"GENERAL" USE AND

MAINTENANCE MANUAL

Screw compressors models:

ESM 2-3-4-5-6

Edition : 02 - March 2013

(Original manual instructions)

COMPLETED BY THE "SPECIFIC" USE AND MAINTENANCE MANUAL FOR

EACH MODEL

EN
 INSTRUCTIONS MANUAL

CONTENTS
Page
1. DECLARATION OF CONFORMITY – CE .........................................................................................................3
2. GENERAL INFORMATION ................................................................................................................................4
3. PICTOGRAMS AND WARNING SYMBOLS .....................................................................................................5
4. CONDITIONS OF INTENDED USE ...................................................................................................................7
5. CONDITIONS OF IMPROPER USE ..................................................................................................................7
6. RISK ANALYSIS ................................................................................................................................................8
7. TECHNICAL CHARACTERISTICS ...................................................................................................................8
8. OPERATING PRINCIPLE ..................................................................................................................................9
9. PNEUMATIC DIAGRAM ....................................................................................................................................9
10. ELECTRIC MOTORS - TECHNICAL CHARACTERISTICS .......................................................................... 10
11. HANDLING AND LIFTING .............................................................................................................................. 10
12. INSTALLATION .............................................................................................................................................. 11
13. INSTALLATION DIAGRAM ............................................................................................................................ 12
14. CONNECTION................................................................................................................................................. 13
15. WIRING DIAGRAM ......................................................................................................................................... 13
16. BELT TIGHTENING ........................................................................................................................................ 14
17. RECOMMENDATIONS ................................................................................................................................... 17
18. FIRST START-UP ........................................................................................................................................... 17
19. STARTING AFTER A LONG TIME IN STORAGE ......................................................................................... 19
20. STARTING AT LOW AMBIENT TEMPERATURES....................................................................................... 20
21. REGULATING THE WORKING PRESSURE ................................................................................................. 20
22. STOPPING THE MACHINE ............................................................................................................................ 21
23. MAINTENANCE .............................................................................................................................................. 22
24. MAINTENANCE PROGRAMME ..................................................................................................................... 22
25. RECOMMENDED OIL ..................................................................................................................................... 23
26. TANK ............................................................................................................................................................... 25
27. DISMANTLING ................................................................................................................................................ 27
28. TROUBLESHOOTING ON ELECTRIC SCREW COMPRESSORS .............................................................. 28

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 INSTRUCTIONS MANUAL

1. DECLARATION OF CONFORMITY – CE

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2. GENERAL INFORMATION
a) This manual is intended principally for the user of the compressor and specifically for:

- handling and lifting operators;

- installation personnel;
- electrical connection technicians;
- persons in charge of use and supervision;
- maintenance personnel;
- specialised service and repair technicians.

b) The instructions manual is to be considered an integral part of the compressor and must be "kept for future
reference" for the whole life of the compressor, until it is scrapped, and must accompany the compressor if
sold. As a rule it is applied on the outside of the compressor, in a protective envelope, and must always be
kept with care and be available for consultation in the vicinity of the compressor. You may apply to the
manufacturer's address for a new copy, specifying the data on the identification plate.

c) For information or to request spare parts, consult the respective manual and supply also the serial number
and the model, indicated on the identification plate.
This manual concerns only the compressor and not the other components and accessories of the system,
for which reference must be made to the respective manuals.

d) This manual reflects the state of the art at the time the compressor was placed on the market and it may be
updated on the basis of further experience, without the obligation to update the previous production and
manuals, except in cases where this is deemed necessary.
Any explanations and information or proposals for the improvement of the manual may be sent to the
manufacturer.

e) The identification data of the compressor model must be copied (by the user) onto the Data plate shown on
the last page of the "specific" instructions manual and are the same ones shown on the PLATE APPLIED
ON THE COMPRESSOR (a fundamental requirement of the EC Directive).
Other interesting data, such as noise production and weight, are shown on the page “TECHNICAL
CHARACTERISTICS” (see the “specific” instructions manual for each type of machine).

f) In this manual, the compressor model is identified by the initials and by the motor power expressed in kW,
as indicated on the page “TECHNICAL CHARACTERISTICS” (see the “specific” instructions manual
for each type of machine).

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3. PICTOGRAMS AND WARNING SYMBOLS

An adhesive label, applied in a visible position on the compressor cowling, shows a series of symbols
(pictograms) to inform anyone about the risks and residual hazards contained inside the compressor.

Description of Pictograms according to Standards: EN 1012-1 / ISO 7000 / EC 245/24

MANDATORY: OPERATING PERSONNEL MUST READ THE INSTRUCTIONS

MANUAL

WARNING, MAINTENANCE WORK IN PROGRESS; FOLLOW THE INSTRUCTIONS

MANUAL

RISK OF ELECTRIC SHOCK

DO NOT REMOVE THE GUARDS AND SAFETY DEVICES

DO NOT REMOVE THE GUARDS AND SAFETY DEVICES

RISK OF HIGH TEMPERATURE: DO NOT TOUCH HOT SURFACES

DANGER OF COMPONENTS AND SYSTEM UNDER HIGH PRESSURE

DANGER, MACHINE IS REMOTELY CONTROLLED AND MAY START WITHOUT

WARNING

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DANGER, HOT OR HARMFUL GAS OUTLET

DO NOT BREATHE THE COMPRESSED AIR

MACHINE LIFTING POINTS

RISK OF LOW TEMPERATURES: READ THE RESPECTIVE PARAGRAPH

ON / START SWITCH “ON”

OFF / START SWITCH “OFF”

WARNING: 15 SEC. DELAY IN SWITCHING OFF WHEN PRESSING THE "OFF"

BUTTON

DO NOT SWITCH ON THE COMPRESSOR WITH THE DOORS OPEN

THE OPERATIONS MARKED WITH THIS SYMBOL IN THE MANUAL MUST BE

PERFORMED BY SPECIALISED PERSONNEL

DANGER OF ELECTRIC SHOCK DUE TO CHARGED CAPACITORS.

WAIT 10 MINUTES BEFORE ACCESSING THE ELECTRIC PANEL

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4. CONDITIONS OF INTENDED USE

a) The compressor with electric motor described in this manual is suitable exclusively for the compression of
air only, taken in at atmospheric pressure, up to a maximum pressure value as indicated on the data plate,
after the initials: MAX PRESS - bar ..............

b) The air produced by the compressor is not suitable for direct breathing because it is not sufficiently filtered
for the human organism.

c) The intended use of this compressor is "professional", used according to the indications given in the
technical characteristics for the specific model.

d) Compressor operation is completely automatic and does not require the presence of the operator. All that is
required is that it be supervised and maintained by an operator who is sufficiently trained and has learned
all the safety and operating procedures that concern him, contained in this manual.

e) The compressor operating system is contemplated exclusively by connection to a regulatory tank

downstream from the compressor with maximum pressure at least 10% higher than the Pmax of the
compressor and with an adequate capacity, for example:

compressor POWER kW 2.2 – 7.5 11 - 22 30 - 45 55 - 90

MINIMUM TANK CAPACITY Litres 200 500 720 1000

f) Compressor operation is contemplated only complete with its closing panels both for cooling and for
protection and soundproofing.

g) The compressor is not suitable for installation in environments with a potentially explosive atmosphere.

5. CONDITIONS OF IMPROPER USE

The manufacturer is relieved of any liability for:

a) Improper use or use by untrained or negligent personnel.

b) Use contrary to the regulations in force.
c) Incorrect installation.
d) Installation without a tank.
e) Installation in very dusty environments (cement, silica...)
f) Installation in environments with a potentially explosive atmosphere.
g) Irregular electrical connection.
h) Severe shortcomings in the intended maintenance.
i) Use of non authentic spare parts for the model.
j) Total or partial failure to observe the instructions.
k) Damage due to natural or exceptional events.
l) Tampering with the safety valves.
m) Exceeding the maximum working pressure as a result of tampering.
n) Compressor operation without the panels and enclosures.
o) Anything else not expressly indicated in this manual.

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6. RISK ANALYSIS
Below are indicated the safety measures taken in the design stage or the recommendations for the user,
for protection in dangerous situations.

RISK REMEDY
Handling Base designed for inserting forks of a pallet truck or forklift
Electrical connection Built-in disconnecting switch under load in AC23 (where provided)
Bolted on with opening provided with door-locking disconnecting switch
Electric panel
(where provided)
Mechanical hold-down button or yellow/red disconnecting switch (where
Emergency
provided)
Short circuit Built-in line fuses (where provided)
Motor overload Thermal overload relay
Electrostatic currents Oil separating filter with metallic continuity
Compressor excess
Thermostat
temperatures
Insufficient lubrication Thermostat for "adiabatic" compression
Starting under load 10 sec. delay on restarting (only for versions with control unit)
Excess pressure Regulatory safety valve
Back pressure Check valve
Residual pressure Discharge tap and internal pressure gauge
Standard protection controlled by RSF relay (only for versions with
Incorrect direction of rotation
control unit)
Temperature:
a) Maximum ambient > Tmax a) Thermostat (see specific manual)
b) Minimum ambient < Tmin b) See recommendations for starting
Containers under pressure Built according to CE regulation in force
Hoses Use of high pressure hoses (4/6 times the working pressure)
Thermal risks Warning plate on points > 70 °C
- Machine closed by panels
Rotating parts - Guard on belt transmission;
- Transmission danger label

7. TECHNICAL CHARACTERISTICS

For the full technical characteristics see the specific instructions manual for the
compressor.

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8. OPERATING PRINCIPLE
This is a single-stage screw compressor. The air end is composed of 2 asymmetric screws driven by an
electric motor. The air is compressed by the rotation of the male and female rotors which are parallel and
perfectly mated with each other and contained in a cast iron casing.

The oil injected into the screw has the dual function of cooling and of creating a perfect seal during screw
rotation. The compressed air leaves the air end mixed with lubricant and enters the separating tank. In the
tank there is the first separation of the oil by centrifugal action and by gravity and a final separation through a
special high-efficiency filter, which purifies the compressed air down to 2-3 ppm traces of oil. After separation
from the compressed air the oil, controlled by a thermostatic valve, enters a cooling radiator and is injected
at low temperature into the air end.
The air cooling system is of the forced type. The air is sucked in by a fan and forced through the air/oil
radiator, removing the heat.
The compressor is soundproofed by means of a coating of fireproof sound-deadening material on all the
external panels.

9. PNEUMATIC DIAGRAM

P. NAME P. NAME
1 ELECTRIC MOTOR 11 SUCTION FILTER
2 COMPRESSOR 13 SUCTION VALVE
3 OIL DISCHARGE 14 OIL RECOVERY
4 OIL SEPARATING FILTER 15 PRESSURE GAUGE
5 SAFETY THERMOSTAT 16 DISCHARGE VALVE
6 OIL SEPARATING TANK 18 PRESSURE SWITCH/PRESSURE TRANSDUCER
7 SAFETY VALVE 19 MINIMUM PRESSURE CHECK VALVE
8 OIL FILTER 20 AIR RADIATOR (MODELS > 5.5 Kw)
9 OIL RADIATOR
10 THERMOSTATIC VALVE

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10. ELECTRIC MOTORS - Technical Characteristics

- Construction - IP 55 - Class F - Efficiency IE2 2 - 3 kW 4 - 90 kW

- Universal voltage according to standards DIN-IEC 38 230/400 V 400/690 V
- Standard rated connection voltage ± 5% 400 V 400 V
- Rated amperes indicated on the data plate referring to 400 V 400 V

11. HANDLING AND LIFTING

N.B. • When moving, avoid jolts and ensure the load is in a barycentric position.
• Use lifting equipment suitable for the weight of the machine and with fork
length (A) (C) suitable for the width.
• Avoid lifting the compressor by exerting force on the panelling.
• Respect the distance of the forks (B) (D) according to the indicated lifting
points.

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12. INSTALLATION

12.1 Place of installation

a) The compressor must stand on a flat surface, suitable to bear the weight of the compressor (refer to the
technical specifications). It does not require anchoring, as the rotating parts are mounted on vibration
dampers which absorb any vibrations.

b) Consult the compressor overall dimensions drawing to establish the minimum distance necessary from
walls and from other machinery.

c) Ensure that the place where the compressor is located is adequately ventilated. The temperature of the
cooling air must not be higher than +45°C or lower than 0°C. Do not allow the cooling air to recirculate. If the
compressor is provided with air ducts, respect the requested air volume and the maximum load loss in the
ducts. Also consider the possibility of cleaning the radiators (refer to the technical specifications).

d) The condensate discharge contains water and traces of oil which must be properly disposed of, as required
by the law.

e) The compressor transfers heat to the environment in which it is positioned.

Provide an adequate change of air.

f) The compressor must not be installed in environments with presence of cement dust, silica or other types of
dust without any particular measures for prefiltering the air taken in.
If you have any doubts, contact the GARDNER DENVER assistance service.

g) Installation in an environment with a potentially explosive atmosphere is forbidden.

h) Installation outdoors is forbidden:

0°C

12.2 Recommendations
a) The air sucked in by the compressor must be absolutely free from inflammable vapours and toxic fumes of
solvents or paints which could cause fires or explosions and pollute the air in the working environments.
b) The absence of a storage tank is prejudicial to the safety of operation of the compressor, because it may
overload the electric regulating components and cause an excessive number of starts per hour, which are
harmful for the electric motor.
c) Do not remove or tamper with the safety devices, guards or insulations applied on the compressor.
d) Absolutely do not tamper with the pressure regulator and the pressure switch beyond the value allowed by
the compressor model and by the tank pressure. In any case the allowed working pressure is always lower
than the opening pressure of the safety valve of the tank constructed according to the regulations in force.

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12.3 Initial check

After having removed the compressor from its packaging and before connecting it, check it thoroughly to ensure
it has not suffered any damage during transport. Do not leave the used packaging, such as wood, nails or
plastic sheets, within reach of children as they may be a source of danger, dispose of them in an
environment-friendly way!
a) Check that all the fuses in the electric panel of the compressors are correctly positioned and secured;
b) Check the tightness of the main fixing bolts and protections.

13. INSTALLATION DIAGRAM

THREE-PHASELINE

LINEA TRIFASE LINEA

MONOFASE

REF. NAME

1 COMPRESSOR
2 TANK
3 DRYER
4 HOSE
5 WATER-OIL SEPARATOR
6 CONDENSATE SEPARATOR
7 AUT. CONDENSATE DISCHARGE
8 CERAMIC FILTER
9 COALESCING FILTER 0.1m
10 COALESCING FILTER 0.01m
11 ACTIVATED CARBON FILTER
12 DIFFERENTIAL PRESSURE GAUGE
COMPRESSED AIR OUTLET

NOTE : MIN. DISTANCE FROM REAR WALL = 1000 MM

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14. CONNECTION

IMPORTANT : Connection pipes

Use a hose with characteristics suitable for the working pressure and temperature, and minimum dimensions
the same as the outlet connector.

14.1 Electrical connection

a) The electrical connections must be made in conformity with IEC standards. Also observe all the local safety
regulations.

b) Ensure that the correct working voltage is used. The rated voltage indicated must be used, ± 5 %. Check
that the same voltage is used in each phase.

c) The installer must protect the power supply cable against short circuiting. For the types of fuses used, refer
to the "specific" manual for each type of machine.

d) If the compressor has a built-in dryer, the electric panel must be connected to a separate 230V supply unit
(refer to the wiring diagrams and the technical data).

e) The correct connection of the protective earth lead is of fundamental importance.

f) The power supply connections must be made exclusively by qualified electricians. Do not install
computers in the vicinity of the compressor.
Ensure that any computers are connected to a different electric circuit from that of the compressor.

15. WIRING DIAGRAM

See the specific wiring diagram (for each version) attached to the machine documentation.

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16. BELT TIGHTENING

16.1 For versions with power from 2.2 to 30 kW

The belt tension is ensured by the vertical movement of the supporting surface of the sliding flange/compressor
(fig.1-ref.3) obtained by adjusting the tightening screw (fig.1-ref.1) (after having slackened the compressor
retaining screws fig.1-ref.4).
This operation can be performed by applying a force F = (SEE TABLE) with a torque wrench on the centre line
of the belts (see fig. 2) so as to obtain sagging f = (SEE TABLE).

If the value of f>7.2 mm, it means that the belt tension is too low, so you must adjust the tightening screw pos.1
to restore the correct value of the belt tension.

If the value of f<6.8mm, it means that the belt tension is too high, so you must adjust the tightening screw pos.1
to restore the correct value of the belt tension.

NOTE 1 : After having restored the correct belt tension, run the compressor for 20-30 minutes. Then
check the belt tension again, measuring the value of "f", and if the tension is not correct restore it
following the procedure described above.

NOTE 2 : Check that the pulleys are perfectly aligned and correct the alignment if necessary to obtain
a maximum misalignment of 1.5 mm. ( fig. 1 )

Fig. 2 1 – TIGHTENING TIE RODS

2 – STOP NUTS
3 – BELTS
4 – COMPRESSOR RETAINING SCREWS
5 – COMPRESSOR PULLEY
6 – MOTOR PULLEY
7 – COMPRESSOR MOTOR SUPPORT
8 – ELECTRIC MOTOR

Fig. 1

LINE FOR
CHECKING
ALIGNMENT

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16.2 For versions with power from 37 to 45 kW

The tightening system is automatically performed by the spring assembly with tie rod.
All that is required is to check the correct position of the indicator which must be within the green area.
If necessary, if the belt has become stretched, as well as automatic recovery, adjust the nut to return the
indicator within the green area.
To replace the belts, adjust the nuts restoring the 138 mm length of the spring and check that the indicator is
within the green area.

BELT TENSION
VISUAL INDICATOR

red
GREEN
red
Loose

Correct
Too tight

INDICATOR

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16.3 For versions with power from 55 to 90 kW

The tightening system is automatically performed by the spring assembly with tie rod.
All that is required is to check the correct position of the indicator which must be within the green area.
If necessary, if the belt has become stretched, as well as automatic recovery, adjust the nut to return the
indicator within the green area.
To replace the belts, adjust the nuts and check that the indicator is within the green area.

1
4

5 Red loose
3
Green correct
6
Red too tight

2° MAX DESCRIPTION
SYSTEM FOR CHECKING
PULLEY ALIGNMENT 1 Compressor
2 Line for checking alignment
3 Motor pulley
4 Belts
5 Compressor pulley
6 Spring and tie rod
7 Tightening nut
Grease nipples(grease every 1600 hours using
8
lithium grease: SKF LGHQ3, about 30 grams)
2
8 2 mm MAX

16.4 Belt tension values

Power (kW) 2.2-5.5 7.5 11 15 18.5-22 30 37-45 55 75 90

Force F (N) 50 25 60 50 80 80 120 160 200 75

Sag f (mm) 8 6 8 10 6 7 7 8 10 13

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17. RECOMMENDATIONS

a When starting the compressor for the first time, ensure that:
- the hoses are well connected and efficient and have no abrasions or cracks
- the direction of rotation is correct, if it is incorrect invert two phases of the
electric power cable.
- It is forbidden to run the compressor with the door open.
- all the guards are in their place, well secured
- all the cables that make up the electric system are in good conditions and
the earth wire is connected
- there are no leaks of oil and air
b Before opening the gate valves and sending compressed air into the connecting hose, ensure that the end
is secured so as to avoid whiplash which would cause injuries.
c At the end of each shift, turn off the power by means of the motor protector or "OFF" button on the control
unit.
d The air produced by the compressor is not suitable for human breathing because it contains oil
vapours.

18. FIRST START-UP

18.1 For versions with direct start for powers 2.2-5.5 kW without control unit
Airbasic 2 (operation with pressure switch)
To start the compressor press the “ON-1” button (BLACK) on the front panel.
The machine operation is automatically controlled by the pressure switch, which stops the machine when the air
pressure in the tank reaches the MAXIMUM value and restarts it when the pressure falls below the MINIMUM
value, according to the work cycle shown in the figure.
This pressure range is set at MIN. 8 bar / MAX. 10 bar
If necessary, to stop the compressor press the “OFF-0” button (RED) on the front panel.

There are allowed MAXIMUM 6 starts per hour.

EXAMPLE of a WORK CYCLE:

kW 2-5,5
Minutes 4 4 4 4
WORKS

Minutes
PAUSE 6 6 6 6 6

N.B.: The compressor must operate with WORK cycles of at least 4 minutes, before switching
off the machine, to avoid the formation of condensate in the oil.

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18.2 For versions with control unit

The compressor is ready to operate in AUTOMATIC mode with the aid of the electronic control unit
AIRBASIC 2.

When the “ON” / “RUN” button is pressed the compressor is started in "star delta" sequence.

Once the "star delta" transition is complete, a timer counts a delay of 1 second at the end of which the
compressor passes to operation under load.

The pressure is measured by a pressure transducer connected to the control unit.

When the pressure reaches the Pmax value the control unit intervenes, making the compressor run idle for a
maximum of 3 minutes.

If the pressure falls to Pmin value during idling, the control unit starts the compressor under load.

Instead, if the pressure remains at values higher than Pmin, the motor is stopped at the end of the idling time.
As soon as the pressure falls to Pmin value, the motor is restarted in "star delta" sequence.

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19. STARTING AFTER A LONG TIME IN STORAGE

19.1 For versions with power from 2.2 to 22 kW

IF THE COMPRESSOR HAS REMAINED IN

STORAGE FOR MORE THAN TWO MONTHS,
BEFORE STARTING IT THE OIL MUST BE
RECIRCULATED

a access the suction valve (A) by removing the

cover (B) and extracting the cartridge of the
suction filter (C)
b pour in about 100 cc of oil
c run the compressor for ten seconds
d repeat operation b once more
e reassemble everything and start work.

19.2 For versions with power from 30 to 90 kW

IF THE COMPRESSOR HAS REMAINED IN

STORAGE FOR MORE THAN TWO MONTHS,
BEFORE STARTING IT THE OIL MUST BE
RECIRCULATED
OIL
a access the suction valve (A) by removing the clamp (B) B
and extracting the pipe of the suction filter (C)
b pour in about 250 cc (for 30-37 kW) or 500 cc (for
45-90 kW) of oil A
c run the compressor for ten seconds C
d repeat operation b twice more
e reassemble everything and start work.

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20. STARTING AT LOW AMBIENT TEMPERATURES

Foreword: if the ambient temperature can fall below 0°C it is indispensable to protect the pipes and all the
condensate dischargers with insulation, to avoid blocking caused by the formation of ice, which could cause
dangerous "water hammer" reactions in the tanks.
It is recommended to use the synthetic oil corresponding to the ones indicated in the table if the
ambient temperature remains constantly at about 0°C.

Procedure recommended for the first start-up (with ambient temperatures below 0 °C )

a Start the motor for 4/5 seconds and switch it off quickly before the pressure rises.
b Repeat point a once more.
c Start the compressor provisionally, checking that the pressure increases almost up to the maximum working
pressure of the compressor .
example: 7 BAR for 8 BAR versions
9 BAR for 10 BAR versions
12 BAR for 13 BAR versions
d Switch the compressor off promptly at the higher pressures indicated in point c
e Repeat points c - d once again
f Finally start the compressor, checking that the pressure is not exceeded due to the formation of ice in the
pipes or blocking of the check valve.

21. REGULATING THE WORKING PRESSURE

21.1 For versions with direct start:

The pressure switch controls the loading/unloading operation of the compressor.

When supplied the compressor is correctly regulated with a differential of 2 bar between Pmax-Pmin.

Should it be necessary to modify the regulation of the pressure switch, contact the authorised Gardner Denver
assistance service.

It is strictly forbidden to set the pressure switch at values higher than 10 bar.

21.2 For versions with control unit:

The control unit controls the loading/unloading operation of the compressor, measuring the output pressure and
comparing it with the set Pmax and Pmin values.

When supplied the compressor is correctly regulated with a differential of 1 bar between Pmax-Pmin.

Should it be necessary to modify the regulation of the Pmax and Pmin values, contact the authorised Gardner
Denver assistance service.

N.B.: It is strictly forbidden to set the pressure at values higher than the pressure Max Press on the compressor
data plate.

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22. STOPPING THE MACHINE

22.1 For versions with direct start:

Press the red "OFF" button.

N.B.: In the event of a power cut, the compressor will stop and then restart automatically, without any delay,
when the mains power returns.

WARNING: Check that automatic restarting cannot produce dangerous situations of any kind.

22.2 For versions with control unit

Press the 0 “OFF” / “STOP” button.

WARNING: the compressor continues to operate for another 15 seconds (soft-stop function)

FOR IMMEDIATE STOP: press the mechanical hold-down button or, if not present, turn the yellow/red
disconnecting switch to "OFF" position (that is counter clockwise).

N.B.:
After a power cut, the compressor will not restart automatically
(parameter P26=0 default).
To activate the automatic restart function you must change the settings in the control unit (parameter P26=1).

WARNING: this particular situation must be carefully evaluated, considering the air reserve in the
storage tank downstream from the compressor, so as to avoid any injuries to persons or damage to
property or materials due to the fall in pressure in the network.

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23. MAINTENANCE
NOTE:

- Maintenance activities indicated in detail with this symbol in this manual must be performed by
authorised Gardner Denver service personnel.
- Always wear protective clothing and gloves during maintenance jobs.
- Always compile a log book.

23.1 Operations before maintenance

Warning: risk of very hot surfaces inside the compressor cowling immediately after stopping.

a Stop the compressor.

b Disconnect the main switch, padlock the disconnecting switch (if present) and ensure that the compressor
cannot be started accidentally.
c The compressed air discharge function empties the tank after stopping; wait 2 minutes.

23.2 Operations after maintenance

a Turn off the main switch.
b Start the compressor.

24. MAINTENANCE PROGRAMME

For the detailed maintenance programme, see the specific instructions manual for the
compressor.

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25. RECOMMENDED OIL

Gardner Denver compressors are filled in the factory with AEON lubricants.
These lubricants are formulated according to the highest quality standards and are authorised, tested and
approved in the factory for use with rotary screw compressors.
AEON lubricants are available from the authorised distributors of Gardner Denver compressors.

25.1 Oil specifications

• Oil specification: -DIN-VDL-ISO VG46

The following lubricants are recommended for the compressor:

- Garden Denver AEON 3000 (type F 2105). Oil, for the first filling.
- Gardner Denver AEON 6000 FG (USDA compatible for uses in the food industry)
- Gardner Denver AEON 9000 SP (SYNTHETIC)

N.B.: The SYNTHETIC lubricant is recommended for:

- oil temperatures > 90°C
- ambient temperatures < 2°C

AEON 3000 (type F 2105) AEON 6000 FG AEON 9000 SP

Size of pack
Order number Order number Order number

10 litres 03389141
20 litres 250531 89795109 89756089
209 litres 03389143 89795239 89767689

For these compressors it is recommended to use AEON specific lubricants.

Other types of lubricants may cause:
- shorter duration of the oil filter, the oil separators and the oil itself
- formation of a patina and obstructions in the oil circuit
- higher oil consumption
- excess of impurities and damage to the compressor

N.B.: Do not mix different types of oil.

If the recommended type of oil has not been used, ask Gardner Denver for instructions on how to clean the oil
circuit.

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25.2 OIL TANK CAPACITY

- Oil filling diagram

kW 2.2-7.5 kW 11-15

1) OIL FILLING CAP

2) GASKET
3) OIL LEVEL INDICATOR
4) OIL AND CONDENSATE
kW 18-22 kW 30-90

1) OIL SEPARATING FILTER

2) SCREW OIL FILTER CARTRIDGE
3) AIR SUCTION FILTER CARTRIDGE
4) OIL FILLING
5) OIL AND CONDENSATE DRAINAGE
6) OIL TANK
7) CAP

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- Oil capacity table

Total machine
Compressor power (kW)
capacity (lt.)
2.2 ÷ 5.5 3

7.5 3

11 - 15 5,5

18.5 - 22 10,5

30 13

37 - 45 - 55 25

75 43

90 45

26. TANK

26.1 Compressed air tank maintenance

a) Periodically drain the condensate.
b) Periodically check the efficiency of the safety valve.
c) Check for internal corrosion of the tank at the intervals
established by the regulations in force in the country of use.
d) Abide by the instructions for use given in the attachment to the
CE Declaration of conformity drawn up by the manufacturer of the
Tank and of the Safety Valve.

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26.2 Condensate discharger (optional)

Clean after the first 10 hours and every 500 hours

Clean the filter of the tap pos. l8, proceeding as follows:

a) turn off the power supply and disconnect the connector pos. 2;
b) turn off the tap upstream from the discharger pos. 10;
c) unscrew the filter holder pos. 9, carefully clean the filter pos.8 and reassemble.

ON OFF
OPEN S
5
m
2 10 30
10
1
15 5
40
20

CLOSED

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27. DISMANTLING

IMPORTANT INFORMATION: more than 90% of the parts of this compressor are
made of recyclable material.

When taking the compressor out of service and demolishing it, its components must be considered in
order to dispose of them in an environment-friendly way:

 lubricating oil: collect and deliver to authorised recycling centres;

 rubber hoses, electric cables and plastic parts: sort for separate waste collection;
 filters: sort for special waste collection;
 sheet metal, compressor, motor: scrap for recycling.

ATTENTION: KEEP THIS BOOKLET WITH CARE

FOR FUTURE REFERENCE

THIS MANUAL MAY BE SUBJECT TO MODIFICATIONS AND UPDATES

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28. TROUBLESHOOTING ON ELECTRIC SCREW COMPRESSORS

N.B.:
a) each job must be performed only by suitably trained technical personnel or
by a service centre!
b) before each job, take all the necessary safety precautions, as indicated in the
paragraph "MAINTENANCE”.

Problem Possible cause and solution

• check fuses and voltage

• check that the voltage protection devices (safety
No power supply switch, circuit breakers or fuses) are suitable for
the frequency converter. For further details,
contact an authorised Gardner Denver distributor.

Find the cause of overheating

• faulty sensor or oil mixing valve
• warm cooling air is recirculating
• insufficient volume of cooling air
Compressor stops due to • ambient temperature too high
overheating • chiller blocked
• wrong type of oil or oil level to low
• oil separator blocked
• oil filter blocked

• check the main switch

• check the motor cables and the
frequency converter and also that the
Fault in electric system connections are secure
IMPOSSIBLE TO START N.B.: after having turned off the power, wait 5
THE COMPRESSOR minutes before touching the connections

• check that the maximum pressure has not

been exceeded
• check the input temperature and the flow
Motor overloaded of cooling air
• check the oil level
• check the pressure loss in the separator
• check that the interception valve between
the compressor and the compressed air
Compressor stops because system is open
pressure too high • after-cooler frozen
• faulty pressure sensor
• line filters blocked
Impossible to start the • remote control panel open
compressor even if “Start” • wait (the circuit pressure is higher than set
button has been pressed pressure)
• check that the main switch has been activated
Emergency stop alarm • check operation of the auxiliary contacts of the
(where provided) main switch. For further details, see the Wiring
diagrams section.

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Air filter blocked • change it

Oil separator blocked • change it
Faulty input valve • repair or change it
If the temperature of the frequency converter or
the ambient temperature exceeds the assigned
value and the motor current exceeds the
maximum allowed value, the maximum
If the circuit pressure is frequency will be automatically limited by the
lower than the set value, controller.
the maximum frequency will • check the flow of cooling air
not be reached • clean the frequency converter and the motor
• check the oil separators
• check the oil level
• check the electric panel filters
INSUFFICIENT OUTPUT • check the level of the power supply voltage
Faulty discharge valve or • repair or change it
condensate drain
Leaks in the compressed • check and repair the leaks
air system
V belt broken • change it
Pressure limits set • correct them
incorrectly
Ambient temperature too • ensure that the flow of cooling air is sufficient
• ensure that the incoming air is arriving
high
from an extremely cold environment
• Prevent the flow of cold cooling air in the
After-cooler frozen compressor
Overpressure valve open • close it
• change it
OIL LEAKS IN THE INPUT
Leaks in the sealing ring of
VALVE AFTER AN
the input valve
EMERGENCY STOP

Limited volume of the • correct it to suit the minimum

FREQUENT STOPS OF compressed air dimensions of the ducts
THE COMPRESSOR system
Blockage in the circuit • find the blockage and correct it
FREQUENCY Ambient temperature too • check the flow of cooling air
CONVERTER high
OVERHEATED (WHERE Electric panel air filters • change them
PROVIDED) blocked
Chiller blocked (dirty) • clean the outside
COMPRESSOR Ambient temperature too • check the flow of cooling air
OVERHEATED high
Oil level too low • add oil

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Wrong type of oil • see “Indications concerning oil”.

Oil filter blocked • change it
Faulty discharge • change it
temperature transducer
COMPRESSOR
OVERHEATED Limited channelling of the • check the size and the pressure loss
cooling air or too high of the channel and correct them
pressure loss
Oil separator blocked • change it

Oil return line blocked • clean it

Faulty oil separator • change it

Oil separator blocked • change it

EXCESSIVE OIL Wrong type of oil • see “Indications concerning oil”.

CONSUMPTION
Excessive discharge • find and eliminate the cause
temperature
Leaks of the sealing • change it
ring on the shaft
Oil level too high • reduce the oil level

N.B.: see also the error messages listed in the manual of the electric control unit (if provided).

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Gardner Denver Compressor Division,1800

Gardner Expressway, Quincy, Illinois 62305

Telephone: (800) 682-9868

Fax: (217) 224-7814

Gardner Denver S.r.l.

Via Tevere n°6
21015 Lonate Pozzolo (VA) ITALY

Telephone: +39 (0)331.349411

Fax: +39 (0)331.301680

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