Gardner Denver INTEGRA EFA99F Service manual

GARDNER DENVER®13-8-639
Version: 00
June 8, 2004
INTEGRA
BASE-MOUNTED
COMPRESSORS
MODELS
EFA99F
5, 7-1/2 & 10 HP
OPERATING AND
SERVICE MANUAL

13-8-639 Page 2
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 is incorporated in our genuine
replacement parts.
Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. A worldwide network of authorized
distributors provides the finest product support in the air compressor industry. Your local authorized distributor maintains a large
inventory of genuine parts and he is backed up for emergency parts by direct access to the Master Distribution Center (MDC) in
Memphis, Tennessee.
Your authorized distributor can support your Gardner Denver air compressor with these services:
1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured airends are maintained
in stock at the 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.
4. Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.
Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They are ready to
respond and assist you by providing fast, expert maintenance and repair services.
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
Master Distribution Center
5585 East Shelby Drive
Memphis, TN 38141
Gardner Denver
1800 Gardner Expressway
Quincy, IL 62301
Phone: [phone]
[phone]
Phone: [phone]
Fax: [phone] Fax: [phone]
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, inspected and analyzed. Only those parts that can be brought back to original
factory specifications are remanufactured. Every remanufactured airend receives a new overhaul 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 measurement machine inspects to +/- .0001”, insuring that
all remanufactured airends meet factory performance specifications.
Warranty
Gardner Denver backs up every remanufactured airend with a new warranty…18 months from purchase, 12 months from service.
Gardner Denver remanufactured airends deliver quality without question…year in and year out.
Call Gardner Denver for information on the airend exchange program and the name of your authorized distributor.
Phone Number: 800-245-4946 or
Fax: [phone]

13-8-639 Page 3
FOREWORD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled
manufacturing. To be assured of receiving maximum service from this machine the owner must exercise
care in its operation and maintenance. This book is written to give the operator and maintenance
department essential information for day-to-day operation, maintenance and adjustment. Careful
adherence to these instructions will result in economical operation and minimum downtime.
DANGER
Danger is used to indicate the presence of a hazard which will cause severe
personal injury, death, or substantial property damage if the warning is ignored.
WARNING
Warning is used to indicate the presence of a hazard which can cause severe
personal injury, death, or substantial property damage if the warning is ignored.
CAUTION
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
Notice is used to notify people of installation, operation or maintenance
information which is important but not hazard-related.
This book covers the following models:
HP PSI Parts List
5, 7-1/2 & 10 100, 125, 150, 175 13-8-532
NOTE: 175 psig only available on 7-1/2 & 10 HP.

13-8-639 Page 4
TABLE OF CONTENTS
Maintain Compressor Reliability And Performance With Genuine
Gardner Denver Compressor Parts And Support Services ..................................................................... 2
Remanufactured Airends .............................................................................................................................. 2
Foreword ....................................................................................................................................................... 3
Index.............................................................................................................................................................. 5
List Of Illustrations......................................................................................................................................... 7
Section 1, General Information ..................................................................................................................... 8
Section 2, Installation .................................................................................................................................. 14
Section 3, Starting & Operating Procedures ............................................................................................... 22
Section 4, Controls & Instrumentation ........................................................................................................ 25
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator............................................................................ 45
Section 6, Air Filter...................................................................................................................................... 57
Section 7, Belt Drive.................................................................................................................................... 58
Section 8, Maintenance Schedule .............................................................................................................. 63
Section 9, Troubleshooting ......................................................................................................................... 65

13-8-639 Page 5
INDEX
Air Cooled Unit .................................................16
Air Filter
Element ........................................................57
Element Life..................................................57
Section 6.......................................................57
Standard Duty...............................................57
Air Flow In Compressor System ........................8
Air Receiver
Auxiliary ........................................................18
Air/Oil Separator...............................................54
Inspection .....................................................55
Pressure Differential Gauging ......................55
Removal Of Oil Separator ............................55
Airpilot Electronic Control Operation................27
Emergency Stop Of The Compressor
Package ....................................................27
Starting The Compressor Package ..............27
Stopping The Compressor Package ............27
Airpilot Electronic Controller
Automatic Start/Stop.....................................26
Compressor Running Fully Loaded..............26
Compressor Running Unloaded ...................26
Control System Operation ............................26
Belt Drive
Replacing Sheave And Shaft Seal ...............61
Replacing The Belts .....................................59
Replacing The Motor Sheave.......................59
Section 7.......................................................58
Cold Weather Operation, Installation For.........17
Compression Principle .......................................8
Compressor........................................................8
Control Devices................................................34
Controls & Instrumentation
Airpilot Electronic Control Operation ............27
Airpilot Electronic Controller .........................25
Control Devices ............................................34
Instrument Panel ..........................................28
Programming & Setup Instructions For Airpilot
Electronic Controller..................................29
Section 4.......................................................25
Starter/Control Box .......................................26
Cooling, Sealing And Lubrication.......................8
Daily Check ......................................................24
Decals ..............................................................12
Discharge Service Line ....................................18
Electric Motor
Grease Recommendations...........................20
Regreasing Interval ......................................21
Electrical Wiring ...............................................19
Emergency Stop...............................................24
Enclosure .........................................................16
Foundation ....................................................... 16
General Information
Section 1 ........................................................ 8
Grounding ........................................................ 19
Inlet Line .......................................................... 18
Installation
Section 2 ...................................................... 14
Instrument Panel.............................................. 28
Lifting Unit ........................................................ 14
Lubricant
Recommended ............................................. 45
Upgrade Procedure...................................... 49
Lubrication
Motor ............................................................ 20
Lubrication, Cooling And Sealing....................... 8
Lubrication, Oil Cooler, Oil Filter & Separator
Section 5 ...................................................... 45
Maintenance Schedule
Section 8 ...................................................... 63
Moisture Separator/Trap.................................. 18
Motor Lubrication ............................................. 20
Multipilot Menu................................................. 32
Oil Cooler
Compressor.................................................. 54
Oil Level
Gauge........................................................... 50
Oil Reservoir .................................................... 54
Drain............................................................. 16
Filling ............................................................ 48
Oil System
Addition Of Oil Between Changes ...............46
Air/Oil Separator........................................... 54
Cold Ambient Operation............................... 46
Compressor.................................................. 45
Draining And Cleaning ................................. 48
Filling Oil Reservoir ...................................... 48
High Temperature Operation ....................... 46
Lubricant Upgrade Procedure ...................... 49
Mopisture In The Oil System........................ 51
Oil Change Interval ...................................... 47
Oil Cooler ..................................................... 54
Oil Filter ........................................................ 53
Oil Level Gauge ........................................... 50
Oil Reservoir................................................. 54
Oil Specifications.......................................... 45
Procedure For Checking Oil Level ............... 46
Recommended Lubricant ............................. 45
Thermal Control Valve ................................. 54
Oil System Check ............................................56
Air And Oil Discharge Temperature ............. 56
Compressor Oil Inlet Temperature............... 56

13-8-639 Page 6
Oil Cooler Oil Pressure Differential ..............56
Oil Cooler Temperature Differential..............56
Oil Inlet Pressure ..........................................56
Operating Principles...........................................9
Piping
Control ..........................................................18
Prestart-Up Instructions ...................................22
Air Filter ........................................................22
Compressor Oil.............................................22
Electrical .......................................................22
Enclosure......................................................23
Grounding.....................................................22
Operating Mode............................................23
Piping............................................................22
Rotation ........................................................22
System Pressure ..........................................23
Programming & Setup Instructions For Airpilot
Electronic Controller
Multipilot Menu .............................................32
Remote Control Operation ...........................33
Service Menu................................................32
User Menu ....................................................30
Programming And Setup Instructions For The
Airpilot Electronic Controller .........................29
Remote Control Operation ...............................33
Safety Precautions .....................................10, 11
Sealing, Lubrication And Cooling.......................8
Separators
Air/Oil............................................................ 54
Service Check List ........................................... 63
Air Filter ........................................................ 63
Every 1000 Hours Operation........................ 63
Every 125 Hours Operation.......................... 63
Every 1500 Hours Operation........................ 63
Every 4000 Hours Operation........................ 63
Every 8 Hours Operation.............................. 63
Every Year.................................................... 63
Motor Lubrication ......................................... 63
Service Menu ................................................... 32
Starting & Operating Procedures
Section 3 ...................................................... 22
Starting The Unit .............................................. 24
Stopping The Unit ............................................ 24
Trouble Shooting
Section 9 ...................................................... 65
Troubleshooting Voltage Problems.................. 69
User Menu ....................................................... 30
Valve
Relief ............................................................ 34
Thermal Control (Thermostatic Mixing)........ 54
Wiring
Electrical....................................................... 19
Wiring Diagrams – 1 Phase ............................. 42
Wiring Diagrams – 3 Phase ............................. 39

13-8-639 Page 7
LIST OF ILLUSTRATIONS
Figure 1-1 – Compressor Cycle .................................................................................................................... 8
Figure 1-2 – Compressor Package Components ......................................................................................... 9
Figure 2-1- Preferred Lifting Method........................................................................................................... 14
Figure 2-2 – Outline, Unit Package............................................................................................................. 15
Figure 2-3 – Air Flow Chart......................................................................................................................... 16
Figure 2-4 – Cold Weather Installation ....................................................................................................... 17
Figure 4-1 – Control Schematic .................................................................................................................. 25
Figure 4-2 – Starter/Control Box And Instrument Panel ............................................................................. 28
Figure 4-3 – Airpilot Electronic Controller ................................................................................................... 29
Figure 4-4 – Compressor Running Loaded................................................................................................. 37
Figure 5-1 – Flow Diagram.......................................................................................................................... 45
Figure 5-2 – Approximate Oil System Capacities ....................................................................................... 47
Figure 5-3 – Oil Change Interval................................................................................................................. 47
Figure 5-4 – Oil Level Gauge, Oil Fill And Oil Drain ................................................................................... 51
Figure 5-5 – Dew Point Chart °F................................................................................................................. 52
Figure 5-6 – Dew Point Chart °C ................................................................................................................ 52
Figure 5-7 – Oil Filter .................................................................................................................................. 54
Figure 6-1 – Air Filter .................................................................................................................................. 57
Figure 7-1 – Belt Drive Tensioner ............................................................................................................... 58
Figure 7-2 – Removing The Motor Sheave................................................................................................. 59
Figure 7-3 – Installing Bushing In Drive Sheave......................................................................................... 60
Figure 7-4 – Installing Drive Sheave On Compressor Or Motor ................................................................. 60
Figure 7-5 – Drive Sheave .......................................................................................................................... 61

13-8-639 Page 8
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 remainder of the radial loads.
COMPRESSION PRINCIPLE (Figure 1-1) - Compression is accomplished by the main and secondary
rotors synchronously meshing in a one-piece cylinder. The main rotor has five (5) helical lobes 72°apart.
The secondary rotor has six (6) matching helical grooves 60°apart to allow meshing with main rotor
lobes.
The air inlet port is located on top of the compressor cylinder near the drive shaft end. The discharge port
is near the bottom at the opposite end of the compressor cylinder. Figure 1-1 is an inverted view to show
inlet and discharge ports. The compression cycle begins as the rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and the secondary rotor grooves (A). When the rotors
pass the inlet port cutoff, air is trapped in the interlobe cavity and flows axially with the meshing rotors (B).
As meshing continues, more of the main rotor lobe enters the secondary rotor groove, normal volume is
reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of compression and seal internal clearances. Volume
reduction and pressure increase continues until the air/oil mixture trapped in the interlobe cavity by the
rotors passes the discharge port and is released to the oil reservoir (C). Each rotor cavity follows the
same “fill-compress-discharge” cycle in rapid succession to produce a discharge air flow that is
continuous, smooth and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 5-1, page 45) - Air enters the air filter and passes
through the inlet unloader valve and into the compression chamber where oil is injected into the air. After
compression, the air/oil mixture passes into the oil reservoir where most of the entrained oil is removed by
velocity change and impingement and drops back into the reservoir. The air and remaining oil then
passes through the air/oil separator. The air then passes through the minimum pressure/check valve, the
aftercooler and the moisture separator and into the plant air lines.
LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through
the oil cooler, thermostatic mixing valve, and oil filter into the compressor main oil gallery. A portion of the
oil is directed through internal passages to the bearings and input 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.

13-8-639 Page 9
OPERATING PRINCIPLES
MAIN COMPONENTS
The Gardner Denver screw compressor is a single stage screw compressor with oil cooler. The
pressurized air is produced with a screw compressor unit driven by an electric motor. Oil is separated
from the compressed air in an oil separation receiver. The pressurized air and the oil are cooled with
separate coolers.
No. Component Purpose
1 Motor Airend drive
2 Belts Power transmission
3 Airend Air compression
4 Inlet Valve Output control
5 Inlet Filter Filtering inlet air
6 Oil Separator Oil separation
7 Minimum Pressure/Check Valve Check valve; maintaining minimum pressure for oil flow to bearings
8 Pressure Relief Valve Protection against too high pressures
9 Oil Cooler Cooling of oil
10 Aftercooler Cooling of compressed air
11 Fan Cooling
12 Oil Filter Oil filtering
13 Instrument Panel Compressor operation and control
14 Moisture Separator Separation of water from compressed air
15 Control Valves Output control;
16 Main Switch Power supply
17 Thermal Mixing Valve Maintains minimum temperature of oil
Figure 1-2 – COMPRESSOR PACKAGE COMPONENTS

13-8-639 Page 10
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:
DANGER
Failure to observe these notices could result in injury to or death of personnel.
•Keep fingers and clothing away from revolving fan, drive coupling, etc.
•Do not use the air discharge from this unit for breathing – not suitable for
human consumption.
•Do not loosen or remove the oil filler plug, drain plugs, covers, the
thermostatic mixing valve or break any connections, etc., in the compressor
air or oil system until the unit is shut down and the air pressure has been
relieved.
•Electric shock can and may be fatal.
•Perform all wiring in accordance with the National Electrical Code (NFPA-70)
and any applicable local electrical codes. Wiring and electrical service must
be performed only by qualified electricians.
•Open the main disconnect switch, lockout and tagout before working on the
control.
•Disconnect the compressor unit from its power source, lockout and tagout
before working on the unit – this machine is automatically controlled and
may start at any time.

13-8-639 Page 11
SAFETY PRECAUTIONS
WARNING
Failure to observe these notices could result in damage to equipment.
•Stop the unit if any repairs or adjustments on or around the compressor are
required
•Disconnect the compressor unit from its power source, lockout and tagout
before working on the unit – this machine is automatically controlled and
may start at any time.
•An Excess Flow Valve should be on all compressed air supply hoses
exceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302, or
local regulations)
•Do not exceed the rated maximum pressure values shown on the nameplate.
•Do not operate unit if safety devices are not operating properly. Check
periodically. Never bypass safety devices.

13-8-639 Page 12
DECALS
El aire de descarga utilizado para respirar ocasionará
lesiones personales graves o la muerte. Consulte un
especialista en filtraciones a modo de informarse sobre
equipo de tratamiento y filtración adicional para cumplir
con las regulaciones de salud y seguridad.
Discharge air used for breathing will cause severe injury
or death. Consult filtration specialist for additional
filtration and treatment equipment to meet health and
safety regulations.
L’air provenant de la purge n’est pas respirable et
entraînera des blessures graves ou la mort. Consulter un
spécialiste en filtration pour obtenir de l’équipement de
filtration et de traitement supplémentaire conforme aux
normes de santé et sécurité au travail.
305EFC077
DANGER
PELIGRO
DANGER WARNING
306EFC077
ADVERTENCIA
Unit can automatically restart and cause personal injury or
death.
Know mode of operation before working on or near the
machine.
La unidad puede arrancar automáticamente y ocasionar
lesiones personales o la muerte.
Familiarícese con el modo de operación antes de trabajar
en o cerca de la máquina.
L’appareil peut redémarrer automatiquement et entraîner
des blessures ou la mort.
Connaître le mode de fonctionnement avant de travailler
sur ou d’être à proximité de la machine.
AVERTISSEMENT
307EFC077
Rotating machinery can cause personal injury or death.
Keep all guards and safety devices in place.
Les machines tournantes peuvent entraîner des blessures
ou la mort. Garder en place toutes les protections et tous
les appareils de sécurité.
Las maquinarias rotatorias pueden ocasionar lesiones
personales o la muerte. Mantenga todas las guardas
de protección y dispositivos de seguridad en su lugar.
WARNING
ADVERTENCIA
AVERTISSEMENT
L’air et l’huile sous pression entraîneront des blessures
graves ou la mort. Arrêter le compresseur, verrouiller et
étiqueter l’alimentation, et purger toute la pression du
système avant de déposer les soupapes, les capuchons,
les prises, les raccords, les boulons et les
filtres.
El aire y el aceite bajo presión pueden ocasionar lesiones
personales graves o la muerte. Apague el compresor,
bloquee y rotule la fuente de alimentación eléctrica, y
alivie el sistema de toda presión antes de extraer válvulas,
sombreretes, tapones, accesorios, pernos y filtros.
Air and oil under pressure will cause severe personal injury
or death. Stop compressor, lockout and tagout power
supply, and relieve system of all pressure before removing
valves, caps, plugs, fittings, bolts and filters.
DANGER
PELIGRO
DANGER
308EFC077
DANGER
Alto voltaje, maquinaria rotatoria, aire y aceite bajo
presión. La modificación inadecuada del equipo puede
ocasionar lesiones personales graves o la muerte.
No modifique la unidad sin el consentimiento por escrito
del fabricante.
High voltage, rotating machinery, air and oil under pressure.
Improper modification of equipment will cause severe
personal injury or death.
Do not modify unit without written permission from
manufacturer.
DANGER
PELIGRO
Haute tension, machines tournantes, air et huile sous
pression. Une modification incorrecte de l’équipement
entraînera des blessures graves ou la mort.
Ne pas modifier l’appareil sans une autorisation écrite du
fabricant.
309EFC077
AVERTISSEMENT
Read operator manual before starting unit.
Failure to adhere to instructions can result in severe
personal injury or death.
Lea el manual del operador antes de poner en marcha esta
unidad. El no observar las instrucciones podría ocasionar
lesiones personales graves o la muerte.
Lire le manuel de l’utilisateur avant de démarrer cet
appareil, négliger de suivre les instructions peut entraîner
des blessures graves ou la mort.
WARNING
ADVERTENCIA

13-8-639 Page 13
DECALS
Haute tension. Un choc électrique peut entraîner des blessures ou la
mort. Ouvrir le sectionneur principal et débrancher tous les circuits avant
de travailler sur cette commande. Voir le schéma de cáblage. Une
modification incorrecte de l’équipement entraînera des blessures graves
ou la mort. Ne pas modifier l’appareil sans une autorisation écrite du
fabricant.
Un choc électrique résultant d’une mise á la terre incorrecte peut entraíner
des blessures ou la mort. Mettre á la terre l’appareil et les équipements
qui lui sont reliés en respectant les réglements du code national de
l’électricité et les réglements locaux.
Un arc électrique peut produire un incendie si l’appareil est monté
sur une surface combustible et entraîner ainsi des blessures ou
endommager la propriété. L’appareil doit être monté sur une
plaque de plancher étendue sur tous les côtés. Consulter
l’illustration d’installation pour connaître les dimensions correctes.
Lire le manuel d’instructions avant de démarrer l’appareil.
Négliger de suivre les instructions peut entraîner des blessures
graves ou la mort.
Lea el manual del operador antes de poner en marcha esta
unidad. El no observar las instrucciones podría ocasionar
lesiones personales graves o la muerte.
Cuando la unidad se monta sobre una superficie combustible, la
formación de arco eléctrica puede provocar un incendio y
ocasionar lesiones personales o daño a la propiedad. La unidad
debe montarse en una placa de apoyo extendida en todos los
extremos. Vel el diagrama de instalación para informarse sobre
las dimensiones correctas.
Las descargas eléctricas producidas por una puesta a tierra inadecuada
pueden ocasionar lesiones o la muerte. Ponga a tierra la unidad y
equipo relacionado de acuerdo con el código eléctrico nacional y las
regulaciones locales.
Alto voltaje. Las descargas eléctricas pueden ocasionar lesiones o la
muerte. Abra el interruptor de desconexión y desconecte todas los
circuitos antes de trabajar en este control. Vea el diagrama de cableado.
La modificación inadecuada del equipo puede ocasionar lesiones
personales graves o la muerte. No modifique la unidad sin el
consentimiento por escrito del fabricante.
DANGER
311EFC077
PELIGRO
Read operator manual before starting unit. Failure to adhere to
instructions can result in severe personal injury of death.
Electrical shock from improper grounding can cause injury or
death. Ground unit and related equipment according to national
electric code and local regulations.
Electrical arcing can cause a fire when unit is mounted on a
combustible surface resulting in personal injury or property
damage. Unit must be mounted on a floor plate extended on
all sides see installation drawing for proper dimensions.
High voltage. Electrical shock can cause personal injury or death.
Open main disconnect switch and disconnect all circuits before
working on this control. See wiring diagram.
Improper modification of equipment will cause severe personal
injury or death. Do not modify unit without written permission from
manufacturer.
DANGER
Las descargas eléctricas pueden ocasionar lesiones o la
muerte. Desconecte todos los circuitos antes de trabajar
en este control. Vea el diagrama de cableado.
Un choc électrique peut entraîner des blessures ou la mort.
Débrancher tous les circuits avant de travailler sur cette
commande. Voir le schéma de câblage.
AVERTISSEMENT
ADVERTENCIA
Electrical shock can cause injury or death. Disconnect all
circuits before working on control. See wiring diagram.
WARNING
ADVERTENCIA
AVERTISSEMENT
La unidad puede arrancar automáticamente y ocasionar
lesiones personales o la muerte.
Familiarícese con el modo de operación antes de
trabajar en o cerca de la máquina.
L’appareil peut redémarrer automatiquement et entraîner
des blessures ou la mort.
Connaître le mode de fonctionnement avant de travailler
sur ou d’être à proximité de la machine. 310EFC077
Unit can automatically restart causing personal injury
or death.
Know mode of operation before working on or near the
machine.
WARNING
Modifier le réglage
CONTROLLER LEGEND
Display
Pressure indicator light
Load indicator light
(not on when machine
is running unloaded)
(Refer to instruction manual for detailed procedure before starting unit)
Scrolling
Stop
Temperature indicator light
Operating hours indicator light
Air/Oil separator indicator light
Air filter indicator light
Change oil indicator light
Reset
Oil filter indicator light
Motor indicator light
Power indicator light
Change setting
Change setting
Start
LEYENDA DEL CONTROLADOR
Pantalla
Luz indicadora de presión
Luz indicadora de carga
(no se enciende durante la
ejecución sin carga de la máquina)
(Antes de poner en marcha la unidad consulte el manual de
instrucciones para obtener información detallada sobre procedimiento)
Desplazamiento
Parada
Luz indicadora de temperatura
Luz indicadora de horas de operación
Luz indicadora
del separador de aire y aceite
Luz indicadora del filtro de aire
Luz indicadora de cambio de aceite
Restablecer
Luz indicadora del filtro de aceite
Luz indicadora del motor
Luz indicadora de alimentación
Cambiar ajuste
Cambiar ajuste
Arranque
Défilement
Arrêter
Modifier le réglage
Réinitialiser
302EFA077
Démarrer
Afficheur
LÉGENDE DU CONTRÔLEUR
Voyant de charge
(éteint lorsque la machine
fonctionne sans charge)
Voyant de pression
Voyant de température
Voyant des heures de fonctionnement
Voyant de changement d’huile
Voyant du filtre à air
Voyant du séparateur air / huile
Voyant du filtre à huile
Voyant du moteur
Voyant de l’alimentation
(Consulter le manuel d’instructions pour connaître les détails
des opérations avant de démarrer l’appareil)

13-8-639 Page14
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.
CAUTION
Do not electric weld on the compressor or base; bearings can be damaged by
passing of current.
LIFTING UNIT (Figure 2-1, page 14) - Proper lifting and/or transporting methods must be used to prevent
damage.
CAUTION
Lift compressor unit by base only. Do not use other places such as motor,
compressor or discharge manifold piping as lifting points.
DANGER
The eyebolts or lugs provided on the motor are for lifting the motor only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motor the lifting angle must not exceed 15 degrees.
Failure to observe this warning may result in damage to equipment or personal
injury.
Figure 2-1- PREFERRED LIFTING METHOD

13-8-639 Page 15
Figure 2-2 – OUTLINE, UNIT PACKAGE
300EFA804-
A
(Ref. Drawing)

13-8-639 Page 16
AIR-COOLED UNIT - A combination oil/aftercooler is supplied as standard equipment on all air-cooled
units. The air-cooled unit with the standard enclosure requires sufficient flow for the compressor
oil/aftercooling system and electric motor cooling (Figure 2-3 below). Air is drawn into the unit above the
motor and discharged through the cooler. Do not block the air flow to and from the unit. Allow three and
one half (3-1/2) feet to the nearest obstruction on the starter end and control box end of the unit. Allow
three (3) feet to the nearest obstruction above and on other sides of unit.
For continuous efficiency, oil cooler cores must be periodically cleaned with either vacuum or compressed
air. If wet cleaning is required, shield motor, spray on a mild soap solution and flush with clean water.
WARNING
For aluminum oil coolers, do not use any cleaning solution that is not
compatible with aluminum. Use of improper solution may result in damage to
the cooler.
Minimum Air Flow* For Compressor
And Cooling (Cubic Feet/Minute)
Air Cooled
All Models 1000 cfm
* 80°F Inlet Air
Figure 2-3 – AIR FLOW CHART
FOUNDATION - The rotary screw compressor requires no special foundation, but should be mounted on
a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be
made at a maximum 5°angle lengthwise or 5°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 moving vehicles may require the use of mounting bolts and shims to provide uniform support
for the base. Belt alignment and tension should be checked after installation. (For information on belt
alignment and tension, see Section 7, page 58.
OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir through a shutoff valve.
A plastic tube is connected to the shutoff valve for draining the oil.
CAUTION
If the compressor unit base is raised above floor level, the space between the
floor and the base bottom must be closed with solid material all around to
prevent recirculation of hot air from the oil cooler end and over temperature
operation.
ENCLOSURE - The compressor, electric motor, oil cooler and aftercooler are mounted inside the
enclosure.
Service panels are provided for maintenance access. Be sure to allow enough space around the unit for
the panels to be removed. Any of the enclosure panels may be removed by opening the top, removing
the screw on the lower left panel and lifting the enclosure panel up to disengage it from the base and the
other enclosure panel. The screw is removed by twisting it a half turn and pulling it out

13-8-639 Page 17
DANGER
Do not operate the compressor with the fan, belts or sheaves exposed.
Exposed fan, belts and sheaves may cause injury to personnel.
CAUTION
The enclosure doors are connected to a shutdown switch that will not allow the
compressor to operate without the complete enclosure in place.
Figure 2-4 – COLD WEATHER INSTALLATION
INSTALLATION FOR COLD WEATHER OPERATION (Figure 2-4) - It is recommended that the unit be
installed inside a shelter that will be heated to temperatures above freezing (32o F, 0o C). This will
eliminate many of the problems associated with operating units in cold climates, such as freezing in
control lines and downstream of the cooler.
Refer to Engineering Data Sheet 13-9-411 for the advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for an adequate shelter for the unit.
When an outside installation must be made, the precautions required will depend on the severity of the
environment. The following are general guidelines for outside installations:

13-8-639 Page 18
Cold Weather (Down To +10o F)
1. Be sure all drains, traps, and control lines, including pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermostat control is generally satisfactory for this purpose
and can be obtained at various local plumbing 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. Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow.
4. Use only Gardner Denver AEON 9000SP lubricant.
5. Monitor unit carefully during start-up and operation 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 - An auxiliary air receiver is not required if the piping system is large and
provides sufficient storage capacity to prevent rapid cycling. When used, an air receiver should be of
adequate size, provided with a relief valve of proper setting, a pressure gauge and a means of draining
condensate
STANDARD MOISTURE SEPARATOR/TRAP - The unit is equipped with a built-in aftercooler, a
combination moisture separator and trap piped into the system down stream of the aftercooler.
CONTROL PIPING - Control piping is not necessary since the rotary screw unit is factory wired and piped
for 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 entering 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 with a moisture and oil-proof sealing lacquer. Up
to ten (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 increased according to “Inlet Line Length Chart”,
page 18.
Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a
remote location.
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
DISCHARGE SERVICE LINE - The discharge service line connection is made on the side of the
package, (See Outline Drawing 300EFA804). A hand operated valve, (air service valve) must be installed
between the unit and the customer’s air system. If a fast operating valve, such as a ball valve is used, it
must be closed slowly to give the intake valve time to shut and keep the discharge pressure from rising
too rapidly.

13-8-639 Page 19
WARNING
The controller has an automatic start/stop sequence built in. You DO NOT need
to close the air service valve. Closing the air service valve on start-up or prior
to shutdown will cause rapid cycling, and could cause a high pressure
shutdown.
When piping two or more rotary screw units on the same line, each unit is isolated by the minimum
pressure/check valve mounted on each compressor package.
If a rotary screw unit is piped to another compressor, 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 piped together, an air receiver must be located
between the two units.
DANGER
Discharge air used for breathing will cause severe injury or death.
Consult filtration specialists for additional filtration and treatment equipment to
meet health and safety standards.
ELECTRICAL WIRING - All of the electrical connections and controls are factory wired for the voltage
specified on the order. Verify that the available voltage source matches that shown on the compressor
package nameplate before installing the compressor package. It is necessary only to connect the
package to the supply and ground of the branch circuit. The connections to the compressor package are
made with the electrical control box, accessible by opening the cover of the box.
Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable local
electrical codes. Wiring must be performed only by qualified electricians.
WARNING
Electrical shock can cause injury or death. Open main disconnect switch,
lockout and tagout before working on control box.
If the optional base mounted air receiver and/or dryer is on this package, 110 volt single phase power will
need to be supplied to the optional dryer and to the moisture drain on the air receiver.
GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical
Code.
.

13-8-639 Page 20
WARNING
Failure to properly ground the compressor package could result in injury or
death. Install ground wiring in accordance with the National Electrical Code
and any applicable local codes.
MOTOR LUBRICATION - 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.
The following procedure should be used in regreasing:
1. Stop the unit.
2. Disconnect, lockout and tagout 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
excess grease.
6. Stop the unit. Replace the relief plug.
7. Restart the unit.
WARNING
Rotating machinery can cause injury or death. Open main disconnect, lockout
and tagout power supply to starter before working on the electric motor.
ELECTRIC MOTOR GREASE RECOMMENDATIONS
Standard
Service
High
Temperature
(104°F, 40°C)
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°F............... 10 3
Rust Inhibiting ......................................................................... Yes Yes