Gardner Denver EFD-25 HP Service manual

GARDNER DENVERR
ELECTRA--SCREW
STATIONARY BASE--MOUNTED
COMPRESSORS
MODELS
EFD -- 25, 30, 40 & 50 HP
PARTS LIST,
OPERATING AND
SERVICE MANUAL
13--8--625
1st Edition
March 24, 2000

13--8--625 Page i
TOTAL PRODUCT SUPPORT -- GARDNER DENVER’S
CONTINUING COMMITMENT
TO YOUR AIR COMPRESSOR PERFORMANCE
Commitment to totalproduct support continueslong after the purchase of yourquality GardnerDenverR
rotary screw compressor.
Gardner Denver original parts incorporate years of experience and improvements in design, materials
and quality assurance. Maintaining your compressor investment with Gardner Denver parts will insure
protection for the air compressor unit and long, dependable service life.
YourauthorizedGardnerDenvercompressordistributormaintainsacompletestockofallcommonmain-
tenanceparts,factoryapprovedAeontlubricants,andGardnerDenverfactorywarrantedexchangeair-
ends. In addition,authorized distributortechniciansarefactory trained, and can provide completediag-
nostic, compressor maintenance and repair services.
This manual is designed to assist you in maintaining high performance and receiving many years of de-
pendable service you expect from your Gardner Denver compressor.
REMANUFACTURED AIRENDS
Whenever an airend requires replacement or repair,
Gardner Denver offers an industry unique, factory
remanufactured airend exchange program. From its
modern Remanufacturing Center in Indianapolis, IN,
Gardner Denver is committed to supplying you with the
highest quality, factory remanufactured airends that are
guaranteed to save you time, aggravation and money.
Immediately Available
Repair downtime costs you money, which is why there
are over 200 remanufactured units in inventory at all
times, ready for immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average
over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, in-
spected and analyzed. Only those parts that can be
brought back to original factory specifications are re-
manufactured. Every remanufactured airend receives
anewoverhaul kit: bearings, gears, seals, sleeves and
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
just don’t do. Magnaflux and ultrasonic inspection spot
cracked or stressed castings, monochromatic light
analysis exposes oil leaks, and coordinate measure-
ment machine inspects to +/-- .0001”, insuring that all
remanufactured airends meet factory performance
specifications.
Warranty
GardnerDenverbacksupeveryremanufacturedairend
with a new warranty . . . 18 months from purchase, 12
months from service.
GardnerDenverremanufacturedairendsdeliverquality
without question ...yearinandyearout.
Call Gardner Denver for information on the airend ex-
change program and the name of your authorized dis-
tributor.
Phone Number: 800--245--4946 or
FAX: [phone]

13--8--625 Page ii
FOREWORD
Rotary screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of re-
ceiving 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 mini-
mum downtime.
Dangerisusedtoindicatethepresenceofahazardwhichwillcauseseverepersonal
injury, death, or substantial property damage if the warning is ignored.
Warning is used to indicate the presence of a hazard which can cause severe per-
sonal injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
Notice is used to notify people of installation, operation or maintenance informa-
tion which is important but not hazard--related.
This book covers the following models:
HP PSI Air Cooled
25, 30, 40 & 50 100, 125, 150, 175 EFD

13--8--625 Page iii
TABLE OF CONTENTS
PAGE
Total Product Support -- Gardner Denver’s Continuing Commitment To Your Air Compressor Performance i....
Remanufactured Airends i...........................................................................
Foreword ii........................................................................................
Maintain Compressor Reliability and Performance With Genuine Gardner Denver Compressor
Parts and Support Services iv..................................................................
Instructions for Ordering Repair Parts iv...............................................................
Index vthruvii.....................................................................................
List of Illustrations viii...............................................................................
Section 1, General Information 1.....................................................................
Section 2, Installation 6.............................................................................
Section 3, Starting & Operating Procedures 11.........................................................
Section 4, Controls & Instrumentation 13..............................................................
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator 27..............................................
Section 6, Air Filter 35..............................................................................
Section7,BeltDrive 36.............................................................................
Section 8, Maintenance Schedule 39.................................................................
Section 9, Trouble Shooting 40.......................................................................
Section 10, Parts List 41............................................................................
Bare Compressor 43..........................................................................
Airend Group 44, 45.........................................................................
Inlet Valve Repair Parts 46, 47.................................................................
Minimum Pressure/Check Valve 48, 49.........................................................
Airend And Inlet Filter Assembly 50, 51.........................................................
Drive Groups 52 Thru 61......................................................................
Cooling Group 62, 63.........................................................................
Control System Assembly And Mounting 64, 65..................................................
Water Separator Assembly 66..................................................................
Control Box 67, 68, 69........................................................................
Enclosure Group 70, 71......................................................................
Quiet Enclosure 72...........................................................................
Main Motor 73...............................................................................
Repair Kits 74, 75............................................................................
Warranty Last Page................................................................................

13--8--625 Page iv
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner Denver 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 are
incorporated in our genuine replacement parts.
Your authorized Gardner Denver Compressor distribu-
tor offers all the backup you’ll need. A worldwide net-
work of authorized distributors provides the finest
product support in the air compressor industry. Your
local authorized distributor maintains a large inventory
of genuine parts.
Your authorized distributor can support your Gardner
Denver air compressor with these services:
1. Trained parts specialists to assist you in select-
ing the correct replacement parts.
2. Factory warranted new and remanufactured
rotary screw air ends. Most popular model
remanufactured air ends are maintained in stock
at Gardner Denver for purchaseon an exchange
basis with liberal core credit available for the re-
placement 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 com-
pressor.
Authorized distributor service technicians are factory--
trained and skilled in compressor maintenance and re-
pair. They are ready to respond and assist you by pro-
viding fast, expert maintenance and repair services.
For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow
pages of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Gardner Denver
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: [phone]
Phone: [phone] Fax: [phone]
(800) 245--4946
Fax: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER (see nameplate on unit).
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 RE-
QUIRED.
DO NOT ORDER BY SETS OR GROUPS.

13--8--616 Page v
INDEX
Addition of Oil Between Changes 28..............
Air Cooled Unit 7...............................
AIR FILTER, SECTION 6 35.....................
Air Filter, Standard Duty 35......................
Air Filter Element 35............................
Air Filter Element Life 35........................
Air Flow in Compressor System 1................
Air Pilot Electronic Control Operation 14...........
Air Pilot Electronic Controller 13..................
Basic Display 16............................
Multi--Compressor Control 18................
Multipilot Menu 18..........................
Remote Control Operation 18................
Service Menu 18...........................
User Menu 17..............................
Air Receiver, Auxiliary 8.........................
Air/Oil Separators, Compressor 33...............
Alarms 22.....................................
Automatic Start/Stop 14.........................
Auxiliary Air Receiver 8.........................
BELT DRIVE, SECTION 7 36....................
Belt Tension, Checking 37.......................
Blowdown Valve 19, 20..........................
Check, Daily 12................................
Checking Belt Tension 37.......................
Cold Ambient Operation 28......................
Cold Weather Operation 8.......................
Cold Weather Operation, Installation for 7.........
Compression Principle 1........................
Compressor 1.................................
Compressor Air/Oil Separators 33................
Compressor Oil Cooler 32.......................
Compressor Oil Filter 31........................
Compressor Oil System 27......................
Compressor Oil System Check 34................
Compressor Running Fully Loaded 14............
Compressor Running Unloaded 14...............
Compressor System, Air Flow 1..................
Control Devices 19.............................
Blowdown Valve 19, 20......................
Changing Minimum Pressure/Check
Valve Seals 20..........................
Inlet Valve 20..............................
Inlet Valve Solenoid 20......................
Minimum Discharge Pressure/Check Valve 19..
Oil Level Gauge 19.........................
Pressure Transducer 22.....................
Purge Valve 20.............................
Relief Valve 19.............................
Control Piping 9................................
Control System Operation 13....................
CONTROLS & INSTRUMENTS, SECTION 4 13...
Controls & Instruments, General Description 13....
Cooler, Compressor Oil 32......................
Cooling, Sealing and Lubrication 1................
Daily Check 12................................
Decals 4, 5....................................
Discharge Service Line 9........................
Drain, Oil Reservoir 7...........................
Draining and Cleaning Oil System 29.............
Electric Motor Grease Recommendations 10.......
Electric Motor Regreasing Interval 10.............
Electrical Wiring 9..............................
Element, Air Filter 35...........................
Element Life, Air Filter 35.......................
Emergency Stop 12............................
Enclosure 7...................................
Filling Oil Reservoir 29..........................
Filter, Compressor Oil 31........................
Foundation 7..................................
Gauge, Oil Level 19, 31.........................
GENERAL INFORMATION, SECTION 1 1........
Grease Recommendations, Electric Motor 10......
Grounding 9...................................
High Temperature Operation 28..................
Inlet Line 9....................................
Inlet Line Lengths 8............................
Inlet Valve 20..................................
Inlet Valve Solenoid 20..........................
INSTALLATION, SECTION 2 6..................
Installation, General 6..........................

13--8--616 Page vi
INDEX
Installation for Cold Weather Operation 7..........
Instrument Panel 15............................
Lifting Unit 6...................................
Line, Discharge Service 9.......................
Line, Inlet 9...................................
Location 6.....................................
Lubricant, Recommended 27....................
Lubricant Upgrade Procedure 30.................
Lubrication, Motor 9............................
Lubrication, Cooling and Sealing 1................
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 27................
MAINTENANCE SCHEDULE, SECTION 8 39.....
Minimum Discharge Pressure/Check Valve 19.....
Minimum Pressure/Check Valve, Changing Seals 20
Moisture in the Oil System 31....................
Moisture Separator/Trap, Optional 9..............
Motor Grease Recommendations 10..............
Motor Lubrication 9.............................
Motor Regreasing Interval 10....................
Multi--Compressor Control 18....................
Oil Carry--Over 41..............................
Oil Change Interval 28..........................
Oil Cooler, Compressor 32......................
Oil Filter, Compressor 31........................
Oil Level, Procedure for Checking 28.............
Oil Level Gauge 19, 31..........................
Oil Reservoir 33................................
Filling 29..................................
Oil Reservoir Drain 7...........................
Oil Separator
Inspection 33..............................
Removal for Inspection or Replacement 33.....
Oil Specifications 27............................
Oil System
Compressor 27.............................
Draining and Cleaning 29....................
Oil System Check 34...........................
Air and Oil Discharge Temperature 34.........
Compressor Oil Inlet Temperature 34..........
Oil Cooler Oil Pressure Differential 34.........
Oil Cooler Temperature Differential 34.........
Oil Inlet Pressure 34........................
Operation, High Temperature 28.................
PARTS LIST
Airend and Inlet Filter Assembly 50, 51........
Airend Group 44, 45.........................
Bare Compressor 43........................
Control Box 67, 68, 69......................
Cooling Group 62, 63........................
Drive Groups 52 Thru 61.....................
Common Parts 53.......................
Enclosure Group 70, 71......................
Control System Assembly and
Mounting 64, 65.........................
Inlet Valve Repair Parts 46, 47................
Main Motors 73............................
Minimum Pressure/Check Valve 48, 49........
Quiet Enclosure 72.........................
Repair Kits 74, 75...........................
Water Separator Assembly 66................
PARTS LIST, SECTION 10 43...................
Piping, Control 9...............................
Pressure Differential Gauging 33.................
Pressure Transducer 22.........................
Prestart--Up Instructions 11......................
Air Filter 11................................
Compressor Oil 11..........................
Electrical 11...............................
Enclosure 12...............................
Grounding 11..............................
Operating Mode 12.........................
Piping 11..................................
Rotation 11................................
System Pressure 12........................
Procedure for Checking Oil Level 28..............
Programming and Setup Instructions for the
Airpilot Electronic Controller 15...............
Purge Valve 20................................
Recommended Lubricant 27.....................
Regreasing Interval, Electric Motor 10............
Relief Valve 19.................................

13--8--616 Page vii
INDEX
Remanufactured Air Ends i......................
Remote Control Operation 18....................
Repair Parts, Ordering Instructions iv.............
Reservoir, Oil 33...............................
Safety Precautions 3–4.........................
Sealing, Lubrication and Cleaning 1..............
Separator/Trap, Moisture, Optional 9.............
Separators, Compressor Air/Oil 33...............
Service Check List 39...........................
Air Filter 39................................
Every 1000 Hours Operation 39..............
Every 125 Hours Operation 39...............
Every 2000 Hours Operation 39..............
Every 8 Hours Operation 39..................
Every Year 39..............................
Motor Lubrication 39........................
Solenoid, Inlet Valve 20.........................
Specifications, Oil 27...........................
Starter 14.....................................
STARTING & OPERATING PROCEDURES,
SECTION 3 11.............................
Starting the Unit 12.............................
Stop, Emergency 12............................
Stopping the Unit 12............................
Thermal Control (Thermostatic Mixing) Valve 32....
Transducer, Pressure 22........................
TROUBLE SHOOTING, SECTION 9 40...........
Upgrade Procedure, Lubricant 30................
Valve
Blowdown 19, 20...........................
Inlet 20....................................
Minimum Discharge Pressure/Check 19.......
Purge 20..................................
Relief 19..................................
Thermal Control (Thermostatic Mixing) 32.....
Warranty Last Page............................
Wiring, Electrical 9.............................

13--8--616 Page viii
LIST OF ILLUSTRATIONS
Figure 1--1 Compressor Cycle 1...............................................................
Figure 1--2 Compressor Package Components 2.................................................
Figure 1--3 Description of Compressor Package Components 2....................................
Figure 2--1 Preferred Lifting Method 6..........................................................
Figure 2--2 Alternate Lifting Method 6...........................................................
Figure 2--3 Typical Compressor Room 7........................................................
Figure 2--4 Air Flow Chart 7...................................................................
Figure 2--5 Cold Weather Installation 8.........................................................
Figure 4--1 Control Schematic 13..............................................................
Figure 4--2 Starter / Control Box and Instrument Panel 15.........................................
Figure 4--3 Air Pilot Electronic Controller 16.....................................................
Figure 4--4 Compressor Running Fully Loaded 21................................................
Figure 4--5 Wiring Diagram 23.................................................................
Figure 4--6 Wiring Diagram 24.................................................................
Figure 4--7 Wiring Diagram 25.................................................................
Figure 4--8 Wiring Diagram 26.................................................................
Figure 5--1 Flow Diagram 27..................................................................
Figure 5--2 Approximate Oil System Capacities 28...............................................
Figure 5--3 Oil Change Interval 29..............................................................
Figure 5--4 Oil Level Gauge, Oil Fill and Oil Drain 31..............................................
Figure 5--5 Oil Filter 32.......................................................................
Figure 6--1 Air Filter 35.......................................................................
Figure 7--1 Drive Belt Tensioner 36.............................................................
Figure 7--2 Removing Drive Sheave 37.........................................................
Figure 7--3 Installing Bushing in Drive Sheave 38................................................
Figure 7--4 Installing Drive Sheave on Compressor or Motor 37....................................
Figure 7--5 Belt Tension -- 5 V Section V--Belts 38................................................

13--8--616 Page 1
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 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.
Ball and roller bearings at the discharge end locate
each rotor axially and carry all thrust loads and the re-
mainder of the radial loads.
COMPRESSION PRINCIPLE (FIGURE1--1)--Com-
pression is accomplished by the main and secondary
rotors synchronously meshing in a one--piece cylinder.
The mainrotor has four (4) helical lobes90_apart.The
secondary rotor has five (5) matching helical grooves
72_apart to allow meshing with main rotor lobes.
Theairinletportislocatedontopofthecompressorcyl-
inder 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 beginsas
the rotors unmesh at the inlet port and air is drawn into
the cavity between the main rotor lobes and the sec-
ondary rotor grooves (A). When the rotors pass the in-
let 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 sec-
ondary 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 re-
ductionandpressureincrease continuesuntiltheair/oil
mixture trapped in the interlobe cavity by the rotors
passes thedischargeportandis releasedtotheoilres-
ervoir (C). Each rotor cavity follows the same “fill--com-
press--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 4--1, page 13) -- 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.
Aftercompression,theair/oilmixturepassesintotheoil
reservoir where most of theentrained 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
forcedby airpressure from theoil reservoir through the
oil cooler, thermostatic mixing valve, and oil filter and
discharge into the compressor main oil gallery. A por-
tion 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 re-
move heat of compression, seal internal clearances
and lubricate the rotors.

13--8--616 Page 2
FIGURE 1--2 -- COMPRESSOR PACKAGE COMPONENTS
No. Component Purpose
1 Electric motor Powers compressor unit
2 Belts Power transmission
3 Compressor unit Generates pressurized air
4 Inlet valve Air output control
5 Inlet filter Cleans inlet air
6 Air/oil reservoir Separates oil from air
7 Minimum pressure/check valve Maintains min. receiver pressure, non--return valve
8 Pressure relief valve Protects receiver against overpressure
9 Oil cooler Cools down oil
10 Aftercooler Cools down pressurized air
11 Fan Circulates cooling air
12 Oil filter Cleans oil
13 Instrument panel Control and adjustment of compressor
14 Water separator * Removes condensate water from output air
15 Control valves Controls air output of compressor
16 Main switch Power supply
17 Automatic belt tightener Maintain tightness of belts automatically correct
18 Thermostatic mixing valve Maintains minimum temperature of oil
* Optional equipment.
FIGURE 1--3 -- DESCRIPTION OF COMPRESSOR PACKAGE COMPONENTS

13--8--616 Page 3
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.
DKeep fingers and clothing away from revolving fan, drive coupling, etc.
DDo not use the air discharge from this unit for breathing -- not suitable for hu-
man consumption.
DDonotloosenorremovetheoilfillerplug,drainplugs,covers,thethermostat-
icmixingvalveorbreakanyconnections,etc.,in thecompressorairoroilsys-
tem until the unit is shut down and the air pressure has been relieved.
DElectrical shock can and may be fatal.
DPerform 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 be qualified electricians.
DOpen main disconnect switch, tag and lockout before working on thecontrol.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit -- this machine is automatically controlled and may
start at any time.
Failure to observe these notices could result in damage to equipment.
DStop the unit if any repairs or adjustments on or around the compressorare
required.
DDisconnect the compressor unit from its power source, tag and lockout be-
foreworking on the unit -- this machineis automaticallycontrolled and may
start at any time.
DAn Excess Flow Valve should be on all compressed air supply hoses ex-
ceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)
DDonot exceedtheratedmaximumpressurevaluesshownonthenameplate.
DDonot operate unit if safety devicesare not operating properly. Checkperi-
odically. Never bypass safety devices.

13--8--616 Page 4
DECALS
206EAQ077 212EAQ077
218EAQ077
211EAQ077 207EAQ077

13--8--616 Page 5
DECALS
216EAQ077
217EAQ077
222EAQ077
221EAQ077 208EAQ077

13--8--625 Page 6
SECTION 2
INSTALLATION
GENERAL -- On receipt of theunit, checkfor anydam-
agethatmay havebeenincurredduringtransit. Report
any damage or missing parts as soon as possible.
Do not electric weld on the compres-
sororbase;bearingscanbedamaged
by passage of current.
LIFTING UNIT (FIGURE 2--1 and FIGURE 2--2) --
Proper lifting and/or transporting methods must be
used to prevent damage. Lifting slots are provided in
thebasefortowmotoruse.Unitmayalsobemovedinto
location by rolling on bars.
Lift compressorunit by 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
exceed15degrees.Failuretoobserve
this warning may result in damage to
equipment or personal injury.
LOCATION (FIGURE 2--3, page 7) -- The compres-
sor should be installed where it is protected from rain,
snow and freezing temperatures, direct sunlight, 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.
Insomecasesitmaybenecessarytoinstalltheairfilter
at some distance from the compressor to obtain proper
air supply.
FIGURE 2--1 -- PREFERRED LIFTING METHOD FIGURE 2--2 -- ALTERNATE LIFTING METHOD

13--8--625 Page 7
AIR--COOLED UNIT -- A combination oil/aftercooler is
suppliedas standardequipment onallair--cooledunits.
The air--cooled unit with the standard enclosure re-
quiressufficientflowforthecompressoroil/aftercooling
systemand electricmotorcooling(FIGURE 2--4,page
7). Air is drawn into the unit above the motor and dis-
charged through the cooler. Do not block the air flow to
and from the unit. Allow three and one half (3--1/2) feet
tothenearestobstructiononthestarterendandcontrol
box end of the unit. Allow three (3) feet to the nearest
obstruction above and on other sides of unit.
For continuousefficiency, oilcooler coresmust beperi-
odically cleanedwith either vacuum or compressed air.
If wet cleaning is required, shield motor and spray on
a mild soap solution and flush with clean water.
For aluminum oil coolers, do not use
any cleaning solution thatis not com-
patiblewithaluminum.Useofimprop-
er solution may result in damage to
the cooler.
FIGURE 2--3 -- TYPICAL COMPRESSOR ROOM
Minimum Air Flow* For Compressor
And Cooling (Cubic Feet/Minute)
Air Cooled
All Models 4800 cfm
*80_F Inlet Air
FIGURE 2--4 -- AIR FLOW CHART
FOUNDATION -- The rotary screw compressor re-
quiresnospecialfoundation,butshouldbemountedon
a smooth, solid surface. Whenever possible install the
unit near level. Temporary installation may be made at
a maximum 10_angle lengthwise or 10_sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt, or danger of shifting from outside vibration or mov-
ing vehicles may require the use of mounting bolts and
shims to provide uniform support for the base. Belt
alignmentandtensionshouldbecheckedafterinstalla-
tion. (For information on belt alignment and tension,
see page 36.)
OIL RESERVOIR DRAIN -- The oil drain is piped from
the bottom of the reservoir to the side of the frame.
ENCLOSURE -- The compressor, electric motor, oil
cooler and aftercooler are mounted inside the enclo-
sure.
Service doors are provided for maintenance access.
Be sure to allow enough space around the unit for the
doors to be opened.
Any of the enclosure doors may be removed by open-
ing the latches using the special key.
Do not attempt to operate the
compressorwiththedoorsopen. The
enclosure doors must be closed to
force the cooling air through the
cooler.
Do not operate the compressor with
the fan and belt guard removed.
Exposed fan and belts may cause
injury to personnel.
INSTALLATION FOR COLD WEATHER OPERA-
TION (FIGURE 2--5, page 8) -- 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.

13--8--625 Page 8
FIGURE 2--5 -- COLD WEATHER INSTALLATION
Refer to Engineering Data Sheet 13--9--411 for the ad-
vantages of using the heat recovered from rotary com-
pressors.Thisheatrecovery couldeasily payforanad-
equate shelter for the unit.
When an outside installation must be made, the pre-
cautions required will depend on the severity of the en-
vironment. The following are general guidelines for
outside installations:
Cold Weather (DownTo+10
oF)
1. Be sure all drains, traps, and control lines, includ-
ing pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermo-
stat control is generally satisfactory for this pur-
pose and can be obtained at various local plumb-
ing or hardware outlets at nominal cost.
2. Provisions to bypass the aftercooler must be
made. Since cold air contains very little moisture,
successful operation can be achieved without the
aftercooler.
3. Provideatleastsomesimplesheltersuchasaply-
wood windbreak to protect against drifting snow.
4. Use only Gardner Denver AEON 9000SP lubri-
cant.
5. Monitor unit carefully during start--up and opera-
tion to be sure it is functioning normally.
Remember unsheltered (outside) installations should
be avoided where possible. Installation next to a
heated building where enough heat can be used to
keep the compressor room above freezing will save
many complications in the operation and installation of
the unit.
AUXILIARY AIR RECEIVER -- Anauxiliary airreceiver
isnotrequiredifthepipingsystemislargeandprovides
sufficient storage capacity to prevent rapid cycling.
Whenused, anairreceiver should beof adequatesize,
providedwith arelief valveofpropersetting, apressure
gauge and a means of draining condensate.
INLET LINE LENGTHS
Length of Inlet Line Diameter of Pipe Size
0 to 10 Feet Same as Compressor Inlet Opening....................................................
10 to 17 Feet One Size Larger Than Inlet Opening...................................................
17 to 38 Feet Two Sizes Larger Than Inlet Opening..................................................

13--8--625 Page 9
OPTIONAL MOISTURE SEPARATOR/TRAP -- The
unit is equipped with a built--in aftercooler, a combina-
tion moisture separator and trap is furnished as an op-
tion to the unit. This should be piped into the system
down stream of the aftercooler.
CONTROL PIPING -- Control piping is not necessary
sincetherotaryscrewunit isfactorywiredandpipedfor
the control system specified.
INLET LINE -- Where an inlet line is used between the
air filter and the compressor, it must be thoroughly
cleaned on the inside to prevent dirt or scale from en-
tering the compressor. If welded construction is
used, the line must be shot blasted and cleaned to
remove welding scale. In either case, the inlet line
must be coated internally by galvanizing or painting
withamoistureandoil--proof sealinglacquer. Uptoten
(10) feet in length, the inlet line should be the full size
of the inlet opening on the compressor. If an extra--
long line is necessary, the pipe size should be in-
creased according to Inlet Line Length Chart below.
Accessibility for inlet air filter servicing must be consid-
eredwhenrelocatingthefiltersfromtheunittoaremote
location.
DISCHARGE SERVICE LINE -- Thedischargeservice
lineconnectionismadeattheopposite endofthepack-
age when viewedfrom the control box end. A hand op-
erated valve, (air service valve) must be installed be-
tween 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.
When manifolding two or more rotary screw units on
the same line, each unit is isolated by the minimum
pressure check valve mounted on each compressor
package.
If arotaryscrewunit is manifoldedtoanother compres-
sor, be sure the other compressor has a check valve in
the line between the machine and the manifold.
If a rotary screw and a reciprocating compressor are
manifolded together, an air receiver must be located
between the two units.
Discharge air used for breathing will
cause severe injury or death.
Consult filtration specialists for addi-
tional filtration and treatment equip-
ment to meet health and safety stan-
dards.
ELECTRICAL WIRING -- All of the electrical connec-
tions and controls are factory wired for the voltage spe-
cified on the order. Verify that the available voltage
source matches that shown on the compressor pack-
age nameplate before installing the compressor pack-
age. It is necessary only to connect the package to the
supply and ground of the branch circuit. The connec-
tions to the compressor package are made with the
electricalcontrolsbox,accessiblebyopeningthecover
of the box.
Electrical shock can cause injury or
death. Open main disconnect switch,
tag and lockout before working on
control box.
GROUNDING -- Equipment must be grounded in ac-
cordance with Section 250 of the National Electrical
Code.
Failure to properly ground the com-
pressorpackagecouldresultininjury
or death. Install ground wiring in ac-
cordance with the National Electrical
Code and any applicable local codes.
MOTOR LUBRICATION -- Long time satisfactory op-
eration of an electric motor depends in large measure
on proper lubrication of the bearings. The following
charts show recommended grease qualities and re-
greasingintervalsforballbearingmotors. Foraddition-
al information refer to the motor manufacturer’s

13--8--625 Page 10
instructions. The following procedure should be used
in regreasing:
1. Stop the unit.
2. Disconnect, tag and lockout the unit from the
power supply.
3. Remove the relief plug and free hole of hardened
grease.
4. Wipe lubrication fitting clean and add grease with
a hand--operated grease gun.
5. Leave the relief plug temporarily off. Reconnect
unit and run for about 20 minutes to expel the ex-
cess grease.
6. Stop the unit. Replace the relief plug.
7. Restart the unit.
Rotating machinery can cause injury
or death. Open main disconnect, tag
and lockout power supply to starter
before working on the electric motor.
ELECTRIC MOTOR GREASE RECOMMENDATIONS
Standard High
Service Temperature
Worked Penetration 265--296 220--240..........................................
Grease Viscosity, SSU At 100_F 400--550 475--525...............................
Soap Type Lithium Lithium..................................................
N--H Bomb, Minimum Hours For 20 PSI Drop at 210_F 750 1000............
Bleeding, Maximum Weight % In 500 Hours 212_F103...............
Rust Inhibiting Yes Yes...............................................
ELECTRIC MOTOR REGREASING INTERVAL
Type of Service Typical Examples Rating Relubrication Interval
Standard One-- or Two--Shift Operation 15 to 50 HP 3200 Hours
Very Severe Dirty Locations, High 15 to 50 HP *
Ambient Temperature
* 3200 Hours should be halved for every 27_F(15_C) over 176_F(80_C) temperature of the grease.

13--8--625 Page 11
SECTION 3
STARTING & OPERATING PROCEDURES
PRESTART--UP INSTRUCTIONS -- A new unit as re-
ceived from the factory has beenprepared for shipping
only. Do not attempt to operate the unit until checked
and serviced as follows:
1. Compressor Oil -- The oil must be checked be-
fore starting the unit and every 8 hours of opera-
tion. For instructions on checking the oil and the
proper oil level, refer to Section 5, page 28.
Donot mix different type oils. Unit is shippedfilled
with Gardner Denver AEON 4000 Lubricating
Coolant which is suitable for the first 4000 hours
under normal operating conditions. AEON
9000SP is also available. Check the decal on the
reservoir to be sure which lubricant is in the ma-
chine.
REPLACE OIL FILTER EVERY 1000 HOURS.
Regular maintenance and replace-
mentatrequiredintervalsofthe oilfil-
ter, air filter and air--oil separator is
necessary to achieve maximum ser-
vice and extended drain intervals of
AEON 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 torelease pressure may
result in personal injury or death.
2. AirFilter-- Inspecttheairfiltertobesureitisclean
andtightly assembled. RefertoSection6,“AirFil-
ter,” page 35, for complete servicing instructions.
Be sure the inlet line, if used, is tight and clean.
3. Piping -- Refer to Section 2, “Installation,” and
make sure piping meets all recommendations.
4. Electrical -- Check the wiring diagrams furnished
with the unit to be sure it is properly wired. See
FIGURE 4--4, page 21, and FIGURE 4--5, page
23, for general wiring diagrams and Section 2,
page 6 for installation instructions.
5. Grounding -- Unit must be properly groundedac-
cording to Section 250 of the National Electrical
Code.
Failure to properly ground the com-
pressor package could result in con-
troller malfunction.
6. Rotation -- Check for correct motor rotation by
bumping the starter using the ON switch. The
emergency stop button must be used to stop the
compressor. Compressor drive shaft rotation is
clockwise when facing the compressor sheave.
The compressor must be stopped
with the emergency stop button in or-
der to get an immediate stop.
Operation with incorrect motor rota-
tion can damage equipment and
cause oil eruption from the compres-
sor inlet. When checking motor rota-
tion, induce minimum rotation (less
than one revolution if possible). Nev-
er allow motor to reach full speed.
The compressor unit’s direction of
rotation must be checked every time
the compressor is reconnected tothe
power supply.