR MAIN OIL FILTER INSTRUCTIONS 1. Stop the unit and be sure no air pressure is in the oil reservoir. Disconnect, tat and lockout power supply to the starter. 2. To remove head assembly, rotate tee handle (9) counterclockwise until head assembly (1) is free of housing (3).

  • Page 60: Figure 5-9 - Thermostatic Mixing Valve Element

    7. Place head assembly (1) onto housing assembly (3) and rotate tee handle (9) clockwise until hand tight; do not exceed 20 foot-pound torque if tools are used. 8. Reconnect starter to power source. 9. If leakage appears around tee handle (9) remove snap ring (11) and remove tee handle (9) from head assembly (1).

  • Page 61: Figure 5-10 - Water Control Valve

    COMPRESSOR OIL COOLER - WATER-COOLED HEAT EXCHANGER ( , page 48) - The Figure 5-3 heat exchanger oil cooler is a multiple pass type, with water in the tubes and oil in the shell. The oil temperature is controlled by the thermal (thermostatic mixing) valve. The optional water control valve may be used to conserve water.
  • Page 62 WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) ( , page Figure 5-10 59) - The water flow control valve is adjustable to compensate for varying water inlet temperatures and pressures and is to be mounted in the water outlet line after the oil cooler ( Figure 5-3 , page 48).

  • Page 63: Figure 5-11 - Oil Separator

    Figure 5-11 – OIL SEPARATOR COMPRESSOR (GD ELIMINATOR™) OIL SEPARATOR located in a separate housing, consists of a renewable cartridge-type separator element and provides the final removal of oil from the air stream ( – OIL SEPARATOR Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity. Oil collected outside the element is returned through tubing to the compressor cylinder.
  • Page 64 Pressure Differential Gauging - The “CHANGE SEPARATOR” advisory will flash when the pressure differential across the oil separator reaches approximately 8 psid (.55 bar). Replace the oil separator element at this time. If ignored, the unit will shut down and the advisory will illuminate steadily when the pressure differential reaches 15 psid (1 bar).
  • Page 65 Remove screws holding the top plate to the oil reservoir. Lift the top plate from the oil reservoir. Lift the separator from the separator housing. Inspect and/or replace the separator as necessary. Before installing (or reinstalling) any separator flanges are not damaged. Remove the gasket material adhering to the top plate or reservoir flange from the old separator.

  • Page 66: Figure 5 12 - Ambient Temperatures

    Oil Cooler Temperature Differential (Air-Cooled Radiator) - The oil temperature differential depends on the temperature of the air at the oil cooler fan and cleanliness of core faces. As ambient temperatures and core restrictions increase, the oil cooler outlet temperature will increase. The oil inlet temperature is approximately the same as air discharge temperature - see the display on the controller.

  • Page 67: Section 6 Air Filter

    Filter Element – Service the air filter element when the “CHANGE AIR FILTER” LED is illuminated. Clean every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor.
  • Page 68 NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through you 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.

  • Page 69: Section 7 Coupling

    SECTION 7 COUPLING Figure 7-1– INSTALLATION OF COUPLING CUSHIONS Rotating machinery can cause personal injury or death. Turn the unit completely off, open the main disconnect, lockout and tagout before servicing the coupling. COUPLING - The motor and compressor are direct connected by a resilient type flexible coupling with a single cushion.
  • Page 70 NOTICE Elements with non-uniform cross sections must be mounted with the rotation arrow on the coupling the same direction as the rotation arrow on the airend. Incorrect rotation will greatly decrease the torque carrying capacity of the coupling. ASSEMBLY OF COUPLING ONTO THE AIREND AND MOTOR ( Figure 7-1 , Page 67).
  • Page 71 3. Apply light oil or grease film to both sides of the hardened steel washer. This is very important, since it will significantly reduce the rubber stresses around the metal bushings when torquing down the cap screws. Place the supplied hardened washers under the cap screw heads and torque the screws down to the torque rating in the assembly instructions supplied with the coupling.

  • Page 72: Section 8 Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter - Operating conditions determine frequency of service. See “Air Filter", Section 6. Oil Separator - Operating conditions determine frequency of service. See “Compressor Oil Separator” in Section 5, for further details. Motor Lubrication - Refer to Section 2, and Maintenance Schedule Chart, page 53.
  • Page 73 MAINTENANCE SCHEDULE Maintenance Action As Indicated Every Every Every Every by AirSmart Every 8 1000 4000 * Year Controller Hours Hours Hours Hours • Change Air Filter ............• Change Oil Separator ..........• Check Reservoir Oil Level ........• Check for Proper Load/Unload.........

  • Page 74: Section 9 Troubleshooting

    SECTION 9 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate tripped. cause of overload. Pressure in reservoir. Inspect blowdown valve. Read error message on Take appropriate action.
  • Page 75 SYMPTOM POSSIBLE CAUSE REMEDY Compressor starts too Wye Delta switch time set Contact your distributor. slowly too long. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Compressor is low on Restricted air filter. Clean or replace filter.
  • Page 76 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. 13-10-617 Page 74...
  • Page 77 13-10-617 Page 75...
  • Page 78 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Telephone: (800) 682-9868 FAX: (217) 224-7814 FAX: (217) 224-7814 Specification subject to change without notice. Copyright © 2011 Gardner Denver, Inc. Litho in U.S.A Visit our Web Site: www.gardnerdenver.com Visit our Web Site: www.gardnerdenver.com...

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