Gardner Denver L Series Troubleshooting guide

13-25-640 v00 Page 1
L-SERIES FRAME 6
BASE MOUNTED COMPRESSOR
OriginalUserandServiceManual
MODELS:
L160-290C
215, 270, 335, 400 HP
LRS160-290C
160, 200, 250, 290 kW
13-25-640
Version 00
November 12, 2020

13-25-640 v00 Page 2
TABLE OF CONTENTS
1FOREWORD ...................................................................................................................... 4
1.1 About these Operating Instructions..............................................................................................4
1.2 Notes.............................................................................................................................................4
1.3 Intended Use.................................................................................................................................5
1.4 Foreseeable Misuse ......................................................................................................................6
1.5 Service...........................................................................................................................................7
1.6 Rating Plate ...................................................................................................................................7
2SAFETY REQUIREMENTS ................................................................................................... 8
2.1 General Safety Instructions ..........................................................................................................8
2.2 Warnings about Special Types of Hazard......................................................................................8
2.3 Protective and Safety Devices......................................................................................................9
2.4 Residual Risks..............................................................................................................................10
2.5 Labeling of Safety Instructions...................................................................................................10
2.6 Safety Symbols............................................................................................................................11
2.7 Transport and Installation ..........................................................................................................14
2.8 Normal Operation.......................................................................................................................14
2.9 Special Work................................................................................................................................15
2.10 Modifications and Changes to the Machine...............................................................................16
3DESIGN AND FUNCTION ................................................................................................. 16
3.1 General Description ....................................................................................................................16
3.2 Construction of the Compressor.................................................................................................17
3.3 System Schematic .......................................................................................................................21
3.4 Oil Circuit.....................................................................................................................................23
3.5 Air Circuit.....................................................................................................................................23
3.6 System Control............................................................................................................................23
3.7 Heat Recovery L160-L290 ...........................................................................................................25
4TRANSPORT AND INSTALLATION..................................................................................... 26
4.1 Transport.....................................................................................................................................26
4.2 Storage........................................................................................................................................28
4.3 Installation ..................................................................................................................................28
5PREPARING FOR COMMISSIONING................................................................................. 30
5.1 Piping...........................................................................................................................................30
5.2 Compressed Air Connection.......................................................................................................31
5.3 Cooling Water Connection..........................................................................................................32
5.4 Electrical Connection ..................................................................................................................35
5.5 Check the Setting of the Fan Overload Protection Switch(es). ......................................................37
5.6 Check the Oil Level......................................................................................................................37

13-25-640 v00 Page 3
6COMMISSIONING AND OPERATION................................................................................ 38
6.1 First Commissioning....................................................................................................................38
6.2 Check the Direction of Rotation of the Drive Motor ..................................................................39
6.3 Normal operation .......................................................................................................................40
6.4 Display of the Compressor Controller.........................................................................................40
6.5 Routine Commissioning ..............................................................................................................41
6.6 Commissioning after extended downtime .................................................................................42
6.7 Commissioning after a fault........................................................................................................42
7CLEARING A FAULT ......................................................................................................... 42
8MAINTENANCE AND SERVICE......................................................................................... 45
8.1 General Notes .............................................................................................................................45
8.2 Service.........................................................................................................................................47
8.3 Inspection of Protective and Safety Devices...............................................................................47
8.4 Routine Maintenance..................................................................................................................49
8.5 Maintenance Schedule ...............................................................................................................50
8.6 Maintenance Work.....................................................................................................................52
8.6.1 Filter Mats ..................................................................................................................................52
8.6.2 Switch Cabinet Inlet Filter ..........................................................................................................53
8.6.3 Oil Change ..................................................................................................................................54
8.6.4 Changing the Oil Filter Cartridge ..............................................................................................55
8.6.5 Oil Fine Separator ......................................................................................................................57
8.6.6 Air Filter ......................................................................................................................................59
8.6.7 Pressure Relief Valve .................................................................................................................60
8.6.8 Connecting Terminals in the Switch Cabinet ............................................................................62
8.6.9 Maintenance Instructions and Lubricant Recommendations for Fixed Compressors................62
9APPENDIX....................................................................................................................... 64
9.1 Decommissioning........................................................................................................................64
9.2 Consumables and Auxiliary Materials.........................................................................................64
9.3 Disassembly.................................................................................................................................65
9.4 Disposal.......................................................................................................................................66
9.5 Installation Plan ..........................................................................................................................67

13-25-640 v00 Page 4
1 FOREWORD
Gardner Denver screw compressors are the result of many years of research and development. This
background and a high-quality standard ensure that the screw compressors we manufacture have long
service lives with higher reliability and economic operation. Naturally, we also ensure that strict
environmental protection requirements are met.
1.1 About these Operating Instructions
These operating instructions are written for operating and maintenance personnel.
These operating instructions are part of the compressor and must be stored near the compressor such
that they are available at all the times.
These operating instructions contain all of the documentation required for safe operation and maintenance
of the compressor. These include:
Installing and connecting the compressor Commissioning andoperating the compressor
Replacing wear parts and consumable materials, such as filters and oil
Identifying faults and clearing system malfunctions
Performing regular visual inspections for damage
Cleaning, maintenance, and repair of the compressor
The dealer's or manufacturer's shop, with its qualified and experienced personnel, is responsible for all
repair work that exceeds typical maintenance and requires specialized technical knowledge.
All pressure values in these operating instructions are gage pressures (positive pressure).
Target groups
The target groups for these operating instructions are the operators, maintenance personnel, and
electrical technicians.
After training, the operator is permitted to start up and shut down the compressor and activate the
emergency-stop.
Maintenance personnel may, in conjunction with the information in these operating instructions,
maintain the compressor, repair it, start it up and shut it down and activate the emergency-stop.
Electricians may electrically install the compressor, carry out direction of rotation checks and carry out
electrical maintenance work.
Safety requirements
In addition to all the other information in these operating instructions, the general safety instructions in
the Chapter “Safety Requirements” must absolutely be read.
1.2 Notes
General notes
The operating instructions must be read and applied by any person assigned to work with and on the
compressor.
Regardless of these operating instructions, the laws, regulations, directives, and standards in force in
the installed location and the country of use must be followed.
Training
Operator training at site is performed by authorized service technicians. These operating instructions
serve as training documents, along with the repair instructions, which are provided only in conjunction
with service training.
These measures ensure that the assigned work can be completed reliably.

13-25-640 v00 Page 5
Guarantee
Gardner Denver is not liable for the functional safety of the compressor if any actions are taken that are
contrary to the intended use, or if used for any other purpose than those listed in the operating
instructions.
Gardner Denver refuses any guarantee or liability for cases of:
Operating errors.
Use of the compressor other than as intended.
Damages resulting from foreseeable misuse or failure to follow the operating instructions.
Damages or injuries caused by third party components.
Use of replacement or wear parts or consumable materials that are not provided or recommended by
Gardner Denver.
Inadequate maintenance. Modifications to the compressor.
The guarantee and liability conditions of the general terms and conditions of Gardner Denver are not
expanded by the notes above.
Warranty
Conditions and exclusions to the warranty by Gardner Denver are indicated in our general terms and
conditions, which were provided with the compressor. The document can also be sent again upon
request.
Copyright
These operating instructions are subject to copyright law and may be used solely for the agreed purpose,
that is, as a reference for internal purposes.
Propagation or reproduction of this document, or the sale and impartation of its contents, are prohibited
unless expressly allowed. Infringement is liable to compensation. All rights are reserved with respect to
registration of a patent, utility patent, or design patent.
Resale
If the compressor is resold, these operating instructions must be provided to the new operator along with
the compressor. If necessary, the operating instructions must be reordered from Gardner Denver by
providing the order confirmation number. The compressor may not be resold without these operating
instructions in any case.
1.3 Intended Use
The compressor uses the best available technology and meets applicable safety requirements at the time
of sale, in the context of correct usage.
The design cannot prevent foreseeable misuse, nor all other residual risks, without limiting the
functionality of correct usage.
The compressor is designed for the compression of atmospheric air (compressed air for driving
pressure equipment). The compressor is not suitable for the compression of other gases.
The compressor is considered to be used correctly if the following points are also covered:
The compressor is used in accordance with these operating instructions.
The operator’s work procedures and operating instructions are followed.
Any other use, or use exceeding these limits, is considered to be improper. The manufacturer is not
liable for any resulting damages. The user alone bears the entire risk.
Correct usage also includes following the operating instructions and complying with the inspection and
maintenance instructions.

13-25-640 v00 Page 6
Other provisions
The use of the compressor can cause hazards to life and limb of the user or third parties, or damage
to the compressor or other property, if the compressor:
Is not used properly.
Is operated by untrained personnel. Is modified or altered.
The safety instructions are not followed.
The following apply in addition to these operating instructions:
Applicable accident prevention regulations. Generally recognized safety rules.
Country-specific regulations.
Installation Site / Altitude
The compressor is intended to be installed in a suitable compressor room.
The compressor is not suitable for outdoor installation.
Depending on the operating pressure, ambient humidity, and ambient temperature at which the
compressor is operated, the permissible altitude of the installation site is limited. The permissible site
altitude is determined by Gardner Denver for each individual case in consultation with the customer.
Pressure equipment
A pressure safeguard (pressure relief or the like) that conforms to the applicable specifications must be
provided for the pressure equipment and systems installed in the compressed air supply network,
considering the weakest pressurized component.
Work environment
The lighting intensity in the area of the compressor must be ≥ 200 lx in normal operation.
The lighting intensity must be ≥ 500 lx for inspection and maintenance work.
The ambient temperature for operation: See “Technical data”.
1.4 Foreseeable Misuse
Incorrect usage and abuse
The following rationally foreseeable applications (incorrect usage) do not comply with the intended use:
Compressing gases other than atmospheric air.
Operation outside of the permissible operating limits, even if exceeded for only a short time, or if not
immediately detectable.
Operation outside of the permissible ambient temperatures.
Intake of non-atmospheric air (over pressure or under pressure).
Use as a respiratory air compressor. Manipulation of sensor signals.
Changing signals from sensors.
Operation without protective and safetydevices.
Operation with defective, deactivated, or manipulated protective and safety devices, or safety values,
or operation with other safety-related defects.
Use by private users or users without technical training.
Operation outside of industrial premises.
Failure to comply with maintenance intervals.
Failure to perform maintenance and repairs.
Incorrectly executed maintenance and repairs.
Limitations on use
Operation of the compressor is not permitted:
Outside of the permissible ambient temperatures.
Above the permissible elevation of the installation site.
On a foundation that does not have sufficient load capacity.
In areas with explosive atmosphere.

13-25-640 v00 Page 7
1.5 Service
In case of questions or problems with compressor, consult your Gardner Denver representative.
Trained technicians provide fast, technically accurate assistance.
For questions
In case of questions or spare parts orders, please provide the model, identification, and year built, as
indicated on the model rating plate. Providing these data ensures that you will receive the correct
information or spare parts.
Your Gardner Denver representative
Use the following table to record data about your local Gardner Denver representative.
Name:
Contact person:
Address:
Telephone
Fax
Email:
Table 1 Local Gardner Denver Representative
1.6 Rating Plate
Figure 1-1 Rating Plate

13-25-640 v00 Page 8
2 SAFETY REQUIREMENTS
Every person involved with the operation, maintenance, and repair of the compressor must read and
follow the safety requirements.
Gardner Denver accepts no responsibility for material damage or injuries that arise from non- observation
of safety conditions or the failure to observe normal levels of care and attention, even where this is not
expressly stated in these operating instructions.
2.1 General Safety Instructions
Organizational measures
The following organizational measures support the safe operation of the compressor:
Only assigned personnel may work on the compressor. Personnel are trained and instructed on the
compressor.
Personnel must have read the operating instructions and particularly the Chapter “Safety
Requirements”. During the assignment is too late. This applies in particular to personnel who are in
action only occasionally, such as for maintenance.
The responsibilities of personnel foroperation, maintenance, and repair must be clearly defined.
Personnelshouldbecheckedregularto ensuretheyareconsciousof safetyandhazardswhenworking.
Personnel in training, under instruction, being taught, or taking part in a general training program
may work with the compressor only under the continuous supervision of an authorized person.
For safety-related changes to the compressor or its operating behavior, the compressor must be
stopped immediately and the fault must be reported to the responsible area orperson.
Faults, especially those that can compromise safety, must be corrected immediately.
Otherwise the compressor must not be operated.
All hazard warning signs on and near the compressor must be checked regularly for completeness
and legibility. Missing hazard warning signs must be replaced immediately.
The time frames from tests and inspections must be adhered to.
The operating instructions must be updated to include instructions for supervisory or reporting
obligations in reaction to special operating conditions, such as with respect to work organization,
process flows, responsibilities, etc.
2.2 Warnings about Special Types of Hazard
Electricity
DANGER
Electric shock
Deadly electrical voltage
Exercise extreme caution when working with electrical equipment.
Before starting maintenance work, disconnect the compressor and lock it out to prevent
restarting.
For all work on the compressor’s electrical equipment, the 5 safety rules for working on electrical
systems must be followed.
The following instructions must also be followed:
Work on the electrical equipment of the compressor may be done only by an electrician in
accordance with electrical rules.
The electrical equipment of the compressor must be inspected regularly. Defects, such as loose
connections or scorched cables, must be corrected immediately.
Only original fuses with the specified current rating may be used.
Only for units with Variable Frequency Drives:
Due to residual voltage in the capacitors, the electrical enclosure must not be opened until at least 10
minutes after disconnecting (main disconnect switch OFF). Follow the hazard warning sign on the
electrical enclosure! See the “safety symbols” table.

13-25-640 v00 Page 9
Noise
The sound pressure level without the sound-proofing enclosure is approx. 95 dB(A). Remaining for
long periods alongside the compressor without its sound-proofing enclosure can result in irreversible
hearing impairment.
Only operate the compressor without the sound- proofing enclosure during test runs. Wear personal
hearing protection.
The sound pressure level with sound-dampening enclosure is about: (See "Technical data".)
During normal operation the compressor may only be operated with a closed acoustic hood.
Oil, Grease, and other chemical substances
Follow the applicable safety requirements when handling oils, greases, and other chemical
substances.
Use caution when handling hot materials, as there is a risk of burning or scalding.
DANGER
Explosion hazard
The compressor is not designed for operation in explosion hazard areas.
Operation of the compressor in explosion hazard areas is not permitted!
2.3 Protective and Safety Devices
The compressor is equipped with the following protective and safety equipment.
Prior to commissioning, particularly after maintenance and repair work, all protective and safety devices
must be installed and checked for proper function.
In addition, the inspection intervals required in the country of use must be complied with.
NOTICE
Operation ofthe compressor is permitted only with complete, functional protective and safety devices in
place.
Emergency Stop
The emergency stop button can be used tobring the compressor to a safe condition in dangerous
situations.
Emergency stop buttons are mounted:
On the control panel of the compressor.
Optional in a pedestal (control console).
Using the Emergency Stop
1. Press the <Emergency stop> pushbutton. The compressor is placed in a safe condition.
2. Rectify the fault that was the cause ofthe emergency-stop. See the "Troubleshooting" chapter.
3. Unlock <Emergency-Stop>button. Turn the pushbuttoncounter-clockwise.
4. Start up the compressor. See section "Commissioning after a fault" in the chapter "Commissioning and
operation".
Pressure Relief Valve / Check valve
Thecompressor isprotected fromexceedingthe permissible operating pressure by a pressure relief valve.
The pressure relief valve opens at 15 bar / 218psi.
Thecompressor is protected against backpressure from the compressed air network by means of a check
valve on the pressure side.

13-25-640 v00 Page 10
Protective covers and enclosure panels
The cooling air fans are covered with protective mesh.
The coupling between the drive and the compressor is protected by a mesh guard.
The housing of the compressor is designed so that any broken parts that may be thrown off are retained
within the compressor.
The compressor housing serves as a sound protection cover.
2.4 Residual Risks
Hot surfaces
Some parts of the compressor become hot in operation (up to 120°C / 248°F). A hazard warning sign
on the compressor enclosure warns of this danger.
Before beginning maintenance and repair work, the compressor must have cooled off sufficiently.
Personal protective equipment
We recommend wearing the following personal protective equipment:
Safety shoes
Safety glasses whenever working with compressed air and open enclosure
Hearing protection when the sound protection cover is open
2.5 Labeling of Safety Instructions
Safety instructions are used as special warning notices in the operating instructions, using the following names
and symbols.
These special warning notices serve to protect against hazards and are close to the potential hazard in space
and time:
On the system, near the source of hazard
In the operating instructions, before a sequence of actions or activities to be performed is described
Structure of safety instructions
The special warning notices in the operating instructions are structured as follows:
Components of safety instructions
Hazard (consequences of hazard): The hazard sequence tells the type of hazard.
Description of the hazard (hazard source): The hazard source indicates the cause of the hazard.
Protective measure (protection against hazard): The protection against the hazard describes the
measures for preventing the hazard.
Alert word: Thealert word classifies the severity of the hazard into four levels, emphasized graphically
with different colors. The alert word is used in the safety instructions as described below.
DANGER Indicates an immediate dangerous situation that, if not prevented, will result in death or
extreme (irreversible) injury.
WARNING Indicates a potential dangerous situation that, if not prevented, can result in death or
extreme (irreversible) injury.
CAUTION Indicates a potential dangerous situation that, if not prevented, can result in slight or minor
(reversible) injury.
CAUTION Indicates information or recommendations that directly or indirectly relate to the safety of
persons or equipment protection.
ALERT WORD
Safety symbol
Hazard (consequences of hazard)
Description of the hazard (source)
Protective measure (protection against hazard)

13-25-640 v00 Page 11
2.6 Safety Symbols
The safety symbols (hazard warning signs) can be used in the operating instructions and in the
environment around the compressor.
Safety Symbol
Meaning
Application / Behavior
General hazard
Warning of a general hazard.
Follow the warning and proceed with the required caution
(e.g., protective clothing) and care.
Slip hazard
Warning of a slip hazard.
Use caution when walking, stepping, or climbing.
Component or system
under pressure
Labeling of devices or areas in which the air pressure is
substantially higher than in the normal atmosphere.
Do not open devices or chambers until the pressure has been
equalized.
Do not operate with open
doors or loose clothing.
It is not permitted to run the compressor with open doors or
loose clothing, except for test runs. High sound pressure level,
risk of injury!
Normal operation requires the enclosure to be closed.
Do not breathe in the
compressed air from this
unit
It is not permitted to use the compressed air produced by this
compressor for breathing. Indrawn materials can be dangerous
to health.
Do not use compressed air as breathing air.
Electrical voltage
Warning against dangerous electrical voltage.
Work on the electrical equipment of the compressor may be
done only by an electrician in accordance with electrical rules.
System continues to run
The compressor continues to run for at least 30 second after
the stop button is pressed.
Do not open the compressor enclosure until the compressor
has stopped.
Read and follow the
instructions for use
Before the machine is operated, the user (operator) must have
read and understood the instructions for use (manufacturer’s
instructions foruse).
Labeling of instructions to the user that additional information
can be found in the (manufacturer’s) operating instructions.
Bacterial contamination
hazard
Warning of the presence of Legionella in the cooling water in
an open-loop cooling water circuit
Continuous monitoring of the cooling water by maintenance
personnel.
Caution: hot liquid
Warning of hot oil or hot coolant.
Allow the compressor to cool before opening the fluid circuit
lines.

13-25-640 v00 Page 12
Safety Symbol
Meaning
Application / Behavior
Secure against being
switched on again
Secure against being switched back on again during electrical
work
Secure against being switched back on again when working on
rotating parts
Secure against being switched back on again during repair work
Use hearing protection
Label for areas with elevated sound pressure level. Enter
the area only with suitable hearing protection.
Warning about industrial
trucks
Warning of industrial trucks traveling within the plant (e.g.,
forklifts) when transporting.
Do not perform any work in traffic lanes with limited visibility
that are not secured or blocked off. Use or crossing of this
traffic lane requires greatcaution.
Warning of suspended
loads
Warning of suspended loads during transport.
During transport, no persons may be present in the hazard
area. In particular, do not reach in or allow the feet to pass
beneath the suspended compressor.
Warning of moving
machine parts.
When performing maintenance work, it is necessary to check
some functions with the enclosure open. Injury hazard due to
rotational or translational motion.
Maintenance work may be performed only by specially trained
technicians.
Warning against hand
injuries
Hazard that the hands may be crushed, drawn in, or otherwise
injured.
Keep clear.
Warning of automatic
start
In normal operation the compressor can start automatically at
any time. Operational readiness of the compressor is indicated
by the green Enabled icons on the control panel.
Do not perform any work on the compressor when the green
Enable icon is lit.
Warning of hot surfaces
Parts of the compressor become very hot when in operation (up
to 235°C / 455°F). Risk of injury from hot surfaces.
Before beginning maintenance and repair work, the compressor
must have cooled off sufficiently.
Suffocation warning
Suffocation hazard due to insufficient ventilation and exhaust
of the compressor space.
The operator must provide sufficient ventilation and exhaust
of the compressor room.

13-25-640 v00 Page 13
Safety Symbol
Meaning
Application / Behavior
Warning of a crushing
hazard
Warning of crush hazards on a piece of equipment (e.g., a
machine) or structural components (e.g., covers, enclosures,
guards, fences) during transport.
Working at the labeled workstations requires increased
vigilance.
Do not go beneath the
load
Do not go beneath a suspended load. The driver is not allowed
to drive the industrial truck if a person is located beneath the
load. The driver must also make sure that no one stands or
walks under the load.
The load must be transported so that it is sufficiently clear of the
ground (max. 20 in above the ground). The driver is responsible
for all travel and load movements of an industrial truck.
Lifting point
Labeling of lifting points.
Only the labeled lifting points may be used for transport.
Pressure relief valve
Opening pressure of the pressure relief valve (for value “xx” see
the sticker on the control panel).
Check connection
terminals and retighten if
needed. For additional
instructions, see the
operating instructions.
Warning of loosened clamp connections. Clamping pressure can
fade after some time.
Check the clamps regularly according to the safety guidelines and
tighten as needed.
Electrical voltage
Residual voltage on the
capacitors
Warning against dangerous electrical voltage.
Warning of stored energy in the form of capacitors. They carry
deadly electrical voltage.
Do not open the electrical switch cabinet (compressors with
variable speed drives) for 10 minutes after disconnecting the
compressor.
Work on the electrical equipment of the compressor may be done
only by an electrician in accordance with electrical rules.
Check the DC bus voltage at the system terminal strip of the
frequency converter by measuring this between the
+DC and -DC terminals (the exact position can be found in the
supplied operating manual of the frequency converter), between the
+DC terminal and the chassis as well as between the -DC terminal
and the chassis.
The voltage must read zero in the case of all three
measurements.
Spring tension
Warning of springs under tension in the interior of the intake
regulator.
Before opening the intake regulator, read the repair manual.
NOTICE
All hazard warning signs must be present and in legible condition.
Check regularly and replace when needed.

13-25-640 v00 Page 14
2.7 Transport and Installation
Transport
A suitable forkliftwith sufficientlylong forks must be used to transport the compressor. Dependent on type,
the compressor weighs up to 4,700 kg / 10,362 lbs.
Insert the forks only at the lifting points provided.
The compressor, even in its packed state, may not be transported by crane.
During transport, no person may be present in the hazard area. In particular, do not reach in or allow the
feet to pass beneath the suspended compressor.
Installation / Installation site
The compressor must be installed with full contact on a foundation with sufficient structural strength.
The installation site (compressor room) must be sized so that the compressor is sufficiently accessible
and the required cooling is ensured.
No flammable or explosive materials may be stored near the compressor.
2.8 Normal Operation
The compressor may be used only if it is in a technically pristine state, and it must be used as intended,
with awareness of safety and hazards, by following the operating instructions.
Operate the compressor only if all protective and safety devices, sound dampeners, ventilation and
exhaust devices, and cooling water supply (for water-cooled compressors only) are present and
functional.
Check regularly that:
All hoses and pipelines are in good condition and securely attached.
There are no leaks (oil, coolant, or cooling water).
The electrical connection lines are in good condition.
Cooling water supply is provided (for water-cooled compressors only).
Behavioral rules for using compressed air.
Do not use any method that involves questionable safety.
Never play around with compressed air.
Never direct compressed air at the skin or at other person.
Never use compressed air to clean clothing.
When using compressed air to clean equipment, use great care and also wear safety glasses as
eye protection.
Safety measures
Operate the compressor only when the enclosure is closed.
Check the compressor at least once per shift for externally visible damage and defects. Report any
changes (including to the operating performance) to the responsible location or person immediately.
Stop and secure the compressor immediately, if needed. Have faults repaired immediately.
Do not switch off or remove the exhaust and vacuum devices when the compressor is running.
Remote control
If there is a remote control, the compressor must bear a clearly visible sign with the following inscription:
“Caution! The compressor is remotely controlled and could start without warning.”
In addition, safety precautions must be taken to ensure that no one is working on the compressor when
it is remotely controlled.

13-25-640 v00 Page 15
2.9 Special Work
Organizational
The maintenance work and intervals are specified in the operating manual, including information about
replacing parts/partial equipment.
Maintenance and repair work may be performed only under supervision, or by a person qualified for this
work.
Secure an ample working area, if needed.
Workshop equipment suitable for the work is absolutely required to perform maintenance and repair work.
Safety measures
Personnel must not wear open, long hair, loose clothing, or jewelry, including rings. When the compressor
is running, there is an injury hazard, such as due to jamming or drawing in. If needed or required by
regulations, use personal protective equipment!
Perform only those maintenance and repair works for which you have sufficient training and where you
feel comfortably sure of your ability.
Do not use machine parts as climbing aids. For maintenance work at greater heights, use fall protection.
Maintenance / Fault Clearing
Perform any maintenance and repair work only when the compressor is switched off and the power grid
supply is disconnected. Secure the compressor against being turned onaccidentally.
Before opening the compressor enclosure:
Allow the compressor to come to a stop.
Wait for automatic pressure relief.
Wait until the residual energy from the capacitors has dissipated.
Cool the compressor down to room temperature.
Cleanliness
Always pay attention to cleanliness during maintenance and repair work. Keep dirt away by covering
parts and exposed openings with a clean cloth, paper, or tape.
Oil loss causes the floor to be slippery. Clean the work area thoroughly after completing the
maintenance and repair work.
Cleaning agents
Never use solvents or cleaning agents that can corrode the materials to clean the parts.
Take preventive action against vapors of solvents or cleaning agents that are hazardous to health.
Weight / Lifting Gear
Carefully attach and secure heavy individual components and assemblies when replacing, so that
they do not present a hazard. Use only suitable lifting gear that is in technically perfect condition, and
a load handling device with sufficient load capacity. Do not stand or work beneath suspended loads.
Spare parts
Use only original spare parts.
Spare parts must comply with the technical requirements stipulated by the manufacturer. This is
guaranteed only when original spare parts are used.
After completing maintenance and repair work
After maintenance and repair work is completed, ensure that no tools, loose parts, or rags have been
left behind in the compressor (particularly in the drive motor or the drivetrain).
Rotate the drive several times in order to make sure that there is no mechanical fault in the
compressor or the drivetrain.
Tighten all bolt connections that were loosened for the maintenance and repair work. Also check all
the other bolt connections.

13-25-640 v00 Page 16
Before releasing the compressor for operation after maintenance and repair work, ensure that the
operating pressures, temperatures, and time settings are correct, and that the control and shutoff
device work perfectly.
If safety or protective devices must be removed, then they must be re-installed and checked for
perfect function immediately after completing the work.
2.10 Modifications and Changes to the Machine
Do not make any modifications, additions, or reconfigurations of the compressor without prior consultation
with Gardner Denver.
Unauthorized changes to the machine are not allowed for safety reasons.
Original parts are specially designed for the machine. We explicitly give notice that parts and special
equipment not provided by Gardner Denver are also not approved by Gardner Denver. The installation
and/or use of such products can therefore degrade active and/or passive safety.
Damage arising from the use of non-original parts or special equipment precludes the liability of the
manufacturer. This also applies to the installation and adjustment of safety devices and valves, and for
the welding of load-bearing or pressurized parts.
3 DESIGN AND FUNCTION
3.1 General Description
The compressor is an oil-lubricated, compressing, single-stage rotary screw compressor with one sound-
proofed enclosure.
The main components are the drive motor, the compressor stage, the oil circuit and the electronic control.
Oil is injected into the compressor stage for lubrication, sealing and cooling.
The rolling bearings and gearbox are lubricated with oil.
Principle of compression
The compressor stages consist of a main rotor and a secondary rotor with spiral teeth that mesh with
each other. Compression chambers bounded by the flanks of the teeth and by the compressor
housing are formed. By rotating the rotors, the volume of the chambers is continuously reduced, until
the compressed air is forced out the outlet port of the staged housing. Screw compressors are rotary
forced displacement compressors, with no oscillating mass but with pulsating output.
Electronic controls
The main components of the electronic control system are the Touchscreen Display and panel
mounted I/O Module.
A detailed description of the controller operation can be found in the controller manual provided with
the package.

13-25-640 v00 Page 17
3.2 Construction of the Compressor
Air Cooled
Figure 3-1 Air Cooled
1.
Intake Filter
16.
Oil Temperature Regulator
2.
Suction Regulator
20.
Base Frame
3.
Electric Motor
21.
Control Panel
4.
Screw Compressor
22.
Emergency Stop Button
5.
Oil Reservoir
23.
Switch Cabinet
6.
Fine Oil Separator
25.
Final Compression Pressure Sensor
7.
Oil Fill
27.
System Pressure Sensor
8.
Oil Drain
28.
Fork Lift opening
10.
Oil Filter
29.
Fan Guard
15.
Fine Oil Separator Extraction
30.
Pressure Relief for Cooler

13-25-640 v00 Page 18
Air Cooled
Figure 3-2 Air Cooled
9. Oil Level Indicator
17.
Cooling Fan
11. Oil Cooler
18.
Cooling Air Inlet Filter Pad
12. Pressure Relief Valve
19.
Compressed Air Outlet
13. Minimum Pressure and Non
Return Valve
24.
Cable Entry
14. Air Cooler
26.
System Pressure Sensor

13-25-640 v00 Page 19
Water Cooled
Figure 3-3 Water Cooled
1. Intake Filter
21.
Control Panel
2. Suction Regulator
22.
Emergency Stop Button
3. Electric Motor
23.
Switch Cabinet
4. Screw Compressor
24.
Cable Entry
10. Oil Filter
28.
Fork Lift opening
18. Cooling Air Inlet Filter Pad

13-25-640 v00 Page 20
Water Cooled
Figure 3-4 Water Cooled
5.
Oil Reservoir
17.
Cooling Fan
6.
Fine Oil Separator
19.
Compressed Air outlet
7.
Oil Fill
20.
Base Frame
8.
Oil Drain
25.
Final Compression Pressure Sensor
9.
Oil Level Indicator
26.
System Pressure Sensor
11.
Oil Cooler
30.
Pressure Relief for Cooler
12.
Pressure Relief Valve
32.
Cooling Water Inlet
13.
Minimum Pressure and Non Return
Valve
33.
Cooling Water Outlet
14.
Air Cooler
35.
Cooling Water Solenoid Valve
15.
Fine Oil Separator Extraction
36.
Regulating Valve
16.
Oil Temperature Regulator