Gardner Denver ELECTRA-SCREW EDEQHH Service manual

GARDNER DENVER
ELECTRA–SCREWSTATIONARY
BASE–MOUNTED
COMPRESSORS
DOMESTIC MODELS
EDEQHH – 40 HP
EDEQJH – 50 HP
INTERNATIONAL MODELS
EDEQHJ – 40 HP (30 KW)
EDEQJJ – 50 HP (37 KW)
OPERATING AND
SERVICE MANUAL
13–8–610
6th Edition
March, 1997

13–8–610 Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVERRCOMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner DenverRCompressor genuine parts, engine-
ered to original tolerances, are designed for optimum
dependability–––specificallyforGardnerDenvercom-
pressor systems. Design and material innovations are
theresultofyearsofexperiencewithhundredsofdiffer-
ent compressor applications. Reliability in materials
and quality assurance are incorporated in our genuine
replacement parts.
Yourauthorized GardnerDenverRCompressordistrib-
utor offers all the backup you’ll need. A worldwide net-
workofauthorizeddistributorsprovidesthefinestprod-
uct support in the air compressor industry.Your local
authorized distributor maintains a large inventory of
genuinepartsandheisbackedup foremergencyparts
by direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
DenverRair compressor with these services:
1. Trained parts specialists to assist you in selecting
the correct replacement parts.
2. Factory warranted new and remanufactured
rotaryscrewair ends.Most popularmodelreman-
ufacturedairendsaremaintainedinstockatMDC
for purchase on an exchange basis with liberal
core credit available for the replacement unit.
3. AfulllineoffactorytestedAEONtcompressorlu-
bricantsspecifically formulatedfor use inGardner
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 Machinery Inc. Gardner Denver Machinery Inc.
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]
REMANUFACTURED AIR ENDS
Whenever an air end requires replacement or repair,
Gardner Denver offers an industry unique, factory re-
manufactured air end exchange program. From its
modern Remanufacturing Center in Indianapolis, IN,
GardnerDenver iscommittedtosupplyingyouwiththe
highest quality, factory remanufactured air ends 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. Everyremanufactured airend receives
anewoverhaulkit: bearings,gears,seals,sleevesand
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
justdon’t do. Magnafluxand ultrasonicinspectionspot
cracked or stressed castings, monochromatic light
analysis exposes oil leaks, and coordinate measure-
ment machine inspects to +/– .0001”, insuring that all
remanufactured air ends meet factory performance
specifications.
Warranty
Gardner Denver backs up every remanufactured air
end with a new warranty . . . 18 months from purchase,
12 months from service.
GardnerDenverremanufacturedairendsdeliver
quali-
ty without question . . . year in and year out.
Call Gardner Denver for information on the air end ex-
change program and the name of your authorized dis-
tributor. Phone Number: 800–245–4946 or
FAX: [phone]

13–8–610 Page ii
FOREWORD
Gardner DenverElectra–Screwcompressors are the result of advanced engineering and skilled manufacturing.
To be assured of receiving maximum service from this machine the owner must exercise care in its operation and
maintenance. This book is written to give the operator and maintenance department essential information for day–
to–day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical
operation and minimum downtime.
Danger is used toindicate the presence of ahazard which will cause severepersonal
injury, death, or substantial property damage if the warning is ignored.
Warningisusedto indicatethepresenceofahazard whichcancausesevereperson-
al 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 tonotify people of installation,operation or maintenanceinformation
which is important but not hazard–related.
This book covers the following models:
HP (KW) PSIG (Bar) Air Cooled Domestic International
40 (30) 100, 125, 150, 175 EDEQHH (EDEQHJ) 13–8–510 13–8–510X
(6.9), (8.6), (10.3), (12.1)
50 (37) 100, 125, 150, 175 EDEQJH (EDEQJJ) 13–8–510 13–8–510X
(6.9), (8.6), (10.3), (12.1)

13–8–610 Page iii
TABLE OF CONTENTS
Maintain Compressor Reliability and Performance With Genuine Gardner DenverCompressor
Parts and Support Services i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index iv – vi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1, General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2, Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3, Starting & Operating Procedures 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4, Controls & Instrumentation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6, Air Filter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7, Belt Drive 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8, Maintenance Schedule 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9, Trouble Shooting 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER(see nameplateonunit). The SerialNumber
isalso stampedon topof thecylinder flangeto theright
of the inlet housing.
All orders for Parts should be placed with the nearest
authorized distributor.
Where NOT specified, quantity of parts required per
compressor or unit is one (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.
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 indi-
cated in parenthesis following the part name, i.e. (RH)
& (LH).

13–8–610 Page iv
INDEX
Addition of Oil Between Changes 28. . . . . . . . . . . . . . .
Air Control Components 18. . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Pressure/Check Valve 18. . . . . . . . . . . .
Air Cooled Unit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Ends, Remanufactured i. . . . . . . . . . . . . . . . . . . . . .
AIR FILTER, SECTION 6 35. . . . . . . . . . . . . . . . . . . . . .
Air Filter, Standard Duty 36. . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element Life 35, 36. . . . . . . . . . . . . . . . . . . . .
Air Flow in Compressor System 1. . . . . . . . . . . . . . . . .
Air Receiver, Auxiliary 11. . . . . . . . . . . . . . . . . . . . . . . . .
AUTO LAG Button with LED 19. . . . . . . . . . . . . . . . . . .
AUTO LEAD Button with LED 19. . . . . . . . . . . . . . . . . .
Auto–Sentry S Controller with Keypad 18. . . . . . . . . .
Auxiliary Air Receiver 11. . . . . . . . . . . . . . . . . . . . . . . . .
BELT DRIVE, SECTION 7 37. . . . . . . . . . . . . . . . . . . . .
Belt Tension, Checking 37. . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 17, 18. . . . . . . . . . . . . . . . . . . . . . . . .
Change Air Filter LED 19. . . . . . . . . . . . . . . . . . . . . . . . .
Change Procedure, Lubricant 28. . . . . . . . . . . . . . . . . .
Change Separator LED 19. . . . . . . . . . . . . . . . . . . . . . .
Check, Daily 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Belt Tension 37. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Draining Oil System 30. . . . . . . . . . . . . .
Cold Ambient Operation 28. . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Operation 10. . . . . . . . . . . . . . . . . . . . . .
Cold Weather Operation, Installation for 10. . . . . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Cooler 32. . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Filter 31. . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Separator 32. . . . . . . . . . . . . . . . . . . . .
Compressor Oil System 27. . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil System Check 33. . . . . . . . . . . . . . . . .
Compressor System, Air Flow 1. . . . . . . . . . . . . . . . . . .
CONSTANT RUN Button with LED 19. . . . . . . . . . . . .
Control Piping 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control System Operation 18. . . . . . . . . . . . . . . . . . . . .
AUTO LAG Button with LED 19. . . . . . . . . . . . . . .
AUTO LEAD Button with LED 19. . . . . . . . . . . . . .
Change Air Filter LED 19. . . . . . . . . . . . . . . . . . . . .
Change Separator LED 19. . . . . . . . . . . . . . . . . . . .
CONSTANT RUN Button with LED 19. . . . . . . . . .
High Air Temperature LED 19. . . . . . . . . . . . . . . . .
Motor Overload LED 19. . . . . . . . . . . . . . . . . . . . . .
Pressure and Temperature Digital Readouts 20.
STOP/RESET Button with LED 18. . . . . . . . . . . . .
Controller, Auto–Sentry S with Keypad 18. . . . . . . . . .
CONTROLS & INSTRUMENTS, SECTION 4 16. . . .
Controls & Instruments, General 16. . . . . . . . . . . . . . .
Cooler, Compressor Oil 32. . . . . . . . . . . . . . . . . . . . . . .
Cooling, Sealing and Lubrication 1. . . . . . . . . . . . . . . .
Daily Check 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 7, 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions of Error Messages 20. . . . . . . . . . . . . . . . . .
Devices, Motor Protection 16. . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 12. . . . . . . . . . . . . . . . . . . . . . .
Discharge Temperature, High 16. . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning Oil System 30. . . . . . . . . . . . . .
Electrical Wiring 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Motor Grease Recommendations 13. . . . . . .
Electric Motor Regreasing Interval 13. . . . . . . . . . . . . .
Element, Air Filter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Air Filter 35, 36. . . . . . . . . . . . . . . . . . . .
Emergency Stop Pushbutton 18. . . . . . . . . . . . . . . . . . .
Enclosure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Compressor Oil 31. . . . . . . . . . . . . . . . . . . . . . . . .
Foundation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Oil Level 18, 30. . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . . . . .

13–8–610 Page v
INDEX
Grease Recommendations, Electric Motor 13. . . . . . .
Grounding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Air Temperature LED 19. . . . . . . . . . . . . . . . . . . . .
High Discharge Temperature 16. . . . . . . . . . . . . . . . . . .
High Temperature Operation 28. . . . . . . . . . . . . . . . . . .
Hourmeter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Line 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Line Lengths 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Tube 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION, SECTION 2 9. . . . . . . . . . . . . . . . . . .
Installation, General 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation for Cold Weather Operation 10. . . . . . . . .
Instructions for Ordering Repair Parts iii. . . . . . . . . . . .
Instruments 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lead–Lag Operation of Two Compressors 22. . . . . . .
Lifting Unit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 12. . . . . . . . . . . . . . . . . . . . . . .
Line, Inlet 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load–Unload Pressure Setpoints, Programming 20.
Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant, Recommended 27. . . . . . . . . . . . . . . . . . . . .
Lubricant Change Procedure 28. . . . . . . . . . . . . . . . . .
Lubrication, Motor 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication, Cooling and Sealing 1. . . . . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 27. . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE, SECTION 8 38. . . . . .
Minimum Pressure/Check Valve 18. . . . . . . . . . . . . . . .
Moisture in the Oil System 30. . . . . . . . . . . . . . . . . . . . .
Moisture Separator/Trap 11. . . . . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 13. . . . . . . . . . . . . .
Motor Lubrication 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Overload LED 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Protection Devices 16. . . . . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 13. . . . . . . . . . . . . . . . . . . . .
Oil Change Interval 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Compressor 32. . . . . . . . . . . . . . . . . . . . . . .
Oil Filter, Compressor 31. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Gauge 18, 30. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator, Compressor 32. . . . . . . . . . . . . . . . . . . .
Inspection 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal for Inspection or Replacement 33. . . . .
Oil Specifications 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System, Compressor 27. . . . . . . . . . . . . . . . . . . . . .
Oil System, Draining and Cleaning 30. . . . . . . . . . . . .
Oil System Check 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air and Oil Discharge Temperature 33. . . . . . . . . .
Compressor Oil Inlet Temperature 33. . . . . . . . . .
Oil Cooler Oil Pressure Differential 34. . . . . . . . . .
Oil Cooler Temperature Differential 34. . . . . . . . . .
Oil Inlet Pressure 34. . . . . . . . . . . . . . . . . . . . . . . . .
Operation
Cold Ambient 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control System 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 28. . . . . . . . . . . . . . . . . . . . . . . .
Lead–Lag, of Two Compressors 22. . . . . . . . . . . .
Piping, Control 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure and Temperature Digital Readouts 20. . . . .
Pressure Differential Gauging 33. . . . . . . . . . . . . . . . . .
Prestart–Up Instructions 14. . . . . . . . . . . . . . . . . . . . . . .
Air Filter 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode 15. . . . . . . . . . . . . . . . . . . . . . . . . .
Piping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 15. . . . . . . . . . . . . . . . . . . . . . . . .

13–8–610 Page vi
INDEX
Programming Load–Unload Pressure Setpoints 20. .
Protective Devices
Blowdown Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . .
High Discharge Temperature 16. . . . . . . . . . . . . . .
Motor Protection Devices 16. . . . . . . . . . . . . . . . . .
Relief Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separator Differential Pressure 16. . . . . . . . . . . . .
Recommended Lubricant 27. . . . . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 13. . . . . . . . . . . . .
Relief Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Instructions for Ordering iii. . . . . . . . . . .
Reservoir, Oil 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions 5, 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing, Lubrication and Cleaning 1. . . . . . . . . . . . . . .
Separator, Compressor Oil 32. . . . . . . . . . . . . . . . . . . .
Separator Differential Pressure 16. . . . . . . . . . . . . . . . .
Separator/Trap, Moisture 11. . . . . . . . . . . . . . . . . . . . . .
SERVICE CHECK LIST, AIR FILTER 38. . . . . . . . . . .
Service Check List 38. . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 1000 Hours Operation 38. . . . . . . . . . . . . . .
Every 125 Hours Operation 38. . . . . . . . . . . . . . . .
Every 6000 Hours Operation 38. . . . . . . . . . . . . . .
Every 8 Hours Operation 38. . . . . . . . . . . . . . . . . .
Every Year 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 38. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications, Oil 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter/Control Box 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto–Sentry S Controller with Keypad 18. . . . . . .
Emergency Stop Pushbutton 18. . . . . . . . . . . . . . .
Hourmeter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES,
SECTION 3 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOP/RESET Button with LED 18. . . . . . . . . . . . . . . .
Stopping the Unit 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature, High Discharge 16. . . . . . . . . . . . . . . . . .
Thermal Control (Thermostatic Mixing) Valve 32. . . .
TROUBLE SHOOTING, SECTION 9 39. . . . . . . . . . . .
Valve
Blowdown 17, 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Control 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Pressure/Check 18. . . . . . . . . . . . . . . . .
Relief 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal Control (Thermostatic Mixing) 32. . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring, Electrical 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–8–610 Page vii
LIST OF ILLUSTRATIONS
Figure 1–1 Compressor Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 Minimum Pressure/Check Valve, Separators & Oil Filter – Package 2. . . . . . . . . . . . . . . . . . . . . . .
Figure 1–3 Oil Level Gauge, Separator & Air Filter – Package 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–4 Controller & Starter Box – Package 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–1 Typical Compressor Room 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Air Flow Chart 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–3 Cold Weather Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–4 Inlet Line Lengths 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–1 Control Schematic 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Inlet Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Minimum Pressure/Check Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Definition of Error Messages 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Pressure Chart 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Subtractive Pilot (Closed) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Subtractive Pilot (Opened) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–8 Maximum Setpoints for Auto–Sentry S Controller, PSIG 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–9 Auto–Sentry S Solid State Control Touch Pad 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–10 Wiring Diagram – Dual Control 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–11 Wiring Diagram – Wye Delta 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Flow Diagram – Air–Oil System 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Approximate Oil System Capacities 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Oil Change Interval 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–4 Oil Level Gauge 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–5 Thermostatic Mixing Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–6 Oil Separator 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy Duty Air Filter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–2 Standard Duty Air Filter, Domestic Only 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Belt Tension 3VX Belts 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–8–610 Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSOR CYCLE
COMPRESSOR – The Gardner DenverRcompres-
sor is a single stage, positive displacement rotary ma-
chine using meshing helical rotors to effect compres-
sion. Both rotors are supported between high capacity
roller bearings located outside the compression cham-
ber. Single width cylindrical roller bearings are used at
the inlet end of the rotors to carry part of the radial
loads. Tapered roller bearings at the discharge end lo-
cateeachrotoraxially andcarryallthrust loadsandthe
remainder of the radial loads.
COMPRESSION PRINCIPLE (FIGURE 1–1) – Com-
pression is accomplished by the main and secondary
rotors synchronously meshing in a one–piece cylinder.
Themain rotorhas four (4)helical lobes90_apart.The
secondary rotor has six (6) matching helical grooves
60_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
.Thecompression cycle begins as
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-
ductionandpressureincreasecontinuesuntiltheair/oil
mixture trapped in the interlobe cavity by the rotors
passesthedischargeportandisreleasedtotheoilres-
ervoir(C). Each rotor cavityfollowsthe 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 5–1, page 27) – Air enters the air filter and
passesthrough the inlet unloader valve andon into the
compression chamber where oil is injected into the air.
Aftercompression,theair/oilmixturepassesintotheoil
reservoirwhere mostof the entrainedoil is removedby
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-
coolerand the moisture separator and intothe plant air
lines.
LUBRICATION, COOLING AND SEALING – Oil is
forcedbyair pressurefromthe oilreservoir throughthe
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.

13–8–610 Page 2
200EDE797
(Ref. Drawing)
FIGURE 1–2 – PACKAGE – MINIMUM PRESSURE/CHECK VALVE, MIXING VALVE & OIL FILTER