Gardner Denver L90 7.5A V4 Quick guide

Translation of the original operating
instructions
Screw compressor
L90 - L132 V4
L90e - L132e V4
L90RS - L132RS V4

CONTENTS
1 Foreword..................................................4
1.1 About these operating instructions......4
1.2 Notes...................................................5
1.3 Intended use....................................... 5
1.4 Intentional misuse...............................6
1.5 Service................................................ 6
1.6 Name plate......................................... 7
2 Safety conditions.................................... 8
2.1 General safety instructions................. 8
2.2 Instructions about particular types of
danger................................................. 8
2.3 Protection and safety equipment........ 9
2.4 Residual hazards................................ 10
2.5 Identification of safety instructions...... 10
2.6 Safety sign.......................................... 10
2.7 Transport and positioning................... 14
2.8 Normal operation................................ 14
2.9 Special tasks.......................................14
2.10 Conversions and changes to the
machine...............................................15
3 Design and function............................... 16
3.1 General description.............................16
3.2 Compressor design.............................17
3.3 System scheme air-cooled
compressor......................................... 20
3.4 Oil circuit.............................................21
3.5 Air circuit.............................................22
3.6 Controller.............................................22
3.7 Lubricant system.................................23
3.8 Heat recovery L90-L132..................... 24
4 Transport and positioning......................26
4.1 Transport.............................................26
4.2 Storage................................................27
4.3 Positioning...........................................27
5 Preparations for commissioning........... 29
5.1 Pipelines..............................................29
5.2 Compressed air connection................ 29
5.3 Electrical connection...........................29
5.4 Cooling water connection................... 31
6 Commissioning and operating.............. 33
6.1 Initial commissioning...........................33
6.2 Normal operation................................ 35
6.3 Routine commissioning.......................36
6.4 Commissioning after a long shutdown 36
6.5 Commissioning after a fault................ 36
7 Troubleshooting...................................... 37
8 Maintenance and Service.......................43
8.1 General information............................ 43
8.2 Service................................................ 44
8.3 Inspection of protection and safety
equipment........................................... 45
8.4 Routine maintenance..........................45
8.5 Maintenance plan with 2000 hour
service package..................................46
8.6 Maintenance plan without 2000 hour
service package..................................48
8.7 Service plan assure............................ 50
8.8 Maintenance work...............................51
8.8.1 Filter mats........................................... 51
8.8.2 Switch cabinet inlet filter..................... 51
8.8.3 Oil change...........................................52
8.8.4 Oil filter................................................53
8.8.5 Oil fine separator................................ 54
8.8.6 Air filter................................................54
8.8.7 Moisture sensor protective cap...........55
8.8.8 Connection terminals in the switch
cabinet / control transformer setting....56
8.8.9 Drive motor / Lubricator...................... 57
8.8.10 Control system....................................57
8.8.11 Checking intervals for pressure
vessel and electrical installation..........58
8.8.12 Maintenance instructions and
lubricant recommendations for fixed
compressors........................................58
9 Appendix..................................................59
9.1 Shutdown............................................ 59
9.2 Lubricants and additives..................... 59
9.3 Removal.............................................. 59
9.4 Disposal.............................................. 60
9.5 Limit values of dissolved matter..........61

9.6 Technical Specification........................62
9.6.1 L90-L110 + L90e - L110e, 50Hz, air-
cooled "A", water-cooled "W"..............62
9.6.2 L90-L110, 60Hz, air-cooled "A",
water-cooled "W”................................ 63
9.6.3 L132 + L132e, 50 Hz, air-cooled "[A]",
water-cooled "W"................................ 65
9.6.4 L132, 60Hz, air-cooled "A", water-
cooled "W".......................................... 66
9.6.5 L90 RS, 50Hz + 60Hz, air-cooled "A",
water-cooled "W"................................ 67
9.6.6 L110 RS, 50Hz + 60Hz, air-cooled
"A", water-cooled "W"......................... 69
9.6.7 L132 RS, 50Hz + 60Hz, air-cooled
"A", water-cooled "W"......................... 70
9.7 Installation plan...................................72
9.8 Declaration of conformity.................... 75

1 FOREWORD
Gardner Denver screw compressors are the prod-
uct of years of research and development. This
experience in conjunction with high quality require-
ments ensures that the manufactured screw com-
pressors are long-lasting, providing guaranteed re-
liability and economic operation.
Equally, the stringent requirements for environ-
mental protection are also met.
1.1 About these operating
instructions
These operating instructions apply for the follow-
ing compressors from Gardner Denver Deutsch-
land GmbH:
L90 7.5A V4
L90 7.5W V4
L90 9A V4
L90 9W V4
L90 10A V4
L90 10W V4
L90 13A V4
L90 13W V4
L110 7.5A V4
L110 7.5W V4
L110 9A V4
L110 9W V4
L110 10A V4
L110 10W V4
L110 13A V4
L110 13W V4
L132 7.5A V4
L132 7.5W V4
L132 9A V4
L132 9W V4
L132 10A V4
L132 10W V4
L132 13A V4
L132 13W V4
L90 RS 13A V4
L90 RS 13W V4
L110 RS 13A V4
L110 RS 13W V4
L132 RS 13A V4
L132 RS 13W V4
L90e 7,5A V4
L90e 7,5W V4
L90e 10A V4
L90e 10W V4
L110e 7,5A V4
L110e 7,5W V4
L110e 10A V4
L110e 10W V4
L132e 7,5A V4
L132e 7,5W V4
L132e 10A V4
L132e 10W V4
These operating instructions are written for operat-
ing- and maintenance personnel.
The basis of these operating instructions are the
master operating instructions ZS1195529/00,
which are relevant for translations of the operating
instructions.
These operating instructions are an inherent part
of the compressor. They must be available and ac-
cessible near the compressor at all times.
These operating instructions provide you with all
the information you need for safe operation and
maintenance of the compressor. This includes:
Installation and connection of the compressor
Commissioning and operation of the compres-
sor
Replacement of wear parts and consumables
such as filters or oil
Identification of faults and rectification of mal-
functions
Carrying out of visual inspections for damage
on a rotational basis
Cleaning, maintenance and repair of the com-
pressor
The dealer's or manufacturer's workshop, with its
qualified and experienced personnel, is respon-
sible for all maintenance work that goes beyond
customary service work and requires specialist
technical knowledge.
All pressures given in these operating instructions
are, where not otherwise specified, positive pres-
sures (gauge pressures).

Target groups
The target groups for these operating instructions
are operators, maintenance personnel and electri-
cians.
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 compres-
sor, carry out direction of rotation checks and carry
out electrical maintenance work.
Safety conditions
Alongside all the other details in these operating
instructions, the general safety instructions, in the
chapter "Safety Conditions", must be read without
fail.
1.2 Notes
General information
The operating instructions must be read and used
by every person who is assigned to work with and
on the compressor.
Irrespective of these operating instructions, the
laws, regulations, directives and standards applic-
able in the place of use must be observed.
Training
The provision of local operator training is under-
taken by authorised service technicians. The train-
ing documentation comprises these operating in-
structions and the repair manual, which is only is-
sued as part of service training.
These measures ensure that the assigned work
can be reliably carried out.
Warranty
Gardner Denver will not be held liable for the safe
functioning of the compressor if it used other than
for its normal use or for purposes not listed in the
operating instructions.
Gardner Denver Deutschland GmbH excludes all
warranty and liability in the event of:
Operating errors.
Use of the compressor for other than the in-
tended purpose.
Damage resulting from deliberate misuse or
non-observance of the operating instructions.
Damage or injuries caused by non-OEM com-
ponents.
Use of spare or wear parts or operating fluids
that do not originate from or are not currently
recommended by or have not been previously
recommended by Gardner Denver Deutschland
GmbH.
Inadequate maintenance.
Compressor conversions.
Warranty and liability conditions of the general
business conditions of Gardner Denver Deutsch-
land GmbH are not expanded by the aforesaid in-
formation.
Guarantee
The conditions and caveats of Gardner Denver
Deutschland GmbH warranty are specified in our
general terms and conditions, which were supplied
with the compressor.. Upon request, an additional
copy of the document can also be sent retrospec-
tively.
Copyright
These operating instructions are subject to copy-
right and may only be used for the agreed pur-
pose, i.e. as a reference for in-plant purposes.
Forwarding or reproduction of this document, ex-
ploitation and sharing of its content are forbid-
den, insofar as this is not expressly authorised.
Infringements will incur payment of compensa-
tion. All rights reserved for the case of granting of
a patent, petty-patent or design registration.
Reselling
If the compressor is resold, these operating in-
structions must be handed over to the new oper-
ator together with the compressor. If necessary,
the operating instructions must be reordered from
Gardner Denver by specification of the order con-
firmation number. The compressor must not under
any circumstances be resold without these operat-
ing instructions.
1.3 Intended use
The compressor conforms to the state of the art
and the applicable safety conditions at the time of
its bringing to market provided it is used for its in-
tended purpose.
From a design point of view, neither intentional
misuse nor all of the residual dangers can be
avoided, without limiting the intended functionality.
The compressor is designed for the compres-
sion of atmospheric air (compressed air for driving
pressure equipment). The compressor is not suit-
able for the compression of other gases.

The compressor is only classed as being used for
its intended purpose if the following points are also
observed:
The compressor is used according to these op-
erating instructions.
The working steps and standard operating pro-
cedures of the operator are followed.
Any other use or use beyond this is defined as
non-intended use. The manufacturer is not liable
for any resulting damage. The user alone bears
the risk.
Intended use also includes observation of the op-
erating instructions and adherence to the inspec-
tion and maintenance instructions.
Other conditions
Danger to life and limb of the user or third parties
can arise from use of the compressor; likewise
damage to the compressor or other material can
arise if the compressor:
Is not used as intended.
Is not operated by trained personnel.
Is changed or modified.
The safety instructions are not observed.
Alongside these operating instructions, the follow-
ing apply:
Relevant accident prevention regulation
Generally recognised safety rules
Country-specific conditions
Installation location / installation altitude
The compressor is intended for installation in a
suitable compressor room. The compressor is not
suitable for open-air installation!
The permissible installation altitude of the com-
pressor is limited dependent on the operating
pressure, ambient humidity and ambient tempera-
ture at which it is operated. The permissible instal-
lation altitude is specified for each individual case
by consultation between the customer and Gard-
ner Denver.
Working environment
The illumination in the region of the compressor
must be ≥ 200 lx during normal operation.
The illumination for inspection and repair work
must be ≥ 500 lx.
Ambient temperature for operation: see "Technical
data".
Pressure equipment
For pressure equipment/systems a pressure re-
lief device (safety valve or similar) dimensioned to
match the weakest pressure carrying component
and conforming to the relevant regulations must
be installed in the compressed air network.
1.4 Intentional misuse
Incorrect use and misuse
The following typical reasonably foreseeable mis-
uses (incorrect uses) are classed as contrary to
the intended use:
Compression of gases other than atmospheric
air.
Operation outside the permissible operating
limits, even if the exceeding of the limits is only
temporary or not immediately identifiable.
Operation outside the permissible ambient tem-
peratures.
Extraction of non-atmospheric air (overpres-
sure or vacuum pressure).
Use as a breathing air compressor.
Manipulation of sensor signals.
Signal modification of sensors.
Operation without protection and safety equip-
ment.
Operation with defective, deactivated or ma-
nipulated protection and safety equipment or
safety valves, or operation with other such
safety relevant defects.
Use by private users or users without technical
training.
Operation outside industrial environments.
Non-adherence to maintenance intervals.
Omission of maintenance and repair work.
Incorrect execution of maintenance and repair
work.
Limitations on use
Operation of the compressor is not permitted
outside the permissible ambient temperatures.
above the permitted altitude of the installation
location.
on an insufficiently load-bearing substrate.
in areas with an explosive atmosphere.
1.5 Service
If you have any questions about or problems with
the compressor please contact your responsible
Gardner Denver agency.

The trained specialised personnel will ensure you
receive quick and proper assistance.
In case of queries
If you have a query or wish to make a spare parts
order, please specify the identification number and
year of manufacture on the name plate. Specifi-
cation of this data will ensure that you receive the
correct information and/or spare parts.
Your Gardner Denver agency
Please enter the details of your local Gardner
Denver agency in the following table.
Name:
Contact:
Address:
Phone
Fax
Email:
Chart 1-1: Local Gardner Denver agency
1.6 Name plate
Fig. 1-1: Name plate

2 SAFETY CONDITIONS
Any person who is involved with the operation,
maintenance or repair of the compressor, must
read and follow the safety conditions.
Gardner Denver accepts no responsibility for ma-
terial damage or injuries that arise from non-obser-
vation of safety conditions or the failure to observe
normal levels of care and attention, even where
this is not expressly stated in these operating in-
structions.
2.1 General safety instructions
Organisational measures
The following organisational measures contribute
to the safe use of the compressor:
Only appointed personnel may work on the
compressor. The personnel have been trained
and briefed about the compressor.
Before starting work, the personnel must have
read the operating instructions, in particular the
"Safety Conditions" chapter. Don’t leave this
until you start work – it’s too late. This applies
in particular to personnel who only work on the
machine occasionally, e.g. to carry out mainte-
nance.
The responsibilities of the personnel for oper-
ation, maintenance and repair must be clearly
defined.
The safe and hazard-aware working of the per-
sonnel must be checked regularly.
Personnel who are to be trained in, taught
about or instructed as part of a general training
course, must only work on the compressor un-
der the constant supervision of an authorised
person.
If safety-relevant changes are made to com-
pressor or arise in its operating behaviour, the
compressor must be immediately shutdown
and the fault reported to the responsible post/
person.
Faults, especially those that could impair
safety, must be immediately rectified. Other-
wise the compressor must not be operated.
All danger signs on and in the surroundings of
the compressor must be regularly checked for
completeness and legibility. Missing danger
signs must be immediately replaced.
The intervals between tests and inspections
must be adhered to.
The operating instructions must be supple-
mented with instructions for the observation of
operating peculiarities including monitoring and
reporting obligations, e.g. in respect of working
organisation, working processes, responsibili-
ties, etc.
Personnel selection and qualification; funda-
mental responsibilities
Only reliable and authorised personnel may work
on the compressor.
The authorised personnel must:
be trained by Gardner Denver.
be trained according to its responsibilities, du-
ties and activities and instructed about the
compressor.
have the physical and mental capabilities to
fulfil its responsibilities and carry out its duties
and activities on the compressor.
have understood the operating instructions in
respect of its responsibilities, duties and activ-
ities on the compressor and be able to practi-
cally implement this.
2.2 Instructions about particular
types of danger
Electrical energy
DANGER
Electric shock
Life-threatening electric shock
➯When carrying out any work on the
electrical equipment, exercise ex-
treme care.
➯Before starting the maintenance
work, switch the compressor to a
voltage-free state and secure to pre-
vent switching back on.
For all work on the electrical equipment of the
compressor the 5 safety rules for working on elec-
trical equipment must be observed.

Moreover, the following instructions must be ob-
served:
Only a qualified electrician following elec-
trotechnical regulations may carry out work on
the electrical equipment of the compressor.
The compressor's electrical equipment must be
checked regularly. Defects such as loose con-
nections or charred cables must be rectified im-
mediately.
Only original fuses of the specified current rat-
ing may be used.
Only for RS compressors::
Due to the residual voltage on the capacitors, a
waiting time of at least 10 minutes must elapse af-
ter voltage-free switching (main switch OFF) be-
fore the switch cabinet can be opened. Observe
the danger sign on the switch cabinet! See table
"Safety signs".
Noise
The sound pressure level without the sound-proof-
ing 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 ear de-
fenders!
The sound pressure level with the sound-proof-
ing enclosure is approximately: (See "Technical
data".)
During normal operation the compressor may only
be operated with a closed acoustic hood.
Oils, grease and other chemical substances
When handling oils, fats and other chemical sub-
stances, observe the applicable safety conditions!
Exercise caution when handling hot lubricants and
additives, there is a risk of burns or scalding!
Explosive areas
DANGER
Risk of explosion
The compressor is not designed for op-
eration in explosive atmospheres.
➯Operation of the compressor in ex-
plosive atmospheres is forbidden!
2.3 Protection and safety
equipment
The compressor is equipped with the protection
and safety equipment described below.
All protective and safety equipment must be at-
tached and checked for trouble-free operation be-
fore every commissioning, in particular after main-
tenance and repair work.
In addition, the legally prescribed checking inter-
vals of the country of use must be adhered to.
NOTE
Operation of the compressor is only permitted
with complete and operational protective and
safety equipment.
Emergency-stop
The compressor can be rendered safe in danger-
ous situations using the emergency-stop pushbut-
ton.
Emergency-stop pushbuttons are attached:
on the compressor control panel
optionally in a control room (control centre)
Using emergency-stop
1. Push <Emergency-Stop> button.
The compressor is placed in a safe condition.
2. Rectify the fault that was the cause of the
emergency-stop.
See the "Troubleshooting" chapter.
3. Unlock <Emergency-Stop> button.
Turn the pushbutton anticlockwise.
4. Start 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 secured by a non-return valve
on the pressure side against reverse flow from the
compressed air network.
Protective covers and enclosure panels
The cooling air fans are covered by grilles.
The clutch between the drive and the compressor
is covered by a grille.
The compressor enclosure is designed so that any
broken bits that might fly out are retained in the
compressor.
The compressor enclosure serves as an acoustic
hood.

2.4 Residual hazards
Hot surfaces
Some parts of the compressor become hot in op-
eration (up to 120 °C / 248 °F). A danger warning
sign on the compressor enclosure warns of the
danger.
Before starting any maintenance and repair work,
the compressor must be sufficiently cooled.
Personal protective equipment
We recommend the wearing of the following per-
sonal protective equipment:
Safety shoes
Safety glasses for all work with compressed air
and open enclosure
Ear defenders during test runs with an open
acoustic hood
2.5 Identification of safety
instructions
Within the operating instructions, safety instruc-
tions are used as special warnings with the follow-
ing described names and symbols.
These special warnings are intended to prevent
danger and are located close to the possible dan-
ger both in terms of space and time:
on the system close to the danger source
in the operating instructions, before a sequence
of actions / activity is described
Structure of safety instructions
The special warnings in the operating instructions
are structured as follows:
DANGER WORD
Safety sign
Danger (danger sequence)
Description of the danger (danger
source)
Protective measure (danger pre-
vention)
Parts of safety instructions
Danger (danger sequence): The danger se-
quence names the type of hazard.
Description of the danger (danger source): The
danger source names the cause of the hazard.
Protective measure (danger prevention): Dan-
ger prevention describes the measures for com-
batting the hazard.
Danger word: The danger word subdivides the
severity of the danger into four steps, graphically
highlighted by different colours. The danger word
is used in the safety instructions as described be-
low.
DANGER indicates a directly dangerous situa-
tion which, if not protected against, could result in
death or serious (irreversible) injuries.
WARNING indicates a potentially dangerous situa-
tion which, if not protected against, could result in
death or serious (irreversible) injuries.
CAUTION indicates a potentially dangerous situa-
tion which, if not protected against, could result in
minor or less serious (reversible) injuries.
ATTENTION indicates information or recommen-
dations that directly or indirectly concern the safety
of persons or system protection.
2.6 Safety sign
The following safety signs (danger signs) may be used in the surroundings of the compressor and in the
operating instructions.
Safety sign Significance Use / Behaviour
General danger Warning of a general danger.
Observe the warning and proceed with the necessary
caution (e.g. protective clothing) or care.
Risk of slipping Warning against the risk of slipping.
Caution during walking, running or climbing.
Chart 2-1: Safety sign

Safety sign Significance Use / Behaviour
Pressurised part or sys-
tem
Identification of devices or rooms in which there is per-
manently or occasionally a significantly higher air pres-
sure than in the normal atmosphere.
Do not open the devices or rooms before pressure
equalisation has taken place.
Never operate the com-
pressor with open doors
or loose enclosure pan-
els.
Running the compressor with open doors or loose enclo-
sure panels is forbidden except during test runs. High
sound pressure level, risk of injury!
Normal operation only with closed enclosure.
Do not breath in any
compressed air from this
system
Use of the compressed air produced by this compressor
as breathing air is forbidden. Drawn in substances could
be harmful to health.
Do not use compressed air as breathing air.
Electrical voltage Warning of dangerous, electrical voltage.
Only a qualified electrician following electrotechnical reg-
ulations may carry out work on the electrical equipment
of the compressor.
System runs on After pressing of the stop button <O> the compressor
runs on for 30 seconds.
Do not open the compressor enclosure before the com-
pressor is stationary.
Observe the instruction
manual
Identification of operating instructions where additional
information is to be found in the operating instructions (of
the manufacturer).
Before the device is operated, the operator (user) must
have read and understood the instruction manual (manu-
facturer's usage instructions).
To secure against
switching on again
•To secure against switching back on when working on
electrical systems
•To secure against switching back on when working on
rotating parts
•To secure against switching back on during repair
work
Wear ear defenders Identification of areas with a heightened sound pressure
level.
Only enter the area wearing suitable ear defenders.
Warning against indus-
trial trucks
Warning of in-plant industrial trucks (e.g. forklifts) trans-
porting materials.
Do not carry out any work on traffic ways that cannot
be seen to be clear and are not made safe or blocked
off. Use or crossing of this traffic way can only be imple-
mented with great care.
Chart 2-1: Safety sign

Safety sign Significance Use / Behaviour
Warning against sus-
pended loads
Warning of suspended loads being transported.
No person may remain in the danger area during trans-
port. In particular, do not encroach into the area under
the raised compressor or place your feet beneath it.
Warning against moving
machine parts
During maintenance work it is necessary to check some
functions with an opened enclosure. There is a risk of
injury due to rotating or translational movements.
Maintenance work must only be carried out by specially
trained personnel.
Warning of hand injuries Danger that the hands could be crushed, drawn in or
otherwise injured.
Maintain a safe distance.
Warning of automatic
start-up
In normal operating mode, the compressor may start up
automatically at any time. The readiness for operation
of the compressor is indicated by the green LED on the
control panel.
Do not carry out any work on the compressor, if the
green LED illuminates.
Warning of hot surfaces Parts of the compressor become very hot during opera-
tion (up to 235 °C / 455 °F). Risk of injury due to hot sur-
faces.
Before starting any maintenance and repair work, the
compressor must be sufficiently cooled.
Warning of suffocation Risk of suffocation due to inadequate ventilation and
extraction in the compressor room.
The operator must provide adequate ventilation of the
compressor room.
Warning of crushing haz-
ards
Warning of crushing hazards due to working materials
(e.g. a machine) or a structural element (e.g. covers,
enclosure panels, protection devices, boundary fences).
When working on the identified workstations, increased
awareness is necessary.
Remaining under the
load is forbidden
It is not permitted to remain under a suspended load.
The driver is not permitted to drive the industrial truck if
there is a person beneath the load. Moreover, the dri-
ver is obliged to check that persons do not stand or walk
under the load.
The load must only be transported so that it is suffi-
ciently clear of the ground (max. 0.5 m / 20 in above the
ground). (In Germany, refer to the law BGV D27 "Indus-
trial trucks”). The driver of an industrial truck is responsi-
ble for all driving and load movements.
Chart 2-1: Safety sign

Safety sign Significance Use / Behaviour
Lifting point Identification of the lifting points.
Only the indicated lifting points may be used for trans-
port.
Safety valve Opening pressure of the safety valves (values "xx" see
sticker on the control panel).
Check the connecting
terminals and tighten if
necessary. For additional
information see the oper-
ating instructions.
Warning against loosened connecting terminals. The
clamping pressure can be released after some time.
Regularly check the terminals according to the safety
guidelines and retighten as necessary.
Electrical voltage
Residual voltage of the
capacitors
Warning of dangerous, electrical voltage.
Warning of electrical energy stores in the form of capaci-
tors. These can conduct a life-threatening electrical volt-
age.
Only open the switch cabinet (RS compressor or ARV)
10 minutes after switching the compressor to a volt-
age-free state.
Only a qualified electrician following electrotechnical reg-
ulations may carry out work on the electrical equipment
of the compressor.
Der following section applies only for the frequency
converter of the Allen Bradley manufacturer :
Check the DC bus voltage of the frequency converter at
the mains connection strip of the frequency converter.
The precise position of the terminals "DC+" and "DC-"
can be taken from the supplied frequency converter
operating instructions.
Spring tension Warning of tensioned spring inside the suction regulator.
Before opening the suction regulator read the repair
manual.
Risk of microbe contami-
nation
Warning against legionella contamination of the cooling
water if an open cooling water circuit is used.
Constant monitoring of the cooling water by the mainte-
nance personnel.
Attention: hot liquid Warning against hot oil or hot coolant.
Before opening coolant circuits, allow the compressor to
cool.
Warning Static Voltage Contact with electronic components can result in dam-
age to them due to static voltages.
Chart 2-1: Safety sign

NOTE
All danger signs must be complete and legible.
Check regularly and replace if necessary.
2.7 Transport and positioning
Transport
A suitable forklift with forks of adequate length
must be used to transport the compressor. De-
pendent on type, the compressor weighs up to
2,800 kg.
Only insert the forks at the intended load support
points.
The compressor must not be transported using a
crane, even when still in its packaging.
No person may remain in the danger area during
transport. In particular, do not encroach into the
area under the raised compressor or place your
feet beneath it.
Positioning / installation location
The entire surface of the compressor must be
placed on an even suitable substrate.
The installation location (compressor room) must
be dimensioned so that there is sufficient access
to the compressor and the necessary cooling is
ensured.
No inflammable or explosive materials may be
stored in the vicinity of the compressor.
2.8 Normal operation
The compressor may only be operated in a techni-
cally fault-free condition for its intended use, with
an awareness of safety and hazards while observ-
ing the operating instructions.
Only operate the compressor if all protective and
safety equipment, sound insulation, ventilation and
extraction equipment and the cooling water supply
(water-cooled compressors only) are present and
serviceable.
Check regularly that:
All hoses and pipelines are serviceable and
firmly attached.
There are no leaks (oil, coolant or cooling wa-
ter).
The electrical power cables are free from faults.
The cooling water supply is guaranteed (wa-
ter-cooled compressors only).
Rules for working with compressed air:
Forbid all working practices that could pose a
risk to safety
Never 'play around' with compressed air.
Never direct compressed air onto the skin or at
other people.
Never use compressed air for cleaning cloth-
ing.
When using compressed air to clean equip-
ment, proceed with great care and always use
eye protection.
Safety measures
Only operate the compressor with the enclosure
closed.
At least once per shift check the compressor for
externally visible damage and defects. Immedi-
ately report changes that have occurred (includ-
ing in the operating behaviour) to the responsi-
ble post/person. If necessary stop the compressor
immediately and secure. Immediately rectify any
faults.
Do not switch off or remove extraction and ventila-
tion equipment when the compressor is running.
Remote control
If a remote control is available, a sign with the fol-
lowing lettering must be clearly visible on the com-
pressor: "Attention! The compressor is remotely
controlled and could start without warning!"
In addition safety precautions must be imple-
mented so that nobody works on the compressor
when it is under remote control.
2.9 Special tasks
Organisational
Adhere to the prescribed maintenance work and
intervals including details about the replacement
of parts/part assemblies contained in the operating
instructions.
Maintenance and repair work must only be carried
out under the supervision of or by a person quali-
fied to carry out this work.
If necessary, cordon off a wide area around the
workplace.
Workshop equipment appropriate for the task is
essential for carrying out maintenance and repair
work.

Safety measures
Personnel must not have loose long hair nor wear
loose clothes or jewellery including rings. If the
compressor is running there is a risk of injury, e.g.
by being caught-up or pulled in. Where necessary
or if required by regulations, wear personal protec-
tive equipment!
Only carry out maintenance and repair work for
which you are adequately trained and which you
feel confident to carry out.
Do not use machine parts as climbing aids. If car-
rying out maintenance work at heights, provide fall
protection.
Maintenance/Troubleshooting
Only carry out maintenance and repair work with
the compressor switched off and mains power
off. Secure the compressor to prevent inadvertent
switching on.
Before opening the compressor enclosure:
Drain the compressor.
Wait for automatic pressure discharge to com-
plete.
Wait until the residual electrical energy has
drained from the capacitors.
Allow the compressor to cool to room tempera-
ture.
Cleanliness
During maintenance and repair work always check
for cleanliness. Keep dirt away by covering parts
and uncovered openings with a clean cloth, paper
or adhesive strips.
Oil leaks lead to a slippery floor. Thoroughly clean
the work area after completion of maintenance
and repair work.
Cleaning agents
When cleaning parts, never use solvents or clean-
ing agents that could chemically attack the materi-
als.
Take precautions to prevent harmful vapours from
solvents or cleaning agents.
Weight / lifting gear
When replacing heavy individual parts and assem-
blies carefully attach and secure to the lifting gear
so that no danger can arise. Use only suitable and
technically flawless lifting gear and load handling
equipment with adequate load capacity. Never
work or remain under suspended loads.
Spare parts
Use only original spare parts.
Spare parts must correspond to the technical re-
quirements specified by the manufacturer. This is
only guaranteed with original spare parts.
Upon completion of maintenance and repair
work
Upon completion of maintenance and repair work,
ensure that no tools, loose parts or cleaning cloths
have been left in the compressor (especially in the
drive motor or drive train).
Turn the drive several times to ensure that there is
no mechanical malfunction within the compressor
or the drive train.
Tighten up all threaded connectors loosened dur-
ing maintenance and repair work. Likewise check
all other threaded connectors.
Before release of the compressor for operation af-
ter maintenance and repair work, ensure that the
operating pressures, temperatures and time set-
tings are correct and that the control and switching
off equipment is fully serviceable.
If safety and protective equipment must be re-
moved, then it must be immediately replaced af-
ter completion of the work and checked for trou-
ble-free operation.
2.10 Conversions and changes to
the machine
Do not make any changes or additions to or re-
build the compressor without prior consultation
with Gardner Denver.
Unauthorised changes to the machine are not au-
thorised for safety reasons.
Genuine parts are designed especially for the ma-
chine. We expressly point out that we also do not
authorise parts and special equipment that are not
supplied by us. The fitting and/or use of such prod-
ucts may therefore impair active and/or passive
safety.
Any liability on the part of the manufacturer for
damage arising from the use of non-original parts
or special equipment is excluded. The same ap-
plies for the fitting and adjustment of safety equip-
ment and valves as well as to the welding of load-
bearing or pressure carrying parts.

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 lubri-
cation, sealing and cooling.
Rolling contact bearings and gearbox are oil-lubri-
cated.
Compression principle
The compressor stages comprise a main rotor and
an auxiliary rotor with intermeshing spiral toothing.
Compression chambers are delimited by the flanks
of the toothing and the compressor casing. The ro-
tation of the rotors continuously reduces the vol-
ume in the chambers until the compressed air is
pushed out through the outlet window of the stage
casing. Screw compressors count amongst rota-
tion-displacement compressors without oscillating
masses but with a pulsing output.
Electronic control unit
The main components of the electronic control
unit are a microprocessor, a touchscreen, film-pro-
tected keys and LEDs.
Detailed description of the operating instructions
for the electronic control unit.

3.2 Compressor design
Air-cooled
Fig. 3-1: Overview part 1 (air-cooled)
[1] Suction filter [17] Cooling air fan
[2] Suction regulator [18] Cooling air inlet filter pad
[3] Electric motor [19] Compressed air outlet
[4] Screw compressor [20] Base frame
[5] Pressure vessel [21] Control system control panel
[6] Fine separator [22] EMERGENCY-Off button
[7] Oil fill [23] Switch cabinet
[8] Oil drain [24] Supply cable, cable inlet
[9] Oil level indicator [25] Final compression temperature sensor
[10] Oil filter [26] Line pressure sensor
[11] Oil cooler [27] Final compression pressure sensor
[12] Safety valve [28] Opening for lifting tool
[13] Pressure-retention and non-return valve [29] Fan guard
[14] Air cooler [30] Cooler pressure relief

[15] Fine separator, suction [31] Heat recovery connection (optional)
[16] Oil temperature regulator [32] Moisture sensor

Fig. 3-2: Overview part 2 (water-cooled)
[1] Suction filter [20] Base frame
[2] Suction regulator [21] Control system control panel
[3] Electric motor [22] EMERGENCY-Off button
[4] Screw compressor [23] Switch cabinet
[5] Pressure vessel [24] Supply cable, cable inlet
[6] Fine separator [25] Final compression temperature sensor
[7] Oil fill [26] Line pressure sensor
[8] Oil drain [27] Final compression pressure sensor
[9] Oil level indicator [28] Opening for lifting tool
[10] Oil filter [29] Fan guard
[11] Oil cooler [30] Cooler pressure relief
[12] Safety valve [31] Heat recovery connection (optional)
[13] Pressure-retention and non-return valve [32] Cooling water inlet (only Lxx W)
[14] Air cooler [33] Cooling water outlet (only Lxx W)
[15] Fine separator, suction [34] Dirt trap (only Lxx W)

[16] Oil temperature regulator [35] Cooling water solenoid valve (only Lxx W)
[17] Cooling air fan [36] Throttle valve (only Lxx W)
[18] Cooling air inlet filter pad [37] Cooling water temperature monitor (only Lxx
W)
[19] Compressed air outlet [38] Moisture sensor
3.3 System scheme air-cooled compressor
28
S7 27
1
17
E9
%
I
2
2.3 2.2 2.1
21
19
33
25
Y4
24
Y1
23
22
R1 4
3
5
R2
20
E5 E4
35
30
S5
18 16
15
26
32
Y6
34
S14
31
I
%
I
14
P
13
B1
12
729
S6
11
B2
69
10
8
3˜
36
Fig. 3-3: Functional schematic
Compressed air Oil
Control air Cooling water
Chart 3-1: Cables