Gardner Denver ELECTRA-SCREW EBE DH-15 HP Service manual

GARDNER DENVER
ELECTRA–SCREWSTATIONARY
BASE–MOUNTED & TANK MOUNTED
COMPRESSORS
DOMESTIC MODELS
EBE_DH – 15 HP
EBE_EH – 20 HP
EBE_FH – 25 HP
EBE_GH – 30 HP
INTERNATIONAL MODELS
EBEQEJ – 20 HP (15 KW)
EBEQFJ – 25 HP (19 KW)
EBEQGJ – 30 HP (22 KW)
OPERATING AND
SERVICE MANUAL
13–8–609
5th Edition
March, 1997

13–8–609 Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVERRCOMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner DenverRCompressor 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.
Yourauthorized GardnerDenverRCompressordistrib-
utor 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
genuinepartsand isbackedup foremergency partsby
direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
DenverRair 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 basis 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 iscommittedtosupplyingyouwiththe
highest quality, factory remanufactured air ends that
are guaranteed to save you time, aggravation and
money.
Immediately Available
Repair downtime costs you money, which is why there
are over 200 remanufactured units in inventory at all
times, ready for immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average
over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, 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]

13–8–609 Page ii
FOREWORD
Gardner DenverElectra–Screwcompressors are the result of advanced engineering and skilled manufacturing.
To be assured of receiving maximum service from this machine the owner must exercise care in its operation and
maintenance. This book is written to give the operator and maintenance department essential information for day–
to–day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical
operation and minimum downtime.
Danger is used toindicate the presence of ahazard which will cause severepersonal
injury, death, or substantial property damage if the warning is ignored.
Warningisusedto indicatethepresenceofahazard whichcancausesevereperson-
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.
This book covers the following models:
HP (KW) PSIG (Bar) Air Cooled Domestic International
15 100, 125 EBE_DH 13–8–509
20 (15) 100, 125, 150 EBE_EH (EBE_EJ) 13–8–509 13–8–509X
(6.9), (8.6), (10.3)
25 (19) 100, 125, 150, 175 EBE_FH (EBE_FJ) 13–8–509 13–8–509X
(6.9), (8.6), (10.3), (12.1)
30 (22) 100, 125, 150, 175 EBE_FH (EBE_GJ) 13–8–509 13–8–509X
(6.9), (8.6), (10.3), (12.1)

13–8–609 Page iii
TABLE OF CONTENTS
Maintain Compressor Reliability and Performance With Genuine Gardner DenverCompressor
Parts and Support Services i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index iv – vi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1, General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2, Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3, Starting & Operating Procedures 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4, Controls & Instrumentation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6, Air Filter 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7, Belt Drive 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8, Maintenance Schedule 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9, Trouble Shooting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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).

13–8–609 Page iv
INDEX
Addition of Oil Between Changes 28. . . . . . . . . . . . . . .
Air Control Components 16. . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Pressure/Check Valve 17. . . . . . . . . . . .
Air Cooled Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Ends, Remanufactured i. . . . . . . . . . . . . . . . . . . . . .
AIR FILTER, SECTION 6 33. . . . . . . . . . . . . . . . . . . . . .
Air Filter, Standard Duty 34. . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element Life 33, 34. . . . . . . . . . . . . . . . . . . . .
Air Flow in Compressor System 1. . . . . . . . . . . . . . . . .
Air Receiver, Auxiliary 10. . . . . . . . . . . . . . . . . . . . . . . . .
AUTO LAG Button with LED 18. . . . . . . . . . . . . . . . . . .
AUTO LEAD Button with LED 18. . . . . . . . . . . . . . . . . .
Auto–Sentry S Controller with Keypad 17. . . . . . . . . .
Auxiliary Air Receiver 10. . . . . . . . . . . . . . . . . . . . . . . . .
BELT DRIVE, SECTION 7 35. . . . . . . . . . . . . . . . . . . . .
Belt Tension, Checking 35. . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 16, 17. . . . . . . . . . . . . . . . . . . . . . . . .
Change Air Filter LED 18. . . . . . . . . . . . . . . . . . . . . . . . .
Change Procedure, Lubricant 27. . . . . . . . . . . . . . . . . .
Change Separator LED 18. . . . . . . . . . . . . . . . . . . . . . .
Check, Daily 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Belt Tension 35. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Draining Oil System 29. . . . . . . . . . . . . .
Cold Ambient Operation 28. . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Operation 10. . . . . . . . . . . . . . . . . . . . . .
Cold Weather Operation, Installation for 10. . . . . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Cooler 31. . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Filter 30. . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Separator 31. . . . . . . . . . . . . . . . . . . . .
Compressor Oil System 26. . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil System Check 32. . . . . . . . . . . . . . . . .
Compressor System, Air Flow 1. . . . . . . . . . . . . . . . . . .
CONSTANT RUN Button with LED 18. . . . . . . . . . . . .
Control Piping 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control System Operation 17. . . . . . . . . . . . . . . . . . . . .
AUTO LAG Button with LED 18. . . . . . . . . . . . . . .
AUTO LEAD Button with LED 18. . . . . . . . . . . . . .
Change Air Filter LED 18. . . . . . . . . . . . . . . . . . . . .
Change Separator LED 18. . . . . . . . . . . . . . . . . . . .
CONSTANT RUN Button with LED 18. . . . . . . . . .
High Air Temperature LED 18. . . . . . . . . . . . . . . . .
Motor Overload LED 18. . . . . . . . . . . . . . . . . . . . . .
Pressure and Temperature Digital Readouts 19.
STOP/RESET Button with LED 17. . . . . . . . . . . . .
Controller, Auto–Sentry S with Keypad 17. . . . . . . . . .
CONTROLS & INSTRUMENTS, SECTION 4 15. . . .
Controls & Instruments, General 15. . . . . . . . . . . . . . .
Cooler, Compressor Oil 31. . . . . . . . . . . . . . . . . . . . . . .
Cooling, Sealing and Lubrication 1. . . . . . . . . . . . . . . .
Daily Check 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 6, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions of Error Messages 19. . . . . . . . . . . . . . . . . .
Devices, Motor Protection 15. . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 11. . . . . . . . . . . . . . . . . . . . . . .
Discharge Temperature, High 15. . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning Oil System 29. . . . . . . . . . . . . .
Electric Motor Grease Recommendations 12. . . . . . .
Electric Motor Regreasing Interval 12. . . . . . . . . . . . . .
Element, Air Filter 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Air Filter 33, 34. . . . . . . . . . . . . . . . . . . .
Emergency Stop Pushbutton 17. . . . . . . . . . . . . . . . . . .
Enclosure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Compressor Oil 30. . . . . . . . . . . . . . . . . . . . . . . . .
Foundation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauges, Oil Sight 17, 28. . . . . . . . . . . . . . . . . . . . . . . .
Gauging, Pressure Differential 31. . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . . . . .

13–8–609 Page v
INDEX
Grease Recommendations, Electric Motor 12. . . . . . .
Grounding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Air Temperature LED 18. . . . . . . . . . . . . . . . . . . . .
High Discharge Temperature 15. . . . . . . . . . . . . . . . . . .
High Temperature Operation 27. . . . . . . . . . . . . . . . . . .
Hourmeter 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Line 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Line Lengths 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Tube 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION, SECTION 2 8. . . . . . . . . . . . . . . . . . .
Installation, General 8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation for Cold Weather Operation 10. . . . . . . . .
Instructions for Ordering Repair Parts iii. . . . . . . . . . . .
Instruments 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lead–Lag Operation of Two Compressors 21. . . . . . .
Lifting Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 11. . . . . . . . . . . . . . . . . . . . . . .
Line, Inlet 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load–Unload Pressure Setpoints, Programming 19.
Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant, Recommended 26. . . . . . . . . . . . . . . . . . . . .
Lubricant Change Procedure 27. . . . . . . . . . . . . . . . . .
Lubrication, Motor 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication, Cooling and Sealing 1. . . . . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 26. . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE, SECTION 8 36. . . . . .
Minimum Pressure/Check Valve 17. . . . . . . . . . . . . . . .
Moisture in the Oil System 28. . . . . . . . . . . . . . . . . . . . .
Moisture Separator/Trap 10. . . . . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 12. . . . . . . . . . . . . .
Motor Lubrication 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Overload LED 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Protection Devices 15. . . . . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 12. . . . . . . . . . . . . . . . . . . . .
Oil Change Interval 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Compressor 31. . . . . . . . . . . . . . . . . . . . . . .
Oil Filter, Compressor 30. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator
Compressor 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal for Inspection or Replacement 32. . . . .
Oil Sight Gauges 17, 28. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Specifications 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System
Compressor 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning 29. . . . . . . . . . . . . . . . . . . . .
Oil System Check 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air and Oil Discharge Temperature 32. . . . . . . . . .
Compressor Oil Inlet Temperature 32. . . . . . . . . .
Oil Cooler Oil Pressure Differential 32. . . . . . . . . .
Oil Cooler Temperature Differential 32. . . . . . . . . .
Oil Inlet Pressure 32. . . . . . . . . . . . . . . . . . . . . . . . .
Operation
Cold Ambient 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control System 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 27. . . . . . . . . . . . . . . . . . . . . . . .
Lead–Lag, of Two Compressors 21. . . . . . . . . . . .
Piping, Control 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure and Temperature Digital Readouts 19. . . . .
Pressure Differential Gauging 31. . . . . . . . . . . . . . . . . .
Prestart–Up Instructions 13. . . . . . . . . . . . . . . . . . . . . . .
Air Filter 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Piping 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–8–609 Page vi
INDEX
Rotation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 14. . . . . . . . . . . . . . . . . . . . . . . . .
Programming Load–Unload Pressure Setpoints 19. .
Protective Devices
Blowdown Valve 16. . . . . . . . . . . . . . . . . . . . . . . . . .
High Discharge Temperature 15. . . . . . . . . . . . . . .
Motor Protection Devices 15. . . . . . . . . . . . . . . . . .
Relief Valve 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separator Differential Pressure 15. . . . . . . . . . . . .
Recommended Lubricant 26. . . . . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 12. . . . . . . . . . . . .
Relief Valve 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Instructions for Ordering iii. . . . . . . . . . .
Reservoir, Oil 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions 4, 5. . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing, Lubrication and Cleaning 1. . . . . . . . . . . . . . .
Separator, Compressor Oil 31. . . . . . . . . . . . . . . . . . . .
Separator Differential Pressure 15. . . . . . . . . . . . . . . . .
Separator/Trap, Moisture 10. . . . . . . . . . . . . . . . . . . . . .
SERVICE CHECK LIST, AIR FILTER 36. . . . . . . . . . .
Service Check List 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 1000 Hours Operation 36. . . . . . . . . . . . . . .
Every 125 Hours Operation 36. . . . . . . . . . . . . . . .
Every 6000 Hours Operation 36. . . . . . . . . . . . . . .
Every 8 Hours Operation 36. . . . . . . . . . . . . . . . . .
Every Year 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 36. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications, Oil 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter/Control Box 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto–Sentry S Controller with Keypad 17. . . . . . .
Emergency Stop Pushbutton 17. . . . . . . . . . . . . . .
Hourmeter 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES,
SECTION 3 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOP/RESET Button with LED 17. . . . . . . . . . . . . . . .
Stopping the Unit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature, High Discharge 15. . . . . . . . . . . . . . . . . .
Thermal Control (Thermostatic Mixing) Valve 31. . . .
TROUBLE SHOOTING, SECTION 9 37. . . . . . . . . . . .
Valve
Blowdown 16, 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Pressure/Check 17. . . . . . . . . . . . . . . . .
Relief 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal Control (Thermostatic Mixing) 31. . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–8–609 Page vii
LIST OF ILLUSTRATIONS
Figure 1–1 Compressor Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 Minimum Pressure/Check Valve, Separators & Oil Filter – Package 2. . . . . . . . . . . . . . . . . . . . . . .
Figure 1–3 Oil Level Gauges, Starter/Control Box & Air Filter – Package 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–1 Typical Compressor Room 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Air Flow Chart 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–3 Cold Weather Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–1 Control Schematic 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Inlet Valve 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Minimum Pressure/Check Valve 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Definition of Error Messages 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Pressure Chart 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Subtractive Pilot (Closed) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Subtractive Pilot (Opened) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–8 Maximum Setpoints for Auto–Sentry S Controller, PSIG 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–9 Auto–Sentry S Solid State Control Touch Pad 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–10 Wiring Diagram – Dual Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–11 Wiring Diagram – Wye Delta 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Flow Diagram – Air–Oil System 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Approximate Oil System Capacities 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Oil Change Interval 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–4 Thermostatic Mixing Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy Duty Air Filter 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–2 Standard Duty Air Filter, Domestic Only 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Belt Tension 3VX Belts 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–8–609 Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSOR CYCLE
COMPRESSOR – The Gardner DenverRcompres-
sor is a single stage, positive displacement rotary ma-
chine using meshing helical rotors to effect compres-
sion. Both rotors are supported between high capacity
roller bearings located outside the compression cham-
ber. Single width cylindrical roller bearings are used at
the inlet end of the rotors to carry part of the radial
loads. Tapered roller bearings at the discharge end lo-
cateeachrotoraxially andcarryallthrust loadsandthe
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
the rotors unmesh at the inlet port and air is drawn into
the cavity between the main rotor lobes and the sec-
ondary rotor grooves (A). When the rotors pass the in-
let port cutoff, air is trapped in the interlobe cavity and
flows axially with the meshing rotors (B). As meshing
continues, more of the main rotor lobe enters the sec-
ondary rotor grove, normal volume is reduced and
pressure increases.
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-
ductionandpressureincreasecontinuesuntiltheair/oil
mixture trapped in the interlobe cavity by the rotors
passesthedischargeportandisreleasedtotheoilres-
ervoir(C). Each rotor cavityfollowsthe same “fill–com-
press–discharge” cycle in rapid succession to produce
a discharge air flow that is continuous, smooth and
shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM
(FIGURE 5–1, page 26) – Air enters the air filter and
passesthrough the inlet unloader valve andon into the
compression chamber where oil is injected into the air.
Aftercompression,theair/oilmixturepassesintotheoil
reservoirwhere mostof the entrainedoil is removedby
velocity change and impingement and drops back into
the reservoir. The air and remaining oil then passes
through the air/oil separator. The air then passes
through the minimum pressure/check valve, the after-
coolerand the moisture separator and intothe plant air
lines.
LUBRICATION, COOLING AND SEALING – Oil is
forcedbyair pressurefromthe oilreservoir throughthe
oil cooler, thermostatic mixing valve, and oil filter and
discharge into the compressor main oil gallery. A por-
tion of the oil is directed through internal passages to
the bearings and shaft oil seal. The balance of the oil
is injected directly into the compression chamber to re-
move heat of compression, seal internal clearances
and lubricate the rotors.

13–8–609 Page 2
200EBE797
(Ref. Drawing)
FIGURE 1–2 – PACKAGE – MINIMUM PRESSURE/CHECK VALVE, SEPARATORS & OIL FILTER