Gardner Denver TWISTAIR EWDQ D Service manual

GARDNER DENVER
TWISTAIR
OIL–FREE ROTARY SCREW
COMPRESSORS
DOMESTIC MODELS
EWDQ_D – 40 to 75 HP – AIR COOLED
EWDS_D – 40 to 75 HP – WATER COOLED
INTERNATIONAL MODELS
EWDQ_E – 30 to 55 KW – AIR COOLED
EWDS_E – 30 to 55 KW – WATER COOLED
OPERATING AND
SERVICE MANUAL
13–11–602
3rd Edition
June, 1996

13–11–602 Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner Denver Compressor genuine parts, engine-
ered to original tolerances, are designed for optimum
dependability–––specificallyforGardnerDenvercom-
pressor systems. Design and material innovations are
theresultofyearsofexperiencewithhundredsofdiffer-
ent compressor applications. Reliability in materials
and quality assurance are incorporated in our genuine
replacement parts.
Your authorized Gardner Denver Compressor distribu-
tor offers all the backup you’ll need. A worldwide net-
workofauthorizeddistributorsprovidesthefinestprod-
uct support in the air compressor industry. Your local
authorized distributor maintains a large inventory of
genuinepartsandheisbackedup foremergencyparts
by direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
Denver air compressor with these services:
1. Trained parts specialists to assist you in selecting
the correct replacement parts.
2. Factory warranted new and remanufactured
rotaryscrewair ends.Most popularmodelreman-
ufacturedairendsaremaintainedinstockatMDC
for purchase on an exchange basic with liberal
core credit available for the replacement unit.
3. AfulllineoffactorytestedAEONtcompressorlu-
bricantsspecifically formulatedfor use inGardner
Denver compressors.
4. Repair and maintenance kits designed with the
necessary parts to simplify servicing your com-
pressor.
Authorized distributor service technicians are factory–
trained and skilled in compressor maintenance and re-
pair. They are ready to respond and assist you by pro-
viding fast, expert maintenance and repair services.
For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow
pages of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: [phone]
Phone: [phone] Fax: [phone]
(800) 245–4946
Fax: [phone]
REMANUFACTURED AIR ENDS
Whenever an air end requires replacement or repair,
Gardner Denver offers an industry unique, factory re-
manufactured air end exchange program. From its
modern Remanufacturing Center in Indianapolis, IN,
GardnerDenver iscommittedto supplyingyou withthe
highest quality, factory remanufactured air ends that
are guaranteed to save you time, aggrevation and
money.
Immediately Available
Repair downtime costs you money, which is why there
are over 200 remanufactured units in inventory at all
times, ready for immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average
over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, in-
spected and analyzed. Only those parts that can be
brought back to original factory specifications are re-
manufactured. Everyremanufactured airend receives
anewoverhaulkit: bearings,gears,seals,sleevesand
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
justdon’t do. Magnafluxand ultrasonicinspectionspot
cracked or stressed castings, monochromatic light
analysis exposes oil leaks, and coordinate measure-
ment machine inspects to +/– .0001”, insuring that all
remanufactured air ends meet factory performance
specifications.
Warranty
Gardner Denver backs up every remanufactured air
end with a new warranty . . . 18 months from purchase,
12 months from service.
GardnerDenverremanufacturedairendsdeliver
quali-
ty without question . . . year in and year out.
Call Gardner Denver for information on the air end ex-
change program and the name of your authorized dis-
tributor. Phone Number: 800–245–4946 or
FAX: [phone]

13–11–602 Page ii
FOREWORD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To
beassuredofreceivingmaximumservicefromthismachinetheownermustexercisecareinitsoperationandmain-
tenance.This book is written to givethe operator and maintenance departmentessential information for day-to-day
operation,maintenanceand adjustment.Careful adherenceto theseinstructionswill resultin economicaloperation
and minimum downtime.
Danger is used toindicate the presenceof a hazardwhich will causesevere personal
injury, death, or substantial property damage if the warning is ignored.
Warning isusedto indicatethepresence ofahazard whichcancause severeperson-
al injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
Notice is used tonotify people of installation,operation or maintenanceinformation
which is important but not hazard–related.

13–11–602 Page iii
This book covers the following models:
DOMESTIC MODELS:
HP Air Cooled Water Cooled Parts List
40 EWDQHD EWDSHD 13–11–503
50 EWDQJD EWDSJD 13–11–503
60 EWDQKD EWDSKD 13–11–503
75 EWDQLD EWDSLD 13–11–503
INTERNATIONAL MODELS:
KW Air Cooled Water Cooled Parts List
30 EWDQHE EWDSHE 13–11–504X
37 EWDQJE EWDSJE 13–11–504X
45 EWDQKE EWDSKE 13–11–504X
55 EWDQLE EWDSLE 13–11–504X
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER(see nameplateonunit). The SerialNumber
isalso stampedon topof thecylinder flangeto theright
of the inlet housing.
All orders for Parts should be placed with the nearest
authorized distributor.
Where NOT specified, quantity of parts required per
compressor or unit is one (1); where more than one is
required per unit, quantity is indicated in parenthesis.
SPECIFY EXACTLY THE NUMBER OF PARTS RE-
QUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left Hand side of a
compressor, stand at the motor end and look toward
the compressor. Right Hand and Left Hand are indi-
cated in parenthesis following the part name, i.e. (RH)
& (LH).

13–11–602 Page iv
TABLE OF CONTENTS
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions For Ordering Repair Parts iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations ix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1, General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2, Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3, Starting & Operating Procedures 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4, Controls & Instrumentation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5, Lubrication 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6, Air Filter 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7, Coupling 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8, Maintenance Schedule 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9, Trouble Shooting 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 10, Trouble Shooting Controls 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–11–602 Page v
Air and Water Discharge Temperature 16. . . . . . .
AIR FILTER, SECTION 6 45. . . . . . . . . . . . . . . . . . .
Air Filter Element Life 45. . . . . . . . . . . . . . . . . . . . . .
Air Filter Vacuum Switch 32. . . . . . . . . . . . . . . . . . .
Air Filter, Heavy Duty (Standard) 45. . . . . . . . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . .
Air Flow in the Compressor System 1. . . . . . . . . . .
Air Receiver, Auxiliary 11. . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Units, Location 9. . . . . . . . . . . . . . . . . .
Air/Water Reservoir 16. . . . . . . . . . . . . . . . . . . . . . . .
Alarm Relay 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Sentry–ES Control Display 22. . . . . . . . . . . . .
Auto Sentry–ES Controller
Alarm Relay 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Sequence Change 29. . . . . . . . . . . .
Connection to External Controls 30. . . . . . . . . .
Establishing Initial Sequence 28. . . . . . . . . . . . .
How Auto Sentry–ES Controls Pressure
while Sequencing 28. . . . . . . . . . . . . . . . . . .
Installation 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Features 29. . . . . . . . . . . . . . . . . . . . . . . . .
Programming and Setup 24. . . . . . . . . . . . . . . .
Remote On / Off 30. . . . . . . . . . . . . . . . . . . . . . . .
Serial Communications 30. . . . . . . . . . . . . . . . . .
Auto Sentry–ES Operation 21. . . . . . . . . . . . . . . . .
Automatic Mode 21. . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode 21. . . . . . . . . . . . . . . . . . . .
Low Demand Mode 21. . . . . . . . . . . . . . . . . . . . .
Sequence Mode 22. . . . . . . . . . . . . . . . . . . . . . . .
Automatic Mode Operation 21. . . . . . . . . . . . . . . . .
Auxiliary Air Receiver 11. . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve Piping 14. . . . . . . . . . . . . . . . . . . .
Breather, Oil 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breather 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Injection Water Filter 16. . . . . . . . . . . . . .
Check, Daily 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Injection Water Cooler – Water
Cooled Heat Exchanger 14. . . . . . . . . . . . . . . .
Compressor Injection Water Inlet Temperature 16
Compressor Injection Water System Check 16. . .
Compressor Oil System Check 42. . . . . . . . . . . . . .
Compressor Oil System 41. . . . . . . . . . . . . . . . . . . .
Compressor Water Drain 13. . . . . . . . . . . . . . . . . . .
Constant Run Mode Operation 21. . . . . . . . . . . . . .
Control Devices, Other 30. . . . . . . . . . . . . . . . . . . . .
Control Piping 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Transformer 33. . . . . . . . . . . . . . . . . . . . . . .
Control Valve, Water Flow for Heat Exchanger 15
CONTROLS & INSTRUMENTS, SECTION 4 21.
Controls & Instruments, General Description 21. .
COUPLING, SECTION 7 47. . . . . . . . . . . . . . . . . . .
Coupling 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Cushion Design 47. . . . . . . . . . . . . . .
Daily Check 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 7, 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 12. . . . . . . . . . . . . . . . . . . .
Discharge Thermistor 32. . . . . . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 10. . . . . . . . . . . . . . . . . . . . . . . .
Drain, Compressor Water 13. . . . . . . . . . . . . . . . . .
Electric Motor Grease Recommendations 17. . . .
Electric Motor Regreasing Interval 17. . . . . . . . . . .
Electrical Wiring 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Units 16. . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Air Filter 45. . . . . . . . . . . . . . . . . . . . .
Element, Oil Filter 41. . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop Push–Button 33. . . . . . . . . . . . . .
Emergency Stop Shutdown 23. . . . . . . . . . . . . . . . .
Enclosure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Device Shutdown 24. . . . . . . . . . . . . . . . . .
Fan and Pump Starter 33. . . . . . . . . . . . . . . . . . . . .
Filter Element 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Heavy Duty Air (Standard) 45. . . . . . . . . . . .

INDEX
13–11–602 Page vi
Filter, Injection Water, Changing 16. . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foundation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Oil Level 31, 32. . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . .
Grease Recommendations, Electric Motor 17. . . .
Grounding 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger, Water Cooled, Compressor
Injection Water Cooler 14. . . . . . . . . . . . . . . . . .
High Pressure Shutdown 23. . . . . . . . . . . . . . . . . . .
High Temperature Operation 41. . . . . . . . . . . . . . . .
High Temperature Shutdown 23. . . . . . . . . . . . . . . .
High Water Level Shutdown 23. . . . . . . . . . . . . . . .
Injection Water Filter, Changing 16. . . . . . . . . . . . .
Inlet Line 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 46. . . . . . . . . . . . . . . . . . . . .
INSTALLATION, SECTION 2 9. . . . . . . . . . . . . . . .
Installation, General 9. . . . . . . . . . . . . . . . . . . . . . . .
Lifting Unit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 12. . . . . . . . . . . . . . . . . . . .
Line, Inlet 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Units 9. . . . . . . . . . . . . . . . . . . . . . . .
Water–Cooled Units 10. . . . . . . . . . . . . . . . . . . .
Low Demand Mode Operation 21. . . . . . . . . . . . . .
Low Oil Pressure Shutdown 23. . . . . . . . . . . . . . . .
Low Water Pressure Shutdown 23. . . . . . . . . . . . .
Lubricant, Recommended 41. . . . . . . . . . . . . . . . . .
Lubrication 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication, Motor 17. . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 41. . . . . . . . . . . . . .
Main Starter 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE, SECTION 8 48. . .
Minimum Discharge Pressure Valve 31. . . . . . . . .
Moisture Separator/Trap 11. . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 17. . . . . . . . . . .
Motor Lubrication 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Protective Devices 23. . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 17. . . . . . . . . . . . . . . . . .
Oil Breather 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Gauge 31, 42. . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Transducer 32. . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 10. . . . . . . . . . . . . . . . . . . . . . . .
Oil Specifications 41. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System, Compressor 41. . . . . . . . . . . . . . . . . . .
Oil Thermistor 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation
Automatic Mode 21. . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode 21. . . . . . . . . . . . . . . . . . . .
High Temperature 41. . . . . . . . . . . . . . . . . . . . . .
Low Demand Mode 21. . . . . . . . . . . . . . . . . . . . .
Sequence Mode 22. . . . . . . . . . . . . . . . . . . . . . . .
Optional Switches 33. . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Piping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping
Blowdown Valve 14. . . . . . . . . . . . . . . . . . . . . . . .
Control 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Series 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Failure Shutdown 24. . . . . . . . . . . . . . . . . . .
Pressure Differential
Water Injection Cooler, Air Cooled Radiator 16
Water Injection Cooler, Water Cooled
Heat Exchanger 16. . . . . . . . . . . . . . . . . . . .
Pressure Regulator 31. . . . . . . . . . . . . . . . . . . . . . . .
Prestart–Up Instructions 19. . . . . . . . . . . . . . . . . . . .
Air Filter 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode 20. . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–11–602 Page vii
Piping 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 20. . . . . . . . . . . . . . . . . . . . . . .
Programming and Setup, Auto Sentry–ES
Controller 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Shutdowns 23. . . . . . . . . . . . . . . . . . . . . .
Pump and Fan Starter 33. . . . . . . . . . . . . . . . . . . . .
Recommended Lubricant 41. . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 17. . . . . . . . . .
Regulator, Pressure 31. . . . . . . . . . . . . . . . . . . . . . .
Relief Valve 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote On / Off 30. . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Ordering Instructions iii. . . . . . . . . . .
Reservoir Pressure Transducer 32. . . . . . . . . . . . .
Reservoir, Air/Water 16. . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions 5, 6. . . . . . . . . . . . . . . . . . . . . . .
Separator/Trap, Moisture 11. . . . . . . . . . . . . . . . . . .
Sequence Mode Operation 22. . . . . . . . . . . . . . . . .
Sequencing Compressors with
Auto Sentry–ES 27. . . . . . . . . . . . . . . . . . . . . . .
Serial Communications 30. . . . . . . . . . . . . . . . . . . .
Series Piping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Check List 48. . . . . . . . . . . . . . . . . . . . . . . .
Air Filter 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 125 Hours Operation 48. . . . . . . . . . . . . .
Every 6000 Hours Operation 48. . . . . . . . . . . . .
Every 8 Hours Operation 48. . . . . . . . . . . . . . . .
Every Year 48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 48. . . . . . . . . . . . . . . . . . . . . . .
Water Filter 48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdowns
Emergency Stop 23. . . . . . . . . . . . . . . . . . . . . . .
External Device 24. . . . . . . . . . . . . . . . . . . . . . . .
High Pressure 23. . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 23. . . . . . . . . . . . . . . . . . . . . .
High Water Level 23. . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure 23. . . . . . . . . . . . . . . . . . . . . . .
Low Water Pressure 23. . . . . . . . . . . . . . . . . . . .
Motor Protective Devices 23. . . . . . . . . . . . . . . .
Other 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Failure 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Filter Differential 23. . . . . . . . . . . . . . . . . .
Shutoff Valve, Cooling Water – Water Cooled
Heat Exchanger 15. . . . . . . . . . . . . . . . . . . . . . .
Shuttle Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valves IVC and IVO 31. . . . . . . . . . . . . . .
Specifications, Oil 41. . . . . . . . . . . . . . . . . . . . . . . . .
Starter
Main 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump and Fan 33. . . . . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES
SECTION 3 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Unit 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Strip, Terminal 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Air Filter Vacuum 32. . . . . . . . . . . . . . . . . . .
Switches
Optional 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Level 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure Transducer 32. . . . . . . . . . . . . . .
System Thermistor 32. . . . . . . . . . . . . . . . . . . . . . . .
Temperature
Air and Water Discharge 16. . . . . . . . . . . . . . . .
Compressor Injection Water Inlet 16. . . . . . . . .
Temperature Differential
Water Injection Cooler, Air Cooled Radiator 16
Water Injection Cooler, Water Cooled
Heat Exchanger 16. . . . . . . . . . . . . . . . . . . .
Terminal Strip 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor
Discharge 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer
Oil Pressure 32. . . . . . . . . . . . . . . . . . . . . . . . . . .
Reservoir Pressure 32. . . . . . . . . . . . . . . . . . . . .

INDEX
13–11–602 Page viii
System Pressure 32. . . . . . . . . . . . . . . . . . . . . . .
Transformer, Control 33. . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING, SECTION 9 49. . . . . . . . .
TROUBLE SHOOTING CONTROLS,
SECTION 10 51. . . . . . . . . . . . . . . . . . . . . . . . . .
Tube, Inlet 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve
Blowdown 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Water Shutoff 15. . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure 31. . . . . . . . . . . .
Relief 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid IVC and IVO 31. . . . . . . . . . . . . . . . . . .
Water Flow Control 15. . . . . . . . . . . . . . . . . . . . .
Water Solenoid 32. . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Cooler, Compressor Injection 14. . . . . . . . .
Water Filter Differential Shutdown 23. . . . . . . . . . .
Water Flow Control Valve for Heat Exchanger 15.
Water Injection Cooler Pressure Differential
Air Cooled Radiator 16. . . . . . . . . . . . . . . . . . . . .
Water Cooled Heat Exchanger 16. . . . . . . . . . .
Water Injection Cooler Temperature Differential
Air Cooled Radiator 16. . . . . . . . . . . . . . . . . . . . .
Water Cooled Heat Exchanger 16. . . . . . . . . . .
Water Level Switches 32. . . . . . . . . . . . . . . . . . . . . .
Water Piping (Water–Cooled Heat Exchanger
Models Only) 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Shutoff Valve, Water Cooled Heat Ex-
changer 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Solenoid Valves 32. . . . . . . . . . . . . . . . . . . . .
Water System Check, Compressor Injection 16. .
Water–Cooled Units, Location 10. . . . . . . . . . . . . .
Wiring, Electrical 16. . . . . . . . . . . . . . . . . . . . . . . . . .

13–11–602 Page ix
LIST OF ILLUSTRATIONS
Figure # Description Page
Figure 1–1 Compression Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 Cooler, Air/Water Separator and Relief Valve 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–3 Compressor, Drive Motor, Minimum Pressure/Check Valve, Moisture Separator 2. . . . .
Figure 1–4 Inlet Valve, All Filters, Oil Level Gauge 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–5 Starter/Control Box, Oil Reservoir, Cooling Valve 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–6 Air/Water Schematic 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–7 Oil Schematic 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–1 Typical Compressor Room 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Air Flow Chart 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–3 Additional Water Limitations 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–4 Inlet Line Lengths 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–5 Heat Exchanger Approximate Water Flow 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–6 Aftercooler Approximate Water Flow 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–7 Series Piping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–8 Parallel Piping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–9 Water Control Valve 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–1 Auto Sentry–ES Display 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Flow Chart for Set–Up Programming 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Blowdown Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Inlet Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Shuttle Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Control Tubing Schematic 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Control Schematic – Compressor At Full Load – Constant Speed Mode 35. . . . . . . . . . .
Figure 4–8 Control Schematic – Compressor Unloaded – Constant Speed Mode 36. . . . . . . . . . . . .
Figure 4–9 Control Schematic – Compressor Unloaded – Low Demand Mode 37. . . . . . . . . . . . . . . .
Figure 4–10 Wiring Diagram – Full Voltage – 202EWD546 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–11 Wiring Diagram – Wye Delta – 203EWD546 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–12 Auto Sentry ES Controller Display 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Oil Level Gauge 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Flow Diagram (Air Cooled) 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Flow Diagram (Water Cooled) 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy Duty Air Filter (Standard) 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Installation of Coupling Cushions 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–11–602 Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSION CYCLE
COMPRESSOR – The Gardner DenverRRotary
Screw compressor is a single stage, positive displace-
mentrotarymachineusingmeshing helicalrotorstoef-
fect compression. Both rotors are supported between
high capacity roller bearings located outside the com-
pression chamber. Single width cylindrical roller bear-
ings are used at the inlet end of the rotors to carry part
of the radial loads. Angular contact ball bearings at the
discharge end locate each rotor axially and carry all
thrust loads and the remainder of the radial loads.
COMPRESSION PRINCIPLE (FIGURE 1–1) – Com-
pression is accomplished by the main and secondary
rotors synchronously meshing in a one–piece cylinder.
Themain rotorhas four(4) helical lobes90_apart. The
secondary rotor has six (6) matching helical grooves
60_apart to allow meshing with main rotor lobes.
Theairinletportislocatedontopofthecompressorcyl-
inder near the drive shaft end. The discharge port is
near the bottom at the opposite end of the compressor
cylinder.
Figure 1–1 is an inverted view to show inlet
and discharge ports
.Thecompression cycle begins as
rotors unmesh at the inlet port and air is drawn into the
cavity between the main rotor lobes and secondary ro-
torgrooves (A). Whenthe rotorspass the inletport cut-
off,airistrappedintheinterlobecavityandflowsaxially
with the meshing rotors (B). As meshing continues,
more of the main rotor lobe enters the secondary rotor
groove, normal volume is reduced and pressure in-
creases.
Water isinjectedinto the cylinder toremove the heat of
compression and seal internal clearances. Volume re-
duction and pressure increase continues until the air/
water mixture trapped in the interlobe cavity by the ro-
tors passes the discharge port and is released to the
air/water reservoir (C). Each rotor cavity follows the
same “fill–compress–discharge” cycle in rapid succes-
sion to produce a discharge air flow that is continuous,
smooth and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM
(FIGURE 1–4, page 3) – Air enters the air filter and
passes through the inlet unloader valve to the com-
pressor.After compression, the air/water mixture flows
to the separator tank where most of the water is re-
moved by velocity change and impingement. The air
thenflowsto theaftercooler,thento themoisturesepa-
rator where the water that has condensed out is re-
turned to the air end. The air then flows through the
minimumpressure/checkvalveandtotheplantairsys-
tem.
WATER SYSTEM (FIGURE 1–6, page 4) – Water is
forced by air pressure from the separator tank through
the heat exchanger, the water filter and into the com-
pression chamber injection ports. The water removes
theheat of compressionand sealsinternal clearances.
Seals minimize water leakage out of the compression
chamber.
LUBRICATION – Oil in the oil reservoir flows to the oil
pump and is pumped through the oil filter and into both
thegearhousinganddischargebearinghousingwhere
it lubricates both the bearings and the gears. The oil
drainsbackout ofthe bottomof thehousingsand flows
back to the reservoir.

13–11–602 Page 2
FIGURE 1–2 – COOLER, AIR/WATER SEPARATOR AND RELIEF VALVE
FIGURE 1–3 – COMPRESSOR, DRIVE MOTOR, MINIMUM
PRESSURE/CHECK VALVE, MOISTURE SEPARATOR

13–11–602 Page 3
FIGURE 1–4 – INLET VALVE, ALL FILTERS, OIL LEVEL GAUGE
FIGURE 1–5 – STARTER/CONTROL BOX, OIL RESERVOIR, COOLING VALVE

13–11–602 Page 4
FIGURE 1–6 – AIR/WATER SCHEMATIC
FIGURE 1–7 – OIL SCHEMATIC

13–11–602 Page 5
SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances
cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for
safety hazards and be cautious.
Some general safety precautions are given below:
Failure to observe these notices could result in injury to or death of personnel.
DKeep fingers and clothing away from revolving fan, drive coupling, etc.
DDo not use the air discharge from this unit for breathing – not suitable for hu-
man consumption.
DDonot loosenorremove theoil fillerplug, drainplugs, covers,the thermostat-
icmixingvalve orbreakanyconnections,etc., inthecompressorair oroilsys-
tem until the unit is shut down and the air pressure has been relieved.
DElectrical shock can and may be fatal.
DCompressor unit mustbe grounded inaccordance withthe National Electrical
Code. A ground jumper equal to the size of the equipment ground conductor
must be used to connect the compressor motor base to the unit base.
DFan motors must remain grounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.
DOpen main disconnect switch, tag and lockout before working on the control.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.

13–11–602 Page 6
Failure to observe these notices could result in damage to equipment.
DStop the unit if any repairs or adjustments on or around the compressor are
required.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.
DAn Excess Flow Valve should be on all compressed air supply hoses ex-
ceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)
DDonot exceed the ratedmaximum pressure values shown on the nameplate.
DDo not operate unit if safety devices are not operating properly. Check peri-
odically. Never bypass safety devices.

13–11–602 Page 7
DECALS
206EAQ077 212EAQ077
218EAQ077
211EAQ077 207EAQ077

13–11–602 Page 8
DECALS
216EAQ077
206EWD077
222EAQ077
221EAQ077 208EAQ077

13–11–602 Page 9
SECTION 2
INSTALLATION
GENERAL– On receipt of theunit, check for any dam-
age that may have occurred during transit or handling.
Report any damage or missing parts as soon as pos-
sible.
Do not electric weld on the compres-
sor or base; bearings can be damaged
by passage of current.
LIFTING UNIT – Proper lifting and/or transporting
methodsmust beusedto preventdamage. Liftingslots
areprovidedinthebasefortowmotoruse.Theunitmay
also be moved into location by rolling on bars.
Lift compressor unit by base only. Do
not use other places such as motor,
compressor or discharge manifold
piping as lifting points.
The eyebolts or lugs provided on the
motor are for lifting the motor only
and should not be used to lift any
additional weight. All eyebolts must
be securely tightened. When lifting
the motor the lifting angle must not
exceed 15 degrees.Failure to observe
this warning may result in damage to
equipment or personal injury.
LOCATION – The compressor should be installed, in
a clean, well–lighted, well–ventilated area with ample
space all around the unit for maintenance. Select a
location that provides a cool, clean, dry source of air.
Insomecasesitmaybenecessarytoinstalltheairfilter
atsome distancefromthe compressorto obtainproper
air supply.
Do not install this compressor in a
location that may be subject to tem-
peratures below 32_F. (0_C.).
Below freezing temperatures will
cause damage to the compressor.
Both the air–cooled and water–cooled units require
coolingairaswellasairtothecompressorinlet.Proper
ventilation MUST be provided; hot air must be ex-
hausted from the compressor operating area. A typical
inlet–outlet air flow arrangement is shown in
FIGURE 2–1.
Air–Cooled Units – A combination water/aftercooler
is supplied as standard equipment on all air–cooled
units.Theair–cooled motorandfan aremountedtothe
FIGURE 2–1 – TYPICAL COMPRESSOR ROOM
* 80_F (27_C) Inlet Air
Minimum Air Flow* For Compression
And Cooling – Cubic Feet/Minute
(Cubic Meters/Minute)
HP (KW) Air Cooled Water Cooled
40 – 75 HP 12,500 1,700
(30 – 55 KW) (354) (48)
FIGURE 2–2 – AIR FLOW CHART

13–11–602 Page 10
cooling module; air is exhausted through the cooler,
then through the top of the unit. The air–cooled unit
with the standard enclosure requires sufficient flow,
FIGURE 2–2, page 9, for the compressor water/after-
cooling system and for electric motor cooling. Air is
drawn into the unit at the motor side of the enclosure
and is exhausted at the cooler side. Do not block the
air flow to and from the unit. Allow three and one–half
(3–1/2) feet (1.1 M) to the nearest obstruction on the
starter end and control box end of the unit. Allow three
(3) feet (.9 M) to the nearest obstruction above and on
other sides of unit.
For continuous efficiency, air cooled cooler cores must
be periodically cleaned with either vacuum or com-
pressed air.
For copper water coolers, do not use
any cleaning solution that is not com-
patible with copper. Use of improper
solution may result in damage to the
cooler.
If wet cleaning is required, shield the motor and spray
on a mild soap solution, then flush with clean water.
Water–Cooled Units – The water–cooled unit withthe
standard enclosure requires sufficient air flow,
FIGURE 2–2, page 9, for electric motor cooling. Air is
drawn into the unit at the top of the enclosure on the
motor end and is exhausted at the top of the enclosure
abovethe coolers. Donot block air flowto and fromthe
unit.Allowthreeandone–half(3–1/2)feet(1.1M)tothe
nearest obstruction on the starter end and control box
sideoftheunit.Allowthree(3)feet(.9 M)tothenearest
obstruction above and on other sides of the unit. For
additional information, see pages 13 through 15.
FOUNDATION – The Gardner Denver Rotary Screw
compressor requires no special foundation, but should
bemountedonasmooth,solidsurface.Wheneverpos-
sible install the unit near level. Temporary installation
may be made at a maximum 10oangle lengthwise or
10_sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt, or danger of shifting from outside vibration or mov-
ing vehicles may require the use of mounting bolts and
shims to provide uniform support for the base.
OIL BREATHER – To prevent oil leakage in shipment,
the breather vent normally located in the top of the res-
ervoir is replaced by a plug. Before operating the unit,
remove the 1–1/4 inch plugs and install the breathers.
Failure to remove the plug from the
top of the reservoir and install the
breather before operation will result
in machine damage.
Potentialcontaminationofoilinletsupplyduetominute
traces of vapors from the oil sump vent can be avoided
by piping the vents to the outside.
When remote mounting theoil breath-
er, be certain there are no low places
in the piping where oil could collect
and prevent proper venting of the oil
sump.
OIL RESERVOIR DRAIN – The oil drain is piped from
thebottomofthereservoirtothe sideoftheframe.This
drain is approximately 4 inches (100 mm) above the
floor level. If this is not sufficient to conveniently drain
the oil, some other methods of providing drain are:
1. Elevate the compressor unit on raised blocks to
obtain the desired drain height.
If the compressor unit base is raised
above floor level, the space between
the floor and the base bottom must be
closed with solid material all around
to prevent recirculation of hotair from
the oil cooler end and over tempera-
ture operation.
2. Construct an oil sump or trough below the floor
level and pump or bail the drained oil.
3. Pump oil from the reservoir filler opening or drain
to a container.
ENCLOSURE– The compressor, electric motor, water
cooler and aftercooler are mounted inside the enclo-
sure. Service doors are provided for maintenance ac-
cess. Be sure to allow enough space around the unit