compair d_drs series operations manual rev.02 nov.11, 2013

GB ZS1101891 / 02 - August 2013

Translation of the original operatinginstructionsScrew compressor

D75 - D160 V2D110RS - D160RS V2

Contents

2 / 100 GB August 2013

CONTENTS

1 Foreword........................................................ 4

1.1 About these operating instructions............41.2 Notes......................................................... 51.3 Intended use............................................. 51.4 Intentional misuse..................................... 61.5 Service...................................................... 61.6 Nameplate.................................................7

2 Safety conditions.......................................... 8

2.1 General safety instructions....................... 82.2 Instructions about particular types of

danger....................................................... 82.3 Protection and safety equipment.............. 92.4 Residual hazards.................................... 102.5 Identification of safety instructions.......... 102.6 Safety sign.............................................. 102.7 Transport and positioning....................... 142.8 Normal operation.................................... 142.9 Special tasks...........................................142.10 Conversions and changes to the

machine...................................................15

3 Design and function................................... 16

3.1 General description.................................163.2 Compressor design.................................173.3 System scheme air-cooled

compressor..............................................213.4 System scheme water-cooled

compressor..............................................233.5 Air circuit................................................. 253.6 External water circuit.............................. 273.7 Internal water circuit................................283.8 Oil circuit................................................. 293.9 Ejector vent system................................ 303.10 Control (automatic operation)................. 30

4 Transport and positioning..........................32

4.1 Transport.................................................324.2 Storage....................................................324.3 Positioning...............................................32

5 Preparations for commissioning............... 35

5.1 Pipelines..................................................35

5.2 Compressed air connection.................... 355.3 Cooling water connection........................365.4 Electrical connection............................... 37

6 Commissioning and operating.................. 39

6.1 Initial commissioning...............................396.1.1 Cooling water control in a water-cooled

compressor system.................................416.2 Normal operation.................................... 426.3 Routine commissioning...........................436.4 Commissioning after a long

shutdown.................................................436.5 Commissioning after a fault.................... 43

7 Troubleshooting.......................................... 44

8 Maintenance and Service........................... 47

8.1 General information................................ 478.2 Service.................................................... 488.3 Inspection of protection and safety

equipment................................................488.4 Routine maintenance.............................. 498.5 Maintenance plan....................................508.6 Maintenance work...................................538.6.1 Accesses.................................................538.6.2 Filter mat cooling air inlet........................548.6.3 Inlet filter cooling air switch cabinet (RS

compressors )..........................................548.6.4 Condensate drain....................................558.6.5 Lubricating oil..........................................568.6.6 Ejector vent system................................ 588.6.7 Cooling system....................................... 618.6.8 ................................................................ 628.6.9 Air Filter...................................................638.6.10 Control air filter....................................... 648.6.11 Drive motor / Lubricator.......................... 658.6.12 Control system........................................ 66

9 Appendix...................................................... 67

9.1 Shutdown................................................ 679.2 Lubricants and additives......................... 679.3 Removal.................................................. 679.4 Disposal...................................................689.5 Limit values of dissolved matter..............699.6 Technical Specification........................... 70

Contents

August 2013 GB 3 /100

9.6.1 D75 + D90, 50Hz, air-cooled "A" andwater-cooled "W" (European version)..... 70


9.6.3 D160, 50Hz, air-cooled "A" and water-cooled "W" (European version)...............72

9.6.4 D110 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)...............73





9.6.9 D160, 60Hz, air-cooled "A" and water-cooled "W" (European version)...............80




9.6.13 D75 + D90, 60Hz, air-cooled "A" andwater-cooled "W" (USA version)............. 86

9.6.14 D110 + D132, 60Hz, air-cooled "A" andwater-cooled "W" (USA version)............. 87

9.6.15 D160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)....................... 88

9.6.16 D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)....................... 89



9.7 Installation plan....................................... 94

1 Foreword

4 / 100 GB August 2013

1 FOREWORDGardner Denver screw compressors are the prod-uct of years of research and development. Thisexperience 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 operatinginstructions

These operating instructions apply for the follow-ing compressors from Gardner Denver Deutsch-land GmbH:

D75-8A V2D75-10A V2D90-8A V2D90-10A V2D110-8A V2D110RS-8A V2D110-10A V2D110RS-10A V2D132-8A V2D132RS-8A V2D132-10A V2D132RS-10A V2D160-10A V2D160RS-10A V2D75-8W V2D75-10W V2D90-8W V2D90-10W V2D110-8W V2D110RS-8W V2D110-10W V2D110RS-10W V2D132-8W V2D132RS-8W V2D132-10W V2D132RS-10W V2D160-10W V2D160RS-10W V2

These operating instructions are written for operat-ing- and maintenance personnel.The basis of these operating instructions are themaster operating instructions ZS1101886 /02,which are relevant for translations of the operatinginstructions.

These operating instructions are an inherent partof the compressor. They must be available and ac-cessible near the compressor at all times.

These operating instructions provide you with allthe information you need for safe operation andmaintenance of the compressor. This includes:

Installation and connection of the compressorCommissioning and operation of the compres-sorReplacement of wear parts and consumablessuch as filters or oilIdentification of faults and rectification of mal-functionsCarrying out of visual inspections for damageon a rotational basisCleaning, maintenance and repair of the com-pressor

The dealer's or manufacturer's workshop, with itsqualified and experienced personnel, is respon-sible for all maintenance work that goes beyondcustomary service work and requires specialisttechnical knowledge.All pressures given in these operating instructionsare, where not otherwise specified, positive pres-sures (gauge pressures).

Target groupsThe target groups for these operating instructionsare operators, maintenance personnel and electri-cians.After training, the operator is permitted to start upand shut down the compressor and activate theemergency-stop.Maintenance personnel may, in conjunction withthe information in these operating instructions,maintain the compressor, repair it, start it up andshut it down and activate the emergency-stop.Electricians may electrically install the compres-sor, carry out direction of rotation checks and carryout electrical maintenance work.

Safety conditionsAlongside all the other details in these operatinginstructions, the general safety instructions, in thechapter "Safety Conditions", must be read withoutfail.

Foreword 1

August 2013 GB 5 /100

1.2 NotesGeneral informationThe operating instructions must be read and usedby every person who is assigned to work with andon the compressor.Irrespective of these operating instructions, thelaws, regulations, directives and standards applic-able in the place of use must be observed.

TrainingThe 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 workcan be reliably carried out.

WarrantyGardner Denver Deutschland GmbH will not beheld liable for the safe functioning of the compres-sor if it used other than for its normal use or forpurposes not listed in the operating instructions.

Gardner Denver Deutschland GmbH excludes allwarranty and liability in the event of:

Operating errors.Use of the compressor for other than the in-tended purpose.Damage resulting from deliberate misuse ornon-observance of the operating instructions.Damage or injuries caused by non-OEM com-ponents.Use of spare or wear parts or operating fluidsthat do not originate from or are not currentlyrecommended by or have not been previouslyrecommended by Gardner Denver DeutschlandGmbH.Inadequate maintenance.Compressor conversions.

Warranty and liability conditions of the generalbusiness conditions of Gardner Denver Deutsch-land GmbH are not expanded by the aforesaid in-formation.

GuaranteeThe conditions and caveats of the Gardner DenverDeutschland GmbH guarantee are specified in ourgeneral terms and conditions, which were suppliedwith the compressor. Upon request, an additionalcopy of the document can also be sent retrospec-tively.

CopyrightThese 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 ofa patent, petty-patent or design registration.

ResellingIf 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 fromGardner Denver by specification of the order con-firmation number. The compressor must not underany circumstances be resold without these operat-ing instructions.

1.3 Intended useThe compressor conforms to the state of the artand the applicable safety conditions at the time ofits bringing to market provided it is used for its in-tended purpose.From a design point of view, neither intentionalmisuse nor all of the residual dangers can beavoided, without limiting the intended functionality.The compressor is designed for the compressionof atmospheric oil-free air (compressed air for dri-ving pressure equipment) the compressor is notsuitable for the compression of other gases.

The compressor is only classed as being used forits intended purpose if the following points are alsoobserved:

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 asnon-intended use. The manufacturer is not liablefor any resulting damage. The user alone bearsthe 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 partiescan arise from use of the compressor; likewisedamage to the compressor or other material canarise if the compressor:

Is not used as intended.

1 Foreword

6 / 100 GB August 2013

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 regulationGenerally recognised safety rulesCountry-specific conditions

Installation location / installation altitudeThe compressor is intended for installation in asuitable compressor room. The compressor is notsuitable for open-air installation!The permissible installation altitude of the com-pressor is limited dependent on the operatingpressure, ambient humidity and ambient tempera-ture at which it is operated. The permissible instal-lation altitude is specified for each individual caseby consultation between the customer and Gard-ner Denver.

Working environmentThe illumination in the region of the compressormust be 200 lx during normal operation.The illumination for inspection and repair workmust be 500 lx.Ambient temperature for operation: see "Technicaldata".

Pressure equipmentFor pressure equipment/systems a pressure re-lief device (safety valve or similar) dimensioned tomatch the weakest pressure carrying componentand conforming to the relevant regulations mustbe installed in the compressed air system.

1.4 Intentional misuseIncorrect use and misuse

The following typical reasonably foreseeable mis-uses (incorrect uses) are classed as contrary tothe intended use:

Compression of gases other than atmosphericair.Operation outside the permissible operatinglimits, even if the exceeding of the limits is onlytemporary 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 orsafety valves, or operation with other suchsafety relevant defects.Use by private users or users without technicaltraining.Operation outside industrial environments.Non-adherence to maintenance intervals.Omission of maintenance and repair work.Incorrect execution of maintenance and repairwork.

Limitations on use

Operation of the compressor is not permittedoutside the permissible ambient temperatures.above the permitted altitude of the installationlocation.on an insufficiently load-bearing substrate.in areas with an explosive atmosphere.

1.5 ServiceIf you have any questions about or problems withthe compressor please contact your responsibleGardner Denver agency.The trained specialised personnel will ensure youreceive quick and proper assistance.

In case of queriesIf you have a query or wish to make a spare partsorder, please specify the identification number andyear of manufacture on the name plate. Specifi-cation of this data will ensure that you receive thecorrect information and/or spare parts.

Your Gardner Denver Deutschland GmbHagencyPlease enter the details of your local GardnerDenver agency in the following table.

Foreword 1

August 2013 GB 7 /100

Name:

Contact:

Address:

Phone

Fax

Email:

Chart 1-1: Local Gardner Denver agency

1.6 Nameplate

Fig. 1-1: Nameplate

Gardner Denver , IncQuincy, Illinois

1 2

Model Serial Number

Type

3

Weightkg6

Machine

4

Version

5COMPRESSOR

Made in Germany 7

Airend8

9

10

11

12

13

14

15

16

17

100016812

KW

rpm

A

psi

psi g

CFM

PhV

Order Mumber

Compression Medium

Voltage / Phase / Frequency

Flow

Stage Pressure

Suction Pressure

/ / Hz

1 2

Full Load Current

Speed

Installed Motor Capacity

Fig. 1-2: Nameplate

2 Safety conditions

8 / 100 GB August 2013

2 SAFETY CONDITIONSAny person who is involved with the operation,maintenance or repair of the compressor, mustread and follow the safety conditions.Gardner Denver Deutschland GmbH accepts noresponsibility for material damage or injuries thatarise from non-observation of safety conditions orthe failure to observe normal levels of care and at-tention, even where this is not expressly stated inthese operating instructions.

2.1 General safety instructionsOrganisational measures

The following organisational measures contributeto the safe use of the compressor:

Only appointed personnel may work on thecompressor. The personnel have been trainedand briefed about the compressor.Before starting work, the personnel must haveread the operating instructions, in particular the"Safety Conditions" chapter. Dont leave thisuntil you start work its too late. This appliesin particular to personnel who only work on themachine occasionally, e.g. to carry out mainte-nance.The responsibilities of the personnel for oper-ation, maintenance and repair must be clearlydefined.The safe and hazard-aware working of the per-sonnel must be checked regularly.Personnel who are to be trained in, taughtabout or instructed as part of a general trainingcourse, must only work on the compressor un-der the constant supervision of an authorisedperson.If safety-relevant changes are made to com-pressor or arise in its operating behaviour, thecompressor must be immediately shutdownand the fault reported to the responsible post/person.Faults, especially those that could impairsafety, must be immediately rectified. Other-wise the compressor must not be operated.All danger signs on and in the surroundings ofthe compressor must be regularly checked forcompleteness and legibility. Missing dangersigns must be immediately replaced.The intervals between tests and inspectionsmust be adhered to.

The operating instructions must be supple-mented with instructions for the observation ofoperating peculiarities including monitoring andreporting obligations, e.g. in respect of workingorganisation, working processes, responsibili-ties, etc.

Personnel selection and qualification; funda-mental responsibilitiesOnly reliable and authorised personnel may workon the compressor.

The authorised personnel must:be trained by Gardner Denver.be trained according to its responsibilities, du-ties and activities and instructed about thecompressor.have the physical and mental capabilities tofulfil its responsibilities and carry out its dutiesand activities on the compressor.have understood the operating instructions inrespect of its responsibilities, duties and activ-ities on the compressor and be able to practi-cally implement this.

2.2 Instructions about particulartypes of danger

Electrical energy

DANGERElectric shockLife-threatening electric shock When carrying out any work on the

electrical equipment, exercise ex-treme care.

Before starting the maintenancework, switch the compressor to avoltage-free state and secure to pre-vent switching back on.

For all work on the electrical equipment of thecompressor 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 onthe electrical equipment of the compressor.The compressor's electrical equipment must bechecked 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.

Safety conditions 2

August 2013 GB 9 /100

Only for RS compressors:Due to the residual voltage on the capacitors, awaiting time of at least 10 minutes must elapseafter switching to a zero volts state (main switchOFF) before the switch cabinet can be opened.Observe the danger sign on the switch cabinet!See table "Safety signs".

NoiseThe sound pressure level without the sound-proof-ing enclosure is 110 dB(A). Remaining for long pe-riods alongside the compressor without its sound-proofing enclosure can result in irreversible hear-ing impairment.Only operate the compressor without the sound-proofing enclosure during test runs. Wear ear de-fenders!The sound pressure level with the sound-proofingenclosure is approximately: see "Technical data".During normal operation the compressor may onlybe operated with a closed acoustic hood.

Oils, fats and other chemical substancesWhen handling oils, fats and other chemical sub-stances, observe the applicable safety conditions!Exercise caution when using hot operating fluidsand additives, there is a risk of burns or scalds!

Explosive areas

DANGERRisk of explosionThe compressor is not designed for op-eration in explosive atmospheres. Operation of the compressor in ex-

plosive atmospheres is forbidden!

Legionella formation with water-cooled com-pressors and an open cooling circuit

WARNINGLegionella contaminationHealth risk with open cooling systems. Constant testing of the water quality

in the cooling circuit for the numberof microbes.

2.3 Protection and safetyequipment

The compressor is equipped with the protectionand 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 testing frequen-cies of the country of use must be adhered to.

NOTEOperation of the compressor is only permittedwith complete and operational protective andsafety equipment.

Emergency-stopThe compressor can be rendered safe in danger-ous situations using the emergency-stop pushbut-ton.

Emergency-stop pushbuttons are attached:on the compressor control paneloptionally in a control room (control centre)

Using emergency-stop1 Press the pushbutton.

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 the pushbutton.Turn the pushbutton anticlockwise.

4 Set the compressor in operation.See section "Commissioning after a fault" in thechapter "Commissioning and operation".

Safety valves / non-return valveThe compressor is protected against exceedingof the permissible operating pressure using safetyvalves. Open the safety valves at 3.5 bar (1stairend) or 11.4 bar (2nd airend).The compressor is secured by a non-return valveon the pressure side against reverse flow from thecompressed air network.

Protective covers and enclosure panelsThe cooling air fans are covered by grilles.The clutch between the drive and the compressoris covered by a grille.The compressor enclosure is designed so that anybroken bits that might fly out are retained in thecompressor.The compressor enclosure serves as an acoustichood.

2 Safety conditions

10 / 100 GB August 2013

2.4 Residual hazardsHot surfacesSome parts of the compressor become very hot inoperation (up to 235 C). A danger warning signon 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 shoesSafety glasses for all work with compressed airand open enclosureEar defenders during test runs with an openacoustic hood

2.5 Identification of safetyinstructions

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 preventdanger and are located close to the possible dan-ger both in terms of space and time:

on the system close to the danger sourcein the operating instructions, before a sequenceof actions / activity is described

Structure of safety instructionsThe special warnings in the operating instructionsare structured as follows:

DANGER WORD

Safety sign

Danger (danger sequence)Description of the danger (dangersource)Protective measure (danger pre-vention)

Parts of safety instructionsDanger (danger sequence): The danger se-quence names the type of hazard.Description of the danger (danger source): Thedanger 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 theseverity of the danger into four steps, graphicallyhighlighted by different colours. The danger wordis used in the safety instructions as described be-low.DANGER indicates a directly dangerous situa-tion which, if not protected against, could result indeath or serious (irreversible) injuries.WARNING indicates a potentially dangerous situa-tion which, if not protected against, could result indeath or serious (irreversible) injuries.CAUTION indicates a potentially dangerous situa-tion which, if not protected against, could result inminor or less serious (reversible) injuries.ATTENTION indicates information or recommen-dations that directly or indirectly concern the safetyof persons or system protection.

2.6 Safety signThe following safety signs (danger signs) may be used in the surroundings of the compressor and in theoperating instructions.

Safety sign Meaning Use / Behaviour

General danger Warning of a general danger.Observe the warning and proceed with the necessarycaution (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 conditions 2

August 2013 GB 11 /100


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 pressureequalisation has taken place.

Never operate the com-pressor with open doorsor loose enclosure pan-els.

Running the compressor with open doors or loose enclo-sure panels is forbidden except during test runs. Highsound pressure level, risk of injury!Normal operation only with closed enclosure.

Do not breath in anycompressed air from thissystem

Use of the compressed air produced by this compressoras breathing air is forbidden. Drawn in substances couldbe 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 equipmentof the compressor.

System runs on After pressing of the stop button , the compressorruns on for 30 seconds.Do not open the compressor enclosure before the com-pressor is stationary.

Observe the instructionmanual

Identification of operating instructions where additionalinformation is to be found in the operating instructions (ofthe manufacturer).Before the device is operated, the operator (user)must have read and understood the instruction manual(manufacturer's usage instructions).

Wear ear defenders Identification of areas with a heightened sound pressurelevel.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 cannotbe seen to be clear and are not made safe or blockedoff. Use or crossing of this traffic way can only be imple-mented with great care.

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 underthe raised compressor or place your feet beneath it.


2 Safety conditions

12 / 100 GB August 2013


Warning against movingmachine parts

During maintenance work it is necessary to check somefunctions with an opened enclosure. There is a risk ofinjury due to rotating or translational movements.Maintenance work must only be carried out by speciallytrained personnel.

Warning of hand injuries Danger that the hands could be crushed, drawn in orotherwise injured.Maintain a safe distance.

Warning of automaticstart-up

In normal operating mode, the compressor may start upautomatically at any time. The readiness for operationof the compressor is indicated by the green LED on thecontrol panel.Do not carry out any work on the compressor, if thegreen LED illuminates.

Warning of hot surfaces Parts of the compressor become very hot during opera-tion (up to 235 C). Risk of injury due to hot surfaces.Before starting any maintenance and repair work, thecompressor must be sufficiently cooled.

Warning of suffocation Risk of suffocation due to inadequate ventilation andextraction in the compressor room.The operator must provide adequate ventilation of thecompressor 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, increasedawareness is necessary.

Remaining under theload is forbidden

It is not permitted to remain under a suspended load.The driver is not permitted to drive the industrial truck ifthere is a person beneath the load. Moreover, the dri-ver is obliged to check that persons do not stand or walkunder the load.The load must only be transported so that it is sufficientlyclear of the ground (max. 0.5 m above the ground). (InGermany, refer to the law BGV D27 "Industrial trucks").The driver of an industrial truck is responsible for all dri-ving and load movements.

Lifting point Identification of the lifting points.Only the indicated lifting points may be used for trans-port.


Safety conditions 2

August 2013 GB 13 /100


XX bar

Safety valve Opening pressure of the safety valves (values "xx" seesticker on the control panel).

Check the connectingterminals and tighten ifnecessary. For additionalinformation see the oper-ating instructions.

Warning against loosened connecting terminals. Theclamping pressure can be released after some time.Regularly check the terminals according to the safetyguidelines and retighten as necessary.

10 min

Electrical voltageResidual voltage of thecapacitors

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) 10 min-utes after switching the compressor off (zero volts).Check the DC bus voltage of the frequency converter atthe mains connection strip of the frequency converter.The precise position of the terminals "DC+" and "DC-"can be taken from the supplied frequency converteroperating instructions.Only a qualified electrician following electrotechnical reg-ulations may carry out work on the electrical equipmentof the compressor.

Spring tension Warning of tensioned spring inside the suction regulator.Before opening the suction regulator read the repairmanual.

Risk of microbe contami-nation

Warning against legionella contamination of the coolingwater if an open cooling 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 tocool.


NOTEAll danger signs must be complete and legible.Check regularly and replace if necessary.

2 Safety conditions

14 / 100 GB August 2013

2.7 Transport and positioningTransportA suitable forklift with forks of adequate lengthmust be used to transport the compressor. Depen-dent on type, the compressor weighs up to 3,800kg.Only insert the forks at the intended load supportpoints.The compressor must not be transported using acrane, even when still in its packaging.No person may remain in the danger area duringtransport. In particular, do not encroach into thearea under the raised compressor or place yourfeet beneath it.

Positioning / installation locationThe entire surface of the compressor must beplaced on an even suitable substrate.The installation location (compressor room) mustbe dimensioned so that there is sufficient accessto the compressor and the necessary cooling isensured.No inflammable or explosive materials may bestored in the vicinity of the compressor.

2.8 Normal operationThe compressor may only be operated in a techni-cally fault-free condition for its intended use, withan awareness of safety and hazards while observ-ing the operating instructions.Only operate the compressor if all protective andsafety equipment, sound insulation, ventilation andextraction equipment and the cooling water supply(water-cooled compressors only) are present andserviceable.

Check regularly that:All hoses and pipelines are serviceable andfirmly 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 arisk to safetyNever 'play around' with compressed air.Never direct compressed air onto the skin or atother people.Never use compressed air for cleaning cloth-ing.

When using compressed air to clean equip-ment, proceed with great care and always useeye protection.

Safety measuresOnly operate the compressor with the enclosureclosed.At least once per shift check the compressor forexternally 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 compressorimmediately and secure. Immediately rectify anyfaults.Do not switch off or remove extraction and ventila-tion equipment when the compressor is running.

Remote controlIf a remote control is available, a sign with the fol-lowing lettering must be clearly visible on the com-pressor: "Attention! The compressor is remotelycontrolled and could start without warning!"In addition safety precautions must be imple-mented so that nobody works on the compressorwhen it is under remote control.

2.9 Special tasksOrganisationalAdhere to the prescribed maintenance work andintervals including details about the replacementof parts/part assemblies contained in the operatinginstructions.Maintenance and repair work must only be carriedout under the supervision of or by a person quali-fied to carry out this work.If necessary, cordon off a wide area around theworkplace.Workshop equipment appropriate for the task isessential for carrying out maintenance and repairwork.

Safety measuresPersonnel must not have loose long hair nor wearloose clothes or jewellery including rings. If thecompressor is running there is a risk of injury, e.g.by being caught-up or pulled in. Where necessaryor if required by regulations, wear personal protec-tive equipment!Only carry out maintenance and repair work forwhich you are adequately trained and which youfeel confident to carry out.Do not use machine parts as climbing aids. If car-rying out maintenance work at heights, provide fallprotection.

Safety conditions 2

August 2013 GB 15 /100

Maintenance/TroubleshootingOnly carry out maintenance and repair work withthe compressor switched off and mains poweroff. Secure the compressor to prevent inadvertentswitching on.

Before opening the compressor enclosure:Drain the compressor.Wait for automatic pressure discharge to com-plete.Wait until the residual electrical energy hasdrained from the capacitors.Allow the compressor to cool to room tempera-ture.

CleanlinessDuring maintenance and repair work always checkfor cleanliness. Keep dirt away by covering partsand uncovered openings with a clean cloth, paperor adhesive strips.Oil leaks lead to a slippery floor. Thoroughly cleanthe work area after completion of maintenanceand repair work.

Cleaning agentsWhen cleaning parts, never use solvents or clean-ing agents that could chemically attack the materi-als.Take precautions to prevent harmful vapours fromsolvents or cleaning agents.

Weight / lifting gearWhen replacing heavy individual parts and assem-blies carefully attach and secure to the lifting gearso that no danger can arise. Use only suitable andtechnically flawless lifting gear and load handlingequipment with adequate load capacity. Neverwork or remain under suspended loads.

Spare partsUse only original spare parts.Spare parts must correspond to the technical re-quirements specified by the manufacturer. This isonly guaranteed with original spare parts.

Upon completion of maintenance and repairworkUpon completion of maintenance and repair work,ensure that no tools, loose parts or cleaning clothshave been left in the compressor (especially in thedrive motor or drive train).Turn the drive several times to ensure that there isno mechanical malfunction within the compressoror the drive train.

Tighten up all threaded connectors loosened dur-ing maintenance and repair work. Likewise checkall other threaded connectors.Before release of the compressor for operation af-ter maintenance and repair work, ensure that theoperating pressures, temperatures and time set-tings are correct and that the control and switchingoff 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 tothe machine

Do not make any changes or additions to or re-build the compressor without prior consultationwith 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 notauthorise parts and special equipment that are notsupplied by us. The fitting and/or use of such prod-ucts may therefore impair active and/or passivesafety.Any liability on the part of the manufacturer fordamage arising from the use of non-original partsor 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

16 / 100 GB August 2013

3 DESIGN AND FUNCTION3.1 General descriptionThe compressor is an oil-free compressing, two-stage screw compressor with one sound-proofedenclosure.The main components are the drive motor, theairend unit, the cooling and lubrication system andthe electronic control.The airend unit comprises the drive gear and thefirst and second airends.The parts of the airends through which the airflows are provided with a special wear-reducingand corrosion-resistant coating.Rolling contact bearings and gearbox are oil-lubri-cated.The air and oil system are designed so that no oilcan get into the air circuit. The ejector ventilationsystem produces a defined vacuum pressure inthe oil-lubricated area of the airend unit thus pre-venting any oil from escaping into the surround-ings.

Compression principleThe airends comprise a main rotor and an auxil-iary rotor with intermeshing spiral toothing. A syn-chronized gearbox in each airend ensures thecontact-free running of the rotors. Compressionchambers are delimited by the flanks of the tooth-ing and the compressor casing. The rotation ofthe rotors continuously reduces the volume in thechambers until the compressed air is pushed outthrough the outlet window of the stage casing.Screw compressors count amongst rotation-dis-placement compressors without oscillating massesbut with a pulsing output.To minimise the power consumption of the airendunit and to limit the airend temperatures to tech-nically permissible values, the compression takesplace in two stages with interstage cooling (in-tercooler). In addition the casing of the stages iscooled by the internal cooling circuit

Electronic control unitThe main components of the electronic controlunit are a microprocessor, a touchscreen, film-pro-tected keys and LEDs.Detailed description of the operating instructionsfor the electronic control unit.

Design and function 3

August 2013 GB 17 /100

3.2 Compressor designAir-cooled

12 3 4 5 6 7 8

9

10

1112

131415

1617

Fig. 3-1: Overview part 1

[1] Condensation trap (intercooler) [10] Silencing baffle with filter mesh[2] Oil / water cooler [11] Aftercooler[3] Oil Filter [12] Intercooler[4] Snubber / silencer [13] Water cooler[5] Maintenance unit [14] Blow-off silencer[6] Compressor unit [15] Condensate separator (intercooler)[7] Control air filter [16] Safety valves (intermediate pressure)[8] Ultra-fine filter [17] Expansion tank (coolant)[9] Snubber


18 / 100 GB August 2013

1

2

34

5

6

7 8 9 10 11 12

13

14

15161718 18

Fig. 3-2: Overview part 2

[1] Suction regulator [10] Drive motor[2] Motor lubrication system [11] Oil pump[3] Non-return valve [12] Water pump[4] Safety valve (line pressure max.) [13] Air Filter[5] Connection flange [14] Switch cabinet cooling air inlet filter (RS)[6] Condensate separator [15] Pushbutton [7] Condensate connectors [16] Electronic control unit[8] Condensate trap [17] Switch cabinet[9] Solenoid valve (Y3) [18] Fan


August 2013 GB 19 /100

Water-cooled

1 2 3 4 5 6 78

9

10

11121314

1516

1718

[1] Condensation trap (interstage cooler) [10] Silencing baffle with filter mesh[2] Oil / water cooler [11] Cooling water manifold[3] Oil Filter [12] Aftercooler[4] Snubber / silencer [13] Interstage cooler[5] Maintenance unit [14] Cooler (internal cooling circuit)[6] Compressor unit [15] Blow-off silencer[7] Control air filter [16] Condensate separator (interstage cooler)[8] Ultra-fine filter [17] Safety valve (interstage cooler)[9] Snubber [18] Expansion tank (coolant)


20 / 100 GB August 2013

1

2

3

4

5

6

7

8 9 10 11 12

13

14

1516

1718

[1] Suction regulator [10] Drive motor[2] Motor lubrication system [11] Oil pump[3] Non-return valve [12] Water pump[4] Safety valve (line pressure max.) [13] Air Filter[5] Connection flange [14] Switch cabinet cooling air inlet filter(speed-

controlled system)[6] Condensate separator [15] Pushbutton [7] Condensate connectors [16] Electronic control unit[8] Condensate trap [17] Switch cabinet[9] Solenoid valve (Y3) [18] Fan


August 2013 GB 21 /100

3.3 System scheme air-cooled compressor

Fig. 3-3: Function scheme

Compressed air Water

Air Oil

Chart 3-1: Cables


22 / 100 GB August 2013

Components

No Name No Name No Name

1 Intake air filter 11 Aftercooler 22 Temperature control valve(oil circuit)

2 Suction regulator 12 Pressure relief valve 23 Heat exchanger

3 First airend 13 Water separator (after-cooler)

24 Oil Filter

4 Snubber 14 Safety valve (final pres-sure)

25 Cooler internal coolingwater circuit

5 Intercooler 15 Filter water separator 26 Temperature control valve(internal cooling water cir-cuit)

6 Water separator (inter-cooler)

16 Shuttle valve 27 Compensating tank

7 Safety valve (intermedi-ate pressure)

17 Blow-off silencer 28 Cooling water pump

8 Second airend 18 Maintenance unit 29 Drive motor

9 Combined silencer andsnubber

19 Vacuum generator 30 Speed control (inverter)

10 Non-return valve 20 Ultra-fine filter 31 Radial fan

21 Oil pump 32 Radial fan

Chart 3-2: Components

Instrumentation & control technology

No Name No Name No Name

B0 Ambient pressureabsolute

R0 Ambient temperature S5 Oil filter differential pres-sure

B1 Inlet pressure first airend R1 Inlet temperature firstairend

S12 Oil level

B2 Outlet pressure firstairend

R2 Outlet temperature firstairend

S18 Water level

B3 Inlet pressure secondairend

R3 Inlet temperature secondairend

M1-PTC

Drive motor positor

B4 Outlet pressure secondairend

R4 Outlet temperature sec-ond airend

Y1 Solenoid valve suctionregulator

B5 Network pressure R5 Network temperature Y2 Solenoid valve suctionregulator

B6 Oil pressure R6 Oil temperature Y3 Solenoid valve gearboxcasing venting

B7 Water pressure jacketcooling inlet

R7 Water temperaturejacket cooling inlet

L Balance piston first airend

B8 Vacuum in gearbox cas-ing

H Balance piston secondairend

Chart 3-3: Instrumentation & control technology


August 2013 GB 23 /100

3.4 System scheme water-cooled compressor

Fig. 3-4: Function scheme

Compressed air Water

Air Oil

Cooling water (external)

Chart 3-4: Cables


24 / 100 GB August 2013

Components

No Designation No Designation No Designation

1 Intake air filter 12 Pressure relief valve 23 Heat exchanger

2 Suction regulator 13 Water separator (after-cooler)

24 Oil Filter

3 First airend 14 Safety valve (final pres-sure)

25 Cooler internal coolingwater circuit

4 Snubber 15 Filter water separator 26 Temperature control valve(internal cooling water cir-cuit)

5 Interstage cooler 16 Shuttle valve 27 Compensating tank

6 Water separator (inter-stage cooler)

17 Blow-off silencer 28 Cooling water pump

7 Safety valve (intermedi-ate pressure)

18 Maintenance unit 29 Drive motor

8 Second airend 19 Vacuum generator 30 Speed control (inverter)

9 Combined silencer andsnubber

20 Ultra-fine filter 31 Radial fan

10 Non-return valve 21 Oil pump 32 Throttle valves externalcooling water circuit

11 Aftercooler 22 Temperature controlvalve (oil circuit)

33 Strainer sieve

34 Safety valve (externalwater circuit)

Chart 3-5: Components

Instrumentation & control technology


B0 Ambient pressureabsolute

R2 Outlet temperature firstairend

S5 Oil filter differential pres-sure

B1 Inlet pressure first airend R3 Inlet temperature secondairend

S12 Oil level

B2 Outlet pressure firstairend

R4 Outlet temperature sec-ond airend

S18 Water level

B3 Inlet pressure secondairend

R5 Network temperature M1-PTC

Drive motor positor

B4 Outlet pressure secondairend

R6 Oil temperature Y1 Solenoid valve suctionregulator

B5 Network pressure R7 Water temperaturejacket cooling inlet

Y2 Solenoid valve suctionregulator

B6 Oil pressure R8 Cooling water tempera-ture inlet (external)

Y3 Solenoid valve gearboxcasing venting

B7 Water pressure jacketcooling inlet

R9 Cooling water tempera-ture outlet (external)

Y4 Cooling water solenoidvalve



August 2013 GB 25 /100


B8 Vacuum in gearbox cas-ing

E1 Condensate drain control L Balance piston first airend

R0 Ambient temperature E2 Condensate drain control H Balance piston secondairend

R1 Inlet temperature firstairend

E4 Motor lubrication system G Gearbox casing

E5 Motor lubrication system


3.5 Air circuit

4

5

6

8

7

2

2

1

3

Fig. 3-5: Air cooling circuit (air-cooled)

[1] Combined silencer and snubber [5] Blow-off silencer[2] Safety valves [6] Suction regulator[3] Aftercooler [7] Blow-off valve[4] Intercooler [8] Snubber


26 / 100 GB August 2013

1

2

3

4

5

6

7

8

Fig. 3-6: Air cooling circuit (water-cooled)

[1] Combined silencer and snubber [5] Blow-off silencer[2] Safety valve [6] Suction regulator[3] Aftercooler [7] Blow-off valve[4] Interstage cooler [8] Snubber

The air is sucked in via a suction filter and reaches the first airend via the suction regulator. Here the airis compressed to the intermediate pressure and then cooled in the intercooler. Compression to the finalcompression pressure desired by the customer then takes place in the second stage. The compressedair is output to the compressed air network via the aftercooler. Condensate formed during cooling is sepa-rated by an automatic condensate separator.If the compressor is operating off-load, the compressed air output from the second stage is discharged viaa blow-off valve to the atmosphere.A snubber after the first airend ensures a uniform air flow to the second stage and reduces pressure fluc-tuations. A combined silencer and snubber after the second airend is used to reduce pressure fluctua-tions and for sound insulation.Safety valves are fitted after the intercooler and the aftercooler to protect the machine components andfor safety reasons.To protect the compressor against backflow from the compressed air network, a non-return valve is in-stalled in the pressure line inside the compressor.


August 2013 GB 27 /100

3.6 External water circuit

1

2

3

Fig. 3-7: External water circuit

[1] Water stop valve [3] Strainer (sieve)[2] Safety valve (external water circuit)

WARNINGRisk of scaldingRisk of scalding due to escaping steam and hot cooling water.

The external cooling water circuit is used to supply the interstage cooler, aftercooler and the heat ex-changer (internal water circuit) with cooling water.


28 / 100 GB August 2013

3.7 Internal water circuit

1

23

4

5

67

W

AI

OI

Fig. 3-8: Internal water circuit

[A] Air-cooled system [4] Expansion line[W] Water-cooled system [5] Expansion tank with level sensor[1] Water pump [6] Cooling water drain[2] Temperature control valve [7] Oil / water cooler[3] Water/air (A) - coolerWater/water (W) -

cooler

The two airend stages are cooled by the internal cooling water circuit (casing cooling) while the lubricatingoil is cooled in the oil/water cooler.The water pump pumps the water to the second airend, to the first airend, to the oil/water cooler and thenback to the water/air cooler.Temperature control is implemented via the cooling water temperature control valve. Water volume fluctu-ations are compensated by the expansion tank.


August 2013 GB 29 /100

3.8 Oil circuit

4

3

2

1

5

7

8

6

Fig. 3-9: Oil circuit

[1] Oil / water cooler [5] Oil filler neck[2] Oil temperature control valve [6] Oil level indicator[3] Oil Filter [7] Oil sump[4] Oil pump [8] Oil drain

The oil circuit lubricates the gearbox and the bearings of the airend unit.Oil is sucked out of the oil sump then pumped via the oil cooler or bypass (temperature control) throughthe oil filter and into the gearbox and bearings of the airend unit. The used oil returns to the oil sump.Temperature control is implemented via the oil temperature control valve.The oil is fed to both airends and goes from there directly into the oil sump.

30 / 100 GB August 2013

3.9 Ejector vent system

5

1

3

4

67

8

2

Fig. 3-10: Ejector vent system

[1] Second stage condensate separator(aftercooler water separator)

[2] Compressed air connection ejector ventsystem

[3] Solenoid valve Y3[4] Maintenance unit (water separator,

pressure regulator, pressure gauge)[5] Ejector (vacuum generator)[6] Extract air[7] Ultra-fine filter[8] Oil return

The ejector ventilation system produces a definedvacuum pressure in the oil-lubricated area of theairend unit thus preventing any oil from escapinginto the surroundings.The ejector vent system uses compressed air fromthe compressed air network. The air passes viathe maintenance unit to the vacuum generator.The air sucked out of the oil system is filtered andoutput to the atmosphere, the separated oil is re-turned to the oil sump.

3.10 Control (automatic operation)Preconditions

The following preconditions must be fulfilled forautomatic running:

All preparations for commissioning are fulfilled.The compressor is correctly connected to thepower supply network.

The compressed air connection is correctlyconnected to the compressed air network.The oil and cooling water levels are OK.Ventilation of the compressor chamber is guar-anteed.The cooling water supply is guaranteed (wa-ter-cooled compressors only).The direction of rotation of the drive motor hasbeen checked.All protective and safety equipment is fitted andserviceable.The electronic control unit indicates [Ready toStart].Pressure demand from the compressed air net-work.

Operating sequenceSwitch on the cooling water supply (wa-ter-cooled compressor only).Press the start button on the controlpanel. The compressor is switched on.Checking of the start parameters (tempera-tures, pressures, sensors, cooling water level)by the electronic control unit.Once the start parameters have been fulfilled,the cooling water pump and the oil pump areswitched on sequentially; the water and oil cir-cuit are running.Simultaneously, solenoid valve Y3 is actuatedso that the ejector vent system starts operating.If the water and oil pressure are correct, thedrive motor is started.After running up of the drive motor, solenoidvalves Y1 and Y2 are switched in a time-de-layed manner, the suction regulator opens. Thetwo fans are switched on. The compressor isnow in load operation.The compressor operates under load until themaximum line pressure [Line Pressure max.] isreached.Once maximum line pressure [Line Pressuremax.] is reached, the solenoid valves Y1 andY2 are switched to zero volts; the suction reg-ulator is closed, the blow-off valve is opened,the compressor is unloaded. The compressoris now operating in off-load mode. Fan 2 isswitched off.The compressor runs off-load until the linepressure has dropped below the minimum linepressure [Line Pressure min.] or until the pro-grammed off-load period has elapsed.

August 2013 GB 31 /100

If the line pressure drops below the min-imum line pressure [Line Pressure min.]:Fan 2 is switched on, solenoid valvesY1 and Y2 are switched on, the blow-offvalve is closed and the suction regulator isopened. The compressor operates underload until the maximum line pressure [LinePressure max.] is reached. Automatic op-eration.

Once the off-load period has elapsed: thedrive motor is switched off, fan 1 runs for 30seconds longer, solenoid valve Y3 closesafter 30 seconds and the ejector vent sys-tem is shutdown. As soon as the drive motor stops, the oiland water pumps are switched off.

Press the stop button < O > on the controlpanel.The compressor is switched off.The compressor enters "Ready tostart" (standby) mode.If the compressor is switched off, then the cool-ing water supply can likewise be switched off(water-cooled compressors only).

4 Transport and positioning

32 / 100 GB August 2013

4 TRANSPORT ANDPOSITIONING

4.1 TransportDeliveryThe compressor is screwed onto a transport palletand packaged with a film cover.The centre of gravity and lifting points are markedon the packaging.

Receipt of goodsUpon receipt of goods check for transport dam-age.1 Check the delivery for visible damage.2 Check the completeness of the delivery using

the delivery note.3 Immediately inform the shipper, Gardner Den-

ver and insurance of any missing parts or dam-age.

WeightDependent on type, the compressor weighs upto 3,800kg (gross). The weight is stated on thenameplate which is visible from the outside.

Transport

DANGERRisk of fatal injuryRisk of fatal injury due to toppling orfalling parts A suitable forklift with forks of ade-

quate length must be used to trans-port the compressor.

Only insert the forks at the intendedlifting points.

The compressor must not be trans-ported using a crane, even whenstill in its packaging.

No person may remain in the dan-ger area during transport. In partic-ular, do not encroach into the areaunder the raised compressor orplace your feet beneath it.

Transporting the compressor

Fig. 4-1: Lifting points

1 Remove the screws from the transport pallet.2 Lift the compressor from the transport pallet.3 Transport the compressor to the destination

point.4 Align the compressor and set down.

4.2 StorageStorage of compressorsThe compressor should be stored in a dry and,where possible, heated room. This applies particu-larly during the winter months.

NOTICEMaterial damageMaterial damage through exceeding of the per-missible temperature range Where there is a risk that the permissible

temperature limits of +2 ...+65 C could beover or undershot, contact Gardner Denver.

Corrosion protectionBefore they leave the factory all compressors areprotected against corrosion during transport andshort term storage before commissioning. If com-pressors are stored for longer than 6 months, ad-ditional precautions must be undertaken.Also compressors that have been taken out of ser-vice for a long period, must be protected againstcorrosion.

4.3 PositioningRequirements for the installation locationThe entire surface of the compressor must beplaced on a sufficiently load bearing substrate.The bearing surface must be level to within 3 mm.

Transport and positioning 4

August 2013 GB 33 /100

The installation location (compressor room) mustbe dimensioned such that the compressor hasa clearance on all sides of 1m ("A" and "B") andabove the compressor of 1.50 m. Moreover, ade-quate access must be provided for maintenance.

Fig. 4-2: Positioning / clearances

Position the compressor so that it is sufficientlyaccessible and the required cooling is ensured.Do not block the air inlet.Avoid moisture.

Ventilation

DANGERRisk of suffocationRisk of suffocation due to inadequateventilation The operator must provide adequate

ventilation of the compressor room.

To be able to dissipate the heat generated duringoperation, the compressor room must be of suffi-cient size and have adequate ventilation.The recommended minimum size of the compres-sor room is 60 m3.The air inlet and outlet openings should have aminimum cross section of 1.2 m2 (air-cooled com-pressor) or 0.45 m2 (water-cooled compressor).The intake air opening should be positioned ashigh as possible. The extract air opening shouldbe positioned as high as possible.Provide the air openings with sieves to preventpenetration of dirt into the compressor room.The design of the ventilation facility is primarilybased on the required cooling air flow. (See "Tech-nical data".)

In the event of unfavourable local conditions, in-stall air ducts in which the flow velocity of the cool-ing air must not exceed 5 m/s. We recommenda minimum channel cross section of 1.2 m2 (air-cooled compressor) and 0.45 m2 (water-cooledcompressor).

NOTETo ensure effective heat removal, the installedauxiliary fans must be dimensioned such thattheir air flow is 15 to 20% greater that the cool-ing air flow required by the compressor.If installing several compressors in one com-pressor room, then this applies to the total of thecooling air flows required by all the compressorspresent in the compressor room.

The following figure shows the recommended ven-tilation requirements.

Fig. 4-3: Compressor room ventilation

4 Transport and positioning

34 / 100 GB August 2013

Positioning the compressor

DANGERRisk of injuryDanger due to incorrect positioning Consider the permissible bearing

force of the substrate. Ensure there is a hard and even

substrate. The entire surface of the compres-

sor must be placed on an even suit-able substrate.

The compressor must not be oper-ated on the transport pallet.

No inflammable or explosive mate-rials may be stored in the vicinity ofthe compressor.

1 Set down the compressor at the destinationpoint.

2 Ensure that the bearing surface is even towithin 3mm. (The compressor does not haveany levelling means fitted on it)

Preparations for commissioning 5

August 2013 GB 35 /100

5 PREPARATIONS FORCOMMISSIONING

5.1 PipelinesRemove all blank flanges, plugs, caps and des-iccant containing pouches before fitting thepipelines.Manifolds and pipe connections must be of thecorrect size and be suitable for the respective op-erating pressure.Label compressed air and water pipes accordingto the local regulations.Support all pipelines with correctly dimensionedsupports; pipes must not support any loads.If compressed air hose is used, it must be cor-rectly dimensioned and be suitable for the oper-ating pressure and temperature. Do not use anyabraded, damaged or inferior quality hose.A shut-off valve must be fitted in the supply lineso that the compressor can be isolated for main-tenance purposes. No additional non-return valvemay be installed. The additional non-return valvewould impede the air supply to the vacuum gener-ator.If a high level of condensate formation is ex-pected, the compressed air connection for theejector vacuum generator must be connected to acondensate-free compressed air supply. In case ofdoubt, contact Gardner Denver.The two automatic condensate drains must beprovided with separate lines that are routed to adrain or a collecting tank.The drains lines leading away from the conden-sate connections must not be designed to risemore than 5 m!An air tank with sufficient volume (as a buffer)must be installed between the compressor and thecompressed air network. As a guide, the tank ca-pacity should equal 10 % of the delivery quantity,e.g. a compressor with a delivery quantity of 10m/min requires a tank volume of 1 m.

5.2 Compressed air connection

1

1

A

25

34

Fig. 5-1: Compressed air and condensate connection

[1] Compressed air connection[A1] Automatic condensate drain, aftercooler[A2] Condensate drain pipe aftercooler via ball

valve (use if there is a malfunction of theautomatic condensate drain)

[A3] Automatic condensate drain, intercooler[A4] Condensate drain pipe intercooler via ball

valve (use if there is a malfunction of theautomatic condensate drain)

DANGERRisk of burstingThe compressed air outlet temperaturecan be up to 95C. The burst strength of the following

components of the supply line (cus-tomer network) must be suitable forthese temperatures.

WARNINGRisk of injury due to hot supply lineThe compressed air outlet temperaturecan be up to 95C. Protect the supply line to prevent

contact with it.

5 Preparations for commissioning

36 / 100 GB August 2013

WARNINGRisk of injuryIf an incorrect connection is made, theconnector could come loose and the freeconnection result in severe personal in-jury. When connecting the compressor

to the compressed air network, theconnecting flange must be checkedin addition to the operating tempera-tures and pressures.

When connecting hoses, suitablemeasures must be taken to preventthe dangerous "whipping" of a loosehose end.

Checking the connection flangeThe pressure connection comprises a DIN flange.The connection label is stamped outside on theflange plate:DN80, PN161 Read off the connection label.2 Ensure that connector and flange match.

Connecting the compressor to the com-pressed air mainsThe compressor is completely assembled in thefactory. The connection to the compressed air net-work must be made with a flexible line, e.g. a com-pressed air hose or expansion joint.Only use hose couplings and connections of thecorrect type and size.1 Ensure that the supply line can be connected

free from tension.2 Connect the connection line to the compressed

air connection of the compressor.3 Secure the hose lines.

5.3 Cooling water connection

1

2

Fig. 5-2: Cooling water connection (1)

[1] Inlet for external cooling water[2] Outlet for external cooling water

WARNINGLegionella contaminationHealth risk with open cooling systems. Constant testing of the water quality

in the cooling circuit for the numberof microbes.

Connecting the compressor to the coolingwater mainsThe compressor is completely assembled in thefactory. The connection to the cooling water mainsmust be made with a flexible line, e.g. a com-pressed air hose or expansion joint.Only use correctly sized connectors.1 Ensure that the lines can be connected free

from tension.2 Connect the connecting line with the compres-

sor cooling water inlet and outlet.3 Shut-off valves must be provided at the cooling

water inlet and outlet.4 Secure the hose lines.

Cooling water inlet and cooling water outlet European version: EN 10226-1 Rp 1 1/4 USA/CANADA version: 1 1/4 - 11 1/2 NPT

Permissible cooling water data Cooling water pressure max.:

8 bar / 115 psi

Preparations for commissioning 5

August 2013 GB 37 /100

Cooling water inlet temperature min.: 5 C / 41 F

Cooling water inlet temperature max.: 42 C / 107 F

Cooling water outlet temperature max.: 57 C / 134 F

Cooling water requirement at maximum power and(T = 15 K , p = 0.7 bar / 13 psi) 75KW = 89 l/min / 23 gal/min 90KW = 111 l/min / 29 gal/min 110KW = 132 l/min / 35 gal/min 132KW = 155 l/min / 41 gal/min 160KW = 170 l/min / 45 gal/min

T:Cooling water outlet temperature =Cooling water inlet temperature + Tp:Cooling water outlet pressure =Cooling water inlet pressure - pThe values relate to fresh water quality without ad-ditives (e.g. antifreeze). If the cooling water qualitydeviates from this, please contact Gardner Den-ver.Set the cooling water volume in accordance withthe description "Cooling water control in a wa-ter-cooled compressor system".

NOTEThe cooling water outlet temperature shouldwhere possible be greater than 57 C to preventheightened limescale formation.

5.4 Electrical connection

NOTICEFaults in the electrical supply networkIn low voltage networks, speed-controlled com-pressor systems (RS) can cause faults. For thisreason, this drive system is not intended for usein public low voltage networks that also supplyresidential areas.

The compressor system is executed completely inthe factory according to EN 60204 (industrial ma-chinery).

The compressor power supply must be suitablefor industrial equipment and must fulfil all therequirements of EN60204-1/IEC60204-1. Con-tact Gardner Denver if the positioning condi-tions differ from the conditions as they are de-scribed in EN 60204.Implement the electrical connection and theprotective measures in accordance with VDE,BS or the appropriate local regulations. In gen-eral, the supplementary regulations of the re-spective power supply utility must be consid-ered.A main switch must be fitted on-site upstreamof the compressor (DIN EN 1012 - 1) insofarthat such a switch has not already been fittedin the factory as a special accessory. The mainswitch must fulfil the requirements of the safetystandard EN 60 204-1 (Electrical equipment ofmachines), as well as EN 60947-2 (low voltageswitchgear).The compressor must be fused using suitablebackup fuses in accordance with EN 60269-1(low voltage directives).If third party circuits are retrospectively con-trolled via the electronic control, e.g. lighting,heating or similar, that cannot be switched offfrom the main switch, these excluded circuitsmust be labelled according to EN 60204 androuted separately. Moreover, warning signsmust be attached close to the main switch andclose to the relevant circuits.Should an electrical connection to an un-earthed AC electrical circuit (IT network) bemade, observe the instructions in the supplieddocumentation of the frequency converter (onlyRS compressors).

5 Preparations for commissioning

38 / 100 GB August 2013

Electrically connecting the compressor

1

2

3

4

Fig. 5-3: Supply line openings

[1] Compressed air connection[2] Filter mat cooling air inlet[3] Condensate drain[4] Supply line cover panel

DANGERElectric shockLife-threatening electric shock Work on the electrical equipment

must only be carried out by autho-rised electricians or electrical techni-cians.

1 Remove the factory-provided cover panel.2 Insert the customer-provided supply line panel.3 Feed the power supply cable through the open-

ings in the switch cabinet.4 Connect the power supply cable, see the wiring

diagram.5 Tighten the cable glands.

Checking the setting of the fan protectionswitch



1 Check the settings of the protection switch ofthe two fan motors, see wiring diagram.

2 Set the safety switch according to the supplynetwork voltage and frequency.

Check the setting of the control transformer



With types D110RS - D160RS thereis a risk of electric shocks due tocharged capacitors!Switch the compressor to a zerovolts state and wait 10 minutes be-fore touching any electrical parts.

Checking the DC bus voltage.

The control transformer is set to the rated volt-age ex works.Experience has shown that the actual supplyvoltage may differ from the rated voltage.To match the local circumstances, the cor-rect setting of the control transformer must bechecked when the compressor is under loadby measuring the control voltages and if neces-sary the transformer then reset.A number of taps are provided for this purpose(see wiring diagram).

NOTICEMaterial damageIncorrect setting of the control transformer en-dangers trouble-free operation. Checking of the setting of the control trans-

former forms part of commissioning and pe-riodic inspection/maintenance, as the mainsvoltage conditions may vary.

Commissioning and operating 6

August 2013 GB 39 /100

6 COMMISSIONING ANDOPERATING

6.1 Initial commissioning

NOTICEMaterial damageAlthough every compressor has already under-gone a test run in the factory and has undergonea careful final inspection in dispatch, the possi-bility of transport damage cannot be excluded. Before commissioning check the compres-

sor once more for damage and monitor itduring its initial operating hours.

If the compressor is being connected to apower supply network and started for thefirst time, then dependent on the version,the direction of rotation of the drive motorand/or fans must be checked. Drive motor for non-RS compressors Fans for RS compressors

PreparationsCheck all electrical and electronic compo-nents/devices for water ingress or condensateformation, in case of complaints, contact Gard-ner Denver.If the compressor has been in storage for asubstantial period of time (up to 2 years), themain switch must be switched on at least onehour prior to starting. This ensures the operabil-ity of the capacitors and prevents any damagefrom occurring.If the compressor has been stored for longerthan 2 years, consult Gardner Denver.

Carry out the initial commissioning as follows1 Check the cooling water level (internal water

circuit).2 Check the oil level.3 Check the settings of the fan motor overload

switch.4 Check the setting of the control transformer.5 Check all the terminals of the electronic control

unit and tighten as necessary.6 Switch on the main switch.

All three LEDs on the control panel illumi-nate.

7 Set the display language.8 Acknowledge faults indicated on the display.

The message [Ready to Start] appears onthe display.

9 Check the factory setting of the pressure set-points (minimum line pressure [Line Pressuremin.] and maximum [Line Pressure max.]) andreadjust if necessary.

10 Ensure the external cooling water supply is ad-equate (water-cooled compressor only).

11 Press the start button .12 Check the direction of rotation of the drive mo-

tor (not RS compressors) or the fans (RS com-pressors ). See the following descriptions.

13 Check the output voltages of the control trans-former in load operation.

Check the direction of rotation of the drivemotor (not RS compressors )

DANGERRisk of injuryThe drive motor rotational direction canonly be checked if the clutch cover is de-mounted. Before switching on, check that

there is nobody in the danger area! Maintain an adequate distance from

rotating machine parts! Wear ear defenders!

Except for test runs, only operatethe compressor with the enclosureclosed.

1

Fig. 6-1: Check the drive motor rotational direction

[1] Protective cover (removed)

1 Switch the main switch OFF.2 Open the enclosure.

6 Commissioning and operating

40 / 100 GB August 2013

3 Remove the protective cover from the clutch.4 Switch the main switch ON.5 Press the start button .6 Check the rotational direction.7 If the rotational direction is incorrect: Immedi-

ately switch the compressor off with the ; not the Stop button < O >, as oth-erwise damage to the compressor may occur,even if it only operates very briefly.

8 Switch the main switch OFF.9 Correct the rotational direction. Change the

compressor rotating field.10 Replace the protective cover on the clutch.11 Close the enclosure.

Checking the direction of rotation of the fans(for RS compressors )

CAUTIONRisk of fallingThe rotational direction of the fan motorscan only be checked "from above". Ensure safe climbing means are

provided.

1

1

Fig. 6-2: Check direction of rotation of fan motors (air-cooled system)

[1] Rotational direction indicator

Fig. 6-3: Check direction of rotation of fan motor (wa-ter-cooled system)

The rotational direction of the fan motors can bechecked with the enclosure still closed.1 Place a suitable ladder alongside the compres-

sor and use it to climb up.2 Check the rotational direction.

The rotational direction arrow can be deter-mined through the protective cover.

3 If the rotational direction is incorrect: switch offthe compressor.

4 Switch the main switch OFF.5 Correct the rotational direction. Change the

compressor rotating field.

Temperature start-up protectionThe compressor does not start up at ambient tem-peratures less than + 2 C.


August 2013 GB 41 /100

6.1.1 Cooling water control in a water-cooled compressor system

Cooler, water-cooled compressor system

-+

+

- + -

Fig. 6-4: Cooler layout

[A] Jacket / oil cooling[B] Interstage cooler[C] Aftercooler

NOTEThe cooling water volumes of the individual cool-ers are preset in the factory and secured using atamper-evident seal.

Adjustment of the hand valves

3 4

1

2

Fig. 6-5: Display schematics Delcos XL

The hand valves A, B and C are preset. Furtheradjustment is not normally necessary. In the eventthat the values given below are not achieved, areadjustment can be undertaken.

The following specified values only apply afterat least 45 minutes operation under full load: Oil temperature "1" approximately 25C / 45F

above the cooling water inlet temperature "4". Second stage air inlet temperature 2" approx-

imately 9C / 16.2F to 10C / 18F above thewater inlet temperature "4".

The temperature difference between cool-ing water outlet "3" and cooling water inlet "4"equals approximately 15C / 27F.

6 Commissioning and operating

42 / 100 GB August 2013

NOTICEMaterial damage

Operating conditions to be adhered to beforethe adjustment work Hand valves A - C completely open before

system starting. Ensure the cooling water supply is ade-

quate. Operate the system for at least 45 minutes

at full load. Maximum pressure and maximum speed

for speed-controlled systems. Maximum pressure for systems without

speed control.

This adjustment work must only be carried outby trained maintenance personnel. Slowly close hand valve A (jacket / oil cooler)

until the oil temperature "1" has risen by about1C / 1.8F.

Slowly close hand valve B (interstage cooler)until the second stage air inlet temperature "2"is approximately 9C / 16.2F to 10C / 18Fabove the water inlet temperature.For water inlet temperatures that are well belowthe ambient temperature, a second stage air in-let temperature 2" of approximately 5C / 9F to10C / 18F above ambient temperature mustbe aimed for (avoidance of condensation).

Slowly close hand valve C (aftercooler) untilthe temperature difference cooling water out-let "3" to cooling water inlet "4" is approximately15C / 27F.

6.2 Normal operationElectronic control unit

Fig. 6-6: Control panel

[1] Touchscreen display[2] Start button [3] Stop button< O >[4] Red LED

Slow flashing: WarningFast flashing: Fault

[5] Yellow LEDSlow flashing: Maintenance necessary

[6] Green LEDLit up permanently: System in operationFlashing: System on standby

[7] Pushbutton

DANGERRisk of injuryThe compressor can start automaticallyat any time when it is in standby modewith the green LED flashing. Do not carry out any work on the

compressor, if the green LED isflashing.

Switching on1 Press the start button on the control

panel. The compressor is switched on. The compressor runs automatically (au-

tomatic operation). See the operating se-quence description in the section "Operatingsequence" in the chapter "Design and func-tion".

Operating conditions

During automatic operation, the compressor canadopt any of the following operating conditions:

Ready to start (standby) [Ready to Start]Operating under load [On-Load]

August 2013 GB 43 /100

Partial load operation (on-load operation at re-duced speed only RS compressors ) [On-Load]Off-load [Off-Load]

Observations during operationDuring operation the compressor must be regu-larly checked to ensure leak-tightness of the cool-ing water circuit and oil circuit.

Condensate drainThe condensate drains from the intercooler and af-tercooler are activated under sensor control.

Switching off1 Press the stop button < O > on the control

panel. The compressor runs on for 30 seconds

(soft stop).After this time, drive motor and fan 1 areswitched off.

Once the drive motor is stationary, oil pump,water pump and fan 2 are switched off.

Emergency-stopThe 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-stop1 Press the pushbutton.

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 the pushbutton.Turn the pushbutton anticlockwise.

4 Set the compressor in operation.See section "Commissioning after a fault" in thechapter "Commissioning and operation".

6.3 Routine commissioningRoutine commissioning is for example commis-sioning after maintenance.1 Open the shut-off valves between the compres-

sor and compressed air network.2 Thereafter proceed as described in the section

"Initial commissioning".

6.4 Commissioning after a longshutdown

If commissioning after a long shutdown, contactGardner Denver.

6.5 Commissioning after a fault

NOTICEMaterial damageAvoid switching the compressor on multipletimes without rectification of the fault as this canlead to considerable mechanical damage. Only switch the compressor back on after

the fault is rectified.

Re-commissioning after a fault (automaticswitching off)Faults are displayed in the display menu "Faultlog".1 Switch main switch off and secure to prevent

switching back on.2 Rectify the fault.

See the "Troubleshooting" chapter.3 Switch on the main switch.4 Acknowledge fault in the fault log.5 After acknowledgement, the message [Ready

to Start] appears on the display, provided noother fault exists.

6 Press the start button on the controlpanel. The compressor is switched on. The compressor runs in automatic mode.

See the operating sequence description inthe section "Control (automatic operation)"in the chapter "Design and function".

7 Troubleshooting

44 / 100 GB August 2013

7 TROUBLESHOOTINGTroubleshooting instructionsThe following tables list possible fault causes andremedies.The troubleshooting measures listed in these op-erating instructions may only be carried out byspecially trained personnel. All work going beyondthis must be carried out by the manufacturer's ser-vice personnel! Work on the electrical equipmentmust only be carried out by authorised electriciansor electrical technicians.Remedies are described in detail in the repairmanual, which is provided as part of operatortraining.

NOTICEMaterial damageMaterial damage due to improper/incorrect trou-bleshooting measures. If the remedies listed here are insufficient

for rectification of the fault, consult GardnerDenver.

For fault and warning messages that areoutput to the display of the electronic controlunit, observe the information in the "Trou-bleshooting" chapter in the operating in-structions of the electronic control unit.

Fault: The system will not start

Possible Cause Remedy

Missing operating or control voltage Check fuses, main switch and power cable.

Fault is not acknowledged Acknowledge fault in the electronic control unit.

Drive motor defective Check connections, winding, etc.

Compressor defective Rotate the compressor by hand, if necessaryreplace.

Ambient temperature < +2 C Ensure that the ambient temperature is at least +2C, if necessary provide stationary heating.

Chart 7-1: Troubleshooting upon: The system will not start

Fault: The system remains stationary during the start-up phase


Short circuit in the compressor Determine the cause of the short circuit and rectify.Replace defective fuses.

Terminals loose Check the terminals and tighten if necessary.

Too frequent manual switching on and off results inexceeding of the maximum motor switching cycles

Avoid frequent manual switching on and off.Allow the electric motor to cool.

Suction regulator does not close completely Provide access to the suction regulator, replace ifnecessary.Check solenoid valves (Y1 and Y2).

Chart 7-2: Troubleshooting upon: The system remains stationary during the start-up phase

Fault: System does not reach the set line pressure


Line pressure sensor defective Check line pressure sensor, replace if necessary.

Too large air bleed Throttle the air bleed valve or switch on/use furthercompressors.

Air filter contaminated Replace air filter cartridge.

Chart 7-3: Troubleshooting upon: System does not reach the set line pressure

Troubleshooting 7

August 2013 GB 45 /100


Heavy leaks Check compressor. For example:Check for leaks.Safety valve defective or open after checking.Condensate drain set to test function.

Suction regulator does not open completely Provide access to the suction regulator, replace ifnecessary.Check solenoid valves (Y1 and Y2).

Chart 7-3: Troubleshooting upon: System does not reach the set line pressure

Fault: System switches off


Water inlet temperature too high(only water-cooled compressors)

Check the cooling water supply.

Ambient temperature too high Ventilate the compressor room.

Electric motor defective Check electric motor and positor.

Fan defective Check fan, replace if necessary.

Sensors, connections or leads defective Check sensors, connections and leads.

Wire cross section of the electrical leads too small Measure current consumption, if necessary replaceleads.

Compressor defective Replace compressor

Chart 7-4: Troubleshooting upon: System switches off

Fault: Off-load pressure too high


Compressor does not discharge Check suction regulator, blow-off silencer, non-return valve and replace if necessary.

Suction regulator does not close completely Provide access to the suction regulator, replace ifnecessary.Check solenoid valves (Y1 and Y2).

Chart 7-5: Troubleshooting upon: Off-load pressure too high

Fault: Safety valve opens


Safety valve defective Replace the safety valve.

Line pressure sensor defective Replace the line pressure sensor.

Electronic control unit defective Replace the electronic control unit.

Suction regulator does not close completely Check the diaphragm in the suction regulator.Check solenoid valves (Y1 and Y2).Check the shuttle valve upstream of the inlet to thetwo solenoid valves.Check the opening of the blow-off valve.

Chart 7-6: Troubleshooting upon: Safety valve opens

7 Troubleshooting

46 / 100 GB August 2013

Troubleshooting: LubricatorIf faults occur when operating the lubricator, please check the possible causes of error using the followingtable.

Fault Possible Cause Remedy

Lubrication system not working Cable incorrectly connectedNo voltageCable failure

Connect up cable correctly.Check voltage at plug.Connect new cable.

Lubrication system signalsSystem running (green LED)although the grease cartridgesare empty.

Setting "VOL" switchPartially

compair d_drs series operations manual rev.02 nov.11, 2013

Documents

watercooledcompressor

general safety instructions

cooling water connection

external water circuit

internal water circuit

air circuit

initial commissioning

routine commissioning