Gardner Denver L160 110A V2 User manual

User manual
Screw compressor
L160 - L290 V2
L160RS- L290RS V2
America ZS1149274 / 03 - January 2017

Table of Contents
2 / 72 America January 2017
TABLE OF CONTENTS
1 Foreword..................................................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................................................ 6
1.6 Rating plate.........................................7
2 Safety 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..................................... 9
2.5 Labeling of safety instructions............ 9
2.6 Safety symbol..................................... 10
2.7 Transport and installation....................13
2.8 Normal operation................................ 13
2.9 Special work....................................... 14
2.10 Modifications and changes to the
machine...............................................15
3 Design and function............................... 16
3.1 General description.............................16
3.2 Construction of the compressor..........17
3.3 System schematic for air-cooled
compressor......................................... 20
3.4 Oil circuit............................................. 21
3.5 Air circuit............................................. 22
3.6 Regulation........................................... 22
3.7 Lubricant system.................................23
3.8 Heat recovery L160-L290................... 24
4 Transport and installation...................... 26
4.1 Transport.............................................26
4.2 Storage................................................27
4.3 Installation........................................... 27
5 Preparing for commissioning................ 30
5.1 Piping.................................................. 30
5.2 Compressed air connection................ 30
5.3 Electrical connection........................... 30
5.4 Cooling water connection................... 32
6 Commissioning and operation.............. 34
6.1 Initial commissioning...........................34
6.2 Normal operation................................ 36
6.3 Routine commissioning.......................37
6.4 Commissioning after extended
downtime.............................................37
6.5 Commissioning after a fault................ 37
7 Clearing a fault........................................38
8 Maintenance and service....................... 44
8.1 General notes..................................... 44
8.2 Service................................................ 45
8.3 Inspection of protective and safety
devices................................................ 45
8.4 Routine maintenance.......................... 46
8.5 Maintenance plan............................... 47
8.6 Maintenance work...............................49
8.6.1 Filter mats........................................... 49
8.6.2 Switch cabinet inlet filter..................... 49
8.6.3 Oil change...........................................50
8.6.4 Oil filter................................................51
8.6.5 Oil fine separator................................ 52
8.6.6 Air filter................................................52
8.6.7 Connection terminals in the switch
cabinet / control transformer setting....53
8.6.8 Drive motor / lubricator....................... 54
8.6.9 Control system....................................55
8.6.10 Checking intervals for pressure
vessel and electrical installation..........55
8.6.11 Maintenance instructions and
lubricant recommendations for fixed
compressors........................................55
9 Appendix..................................................56
9.1 Decommissioning................................56
9.2 Consumables and auxiliary materials. 56
9.3 Disassembly........................................56
9.4 Disposal.............................................. 57
9.5 Limit values of dissolved matter..........57
9.6 Technical data.....................................58
9.6.1 L160-L200, 60Hz, air-cooled "A",
water-cooled "W"................................ 58
9.6.2 L250-L290, 60Hz, air-cooled "A",
water-cooled "W"................................ 59

Table of Contents
January 2017 America 3 /72
9.6.3 L160 RS, 60Hz, air-cooled "A", water-
cooled "W".......................................... 60
9.6.4 L200 RS, 60Hz, air-cooled "A", water-
cooled "W".......................................... 62
9.6.5 L290 RS, 60Hz, air-cooled "A", water-
cooled "W".......................................... 63
9.7 Installation plan...................................65

1 Foreword
4 / 72 America January 2017
1 FOREWORD
Gardner Denver screw compressors are the
product of years of research and development.
Together with high quality requirements, these
conditions guarantee that the screw compressors
are manufactured for long service life, high
reliability, and economical operation.
Of course they also meet high environmental
protection standards.
1.1 About these operating
instructions
This operating instruction applies to the following
compressors:
•L160 110A V2
•L160 130A V2
•L160 190A V2
•L200 110A V2
•L200 130A V2
•L200 190A V2
•L250 110A V2
•L250 130A V2
•L250 190A V2
•L290 110A V2
•L290 130A V2
•L290 190A V2
•L160 RS 190A V2
•L200 RS 190A V2
•L250 RS 190A V2
•L290 RS 190A V2
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
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 and operating 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.

Foreword 1
January 2017 America 5 /72
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.
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.

1 Foreword
6 / 72 America January 2017
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”
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.
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 (overpressure or
underpressure).
Use as a respiratory air compressor.
Manipulation of sensor signals.
Changing signals from sensors.
Operation without protective and safety
devices.
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.
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:
Chart 1-1: Local Gardner Denver representative

Foreword 1
January 2017 America 7 /72
1.6 Rating plate
Fig. 1-1: Rating plate

2 Safety requirements
8 / 72 America January 2017
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 for operation,
maintenance, and repair must be clearly
defined.
Personnel should be checked regular to ensure
they are conscious of safety and hazards when
working.
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 or person.
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 RS compressors:
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.
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.

Safety requirements 2
January 2017 America 9 /72
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.
Explosive hazard areas
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.
NOTE
Operation of the compressor is permitted only
with complete, functional protective and safety
devices in place.
Emergency stop
The emergency stop button can be used to bring
the compressor to a safe condition in dangerous
situations.
Emergency stop buttons are mounted:
On the control panel of the compressor
Optionally in a pedestal (control console)
Using the emergency stop
1Press the <Emergency stop> pushbutton.
The compressor is placed in a safe condition.
2Rectify the fault that was the cause of the
emergency-stop.
See the "Troubleshooting" chapter.
3Unlock <Emergency-Stop> button.
Turn the pushbutton anticlockwise.
4Start up the compressor.
See section "Commissioning after a fault" in the
chapter "Commissioning and operation".
Safety valve / non-return valve
The compressor is protected from exceeding the
permissible operating pressure by a safety valve.
The safety valve opens at 15 bar / 218 psi.
The compressor is protected against backpressure
from the compressed air network by means of a
check valve on the pressure side.
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.

2 Safety requirements
10 / 72 America January 2017
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:
ALERT WORD
Safety
symbol
Hazard (consequences of haz-
ard)
Description of the hazard (source)
Protective measure (protection
against hazard)
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: The alert 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.
2.6 Safety symbol
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 cau-
tion (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 pres-
sure 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.
Chart 2-1: Safety symbol

Safety requirements 2
January 2017 America 11 /72
Safety symbol Meaning Application / behavior
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 electri-
cal rules.
System continues to run The compressor continues to run for 30 second after the
stop button <O> is pressed.
Do not open the compressor enclosure until the com-
pressor has stopped.
Follow the instructions
for use
Labeling of instructions to the user that additional infor-
mation can be found in the (manufacturer’s) operating
instructions.
Before the machine is operated, the user (operator) must
have read and understood the instructions for use (man-
ufacturer’s instructions for use).
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 visi-
bility that are not secured or blocked off. Use or crossing
of this traffic lane requires great caution.
Warning of suspended
loads
Warning of suspended loads during transport.
During transport, no persons may be present in the haz-
ard 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 oth-
erwise injured.
Keep clear.
Chart 2-1: Safety symbol

2 Safety requirements
12 / 72 America January 2017
Safety symbol Meaning Application / behavior
Warning of automatic
start
In normal operation the compressor can start automati-
cally at any time. Operational readiness of the compres-
sor is indicated by the green LED on the control panel.
Do not perform any work on the compressor when the
green LED is lit.
Warning of hot surfaces Parts of the compressor become very hot when in oper-
ation (up to 235 °C / 455 °F). Risk of injury from hot sur-
faces.
Before beginning maintenance and repair work, the com-
pressor 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.
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. 0.5 m / 20 in above the
ground). (In Germany also refer to the law BGV D27
“Industrial trucks”). 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.
Safety valve Opening pressure of the safety valve (for value “xx” see
the sticker on the control panel).
Check connection ter-
minals and retighten if
needed. For additional
instructions, see the
operating instructions.
Warning of loosened clamp connections. Clamping pres-
sure can fade after some time.
Check the clamps regularly according to the safety
guidelines and tighten as needed.
Chart 2-1: Safety symbol

Safety requirements 2
January 2017 America 13 /72
Safety symbol Meaning Application / behavior
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 (RS compres-
sor or ARV ) for 10 minutes after disconnecting the com-
pressor.
Work on the electrical equipment of the compressor may
be done only by an electrician in accordance with electri-
cal rules.
The following section only applies for the frequency
converter of the manufacturer Allen Bradley:
Check the DC bus voltage of the frequency inverter
at the grid terminal strip of the frequency inverter. The
exact position of the “DC+” and “DC-” terminals can be
found in the included operating instructions for the fre-
quency inverter.
Spring tension Warning of springs under tension in the interior of the
intake regulator.
Before opening the intake regulator, read the repair man-
ual.
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 mainte-
nance personnel.
Caution: hot liquid Warning of hot oil or hot coolant.
Allow the compressor to cool before opening the fluid cir-
cuit lines.
Chart 2-1: Safety symbol
NOTE
All hazard warning signs must be present and in legible condition.
Check regularly and replace when needed.
2.7 Transport and installation
Transport
A suitable forklift with sufficiently long forks must
be used to transport the compressor. Dependent
on type, the compressor weighs up to 4,700 kg /
10362 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.

2 Safety requirements
14 / 72 America January 2017
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.
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 on accidentally.
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 agentsthat can
corrode the materials to clean the parts.
Take preventive action against vapors of solvents
or cleaning agents that are hazardous to health.

Safety requirements 2
January 2017 America 15 /72
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.
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 conceived for the
machine. We explicitly give notice that parts and
special equipment not provided by us are also
not approved by us. 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
16 / 72 America January 2017
3 DESIGN AND FUNCTION
3.1 General description
The compressor is an oil-lubricated, compressing,
single-stage 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 a microprocessor, a touch screen, flat
panel keys, and LEDs.
Detailed description operating manual for
electronic controls

Design and function 3
January 2017 America 17 /72
3.2 Construction of the compressor
Air-cooled
15
27
25
6
16
10 4
1228 20 328 21
23
22
Fig. 3-1: Overview Part 1
[1] Suction filter [20] Base frame
[2] Intake regulator [21] Control system control panel
[3] Electric motor [22] EMERGENCY-Off button
[4] Screw compressor [23] Electrical enclosure
[6] Fine precipitator [25] Compression temperature sensor
[10] Oil filter [27] Final compression pressure sensor
[15] Fine separator, suction [28] Opening for lifting tool
[16] Oil temperature regulator

3 Design and function
18 / 72 America January 2017
17 24 26
19
11 14
18
30
13
589712
Fig. 3-2: Overview Part 2 (air-cooled)
[5] Pressure vessel [14] Air cooler
[7] Oil fill [17] Oil cooler cooling air fan
[8] Oil drain [18] Cooling air inlet filter pad
[9] Oil level indicator [19] Compressed air outlet
[11] Oil cooler [24] Aftercooler cooling air fan
[12] Safety valve [26] Line pressure sensor
[13] Pressure retention and check valve [30] Cooler pressure relief

Design and function 3
January 2017 America 19 /72
31
18
11
5
89712
13
30
19
26
17 14
Fig. 3-3: Overview Part 2 (water-cooled)
[5] Pressure vessel [14] Air cooler
[7] Oil fill [17] Cooling air fan
[8] Oil drain [18] Cooling air inlet filter fleece
[9] Oil level indicator [19] Compressed air outlet
[11] Oil cooler [26] Line pressure sensor
[12] Safety valve [30] Cooler pressure relief
[13] Pressure retention and check valve [31] Cooling water connection

3 Design and function
20 / 72 America January 2017
3.3 System schematic for air-cooled compressor
23
S7*
1
2
30
2.2 2.1
19
Y1
20
Y4
14 18
B2
17 25
35
B1
16
15
24
S6*
9
8
7
6S12*
22
29
4
13 33
5R2
12
21
11
10 S5*
34
R1
3
32
E5 E4
31*
28
Y6
27
Fig. 3-4: Functional schematic
Compressed air Oil
Control air Cooling water
Chart 3-1: Lines
Components
No. Designation No. Designation No. Designation
1 Intake air filter 13 Throttle; orifice diameter
1.2 mm / 0.047 "
27 Dirt trap (only LxxxW)
Chart 3-2: Components