13-20-600

Version: 04
August 11, 2009

INTEGRA™
BASE-MOUNTED
COMPRESSORS

AIRSMART™ CONTROL

MODELS – EFC99J
20, 25, 30 HP

60 HZ

OPERATING AND
SERVICE MANUAL
 MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
®
GENUINE GARDNER DENVER COMPRESSOR PARTS AND SUPPORT SERVICES

®
Gardner Denver Compressor genuine parts, manufactured to design tolerances, are developed for optimum dependability –
specifically for Gardner Denver compressor systems. Design and material innovations are the result of years of experience with
hundreds of different compressor applications. Reliability in materials and quality assurance is incorporated in our genuine
replacement parts.
™
Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. An AirSmart network of authorized
distributors provides the finest product support in the air compressor industry.

Your authorized distributor can support your Gardner Denver air compressor with these services:

1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured airends are
maintained in stock at the Remanufacturing Center in Indianapolis, IN., for purchase on an exchange basis with liberal
core credit available for the replacement unit.
3. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.
4. Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.

Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They are ready to
respond and assist you by providing fast, expert maintenance and repair services.

For the location of your local authorized Gardner Denver Air Compressor distributor, refer to the yellow pages of your
phone directory, check the Gardner Denver Web Site at www.gardnerdenver.com or contact:

Gardner Denver
1800 Gardner Expressway
Quincy, IL 62305

Phone: (217) 222-5400

Fax: (217) 224-7814

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Compressor MODEL, Method of Cooling, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). The Airend Serial Number is also stamped on top of the discharge bearing carrier casting.

All orders for Parts should be placed with the nearest authorized distributor.

Where NOT specified, quantity of parts required per compressor or unit is one (1); where more than one is required
per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED.

DO NOT ORDER BY SETS OR GROUPS.

To determine the Right-Hand and Left-Hand side of a compressor, stand at the motor end and look toward the
compressor. Right-Hand and Left- Hand are indicated in parenthesis following the part name, i.e. (RH) and (LH),
when appropriate.

13-20-600 Page 1
 WARNING – PROHIBITION – MANDATORY LABEL INFORMATION

Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled
manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise
care in its operation and maintenance. This book is written to give the operator and maintenance
department essential information for day-to-day operation, maintenance and adjustment. Careful
adherence to these instructions will result in economical operation and minimum downtime.

Boxed text formats are used, within this manual, to alert users of the following
conditions:

Safety Labels are used, within this manual and affixed to the appropriate areas of
the compressor package, to alert users of the following conditions:

Indicates a hazard with a high level of risk, which if not avoided, WILL result in death or serious
injury.

Equipment starts automatically

Health Hazard – Explosive Release of Pressure

Cutting of Finger or Hand Hazard – Rotating

impeller blade High Voltage – Hazard of Shock, Burn, or Death
Present until Electrical Power is Removed

Cutting of Finger or Hand Hazard – Rotating fan

blade Entanglement of Fingers or Hand/Rotating Shaft

13-18-601 Page 2
Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or
serious injury.

Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air

Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or
moderate injury.

Burn Hazard – Hot surface

PROHIBITION/MANDATORY ACTION REQUIREMENTS

Do not Operate Compressor with Guard Removed Lockout Electrical Equipment in De-Energized
State

Loud Noise Hazard – Wear Ear Protection

Do Not Lift Equipment with Hook – No Lift Point

Handle Package at Forklift Points Only Read the Operator’s Manual Before Proceeding
with Task

13-18-601 Page 3
 SAFETY PRECAUTIONS

Safety is everybody’s business and is based on your use of good common sense. All situations or
circumstances cannot always be predicted and covered by established rules. Therefore, use your past
experience, watch out for safety hazards and be cautious. Some general safety precautions are given
below:

Failure to observe these notices could result in injury to or death of personnel.

• Keep fingers and clothing away from rotating fan, drive coupling, etc.

• Disconnect the compressor unit from its power source, lockout and tagout before working on the
unit – this machine is automatically controlled and may start at any time.

• Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostatic mixing valve or
break any connections, etc., in the compressor air or oil system until the unit is shut down and
the air pressure has been relieved.

• Electrical shock can and may be fatal.

• Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.

• Open main disconnect switch, lockout and tagout before working on the control, wait 10 minutes
and check for voltage.

Failure to observe these notices could result in damage to equipment.

• Stop the unit if any repairs or adjustments on or around the compressor are required.

• Do not use the air discharge from this unit for breathing – not suitable for human consumption.

• An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).

• Do not exceed the rated maximum pressure values shown on the nameplate.

• Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.

13-18-601 Page 4
 TABLE OF CONTENTS

Maintain Compressor Reliability And Performance With

Genuine Gardner Denver Compressor Parts And Support Services............................................................ 1
Instructions For Ordering Repair Parts ......................................................................................................... 1
Warning – Prohibition – Mandatory Label Information.................................................................................. 2
Safety Precautions ........................................................................................................................................ 4
Index.............................................................................................................................................................. 6
List Of Illustrations......................................................................................................................................... 8
Section 1, General Information ..................................................................................................................... 9
Section 2, Installation .................................................................................................................................. 11
Section 3, Starting & Operating Procedures ............................................................................................... 18
Section 4, Controls & Instrumentation ........................................................................................................ 24
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator............................................................................ 51
Section 6, Air Filter...................................................................................................................................... 62
Section 7, Belt Drive.................................................................................................................................... 64
Section 8, Maintenance Schedule .............................................................................................................. 67
Section 9, Troubleshooting ......................................................................................................................... 69

This book covers the following models:

HP PSI Air Cooled Parts List Controller Manual Communication

Module
20, 25 & 30 100, 125, 150, 175 EFC99J 13-20-500 13-17-600 13-17-604

13-18-601 Page 5
 INDEX

Air Cooled Unit .................................................11 Upgrade Procedure...................................... 55

Air Filter Lubrication
Element.........................................................62 Motor ............................................................ 16
Element Life..................................................63 Lubrication, Cooling And Sealing....................... 9
Section 6.......................................................62 Lubrication, Oil Cooler, Oil Filter & Separator
Standard Duty...............................................62 Section 5 ...................................................... 51
Air Flow In Compressor System ........................9
Air Receiver Maintenance Schedule
Auxiliary ........................................................14 Section 8 ...................................................... 67
Air/Oil Separators.............................................59 Moisture Separator/Trap
Optional ........................................................ 14
Belt Drive Motor Lubrication ............................................. 16
Checking Belt Tension..................................65
Replacing Belts.............................................64 Oil Cooler
Replacing Compressor Sheave....................65 Compressor.................................................. 59
Section 7.......................................................64 Oil Filter............................................................ 57
Oil Level
Cold Ambient Operation...................................52 Gauge........................................................... 57
Cold Weather Procedure For Checking .............................. 52
Installation ....................................................14 Oil Reservoir .................................................... 59
Compression Principle .......................................9 Drain............................................................. 12
Compressor........................................................9 Filling ............................................................ 54
Controls & Instrumentation Oil Separator
Airsmart Operation .......................................24 Inspection ..................................................... 60
Control Devices ............................................25 Removal For Inspection Or Replacement.... 60
General Description......................................24 Oil Specifications ............................................. 51
Section 4.......................................................24 Oil System
Cooler Addition Of Oil Between Changes................ 52
Compressor Oil.............................................59 Compressor.................................................. 51
Cooling, Sealing And Lubrication.......................9 Draining And Cleaning ................................. 54
Moisture........................................................ 57
Daily Check ......................................................21 Oil Change Interval ...................................... 53
Discharge Service Line ....................................15 Oil System Check ............................................ 61
Air And Oil Discharge Temperature ............. 61
Electrical Wiring ...............................................15 Compressor Oil Inlet Temperature............... 61
Enclosure .........................................................13 Oil Cooler Oil Pressure Differential .............. 61
Oil Cooler Temperature Differential ............. 61
Foundation .......................................................12 Oil Inlet Pressure.......................................... 61

General Information Piping

Section 1.........................................................9 Control.......................................................... 14
Grounding.........................................................16 Pressure Differential Gauging.......................... 59
Prestart-Up Instructions ................................... 18
High Temperature Operation ...........................52 Air Filter ........................................................ 18
Compressor Oil ............................................ 18
Inlet Line...........................................................14 Electrical....................................................... 18
Installation Enclosure ..................................................... 20
Cold Weather................................................14 Grounding..................................................... 18
General .........................................................11 Operating Mode............................................ 19
Section 2.......................................................11 Piping ........................................................... 18
Rotation ........................................................ 19
Lifting Unit ........................................................11 System Pressure .......................................... 19
Location............................................................11
Lubricant Quick Start Guide............................................. 22
Recommended .............................................51

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Safety Precautions .............................................4 Unit Cold....................................................... 20
Sealing, Lubrication And Cleaning.....................9 Unit Hot ........................................................ 21
Separators Stopping The Unit ............................................ 21
Air/Oil ............................................................59
Service Check List ...........................................67 Trouble Shooting
Air Filter ........................................................67 Section 9 ...................................................... 69
Every 1000 Hours Operation........................67 Troubleshooting Voltage Problems.................. 72
Every 125 Hours Operation..........................67
Every 4000 Hours Operation........................67 Valve
Every 8 Hours Operation ..............................67 Thermal Control (Thermostatic Mixing)........ 59
Every Year....................................................67
Motor Lubrication..........................................67 Warning – Prohibition – Mandatory Label
Sheave Alignment ............................................64 Information ..................................................... 2
Starting & Operating Procedures Wiring
Section 3.......................................................18 Electrical....................................................... 15
Starting The Unit ..............................................20

13-18-601 Page 7
 LIST OF ILLUSTRATIONS

Figure 1-1 – Compressor Cycle .................................................................................................................... 9

Figure 1-2 – Compressor Illustration........................................................................................................... 10

Figure 2-1 – Typical Compressor Room ..................................................................................................... 12

Figure 2-2 – Air Flow Chart ......................................................................................................................... 12
Figure 2-3 – Cold Weather Installation ....................................................................................................... 13

Figure 4-1 – Control Schematic .................................................................................................................. 24

Figure 4-2 – Key Pad .................................................................................................................................. 25
Figure 4-3 – Wiring Diagram – Wye Delta 20, 25 & 30 HP (200 & 460 Volt) ............................................. 29
Figure 4-4 – Wiring Diagram – Wye Delta 20, 25 & 30 HP (230 Volt) ........................................................ 31
Figure 4-5 – Wiring Diagram – Full Voltage 20, 25 & 30 HP (460 Volt) ..................................................... 33
Figure 4-6 – Wiring Diagram – Full Voltage 20, 25 & 30 HP (200 Volt) ..................................................... 35
Figure 4-7 – Wiring Diagram – Full Volt - 20 HP (230 Volt)........................................................................ 37
Figure 4-8 – Wiring Diagram - Full Voltage 25 & 30 HP (230 Volt) ............................................................ 39
Figure 4-9 – Wiring Diagram – Less Starter (200 & 460 Volt) .................................................................... 41
Figure 4-10 – Wiring Diagram – Less Starter (230 Volt)............................................................................. 43
Figure 4-11 – Wiring Diagram – Wye Delta (575 Volt) ............................................................................... 45
Figure 4-12 – Wiring Diagram – Full Voltage (575 Volt) ............................................................................. 47
Figure 4-13 – Wiring Diagram – Less Starter (575 Volt)............................................................................. 49

Figure 5-1 – Flow Diagram.......................................................................................................................... 51

Figure 5-2 – Approximate Oil System Capacities ....................................................................................... 53
Figure 5-3 – Oil Change Interval................................................................................................................. 53
Figure 5-4 – Oil Level Gauge, Oil Fill And Oil Drain ................................................................................... 57
Figure 5-5 – Oil Filter .................................................................................................................................. 58
Figure 5 6 – Oil Separator........................................................................................................................... 61

Figure 6-1 – Air Filter .................................................................................................................................. 62

Figure 7-1 – Belt Tension – J Section Micro-V Belts .................................................................................. 66

13-18-601 Page 8
SECTION 1
GENERAL INFORMATION

Figure 1-1 – COMPRESSOR CYCLE

COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine
using meshing helical rotors to effect compression. Both rotors are supported between high capacity
roller bearings located outside the compression chamber. Single width cylindrical roller bearings are
used at the inlet end of the rotors to carry part of the radial loads. Ball and roller bearings at the
discharge end locate each rotor axially and carry all thrust loads and the remainder of the radial loads.

COMPRESSION PRINCIPLE (Figure 1-1) - Compression is accomplished by the main and secondary
rotors synchronously meshing in a one-piece cylinder. The main rotor has four (4) helical lobes 90° apart.
The secondary rotor has five (5) matching helical grooves 72° apart to allow meshing with main rotor
lobes.

The air inlet port is located on top of the compressor cylinder near the drive shaft end. The discharge port
is near the bottom at the opposite end of the compressor cylinder. Figure 1-1 is an inverted view to show
inlet and discharge ports. The compression cycle begins as the rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and the secondary rotor grooves (A). When the rotors
pass the inlet port cutoff, air is trapped in the interlobe cavity and flows axially with the meshing rotors (B).
As meshing continues, more of the main rotor lobe enters the secondary rotor grove, normal volume is
reduced and pressure increases.

Oil is injected into the cylinder to remove the heat of compression and seal internal clearances. Volume
reduction and pressure increase continues until the air/oil mixture trapped in the interlobe cavity by the
rotors passes the discharge port and is released to the oil reservoir (C). Each rotor cavity follows the
same “fill-compress-discharge” cycle in rapid succession to produce a discharge air flow that is
continuous, smooth and shock free.

AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 5-1, page 51) - Air enters the air filter and passes
through the inlet unloader valve and on into the compression chamber where oil is injected into the air.
After compression, the air/oil mixture passes into the oil reservoir where most of the entrained oil is
removed by velocity change and impingement and drops back into the reservoir. The air and remaining
oil then passes through the air/oil separator. The air then passes through the minimum pressure/check
valve, the aftercooler and the moisture separator and into the plant air lines.

LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through
the oil cooler, thermostatic mixing valve, and oil filter and discharge into the compressor main oil gallery.
A portion of the oil is directed through internal passages to the bearings and shaft oil seal. The balance
of the oil is injected directly into the compression chamber to remove heat of compression, seal internal
clearances and lubricate the rotors.

13-20-600 Page 9
13-20-600
Page 10

302EFC797-B
(Ref. Drawing)
Figure 1-2 – COMPRESSOR ILLUSTRATION
SECTION 2
INSTALLATION
GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit.
Report any damage or missing parts as soon as possible.

Do not electric weld on the compressor or base; bearings can be damaged by

passing of current.

LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Unit may
be moved into location by lift truck.

Lift compressor unit under base only. Do not use other places such as motor,
compressor or discharge manifold piping as lifting points.
The eyebolts or lugs provided on the motor are for lifting the motor only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motor the lifting angle must not exceed 15 degrees.
Failure to observe this warning may result in damage to equipment or personal
injury.

Compressor, air/oil reservoir, separator chamber and all piping and tubing may
be at high temperature during and after operation.

LOCATION (Figure 2-1, page 12) - The compressor should be installed where it is protected from rain,
snow and freezing temperatures, in a clean, well-lighted, well-ventilated area with ample space all around
for maintenance. Select a location that provides a cool, clean, dry source of air. In some cases it may be
necessary to install the air filter at some distance from the compressor to obtain proper air supply.

AIR-COOLED UNIT - A combination oil/aftercooler is supplied as standard equipment on all air-cooled

units. The air-cooled unit with the standard enclosure requires sufficient flow for the compressor
oil/aftercooling system and electric motor cooling (Figure 1-2, page 10). Air is drawn into the unit above
the motor and discharged through the cooler. Do not block the air flow to and from the unit. Allow three
and one half (3-1/2) feet to the nearest obstruction on the control box end of the unit. Allow two (2) feet to
the nearest obstruction above and on other sides of unit.

13-20-600 Page 11
 For continuous efficiency, oil cooler cores must be periodically cleaned with either vacuum or
compressed air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with
clean water.
N
NOOTTIIC
CEE
For aluminum oil coolers, do not use any cleaning solution that is not
compatible with aluminum. Use of improper solution may result in damage to
the cooler.

Figure 2-1 – TYPICAL COMPRESSOR ROOM

Minimum Air Flow* For Compressor

And Cooling (cubic Feet/Minute)
Air Cooled
All Models 3000 cfm
* 80°F Inlet Air

Figure 2-2 – AIR FLOW CHART

FOUNDATION - The rotary screw compressor requires no special foundation, but should be mounted on
a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be
made at a maximum 5° angle lengthwise or 5° sidewise. Mounting bolts are not normally required.
However, installation conditions such as piping rigidity, angle of tilt, or danger of shifting from outside
vibration or moving vehicles may require the use of mounting bolts and shims to provide uniform support
for the base. Belt alignment and tension should be checked after installation. (For information on belt
alignment and tension, see SECTION 7, page 64.

OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the side of the frame.
This drain is approximately 20 inches above the floor level.

13-20-600 Page 12
 If the compressor unit base is raised above floor level, the space between the
floor and the base bottom must be closed with solid material all around to
prevent recirculation of hot air from the oil cooler end and over temperature
operation.

ENCLOSURE - The compressor, electric motor, oil cooler and aftercooler are mounted inside the
enclosure.

Service panels are provided for maintenance access. Be sure to allow enough space around the unit for
the panels to be removed. Any of the enclosure panels may be removed by opening the latch and lifting it
up slightly.

Do not operate the compressor with the fan and belt guard removed. Exposed
fan and belts may cause injury to personnel.

The enclosure doors and panels must be closed and latched while the
compressor is operating. Failure to close and latch the doors and panels will
cause high temperature shutdowns.

Figure 2-3 – COLD WEATHER INSTALLATION

13-20-600 Page 13
INSTALLATION FOR COLD WEATHER OPERATION (Figure 2-3, page 13) - It is recommended that the
unit be installed inside a shelter that will be heated to temperatures above freezing (32oF, 0oC). This will
eliminate many of the problems associated with operating units in cold climates, such as freezing in
control lines and downstream of the cooler.

Refer to Engineering Data Sheet 13-9-411 for the advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for an adequate shelter for the unit.

When an outside installation must be made, the precautions required will depend on the severity of the
environment. The following are general guidelines for outside installations:

Cold Weather (Down To +10oF)

1. Be sure all drains, traps, and control lines, including pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermostat control is generally satisfactory for this purpose
and can be obtained at various local plumbing or hardware outlets at nominal cost.

2. Provisions to bypass the aftercooler must be made. Since cold air contains very little moisture,
successful operation can be achieved without the aftercooler.

3. Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow.

4. Use only Gardner Denver AEON 9000SP lubricant.

5. Monitor unit carefully during start-up and operation to be sure it is functioning normally.

Remember unsheltered (outside) installations should be avoided where possible. Installation next to a
heated building where enough heat can be used to keep the compressor room above freezing will save
many complications in the operation and installation of the unit.

AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and
provides sufficient storage capacity to prevent rapid cycling. When used, an air receiver should be of
adequate size, provided with a relief valve of proper setting, a pressure gauge and a means of draining
condensate

STANDARD MOISTURE SEPARATOR/TRAP - The unit is equipped with a built-in aftercooler, a

combination moisture separator and trap piped into the system down stream of the aftercooler.

CONTROL PIPING - Control piping is not necessary since the rotary screw unit is factory wired and piped
for the control system specified.

INLET LINE - Where an inlet line is used between the air filter and the compressor, it must be thoroughly
cleaned on the inside to prevent dirt or scale from entering the compressor. If welded construction is
used, the line must be shot blasted and cleaned to remove welding scale. In either case, the inlet
line must be coated internally by galvanizing or painting with a moisture and oil-proof sealing lacquer. Up
to ten (10) feet in length, the inlet line should be the full size of the inlet opening on the compressor. If an
extra-long line is necessary, the pipe size should be increased according to “Inlet Line Length Chart”,
page 15.

Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a
remote location.

13-20-600 Page 14
 INLET LINE LENGTHS

Length of Inlet Line Diameter of Pipe Size

0 to 10 Feet ............................................. Same as Compressor Inlet Opening
10 to 17 Feet ........................................... One Size Larger Than Inlet Opening
17 to 38 Feet ........................................... Two Sizes Larger Than Inlet Opening

DISCHARGE SERVICE LINE - The discharge service line connection is made at the left hand corner of
the package when viewed from the control box end. A hand operated valve, (air service valve) must be
installed between the unit and the customer’s air system. If a fast operating valve such as a ball valve is
used, it must be closed slowly to give the intake valve time to shut and keep the discharge pressure from
spiking.

The controller has an automatic start/stop sequence built in. You do NOT need
to close the air service valve. Closing the air service valve on start-up or prior
to shutdown will cause rapid cycling, and could cause a high pressure
shutdown.

When manifolding two or more rotary screw units on the same line, each unit is isolated by the check
valve in the unit discharge line.

If a rotary screw unit is manifolded to another compressor, be sure the other compressor has a check
valve in the line between the machine and the manifold.

If a rotary screw and a reciprocating compressor are manifolded together, an air receiver must be located
between the two units.

Discharge air used for breathing will cause severe injury or death.

Consult filtration specialists for additional filtration and treatment equipment to

meet health and safety standards.
ELECTRICAL WIRING - Standard Units - The compressor package is factory wired for all connections
from the starter to the motor, for the horsepower and voltage specified on the order. The standard unit is
supplied with open drip proof motors and a UL/NEMA Type 4 starter and controls enclosure. Totally
enclosed motors are available as factory options. See “Location” paragraph on page 11, for distance to
the nearest obstruction on the control box side of the package.

The overload settings are to be selected based on motor nameplate full load amperage.

Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable local
electrical codes. Wiring must be performed only by qualified electricians.

13-20-600 Page 15
 Electrical shock can cause injury or death. Open main disconnect switch,
lockout and tagout before working on control box.

GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical
Code.

Failure to properly ground the compressor package could result in injury or

death. Install ground wiring in accordance with the National Electrical Code
and any applicable local codes.

MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure
on proper lubrication of the bearings. The following charts show recommended grease qualities and
regreasing intervals for ball bearing motors. For additional information, refer to the motor manufacturer’s
instructions.

The following procedure should be used in regreasing:

1. Stop the unit.

2. Disconnect, lockout and tagout the unit from the power supply.

3. Remove the relief plug and free hole of hardened grease.

4. Wipe lubrication fitting clean and add grease with a hand-operated grease gun.

5. Leave the relief plug temporarily off. Reconnect unit and run for about 20 minutes to expel the
excess grease.

6. Stop the unit. Replace the relief plug.

7. Restart the unit.

Rotating machinery can cause injury or death. Open main disconnect, lockout
and tagout power supply to starter before working on the electric motor.

13-20-600 Page 16
 ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30° TO 50°C)

MANUFACTURER TRADE NAME

CHEVRON SRI #2
SHELL DOLIUM R
EXXON UNIREX #2
EXXON POLYREX

ELECTRIC MOTOR REGREASING INTERVAL

Type of
Service Typical Rating Relubrication Interval
Up to 150 HP (112 KW) 18 Months
Standard One or Two Shift Operation
Above 150 HP (112 KW) 12 Months
Up to 150 HP (112 KW) 9 Months
Severe Continuous Operation
Above 150 HP (112 KW) 6 Months
Dirty Locations, High Ambient Up to 150 HP (112 KW) 4 Months
Very Severe
Temperature Above 150 HP (112 KW) 2 Months

13-20-600 Page 17
SECTION 3
STARTING & OPERATING PROCEDURES
PRESTART-UP INSTRUCTIONS - A new unit as received from the factory has been prepared for
shipping only. Do not attempt to operate the unit until checked and serviced as follows:

1. Compressor Oil - The oil must be checked before starting the unit and every 8 hours of operation.
For instructions on checking the oil and the proper oil level, refer to “Compressor Oil Filter”,
SECTION 5, page 51.

Do not mix different type oils. Unit is shipped filled with Gardner Denver AEON 4000 Lubricating
Coolant which is suitable for the first 4000 hours under normal operating conditions. AEON 9000SP
is also available. Check the decal on the reservoir to be sure which lubricant is in the machine.

REPLACE OIL FILTER EVERY 1000 HOURS.

NOTICE
Regular maintenance and replacement at required intervals of the oil filter, air
filter and air/oil separator is necessary to achieve maximum service and
extended drain intervals of AEON 4000 lubricant. Use only genuine Gardner
Denver filters designed and specified for this compressor.

Always stop the unit and release air pressure before removing oil filler plug.
Failure to release pressure may result in personal injury or death.

2. Air Filter - Inspect the air filter to be sure it is clean and tightly assembled. Refer to SECTION 6,
page 62 for complete servicing instructions. Be sure the inlet line, if used, is tight and clean.

3. Piping – Refer SECTION 2, page 15 “Discharge Service Line” and make sure all piping meets all
recommendations.

4. Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See
Figure 4-3 thru Figure 4-13, pages 29 thru 49, for general wiring diagrams and SECTION 2, page 15,
for “Electrical Wiring”.

5. Grounding - Unit must be properly grounded according to Section 250 of the National Electrical
Code.

13-20-600 Page 18
 Failure to properly ground the compressor package could result in controller
malfunction.

Failure to properly ground the compressor package could result in controller

malfunction.

6. Rotation - Check for correct motor rotation by jogging the motor. See “Unit Setup Adjust Menu” in
Controller Operating and Service Manual. Compressor drive shaft rotation must be
counterclockwise, standing facing the compressor sheave.

Operation with incorrect motor rotation can damage equipment and cause oil
eruption from the compressor inlet. When checking motor rotation, induce
minimum rotation (less than one revolution if possible). Never allow motor to
reach full speed.

The compressor unit’s direction of rotation must be check every time the
compressor is reconnected to the power supply.

7. System Pressure - The discharge pressure of the unit is set at the factory. To change the
discharge pressure, set the controls to the desired load pressure. DO NOT EXCEED THE
MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE. See "Operation
Adjustments Menu" in Controller Operating and Service Manual.

Operation at excessive discharge air pressure can cause personal injury or

damage to equipment. Do not adjust the full discharge air pressure above the
maximum stamped on the unit nameplate.

8. Operating Mode - Refer to SECTION 4, page 24 for detailed information on the control system.

13-20-600 Page 19
9. Enclosure - Check for damaged panels or doors. Check all screws and latches for tightness. Be
sure doors are closed and latched.

The compressor starts and stops automatically. Automatic restarting can

cause injury or death. Open, lockout and tagout main disconnect and any other
circuits before servicing the unit.

The enclosure doors must be in place and fastened down to keep the
compressor package from overheating when the compressor is running.

After an emergency stop, be sure that the pressure in the air/oil reservoir is less
than 5 psig. Wait one minute or more before restarting.

The controller has an automatic start/stop sequence built in. You do NOT need
to close the air service valve. Closing the air service valve on start-up or prior
to shutdown will cause rapid cycling, and could cause a high pressure
shutdown.

STARTING THE UNIT - Observe the following starting procedures:

Unit Cold:

1. Open the air service valve (customer furnished) between the main air system and the check valve on
the package.

2. Turn on power to the compressor package. To start press STOP/RESET, then press RUN.

3. Run for approximately five minutes or until the temperature stabilizes.

The unit is equipped with a minimum (45 psig) pressure/check valve. No special procedure is
required to maintain the unit reservoir pressure.

13-20-600 Page 20
Unit Hot (No warm-up period is required):

1. Open the air service valve (customer furnished) between the main air system and the check valve on
the package.

2. Run for approximately one minute. The unit is equipped with a minimum (45 psig) pressure/check
valve, no special procedure to maintain the unit reservoir pressure is required.

DAILY CHECK - Refer to “Maintenance Schedule,” SECTION 8 page 67.

STOPPING THE UNIT:

1. To stop compressor operation, press STOP/RESET.

2. Wait approximately one minute to allow the compressor to stop. The oil reservoir will automatically
blow down as the motor stops.

13-20-600 Page 21
Quick Start Guide

Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run

button to start the compressor, no other settings are required. The Target Pressure comes
preset to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure
setting is desired, the following steps can be used as a guide.

Setting the Target Pressure

The Target Pressure setting is used to set the operating point of the compressor. To make any
adjustments in the operation of the compressor, the machine must be stopped and in the Ready

mode. Stop the compressor by pressing the Stop/Reset button. The front panel display
should read “READY” on line 3.

0 PSI 75°F
10 HRS AUTOMATIC
READY
NO SERVICE ADVISORY

Next, press the Enter button to access the Adjustment Menu tree

ADJUSTMENT MENU
OPERATION ADJUSTMENT

(SELECT SUB MENU)

Since the Target Pressure setting is under the Operation Adjustment menu, press Enter again
to access that sub-menu

OPERATION ADJUSTMENT
LANGUAGE-LANGUAGE
ENGLISH (US)
(SELECT PARAMETER)

The Target Pressure is the second item in the Operation Adjustment sub-menu so press the Down
button to navigate to the Target Pressure setting.

OPERATION ADJUSTMENT
TARGET PRESSURE
100 PSI
(SELECT PARAMETER)

13-20-600 Page 22
 To change the Target Pressure, press the Enter button to edit the value.

OPERATION ADJUSTMENT
TARGET PRESSURE
100 PSI
(EDIT PARAMETER)

A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the
Plus and Minus buttons to change its value. Use the Right and Left buttons to
move the cursor to other digits in the Target Pressure value. When the desired Target Pressure
value is displayed, press the Enter button to save the new value. Pressing the Stop/Reset

button will abort the change and restore the previous value.

In order to save the changes made to parameters, press the Stop/Reset button to go back to the
heading of the current menu and then press the Stop/Reset button again. If parameter changes have
been made, the following screen will appear.

STORE MODIFIED
PARAMETERS?
STOP = NO
ENTER = YES

To permanently save the changes that were made, press the Enter button. If the Stop/Reset
button is pressed, the parameter changes will be lost the next time the compressor power is turned
off.

Setting The Unload and Load Pressure

After setting the Target Pressure, set the Unload and Load Pressures values in a similar fashion. The
Unload pressure is the third item in the Operation Adjustment sub-menu so press the Down
button to navigate to the Unload Pressure setting. The Unload Pressure will control at which
pressure the compressor unload and stops.

OPERATION ADJUSTMENT
UNLOAD PRESSURE
110 PSI
(SELECT PARAMETER)

The Load pressure is the fourth item in the Operation Adjustment sub-menu so press the Down
button to navigate to the Load Pressure setting. The Load Pressure will control at which pressure the
compressor will startup again after unloading.

OPERATION ADJUSTMENT
LOAD PRESSURE
100 PSI
(SELECT PARAMETER)

13-20-600 Page 23
SECTION 4, CONTROLS & INSTRUMENTATION
GENERAL DESCRIPTION

The Gardner Denver rotary screw compressor is prewired with all controls, motor, and starter for the
voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the
correct power supply and to the shop air line. A standard compressor unit consists of the compressor, oil
reservoir, oil cooling system and filter, motor type as specified, UL/NEMA Type 4 starter / control box, and
control components as described below.

AirSmart® OPERATION

Operation of the "AirSmart" is dependent on selection of an operating mode from the controller keypad.
Prior to starting, the STOP/RESET key must be pressed to place the controller into its READY state (as
indicated on the display). Compressor operation may then be started by pressing the RUN key. While in
any operating mode, the display will indicate the mode, and the operating light will be on.

Press the STOP/RESET key at any time to stop the compressor under normal conditions.

AUTOMATIC is the most common selected mode of operation, as it automatically will operate the
compressor unit in the most efficient manner for the demand of the air system. Refer to the controller
manual for descriptions of other modes.

Automatic restarting or electrical shock can cause injury or death. Open,

lockout and tagout main disconnect and any other circuits before servicing
unit.

303EFC797-B
(Ref. Drawing)

Figure 4-1 – CONTROL SCHEMATIC

13-20-600 Page 24
CONTROL DEVICES

Controller - This compressor unit features the "AirSmart" controller, which integrates all the control
functions under microprocessor control. Its functions include safety and shutdown, compressor
regulation, operator control, and advisory/maintenance indicators. The keypad and display provide the
operator with a logical and easily operated control of the compressor and indication of its condition. The
controller is factory adjusted for the compressor package, but allows tuning for specific applications.

Detailed instructions for the controller are found in the “AirSmart” Controller Operating and Service
Manual.

Figure 4-2 – KEY PAD

Relief Valve - A pressure relief valve is installed in the final discharge line and set to approximately 120-
125% of the unit's full load operating pressure for protection against overpressure. Periodic checks
should be made to ensure its operation.

The relief valve should be tested for proper operation at least once every year. To test the relief valve,
raise the system operating pressure to 75% of the relief valve set pressure and manually open the valve
by turning the cap.

When the relief valve opens, a stream of high velocity air is released, resulting
in a high noise level and possible discharge of accumulated dirt or other debris.
Always wear eye and ear protection and stand clear of the discharge port when
testing the relief valve to prevent injury.

13-20-600 Page 25
 Never paint, lubricate or alter a relief valve. Do not plug vent or restrict
discharge.

Operation of the unit with improper relief valve setting can result in severe
personal injury or machine damage. Ensure properly set valves are installed
and maintained.

Oil Level Gauge - This gauge is located on the oil reservoir and indicates the oil level. See “Oil Level
Gauge”, Figure 5-4, page 57, for how to read oil level.

Minimum Discharge Pressure/Check Valve - An internal spring-loaded minimum pressure valve is used
in the final discharge line to provide a positive pressure on the coolant system of the compressor even if
the air service valve is fully open to atmospheric pressure. This valve also functions as a check valve to
prevent back flow of air from the shop air line when the unit stops, unloads, or is shut down.

The valve incorporates an orifice which, when air is flowing through it, maintains pressure in the oil
reservoir. A spring-loaded piston valve senses air pressure on the upstream (reservoir) side of the valve.
When the system pressure rises, the spring is overridden and the valve opens to full porting.

Inlet Valve (Figure 4-1, page 24) - The Inlet valve restricts the inlet to control delivery and closes to
unload the compressor. At shutdown, the inlet valve closes to prevent the back flow of air.

The inlet valve position is controlled by air pressure in its piston cylinder, which is controlled by the
"AirSmart" through the magnetic unloader solenoid valve. When the top of the cylinder is pressurized, the
inlet opens for full air delivery. When pressure is relieved from the cylinder, the inlet valve closes to
restrict air flow and compressor delivery.

Magnetic Unloader Solenoid Valve (Figure 4-1, page 24) - This valve controls the position of the inlet
valve in response to signals from the "AirSmart". When de-energized, pressure is relieved from the top of
the inlet valve cylinder to unload the compressor. When the solenoid valve is energized, reservoir
pressure is supplied to the top of the cylinder to load the compressor.

Check Valve (Figure 4-1, page 24) - This valve is normally closed while the compressor is loaded or
stopped. While running unloaded, it opens to admit a small amount of purge air to the compressor inlet.
This reduces compressor knock, and provides enough air to pressurize the controls during startup.

Blowdown Valve (Figure 4-1, page 24) - The blowdown valve is a two-way solenoid valve which is piped
into the oil reservoir outlet ahead of the minimum pressure valve. When the solenoid is de-energized, the
valve opens and the coolant system is blown down. When the solenoid is energized, the valve closes to
allow the coolant system to pressurize.

System Pressure Transducer (Figure 4-1, page 24) - This transducer is connected after the minimum
pressure valve. It converts the pressure in the plant air system into an electrical signal for use by the
"AirSmart" controller for modulation and control.

13-20-600 Page 26
Reservoir Pressure Transducer (Figure 4-1, page 24) - This transducer is connected to the coolant
system. Its signal is used to prevent loaded starts, monitor oil pressure, and to monitor the condition of
the separator.

Air Filter Vacuum Switch (Figure 4-1, page 24) - This switch is used to monitor air filter condition and
alert the user if the filter requires service or replacement.

Machine damage will occur if compressor is repeatedly restarted after any one
of the shutdown modes stops operation of the unit. Find and correct the
malfunction before resuming operation.

Discharge Thermistor (Figure 4-1, page 24) - This sensor is located directly in the compressor
discharge. Its signal is used to monitor compressor temperature and shut down the compressor if a
coolant problem is detected.

Reservoir Thermistor (Figure 4-1, page 24) - This sensor is located in the reservoir/separator housing
and is used to monitor temperature and shut down the compressor if temperature problems occur at the
separator.

Emergency Stop Pushbutton - This is a maintained pushbutton, and removes power from the controller
outputs regardless of controller status. It is located on the middle section of the control box door, below
the keypad. This should be used for emergency purposes only - use the keypad [STOP/RESET] for
normal controlled stopping.

Automatic restarting or electrical shock can cause injury or death. Open and
lock main disconnect and any other circuits before servicing unit.

Control Transformer – For 575 volt AC units, a control transformer is provided to supply 230 volts AC
input to the power supply. A secondary fuse is provided on the control transformer. Refer to adjacent
labeling for replacement information.

For 230 volt AC units, that can be converted for 460 volt AC operation using conversion kit 313EFC6005,
a control transformer is provided to supply 115-120 volts AC input to the power supply. Two primary and
one secondary fuse are provided, mounted on the transformer. Refer to adjacent labeling for fuse
replacement information.

Fuse Blocks – For except 230 volt AC units, two class CC fuse blocks provide line side protection for the
power supply and control transformer, as applicable.

Power Supply – This device changes the incoming AC supply voltage, or transformer supply voltage, to
24 volts DC for use by all unit control devices.

Terminal Strip - This provides connections for all 24 volt devices not contained within the enclosure.

13-20-600 Page 27
Main Starter - This starter is used to provide control and overload protection for the main drive motor.
Wiring diagrams for typical full voltage applications are illustrated on pages 29 thru 49. For Wye Delta
and less starter applications, refer to the wiring diagram included in each control box enclosure.

Overload protection is provided for each motor on full voltage and Wye Delta applications. The overloads
are adjustable and are factory set based on the motor nameplate amps and the instructions located inside
the control box door. Less starter applications utilize a control relay for control of a remote mounted
motor starter (not provided with compressor package).

Changing Minimum Pressure/Check Valve Seals

Air/oil pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters.

1. Be sure the unit is completely off and that no air pressure is in the oil reservoir.

2. Disconnect, lockout and tagout the power supply to the starter.

3. Tighten the nut down on the minimum pressure/check valve cover.

4. Remove the six (6) bolts holding the cover onto the separator housing.

5. Remove the snap ring in the cover.

6. Remove the internal parts (see Parts List Book) and replace the seals in the minimum
pressure/check valve.

7. Re-assemble valve, including the snap ring.

8. Tighten the cover down to the separator housing.

9. Loosen the nut on top of the minimum pressure/check valve .05 to .08 inches.

10. Run the unit and check for leaks.

13-20-600 Page 28
13-20-600
Page 29

307EBE546-D
Figure 4-3 – WIRING DIAGRAM – WYE DELTA 20, 25 & 30 HP (200 & 460 VOLT) (Ref. Drawing)
Page 1 of 2
13-20-600
Page 30

307EBE546-D
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 31

315EBE546-A
(Ref. Drawing)
Page 1 of 2

Figure 4-4 – WIRING DIAGRAM – WYE DELTA 20, 25 & 30 HP (230 VOLT)
13-20-600
Page 32

315EBE546-A
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 33

308EBE546-D
(Ref. Drawing)
Page 1 of 2

Figure 4-5 – WIRING DIAGRAM – FULL VOLTAGE 20, 25 & 30 HP (460 VOLT)
13-20-600
Page 34

308EBE546-D
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 35

313EBE546-C
(Ref. Drawing)
Page 1 of 2

Figure 4-6 – WIRING DIAGRAM – FULL VOLTAGE 20, 25 & 30 HP (200 VOLT)
13-20-600
Page 36

313EBE546-C
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 37

314EBE546-A
(Ref. Drawing)
Page 1 of 2

Figure 4-7 – WIRING DIAGRAM – FULL VOLT - 20 HP (230 VOLT)

13-20-600
Page 38

314EBE546-A
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 39

317EBE546-A
(Ref. Drawing)
Page 1 of 2
Figure 4-8 – WIRING DIAGRAM - FULL VOLTAGE 25 & 30 HP (230 VOLT)
13-20-600
Page 40

317EBE546-A
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 41

309EBE546-D
(Ref. Drawing)
Figure 4-9 – WIRING DIAGRAM – LESS STARTER (200 & 460 VOLT) Page 1 of 2
13-20-600
Page 42

309EBE546-D
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 43

316EBE546-A
(Ref. Drawing)
Page 1 of 2

Figure 4-10 – WIRING DIAGRAM – LESS STARTER (230 VOLT)

13-20-600
Page 44

316EBE546-A
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 45

310EBE546-C
(Ref. Drawing)
Page 1 of 2
Figure 4-11 – WIRING DIAGRAM – WYE DELTA (575 VOLT)
13-20-600
Page 46

310EBE546-C
(Ref. Drawing)
Page 2 of 2
13-20-600
Page 47

311EBE546-C
(Ref. Drawing)
Page 1 of 2

Figure 4-12 – WIRING DIAGRAM – FULL VOLTAGE (575 VOLT)

13-20-600
Page 48

311EBE546-C
(Ref. Drawing)
Page 2 of 2
13-20-600 Page 49

312EBE546-C
(Ref. Drawing)
Page 1 of 2
Figure 4-13 – WIRING DIAGRAM – LESS STARTER (575 VOLT)
13-20-600 Page 50

312EBE546-C
(Ref. Drawing)
Page 2 of 2
SECTION 5
LUBRICATION
OIL COOLER, OIL FILTER & SEPARATOR
COMPRESSOR OIL SYSTEM (Figure 5-1) The compressor oil system cools the compressor, lubricates
moving parts and seals internal clearances in the compression chamber.

Air pressure in the oil reservoir forces oil through the oil cooler, thermostatic mixing valve, oil filter and into
the compressor main oil gallery.

The oil passes through internal passages for lubrication, cooling and sealing. The air-oil mixture is then
discharged to the oil reservoir where a large part of the entrained oil drops out of the air stream. The
remaining mixture then passes through the final oil separator where most of the remaining oil is removed.
The air then passes to the aftercooler. The oil separated from the air is sent to the oil cooler and
recirculated throughout the system. Oil separated at the air/oil separator is sent via an oil return line
through an orifice and back into the compressor.

RECOMMENDED LUBRICANT - Gardner Denver compressors are factory filled with AEON lubricants.
These lubricants are formulated to the highest quality standards and are factory authorized, tested and
approved for use in rotary screw compressors. AEON lubricants are available through your authorized
Gardner Denver compressor distributor.

Ref.
No. Description
1 Air/oil Separators
2 Oil Scavenge Line
3 Orifice
4 Oil Filter
5 Thermostatic Mixing
Valve
6 Minimum
Pressure/Check Valve
7 Aftercooler
8 Oil Cooler
9 Moisture Separator
10 Electronic Drain
11 Pressure Relief Valve

Figure 5-1 – FLOW DIAGRAM

OIL SPECIFICATIONS - The recommended compressor lubricant is Gardner Denver AEON 4000
Lubricating Coolant which can be used for year-round operation except as noted in the “High
Temperature Operation” paragraph, page 52, or low temperature, see “Installation for Cold Weather
Operation,” page 14. AEON 4000 Lubricating Coolant is a superior petroleum base lubricant formulated
and containing additives for use in Gardner Denver compressors.

13-20-600 Page 51
 Specific AEON™ lubricants are recommended for use in this equipment. Other
lubricants may cause excessive carryover or compressor damage. Do not mix
different types of lubricants or use inferior lubricants. Check the decal on the
oil reservoir for lubricating coolant specification.

HIGH TEMPERATURE OPERATION - If the discharge temperature is sustained between 200-210° F. for
a period of more than four (4) hours due to continuing high ambient air temperature, use Gardner Denver
AEON 9000SP Lubricating Coolant which is a superior synthetic lubricant. Short periods of up to four (4)
hours of sustained discharge temperatures up to 210° F. do not require a change from the recommended
year-round lubricant AEON 4000.

COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation,” page 14 and Figure 2-3,
page 13.

PROCEDURE FOR CHECKING OIL LEVEL (Figure 5-4, page 57) - Check the oil level when the
compressor is shutdown and the oil/air mixture has separated. The oil should be visible between the min.
and max. range, shown in Figure 5-4, page 57. If the oil level is above the max. range, the oil must be
drained. If the oil level is below the min. range, oil must be added.

ADDITION OF OIL BETWEEN CHANGES - Oil must be added when the oil level is below the min. range
on the oil gauge. The oil must be checked with the machine shutdown, blowndown and the air/oil mixture
settled out to air and oil.

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters.

Compressor, air/oil reservoir, separation chamber and all piping and tubing
may be at high temperature during and after operation.

Excessive oil carryover can damage equipment. Never fill oil reservoir above
the max. range of the gauge.

13-20-600 Page 52
To add oil, follow these steps:

1. Be sure the unit is completely off and that no air pressure is in the oil reservoir.

2. Disconnect, lockout and tagout the power supply to the starter.

3. Wipe away all dirt around the oil filler plug. It is located by the oil filter.

4. Remove the oil filler plug and add oil as required to return the oil level to the max. line on the site
glass.

5. Install the oil filler plug, run and check for leaks.

DO NOT OVERFILL. The quantity required to raise the oil level from the min. line to the max. line, (See
Figure 5-4, page 57), is two (2) quarts (Figure 5-2, page 53). Repeated addition of oil between oil
changes may indicate excessive oil carryover and should be investigated.

Use only CLEAN containers and funnels so no dirt enters the reservoir. Provide for clean storage of oils.
Changing the oil will be of little benefit if done in a careless manner.

20 to 30 HP (15 – 22 kW)
Refill Capacity For Normal Oil Change 2.00 U. S. Gallons (8.5 Liters)
Bottom of Site Glass to Top of Site Glass 2 U. S. Quart (2 Liters)

Figure 5-2 – APPROXIMATE OIL SYSTEM CAPACITIES

OIL CHANGE INTERVAL - Recommended oil change intervals are based on oil temperature. Figure 5-3,
shows how the change interval is affected by temperature.

When operating conditions are severe (very dusty, high humidity, etc.), it will be necessary to change the
oil more frequently. Operating conditions and the appearance of the drained oil must be surveyed and
the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis
program with the AEON lubricants and we recommend a sample be sent in at 100 hours on a new unit.

Discharge AEON™ 4000 AEON™ 9000SP

Temperature Change Interval Change Interval
Up to 180° F (82° C) 4000 hrs. 8000 hrs.
180° F to 190° F (82° C to 88° C) 3000 hrs. 6000 hrs.
190° F to 200° F (88° C to 93° C) 2000 hrs. 4000 hrs.
200° F+ (93° C) 1000 hrs. 2000 hrs.

Figure 5-3 – OIL CHANGE INTERVAL

13-20-600 Page 53
DRAINING AND CLEANING OIL SYSTEM

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters.

Always drain the complete system. Draining when the oil is hot will help to prevent varnish deposits and
carry away impurities.

To drain the system:

1. Be sure the unit is completely off and that no air pressure is in the air/oil reservoir.

2. Disconnect, lockout and tagout the power supply to the starter.

3. Stick the end of the drain tube into a suitable container, such as a 5 gallon pail.

4. Open the drain valve and allow oil to drain out of the air/oil reservoir.

5. Close the drain valve.

If the drained oil and/or the oil filter element are contaminated with dirt, flush the entire system: the
reservoir, oil cooler and lines. Inspect the air/oil separator element for dirt accumulation; replace if
necessary. If a varnish deposit exists, contact the factory for recommendations for removal of the deposit
and prevention of varnish.

FILLING OIL RESERVOIR

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters.

13-20-600 Page 54
 Compressor, air/oil reservoir, separation chamber and all piping and tubing
may be at high temperature during and after operation.

1. Be sure the unit is completely off and that no air pressure is in the oil reservoir.

2. Disconnect, lockout and tagout the power supply to the starter.

3. Wipe away all dirt around the oil filler plug.

4. Remove the oil filler plug and add oil as required to return the oil level to the max. range on the oil
gauge.

5. Install the oil filler plug and operate the unit for about a minute allowing oil to fill all areas of the
system. Check for leaks.

6. Shut down unit, allowing the oil to settle, and be certain all pressure is relieved.

7. Add oil, if necessary, to bring level to the max. range on the oil level gauge (Figure 5-4, page 57).

DO NOT OVERFILL as oil carryover will result. The quantity of oil required to raise the oil level from the
min. range to the max range on the site glass is shown in Figure 5-2, page 53. Repeated addition of oil
between oil changes may indicate excessive oil carryover and should be investigated.

Use only CLEAN containers and funnels so no dirt enters the reservoir. Provide for clean storage of oils.
Changing the oil will be of little benefit if done in a careless manner.

Excessive oil carryover can damage equipment. Never fill oil reservoir above
the top of the site glass.

LUBRICANT UPGRADE PROCEDURE - Upgrading to a longer life lubricant is essentially a very

worthwhile practice. The following are the primary steps to be completed when upgrading or changing
the type of lubricant.

Improper equipment maintenance with use of synthetic lubricants will damage

equipment. Oil filter and oil separator change intervals remain the same as for
AEON 4000 -- See Maintenance Schedule, Page 67 .

13-20-600 Page 55
 Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters.

High temperature operation can cause damage to equipment or personal injury.

Do not repeatedly restart the unit after high temperature stops operation. Find
and correct the malfunction before resuming operation.

All materials used in Gardner Denver® compressor units are compatible with
AEON 9000SP Lubricating Coolant. Use caution when selecting downstream
components such as air line lubricating bowls, gaskets and valve trim.

AEON 9000SP Synthetic Lubricant is not compatible with low nitrile Buna N or
acrylic paints. AEON 9000SP is compatible with most air system downstream
components.
1. Be sure the unit is completely off and that no air pressure is in the air/oil reservoir.

2. Disconnect, tag and lock out the power supply to the starter.

3. Thoroughly drain system:

• Drain oil from airend and cooler while hot.
• Break low point connections and drain oil from pipe runs.
• Dump Oil from filter and reinstall used filter.

4. Fill system with a 50 percent charge of the new lubricant:

• Start the machine and stay there to observe.
• Allow the machine to run about five minutes at temperature, or until temperature stabilizes, then
shut down

5. Thoroughly drain machine.

6. Change to a new filter and separator.

7. Fill system with a full charge of the new lubricant.

8. Machine should then be run normally; however, total run time after the initial changeouts should be
50 percent of normal anticipated service life of the new lubricant.
• Drain all lubricant from system, change filter and separator, and replace with full charge of the
new lubricant.
9. Subsequent lubricant changeouts should be at normal intervals. (See “Oil Change Interval” and chart,
page 53.
Material Safety Data Sheets (MSDS) are available for all AEON lubricants from your authorized Gardner
Denver distributor or by calling (901) 542-6100.

13-20-600 Page 56
OIL LEVEL GAUGE (Figure 5-4, page 57) - The oil level gauge indicates the amount of oil in the air/oil
reservoir. Read oil level only when the unit is shut down and the air/oil mixture has separated. Add oil
only when the oil level is below the min. range on the site glass. Drain oil only when the oil level is above
the max. range on the site glass.

Ref.
No. Name

1 Oil Fill
2 Pressure
Relief Valve
3 Oil Drain

Figure 5-4 – OIL LEVEL GAUGE, OIL FILL AND OIL DRAIN

MOISTURE IN THE OIL SYSTEM - In normal humidity and with normal operating temperatures and
pressures, the thermal mixing valve controls the oil temperature and prevents moisture contamination of
the oil. Unusual cooling of the oil reservoir, short loaded cycle in high humidity or malfunctions of the
thermal valve may result in moisture in the oil system which is detrimental to compressor lubrication and
could cause oil carryover. If moisture is observed in the oil reservoir, drain the moisture and correct the
condition causing the accumulation.

See “Compressor Oil System Check”, page 61 and “Thermal Control Valve", page 59.

COMPRESSOR OIL FILTER (Figure 1-2, page 10 and Figure 5-5, page 58) - This replaceable element
filter is a vital part in maintaining a trouble-free compressor, since it removes dirt and abrasives from the
circulated oil.

Improper oil filter maintenance will cause damage to equipment. Replace filter
element every 1000 hours of operation. More frequent replacement could be
required depending on operating conditions. A filter element left in service too
long may damage equipment.

Use only the replacement element shown on the filter tag or refer to the parts list for the part number. Use
the following procedure to replace the filter element. Do not disturb the piping.

13-20-600 Page 57
 Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters.

Compressor, air/oil reservoir, separation chamber and all piping and tubing
may be at high temperature during and after operation.

1. Stop unit and be sure no air pressure is in the oil reservoir.

2. Disconnect, tag and lock out the power supply to the starter.

3. Remove the spin-on element.

4. Clean the gasket face of the filter body.

5. Coat the new element gasket with clean lubricant used in the unit.

6. Screw new element on filter body and tighten clockwise by hand 3/4 turn after contact. DO NOT
OVERTIGHTEN ELEMENT.

7. Reset the filter life setting to 1000 hours, see “Maintenance Adjustments” in Controller Operating and
Service Manual.

8. Run the unit and check for leaks.

Figure 5-5 – OIL FILTER

13-20-600 Page 58
COMPRESSOR OIL COOLER - The cooler fan is mounted on the compressor motor shaft; air is
exhausted through the oil cooler and away from the unit. Do not obstruct air flow to and from the oil
cooler. Allow a minimum of two (2) feet (.6M) clearance around the cooler. Keep both faces of the cooler
core clean for efficient cooling of compressor oil.

THERMAL CONTROL (THERMOSTATIC MIXING) VALVE (Figure 5-1 page 51) - is installed in the
system. This valve is used to control the temperature of the oil. On start-up with unit cold, the element is
open to bypass, allowing oil to pass directly from the reservoir to the compressor during warm-up. As oil
warms, the element gradually closes to the bypass allowing more of the oil from the cooler to mix with oil
from the bypass.

After the unit is warmed up, the mixing valve maintains oil injection temperature into the compressor at a
minimum of 150° F (66° C). This system provides proper compressor warm-up and prevents moisture
contamination of the oil.

To check the element, heat it in oil - it should be fully extended at 150° F (66° C). If the unit shuts down
due to high air discharge temperature, the cause may be that the element is stuck open to the bypass.
When flushing the oil system, remove the mixing valve and clean all parts thoroughly.

OIL RESERVOIR - The oil reservoir-separator combines multiple functions into one vessel. The lower
half is the oil reservoir, providing oil storage capacity for the system and the top portion, a primary oil
separation means. The reservoir also provides limited air storage for control and gauge actuation.

COMPRESSOR AIR/OIL SEPARATOR (Figure 5 6, page 61) Located in a separate housing, consists of
a renewable cartridge-type separator element and provides the final removal of oil from the air stream.

Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity.
Oil collected outside the element is returned through tubing to the compressor cylinder.

Oil carryover through the service lines may be caused by a faulty oil separator, overfilling of the oil
reservoir, oil that foams, oil return line malfunction, or water condensate in the oil. If oil carryover occurs,
inspect the separator only after it is determined that the oil level is not too high, the oil is not foaming
excessively, the oil return tube from the bottom of the separator to the compressor cylinder is not clogged
or pinched off, the check valve in the oil return is functioning properly, and there is not water or an
oil/water emulsion in the oil.

Oil carryover malfunctions of the oil separator are usually due to using elements too long, heavy dirt or
varnish deposits caused by inadequate air filter service, use of improper oil, or using oil too long for
existing conditions. Excessive tilt angle of the unit will also hamper separation and cause oil carryover.

Oil separator element life cannot be predicted; it will vary greatly depending on the conditions of
operation, the quality of the oil used and the maintenance of the oil and air filters. The condition of the
separator can be determined by pressure differential or by inspection.

Pressure Differential Gauging – The “CHANGE SEPARATOR” advisory will flash when the pressure
differential across the oil separator reaches approximately 8 psid (.55 bar). Replace the oil separator
element at this time. If ignored, the unit will shutdown and the advisory will illuminate steadily when the
pressure differential reaches 15 psid (1 bar).

Using an oil separator element at excessive pressure differential can cause

damage to equipment. Replace the separator when the differential pressure is
greater than 8 psi or every 4,000 hours (at least once a year).

13-20-600 Page 59
 NOTICE
A sudden drop of zero pressure differential or sudden heavy oil carryover may
indicate a ruptured element.

Inspection - After removal of separator element, shine a light inside the element to reveal areas of heavy
dirt or varnish deposits or breaks (ruptures) in element media.

Removal of Oil Separator For Inspection or Replacement:

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters.

Compressor, air/oil reservoir, separation chamber and all piping and tubing
may be at high temperature during and after operation.

1. Be certain the unit is off and that no air pressure is in the oil reservoir. The compressor package will
automatically blowdown in about 2 minutes.

2. Close the air service valve located after the compressor package discharge.

3. Disconnect, lockout and tagout the power supply to the starter.

4. Remove the minimum pressure/check valve, see Item 1, Figure 5 6, page 61(air/oil separator
housing) cover.

5. Lift out the air/oil separator element. See Item 2, Figure 5 6, page 61.

6. Inspect and/or replace the separator as necessary.

7. Clean the sealing surfaces on the air/oil separator and the minimum pressure/check valve.

8. Clean the orifice, Item 3, Figure 5 6, page 61, in the oil return line, the strainer, Item 4, Figure 5 6,
page Error! Bookmark not defined., in the oil return line, and if necessary, the air/oil separator
housing.

9. Grease the O-Ring on the separator element and install the separator into the housing.

13-20-600 Page 60
10. Replace the O-Ring, Item 5, Figure 5 6, page 61, between the minimum pressure/check valve and
the air/oil separator housing.

11. Replace the sealing kit in the minimum pressure/check valve. After the assembling of the valve,
leave about .08 inch gap between the nut, Item 6, Figure 5-1, page 61, and the cover of the valve.
See “Changing Minimum Pressure/Check Valve Seals,” Section 4, page 28.

12. Install the minimum pressure/check valve assembly and tighten the bolts alternately for even
tightness.

13. Open the air service valve.

14. Run the unit and check for leaks.

COMPRESSOR OIL SYSTEM CHECK - The following readings are based on ambient temperature of
80° F (27° C) with the system in good condition. The compressor should be at operating temperature at
the time of the checks. One-half hour of loaded operation is usually sufficient to reach level-out operating
temperatures.

Air and Oil Discharge Temperature - 160° F to 180° F (71°C to 82° C) - Check with a thermometer at
the discharge housing.

Compressor Oil Inlet Temperature - 150° F to 165° F (66° C to 74° C) - Install a tee at the oil filter outlet
and check with a thermometer.

Oil Inlet Pressure - Check at the fitting in the line near the compressor oil inlet. With air receiver
pressure at 100 psi (6.9 Bar), oil inlet pressure should be 80 to 90 psig (5.5 to 6.2 Bar).

Oil Cooler Oil Pressure Differential (Air-Cooled Radiator) - Check differential across the oil system by
measuring oil inlet pressure as described above.

Oil Cooler Temperature Differential (Air-Cooled Radiator) - The oil temperature differential depends
on the temperature of the air at the oil cooler fan and cleanliness of the core faces. As ambient
temperatures and core restrictions increase, the oil cooler outlet temperature will increase. The oil inlet
temperature is approximately the same as the air discharge temperature.
Figure 5 6 – OIL SEPARATOR

Ref.
No. Description

1 Minimum Pressure/Check Valve

2 Air/Oil Separator Element
3 Oil Scavenge Line Orifices
4 Oil Scavenge Line Strainer
5 O-Ring
6 Minimum Pressure/Check Valve
Adjusting Nut

13-20-600 Page 61
SECTION 6
AIR FILTER

Figure 6-1 – AIR FILTER

STANDARD DUTY AIR FILTER (Figure 6-1) - Replacement instructions are given in the following
sections:

Compressor, air/oil reservoir, separation chamber and all piping and tubing
may be at high temperature during and after operation.

The air filter element can not be cleaned or reused.

Filter Element - The element should be replaced when inspection indicates an accumulation of dirt on
the outside of the element. Inspect every few days until experience determines the proper time interval
for servicing.

To Service:

1. Be certain the unit is off and that no air pressure is in the air/oil reservoir. The compressor package
will automatically blow down in about 2 minutes.

2. Close the air service valve located after the compressor package discharge.

3. Disconnect, lockout and tagout the power supply to the starter.

4. Remove the air filter cover (Figure 6-1).

5. Clean the inside of the air filter housing.

6. Install new air filter element and the air filter cover.

7. Open the air service valve.

13-20-600 Page 62
Filter Element Life - The element should be replaced if visual inspection indicates an accumulation of
dirt, or a rupture, crack or pin holes in the pleated media. Inspection should be done by placing a bright
light inside the element.

Do not oil this element. Never operate unit without element. Never use
elements that are damaged or ruptured. Never use elements that won’t seal.
Keep spare elements on hand to reduce downtime. Store elements in a
protected area free from damage, dirt and moisture. Handle filter parts with
care.

13-20-600 Page 63
SECTION 7
BELT DRIVE
Proper drive belt tension and alignment are provided at the factory, however, good practice dictates
checking the drive alignment and tension after shipment and before initial start-up.

Sheaves should align straight across the front with a straight edge. The best tension is just enough
tension to keep belts from “squealing” on start-up.

Excessive belt tension can damage the equipment. Tension the belts as shown
in Figure 7-1, page 66.

REPLACING THE COMPRESSOR BELTS

1. Disconnect, lockout and tagout the power supply to the starter.

2. Remove the belt guards.

3. Using adjusting screws, jack the motor base up to loosen the belt tension. Remove the belts.

4. Install new belts, tighten belts using the adjust screws. Check for correct belt tension.

5. Check sheave alignment. (See “SHEAVE ALIGNMENT”).

6. Assemble the guards.

SHEAVE ALIGNMENT

The sheave alignment and belt tightening system consists of a hinged plate for the motor which is
supported between (2) posts and a slotted platform for the Tempest units. To achieve proper sheave
alignment the sheaves must be adjusted for both parallel and angular alignment. The alignment between
the motor and air-end sheaves should be confirmed with the use of a straight edge. If the sheaves are
properly aligned, the straight edge should touch the two outer edges of each sheave for a total of four
points of contact. Gaps between the outer edges of either of the sheaves and the straight edge indicate
sheave misalignment.

The airend sheave is set in the parallel and angular direction by mounting it on the air-end shaft that is
part of the Tempest unit that is bolted to the platform. The platform has been set in the parallel and
angular directions by its inherent design. The motor sheave is set in the parallel direction by sliding it on
the motor shaft to position it in line with the airend sheave. (Check for alignment with straight edge.)
Note: It may be necessary to loosen the Tempest unit and slide it in the platform mounting slots to keep
the motor sheave fan blades in the correct position in the cooler orifice ring.

The motor sheave is set in the angular direction by means of (2) jack bolts and the hinged plate. To start
the angular alignment process check to make sure the locking nuts on the jack bolts are loose. The
motor sheave can be aligned in the angular direction to the same plane as the airend sheave by turning
down the jack bolts on one side or the other of the hinged plate. (Check for alignment with straight edge.)
It also may be necessary to use the nuts that are on the jack bolts to push up on one side or the other of
the hinged plate. Note: At this point it may also be necessary to make minor adjustments of the position

13-20-600 Page 64
of the sheave on the motor shaft to get proper alignment. Once proper alignment has been obtained, lock
the sheave in place on the motor shaft; then the jack bolt lock nuts must be tightened. One set of nuts is
tightened down against the base to lock the jack bolts in place. The second set is locked down to
sandwich the hinged plate against the jack bolt heads. When lock nuts are in place, a final alignment
check should be made with the straight edge.

Note: Any of the following actions will require the sheave alignment be checked and any or all of the
above steps repeated. (Initial start up at customer site, compressor change, motor change, unit
relocation, or when the belts are replaced.)

It’s important to note that the belts should not be over tightened. To check belt tension use a Gardner
Denver Belt Tension Gauge, Part Number 00543217. V-belt tension will drop after the first 8-24 hrs of
unit run time. Failure to check and re-tension the belts after the initial run-in period will result in belt
slippage and premature belt failure. Please see Figure 7-1, page 66, for proper belt tension.

Interference between the fan and the orifice can damage equipment. Be certain
the orifice has even clearance around the fan before starting the unit.

REPLACING THE COMPRESSOR SHEAVE

1. Disconnect, lockout and tagout the power supply to the starter.

2. Remove the guards.

3. Using the adjusting screws, jack the motor base up to loosen the belt tension, Remove the belts.

4. Remove bolts from tapered bushing.

5. Pull the sheave off the rotor shaft with a gear puller, if necessary.

6. Install new sheave and tapered bushing.

7. Install new belts. Check for correct belt tension and reattach the wire guard.

8. Align sheaves with a straight edge. (See “SHEAVE ALIGNMENT”, page 64).

9. Assemble the guards.

CHECKING BELT TENSION - Using a spring scale, apply a perpendicular force to each belt at the
midpoint of the span and measure the deflection. Correct deflection force and deflection are shown in
Figure 7-1. To tighten belts, merely increase the center distance.

NOTICE
When a new set of belts is installed on a drive, the initial deflection force should
be 1/3 greater than shown in Figure 7-1. Recheck tension frequently during the
first 24 hours of operation

13-20-600 Page 65
 Deflection
Motor H.P. No. of Belts Force Pounds Deflection In Inches
20 4 6 – 8.5 3/8
25 4 6 – 8.5 3/8
30 4 6 – 8.5 3/8

Figure 7-1 – BELT TENSION – J SECTION MICRO-V BELTS

13-20-600 Page 66
SECTION 8
MAINTENANCE SCHEDULE

SERVICE CHECK LIST –

Air Filter - Operating conditions determine frequency of service. See “Air Filter,” SECTION 6, page 62.

Motor Lubrication - Refer to SECTION 2, page 16.

Every 8 Hours Operation

1. Check the reservoir oil level - add oil if required. See SECTION 5, page 51. If oil consumption is
high, refer to “Excessive Oil Consumption,” page 70.

2. Observe if the unit loads and unloads properly.

3. Check discharge pressure and temperature.

4. Check control panel display for advisory text messages.

Every 125 Hours Operation

1. Check for dirt accumulation on oil/aftercooler core faces and the cooling fan. If cleaning is required,
clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable
safety solvent in a direction opposite that of the cooling fan air flow. This cleaning operation will
keep the exterior cooling surfaces clean and ensure effective heat dissipation.

Every 1000 Hours Operation

1. Change oil filter element.

Every 4000 Hours Operation

1. Change the compressor lubricant. UNDER ADVERSE CONDITIONS, CHANGE MORE

FREQUENTLY (refer to “Oil Change Interval”, Figure 5-3, page 53). Flush system if required.

Every Year

1. Check the relief valve for proper operation. See Section 4, page 24.

2. Change oil separator, see “Removal of Oil Separator for Inspection or Replacment”, Section 5, page
51, for further details (or when 8 psid pressure differential across the element).

13-20-600 Page 67
 MAINTENANCE SCHEDULE (See Detail Notes above)

Maintenance Action
As Indicated by Every Every Every Every
AirSmart Every 8 125 1000 4000 Year
Controller Hours Hours Hours Hours
Check/Change Air Filter ..................................................... •
Change Oil Separator ....................................................... • •
Check Reservoir Oil Level **.............................................. •
Check for Proper Load/Unload........................................... •
Check Dirt Accumulation on Cooler ................................... •
Change Oil Filter Element & Clean Oil Return Strainer ..... •
Change Compressor Lubricant (AEON 4000) * ................. •

Check Relief Valve............................................................. •

Check Condition of Hoses.................................................. • •
Check Operation of Condensate Removal Solenoid Valve •
Change Inlet Valve Seals................................................... •

* See “Oil Change Interval Chart”, Figure 5-3, page 53, for specific lubricant life.

** Must be checked when the compressor is stopped and the air/oil mixture is separated.

13-20-600 Page 68
SECTION 9
TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

Compressor fails to start 1. Wrong lead connections. 1. Change leads.

2. Blown fuses in control 2. Replace fuse.
box.
3. Motor starter overload 3. Reset and investigate
relay tripped . cause of overload.
4. Pressure in reservoir. 4. Inspect blowdown valve.
5. Emergency stop 5. Release button.
depressed.

Compressor starts but 1. High discharge 1. See “High Discharge Air

stops after a short time temperature. Temperature,” this
section.
2. High separator/ high 2. See “High Discharge Air
compressor temperature Temperature”, this
light on. section.
3. Blown fuse in starter/ 3. Replace fuse (investigate
control box. if fuses continue to blow).
4. Motor starter overload 4. Reset and investigate
relay tripped. cause of overload.

Compressor does not 1. Improperly adjusted 1. Refer to Control Manual

unload (or load) control. 13-17-600 and adjust
control.
2. Air leak in control lines. 2. Determine source of leak
and correct.
3. Restricted control line. 3. Clean control lines.
4. Faulty inlet valve solenoid. 4 Replace solenoid valve.

Compressor cycles from 1. Insufficient receiver 1. Increase receiver size.

load to unload capacity.
excessively
2. Restriction in service 2. Inspect and clean service
piping. piping.
3. Restriction in control 3. Inspect and clean control
tubing. tubing.
4. Plugged aftercooler. 4. Inspect and clean
aftercooler.

Compressor runs 1. Volume of compressed air 1. Check the volume of the

unloaded too often system too small. piping and air receivers.
An additional air receiver
may be required.
2. Pressure range too 2. Extend pressure range.
narrow.

13-20-600 Page 69
SYMPTOM POSSIBLE CAUSE REMEDY

Compressor starts too 1. Wye Delta switch time set 1. Contact your Gardner
slowly too long. Denver distributor.
2. Minimum Pressure/Check 2. Repair or replace.
Valve is faulty.
3. Supply voltage is too low. 3. Check the supply voltage.

Compressor is low on 1. Restricted air filter. 1. Clean or replace filter.

delivery and pressure
2. Sticking inlet valve. 2. Inspect and clean inlet
valve.
3. Minimum pressure valve 3. Replace valve.
stuck closed.
4. Oil separator clogged. 4. Replace.
5. Intervals of moisture 5. Check the setting in the
separator drainage AirSmart controller.
incorrectly set.
6. Condensate drain 6. Replace.
solenoid valve is faulty.
7. Leaks in the compressed 7. Check for leaks, fix any
air system. leaks found.
8. V-Belts broken. 8. Replace.
9. V-Belts slipping. 9. Test belt tensioning.
10. Pressure limits incorrectly 10. Check/correct pressure
set. limits in the AirSmart
Controller.

11. Aftercooler is frozen 11. Thaw out. This machine

cannot operate in
temperatures below 32° F
(0° C).

High discharge air 1. Dirty or clogged cooler 1. Clean cooler.

temperature face.

2. Insufficient cooling air 2. Provide unrestricted

flow. supply of cooling air.

3. Clogged oil filter or cooler 3. Replace filter or clean

(interior). cooler.

4. Low compressor oil. 4. Add oil to proper level.

5. Faulty temperature 5. Replace sensor.

sensor.

6. Thermostatic mixing valve 6. Repair or replace valve.

stuck open.

Excessive oil 1. Oil carryover through 1. See “Oil Carryover”, in this

consumption lines. section.

13-20-600 Page 70
SYMPTOM POSSIBLE CAUSE REMEDY

2. Oil leaks at all fittings and 2. Tighten or replace fittings

gaskets. or gaskets.

3. Shaft seal leaking. 3. Replace shaft seal.

Oil carryover 1. Overfilling the reservoir. 1. Drain excess oil from

system.
2. Clogged, broken or loose 2. Tighten or replace faulty
oil return lines. lines.
3. Ruptured oil separator 3. Replace element.
element.
4. Loose assembly. 4. Tighten all fittings and
gaskets.
5. Foam caused by use of 5. Use Gardner Denver
incorrect oil. AEON 2000, 4000 or
9000SP lubricating
coolant.
6. Inoperative minimum 6. Replace seals in valve.
pressure valve.
7. Operation at elevated 7. Reduce temperature. See
discharge temperatures. “High Discharge Air
Temperature”, this
section.
8. Scavenge line check valve 8. Replace check valve.
failure.
9. Water condensate in oil. 9. Check oil reservoir
temperature and if low,
change thermal mixing
valve element to higher
temperature.

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the starter before removing valves, caps, plugs, fittings, bolts
and filters

13-20-600 Page 71
TROUBLESHOOTING VOLTAGE PROBLEMS

The compressor package has been designed, built, and tested to operate within one of the following
standard ranges:

200-208 Volts, 60 Hertz

230-240 Volts, 60 Hertz
460-480 Volts, 60 Hertz
575-600 Volts, 60 Hertz
Connection to higher voltages will reduce the life of electrical devices within the compressor package. As
voltages get further above the design range, other symptoms may show up.

High voltages may lead to high motor currents. The overload relay will sense these and shut down the
compressor to protect the motor.

If the power supply and/or control transformer primary fuses blow, check that the devices are properly
connected for the incoming line voltage.

Operation with lower voltages will reduce motor life and load capacity. As voltages get further below the
design range, other symptoms may show up.

Low voltages may lead to high motor currents. The overload relay will sense these and shut down the
compressor to protect the motor. If voltage is low while the compressor is off, locate and correct the
cause. If the voltage drops low only while the compressor is running, look for poor connections or
undersized wiring.

If any of the starters or contactors within the box chatters, or if the electronic controller drops out while
attempting to start, it is a clear indication that the wiring is inadequate for the compressor. Look for poor
connections or undersized wiring.

NOTICE
Gardner Denver factory remanufactured replacement compressor airend units
are available from your authorized distributor, on an exchange basis, for all
rotary screw compressor units.

13-20-600 Page 72
 For additional information contact your local representative or
Gardner Denver Compressor
1800 Gardner Expressway, Quincy, Illinois 62305

Customer Service Department Telephone:

(800) 682-9868
Specifications subject to change without notice. FAX: (217) 224-7814
Copyright © 2009 Gardner Denver, Inc. Litho in U.S.A.
Visit our Web Site: www.gardnerdenver.com