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EQUION ENERGIA LIMITED

ASERVIN AIR PACKAGE

x
A.RESTREPO 28-FEB-2014

GARDNER DENVER AIR PACKAGE

N01 TECHNICAL OPERATING AND


MAINTENANCE

Aservin S.A. Aservin Export LLC


Cll 86 # 19a – 21 of 201, Bogotá, D.C., Colombia 7225 NW 68th St. # 7; Miami, FL 33166, U.S.A.
Tel: (57-1) 6 21 05 44; Fax: (57-1) 6 21 05 44 Ph.: (305) 883-4324, Fax: (305) 883-4341

info@aservin.com
EQUION ENERGIA LIMITED
ASERVIN AIR PACKAGE

TABLA DE CONTENIDO

CAPITULO 1: N03 RECOMMENDED SPARES FOR TWO YEARS


OPERATION

CAPITULO 2: N05 LUBE OIL & OPERATING SCHEDULE

CAPITULO 3: N06 OPERATING & MAINTENANCE DATA


MANUAL. (INCLUYED N01, N02, P02, R01)

CAPITULO 4: P01 FUNCTIONAL & PERFORMANCE TEST


PROCEDURES

CAPITULO 5: P03 START UP PROCEDURE


N03_Recommended Spares for Two Years Operation

1 N03

;
$5(675(32(1(
N03_Recommended Spares for
Two Years Operation
ENERO 22 DE 2014 N03

N03_Recommended Spares for Two Years Operation

ITEM NAME OF PART PART NUMBER


1 ROUTINE MAINTENANCE KIT (Heavy Duty Air Filter) 302EBP6013*
2 SEPARATOR KIT 208EAP6013
3 PNEUMATIC CONTROLS & GAUGES 302EAQ6013
4 ELECTRICAL CONTROL KIT 304EBP6013
5 LUBRICANT (AEON 9000SP) 55-GALLON DRUM 28H103**
6 INLET VALVE KIT 302SSM6013
7 BEARING KIT 320SSM6013
8 GASKET KIT 321SSM6013

* Se recomienda se adquiera en el momento de comprar el equipo y use en las rutinas de mantenimiento


sugeridas en el Operate and Service Manual.

** La carga inicial de aceite viene incluido con los compresores. Sin embargo se recomienda tener aceite
de reserva.

Aservin S.A. Aservin Export LLC


Cll. 86 # 19A-21 Of. 201, Bogotá, D.C., Colombia 7225 NW 68th St. # 7; Miami, FL 33166, U.S.A.
Tel: (57-1) 621-0544; Fax: (57-1) 621-0544 Ph.: (305) 883-4324, Fax: (305) 883-4341

info@aservin.com
CONTRATO MARCO DE INGENIERIA No. 4610006355
DESARROLLO INTEGRADO DE PIEDEMONTE
INGENIERIA DE DETALLE ETAPA 2

SELLER ASERVIN – GARDNER DENVER


PACKAGE
INSTRUMENT AND UTILITY AIR COMPRESSOR
DESC.
EQPT Nos. 63-K-301 / 302
N05_Lube Oil & Operating Fluid
Schedule
SDRL
P.O. NUMBER DATE REV. NO.
CAT.
4300001978 30 de Mayo 2013 0 N05

<1253_050 >

SELLER DOCUMENT REVIEW

PERMISSION TO PROCEED DOES NOT CONSTITUTE ACCEPTANCE


OF DESIGN DETAILS, CALCULATIONS, TEST METHODS OR MATERIALS
DEVELOPED OR SELECTED BY SELLER AND DOES NOT RELIEVE
SELLER FROM FULL COMPLIANCE WITH CONTRACTURAL OR OTHER
OBLIGATIONS NOR DETRACT FROM ANY OTHER BUYER’S RIGHTS.

REVIEWED AND ACCEPTED. NO FURTHER REVIEW


REQUIRED.

REVISE AND RESUBMIT. WORK MAY PROCEED


SUBJECT TO INCORPORATION OF CHANGES
INDICATED.

REVISE AND RESUBMIT. WORK MAY NOT


PROCEED.

X FOR INFORMATION ONLY.

BUYER’S A.RESTREPO 16-SEP-2013


SIGNATURE............................................... DATE...................................................
"12788"9;

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g z r q u g f !vq !g ng x c vg f !vg o r g t c vw t g u !hq t !g z vg p f g f !r g t kq f u !q h!vko g /
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CGQ P !;111U R !ku !kf g c n!hq t !c r r nke c vkq p u !y j ke j !t g s w kt g !g z vg p f g f


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;111U R ! vq ! r t q x kf g ! u w r g t kq t ! u g t x ke g ! nkhg -! y j kng ! o kp ko k| kp i ! q kn
CGQ P !5111!ku !c !u g o k.u { p vj g vke -!u g x g t g n{ !j { f t q vt g c vg f !nw d t ke c p v
e c t t { !q x g t !c p f !w p kv!o c kp vg p c p e g /
hq t o w nc vg f !y kvj !c !w p ks w g !r c vg p vg f !c p vk.q z kf c p v!r c e m c i g /
C G Q P !;111V J
Kv! q hhg t u ! q w vu vc p f kp i ! vj g t o c n! c p f ! q z kf c vkq p ! u vc d knkv{-! y j kng
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¦ !Eq o r ng vg n{ !f g o w nu kd ng
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e j c t c e vg t ku vke u !c p f !c o d kg p v!e q p f kvkq p u /
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e w u vq o !d ng p f !hq t o w nc vkq p !hq t !r t q x g p !r g t hq t o c p e g /
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¦ !Gz e g nng p v!f g o w nu kd knkv{
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CGQ P ! 3111! ku ! c ! d ng p f ! q h! j ki j n{ ! r w t khkg f ! j { f t q e c t d q p ! d c u g
kp ! j ki j ! j w o kf kv{ ! c r r nke c vkq p u /! ! O c { ! p q v! d g ! c r r t q r t kc vg ! kp
u vq e m u !c p f !u r g e kc nn{ !d ng p f g f !c f f kvkx g u !y j ke j !r t q x kf g !g e q p q o ke c n
c r r nke c vkq p u !y kvj !nq y !c o d kg p v!vg o r g t c vw t g u /
q r g t c vkp i !c p f !u g t x ke g !nkhg !kp !t q vc t { !u e t g y !e q o r t g u u q t !u { u vg o u /
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CGQ P !3111!q hhg t u !u w r g t kq t !q z kf c vkq p !u vc d knkv{-!x ku e q u kv{ !e q p vt q n-
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e q p f g p u c vg !f g o w nu kd knkv{ !c p f !nq y !hq c o kp i !vg p f g p e kg u /
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c w vj q t k| g f !d { !vj g !W U FC!c u !c p !J.2!c r r t q x g f !nw d t ke c p v!hq t !w u g !kp
hg f g t c nn{ !kp u r g e vg f !o g c v!c p f !r q w nvt { !r nc p vu /!Kv!e q o r nkg u !y kvj !HFC
32EHT !289/4681Ñ nw d t ke c p vu !hq t !kp e kf g p vc n!hq q f !e q p vc e v/
R g v t q ng w o
C G Q P !911
CGQ P !7111!Hq q f !It c f g !ku !c p !g z vg p f g f !nkhg !nw d t ke c p v
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f g vg t i g p vu !c p f !f g hq c o c p vu /
t g c nk| g f
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¦ !T g f w e g f !q kn!e c t t { !q x g t

CGQ P ! CE U [ ! ku ! c ! r t g o kw o ! i t c f g ! f kg u vg t ! nw d t ke c p v! y j ke j
ng c x g u !x kt vw c nn{ !p q !e c t d q p !f g r q u kvu /!Gz e g nng p v!hq t !w u g !kp !211&
f w v{ !e { e ng !c r r nke c vkq p u /

Jki j !x ku e q u kv{ !kp f g z !q hhg t u !u w r g t kq t !r g t hq t o c p e g !kp !d q vj !j ki j


c p f !nq y !vg o r g t c vw t g !c r r nke c vkq p u /

H q q f !I t c f g
C G Q P !C E !H I
¦ !Hq q f !i t c f g -!g z vg p f g f !nkhg !t g e kr t q e c vkp i !nw d t ke c p v
¦ !Gz e g nng p v!f g o w nu kd knkv{ !hq t !g c u { !e q p f g p u c vg !u g r c t c vkq p /

CGQ P !CE HI!ku !c w vj q t k| g f !d { !vj g !W U FC c u !c p !J.2!c r r t q x g f


nw d t ke c p v!u w kvc d ng !hq t !kp e kf g p vc n!hq q f !e q p vc e v/

U g o k.U { p v j g v ke
C G Q P !6111
¦ !N q p i .nkhg !u g o k.u { p vj g vke !nw d t ke c p v
¦ !O kp ko k| g u !e c t d q p !d w knf w r
¦ !O c z ko k| g u ! e q o r t g u u q t ! g hhke kg p e {-! o kp ko k| g u ! q kn! e c t t { ! q x g t
c p f !o c kp vg p c p e g

CGQ P ! 6111! ku ! c ! nq p i .nkhg -! r t g o kw o ! i t c f g -! u g o k.u { p vj g vke


nw d t ke c p v! vj c v! r t q x kf g u ! g z vg p f g f ! vko g ! kp vg t x c nu ! d g vy g g p
e j c p i g u /!Kv!ku !t g e q o o g p f g f !hq t !w u g !kp !kp f w u vt kc n!c r r nke c vkq p u
y j g t g !c o d kg p v!vg o r g t c vw t g u !e c p !d g !d g nq y !.31ùH/

CGQ P ! 6111! t g f w e g u ! nw d t ke c p v! e q p u w o r vkq p ! c p f ! e c t t { ! q x g t


y j kng !o c kp vc kp kp i !c hvg t e q q ng t !e ng c p nkp g u u !c p f !g hhke kg p e {/!X c nx g
e c t d q p ! d w knf w r ! ku ! x kt vw c nn{ ! g nko kp c vg f -! t g u w nvkp i ! kp ! u ki p khke c p v
o c kp vg p c p e g !u c x kp i u /

R g v t q ng w o
C G Q P !611
¦ !Gp j c p e g f !nw d t ke kv{ !c p f !c p vk.y g c t !r t q r g t vkg u
¦ !O kp ko k| g u !e c t d q p !c p f !t g u kf w g !d w knf w r
¦ !Gz e g nng p v!e q o r t g u u q t !u { u vg o !e q o r c vkd knkv{

CGQ P ! 611! ku ! c ! r t g o kw o ! i t c f g -! p q p .f g vg t i g p v-! r g vt q ng w o


nw d t ke c p v/!Kv!ku !u r g e khke c nn{ !d ng p f g f !c p f !t g e q o o g p f g f !hq t !w u g
kp ! kp f w u vt kc n! t g e kr t q e c vkp i ! e q o r t g u u q t u Õ! e t c p m e c u g u ! c p f
e { nkp f g t u /!

CGQ P !611Õu !j ki j !x ku e q u kv{ !kp f g z !r t q x kf g u !c f g s w c vg !nw d t ke c vkq p


q x g t ! c ! y kf g ! q r g t c vkp i ! vg o r g t c vw t g ! t c p i g /! T w u v! kp j kd kvq t u
r t q vg e v! e t c p m e c u g ! nw d t ke c vg f ! e q o r q p g p vu -! y j kng ! q z kf c vkq p
kp j kd kvq t u ! r t g x g p v! q kn! f g i t c f c vkq p ! f w t kp i ! p q t o c n! u g t x ke g
kp vg t x c nu /

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r t g u u w t g ! ng c x g ! ng u u ! ! e c t d q p ! t g u kf w g ! q p ! x c nx g u ! c p f ! kp vg t p c n
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"#$%!&'()*+,%-.
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R g v t q ng w o !D c u g f
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N w d t ke c p v u U k| g P wo dgt N w d t ke c p v u U k| g P wo dgt

C G Q P !C E U [ C G Q P !;111U R
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C G Q P !C E !H I
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u r g e khke c nn{ !hq t !w u g ! 6!Ic n/ 39I2; u g o k.u { p vj g vke
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¦ !Hc e vq t { !Cr r t q x g f

U g g !{ q w t !c w vj q t k| g f !Ic t f p g t !Fg p x g t !Fku vt kd w vq t !hq t !c


P GY !N g x g n!q h!Gs w kr o g p v!c p f !R c t vu !Kp vg i t kv{-!S w c nkv{
c p f !U g t x ke g /!

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{ q w t !nq e c n!t g r t g u g p vc v kx g !q t
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)911*!793.;979!HCZ <!)328*!339.9354
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29.9.321!4t f !Gf !!4016 N kvj q !kp !W /U /C/ V g ng r j q p g <!)911*!356.5;57!HCZ <!);12*!653.726;
SECTION 5
LUBRICATION
OIL COOLER, OIL FILTER & SEPARATOR

COMPRESSOR OIL SYSTEM (Figure 5-3, page 76) cools the compressor, lubricates moving parts and
seals internal clearances in the compression chamber.

The oil inlet line is connected at the bottom of the oil reservoir. 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 air
then passes through the final oil separator where most of the remaining oil is removed. The separated oil
is returned to the compressor and the air passes to the final discharge line.

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.

OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000 SP
lubricating coolant which can be used for year-round operation. AEON 9000 SP is a synthetic, extended
life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based
lubricant.

A lubricant analysis program for a periodic check of lubricant quality and remaining life can maximize the
change interval.

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Use of improper lubricants will cause damage to equipment. Do not mix


different types of lubricants or use inferior lubricants.

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Improper equipment maintenance with use of synthetic lubricants will damage


equipment. For oil filter and oil separator change intervals, see Maintenance
Schedule, page 80.
HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000 SP lubricating coolant will operate at
a sustained discharge temperature up to 210° F (99° C). When unusually high ambient air temperature is
encountered, it will shorten the lubricant life; see Figure 5-7, page 82.

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.

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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.

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

AEON 9000 SP Synthetic Lubricant is not compatible with low nitrile Buna N or
acrylic paints. AEON 9000 SP is compatible with most air system downstream
components.
Material Safety Data Sheets (MSDS) are available for all AEON lubricants from your authorized Gardner
Denver distributor or by calling 217-222-5400.

MOISTURE IN THE OIL SYSTEM – In environments with normal operating temperatures and pressures
and low relative humidity, the thermal mixing valve controls the oil temperature and prevents moisture
accumulation in the oil. Unusual cooling of the oil reservoir, light duty cycles, high humidity, gross
compressor over-sizing or malfunctions of the thermal mixing valve may result in moisture accumulation
which is detrimental to compressor lubrication and may cause excessive oil carryover in the lubricant or
compressor failure. Please note that the airend discharge temperature must be maintained a minimum of
10° F above the pressure dew point temperature in Figure 5-1, page 75. Failure to maintain the
discharge temperature will cause moisture formation and compressor damage. The compressor must be
observed to ensure that it is operating properly. The best method for detecting moisture is a disciplined
lubricant sampling analysis program every 2,000 hours of operation. If moisture is observed in the oil
reservoir, drain the moisture and correct the operating conditions to reduce moisture. See “Thermal
Control (Thermostatic Mixing) Valve, page 85, “Water Shutoff Valve”, page 70 and “Compressor Oil
System Check”, page 90, for additional system considerations. If moisture accumulation is observed in
the lubricant, the best option is a higher temperature mixing valve, AEON 9000TH lubricating fluid and
setting the high discharge temperature shutdown to 240° F (new controller software may be required), to
prevent water from forming in the oil. Please contact Technical Services in MDC for part numbers,
availability and controller software version verification (S/N required).
Dew-Point Temperature vs. Ambient Temperature
(100% Relative Humidity)

230
220
210
200
190
180
170
160
Dew-Point Temp. F

150
140
130
120
110

100 psig
90
125 psig
80
150 psig
70
60 175 psig

50
40
20 30 40 50 60 70 80 90 100 110 120
Ambient Temp. F

Figure 5-1 – DEW POINT CHART °F

De w -Point Te m pe rature vs. Am bie nt Te m pe rature


(100% Re lative Hum idity)

110

100

90
Dew-Point Temp. C

80

70

60

50
6.9 bar

40
8.6 bar
10.4 bar
30
12.1 bar
20
-10 -5 0 5 10 15 20 25 30 35 40 45 50
Am bie nt Te m p. C

Figure 5-2 – DEW POINT CHART °C

These charts are easily used by reading the ambient temperature along the bottom axis of the chart and then
reading the appropriate pressure curve to determine the corresponding dew-point temperature on the left axis
of the chart. The compressor discharge temperature must be maintained at a minimum of 10° F above this
dew-point temperature to prevent condensation accumulation in the lubricant reservoir. These charts assume
100% relative humidity.
13-21-601
Page 76
221ECM797-B
(Ref. Drawing)

Figure 5-3 – FLOW DIAGRAM – AIR/OIL SYSTEM


201EAP797-A
(Ref. Drawing)

218ECM797-A
(Ref. Drawing)

Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED COOLER


REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will
be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be
disconnected after test and the vent fan motor connected in its place. The vent fan will be mounted in the
enclosure. A contactor (starter) will be shipped loose and remote mounted with the cooler by others upon
start-up at the job site. The control box will be wired for remote elevated coolers at the factory.

NOTICE
All requirements of local codes should be followed.
When connecting pipe fittings to the cooler, support the threaded coupling with a pipe wrench when
tightening the connection. Use silicone sealant on all steel to aluminum threaded connections. All piping
should be firmly supported to avoid strain on the cooler manifold and connections. Flexible connections
should be installed in all interconnecting piping, adjacent to the cooler, to avoid transmitting piping weight
or vibrations to the cooler elements. Before beginning installations, check to be sure that no debris or
foreign matter remains in the couplings or cooler bodies. Be certain interconnecting piping is clean to
avoid clogging the cooler passages.

Figure 5-5 – COOLER DRAIN DETAIL

AFTERCOOLER PIPING - At shutdown of the system, all units should be drained completely of
condensate if there is any possibility of freezing or corrosion damage. To help remove the condensate,
the cooler may be tapped per Figure 5-5, page 78, and a drain cock installed. After opening the drain
cock, blow air into the cooler from a connection on the opposite side of the cooler. At the same time the
connection on the drain side of the cooler should be plugged. The drain cock should be left open until the
machines are ready for start-up.

Failure to remove condensate from an idle cooler in freezing temperatures will


cause permanent cooler damage. Drain condensate after system shutdown. It
is the owner/operator's responsibility to ensure that condensate has been
drained and cooler dried out to prevent cooler damage.
NOTICE
When removing the cooling module from the package for remote operation, do
not use the flexible coupling (when supplied) between the air/oil separator
housing and the minimum pressure/check valve. The discharge piping from the
air/oil separator housing should be piped into the minimum pressure/check
valve, then into piping to the cooler, with a flexible connection between the
minimum pressure/check valve and aftercooler to keep the weight of the piping
off of the cooler.

HEAT EXCHANGER (OIL) PIPING - All remote elevated cooler applications must be sent through
Engineering for approval and for recommending pipe size. When the cooling module is removed from the
package, the thermal mixing valve (H) remains on the package. Control group part number 200ECM4002
will be mounted on package at the factory. This group controls the oil stop valve as well as not allowing
machine to run blown down. See Figure 5-4, page 77.

NOTICE
Remote mounted elevated coolers have a maximum pipe length of 30 feet (9 M)
(each way) and a maximum height of 20 feet (6 M) with a minimum of fittings. A
remote elevated cooler form, J214, is required to be filled out. Customer
Service will review all forms while in the quote stage. Customer Service will
include the filled out J214 form on any special orders sent to Engineering.

NOTICE
When removing the cooling module from the package for remote operation, the
oil stop valve and the check valve that are shipped loose should be mounted as
close to the compressor package as possible. Flexible connections should be
used to keep the weight of the piping off of the cooler.

Kit number 200EAP4013 includes the oil stop valve, check valve and flanges and must be installed on all
remote elevated coolers per Figure 5-4, page 77, and the following instructions:

1. Mount the check valve (90J113) as shown.

2. Mount the drain valves in the lowest section of the pipe on each side of the cooler connections.

3. Mount the oil stop valve (90AR243) in the line after the thermal mixing valve as shown.

Modifications to the control lines will be made at the factory per 288ECM810 schematic. Air to the oil stop
valve must come from the upper fitting in the separator housing, and then pass through the 3-way
pneumatic valve. Control air to the valve must be from the line between the tee and the orifice in the
blowdown muffler line per Figure 5-4, page 77. When the machine blows down, it will activate the
pneumatic valve and it will shut off the air and vent the line between the pneumatic control valve and the
oil stop valve to atmosphere. This will shut the oil stop valve and prevent excessive oil from running into
the reservoir.
Failure to install these parts or installations with pipe lengths and/or vertical runs outside the
recommended limits, could result in high oil carryover and cause the machine to shut down on
high discharge temperature.
COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation,” Section 2.

ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is in the red range on the
gauge as read while the unit is on. 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.

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

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

DO NOT OVERFILL. The quantity required to raise the oil level from the red range center of the green
range is shown in Figure 5-6, page 81. Repeated addition of oil between oil changes may indicate
excessive oil carry-over and should be investigated.

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.

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Excessive oil carry-over can damage equipment. Never fill oil reservoir above
the "FULL" marker.

LUBRICANT CHANGE PROCEDURE - Following are the primary steps to be completed when upgrading
or changing the type of lubricant.

1. Thoroughly drain system:

- Drain oil from air end and cooler while hot.


- Break low point connections and drain oil from pipe runs.
- Dump oil from the filter and reinstall used filter.
2. Fill the 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.

3. Thoroughly drain the machine.

4. Change to a new filter and separator.

5. Fill the system with a full charge of the new lubricant, then reinstall drain plug.

6. Machine should then be run normally; however, total run time after the initial change out should be
50 percent of normal anticipated service life of the new lubricant.

- Drain all lubricant from the system, change the filter and separator, and replace with a full
charge of the new lubricant.

7. Subsequent lubricant change outs should be at normal intervals. (See “Oil Change Interval” and
Figure 5-7, page 82).

OIL LEVEL GAUGE (Figure 1-6, page 12 and Figure 5-6) indicates the amount of oil in the oil reservoir.
Read oil level only when unit is on. In operation the oil level will fluctuate as the compressor loads and
unloads. Add oil only when the oil is at the bottom of the red range on the gauge as read when the
compressor is on. Drain oil only when the oil level is above the center of the green range on the gauge
as read when the compressor is on.

Figure 5-6 – OIL LEVEL GAUGE

OIL CHANGE INTERVAL - Recommended oil change intervals are based on oil temperature. Figure 5-7,
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 9000 SP
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 5-7 – OIL CHANGE INTERVAL

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.

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

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, use one of the following methods:

1. If the unit is not elevated high enough to use the oil reservoir drain line to drain oil, a small
hand, electric or air operated pump should be used to drain reservoir through the oil filler
opening or from the drain valve.

2. If the unit is elevated so that the oil reservoir drain can be used, empty the oil reservoir through
the drain valve to a suitable container or sump.

3. If the drained oil and/or the oil filter element are contaminated with dirt, flush the entire system:
reservoir, oil cooler, mixing valve and lines. Inspect the oil separator elements 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.

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 center of the green
range on the 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 center of the green range on the gauge.

On unloaded operation and after shutdown some oil will drain back into the oil reservoir and the oil level
gauge will read “FULL.” DO NOT DRAIN OIL TO CORRECT. On the next start, oil will again fill the
system and the gauge will indicate operating at the proper level. DO NOT OVERFILL as oil carryover will
result. The quantity of oil required to raise the oil level from “ADD” to “FULL” is shown in Figure 5-8.
Repeated addition of oil between 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.

C
CAAU
UTTIIO
ONN
Excessive oil carry-over can damage equipment. Never fill oil reservoir above
the "FULL" marker.

40 & 50 HP 60, 75 & 100 HP


(45, 55 & 75 KW)

Refill Capacity for Normal Oil Change 5.5 U.S. Gallons 8.5 U.S. Gallons
(32 Liters)
Red to Yellow Range 1.25 U.S. Gallons 2.0 U.S. Gallons
(7.5 Liters)
Figure 5-8 – APPROXIMATE OIL SYSTEM CAPACITIES
COMPRESSOR OIL FILTER (Figure 5-3, Page 76) - This screw on oil filter is a vital part in maintaining a
trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief
valve is located in the oil filter head. The relief valve opens in the event the element becomes dirty
enough to block the flow of oil.
C
CAAU
UTTIIO
ONN
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.

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

2. Remove the spin-on element.

3. Clean the gasket face of the filter body.

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

5. Screw the new element on the filter body and tighten by hand. DO NOT OVER TIGHTEN THE
ELEMENT.

6. Run the unit and check for leaks.


COMPRESSOR OIL COOLER - RADIATOR TYPE (Figure 1-5, page 11) - The oil cooler motor and fan is
mounted on the oil cooler module; 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 three (3) feet clearance around the cooler.
Keep both faces of cooler core clean for efficient cooling of compressor oil.

Figure 5-9 – THERMOSTATIC MIXING VALVE ELEMENT

THERMAL CONTROL (THERMOSTATIC MIXING) VALVE (Figure 5-9) is installed in system as shown
in Figure 5-3, page 76. This valve is used to control temperature of the oil in both air-cooled radiator and
water-cooled heat exchanger type oil cooler systems. On start-up with unit cold, element is open to
bypass, allowing oil to pass directly from the reservoir to compressor during warm-up. As oil warms,
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 160° F (71° C). This system provides proper compressor warm-up and helps prevent
moisture contamination of oil.

To check element, heat in oil - it should be fully extended at 160° F (71° C). If unit shuts down due to
high air discharge temperature, it may be that one or both thermostatic mixing valve elements (Figure 5-3,
page 76) are stuck open. Remove mixing valve and clean all parts thoroughly when flushing the oil
system.

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

COMPRESSOR OIL COOLER - WATER-COOLED HEAT EXCHANGER (Figure 5-3, page 76) - The
heat exchanger oil cooler is a multiple pass type, with water in the tubes and oil in the shell. The oil
temperature is controlled by the thermal (thermostatic mixing) valve. The optional water control valve
may be used to conserve water.
It is mandatory that any water-cooled unit be installed in a shelter heated to
temperatures above freezing (32° F, 0° C).

Oil cooler malfunction may be traced by checking pressure at oil inlet and outlet. At normal operating air
service pressure (65 psig to 150 psig, 4.5 bar to 10.3 bar) with the unit warm, a pressure drop of 3 psi to
15 psi (.2 bar to 1 bar) can be expected between the oil inlet and the oil outlet.

Water pressure drop from water inlet to outlet will vary with the inlet pressure and amount of water
flowing. A normal pressure drop may range from 5 psi to 10 psi (.3 bar to .7 bar). Any change in the
pressure drop from that normally held may indicate tube leakage or fouling and should be investigated.

In many instances, the cooling water supply for the heat exchanger will contain impurities in solution
and/or suspension. These substances can cause scale formation, corrosion and plugging of any water-
cooled heat exchanger equipment. Disregarding the possibility that one or more of these conditions exist
may result in increased maintenance and operation expense, reduced equipment life and emergency
shutdown. It is strongly recommended that a reputable, local water treatment concern be engaged to
establish the corrosion, scale forming and fouling tendency of the cooling water and take steps necessary
to remedy the situation if a problem does exist. The need for water treatment may involve only filtration
(screening) to remove debris, sand and/or salt in the cooling water supply. However, chemical treatment
methods may be necessary in certain instances to inhibit corrosion and/or remove dissolved solids, to
alter the water’s tendency to form scale deposits, or prevent the growth of microorganisms. The normal
maintenance program for the unit should also include periodic cleaning of the tubes (water side) of the
heat exchanger to remove deposits which enhance fouling and corrosion.

Hex head zinc anodes are used in the return bonnet (opposite end to the water pipe connections) of heat
exchangers to provide internal water system corrosion protection. These anodes should be inspected
periodically and replaced when the zinc has been reduced to about 1/2 inch (13mm) in length.

Figure 5-10 – WATER CONTROL VALVE


WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) (Figure 5-10, page
86) - The water flow control valve is adjustable to compensate for varying water inlet temperatures and
pressures and is to be mounted in the water outlet line after the oil cooler (Figure 5-3, page 76). Use the
compressor discharge air temperature gauge on the instrument panel in setting the flow control valve.
The compressor discharge temperature must be maintained a minimum of 10° F (5° C) above the dew
point temperature at the maximum anticipated ambient; refer to Figure 5-11, for the dew point
temperature at the operating pressure and ambient temperature of the application.

Figure 5-11 – DEW POINT TEMPERATURE VS. AMBIENT TEMPERATURE


(100% RELATIVE HUMIDITY)

To decrease water flow (increase compressor discharge air temperature) turn the adjusting screw from
left to right, increasing spring tension. To increase water flow (decrease compressor discharge air
temperature) turn the adjusting screw in the opposite direction. The groove at the lower edge of the
adjusting screw is an index line for use with the index scale 0 to 8 in obtaining a desired setting.

These valves must be handled with care and proper tools and techniques must be used when working on
the valve.

Care must be used when handling the capillary tube; a kink or break in the tubing or connections will
make the valve inoperative. Never attempt to change capillary length. Excess capillary tube should be
carefully coiled and placed so that damage will not occur in normal maintenance or traffic past the unit.

If a leak develops through the packing, tighten the packing gland nut firmly with a wrench to reseat the
packing around the valve stem, then back off the nut until loose, and finally retighten the nut finger tight.
Tightening the packing nut too tight may cause erratic operation. An occasional drop of oil on the valve
stem at the packing nut will prolong packing life.

If valve malfunctions, check for bent or binding, paint or corrosion on valve stem, foreign material in valve,
erosion, or thermal system (capillary) failure. If foreign material or scale is likely, the use of a strainer in
the inlet water line is recommended.
WATER SHUTOFF VALVE - WATER-COOLED HEAT EXCHANGER (Optional Equipment) (Figure 5-3,
page 76) - A magnetic solenoid-operated water shutoff valve rated at 150 psig (10.3 bar) water pressure
should be mounted in the water outlet line after the oil cooler. The valve should be wired into the
compressor control circuit so that the valve opens to allow water to flow any time the compressor is
running. When compressor stops under automatic control, or is shut off manually, the valve should close,
stopping water flow through the system. See Wiring Diagrams in Section 4.

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.

Figure 5-12 – OIL SEPARATOR

COMPRESSOR (GD ELIMINATOR™) OIL SEPARATOR located in a separate housing, consists of a


renewable cartridge-type separator element and provides the final removal of oil from the air stream
(Figure 5-12).

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, faulty minimum pressure
valve, over-filling 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 line from the separator housing to the compressor cylinder
is not clogged or pinched off, the check valve in the oil return line 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. A ruptured or collapsed separator element is usually due to heavy dirt or varnish
buildup in the filtering material. 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 gauging 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 shut down 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 "Change Separator"
advisory appears.

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 the 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.

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

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

3. Remove screws holding the top plate to the separator housing. Lift the top plate from the
separator housing.

4. Lift the separator from the separator housing.

5. Inspect and/or replace the separator as necessary. Be sure the o-ring is not damaged. Before
installing (or reinstalling) any separator apply grease to the o-ring. Oil will be wiped off by the
chamfer and the o-ring could be damaged.

6. Remove any gasket material adhering to top plate or separator housing, and install new gasket.

7. Lower the separator into the housing and center the separator on the chamfer. Press separator
down into the housing. Do not use excessive force as separator damage can occur.

8. Place the spacer on the indent in the separator. Seat the top plate to the separator, spacer and
separator housing. Install and tighten all cap screws.

9. Run the unit and check for leaks.

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

Air and Oil Discharge Temperature - 165° F to 195° F (74° C to 91° C) - Read at gauge on the
instrument panel or check with a thermometer at the discharge housing.

Compressor Oil Inlet Temperature - 150° F to 160° F (66° C to 71° 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 55 psig to 60 psig (3.8 bar to 4.1 bar).
Oil Cooler Oil Pressure Differential (Air-Cooled Radiator) - Check differential across oil system by
measuring oil inlet pressure as described above.

Oil Cooler Oil Pressure Differential (Water-Cooled Heat Exchanger) – 2 psid to 25 psid (.1 bar to 1.7
bar) (65 psig to 150 psig, 4.5 bar to 10.3 bar receiver pressure) - Check that oil inlet pressure is correct or
measure the differential between drains on the oil cooler shell.

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 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 air discharge temperature - see the gauge on the instrument panel. The
outlet oil temperature may be checked by installing a tee at the oil filter outlet.

Oil Cooler Temperature Differential (Water-Cooled Heat Exchanger) - The oil temperature differential
depends on the inlet water temperature and the water flow rate permitted by the water flow control valve
setting. The oil inlet temperature is approximately the same as the air discharge temperature - see the
gauge on the instrument panel. The oil outlet temperature may be checked by installing a tee at the oil
filter outlet.

Oil Cooler Water Pressure Differential (Water-Cooled Heat Exchanger) - The water pressure
differential through the heat exchanger will depend on the supply pressure, flow rate, cooler tube
cleanliness and outlet pressure. The inlet and outlet water pressure may be checked at the pipe fittings
supplied by the customer.
CONTRATO MARCO DE INGENIERIA No. 4610006355
DESARROLLO INTEGRADO DE PIEDEMONTE
INGENIERIA DE DETALLE ETAPA 2

SELLER ASERVIN – GARDNER DENVER


PACKAGE
INSTRUMENT AND UTILITY AIR COMPRESSOR
DESC.
EQPT Nos. 63-K-301 / 302
N06 Operating & Maintenance Data Dossier

SDRL
P.O. NUMBER DATE REV. NO.
CAT.
4300001978
29 de Mayo 2013 0 N06

<1253_050 >

SELLER DOCUMENT REVIEW

PERMISSION TO PROCEED DOES NOT CONSTITUTE ACCEPTANCE


OF DESIGN DETAILS, CALCULATIONS, TEST METHODS OR MATERIALS
DEVELOPED OR SELECTED BY SELLER AND DOES NOT RELIEVE
SELLER FROM FULL COMPLIANCE WITH CONTRACTURAL OR OTHER
OBLIGATIONS NOR DETRACT FROM ANY OTHER BUYER’S RIGHTS.

REVIEWED AND ACCEPTED. NO FURTHER REVIEW


REQUIRED.

REVISE AND RESUBMIT. WORK MAY PROCEED


SUBJECT TO INCORPORATION OF CHANGES
INDICATED.

REVISE AND RESUBMIT. WORK MAY NOT


PROCEED.

X FOR INFORMATION ONLY.

BUYER’S
A.RESTREPO
SIGNATURE...............................................
16-SEP-2013
DATE...................................................
CONTRATO MARCO DE INGENIERIA No. 4610006355
DESARROLLO INTEGRADO DE PIEDEMONTE
INGENIERIA DE DETALLE ETAPA 2

ÍNDICE

CAPÍTULO 1: Operating & Service Manual Compressor

CAPÍTULO 2: User Manual AIRSMART® COMM module


CONTRATO MARCO DE INGENIERIA No. 4610006355
DESARROLLO INTEGRADO DE PIEDEMONTE
INGENIERIA DE DETALLE ETAPA 2

N01 Operating & Maintenance Data Dossier

CAPÍTULO 1:

Operating & Service Manual Compressor


13-9-663
Version: 02
June 15, 2009

ELECTRA SCREW
ELECTRA-SAVER
ELECTRA-SAVER II
STATIONARY BASE-MOUNTED
COMPRESSOR
AUTO SENTRY® -- ES+ CONTROLS

EAH99C, EBH99G - 40, 50 HP


EAM99C, EBM99K - 60, 75 HP
ERH99E, EAP99J, EBP99J - 100 HP
INTERNATIONAL MODELS
EBM99L 60, 75, 100 HP (45, 56, 75 KW)

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/REMANUFACTURED AIRENDS

Whenever an airend requires replacement or repair, Gardner Denver offers an industry unique, factory
remanufactured airend exchange program. From its modern Remanufacturing center in Indianapolis, IN., Gardner
Denver is committed to supplying you with the highest quality, factory remanufactured airends that are guaranteed to
save you time, aggravation and money

When ordering parts, specify Compressor MODEL, Method of Cooling, POWER and SERIAL NUMBER (see
nameplate on unit). The Airend Serial Numbers are also stamped on top of the discharge bearing carrier castings.

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.

13-9-663 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 High Voltage – Hazard of Shock, Burn, or Death
impeller blade Present until Electrical Power is Removed

Cutting of Finger or Hand Hazard – Rotating fan


Entanglement of Fingers or Hand/Rotating Shaft
blade

13-9-663 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 Lockout Electrical Equipment in De-Energized


Removed State

Loud Noise Hazard – Wear Ear Protection


Do Not Lift Equipment with Hook – No Lift Point

Read the Operator’s Manual Before Proceeding


Handle Package at Forklift Points Only with Task

13-9-663 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.

13-9-663 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/Remanufactured Airends ................................................................ 1
Warning – Prohibition – Mandatory Label Information.................................................................................. 2
Safety Precautions ........................................................................................................................................ 4
Index.............................................................................................................................................................. 6
List Of Illustrations......................................................................................................................................... 8
Section 1, General Information ..................................................................................................................... 9
Section 2, Installation .................................................................................................................................. 13
Section 3, Starting & Operating Procedures ............................................................................................... 23
Section 4, Controls & Instrumentation ........................................................................................................ 26
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator............................................................................ 44
Section 6, Air Filter...................................................................................................................................... 63
Section 7, Coupling ..................................................................................................................................... 65
Section 8, Maintenance Schedule .............................................................................................................. 68
Section 9, Troubleshooting ......................................................................................................................... 70

This book covers the following models:


HP PSIG Model Parts List Controller Manual

50 100, 125 EAH99C 13-9-585 13-9-653

40, 50 100, 125, 150, 175, 200 EBH99G 13-9-586 13-9-653

75 100, 125, 150


13-9-653
EAM99C 13-9-588
60 150

60, 75 100, 125, 150, 175, 200 EBM99K 13-9-589 13-9-653

100, 125, 150 EAP99J 13-9-588 13-9-653

100 100, 125, 150, 175, 200 EBP99J 13-9-589 13-9-653

100, 125 ERH99E 13-8-530 13-9-653

60, 75, 100 100, 125, 150 EBM99L 13-9-594 13-9-653

13-9-663 Page 5
INDEX

Addition Of Oil Between Changes ...................51 Inlet Valve ........................................................ 29


Aftercooler Piping.............................................49 Installation For Cold Weather Operation ......... 16
Air Filter Element Life.......................................64 Installation, Section 2....................................... 13
Air Filter Vacuum Switch ..................................31
Air Filter, Heavy Duty (Standard) .....................63 Lifting Unit ........................................................ 13
Air Filter, Section 6...........................................63 Location ........................................................... 13
Air Flow In The Compressor System .................9 Air-Cooled Units ........................................... 14
Air-Cooled Units, Location ...............................14 Water-Cooled Units...................................... 15
Auto Sentry Operation......................................26 Lubricant
Auxiliary Air Receiver .......................................17 Recommended ............................................. 44
Lubricant Change Procedure........................... 51
Blowdown Valve...............................................28 Lubrication
Blowdown Valve Piping....................................18 Motor ............................................................ 22
Check Lubrication, Cooling And Sealing..................... 10
Daily..............................................................25 Lubrication, Oil Cooler, Oil Filter & Separator . 44

Cold Ambient Operation...................................51 Main Starter ..................................................... 32


Cold Weather Operation ..................................16 Maintenance Schedule, Section 8 ................... 68
Cold Weather Operation, Installation For.........16 Minimum Discharge Pressure Valve................ 28
Compression Principle .......................................9 Moisture In The Oil System ............................. 45
Compressor........................................................9 Moisture Separator/Trap.................................. 17
Compressor Capacity Control - Turn Valve Units Motor Lubrication ............................................. 22
Only ..............................................................33
Compressor Oil Cooler - Water-Cooled Heat Oil Change Interval .......................................... 52
Exchanger ....................................................56 Oil Cooler - Radiator Type ............................... 56
Control Devices................................................26 Oil Filter............................................................ 55
Control Piping...................................................17 Oil Level Gauge ......................................... 28, 52
Control Transformer .........................................32 Oil Reservoir .................................................... 59
Controller..........................................................26 Oil Reservoir Drain........................................... 15
Controls & Instrumentation, Section 4 .............26 Oil Separator
Cooling, Sealing And Lubrication.....................10 Compressor (Gd Eliminator) ........................ 59
Coupling ...........................................................65 Inspection ..................................................... 60
Oil Carryover ................................................ 59
Daily Check ......................................................25 Pressure Differential Gauging ...................... 60
Discharge Service Line ....................................18 Removal For Inspection Or Replacement.... 61
Discharge Thermistor.......................................32 Oil Specifications ............................................. 44
Drain Oil System
Oil Reservoir.................................................15 Compressor.................................................. 44
Draining And Cleaning Oil System...................53 Draining And Cleaning ................................. 53
Oil System Check ............................................ 61
Electrical Wiring ...............................................21 Air And Oil Discharge Temperature ............. 61
Emergency Stop Push-Button..........................32 Oil Cooler Oil Pressure Differential (Air-
Enclosure .........................................................15 Cooled Radiator) ...................................... 62
Oil Cooler Oil Pressure Differential (Water-
Fan Starter .......................................................32 Cooled Heat Exchanger) .......................... 62
Filling Oil Reservoir ..........................................54 Oil Cooler Temperature Differential (Air-
Filter Element ...................................................63 Cooled Radiator) ...................................... 62
Foundation .......................................................15 Oil Cooler Temperature Differential (Water-
Cooled Heat Exchanger) .......................... 62
General Information, Section 1 ..........................9 Oil Cooler Water Pressure Differential (Water-
Grounding.........................................................21 Cooled Heat Exchanger) .......................... 62
Oil Inlet Pressure.......................................... 61
Heat Exchanger (Oil) Piping.............................50 Oil Inlet Temperature ................................... 61
High Temperature Operation ...........................45 Operation
High Temperature ........................................ 45
Inlet Line...........................................................17
Inlet Screen And Tube .....................................64

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Parallel Piping ..................................................21 Air Filter ........................................................ 68
Piping Shuttle Valve.................................................... 30
Series............................................................20 Solenoid Valves Ivc And Ivo ............................ 30
Pressure Differential Gauging ..........................60 Solenoid Valves Tvc And Tvo.......................... 31
Pressure Regulator ..........................................30 Starting & Operating Procedures, Section 3.... 23
Prestart-Up Instructions ...................................23 Starting The Unit .............................................. 25
Purge Valve......................................................30 Unit Cold....................................................... 25
Unit Hot ........................................................ 25
Relief Valve ......................................................26 Stopping The Unit ............................................ 25
Remote Mounted Elevated Cooler Assembly ..49 System Pressure Transducer .......................... 31
Reservoir Pressure Transducer .......................31
Reservoir Thermistor........................................32 Terminal Strip................................................... 32
Thermal Control (Thermostatic Mixing) Valve . 56
Safety Precautions .............................................4 Troubleshooting, Section 9 .............................. 70
Sealing, Lubrication And Cleaning...................10 Turn Valve.................................................. 10, 31
Series Piping ....................................................20 Turn Valve Actuator ......................................... 31
Service Check List ...........................................68
Every 1000 Hours Operation........................68 Warning – Prohibition – Mandatory Label
Every 125 Hours Operation..........................68 Information ..................................................... 2
Every 8 Hours Operation ..............................68 Water Flow Control Valve For Heat Exchanger
Every 8000 Hours Operation........................68 ..................................................................... 58
Every Year....................................................68 Water Piping .................................................... 19
Motor Lubrication..........................................68 Water Shutoff Valve - Water-Cooled Heat
Oil Separator ................................................68 Exchanger .................................................... 59
Service Check List Water-Cooled Units, Location.......................... 15

13-9-663 Page 7
LIST OF ILLUSTRATIONS

Figure 1-1 – Compression Cycle .................................................................................................................. 9


Figure 1-2 – Starter Box.............................................................................................................................. 10
Figure 1-3 – Control Box ............................................................................................................................. 10
Figure 1-4 – Compressor / Motor Side........................................................................................................ 11
Figure 1-5 – Cooler / Reservoir Side .......................................................................................................... 11
Figure 1-6 – Air/Oil Flow Diagram............................................................................................................... 12

Figure 2-1 – Typical Compressor Room ..................................................................................................... 14


Figure 2-2 – Air Flow Chart ......................................................................................................................... 14
Figure 2-3 – Cold Weather Installation ....................................................................................................... 16
Figure 2-4 – Inlet Line Lengths ................................................................................................................... 17
Figure 2-5 – Heat Exchanger (Oil Cooler) Approximate Water Flow.......................................................... 18
Figure 2-6 – Aftercooler Approximate Water Flow..................................................................................... 19
Figure 2-7 – Series Piping........................................................................................................................... 20
Figure 2-8 – Parallel Piping......................................................................................................................... 20

Figure 4-1 – Schematic Tubing Diagram .................................................................................................... 27


Figure 4-2 – Blowdown Valve ..................................................................................................................... 28
Figure 4-3 – Minimum Discharge Pressure/Check Valve ........................................................................... 28
Figure 4-4 – Inlet Valve ............................................................................................................................... 29
Figure 4-5 – Shuttle Valve........................................................................................................................... 30
Figure 4-6 – Turn Valve – Electra-Saver Only ............................................................................................ 31
Figure 4-7 – Control Schematic – Compressor Unloaded – Constant Speed Mode .................................. 34
Figure 4-8 – Control Schematic – Compressor At Full Load – Constant Speed Mode .............................. 35
Figure 4-9 – Control Schematic – Compressor Unloaded – Low Demand Mode Or Auto Mode ............... 36
Figure 4-10 – Control Schematic – Compressor At Full Load .................................................................... 37
Figure 4-11 – Control Schematic – Compressor Fully Unloaded – Low Demand Mode Switch Off .......... 38
Figure 4-12 – Control Schematic – Compressor Fully Loaded – Low Demand Mode Switch On.............. 39
Figure 4-13 – Wiring Diagram – Wye Delta ................................................................................................ 40
Figure 4-14 – Wiring Diagram – Full Voltage.............................................................................................. 41
Figure 4-15 – Wiring Diagram – Wye Delta ................................................................................................ 42
Figure 4-16 – Wiring Diagram – Full Voltage.............................................................................................. 43

Figure 5-1 – Dew Point Chart °F................................................................................................................. 46


Figure 5-2 – Dew Point Chart °C ................................................................................................................ 46
Figure 5-3 – Flow Diagram – Air/Oil System............................................................................................... 47
Figure 5-4 – Oil Flow Diagram – Remote Overhead Mounted Cooler........................................................ 48
Figure 5-5 – Cooler Drain Detail ................................................................................................................. 49
Figure 5-6 – Oil Level Gauge ...................................................................................................................... 52
Figure 5-7 – Oil Change Interval................................................................................................................. 53
Figure 5-8 – Approximate Oil System Capacities ....................................................................................... 54
Figure 5-9 – Thermostatic Mixing Valve Element ....................................................................................... 56
Figure 5-10 – Water Control Valve ............................................................................................................. 57
Figure 5-11 – Dew Point Temperature Vs. Ambient Temperature ............................................................. 58
Figure 5-12 – Oil Separator......................................................................................................................... 59

Figure 6-1 – Heavy Duty Air Filter............................................................................................................... 63

Figure 7-1 – Installation Of Coupling Cushions .......................................................................................... 65

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SECTION 1
GENERAL INFORMATION

Figure 1-1 – COMPRESSION CYCLE

COMPRESSOR - The Gardner Denver 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. Tapered 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 six (6) matching helical grooves 60° 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 rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and 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 groove, 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 5-3, page 47) - Air enters the air filter and passes
through the inlet unloader valve to the compressor. 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 passes into the separator and separator housing where
the oil is separated and passes through tubing connecting the separator housing and compressor. The
air passes through the minimum pressure valve, discharge check valve and cooler, then to the plant air
lines.

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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 discharges into the compressor main oil gallery.
A portion of the oil is directed through internal passages to the bearings, gears 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.

TURN VALVE (ELECTRA-SAVER ONLY) - The turn valve is a rotary helical valve located on the
discharge side of the cylinder toward the inlet end. The valve opens and closes ports in the cylinder
which communicates with the inlet passage. This varies the compressor rotor volume to match the
demand for air, thus reducing the part-load power requirement.

217ECM797-A
(Ref. Drawing)

Figure 1-2 – STARTER BOX

Figure 1-3 – CONTROL BOX

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Figure 1-4 – COMPRESSOR / MOTOR SIDE

217ECM797-A
(Ref. Drawing)

Figure 1-5 – COOLER / RESERVOIR SIDE

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219ECM797-A
(Ref. Drawing)

Figure 1-6 – AIR/OIL FLOW DIAGRAM

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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

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


passage of current.

LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Lifting slots are
provided in the base for tow motor use. The unit may also be moved into location by rolling on bars.

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Lift compressor package by base only. Do not use other places such as
motors, compressors or discharge manifold piping as lifting points.

The eyebolts or lugs provided on the motors are for lifting the motors only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motors, 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 - The compressor should be installed, whenever possible, 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.

13-9-663 Page 13
Both the air-cooled and water-cooled units require cooling air as well as air to the compressor inlet.
Proper ventilation MUST be provided; hot air must be exhausted from the compressor operating area. A
typical inlet-outlet air flow arrangement is shown in Figure 2-1.

Figure 2-1 – TYPICAL COMPRESSOR ROOM

Air-Cooled Units - 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, Figure 2-2, for the
compressor oil/aftercooling system and for electric motor cooling. Air is drawn into the unit at the motor
side of the enclosure and is exhausted at the oil cooler side. Do not block the air flow to and from the
unit. Allow three and one-half (3-1/2) feet (1.1 M) to the nearest obstruction on the starter end and control
box end of the unit. Allow three (3) feet (.9 M) to the nearest obstruction above and on other sides of unit.
For continuous efficiency, 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.

Minimum Air Flow * For Compression and Cooling – Cubic Feet/Minute


(Cubic Meters/Minute)

HP (kW) Air Cooled Water Cooled

40 & 50 HP 6,500 1.400


60-100 HP (45-75 kW) 12,500 (354) 1,700 (48)

* 80° F (27° C) Inlet Air

Figure 2-2 – AIR FLOW CHART

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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.

Water-Cooled Units - The water-cooled unit with the standard enclosure requires sufficient air flow,
Figure 2-2, for electric motor cooling. Air is drawn into the unit at the top of the enclosure and is
exhausted at the motor side. Do not block air flow to and from unit. Allow three and one-half (3-1/2) feet
(1.1 m) to the nearest obstruction on the starter end and control box side of the unit. Allow three (3) feet
(.9 m) to the nearest obstruction above and on other sides of the unit.

FOUNDATION - The Gardner Denver 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 10° angle lengthwise or 10° sidewise.

Mounting bolts are not normally required. However, installation conditions such as piping rigidity, angle of
tilt, or danger of shifting from outside vibration or moving vehicles may require the use of mounting bolts
and shims to provide uniform support for the base.

OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the side of the frame.
This drain is approximately 4.50 inches (115 mm) above the floor level. If this is not sufficient to
conveniently drain the oil some other methods of providing drain are:

1. Elevate the compressor unit on a suitable structure to obtain the desired drain height.

2. Construct an oil sump or trough below the floor level and pump or bail the drained oil.

3. Pump oil from the reservoir filler opening or drain to a container.

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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 doors are provided for maintenance access. Be sure to allow enough space around
the unit for the doors to open completely. Any of the enclosure doors may be removed by opening the
door and lifting it up slightly to disengage the hinges.

The motor inspection/air filter service panel is held by two latches and lifts away from the enclosure. The
air outlet panel is attached by screws to the enclosure and is not readily removable.

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

13-9-663 Page 15
Figure 2-3 – COLD WEATHER INSTALLATION

INSTALLATION FOR COLD WEATHER OPERATION (Figure 2-3) - It is recommended that the unit be
installed inside a shelter that will be heated to temperatures above freezing (32°F, 0°C). This will
eliminate many of the problems associated with operating units in cold climates where freezing rain,
drifting snow, freezing condensate and bitter cold temperatures are encountered.

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 +10°F, -12°C)

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. If an air-cooled aftercooler is to be used, 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 9000 SP lubricant.

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

6. Specify NEMA 4 enclosure for electrical devices.

13-9-663 Page 16
Extreme Cold Weather Operation (Down To -10°F, -23°C)

In addition to the above, the following should be provided:

1. It will be necessary to provide shutters or to block off part of the cooler in some manner since the
cooler is greatly oversized for operation in these low temperatures. Since shutters are not provided
as a factory option, blocking off a portion of the cooler with plywood should be satisfactory.

2. Auto operation should not be used in extreme environments.

3. Some means of providing heat during shutdown. Start-up should be provided. There are various
methods to accomplish this, but since openings are not provided for sump heaters, the use of radiant
heaters is recommended. The heaters should be sized to provide at least a +10° F (-12 C)
environment for coolers, motor and sump. Figure 2-3, page 16, shows how these might be located
in a typical installation and sizes required.

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.

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

MOISTURE SEPARATOR/TRAP - Since the unit is equipped with a built-in aftercooler, a combination
moisture separator and trap is furnished with the unit.

CONTROL PIPING - Control piping is not necessary since the Rotary Screw compressor 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 (3 meters) 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, Figure 2-4.

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

INLET LINE LENGTHS

Length of Inlet Line Diameter of Pipe Size


0 to 10 Feet (0 to 3 Meters)........................ Same as Compressor Inlet Opening
10 to 17 Feet (3 to 5 Meters)...................... One Size Larger Than Inlet Opening
17 to 38 Feet (5 to 11.5 Meters)................. Two Sizes Larger Than Inlet Opening
Figure 2-4 – INLET LINE LENGTHS

13-9-663 Page 17
DISCHARGE SERVICE LINE - The discharge service line connection on both water-cooled and air-
cooled units is made at the right hand corner of the unit, viewed from the opposite end from control panel
side. 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.
BLOWDOWN VALVE PIPING - The blowdown valve is piped back into the airend between the inlet valve
and air filter.
HEAT EXCHANGER
Water Temperature to Heat
Exchanger
Gallons/minute
Maximum Water Approximate Water
Flow Pressure Drop @ 90° F
HP Model 60° F 70° F 80° F 90° F
Gallons/minute * Water Temperature PSI
EAH99C
40 3.4 4.3 5.7 8.6 30.0 1.0
EBH99G
EAH99C
50 4.1 5.1 6.8 10.2 30.0 1.5
EBH99G
EAM99C
60 5.0 6.2 8.3 12.5 40.8 2.0
EBM99K
EAM99C
75 6.0 7.6 10.1 15.1 40.8 1.5
EBM99K
EAP99J
8.4
100 EBP99J 10.5 14.1 21.1 40.8 5.0
ERH99E

* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.

HEAT EXCHANGER (INTERNATIONAL)

Water Temperature to Heat


Exchanger Maximum Approximate Water
Liters/seconds Water Flow Pressure Drop @ 32° C
Liters per Water Temperature (bar)
KW Model 16° C 21° C 27° C 32° C
Second *
45 EBM99L .32 .38 .51 .77 2.52
Less than .15 bar for any
56 EBM99L .44 .53 .72 1.08 2.52
flow rate shown in the table
75 EBM99L .57 .70 .94 1.41 2.52

* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.

Figure 2-5 – HEAT EXCHANGER (OIL COOLER) APPROXIMATE WATER FLOW

13-9-663 Page 18
AFTERCOOLER
Water Temperature to Heat
Exchanger
Gallons/minute
Maximum Water Approximate Water
Flow Pressure Drop @ 90° F
HP Model 60° F 70° F 80° F 90° F
Gallons/minute * Water Temperature PSI
EAH99C
40 .5 .7 .9 1.3 26.0
EBH99G
EAH99C
50 .7 .9 1.2 1.8 26.0
EBH99G
EAM99C
60 .8 1.0 1.4 2.1 26.0 Less than 1 PSI for any
EBM99K
flow rate shown in the table
EAM99C
75 1.2 1.5 2.0 3.0 26.0
EBM99K
EAP99J
100 EBP99J 1.7 2.1 2.8 4.1 26.0
ERH99E

* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.

AFTERCOOLER (INTERNATIONAL)

Water Temperature to Heat


Exchanger Maximum Approximate Water
Liters/seconds Water Flow Pressure Drop @ 32° C
Liters per Water Temperature (bar)
KW Model 16° C 21° C 27° C 32° C
Second *
45 EBM99L .05 .06 .09 .13 3.47
Less than .1 bar for any flow
56 EBM99L .08 .09 .13 .19 3.47
rate shown in the table
75 EBM99L .11 .14 .19 .28 3.47

* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.

Figure 2-6 – AFTERCOOLER APPROXIMATE WATER FLOW

WATER PIPING (Water-Cooled Heat Exchanger Models Only) - On machines equipped with water-
cooled heat exchangers, the water inlet and outlet connections are located in the unit base flange on the
left side of the unit.

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It is mandatory that any water cooled unit be installed in a shelter heated to


temperatures above freezing (32° F., 0° C).
The water source should be capable of supplying up to the maximum flow shown in
Figure 2-5, page 18, and
Figure 2-6, page 19, at a minimum pressure of 40 psig (2.8 bar); maximum allowable water pressure is
150 psig (10.3 bar). The water flow rates shown are approximate and a guide to sizing piping, cooling
tower and other water system equipment.

The heat exchanger system is designed to operate with water inlet temperatures from 60° F to 90° F (16°
C to 32° C) and a water outlet temperature not to exceed 110° F (43° C). If water cooler than 60° F is
used, high water outlet temperatures (over 110° F, 43° C) will be experienced along with shortened heat
exchanger life caused by tube fouling and corrosion. If water warmer than 90° F (32° C) is used, higher
compressor oil inlet temperatures and high water usage will result.

13-9-663 Page 19
Most water systems will require control of impurities: filtration, softening or other treatment. See Section
5, “Compressor Oil Cooler - Water-Cooled Heat Exchanger” for more information on the water system.

* (Optional) Water Control Valve and Water Shutoff Valve Must Be Ordered Separately

Figure 2-7 – SERIES PIPING

SERIES PIPING (Figure 2-7) - Water flow must be through aftercooler first for effective cooling of
discharge air and is so piped on the standard water-cooled unit.

* (Optional) Water Control Valve and Water Shutoff Valve Must be Ordered Separately

Figure 2-8 – PARALLEL PIPING

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PARALLEL PIPING (Figure 2-8, page 20) - A separate water control valve is required to control the
discharge air temperature. If a remote (externally mounted) water-cooled aftercooler is piped in parallel
with the heat exchanger, provide a separate water control valve for the aftercooler and pipe separate inlet
water lines to both the aftercooler and heat exchanger.

The water control valve is to be adjusted to maintain oil out of the heat exchanger within the 140° F to
150° F (60° C to 66° C) range regardless of inlet water flow or temperature as long as a minimum flow for
a given temperature is met (
Figure 2-5, page 18, and
Figure 2-6, page 19. See Section 5 for adjustment instructions and maximum allowable lubricant
temperature.

ELECTRICAL WIRING - Standard Units - The Gardner Denver Rotary Screw compressor is factory
wired for all starter to motor and control connections for the voltage specified on the order. It is necessary
only to connect the unit starter to the correct power supply. The standard unit is supplied with an open
drip-proof motor, a NEMA 12 starter and control enclosure. See Section 2, “Location” paragraph, for
distance to the nearest obstruction on starter and control box sides of the unit.

Lower operating voltages (200/208) require that the unit starter be remote mounted since the starter is too
large to be mounted within the control enclosure. If not supplied with the compressor unit, the starter is to
be a size 6 full voltage non-reversing type in NEMA (CEMA) enclosure suitable for the environment, with
two (2) rejection type control circuit fuses (size according to motor starter manufacturer’s standard), a 200
(208) volt coil, and three (3) overload heaters for 200 (208) volt 100 HP (75 kW), 1.15 service factor
motor.

The overload heaters are to be selected according to starter manufacturer’s tables based on motor
nameplate full load amperage.

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 Table 250-95 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.

13-9-663 Page 21
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. Only enough grease
should be added to replace the grease used by the bearing. Too much grease can be as harmful as
insufficient grease. The grease cavity should be about 1/2 full.

5. Leave the relief plug temporarily off. Reconnect the 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.

ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30° C 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

13-9-663 Page 22
SECTION 3
STARTING & OPERATING PROCEDURES

PRESTART-UP INSTRUCTIONS - A new unit as received from the factory has been tested and then prepared
for shipping only. Do not attempt to operate the unit until checked and serviced as follows:

1. Compressor Oil - Check the oil level in the reservoir. Add oil only if the oil level gauge reads in the
red “ADD OIL” range. Do not mix different type oils. The unit is shipped filled with Gardner Denver
AEON 9000 SP Lubricating Coolant which is suitable for the first 8000 hours under normal operating
conditions.

REPLACE OIL FILTER EVERY 1000 HOURS

Initial fill, or filling after a complete draining of the system, may show the oil level in the yellow
“EXCESS OIL” range. After start-up, the oil will fall into the green operating range as system
components are filled. If necessary, add oil to bring the level to the top of the green range as read
when the unit is operating at full load and normal pressure. See Figure 5-7, page 53.

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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 9000 SP synthetic lubricant. Use only
genuine Gardner Denver filters designed and specified for this compressor.

Before removing the oil filler plug, always stop the unit and release air
pressure, lockout and tagout the power supply to the starter. Failure to release
pressure or properly disconnect the power may result in personal injury or
death.

During unloaded operation and after shutdown, the system will partially drain back into the oil
reservoir and the oil level may read higher than when operating on load. DO NOT DRAIN OIL TO
CORRECT; on the next loaded cycle or start, oil will again fill the system and the gauge will indicate
the operating level.

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

3. Coupling - Check all bolts and cap screws for tightness. See Section 7.

4. Piping - Refer to Section 2, “Installation", and make sure piping meets all recommendations.

5. Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See
Figure 4-13 thru Figure 4-16, pages 40 thru 43, for general wiring diagrams and Section 2, for
installation instructions.

13-9-663 Page 23
6. Grounding - Equipment must be properly grounded according to Table 250-95 of the National
Electrical Code.

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Failure to properly ground the compressor package could result in controller
malfunction.

7. Rotation - Check for correct motor rotation using “JOG MODE.” Compressor drive shaft rotation
must be clockwise standing facing the compressor coupling.

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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.

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

8. System Pressure - Set the controls to the desired load pressure. DO NOT EXCEED THE
MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE. See Controller
Manual 13-9-653.

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.

9. Operating Mode - Refer to Section 4 for detailed information on the control system.

10. Enclosure - Check for damaged panels or doors. Check all screws and latches for tightness. Be
sure doors are closed and latched.

13-9-663 Page 24
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.

STARTING THE UNIT - Observe the following starting procedures.

Unit Cold - If the unit is a water-cooled heat exchanger model, open any manual water inlet valves wide
open. Start the unit by pushing either the “CONSTANT RUN” button or one of the “AUTO” buttons. Since
the unit is equipped with a minimum (65 psig, 4.5 bar) pressure discharge valve, no special procedure to
maintain unit reservoir pressure is required.

Unit Hot - No warm-up period is required. If the unit is a water-cooled heat exchanger model, open any
manual water inlet valves wide open. Start the unit by pushing either the “CONSTANT RUN” button or
one of the “AUTO” buttons.

DAILY CHECK - Refer to Section 8, “Maintenance Schedule,” page 69.

STOPPING THE UNIT - Press “STOP-RESET” button. The oil reservoir will automatically blow down as
the motor stops. If the unit is a water-cooled heat exchanger type, close any manual water inlet valves.

13-9-663 Page 25
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 (and to the appropriate
water supply if water-cooled). A standard compressor unit consists of the compressor, oil reservoir, oil
cooling system and filter, motor type as specified, NEMA 12 starter / control box, and control components
as described below.

AUTOSENTRY OPERATION
Operation of the “AutoSentry” 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 an operating mode key.

AUTOMATIC is the most commonly selected mode of operation, as it will operate the compressor unit
automatically in the most efficient manner for the demand of the air system.

Once operating, the mode may be changed at any time by pressing a key, and the selected mode will be
displayed in the lower right corner of the message window. Press the [STOP/RESET] key at any time to
stop the compressor under normal conditions.

Detailed instructions for the controller are found in the manual 13-9-653.

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


lockout and tagout the unit from the power supply and any other circuits before
servicing unit.

CONTROL DEVICES

Controller - This compressor unit features the “AUTOSENTRY” 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.

Relief Valve - A pressure relief valve(s) is (are) installed in the final discharge line and set to
approximately 120-125% of the unit’s full load operating pressure for protection against over pressure.
Periodic checks should be made to ensure its (their) 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
with the hand lever. Hold the valve open for a few seconds and allow it to snap shut.

13-9-663 Page 26
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.

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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.

211ECM797-B
(Ref. Drawing)

Figure 4-1 – SCHEMATIC TUBING DIAGRAM

13-9-663 Page 27
Figure 4-2 – BLOWDOWN VALVE

Blowdown Valve (Figure 4-2) - This valve normally is used for control functions, but also serves to
relieve reservoir pressure following a shutdown. 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. A control air check valve is provided to ensure
that the inlet valve is closed during blowdown.

Oil Level Gauge (Figure 1-6, page 12) - This gauge is located on the oil reservoir and indicates the oil
level. See Section 5 for information on how to correctly read the gauge and proper lubrication.

Figure 4-3 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE

Minimum Discharge Pressure/Check Valve (Figure 4-3, page 43) - 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.

13-9-663 Page 28
The valve incorporates a spring-loaded piston which maintains approximately 65 psig in the oil reservoir.
When the air pressure on the upstream (reservoir) side of the valve rises above 65 psig, the spring is
overridden and the valve opens to full porting.

The valve does not require maintenance or adjustment. If the valve fails to function, check the valve stem
O-ring for sealing, valve orifices for restriction, or valve and valve seat for burrs and dirt.

The valve is adjustable within a small range. It is adjusted by a screw on the side of the valve. By turning
the screw, the minimum pressure to open the valve increases. Conversely, backing it out decreases the
minimum pressure required to open the valve.

To service the valve, make sure all pressure is relieved, disconnect the unit from the power supply,
lockout and tagout, then unscrew the valve cap from the body. The internal parts will come out after the
cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor.

224ECM797-B
(Ref. Drawing)

Figure 4-4 – INLET VALVE

Inlet Valve (Figure 1-4, page 11 and Figure 4-4, page 29) - 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
“AutoSentry” Controller through solenoid valves IVC and IVO. As Pressure to the piston is increased, the
valve closes to restrict air flow and compressor delivery.

13-9-663 Page 29
Solenoid Valves IVC and IVO - These valves control position of the inlet valve in response to signals
from the “AutoSentry” Controller. With both valves de-energized, the normally open IVC valve allows
control pressure to the inlet piston to close the valve. If IVC only is energized, the inlet valve is held in its
current position. If both valves are energized, control pressure is relieved from the inlet piston to allow
the valve to open.

Pressure Regulator - The pressure regulator is used to supply a constant and low control pressure to
prevent damage to the inlet valve from “slamming". The regulator should be set for 25-30 psig.

Figure 4-5 – SHUTTLE VALVE

Shuttle Valve (Figure 4-5) - Also known as a double check valve, the shuttle valve is a device which will
take two (2) supply signals and allow the one with the highest pressure to pass through. The shuttle
valve is used to provide control air pressure from either the reservoir or plant air system, as required
during different operating conditions.

Purge Air Valve - The purge valve is a normally closed two-way air actuated valve that admits purge air
from the final discharge manifold to the compressor to counteract the oil knock that occurs in oil-flooded
rotary screw compressors when they are completely unloaded with pressure in the oil reservoir. This
valve is controlled by the same control pressure which controls the inlet valve.

13-9-663 Page 30
213ECM797-A
(Ref. Drawing)

Figure 4-6 – TURN VALVE – ELECTRA-SAVER ONLY

Turn Valve (Electra-Saver only) (Figure 4-6)- The turn valve is a helical valve which, when rotated, opens
and closes a series of ports cast into the compressor cylinder. When these ports are open, they direct
some of the air which would otherwise be compressed back to the inlet, reducing both capacity and
power consumption.

Turn Valve Actuator (Electra-Saver only) - The turn valve actuator is a rotary rack and pinion device
which positions the turn valve according to system demand. Filtered oil from the compressor sump is
directed to the outboard end of the two actuating cylinders to move the rack and rotate the valve.
Located on the ends of the cylinders are adjusting screws which limit the travel of the actuator. When
looking at the rear of the compressor, the adjusting screw on the right on the compressor adjusts the fully
closed (full-load) position of the valve. The full load position of the actuator may be checked by removing
the adjusting screw at the unloaded end of the actuator (left side of the compressor) and using a rod to
push the pistons to the full load position. The rod must be clean and free of burrs and scale. Take care
not to scrape the cylinder walls when moving the pistons.

Solenoid Valves TVC and TVO (Electra-Saver only) - These valves control the position of the turn valve
in response to signals from the “AutoSentry” controller. With both valves de-energized, equal pressure is
applied to both ends of the actuator to hold it in its present position. If TVC only is energized, the right
side of the turn valve actuator is exhausted to the compressor inlet cavity, causing the turn valve to move
towards the full load position. If TVO only is energized, the left end of the turn valve actuator is
exhausted to the compressor inlet cavity, causing the turn valve to move towards the unload position.
See “AutoSentry Operation” in Controller Manual 13-9-653, for a description of how the turn valve position
is controlled during normal operation.

System Pressure Transducer - 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 “AutoSentry” controller
for modulation and control.

Reservoir Pressure Transducer - This transducer is connected to the coolant system. Its signal is
used to prevent loaded starts, monitor reservoir pressure, and monitor the condition of the air/oil
separator.

Air Filter Vacuum Switch - This switch is used to monitor air filter condition and alert the user if the
filter requires service or replacement.

13-9-663 Page 31
Discharge Thermistor - 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 - This sensor is located near the separator and is used to monitor temperature
and shut down the compressor if high temperatures are detected.

Emergency Stop Push-Button - This is a maintained push-button, and removes power from the
controller outputs regardless of controller status. It is located on the upper section of the panel, next to
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,


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

Control Transformer - This control device changes the incoming power voltage to 110-120 volts for use
by all unit control devices. The transformers employed are usually connectable for several input voltages,
refer to the transformer label for connection prior to energizing. Two primary and one secondary fuse are
provided. Refer to adjacent labeling for replacement information.

Terminal Strip - This provides connections for all 110-120 volt devices not contained within the
enclosure.

Fan Starter - The starter is used to provide control and overload protection for the cooling fan or the
ventilation fan of water-cooled units with enclosure. Overload heaters should be selected and adjusted
based on the motor nameplate amps and the instructions located inside the cover of the electrical
enclosure. Three fuses are provided. Refer to adjacent labeling for replacement information.

Main Starter - This starter is used to provide control and overload protection for the main drive motor.
Full voltage starters employ a single contactor, overload heaters should be selected and adjusted based
on the motor nameplate amps and the instructions located inside the cover of the enclosure. Wye-delta
starters employ three contactors which are controlled sequentially to provide low current starting. For
wye-delta starters, the motor nameplate amps must be first multiplied by 0.577 before using the heater
table.

13-9-663 Page 32
COMPRESSOR CAPACITY CONTROL - TURN VALVE UNITS ONLY

The capacity of the compressor is controlled by the action of the turn valve and the compressor inlet
valve.

The turn valve controls compressor delivery to match demands of 40% to 100% of the compressor’s
maximum capacity. The inlet valve throttles to control compressor delivery to match demands of 0% to
40% of the compressors maximum capacity.

Example with normal setting of 100 PSIG:

Compressor Delivery Discharge Manifold


Capacity Inlet Valve Turn Valve Pressure

Full Open Closed 100


70% Open 50% Open 100
40% Open Full Open 100
30% Closing Full Open 103
20% Closing Full Open 103
0% Closed Full Open 103

13-9-663 Page 33
13-9-663
Page 34

225ECM797-B
(Ref. Drawing)

Figure 4-7 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – CONSTANT SPEED MODE


ERH, EBH, EBM & EBP UNITS ONLY
13-9-663
Page 35

226ECM797-B
(Ref. Drawing)

Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD – CONSTANT SPEED MODE
ERH, EBH, EBM & EBP UNITS ONLY
13-9-663
Page 36

227ECM797-B
(Ref. Drawing)

Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – LOW DEMAND MODE OR AUTO MODE
ERH, EBH, EBM & EBP UNITS ONLY
13-9-663

214ECM797-B
(Ref. Drawing)
Page 37

Figure 4-10 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD


EAH, EAM & EAP UNITS ONLY
13-9-663

215ECM797-B
(Ref. Drawing)
Page 38

Figure 4-11 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF
EAH, EAM & EAP UNITS ONLY
216ECM797-B
13-9-663

(Ref. Drawing
Page 39

Figure 4-12 – CONTROL SCHEMATIC – COMPRESSOR FULLY LOADED – LOW DEMAND MODE SWITCH ON
EAH, EAM & EAP UNITS ONLY
214ECP546-B
(Ref. Drawing)
13-9-663
Page 40

Figure 4-13 – WIRING DIAGRAM – WYE DELTA


EBH, EBM & EBP UNITS WITH ES+ CONTROLS
218ECP546-A
(Ref. Drawing)
13-9-663
Page 41

Figure 4-14 – WIRING DIAGRAM – FULL VOLTAGE


ERH, EBH, EBM & EBP UNITS WITH ES+ CONTROLS
216EAP546-B
(Ref. Drawing)
13-9-663
Page 42

Figure 4-15 – WIRING DIAGRAM – WYE DELTA


EAH, EAM & EAP UNITS WITH ES+ CONTROLS AND CURRENT MONITOR
13-9-663
Page 43

220EAP546-B
(Ref. Drawing)

Figure 4-16 – WIRING DIAGRAM – FULL VOLTAGE


EAH, EAM & EAP UNITS WITH ES+ CONTROLS AND CURRENT MONITOR
SECTION 5
LUBRICATION
OIL COOLER, OIL FILTER & SEPARATOR

COMPRESSOR OIL SYSTEM (Figure 5-3, page 47) cools the compressor, lubricates moving parts and
seals internal clearances in the compression chamber.

The oil inlet line is connected at the bottom of the oil reservoir. 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 air
then passes through the final oil separator where most of the remaining oil is removed. The separated oil
is returned to the compressor and the air passes to the final discharge line.

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.

OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000 SP
lubricating coolant which can be used for year-round operation. AEON 9000 SP is a synthetic, extended
life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based
lubricant.

A lubricant analysis program for a periodic check of lubricant quality and remaining life can maximize the
change interval.

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Use of improper lubricants will cause damage to equipment. Do not mix
different types of lubricants or use inferior lubricants.

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Improper equipment maintenance with use of synthetic lubricants will damage
equipment. For oil filter and oil separator change intervals, see Maintenance
Schedule, page 69.

13-9-663 Page 44
HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000 SP lubricating coolant will operate at
a sustained discharge temperature up to 210° F (99° C). When unusually high ambient air temperature is
encountered, it will shorten the lubricant life, see Figure 5-7, page 53.

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.

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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.

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

AEON 9000 SP Synthetic Lubricant is not compatible with low nitrile Buna N or
acrylic paints. AEON 9000 SP is compatible with most air system downstream
components.
Material Safety Data Sheets (MSDS) are available for all AEON lubricants from your authorized Gardner
Denver distributor or by calling 217-222-5400.

MOISTURE IN THE OIL SYSTEM – In environments with normal operating temperatures and pressures
and low relative humidity, the thermal mixing valve controls the oil temperature and prevents moisture
accumulation in the oil. Unusual cooling of the oil reservoir, light duty cycles, high humidity, gross
compressor over-sizing or malfunctions of the thermal mixing valve may result in moisture accumulation
which is detrimental to compressor lubrication and may cause excessive oil carryover in the lubricant or
compressor failure. Please note that the airend discharge temperature must be maintained a minimum of
10° F above the pressure dew point temperature in Figure 5-1, page 46. Failure to maintain the
discharge temperature will cause moisture formation and compressor damage. The compressor must be
observed to ensure that it is operating properly. The best method for detecting moisture is a disciplined
lubricant sampling analysis program every 2,000 hours of operation. If moisture is observed in the oil
reservoir, drain the moisture and correct the operating conditions to reduce moisture. See “Thermal
Control (Thermostatic Mixing) Valve, page 56, “Water Shutoff Valve”, page 53 and “Compressor Oil
System Check”, page 61, for additional system considerations. If moisture accumulation is observed in
the lubricant, the best option is a higher temperature mixing valve, AEON 9000TH lubricating fluid and
setting the high discharge temperature shutdown to 240° F (new controller software may be required), to
prevent water from forming in the oil. Please contact Technical Services in MDC for part numbers,
availability and controller software version verification (S/N required).

13-9-663 Page 45
Dew-Point Temperature vs. Ambient Temperature
(100% Relative Humidity)

230
220
210
200
190
180
170
160
Dew-Point Temp. F

150
140
130
120
110
100
100 psig
90
125 psig
80
70 150 psig

60 175 psig

50
40
20 30 40 50 60 70 80 90 100 110 120
Ambient Temp. F

Figure 5-1 – DEW POINT CHART °F

Dew -Point Tem perature vs. Am bient Tem perature


(100% Relative Hum idity)

110

100

90
Dew-Point Temp. C

80

70

60

50
6.9 bar

40
8.6 bar

10.4 bar
30
12.1 bar
20
-10 -5 0 5 10 15 20 25 30 35 40 45 50
Am bient Tem p. C

Figure 5-2 – DEW POINT CHART °C

These charts are easily used by reading the ambient temperature along the bottom axis of the chart and then
reading the appropriate pressure curve to determine the corresponding dew-point temperature on the left axis
of the chart. The compressor discharge temperature must be maintained at a minimum of 10° F above this
dew-point temperature to prevent condensation accumulation in the lubricant reservoir. These charts assume
100% relative humidity.

13-9-663 Page 46
13-9-663
Page 47

221ECM797-B
(Ref. Drawing)

Figure 5-3 – FLOW DIAGRAM – AIR/OIL SYSTEM


201EAP797-A
(Ref. Drawing)

218ECM797-A
(Ref. Drawing)

Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED COOLER

13-9-663 Page 48
REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will
be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be
disconnected after test and the vent fan motor connected in its place. The vent fan will be mounted in the
enclosure. A contactor (starter) will be shipped loose and remote mounted with the cooler by others upon
start-up at the job site. The control box will be wired for remote elevated coolers at the factory.

NOTICE
All requirements of local codes should be followed.
When connecting pipe fittings to the cooler, support the threaded coupling with a pipe wrench when
tightening the connection. Use silicone sealant on all steel to aluminum threaded connections. All piping
should be firmly supported to avoid strain on the cooler manifold and connections. Flexible connections
should be installed in all interconnecting piping, adjacent to the cooler, to avoid transmitting piping weight
or vibrations to the cooler elements. Before beginning installations, check to be sure that no debris or
foreign matter remains in the couplings or cooler bodies. Be certain interconnecting piping is clean to
avoid clogging the cooler passages.

Figure 5-5 – COOLER DRAIN DETAIL

AFTERCOOLER PIPING - At shutdown of the system, all units should be drained completely of
condensate if there is any possibility of freezing or corrosion damage. To help remove the condensate,
the cooler may be tapped per Figure 5-5, page 49, and a drain cock installed. After opening the drain
cock, blow air into the cooler from a connection on the opposite side of the cooler. At the same time the
connection on the drain side of the cooler should be plugged. The drain cock should be left open until the
machines are ready for start-up.

Failure to remove condensate from an idle cooler in freezing temperatures will


cause permanent cooler damage. Drain condensate after system shutdown. It
is the owner/operator's responsibility to ensure that condensate has been
drained and cooler dried out to prevent cooler damage.

13-9-663 Page 49
NOTICE
When removing the cooling module from the package for remote operation, do
not use the flexible coupling (when supplied) between the air/oil separator
housing and the minimum pressure/check valve. The discharge piping from the
air/oil separator housing should be piped into the minimum pressure/check
valve, then into piping to the cooler, with a flexible connection between the
minimum pressure/check valve and aftercooler to keep the weight of the piping
off of the cooler.

HEAT EXCHANGER (OIL) PIPING - All remote elevated cooler applications must be sent through
Engineering for approval and for recommending pipe size. When the cooling module is removed from the
package, the thermal mixing valve (H) remains on the package. Control group part number 200ECM4002
will be mounted on package at the factory. This group controls the oil stop valve as well as not allowing
machine to run blown down. See Figure 5-4, page 48.

NOTICE
Remote mounted elevated coolers have a maximum pipe length of 30 feet (9 M)
(each way) and a maximum height of 20 feet (6 M) with a minimum of fittings. A
remote elevated cooler form, J214, is required to be filled out. Customer
Service will review all forms while in the quote stage. Customer Service will
include the filled out J214 form on any special orders sent to Engineering.

NOTICE
When removing the cooling module from the package for remote operation, the
oil stop valve and the check valve that are shipped loose should be mounted as
close to the compressor package as possible. Flexible connections should be
used to keep the weight of the piping off of the cooler.

Kit number 200EAP4013 includes the oil stop valve, check valve and flanges and must be installed on all
remote elevated coolers per Figure 5-4, page 48, and the following instructions:

1. Mount the check valve (90J113) as shown.

2. Mount the drain valves in the lowest section of the pipe on each side of the cooler connections.

3. Mount the oil stop valve (90AR243) in the line after the thermal mixing valve as shown.

Modifications to the control lines will be made at the factory per 288ECM810 schematic. Air to the oil stop
valve must come from the upper fitting in the separator housing, then pass through the 3-way pneumatic
valve. Control air to the valve must be from the line between the tee and the orifice in the blowdown
muffler line per Figure 5-4, page 48. When the machine blows down, it will activate the pneumatic valve
and it will shut off the air and vent the line between the pneumatic control valve and the oil stop valve to
atmosphere. This will shut the oil stop valve and prevent excessive oil from running into the reservoir.

Failure to install these parts or installations with pipe lengths and/or vertical runs outside the
recommended limits, could result in high oil carryover and cause the machine to shut down on
high discharge temperature.

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COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation,” Section 2.

ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is in the red range on the
gauge as read while the unit is on. 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.

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

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

DO NOT OVERFILL. The quantity required to raise the oil level from the red range center of the green
range is shown in Figure 5-6, page 52. Repeated addition of oil between oil changes may indicate
excessive oil carry-over and should be investigated.

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.

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Excessive oil carry-over can damage equipment. Never fill oil reservoir above
the "FULL" marker.

LUBRICANT CHANGE PROCEDURE - Following are the primary steps to be completed when upgrading
or changing the type of lubricant.

1. Thoroughly drain system:

- Drain oil from air end and cooler while hot.

- Break low point connections and drain oil from pipe runs.

- Dump oil from the filter and reinstall used filter.

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2. Fill the 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.

3. Thoroughly drain the machine.

4. Change to a new filter and separator.

5. Fill the system with a full charge of the new lubricant, then reinstall drain plug.

6. Machine should then be run normally, however, total run time after the initial changeout should be 50
percent of normal anticipated service life of the new lubricant.

- Drain all lubricant from the system, change the filter and separator, and replace with a full
charge of the new lubricant.

7. Subsequent lubricant changeouts should be at normal intervals. (See “Oil Change Interval” and
Figure 5-7, page 53).

OIL LEVEL GAUGE (Figure 1-6, page 12 and Figure 5-6) indicates the amount of oil in the oil reservoir.
Read oil level only when unit is on. In operation the oil level will fluctuate as the compressor loads and
unloads. Add oil only when the oil is at the bottom of the red range on the gauge as read when the
compressor is on. Drain oil only when the oil level is above the center of the green range on the gauge
as read when the compressor is on.

Figure 5-6 – OIL LEVEL GAUGE

OIL CHANGE INTERVAL - Recommended oil change intervals are based on oil temperature. Figure 5-7,
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.

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Discharge AEON 4000 AEON 9000 SP
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 5-7 – OIL CHANGE INTERVAL

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.

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

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, use one of the following methods:

1. If the unit is not elevated high enough to use the oil reservoir drain line to drain oil, a small
hand, electric or air operated pump should be used to drain reservoir through the oil filler
opening or from the drain valve.

2. If the unit is elevated so that the oil reservoir drain can be used, empty the oil reservoir through
the drain valve to a suitable container or sump.

3. If the drained oil and/or the oil filter element are contaminated with dirt, flush the entire system:
reservoir, oil cooler, mixing valve and lines. Inspect the oil separator elements 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.

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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.

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 center of the green
range on the 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 center of the green range on the gauge.

On unloaded operation and after shutdown some oil will drain back into the oil reservoir and the oil level
gauge will read “FULL.” DO NOT DRAIN OIL TO CORRECT. On the next start, oil will again fill the
system and the gauge will indicate operating at the proper level. DO NOT OVERFILL as oil carryover will
result. The quantity of oil required to raise the oil level from “ADD” to “FULL” is shown in Figure 5-8.
Repeated addition of oil between 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.

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Excessive oil carry-over can damage equipment. Never fill oil reservoir above
the "FULL" marker.

40 & 50 HP 60, 75 & 100 HP


(45, 55 & 75 KW)

Refill Capacity for Normal Oil Change 5.5 U.S. Gallons 8.5 U.S. Gallons
(32 Liters)
Red to Yellow Range 1.25 U.S. Gallons 2.0 U.S. Gallons
(7.5 Liters)
Figure 5-8 – APPROXIMATE OIL SYSTEM CAPACITIES

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COMPRESSOR OIL FILTER (Figure 5-3) - This screw on oil filter is a vital part in maintaining a trouble-
free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is
located in the oil filter head. The relief valve opens in the event the element becomes dirty enough to
block the flow of oil.
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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.

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

2. Remove the spin-on element.

3. Clean the gasket face of the filter body.

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

5. Screw the new element on the filter body and tighten by hand. DO NOT OVER TIGHTEN THE
ELEMENT.

6. Run the unit and check for leaks.

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COMPRESSOR OIL COOLER - RADIATOR TYPE (Figure 1-5, page 11) - The oil cooler motor and fan is
mounted on the oil cooler module; 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 three (3) feet clearance around the cooler.
Keep both faces of cooler core clean for efficient cooling of compressor oil.

Figure 5-9 – THERMOSTATIC MIXING VALVE ELEMENT

THERMAL CONTROL (THERMOSTATIC MIXING) VALVE (Figure 5-9) is installed in system as shown
in Figure 5-3, page 47. This valve is used to control temperature of the oil in both air-cooled radiator and
water-cooled heat exchanger type oil cooler systems. On start-up with unit cold, element is open to
bypass, allowing oil to pass directly from the reservoir to compressor during warm-up. As oil warms,
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 160° F (71° C). This system provides proper compressor warm-up and helps prevent
moisture contamination of oil.

To check element, heat in oil - it should be fully extended at 160° F (71° C). If unit shuts down due to
high air discharge temperature, it may be that one or both thermostatic mixing valve elements (Figure 5-3,
page 47) are stuck open. Remove mixing valve and clean all parts thoroughly when flushing the oil
system.

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

COMPRESSOR OIL COOLER - WATER-COOLED HEAT EXCHANGER (Figure 5-3, page 47) - The
heat exchanger oil cooler is a multiple pass type, with water in the tubes and oil in the shell. The oil
temperature is controlled by the thermal (thermostatic mixing) valve. The optional water control valve
may be used to conserve water.

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It is mandatory that any water-cooled unit be installed in a shelter heated to
temperatures above freezing (32° F, 0° C).

Oil cooler malfunction may be traced by checking pressure at oil inlet and outlet. At normal operating air
service pressure (65 psig to 150 psig, 4.5 bar to 10.3 bar) with the unit warm, a pressure drop of 3 psi to
15 psi (.2 bar to 1 bar) can be expected between the oil inlet and the oil outlet.

Water pressure drop from water inlet to outlet will vary with the inlet pressure and amount of water
flowing. A normal pressure drop may range from 5 psi to 10 psi (.3 bar to .7 bar). Any change in the
pressure drop from that normally held may indicate tube leakage or fouling and should be investigated.

In many instances, the cooling water supply for the heat exchanger will contain impurities in solution
and/or suspension. These substances can cause scale formation, corrosion and plugging of any water-
cooled heat exchanger equipment. Disregarding the possibility that one or more of these conditions exist
may result in increased maintenance and operation expense, reduced equipment life and emergency
shutdown. It is strongly recommended that a reputable, local water treatment concern be engaged to
establish the corrosion, scale forming and fouling tendency of the cooling water and take steps necessary
to remedy the situation if a problem does exist. The need for water treatment may involve only filtration
(screening) to remove debris, sand and/or salt in the cooling water supply. However, chemical treatment
methods may be necessary in certain instances to inhibit corrosion and/or remove dissolved solids, to
alter the water’s tendency to form scale deposits, or prevent the growth of microorganisms. The normal
maintenance program for the unit should also include periodic cleaning of the tubes (water side) of the
heat exchanger to remove deposits which enhance fouling and corrosion.

Hex head zinc anodes are used in the return bonnet (opposite end to the water pipe connections) of heat
exchangers to provide internal water system corrosion protection. These anodes should be inspected
periodically and replaced when the zinc has been reduced to about 1/2 inch (13mm) in length.

Figure 5-10 – WATER CONTROL VALVE

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WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) (Figure 5-10, page
57) - The water flow control valve is adjustable to compensate for varying water inlet temperatures and
pressures and is to be mounted in the water outlet line after the oil cooler (Figure 5-3, page 47). Use the
compressor discharge air temperature gauge on the instrument panel in setting the flow control valve.
The compressor discharge temperature must be maintained a minimum of 10° F (5° C) above the dew
point temperature at the maximum anticipated ambient; refer to Figure 5-11, for the dew point
temperature at the operating pressure and ambient temperature of the application.

Figure 5-11 – DEW POINT TEMPERATURE VS. AMBIENT TEMPERATURE


(100% RELATIVE HUMIDITY)

To decrease water flow (increase compressor discharge air temperature) turn the adjusting screw from
left to right, increasing spring tension. To increase water flow (decrease compressor discharge air
temperature) turn the adjusting screw in the opposite direction. The groove at the lower edge of the
adjusting screw is an index line for use with the index scale 0 to 8 in obtaining a desired setting.

These valves must be handled with care and proper tools and techniques must be used when working on
the valve.

Care must be used when handling the capillary tube; a kink or break in the tubing or connections will
make the valve inoperative. Never attempt to change capillary length. Excess capillary tube should be
carefully coiled and placed so that damage will not occur in normal maintenance or traffic past the unit.

If a leak develops through the packing, tighten the packing gland nut firmly with a wrench to reseat the
packing around the valve stem, then back off the nut until loose, and finally retighten the nut finger tight.
Tightening the packing nut too tight may cause erratic operation. An occasional drop of oil on the valve
stem at the packing nut will prolong packing life.

If valve malfunctions, check for bent or binding, paint or corrosion on valve stem, foreign material in valve,
erosion, or thermal system (capillary) failure. If foreign material or scale is likely, the use of a strainer in
the inlet water line is recommended.

13-9-663 Page 58
WATER SHUTOFF VALVE - WATER-COOLED HEAT EXCHANGER (Optional Equipment) (Figure 5-3,
page 47) - A magnetic solenoid-operated water shutoff valve rated at 150 psig (10.3 bar) water pressure
should be mounted in the water outlet line after the oil cooler. The valve should be wired into the
compressor control circuit so that the valve opens to allow water to flow any time the compressor is
running. When compressor stops under automatic control, or is shut off manually, the valve should close,
stopping water flow through the system. See Wiring Diagrams in Section 4.

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.

Figure 5-12 – OIL SEPARATOR

COMPRESSOR (GD ELIMINATOR™) OIL SEPARATOR located in a separate housing, consists of a


renewable cartridge-type separator element and provides the final removal of oil from the air stream
(Figure 5-12).

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, faulty minimum pressure
valve, over-filling 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 line from the separator housing to the compressor cylinder
is not clogged or pinched off, the check valve in the oil return line is functioning properly, and there is not
water or an oil/water emulsion in the oil.

13-9-663 Page 59
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. A ruptured or collapsed separator element is usually due to heavy dirt or varnish
buildup in the filtering material. 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 gauging 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 shut down 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 "Change Separator"
advisory appears.

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 the element media.

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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.

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

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

3. Remove screws holding the top plate to the separator housing. Lift the top plate from the
separator housing.

4. Lift the separator from the separator housing.

5. Inspect and/or replace the separator as necessary. Be sure the o-ring is not damaged. Before
installing (or reinstalling) any separator apply grease to the o-ring. Oil will be wiped off by the
chamfer and the o-ring could be damaged.

6. Remove any gasket material adhering to top plate or separator housing, and install new gasket.

7. Lower the separator into the housing and center the separator on the chamfer. Press separator
down into the housing. Do not use excessive force as separator damage can occur.

8. Place the spacer on the indent in the separator. Seat the top plate to the separator, spacer and
separator housing. Install and tighten all cap screws.

9. Run the unit and check for leaks.

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

Air and Oil Discharge Temperature - 165° F to 195° F (74° C to 91° C) - Read at gauge on the
instrument panel or check with a thermometer at the discharge housing.

Compressor Oil Inlet Temperature - 150° F to 160° F (66° C to 71° 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 55 psig to 60 psig (3.8 bar to 4.1 bar).

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

Oil Cooler Oil Pressure Differential (Water-Cooled Heat Exchanger) – 2 psid to 25 psid (.1 bar to 1.7
bar) (65 psig to 150 psig, 4.5 bar to 10.3 bar receiver pressure) - Check that oil inlet pressure is correct or
measure the differential between drains on the oil cooler shell.

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 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 air discharge temperature - see the gauge on the instrument panel. The
outlet oil temperature may be checked by installing a tee at the oil filter outlet.

Oil Cooler Temperature Differential (Water-Cooled Heat Exchanger) - The oil temperature differential
depends on the inlet water temperature and the water flow rate permitted by the water flow control valve
setting. The oil inlet temperature is approximately the same as the air discharge temperature - see the
gauge on the instrument panel. The oil outlet temperature may be checked by installing a tee at the oil
filter outlet.

Oil Cooler Water Pressure Differential (Water-Cooled Heat Exchanger) - The water pressure
differential through the heat exchanger will depend on the supply pressure, flow rate, cooler tube
cleanliness and outlet pressure. The inlet and outlet water pressure may be checked at the pipe fittings
supplied by the customer.

13-9-663 Page 62
SECTION 6
AIR FILTER

Figure 6-1 – HEAVY DUTY AIR FILTER

HEAVY-DUTY AIR FILTER (Figure 6-1) furnished as standard equipment on units with an enclosure is a
heavy-duty washable element dry type air filter. The air filter must receive proper maintenance if
maximum service is to be obtained from the unit. Establishing adequate and timely filter service is MOST
IMPORTANT. An improperly maintained air filter can cause a loss of compressor air delivery.

Filter Element - Service the air filter element when the ”CHANGE AIR FILTER” LED is illuminated.
Clean every 50 to 150 operating hours depending on dust conditions.

NOTICE
Use only genuine Gardner Denver air filter elements on Gardner Denver
compressor units. Genuine parts are available through your authorized
Gardner Denver distributor.
To service:

1. Remove the wingnut and pull out the filter element.

2. Visually inspect the element. If cleaning is not necessary, reinstall the filter element. If the element
requires cleaning, follow steps 3, 4 and 5.

3. Wash the element by soaking about 15 minutes in warm water with a mild non-sudsing detergent.
Rinse the element thoroughly with clean water; a hose may be used if the water pressure does not
exceed 40 psig (2.8 bar).

4. Inspect the element for ruptures or cracks in the pleated media; replace the element if any are found.
Inspect the gasket on the bottom (outlet end) of the element; replace the entire element if the gasket
is damaged. A spare element will keep down time to a minimum.

5. Allow the element to air dry COMPLETELY. Do not expose the element to heat over 150° F (66° C).
Install the element in the filter body and fasten securely with the wing nut.

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Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use
solvents other than water. Improper cleaning may damage the element.

NOTICE
Never operate the unit without the element. Never use elements that are
damaged, ruptured or wet. Never use gaskets that won't seal. Keep spare
elements and gaskets on hand to reduce downtime. Store elements in a
protected area free from damage, dirt and moisture. Handle all parts with care.

Filter Element Life - The element should be replaced after six (6) cleanings or if:

1. Visual inspection indicates a rupture, crack or pin hole in the pleated media. Inspection should be
done by placing a bright light inside the element.

2. Pressure drop through a filter with a freshly cleaned element is below three (3) inches (76 mm) of
water with the compressor running at full load - this would indicate a rupture or crack.

Inlet Tube - Inspect the inlet screen and tube for dirt accumulation each time the filter is serviced. Clean
the tube when required by ramming a clean dry cloth through the tube. Wipe the inside of the filter body
to remove any dirt falling from the inlet tube before reinstalling the element.

Causes of short element life include: severe dust conditions, infrequent servicing, improper cleaning, or
contamination by oil or chemical fumes.

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SECTION 7
COUPLING

Figure 7-1 – INSTALLATION OF COUPLING CUSHIONS

Rotating machinery can cause personal injury or death. Turn the unit
completely off, open the main disconnect, lockout and tagout before servicing
the coupling.

COUPLING - The motor and compressor are direct connected by a resilient type flexible coupling with a
single cushion. The coupling does not require lubrication.

If maintenance on mating parts is required, reassemble coupling as follows:

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ASSEMBLY OF COUPLING ONTO THE AIREND AND MOTOR (Figure 7-1).

NOTICE
Elements with non-uniform cross sections must be mounted with the rotation
arrow on the coupling the same direction as the rotation arrow on the airend.
Incorrect rotation will greatly decrease the torque carrying capacity of the
coupling.

1. Slide coupling halves over shaft extensions. Lock compressor half (half with element pre-bolted to it)
down with set screw.
2. Assemble the motor to the compressor.
3. Working through the coupling guard opening, slide motor half into compressor half.
4. Place the supplied hardened washers under the cap screw heads and torque the screws down to the
given specification. Keep the surfaces between the steel bushing in the elastomeric element, the
hardened washer and the cap screw head free from dirt and apply a light oil or grease film to both
sides of the hardened washer. This is very important since it will significantly reduce the rubber
stresses around the metal bushings when torquing down the cap screws.
5. Check to see if element is centered between shaft ends. If element is centered, using the loctite
supplied with the coupling, lock all set screws to 50 ft-lbs. If element is not centered, unlock set
screws and slide coupling to center element between shaft ends and then, using the loctite supplied
with the coupling, lock all set screws to 50 ft-lbs.

Rotating machinery can cause personal injury or death. Do not operate unit
with either the coupling guard or the collar removed. All bolts and screws must
be properly tightened.

ALIGNMENT - The coupling is permanently aligned by the flanges on the compressor and motor.

Replacing Element:

NOTICE
Elements with non-uniform cross sections must be mounted with the rotation
arrow on the coupling the same direction as the rotation arrow on the airend.
Incorrect rotation will greatly decrease the torque carrying capacity of the
coupling.

1. Remove cap screws and washers.

2. Remove the element between the hubs.

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3. Apply a light oil or grease film to both sides of the hardened steel washer. This is very important,
since it will significantly reduce the rubber stresses around the metal bushings when torquing down
the cap screws. Place the supplied hardened washers under the cap screw heads and torque the
screws down to the torque rating in the assembly instructions supplied with the coupling. Keep the
surfaces between the steel bushing in the elastomeric element, the hardened washer and the cap
screw head free from dirt.

4. Check to see if element is centered between shaft ends. If element is centered, using the loctite
supplied with the coupling, lock all set screws (must have loctite, supplied with the coupling, applied
to set screws) to 50 ft-lbs. If element is not centered, unlock the set screws and slide coupling to
center element between shaft ends and then, using the loctite supplied with the coupling, lock all set
screws to 50 ft-lbs.

Rotating machinery can cause personal injury or death. Do not operate unit
with either the coupling guard or the collar removed. All bolts and screws must
be properly tightened.

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SECTION 8
MAINTENANCE SCHEDULE
SERVICE CHECK LIST

Air Filter - Operating conditions determine frequency of service. If the “CHANGE AIR FILTER” message
is displayed, air filter requires servicing or changing. See “Air Filter", Section 6.

Oil Separator - Operating conditions determine frequency of service. If the “CHANGE SEPARATOR”
message is displayed, the oil separator element requires changing. See “Compressor Oil Separator” in
Section 5, for further details.

Motor Lubrication - Refer to Section 2, and Maintenance Schedule Chart, page 69.

Every 8 Hours Operation

1. Check the reservoir oil level - add oil if required. See Section 5. If oil consumption is high, refer to
“Excessive Oil consumption, page 71. DO NOT MIX LUBRICANTS.

2. Observe if the unit loads and unloads properly.

3. Check discharge pressure and temperature.

4. Check Panel LED’s for advisories.

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 the oil filter element.

Every 8000 Hours Operation

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


FREQUENTLY (refer to “Oil Change Interval”, page 52). Flush system if required.

Every Year

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

2. Check shutdowns for proper operation.

13-9-663 Page 68
MAINTENANCE SCHEDULE

Maintenance Action
As Indicated by Every Every Every Every
AutoSentry Every 8 125 1000 8000 * Year
Controller Hours Hours Hours Hours
Change Air Filter ................................................................ •
Change Oil Separator ....................................................... •
Check Reservoir Oil Level ................................................. •
Check for Proper Load/Unload........................................... •
Check Discharge Pressure/Temp ...................................... •
Check Dirt Accumulation on Cooler ................................... •
Change Oil Filter Element .................................................. • •
Change Compressor Lubricant (AEON 9000 SP) * ........... • •

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

* See Oil Change Interval Chart, Figure 5-7, page 53, for specific lubricant life.

13-9-663 Page 69
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
heaters tripped . cause of overload.
4. Pressure in reservoir. 4. Inspect blowdown valve.
5. Read error message on 5. Take appropriate action.
control panel See Manual 13-9-653.
6. Remote Contact is open 6. Replace switch or jumper.
(terminals 6 & 9).

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


stops after a short time temperature. Temperature,” this
section.
2. High discharge 2. Replace switch
temperature switch
malfunction.
3. Blown fuse in starter/ 3. Replace fuse (investigate
control box. if fuses continue to blow).
4. Motor starter overload 4. Reset and investigate
heaters trip. cause of overload.

Compressor does not 1. Improperly adjusted 1. Refer to Manual 13-9-653


unload (or load) control. 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. Blowdown valve 4 Repair, clean or replace
malfunction. 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.

13-9-663 Page 70
SYMPTOM POSSIBLE CAUSE REMEDY

Compressor starts too 1. Wye Delta switch time set 1. Contact your Champion
slowly too long. 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. Leaks in the compressed 4. Check for leaks, fix any
air system. leaks found.
5. Aftercooler is frozen 5. Thaw out. This machine
cannot operate in
temperatures below 32° F
(0° C).
6. Unload pressure adjusted 6. Adjust the unload
too low. pressure. See Manual
13-9-653.

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


consumption lines. section.
2. Oil leaks at all fittings and 2. Tighten or replace fittings
gaskets. or gaskets.
3. Shaft seal leaking. 3. Replace shaft seal.

High discharge air 1. Thermostatic mixing valve 1. Repair or replace valve.


temperature stuck open.
2. Dirty or clogged cooler 2. Clean cooler.
face.
3. Insufficient cooling air flow 3. Provide unrestricted
supply of cooling air.
4. Clogged oil filter or cooler 4. Replace filter or clear
(interior) cooler.
5. Low compressor oil. 5. Add oil to proper level.

13-9-663 Page 71
SYMPTOM POSSIBLE CAUSE REMEDY

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 4000 or 9000 SP
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.

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.

13-9-663 Page 72
For additional information contact your local representative or
Gardner Denver Compressor Division,
1800 Gardner Expressway, Quincy, Illinois 62305

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
Sales and Service in all major cities.
N01 Operating & Maintenance Data Dossier

CAPÍTULO 2:

User Manual AIRSMART® COMM module


13-17-604
Version: 02
October 2, 2009

AIRSMART™
CONTROLLER
COMM
MODULE

USER’S
MANUAL
WARNING – PROHIBITION – MANDATORY LABEL INFORMATION
Gardner Denver positive displacement blowers 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
blower 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 High Voltage – Hazard of Shock, Burn or Death
Impeller Blade Present Until Electrical Power is Removed

Cutting of Finger or Hand Hazard – Rotating Fan


Entanglement of Fingers or Hand – Rotating Shaft
Blade

13-17-604 Page 1
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 Gas 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

Lockout Electrical Equipment in De-Energized


Do Not Operate Blower with Guard Removed
State

Do Not Lift Equipment with Hook – No Lift Point Loud Noise Hazard – Wear Hearing Protection

Read the Operator’s Manual Before Proceeding


Handle Package at Forklift Points Only
with Task

13-17-604 Page 2
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, belt drive, etc.

• Disconnect the blower unit from its power source, lockout and tag out 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 blower 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 tag out 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 blower 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.

13-17-604 Page 3
Table of Contents

1 General Information ................................................................................................................................. 5


1.1 AirSmart Communications Module Features .................................................................................... 5
2 Communications Module Installation..................................................................................................... 6
3 AirSmart Controller Menus...................................................................................................................... 9
3.1 Operational Menus............................................................................................................................... 9
3.2 Adjustment Menus ............................................................................................................................. 13
4 Using The Real Time Clock ................................................................................................................... 26
4.1 Programming the Real Time Clock .................................................................................................. 26
4.2 Programming Start/Trough Times.................................................................................................... 28
4.3 Real Time Clock Battery.................................................................................................................... 30
5 Sequencing ............................................................................................................................................. 31
5.1 Sequencing Operation (Compressor application).......................................................................... 31
5.2 Sequencing Operation (Blower application) ................................................................................... 32
5.3 Install Pressure Transducers............................................................................................................ 34
5.4 Configure Controller I/O Map............................................................................................................ 37
5.5 Install Communications Network ..................................................................................................... 38
6 Remote Monitoring................................................................................................................................. 42
6.1 Modbus RTU over Serial Line ........................................................................................................... 42
6.2 Modbus RTU over UDP/IP ................................................................................................................. 43
6.3 Modbus Address Map (Compressor application)........................................................................... 44
6.4 Modbus Address Map (Blower application) .................................................................................... 59

13-17-604 Page 4
1 General Information
The AirSmart™ Controller was designed for use in the Gardner Denver Global Line of variable speed, rotary
screw air compressors and positive displacement blowers. The AirSmart™ Controller is also capable of
controlling fixed speed air compressors and blower which use traditional motor starters. The microprocessor-
based unit can control up to three Variable Frequency motor Drives (VFDs) while monitoring all necessary
temperature and pressure points in order to safely operate the machine and satisfy user air demand. The
Control Panel displays a comprehensive overview of the machine status and allows easy access to
operational parameters such as pressure set points, alarm set points and language selection.

The AirSmart Communications Module is an extension of the AirSmart Controller, which provides a means of
sequencing multiple compressors or blowers together so that they may act as one machine. The AirSmart
Communications Module also provides the ability to monitor machine operation from a remote location
through serial and Ethernet connections. Finally, the AirSmart Communications Module can start and stop a
machine up to seven different times using a programmable week clock.

1.1 AirSmart Communications Module Features

9 Easy Installation.
9 Battery-backed real time clock.
9 Week clock timer with seven programmable start/stop times.
9 Sequencing control for up to eight compressors or blowers.
9 Two additional pressure transducer inputs for system pressure.
9 Remote monitoring through RS-232 serial port on 9-pin D-Sub connector.
9 Remote monitoring through IEEE 802.3 100 megabit Ethernet port on RJ-45 connector.

13-17-604 Page 5
2 Communications Module Installation
The AirSmart Communication Module is simple to install. Follow the steps below to attach the
Communications Module to the AirSmart Controller.

1. Step 1 – Remove all power from the compressor or blower package. Make sure the electrical
disconnect is OFF AND LOCKED OUT in accordance with the lockout/tagout procedure. After power
has been removed, open the control box to gain access to the AirSmart Controller.

Failure to observe lockout/tagout procedures can cause injury or death!

Step 2 – Remove the rubber plug on the enclosure of the AirSmart Controller to expose the expansion
connector as seen in Figure 1 and Figure 2.

Figure 1 - Remove Rubber Cover – Value Controller

13-17-604 Page 6
Figure 2 – Remove Rubber Cover – Full Controller

Note – The AirSmart Controllers shown in the photos are not installed in a machine. It is NOT necessary to
remove the AirSmart Controller from the machine to install the Communications Module.

Step 3 – Inset the connector protruding from the backside of the Communications Module into the expansion
connector on the AirSmart controller, as seen in Figure 3, and press into place. Do not force the connectors
together; the two pieces should fit together easily.

Figure 3 - Insert Comm Module Connector

Step 4 – Secure the Communications Module in place by tightening the captive screw with a #2 Phillips
screwdriver as seen in Figure 4 below.

13-17-604 Page 7
Figure 4 - Tighten Captive Screw

Step 5 – Be sure to read all sections below for proper configuration of the AirSmart Communications Module.

13-17-604 Page 8
3 AirSmart Controller Menus

3.1 Operational Menus

The Operational Menus are available at all times - while the compressor or blower is running, stopped
or even while in a fault condition. To enter the Operational Menu trees press the Right or Left
buttons to access up to eight different menus. Once the desired menu heading is shown in the
fourth line of the display, use the Up and Down buttons to access the individual items in
the selected menu, which are also shown in the fourth line of the display. If the Up or Down buttons
are not pressed within five seconds of pressing the Right or Left buttons, the fourth line of the display
will return to its previous state.

It is not necessary to navigate back to the top of a particular menu in order to enter another menu.
Simply press the Right or Left buttons to go back to the heading of the current menu and
then use the Right or Left buttons again to find the desired menu heading as described above.

¾ Note: Advisory fault information is also shown in the fourth line of the display. If an advisory is
active and the fault condition has not been cleared, the Operational Menu text will be periodically
replaced by the advisory text.

¾ Note: Only the information associated with the Communications Module is shown below. For a
full listing of other menu items, refer to the AirSmart Controller User’s Manual, Gardner Denver
document 13-17-600 for the compressor application or IQ-7-200 for the blower application.

13-17-604 Page 9
13-17-604 Page 10
13-17-604 Page 11
3.1.1 Maintenance Info Menu
The Maintenance Menu gives the user access to the current status of all the maintenance counters
and system timers.

0 PSI 75°F
125 HRS AUTOMATIC
READY
MAINTENANCE INFO

1. ACM Firmware Version

When the AirSmart Communications Module (ACM) is installed, the version number of the
firmware loaded in the module is displayed as the next to last item in the Maintenance Info menu.

0 PSI 75°F
125 HRS AUTOMATIC
READY
V1.03 ACM

2. Time and Date

The last item in the Maintenance Info Menu is the current time and date kept by the battery
backed, real time clock on the Communications Module. The time and date can be changed
under the Time Adjust menu.

0 PSI 75°F
125 HRS AUTOMATIC
READY
07/04/10 12:59 MON

The date & time format reads as follows:

YY/MM/DD HH:MM DOW

Where:
YY = Year
MM = Month
DD = Date
HH = Hour (using 24 hour clock)
MM = Minute
DOW = Day of week

13-17-604 Page 12
3.2 Adjustment Menus

The Adjustment Menus are only available when the compressor or blower is stopped. To enter the
Adjustment Menu tree, press the Enter button and then press the Right or Left
buttons to access up to six different menus. Once the desired menu heading is shown in the second
line of the display, press the Enter button again to access that menu. Use the Up and
Down buttons to access the individual items in the selected menu, which are also shown in the
second line of the display.

It is not necessary to navigate back to the top of a particular menu in order to enter another menu.

Simply press the Stop/Reset button to go back to the heading of the current menu and then
use the Right or Left buttons again to find the desired menu heading as described above.

To completely exit from the Adjustment menus, 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 that have been made are still valid but will be lost
the next time the compressor is disconnected from main power.

¾ Note: Only the information associated with the Communications Module is shown below. For a
full listing of other menu items, refer to the AirSmart Controller User’s Manual, Gardner Denver
document 13-17-600 for the compressor application or IQ-7-200 for the blower application.

13-17-604 Page 13
13-17-604 Page 14
13-17-604 Page 15
3.2.1 Operation Adjustment Menu
The Operation Adjustment menu provides access to the parameters that control the basic operation
of the compressor or blower.

ADJUSTMENT MENU
OPERATION ADJUSTMENT

(SELECT SUB MENU)

1. Operating Mode

Under the Operation Adjustment menu is the operating mode. The controller can be set to one of
four operational modes.

AUTOMATIC: (Default mode) the compressor or blower uses its internal modulation algorithms
to control the operation of the machine. Refer to the appropriate AirSmart Users manual for
machine operation in Automatic mode (Gardner Denver document 13-17-600 for the compressor
application or IQ-7-200 for the blower application).

SEQUENCE: The compressor or blower operates similar to Automatic mode but is part of a
sequenced group of machines.

LOW DEMAND: (compressor application only – refer to Gardner Denver document 13-17-600).

CONSTANT: (compressor application only – refer to Gardner Denver document 13-17-600).

OPERATION ADJUSTMENT
OPERATING MODE
AUTOMATIC
(SELECT PARAMETER)

13-17-604 Page 16
2. Week Clock Control

The last item in the Operation Adjustment menu is the Week Clock Control function. When the
Week Clock Control is turned on, the compressor or blower can be started and stopped using the
seven programmable timers under the Time Adjust menu.

OPERATION ADJUSTMENT
WEEK CLOCK CONTROL
ON
(SELECT PARAMETER)

Default Value: OFF

Automatic starting of the compressor or blower can cause injury or death

13-17-604 Page 17
3.2.2 Sequence Adjustment Menu
The Sequence Adjustment menu provides access to the parameters that control the sequencing
operation of the compressor or blower. This menu is only visible if the AirSmart Communications
Module is installed.

ADJUSTMENT MENU
SEQUENCE ADJUSTMENT

(SELECT SUB MENU)

1. Number of Sequence Units

The first item in the Sequence Adjust menu is the Number of Sequence Units, which specifies the
number of compressors or blower connected in a sequence group. For stand-alone operation,
this parameter is set to 1. When set to 1, all other sequence related items in the menu are not
visible.

SEQUENCE ADJUSTMENT
NUMBER OF SEQ UNITS
2 UNITS
(SELECT PARAMETER)

Min Value: 1
Max Value: 8
Default Value: 1

2. Unit Number

The next item in the Sequence Adjust menu is the Unit Number. A unique number must identify
each of the possible eight units in a sequence group. The primary Lead, which is always the
largest capacity compressor or blower in the group, must be programmed as Unit Number 1.

SEQUENCE ADJUSTMENT
UNIT NUMBER
1
(SELECT PARAMETER)

Min Value: 1
Max Value: 8
Default Value: 1

13-17-604 Page 18
3. Sequence Group

The next item in the Sequence Adjust menu is the Sequence Group, which simply identifies a
group of up to eight machines for remote monitoring purposes. All compressors or blowers within
a group must be set to the same group.

SEQUENCE ADJUSTMENT
SEQUENCE GROUP
SEQUENCE GROUP A
(SELECT PARAMETER)

Min Value: SEQUENCE GROUP A


Max Value: SEQUENCE GROUP H
Default Value: SEQUENCE GROUP A

4. Transfer Interval

The next item in the Sequence Adjust menu is the Transfer Interval. This parameter controls how
often the group Lead is transferred to a dormant compressor or blower during periods of low
demand. This parameter is referenced to the Total Hour meter value as seen in the second line
of the display or the Maintenance Info menu. A value of zero will disable this feature.

SEQUENCE ADJUSTMENT
TRANSFER INTERVAL
4 HRS
(SELECT PARAMETER)

Min Value: 0 Hours


Max Value: 5000 Hours
Default Value: 4 Hours

5. Lag Start Delay

The next item in the Sequence Adjust menu is the Lag Start Delay timer value. This parameter
controls the delay between The Transfer Load Increment trigger (see below) and the starting of
the next available compressor or blower during periods of increasing demand. The Lag Start
Delay time is reset and begins to count down whenever a dormant machine is brought on line. If
the Lag Start Delay timer expires before the next available unit comes on line, there will be no
delay during startup.

SEQUENCE ADJUSTMENT
LAG START DELAY
15 SECONDS
(SELECT PARAMETER)

Min Value: 1 Second


Max Value: 60 Seconds
Default Value: 15 Seconds

13-17-604 Page 19
6. Transfer Load Decrement

The next item in the Sequence Adjust menu is the Transfer Load Decrement value, which
controls the load level the group must reach before dropping a compressor or blower from the
sequence group during periods of decreasing demand.

SEQUENCE ADJUSTMENT Note: Do not adjust this parameter


TRANSFER LOAD DEC unless it is absolutely necessary! The
35 % factory default value will provide the
(SELECT PARAMETER) most efficient operation of the sequence
group.

Min Value: 20%


Max Value: 100%
Default Value: 35% (variable speed compressor), 40% (variable speed blower),
100% (fixed speed compressor or blower)

7. Transfer Load Increment

The next item in the Sequence Adjust menu is the Transfer Load Increment value, which controls
the load level the group must reach before adding a compressor or blower to the sequence group
during periods of increasing demand.

SEQUENCE ADJUSTMENT Note: Do not adjust this parameter


TRANSFER LOAD INC unless it is absolutely necessary! The
80 % factory default value will provide the
(SELECT PARAMETER) most efficient operation of the sequence
group.

Min Value: 70%


Max Value: 100%
Default Value: 80% (variable speed compressor or blower),
100% (fixed speed compressor or blower)

8. Baud Rate

The next item in the Sequence Adjust controls the Baud Rate of the RS-232 port (9-pin D-Sub
connector) used for remote monitoring.

SEQUENCE ADJUSTMENT
BAUD RATE
9600
(SELECT PARAMETER)

Baud Rate Values: 1200, 2400, 4800, 9600, 19200


Default Value: 9600

13-17-604 Page 20
9. Sequence Hour Offset

The next item in the Sequence Adjust menu is the Sequence Hour Offset. This parameter value
is added to the Total Hour meter and allows two machines with large differences in Total Hour
meter values to transfer the sequence lead using the Transfer Interval Timer.

SEQUENCE ADJUSTMENT
SEQUENCE HOUR OFFSET
0 HRS
(SELECT PARAMETER)

Min Value: 0 Hours


Max Value: 87600 Hours
Default Value: 0 Hours

10. Release Pressure (Used in blower application only)

The next item in the Sequence Adjust menu is the Release Pressure value, which controls when
a blower will be released from the sequence group during periods of decreasing demand. This
parameter is used in an equivalent fashion as the Unload Pressure value in the compressor
application.

SEQUENCE ADJUSTMENT
RELEASE PRESSURE
0 HRS
(SELECT PARAMETER)

Min Value: 0 PSI


Max Value: Blower package dependant
Default Value: Blower package dependant

11. IP Address

The next four items in the Sequence Adjust menu make up the four octets (eight bit segments) of
the IP (Internet Protocol) Address used by the Ethernet port for remote monitoring. The
Communications Module does not support Dynamic Host Configuration Protocol (DHCP) so it is
necessary for each unit to be programmed with a unique IP address.

The LSB (Least Significant Byte) of the IP address also doubles as the Modbus RTU packet
address when using the RS-232 port for remote monitoring.

SEQUENCE ADJUSTMENT
IP NNN.-.-.-
255
(SELECT PARAMETER)

Min Value: 0.0.0.0


Max Value: 255.255.255.255

13-17-604 Page 21
12. Sub-Network Mask

The next four items in the Sequence Adjust menu make up the four octets (eight bit segments) of
the Sub-Network (Subnet) Mask used by the Ethernet port for remote monitoring. Contact the
network administrator to obtain the value for the Subnet Mask.

SEQUENCE ADJUSTMENT
SUBNET NNN.-.-.-
255
(SELECT ARAMETER)

Min Value: 0.0.0.0


Max Value: 255.255.255.255

13. Gateway Address

The next four items in the Sequence Adjust menu make up the four octets (eight bit segments) of
the Gateway Address used by the Ethernet port for remote monitoring. A gateway is a device
(usually a computer) that serves as an access point to other networks outside the local network.
Contact the network administrator to obtain the network Gateway Address. A gateway address is
only necessary for communications beyond the local network.

SEQUENCE ADJUSTMENT
GATEWAY NNN.-.-.-
255
(SELECT PARAMETER)

Min Value: 0.0.0.0


Max Value: 255.255.255.255

13-17-604 Page 22
3.2.3 Time Adjustment Menu
The Time Adjustment menu provides access to the parameters that control the real time clock
operation of the compressor or blower. This menu is only visible if the AirSmart Communications
Module is installed.

ADJUSTMENT MENU
TIME ADJUST

(SELECT SUB MENU)

1. Set Year

The first item in the Time Adjust menu is the year setting for the real time clock.

TIME ADJUST
SET YEAR (20XX)
2005
(SELECT PARAMETER)

Min Value: 2000


Max Value: 2063

2. Set Month

The next item in the Time Adjust menu is the month setting for the real time clock.

TIME ADJUST
SET MONTH (1 – 12)
1
(SELECT PARAMETER)

Min Value: 1
Max Value: 12

3. Set Date

The next item in the Time Adjust menu is the date setting for the real time clock.

TIME ADJUST
SET DATE (1 – 31)
1
(SELECT PARAMETER)

Min Value: 1
Max Value: 31

13-17-604 Page 23
4. Set Time

The next item in the Time Adjust menu is the time setting for the real time clock.

TIME ADJUST
SET TIME
SUN:00:00 (24)
(SELECT PARAMETER)

Day of Week range: SUN, MON, TUE, WED, THU, FRI, SAT
Hour range: 00 to 23
Minute range: 00 to 59

5. Week Clock Mode (Used in compressor application only)

The next item in the Time Adjust menu is the Week Clock Mode setting which controls how the
seven start/stop timers are used in the compressor application. Refer to the AirSmart User’s
manual for the compressor application (Gardner Denver document 13-17-600) for more
information about using the secondary pressure settings.

TIME ADJUST
WEEK CLOCK MODE
COMPRESSOR ON/OFF
(SELECT PARAMETER)

Min Value: COMPRESSOR ON/OFF


Max Value: SECONDARY PRESSURES

13-17-604 Page 24
6. Start/Through Times 1 through 7

The next fourteen items in the Time Adjust menu make up the week clock for starting and
stopping the compressor or blower up to seven times inside a period of one week. In order for
the week clock to be active, Week Clock Control under the Operation Adjustment menu must set
to ON. The START and THROUGH time parameters must be programmed as a pair, the
compressor will not start at a designated START time if the associated THROUGH time
parameter has not also been programmed.

TIME ADJUST
START ON #1
MON:08:00 (24)
(SELECT PARAMETER)

TIME ADJUST
THROUGH #1
MON:16:59 (24)
(SELECT PARAMETER)

Day of Week range: SUN, MON, TUE, WED, THU, FRI, SAT
Hour range: 00 to 23
Minute range: 00 to 59

The THROUGH time parameter tells the compressor to run through the programmed time and
then stop. If the compressor is programmed to run through 16:59, as shown in the display above,
the machine will actually stop at 17:00 (5:00 PM).

The concept of “through” time is used instead of stop time so that it is possible to have run
periods that span from the week’s end through the week’s beginning. For example, with a
START / THROUGH time of SAT: 23:00 / SUN: 00:59, the compressor will run exactly 120
minutes centered around midnight on Saturday

13-17-604 Page 25
4 Using The Real Time Clock
The AirSmart Communications Module has a built-in battery-backed real time clock, which can be used to
automatically start and stop a compressor or blower up to seven times inside of one week. The
programmable week clock is similar that found in a home video recorder and used to record your favorite
television programs. Follow the simple steps below for setting up the programmable week clock.

4.1 Programming the Real Time Clock

Program the year, month, date and time parameters using the first four pages of the Time Adjust menu
as shown above. Once these values are set, they do not need to be entered again, even if the power
is removed from the machine.

4.1.1 Program the Year

1. Press the Enter key on the display to access the Adjustment menu tree.
2. Use the Left or Right keys to navigate to the Time Adjust menu.
3. Press the Enter key to enter the Time Adjust menu.
4. The Year parameter will be the first item in the Time Adjust menu. Press the Enter key to
edit the Year.
5. Use the Plus and Minus keys the change the value of each digit.
6. Use the Left or Right keys to select individual digits.
7. Press the Enter key to program the new Year value.

4.1.2 Program the Month

1. Press the Down key once to access the Month parameter.


2. Press the key to edit the Month.
3. Use the Plus and Minus keys the change the parameter value.
4. Press the key to program the new Month value.

4.1.3 Program the Date

1. Press the Down key once to access the Date parameter.


2. Press the Enter key to edit the Month.
3. Use the Plus and Minus keys the change the parameter value.
4. Press the Enter key to program the new Date value.

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4.1.4 Program the Time

1. Press the Down key once to access the Time parameter.


2. Press the Enter key to edit the Time.
3. Use the Plus and Minus keys the change the day of the week or the value of each
digit.
4. Use the Left or Right keys to select individual digits.
5. Press the Enter key to program the new Date value.

6. Press the Stop/Reset key twice to return to the Main display screen.

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4.2 Programming Start/Trough Times

The Start/Trough times control when the compressor or blower will and stop during a period of one
week. The next fourteen parameters after the Year, Month Date and Time are the seven Start/Through
time pairs.

¾ Important Note: The START and THROUGH time parameters must be programmed as a pair, the
compressor will not start at a designated START time if the associated THROUGH time parameter
has not also been programmed.

4.2.1 Program the Start Time

1. Press the Enter key on the display to access the Adjustment menu tree.
2. Use Left or Right keys to navigate to the Time Adjust menu.
3. Press the Enter key to enter the Time Adjust menu.
4. The Year parameter will be the first item in the Time Adjust menu. Press the Down key until
Start Time #1 shows in the display. If the Real Time Clock has just been set, you will only have
to press the Down key once.
5. Press the Enter key to edit the Start time.
6. Use the Plus and Minus keys the change the day of the week or the value of each
digit.
7. Use the Left or Right keys to select individual digits.
8. Press the Enter key to program the new Start time.

4.2.2 Program the Through Time

1. Press the Down key once to access the Through time #1 parameter.
2. Press the Enter key to edit the Through time.
3. Use the Plus and Minus keys the change the day of the week or the value of each
digit.
4. Use the Left or Right keys to select individual digits.
5. Press the Enter key to program the new Date value.

7. Press the Stop/Reset key twice.


8. Press the Enter key to permanently save the programmed parameters in the controller’s
memory.

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4.2.3 Enable Week Clock Control
After programming the Start and Through times under the Time Adjust menu, it will be necessary to
enable the Week Clock so that it may control the compressor or blower. The Week Clock enable is
found under the Operation Adjustment menu.

Automatic starting of the compressor or blower can cause injury or death

1. Press the Enter key on the display to access the Adjustment Menu tree.
2. Use Left or Right keys to navigate to the Operation Adjustment menu.
3. Press the Enter key to enter the Operation Adjustment menu.
4. The Language setting will be the first item in the Operation Adjustment menu. Press the Up
key once to get to Week Clock Control.
5. Press the Enter key to edit the Week Clock Control parameter.
6. Use the Up or Down keys to change the parameter from OFF to ON.
7. Press the Enter key to save the new setting.

8. Press the Stop/Reset key twice.


9. Press the Enter key to permanently save the programmed parameters in the controller’s
memory.

10. To start the compressor or blower under Week Clock control, press the Run key.

When the compressor is enabled to run under Week Clock control and the Run key has been
pressed, the display will appear as shown below. The third line of the display will show the next start
time and the fourth line of the display will show the current time.

0 PSI 75°F
125 HRS AUTOMATIC
START ON THU 08:00
08/12/15 13:45 WED

¾ Important Note: If the Week Clock Control is turned ON and there are no Start/Through times
programmed, the machine will not start when the Run key is pressed. Be sure that the
Week Clock Control is turned OFF to operate the compressor or blower normally.

¾ Important Note: The Run and Stop/Reset keys will function normally when the Week
Clock is operating inside of a Start/Through time window.

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4.3 Real Time Clock Battery

The Real Time Clock on the AirSmart Communications Module is equipped with a backup battery,
which enables the clock to keep time when the no power is applied to the AirSmart Controller. The
battery that has been installed is a type CR2016 Lithium coin battery and has an expected life of ten
years.

Should the battery become exhausted (clock no longer keeps time when power removed), it can be
removed from its socket and replaced. First remove power from the compressor or blower. Next
remove the Communications Module from the AirSmart Controller and replace the battery located on
the backside of the module. Be sure to follow the instructions for replacement silk-screened onto the
module circuit board cover.

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5 Sequencing
The AirSmart Communications Module will allow up to eight compressors or blowers to be connected together
in a sequence group. The Lead machine of the group will seamlessly start and stop other machines as
necessary to meet the plant air demand. In order to equalize machine run time during periods of low system
demand, the Lead machine can also trade with a dormant machine in the group.

A proper sequencing installation requires two or more compressors or blowers piped into a common air
delivery system and connected as described in the sections to follow. For best results, connect each machine
directly to a common manifold or receiver without any intervening dryers, filters or other restrictions. If any
equipment must be installed on individual compressors or blowers, select equipment with as minimal of a
pressure drop as possible. If filters are installed, establish a maintenance procedure to prevent clogged filters
from upsetting the system. There should be no check valves or other devices, which isolate any member
from the air system. During operation, be sure that any unit is taken off line before closing its service valve.

For compressor networks, the receiver should be sized to prevent excessive drops or rapid rises in pressure
during operation. Note that “receiver” applies to the entire storage volume of a physical receiver and the air
delivery pipe network installed in the plant. Sequenced systems of Gardner Denver VS/VST Series variable
speed air compressors work best when the receiver size is at lest one-half gallon for the rated CFM of the
entire sequence group.

All standard practices common to sound air compressor and blower installations such as proper sizing of
piping, proper electrical supply, conductor sizing and grounding should be observed.

5.1 Sequencing Operation (Compressor application)

Each member compressor in a sequence group operates similarly to the Automatic mode of operation.
It will start, load, modulate, unload, blowdown and automatically stop as necessary to meet the system
demand for air. There are several differences, however, when running in the Sequence mode.

Normally, in Automatic mode, each compressor would respond to pressure changes seen at the
discharge of each individual machine. In Sequence mode, each compressor responds to the system
pressure as seen by the Lead compressor in the group. Each Lag compressor will be commanded by
the group Leader to run the same percentage of full capacity. In other words, the Lag compressors do
not use their own internal modulation algorithm to govern their speed. Instead, the Lead compressor
dictates the operating speed of all compressors in the group based on the pressure seen at the system
sample point on the receiver or manifold.

The Lead compressor will automatically show the system pressure in the fourth line of the display
unless the operator chooses a different parameter from the front panel or an Advisory Fault needs to
be displayed by the controller. The following sections describe the different possible scenarios during
sequencing operation.

¾ Important Note: It is very important that the Target, Load and Unload pressure values under the
Operation Adjustment menu are programmed identically in all members of a sequence group.

¾ Important Note: Fixed speed compressors that are equipped with an AirSmart Controller and a
Communications Module can be added to any sequencing network, however, they will always
operate at full speed (100%) when commanded to start.

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5.1.1 Increasing Air Demand
As the plant demand for air increases, the speed of the Lead compressor will also increase to meet
the demand. When the speed of the Lead compressor reaches the Transfer Load Increment value
(usually 80%), it will not increase any further. If the demand continues to increase, the system
pressure will drop below the Load Pressure value programmed into the Lead compressor and the
next Lag compressor is brought on-line provided that the Lag Start Delay timer has expired. The
Lag Start Delay timer begins counting down as soon as the Lead (or most recently started Lag)
compressor begins modulation. As each Lag compressor is started, the operating speed of the
sequence group decreases due to the increased air capacity of the sequence group. Each
compressor in the group will be commanded by the Leader to run the same percentage of individual
full speed regardless of compressor size. If the air demand continues to increase, the Lead will start
another Lag machine when the group speed reaches the Transfer Load Increment value. When all
possible Lag compressors are running, the speed of the sequence group is allowed to rise above the
Transfer Load Increment value up to 100%.

5.1.2 Decreasing Air Demand


As the plant demand for air decreases, the speed of the sequence group will also decrease down to
the Transfer Load Decrement value (usually 35%) and freeze. If the demand for air continues to
decrease, the system pressure will increase until it reaches the Unload Pressure value programmed
into the Lead compressor at which time the Lag machine with the largest Unit Number will be
commanded to stop. As each Lag compressor is stopped, the operating speed of the sequence
group increases due to the loss of total air capacity in the sequence group. As the air demand
continues to decrease, the Lead will drop off all Lag compressors in a similar fashion until only the
Lead compressor remains. After all Lag compressors have stopped, the Lead machine is allowed to
operate below the Transfer Load Decrement level down to 20%.

5.1.3 Transfer of Lead Control


The transfer of lead control of the sequence group can occur in three different ways. The first method
of control transfer occurs when the Transfer Interval parameter under the Sequence Adjust menu is
set to an hour value other than zero. During long periods of low plant air demand when
compressor(s) in the group are sitting idle, the Lead compressor will transfer its control to an equal
sized Lag compressor after the Transfer Interval time elapses.

The second method of control transfer occurs when the operator presses the Stop/Reset button on
the display panel stopping the current Lead compressor. In this case, control is transferred to the
compressor with the next largest Unit Number, regardless of compressor size.

The third method of control transfer occurs when a shutdown fault stops the current Lead
compressor. In this case, control is transferred to the compressor with the next largest Unit Number,
regardless of compressor size.

5.2 Sequencing Operation (Blower application)

Each member blower in a sequence group operates similarly to the Automatic mode of operation. It
will start, load, and automatically stop (lead machine will not stop) as necessary to meet the system
demand for air. There are several differences, however, when running in the Sequence mode.

Normally, in Automatic mode, each blower would respond to pressure changes seen at the discharge
or inlet of each individual machine. In Sequence mode, each blower responds to the system pressure
as seen by the Lead blower in the group. Each Lag blower will be commanded by the group Leader to
run the same percentage of full capacity. In other words, the Lag blowers do not use their own internal

13-17-604 Page 32
modulation algorithm to govern their speed. Instead, the Lead blower dictates the operating speed of
all blowers in the group based on the pressure seen at the system sample point on the manifold.

¾ Important Note: It is very important that the Target and Release pressure values under the
Operation Adjustment and Sequence Adjustment menus are programmed identically in all members
of a sequence group.

¾ Important Note: Fixed speed blowers that are equipped with an AirSmart Controller and a
Communications Module can be added to any sequencing network, however, they will always
operate at full speed (100%) when commanded to start.

5.2.1 Increasing Air Demand


As the plant demand for air increases, the speed of the Lead blower also increases to meet the
demand. When the speed of the Lead blower reaches the Transfer Load Increment value (usually
80%), it will not increase any further. If the demand continues to increase, the system pressure will
drop below the Target Pressure value programmed into the Lead blower and the next Lag blower is
brought on-line provided that the Lag Start Delay timer has expired. The Lag Start Delay timer
begins counting down as soon as the Lead (or most recently started Lag) blower begins modulation.
As each Lag blower is started, the operating speed of the sequence group decreases due to the
increased air capacity of the sequence group. Each blower in the group will be commanded by the
Leader to run the same percentage of individual full speed regardless of blower size. If the air
demand continues to increase, the Lead will start another Lag machine when the group speed
reaches the Transfer Load Increment value. When all possible Lag blowers are running, the speed of
the sequence group is allowed to rise above the Transfer Load Increment value up to 100%.

5.2.2 Decreasing Air Demand


As the plant demand for air decreases, the speed of the sequence group will also decrease down to
the Transfer Load Decrement value (usually 40%) and freeze. If the demand for air continues to
decrease, the system pressure will increase until it reaches the Release Pressure value
programmed into the Lead blower at which time the Lag machine with the largest Unit Number will
be commanded to stop. As each Lag blower is stopped, the operating speed of the sequence group
increases due to the loss of total air capacity in the sequence group. As the air demand continues to
decrease, the Lead will drop off all Lag blowers in a similar fashion until only the Lead blower
remains. After all Lag compressors have stopped, the Lead machine is allowed to operate below the
Transfer Load Decrement level down to 20%.

5.2.3 Transfer of Lead Control


The transfer of lead control of the sequence group can occur in three different ways. The first method
of control transfer occurs when the Transfer Interval parameter under the Sequence Adjust menu is
set to an hour value other than zero. During long periods of low plant air demand when blower(s) in
the group are sitting idle, the Lead blower will transfer its control to an equal sized Lag blower after
the Transfer Interval time elapses.

The second method of control transfer occurs when the operator presses the Stop/Reset button on
the display panel stopping the current Lead blower. In this case, control is transferred to the blower
with the next largest Unit Number, regardless of blower size.

The third method of control transfer occurs when a shutdown fault stops the current Lead blower. In
this case, control is transferred to the blower with the next largest Unit Number, regardless of blower
size.

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5.3 Install Pressure Transducers

Figure 5 – Sequencing Connections

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5.3.1 Install System Pressure Transducer
In order for the Communications Module to properly control the sequencing of multiple compressors
or blowers, it requires an additional pressure reading from the air system receiver or manifold. Each
member of the sequence group is to become a Lead machine is required to have a system pressure
transducer so that lead control transfers can occur.

The transducer is installed into either the roof or the side of the control box or package. A typical
compressor installation is shown in Error! Reference source not found. below. For a typical blower
installation, see Figure 7. Refer to the Operators Manual of the machine being sequenced for the
proper location. Item 2, in the figure below, is a weatherproof bulkhead (GDI Part No. 64EB368) in
which the pressure transducer, item 3 (GDI Part No. VP1011577 for a compressor or VP1033786 for
a blower) is installed. In addition, a ¼ inch pressure sample tube is connected from the plant air
system receiver or manifold to the system pressure transducer in the control box.

Figure 6 – Typical System Pressure Transducer Installation (Compressor)

The cable harness from the system pressure transducer is connected to pins 1 through 3 of
connector P17 on the Communications Module as shown in Figure 5Error! Reference source not
found. above.

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Figure 7 – Typical System Pressure Transducer Installation (Blower)

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5.3.2 Move Plant Pressure Transducer Connection
The Plant Pressure transducer, which is already installed in the compressor or blower, must also be
connected to the Communications Module in order to eliminate the error in the signal when used in a
sequenced system. The Plant Pressure transducer is normally connected to pins 4 through 6 of
connector P5 on a Value Controller or pins 7 through 9 of connector P14 on a Full-sized Controller.
Move the Plant Pressure transducer connection to pins 4 through 6 of P17 on the Communications
Module as shown in Figure 5 above. Be sure to observe the wire colors shown in Figure 5.

5.4 Configure Controller I/O Map

After installing the pressure transducers, the AirSmart Controller must be configured to read the new
signals. Follow the steps below to configure the I/O map in the controller.

1. Press the Enter key on the display to access the Adjustment menu tree.
2. Use Left or Right keys to navigate to the Unit Setup Adjust menu.
3. Press the Enter key to enter the Unit Setup Adjust menu.
4. The Unit Password parameter will be the first item in the Unit Setup Adjust menu. Press the Enter
key to change the Password to 8412.
5. Use the Plus and Minus keys the change the value of each digit.
6. Use the Left or Right keys to select individual digits.
7. Press the Enter key to confirm the password value.

8. Press the Stop/Reset key to return to the Adjustment menu tree.


9. Press the Right key twice to navigate to the Prog I/O Adjust menu.
10. Press the Enter key to access the Prog I/O Adjust menu.
11. Press the Up key to navigate to the System Pres Analog Input address. The display should
read as shown below.

PROG I/O ADJUST


SYSTEM PRES
0 ANALOG IN
(SELECT PARAMETER)

12. Press the Enter key to change the System Pres Analog Input address to 113.
13. Use the Plus and Minus keys the change the value of each digit.
14. Use the Left or Right keys to select individual digits.
15. Press the Enter key to confirm the address value.
16. Press the Up key to navigate to the Plant Pres Analog Input address. The display should
read as shown below.(the I/O address shown may be different depending on machine type)

13-17-604 Page 37
PROG I/O ADJUST
PLANT PRES
35 ANALOG IN
(SELECT PARAMETER)

17. Press the Enter key to change the Plant Pres Analog Input address to 114
18. After changing the address, press the Enter key to confirm the address value.

19. Press the Stop/Reset key twice.


20. Press the Enter key to permanently save the programmed parameters in the controller’s
memory.

¾ Important Note: DO NOT change any other I/O address parameters or the controller and
compressor will not operate correctly.

5.5 Install Communications Network

The final step in the sequencing setup is to install the communications network so that the Lead
compressor or blower can communicate with and control the Lag machines. Error! Reference source
not found. shows a typical control box installation where item 1 is a weatherproof bulkhead (GDI Part
No. 24CA615) through which the network wires (Belden 3106A or equivalent – GDI Part No. 97J93)
may pass. Error! Reference source not found. above and Figure 10 below show the wire
connections to connector P19 on the Communications Module.

Figure 8– Serial (P18) and Network (P19) Connectors

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5.5.1 Dip Switch Settings
The communications module has eight DIP switches which configure the function of one of the analog
inputs and the RS-485 sequencing network terminations. The switches are located on the end of the
module behind a round plastic plug. The switches should be set as shown in the table and Figure 10
below.

Figure 9 – DIP Switch Positions

DIP Switch Function and Position


(Left to Right)
1 Configure analog input on P17, pins 4 – 6 as:
ON (down) - Thermistor input.
Note: DIP switch 2 must be OFF (up)
2 Configure analog input on P17, pins 4 – 6 as:
ON (down) - Pressure transducer input.
Note: DIP switch 1 must be OFF (up)
3 OFF (up) - Not used
4 OFF (up) - Not used
5 OFF (up) - Not used
6 Pull down for RS-485 differential negative.
ON (down) - Module is 1st in chain.
OFF (up) - Module is not 1st in chain.
7 Pull up for RS-485 differential positive.
ON (down) - Module is 1st in chain.
OFF (up) - Module is not 1st in chain.
8 Termination for RS-485 sequencing network.
ON (down) - Module is 1st or last in chain.
OFF (up) - Module is not 1st or last in chain.

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Figure 10 – Example of Sequencing Electrical Connections

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Figure 11 – Example of Sequencing Pressure Connections

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6 Remote Monitoring
Remote monitoring allows the user to observe the operation of the compressor or blower from a remote
location using the serial and/or Ethernet connection on the Communications Module. The serial port uses the
Modbus RTU protocol while the Ethernet port uses Modbus RTU over UDP/IP.

Important Note: The serial port and the Ethernet port should NOT be used at the same time.

6.1 Modbus RTU over Serial Line

The Modbus RTU protocol used on the serial port uses Function code 0x03 (03 decimal) to read all the
registers listed in the following pages. The Modbus address used to communicate with the
Communications Module is equal to the least significant byte of the IP address set in the Sequencing
Adjust menu. For more information about Modbus, the Modbus Application Protocol Specification can
be downloaded free of charge at www.Modbus-IDA.org.

The following shows an example of reading Registers 1001 – 1005 from the Communications Module.

Query

Field Name Decimal Hexadecimal


Slave Address IP Address LSB 0x--
Function Code 03 0x03
Starting Address High 03 0x03
Starting Address Low 233 0xE9
Number of Points High 00 0x00
Number of Points Low 05 0x05
CRC Low -- 0x--
CRC High -- 0x--

Response

Field Name Decimal Hexadecimal


Slave Address IP Address LSB 0x--
Function Code 03 0x03
Byte Count 10 0x0A
Data High (Addr 1001) 11 0x0B
Data Low (Addr 1001) 208 0xD0
Data High (Addr 1002) 04 0x04
Data Low (Addr 1002) 176 0xB0
Data High (Addr 1003) 05 0x05
Data Low (Addr 1003) 80 0x50
Data High (Addr 1004) 12 0x0C
Data Low (Addr 1004) 48 0x30
Data High (Addr 1005) 12 0x0C
Data Low (Addr 1005) 128 0x80
CRC Low -- 0x--
CRC High -- 0x--

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6.2 Modbus RTU over UDP/IP

The Modbus RTU protocol used on the Ethernet port is identical to that described in the serial port
section above except that the Modbus data packet is wrapped inside of a UDP datagram before being
sent over the network.

The Communications Module (server) automatically opens UDP port number 2001 for receiving data
packets from the client. The client, in turn, must open UDP port number 2000 to receive data from the
Communications Module. The Communications Module does not support Dynamic Host Configuration
Protocol (DHCP) so it is necessary for each unit to be programmed with a unique IP address.

The response time for the Communications Module over Ethernet will be determined mostly by network
traffic and how many network devices (switches, routers, etc.) the data must pass through. A typical
response time over a local network is around two seconds.

Figure 12 – Analog Input (P17) and Ethernet (P20) Connectors

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6.3 Modbus Address Map (Compressor application)

Address Parameter Units / Range / Description Data Type Access


0x0000 = ADJUSTMENT
0x0100 = AUTO RESTART
0x0200 = SHUTDOWN
0x0300 = READY Read Only
0x0400 = ENABLED Note: This
0x0800 = START register is
not
0x0900 = PAUSE unsigned contiguous
Controller
1000 0x0A00 = BLOWDOWN short with other
State
0x0B00 = UNLOAD (16 bits) registers
0x0D00 = MODULATE and must be
read as a
0x0E00 = NORMAL STOP
single 16-bit
0x1000 = REMOTE HALT register.
0x1100 = SEQ SHUTDOWN
0x1200 = POWER ON RESET

Use the following masks to


isolate flag bits:

0x0001 = VALVE ACT COMM ERROR


0x0002 = ADVISORY ACTIVE
0x0004 = STOP KEY LATCH
0x0008 = CAME FROM MODULATE
0x0010 = BLOWDOWN LATCH
0x0020 = INTERNAL ERROR
Controller 0x0040 = AUTO ALTERNATE DISPLAY unsigned
12000 Status short Read Only
0x0080 = FAN START RELAY (16 bits)
Flags 1
0x0100 = STATE TIMER EXPIRED
0x0200 = MOTORS RUNNING
0x0400 = LOADED
0x0800 = WRITE DECIHOUR COUNTER
0x1000 = EXP BRD COMM ERROR
0x2000 = DRIVE 1 COMM ERROR
0x4000 = DRIVE 2 COMM ERROR
0x8000 = DRIVE 3 COMM ERROR

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Address Parameter Units / Range / Description Data Type Access
Use the following masks to
isolate flag bits:

0x0001 = DRIVE 2 AT FREQUENCY


0x0002 = CHECK DISCHARGE TEMP
0x0004 = EXP BRD NEEDED
0x0008 = RESET ALARM EDGE
0x0010 = LAST RESET ALARM
0x0020 = HVY CONSUM START EDGE
Controller 0x0040 = LAST HVY CONSUM START unsigned
12001 Status short Read Only
0x0080 = HVY CONSUM LOAD EDGE (16 bits)
Flags 2
0x0100 = AUTO RESTART ENABLED
0x0200 = PROGRAM FLASH CRC OK
0x0400 = LANGUAGE TABLE CRC OK
0x0800 = EEPROM PARAMS RESTORED
0x1000 = EEPROM PARAMS RESET
0x2000 = BACKUP PARAMS UPDATED
0x4000 = ADC ERROR
0x8000 = DRIVE 1 AT FREQUENCY

Use the following masks to


isolate flag bits:

0x0001 = LAST MOTOR RUNNING


0x0002 = MANTENANCE ADVISORY
0x0004 = REMOTE LOAD ENABLE
0x0008 = REMOTE LOAD
0x0010 = REMOTE UNLOAD
0x0020 = VALVE ACT NEEDED
Controller 0x0040 = DRIVE1 AT MAX SPEED unsigned
12002 Status short Read Only
0x0080 = IN MODULATION (16 bits)
Flags 3
0x0100 = LAST HVY CONSUM LOAD
0x0200 = MODEL TABLE VALID
0x0400 = INVALID LANGUAGE TABLE
0x0800 = SAVING EEPROM PARAMS
0x1000 = DRIVES BEING RESET
0x2000 = COMM MODULE INSTALLED
0x4000 = MOTORS JUST STARTED
0x8000 = MOTORS JUST STOPPED

13-17-604 Page 45
Address Parameter Units / Range / Description Data Type Access
Use the following masks to
isolate flag bits:

0x0001 = DOUT ADVISORY ALARM


0x0002 = DOUT MANTENANCE ALARM
0x0004 = DOUT ANY ALARM
0x0008 = ALARM CHANGE PULSE
0x0010 = RTC SECONDARY PRESSURE
0x0020 = IV PID UNLOAD
Controller 0x0040 = RATE OF RISE EVENT unsigned
12003 Status short Read Only
0x0080 = NOT USED (16 bits)
Flags 4
0x0100 = GOOD TO GO
0x0200 = GENERAL PURPOSE 1Hz
0x0400 = LOW DISCHARGE TEMP
0x0800 = RTC DRYER
0x1000 = RTC RUN
0x2000 = RTC STOP
0x4000 = MAINTENANCE CTRS RESET
0x8000 = RUNTIME EDIT PROGRESS

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Maintenance Information

Address Parameter Units / Range / Description Data Type Access


LSB = 6 minutes (1/10 hour) signed long
13000 Total Hours Read Only
(32 bits)
LSB = 6 minutes (1/10 hour) signed long
13002 Loaded Hours Read Only
(32 bits)
Total Hours at last oil signed long
10050 Last Oil Change Read Only
change. (32 bits)
Oil Change Units: Hours signed short
10052 Min/Max: 1000 - 12000 Read Only
Interval (16 bits)
Last Oil Filter Total Hours at last oil filter signed long
10053 change. Read Only
Change (32 bits)
Oil Filter Units: Hours signed short
10055 Min/Max: 100 - 4000 Read Only
Change Interval (16 bits)
Last Oil Total Hours at last oil signed long
10056 separator element change. Read Only
Separator Change (32 bits)
Oil Separator Units: Hours signed short
10058 Min/Max: 1000 - 9000 Read Only
Change Interval (16 bits)
Last Air Filter Total Hours at last air filter signed long
10059 change. Read Only
Change (32 bits)
Air Filter Units: Hours signed short
10061 Min/Max: 1000 - 4000 Read Only
Change Interval (16 bits)
Last Control Box Total Hours at last control signed long
10148 box filter change Read Only
Filter Change (32 bits)
Control Box Units: Hours
Min/Max: 400 - 1000 signed short
10150 Filter Change Read Only
(16 bits)
Interval
Total Hours at last motor signed long
10062 Last Motor Lube Read Only
lubrication (32 bits)
Motor Lube Units: Hours signed short
10064 Min/Max: 500 - 10000 Read Only
Interval (16 bits)
Controller Units: 1/100 signed short
2057 (203 = version 2.03) Read Only
Firmware Version (16 bits)

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Real Time Pressures and Temperatures

Address Parameter Units/Range Data Type Access


Interstage Units: 1/16 Deg. F signed short
1001 Min/Max: 31 – 257 (x 16) Read Only
Temperature (16 bits)
Inlet Units: 1/16 Deg. F signed short
1002 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Plant Units: 1/16 Deg. F signed short
1003 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Separator Units: 1/16 Deg. F signed short
1004 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Discharge Units: 1/16 Deg. F signed short
1005 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Dryer Units: 1/16 Deg. F signed short
1006 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Units: 1/16 Deg. F signed short
1007 Oil Temperature Read Only
Min/Max: 31 – 257 (x 16) (16 bits)
Interstage Units: 1/16 PSI signed short
1008 (16 bits) Read Only
Pressure Min/Max: 0 – 250 (x 16)
Units: 1/16 PSI signed short
1009 Inlet Pressure (16 bits) Read Only
Min/Max: 0 – 250 (x 16)
Units: 1/16 PSI signed short
1010 Plant Pressure (16 bits) Read Only
Min/Max: 0 – 250 (x 16)
Separator Units: 1/16 PSI signed short
1011 (16 bits) Read Only
Pressure Min/Max: 0 – 250 (x 16)
Reservoir Units: 1/16 PSI signed short
1012 (16 bits) Read Only
Pressure Min/Max: 0 – 250 (x 16)
Units: 1/16 PSI signed short
1013 Oil Pressure (16 bits) Read Only
Min/Max: 0 – 250 (x 16)
Units: 1/16 PSI signed short
1014 System Pressure (16 bits) Read Only
Min/Max: 0 – 250 (x 16)

13-17-604 Page 48
Variable Frequency Drive and Motor Parameters

Address Parameter Units/Range Data Type Access

V1 Frequency Units: 1/100 Hz signed short


2003 VFD frequency command Read Only
Command (16 bits)
from controller.
V2 Frequency Units: 1/100 Hz signed short
2004 VFD frequency command Read Only
Command (16 bits)
from controller.
V3 Frequency Units: 1/100 Hz signed short
2005 VFD frequency command Read Only
Command (16 bits)
from controller.
Use the following
masks to isolate
status bits:

0x0001 = READY
0x0002 = RUNNING
0x0004 = COMMAND FWD
0x0008 = ROTATE FWD
0x0010 = ACCELERATING
0x0020 = DECELERATING
0x0040 = ALARM unsigned short
2006 V1 Status Read Only
(16 bits)
0x0080 = FAULT
0x0100 = AT FREQUENCY
0x0200 = WARNING
0x0400 = NOT USED
0x0800 = NOT USED
0x1000 = DIN1 BIT
0x2000 = DIN2 BIT
0x4000 = NOT USED
0x8000 = NOT USED

See V1 Status bit masks unsigned short


2007 V2 Status Read Only
above (16 bits)
See V1 Status bit masks unsigned short
2008 V3 Status Read Only
above (16 bits)
See VFD User’s Manual for signed short
2009 V1 Fault Code Read Only
fault code listing. (16 bits)
See VFD User’s Manual for signed short
2010 V2 Fault Code Read Only
fault code listing. (16 bits)
See VFD User’s Manual for signed short
2011 V3 Fault Code Read Only
fault code listing. (16 bits)

V1 Actual Units: 1/100 Hz


signed short
2012 Actual motor operating Read Only
Frequency (16 bits)
frequency.

13-17-604 Page 49
Address Parameter Units/Range Data Type Access

V2 Actual Units: 1/100 Hz


signed short
2013 Actual motor operating Read Only
Frequency (16 bits)
frequency.
V3 Actual Units: 1/100 Hz
signed short
2014 Actual motor operating Read Only
Frequency (16 bits)
frequency.
Units: 1/10 Amp signed short
2018 V1 Current Read Only
(16 bits)
Units: 1/10 Amp signed short
2019 V2 Current Read Only
(16 bits)
Units: 1/10 Amp signed short
2020 V3 Current Read Only
(16 bits)
V1 DC Bus Units: Volts signed short
2021 Read Only
Voltage (16 bits)
V2 DC Bus Units: Volts signed short
2022 Read Only
Voltage (16 bits)
V3 DC Bus Units: Volts signed short
2023 Read Only
Voltage (16 bits)
Units: RPM signed short
2024 V1 Motor Speed Read Only
(16 bits)
Units: RPM signed short
2025 V2 Motor Speed Read Only
(16 bits)
Units: RPM signed short
2026 V3 Motor Speed Read Only
(16 bits)
Units: 1/10 kW signed short
2033 V1 Motor Power Read Only
(16 bits)
Units: 1/10 kW signed short
2034 V2 Motor Power Read Only
(16 bits)
Units: 1/10 kW signed short
2035 V3 Motor Power Read Only
(16 bits)
V1 Heat Sink Units: Deg. C signed short
2036 Read Only
Temperature (16 bits)
V2 Heat Sink Units: Deg. C signed short
2037 Read Only
Temperature (16 bits)
V3 Heat Sink Units: Deg. C signed short
2038 Read Only
Temperature (16 bits)
V1 Firmware See VFD User’s Manual for signed short
2048 data format. Read Only
Version (16 bits)
V2 Firmware See VFD User’s Manual for signed short
2049 data format. Read Only
Version (16 bits)
V3 Firmware See VFD User’s Manual for signed short
2050 data format. Read Only
Version (16 bits)
Units: Volts signed short
2054 V1 Motor Voltage Read Only
(16 bits)
Units: Volts signed short
2055 V2 Motor Voltage Read Only
(16 bits)

13-17-604 Page 50
Address Parameter Units/Range Data Type Access
Units: Volts signed short
2056 V3 Motor Voltage Read Only
(16 bits)
V1 Motor Units: Volts signed short
2074 Read Only
Nameplate Volts (16 bits)
V2 Motor Units: Volts signed short
2075 Read Only
Nameplate Volts (16 bits)
V3 Motor Units: Volts signed short
2076 Read Only
Nameplate Volts (16 bits)
V1 Motor Units: 1/100 Hz signed short
2077 Read Only
Nameplate Hertz (16 bits)
V2 Motor Units: 1/100 Hz signed short
2078 Read Only
Nameplate Hertz (16 bits)
V3 Motor Units: 1/100 Hz signed short
2079 Read Only
Nameplate Hertz (16 bits)
V1 Motor Units: 1/10 Amp signed short
2080 Read Only
Nameplate FLA (16 bits)
V2 Motor Units: 1/10 Amp signed short
2081 Read Only
Nameplate FLA (16 bits)
V3 Motor Units: 1/10 Amp signed short
2082 Read Only
Nameplate FLA (16 bits)

13-17-604 Page 51
Front Panel Display

Address Parameter Units/Range Data Type Access


Use the following
masks to isolate LED
bits:

unsigned short
4096 Front Panel LEDs 0x0001 = POWER Read Only
(16 bits)
0x0002 = AUTOMATIC
0x0004 = SERVICE
0x0008 = SHUTDOWN

4097 - Front Panel 20 characters / line unsigned short


Read Only
4106 Display Line 1 2 characters / 16-bit word (16 bits)
4107 - Front Panel 20 characters / line unsigned short
Read Only
4116 Display Line 2 2 characters / 16-bit word (16 bits)
4117 – Front Panel 20 characters / line unsigned short
Read Only
4126 Display Line 3 2 characters / 16-bit word (16 bits)
4127 - Front Panel 20 characters / line unsigned short
Read Only
4136 Display Line 4 2 characters / 16-bit word (16 bits)

13-17-604 Page 52
Operational Settings

Address Parameter Units/Range Data Type Access


Target Pressure Units: 1/16 PSI signed short
10000 Min/Max: 45 – 250 (x 16) Read Only
Setting (16 bits)
Unload Pressure Units: 1/16 PSI signed short
10001 Min/Max: 0 – 250 (x 16) Read Only
Setting (16 bits)
Load Pressure Units: 1/16 PSI signed short
10002 Min/Max: 30 – 250 (x 16) Read Only
Setting (16 bits)
0 = Constant, 1 = Automatic, signed short
10008 Operating Mode Read Only
2 = Sequence (16 bits)
0 = Fixed Speed, signed short
10009 Compressor Type Read Only
1 = Variable Speed (16 bits)
Units: CFM signed short
10034 Local Capacity Read Only
Min/Max: 0 - 5000 (16 bits)
10035 Remote Halt Units: None unsigned char
Read Only
(LSB) Enabled Min/Max: 0 = OFF, 1 = ON (8 bits)
10038 Units: None unsigned char
Auto Restart Read Only
(MSB) Min/Max: 0 = OFF, 1 = ON (8 bits)
10039 0 = Standard, 1 = High Temp unsigned char
Oil Type Read Only
(LSB) 2 = Food Grade (8 bits)
10042 Week Clock Units: None unsigned char
Read Only
(MSB) Enabled Min/Max: 0 = OFF, 1 = ON (8 bits)
Blowdown Timer Units: Seconds unsigned short
10043 Read Only
Setting Min/Max: 1 - 1200 (16 bits)
Blowdown Counter Units: None unsigned short
10044 Read Only
Setting Min/Max: 0 - 10 (16 bits)
Auto Timer Units: 1/10 Minutes unsigned short
10045 Read Only
Setting Min/Max: 0 - 200 (16 bits)
Start Timer Units: Seconds unsigned short
10046 Read Only
Setting Min/Max: 0 - 600 (16 bits)
High Plant Units: 1/16 PSI signed short
10047 Min/Max: 70 – 200 (x 16) Read Only
Pressure Limit (16 bits)
Over Temperature Units: 1/16 Deg. F signed short
10048 Min/Max: 175 - 240 (x 16) Read Only
Shutdown Limit (16 bits)
Auto Restart Units: Seconds signed short
10049 Read Only
Delay Time Min/Max: 5 - 30 (16 bits)
Units: Volts signed short
10065 System Voltage Read Only
Min/Max: 115 - 1000 (16 bits)
Over Temperature Units: 1/16 Deg. F signed short
10067 Min/Max: 175 - 240 (x 16) Read Only
Alarm Limit (16 bits)

13-17-604 Page 53
Address Parameter Units/Range Data Type Access
Plant Units: 1/16 Deg. F
Min/Max: 122 - 176 (x 16) signed short
10068 Temperature Read Only
(16 bits)
Shutdown Limit
Plant Units: 1/16 Deg. F
Min/Max: 104 - 176 (x 16) signed short
10069 Temperature Read Only
(16 bits)
Alarm Limit
Dryer Units: 1/16 Deg. F
Min/Max: 50 - 250 (x 16) signed short
10132 Temperature Read Only
(16 bits)
Shutdown Limit
Dryer Units: 1/16 Deg. F
Min/Max: 50 - 250 (x 16) signed short
10133 Temperature Read Only
(16 bits)
Alarm Limit
Stop Timer Units: 1/10 Minutes unsigned short
10137 Read Only
Setting Min/Max: 0 - 120 (16 bits)
Idle Timer Units: 1/10 Minutes unsigned short
10147 Read Only
Setting Min/Max: 0 - 120 (16 bits)
Units: Feet signed short
10151 Elevation Read Only
Min/Max: 0 - 30000 (16 bits)

13-17-604 Page 54
Sequencing Settings

Address Parameter Units/Range Data Type Access


Number of Units: None signed short
10003 Read Only
Sequenced Units Min/Max: 1 – 8 (16 bits)
Sequence Unit Units: None signed short
10004 Read Only
Number Min/Max: 1 – 8 (16 bits)
Units: None signed short
10005 Sequence Group Read Only
Min/Max: 0 – 7 (A – H) (16 bits)
Transfer Units: Hours signed short
10006 Read Only
Interval Min/Max: 0 – 5000 (16 bits)
Units: Seconds signed short
10007 Lag Start Delay Read Only
Min/Max: 1 - 60 (16 bits)
Transfer Load Units: % of Full Speed signed short
10025 Read Only
Decrement Min/Max: 20 - 100 (16 bits)
Transfer Load Units: % of Full Speed signed short
10026 Read Only
Increment Min/Max: 70 - 100 (16 bits)

Remote Monitoring Settings

Address Parameter Units/Range Data Type Access


Min/Max: 0x00000000 – signed short (x 2)
10028 IP Address Read Only
0xFFFFFFFF (16 bits)
Min/Max: 0x00000000 – signed short (x 2)
10030 Subnet Mask Read Only
0xFFFFFFFF (16 bits)
Min/Max: 0x00000000 – signed short (x 2)
10032 Gateway Address Read Only
0xFFFFFFFF (16 bits)

13-17-604 Page 55
Shutdown / Advisory History

Address Parameter Units/Range Data Type Access


11000 - Shutdown Data See structure below
Read Only
11029 Structure #1

11002 Refer to document No. 13- signed char


Shutdown Code 17-600 for Shutdown & Read Only
(MSB) (8 bits)
Advisory codes
Interstage Units: 1/16 Deg. F signed short
11004 Min/Max: 31 – 257 (x 16) Read Only
Temperature (16 bits)
Inlet Units: 1/16 Deg. F signed short
11005 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Plant Units: 1/16 Deg. F signed short
11006 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Separator Units: 1/16 Deg. F signed short
11007 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Discharge Units: 1/16 Deg. F signed short
11008 Min/Max: 31 – 257 (x 16) (16 bits) Read Only
Temperature
Interstage Units: 1/16 PSI signed short
11009 (16 bits) Read Only
Pressure Min/Max: 0 – 250 (x 16)
Units: 1/16 PSI signed short
11010 Inlet Pressure (16 bits) Read Only
Min/Max: 0 – 250 (x 16)
Units: 1/16 PSI signed short
11011 Plant Pressure (16 bits) Read Only
Min/Max: 0 – 250 (x 16)
Separator Units: 1/16 PSI signed short
11012 (16 bits) Read Only
Pressure Min/Max: 0 – 250 (x 16)
Reservoir Units: 1/16 PSI signed short
11013 (16 bits) Read Only
Pressure Min/Max: 0 – 250 (x 16)
LSB = 6 minutes (1/10 hour) signed long
11014 Total Hours Read Only
(32 bits)

13-17-604 Page 56
Address Parameter Units/Range Data Type Access
32-bits of real time data as:
YYYYYYMMMMTTTTTHHH
HHNNNNNNDDDDDD
Where:
Y = 6 bits representing year 0
- 63
M = 4 bits representing
month 1 - 12, unsigned long
11016 Real Time Stamp Read Only
T = 5 bits representing date 1 (32 bits)
- 31,
H = 5 bits representing hour
0 - 23,
N = 6 bits representing
minute 0 - 59,
D = 6 bits representing day of
week 1 - 7.
Use the following
masks to isolate
status bits:

0x0001 = READY
0x0002 = RUNNING
0x0004 = COMMAND FWD
0x0008 = ROTATE FWD
0x0010 = ACCELERATING
0x0020 = DECELERATING
0x0040 = ALARM unsigned short
11018 V1 Status Read Only
(16 bits)
0x0080 = FAULT
0x0100 = AT FREQUENCY
0x0200 = WARNING
0x0400 = NOT USED
0x0800 = NOT USED
0x1000 = DIN1 BIT
0x2000 = DIN2 BIT
0x4000 = NOT USED
0x8000 = NOT USED

V1 Actual Units: 1/100 Hz


signed short
11019 Actual motor operating Read Only
Frequency (16 bits)
frequency.
Units: RPM signed short
11020 V1 Motor Speed Read Only
(16 bits)
Units: 1/10 Amp signed short
11021 V1 Current Read Only
(16 bits)
V1 Heat Sink Units: Deg. C signed short
11022 Read Only
Temperature (16 bits)

13-17-604 Page 57
Address Parameter Units/Range Data Type Access
V1 DC Bus Units: Volts signed short
11023 Read Only
Voltage (16 bits)
See V1 Status bit masks unsigned short
11024 V2 Status Read Only
above (16 bits)

V2 Actual Units: 1/100 Hz


signed short
11025 Actual motor operating Read Only
Frequency (16 bits)
frequency.
Units: RPM signed short
11026 V2 Motor Speed Read Only
(16 bits)
Units: 1/10 Amp signed short
11027 V2 Current Read Only
(16 bits)
V2 Heat Sink Units: Deg. C signed short
11028 Read Only
Temperature (16 bits)
V2 DC Bus Units: Volts signed short
11029 Read Only
Voltage (16 bits)
11030 - Shutdown Data Same a Shutdown #1
structure above Read Only
11059 Structure #2
11060 - Shutdown Data Same a Shutdown #1
structure above Read Only
11089 Structure #3
11090 - Shutdown Data Same a Shutdown #1
structure above Read Only
11119 Structure #4
11120 - Shutdown Data Same a Shutdown #1
structure above Read Only
11149 Structure #5
11150 - Shutdown Data Same a Shutdown #1
structure above Read Only
11179 Structure #6
11180 - Advisory Data Same a Shutdown #1
structure above Read Only
11209 Structure #1
11210 - Advisory Data Same a Shutdown #1
structure above Read Only
11239 Structure #2
11240 - Advisory Data Same a Shutdown #1
structure above Read Only
11269 Structure #3
11270 - Advisory Data Same a Shutdown #1
structure above Read Only
11299 Structure #4
11300 - Advisory Data Same a Shutdown #1
structure above Read Only
11329 Structure #5
11330 - Advisory Data Same a Shutdown #1
structure above Read Only
11359 Structure #6

13-17-604 Page 58
6.4 Modbus Address Map (Blower application)

Address Parameter Units / Range / Description Data Type Access


0x0000 = ADJUSTMENT
0x0001 = POWER ON RESET
0x0004 = SHUTDOWN
0x0007 = REMOTE HALT
0x0008 = AUTO RESTART
Controller 0x000A = ENABLED unsigned short
1000 Read Only
State 0x000B = READY (16 bits)
0x000C = START
0x000F = PAUSE
0x0010 = MODULATE
0x0012 = NORMAL STOP

Use the following masks to


isolate flag bits:

0x0001 = DELAY TIMER EXPIRED


0x0002 = MOTORS RUNNING
0x0004 = LOADED
0x0008 = WRITE DECIHOUR COUNTER
0x0010 = EXP BRD COMM ERROR
0x0020 = DRIVE1 COMM ERROR
Controller 0x0040 = NOT USED unsigned short
12000 Status Read Only
0x0080 = NOT USED (16 bits)
Flags 1
0x0100 = NOT USED
0x0200 = ADVISORY ACTIVE
0x0400 = STOP SOURCE
0x0800 = NOT USED
0x1000 = AIR FILTER CLOGGED
0x2000 = INTERNAL ERROR
0x4000 = AUTO ALTERNATE DISPLAY
0x8000 = NOT USED

13-17-604 Page 59
Address Parameter Units / Range / Description Data Type Access
Use the following masks to
isolate flag bits:

0x0001 = AUTO RESTART ENABLED


0x0002 = PROGRAM FLASH CRC OK
0x0004 = LANGUAGE TABLE CRC OK
0x0008 = EEPROM PARAMS RESTORED
0x0010 = EEPROM PARAMS RESET
0x0020 = BACKUP PARAMS UPDATED
Controller 0x0040 = ADC ERROR unsigned short
12001 Status Read Only
0x0080 = DRIVE1 AT FREQUENCY (16 bits)
Flags 2
0x0100 = NOT USED
0x0200 = NOT USED
0x0400 = XB1 CALLED FOR
0x0800 = RESET ALARM EDGE
0x1000 = LAST RESET ALARM
0x2000 = STOP KEY STATE
0x4000 = NOT USED
0x8000 = NOT USED

Use the following masks to


isolate flag bits:

0x0001 = NOT USED


0x0002 = MODEL TABLE VALID
0x0004 = NOT USED
0x0008 = SAVING EEPROM PARAMS
0x0010 = DRIVES BEING RESET
0x0020 = COMM MODULE INSTALLED
Controller 0x0040 = NOT USED unsigned short
12002 Status Read Only
0x0080 = NOT USED (16 bits)
Flags 3
0x0100 = NOT USED
0x0200 = NOT USED
0x0400 = NOT USED
0x0800 = NOT USED
0x1000 = NOT USED
0x2000 = NOT USED
0x4000 = NOT USED
0x8000 = IN MODULTAION

13-17-604 Page 60
Address Parameter Units / Range / Description Data Type Access
Use the following masks to
isolate flag bits:

0x0001 = NOT USED


0x0002 = GENERAL PURPOSE 1Hz
0x0004 = NOT USED
0x0008 = NOT USED
0x0010 = RTC RUN
0x0020 = RTC STOP
Controller 0x0040 = MAINTENACE CNTR RESET unsigned short
12003 Status Read Only
0x0080 = RUNTIME EDIT PROGRSS (16 bits)
Flags 4
0x0100 = DOUT ADVISORY ALARM
0x0200 = NOT USED
0x0400 = DOUT ANY ALARM
0x0800 = ALARM CHANGE PULSE
0x1000 = NOT USED
0x2000 = FAN RUNNING
0x4000 = ENTER TO CLR ADVISORY
0x8000 = VFD OVERCURRENT

13-17-604 Page 61
Maintenance Information

Address Parameter Units / Range / Description Data Type Access


LSB = 6 minutes (1/10 hour) signed long
13000 Total Hours Read Only
(32 bits)
LSB = 6 minutes (1/10 hour) signed long
13002 Total Hours Read Only
(32 bits)
Oil Change Units: Hours signed short
10066 Min/Max: 1000 - 12000 Read Only
Interval (16 bits)
Total Hours at last oil signed long
14000 Last Oil Change Read Only
change. (32 bits)
Air Filter Units: Hours signed short
10065 Min/Max: 1000 - 4000 Read Only
Change Interval (16 bits)
Last Air Filter Total Hours at last air filter signed long
14002 change. Read Only
Change (32 bits)
Motor Lube Units: Hours signed short
10068 Min/Max: 500 - 10000 Read Only
Interval (16 bits)
Total Hours at last motor signed long
14004 Last Motor Lube Read Only
lubrication (32 bits)
Control Box Units: Hours
Min/Max: 400 - 1000 signed short
10067 Filter Change Read Only
(16 bits)
Interval
Last Control Box Total Hours at last control signed long
14006 box filter change Read Only
Filter Change (32 bits)
Controller Units: 1/100 signed short
2057 (203 = version 2.03) Read Only
Firmware Version (16 bits)

13-17-604 Page 62
Real Time Pressures and Temperatures

Address Parameter Units/Range Data Type Access


Inlet Units: 1/16 Deg. F signed short
1001 Min/Max: 15 – 250 (x 16) Read Only
Temperature (16 bits)
Discharge Units: 1/16 Deg. F signed short
1002 Min/Max: 15 – 400 (x 16) (16 bits) Read Only
Temperature
Enclosure Units: 1/16 Deg. F signed short
1003 Min/Max: 15 – 250 (x 16) (16 bits) Read Only
Temperature
Drive End Oil Units: 1/16 Deg. F signed short
1004 Min/Max: 15 – 250 (x 16) (16 bits) Read Only
Temperature
Gear End Oil Units: 1/16 Deg. F signed short
1005 Min/Max: 15 – 250 (x 16) (16 bits) Read Only
Temperature
Discharge Units: 1/16 PSI signed short
1006 (16 bits) Read Only
Pressure Min/Max: -15 – 35 (x 16)
Units: 1/16 PSI signed short
1007 Inlet Pressure (16 bits) Read Only
Min/Max: -15 - 35 (x 16)
Differential Units: 1/16 PSI signed short
1008 (16 bits) Read Only
Pressure Min/Max: 0 - 50 (x 16)
Drive End Oil Units: signed short
1012 (16 bits) Read Only
Level Min/Max:
Gear End Oil Units: signed short
1013 (16 bits) Read Only
Level Min/Max:
Units: 1/16 PSI signed short
1014 System Pressure (16 bits) Read Only
Min/Max: -15 - 35 (x 16)

13-17-604 Page 63
Variable Frequency Drive and Motor Parameters

Address Parameter Units/Range Data Type Access

V1 Frequency Units: 1/100 Hz signed short


2003 VFD frequency command Read Only
Command (16 bits)
from controller.
Use the following
masks to isolate
status bits:

0x0001 = READY
0x0002 = RUNNING
0x0004 = COMMAND FWD
0x0008 = ROTATE FWD
0x0010 = ACCELERATING
0x0020 = DECELERATING
0x0040 = ALARM unsigned short
2006 V1 Status Read Only
(16 bits)
0x0080 = FAULT
0x0100 = AT FREQUENCY
0x0200 = WARNING
0x0400 = NOT USED
0x0800 = NOT USED
0x1000 = DIN1 BIT
0x2000 = DIN2 BIT
0x4000 = NOT USED
0x8000 = NOT USED

See VFD User’s Manual for signed short


2009 V1 Fault Code Read Only
fault code listing. (16 bits)

V1 Actual Units: 1/100 Hz


signed short
2012 Actual motor operating Read Only
Frequency (16 bits)
frequency.
Units: 1/10 Amp signed short
2018 V1 Current Read Only
(16 bits)
V1 DC Bus Units: Volts signed short
2021 Read Only
Voltage (16 bits)
Units: RPM signed short
2024 V1 Motor Speed Read Only
(16 bits)
Units: 1/10 kW signed short
2033 V1 Motor Power Read Only
(16 bits)
V1 Heat Sink Units: Deg. C signed short
2036 Read Only
Temperature (16 bits)
V1 Firmware See VFD User’s Manual for signed short
2048 data format. Read Only
Version (16 bits)
Units: Volts signed short
2054 V1 Motor Voltage Read Only
(16 bits)

13-17-604 Page 64
Address Parameter Units/Range Data Type Access
V1 Motor Units: Volts signed short
2074 Read Only
Nameplate Volts (16 bits)
V1 Motor Units: 1/100 Hz signed short
2077 Read Only
Nameplate Hertz (16 bits)
V1 Motor Units: 1/10 Amp signed short
2080 Read Only
Nameplate FLA (16 bits)

Front Panel Display

Address Parameter Units/Range Data Type Access


Use the following
masks to isolate LED
bits:

unsigned short
4096 Front Panel LEDs 0x0001 = POWER Read Only
(16 bits)
0x0002 = AUTOMATIC
0x0004 = SERVICE
0x0008 = SHUTDOWN

4097 - Front Panel 20 characters / line unsigned short


Read Only
4106 Display Line 1 2 characters / 16-bit word (16 bits)
4107 - Front Panel 20 characters / line unsigned short
Read Only
4116 Display Line 2 2 characters / 16-bit word (16 bits)
4117 – Front Panel 20 characters / line unsigned short
Read Only
4126 Display Line 3 2 characters / 16-bit word (16 bits)
4127 - Front Panel 20 characters / line unsigned short
Read Only
4136 Display Line 4 2 characters / 16-bit word (16 bits)

13-17-604 Page 65
Operational Settings

Address Parameter Units/Range Data Type Access


Target Pressure Units: 1/16 PSI signed short
10000 Min/Max: 45 – 250 (x 16) Read Only
Setting (16 bits)
0 = Constant, 1 = Automatic, signed short
10008 Operating Mode Read Only
2 = Sequence (16 bits)
0 = Fixed Speed, signed short
10009 Blower Type Read Only
1 = Variable Speed (16 bits)
Start Timer Units: Seconds unsigned short
10010 Read Only
Setting Min/Max: 0 - 600 (16 bits)
Stop Timer Units: Seconds unsigned short
10011 Read Only
Setting Min/Max: 0 - 600 (16 bits)
Units: CFM signed short
10034 Local Capacity Read Only
Min/Max: 0 - 5000 (16 bits)
Differential Units: 1/16 Deg. F signed short
10038 Min/Max: 0 - 250 (x 16) Read Only
Temp Fault Limit (16 bits)
Differential Units: 1/16 Deg. F signed short
10039 Min/Max: 0 - 250 (x 16) Read Only
Temp Alarm Limit (16 bits)
Discharge Temp Units: 1/16 Deg. F unsigned short
10040 Min/Max: 0 - 350 (x 16) Read Only
Fault Limit (16 bits)
Discharge Temp Units: 1/16 Deg. F unsigned short
10041 Min/Max: 0 - 350 (x 16) Read Only
Alarm Limit (16 bits)
Enclosure Temp Units: 1/16 Deg. F unsigned short
10042 Min/Max: 15 - 250 (x 16) Read Only
Fault Limit (16 bits)
Enclosure Temp Units: 1/16 Deg. F unsigned short
10043 Min/Max: 15 - 250 (x 16) Read Only
Alarm Limit (16 bits)
Inlet Temp High Units: 1/16 Deg. F unsigned short
10044 Min/Max: 15 -150 (x 16) Read Only
Limit (16 bits)
Inlet Temp Low Units: 1/16 Deg. F signed short
10045 Min/Max: 15 -150 (x 16) Read Only
Fault Limit (16 bits)
Inlet Temp Low Units: 1/16 Deg. F signed short
10046 Min/Max: 15- 150 (x 16) Read Only
Alarm Limit (16 bits)
Differential Units: 1/16 PSI signed short
10047 Read Only
Pres Fault Limit Min/Max: 0 – 50 (x 16) (16 bits)

Differential Units: 1/16 PSI signed short


10048 Read Only
Pres Alarm Limit Min/Max: 0 – 50 (x 16) (16 bits)

Control Pressure Units: 1/16 PSI signed short


10049 Read Only
Fault Limit Min/Max: 0 – 20 (x 16) (16 bits)

Control Pressure Units: 1/16 PSI signed short


10050 Read Only
Alarm Limit Min/Max: 0 – 20 (x 16) (16 bits)

13-17-604 Page 66
Address Parameter Units/Range Data Type Access
Oil Temperature Units: 1/16 Deg. F signed short
10051 Min/Max: 15 - 350 (x 16) Read Only
Fault Limit (16 bits)
Oil Temperature Units: 1/16 Deg. F signed short
10052 Min/Max: 15 - 350 (x 16) Read Only
Alarm Limit (16 bits)
Drive End Low Units:
Min/Max: signed short
10053 Oil Level Fault Read Only
(16 bits)
limit
Drive End Low Units:
unsigned short
10054 Oil Level Alarm Min/Max: Read Only
(16 bits)
limit
Drive End High Units:
unsigned short
10055 Oil Level Fault Min/Max: Read Only
(16 bits)
limit
Gear End Low Oil Units:
signed short
10056 Level Fault Min/Max: Read Only
(16 bits)
limit
Gear End Low Oil Units:
unsigned short
10057 Level Alarm Min/Max: Read Only
(16 bits)
limit
Gear End High Units:
signed short
10058 Oil Level Fault Min/Max: Read Only
(16 bits)
limit

13-17-604 Page 67
Sequencing Settings

Address Parameter Units/Range Data Type Access


Sequence Unit Units: None signed short
10004 Read Only
Number Min/Max: 1 – 8 (16 bits)
Units: None signed short
10005 Sequence Group Read Only
Min/Max: 0 – 7 (A – H) (16 bits)
Transfer Units: Hours signed short
10006 Read Only
Interval Min/Max: 0 – 5000 (16 bits)
Units: Seconds signed short
10007 Lag Start Delay Read Only
Min/Max: 1 - 60 (16 bits)
Number of Units: None signed short
10020 Read Only
Sequence Units Min/Max: 1 – 8 (16 bits)
Transfer Load Units: % of Full Speed signed short
10025 Read Only
Decrement Min/Max: 20 - 100 (16 bits)
Transfer Load Units: % of Full Speed signed short
10026 Read Only
Increment Min/Max: 70 - 100 (16 bits)
Release Pressure Units: 1/16 PSI signed short
10027 Min/Max: -15 – 35 (x 16) Read Only
Setting (16 bits)

Remote Monitoring Settings

Address Parameter Units/Range Data Type Access


Min/Max: 0x00000000 – signed short (x 2)
10028 IP Address Read Only
0xFFFFFFFF (16 bits)
Min/Max: 0x00000000 – signed short (x 2)
10030 Subnet Mask Read Only
0xFFFFFFFF (16 bits)
Min/Max: 0x00000000 – signed short (x 2)
10032 Gateway Address Read Only
0xFFFFFFFF (16 bits)

13-17-604 Page 68
Shutdown / Advisory History

Address Parameter Units/Range Data Type Access


11000 - Shutdown Data See structure below
Read Only
11017 Structure #1

11000 Refer to document No. IQ-7- signed char


Shutdown Code 200 for Shutdown & Advisory Read Only
(MSB) (8 bits)
codes
signed short
11001 Not used Read Only
(16 bits)
Inlet Units: 1/16 Deg. F signed short
11002 Min/Max: 15 – 250 (x 16) (16 bits) Read Only
Temperature
Discharge Units: 1/16 Deg. F signed short
11003 Min/Max: 15 – 400 (x 16) (16 bits) Read Only
Temperature
Discharge Units: 1/16 PSI signed short
11004 (16 bits) Read Only
Pressure Min/Max: -15 – 35 (x 16)
Units: 1/16 PSI signed short
11005 Inlet Pressure (16 bits) Read Only
Min/Max: -15 - 35 (x 16)
Differential Units: 1/16 PSI signed short
11006 (16 bits) Read Only
Pressure Min/Max: 0 – 50 (x 16)
LSB = 6 minutes (1/10 hour) signed long
11007 Total Hours Read Only
(32 bits)
32-bits of real time data as:
YYYYYYMMMMTTTTTHHH
HHNNNNNNDDDDDD
Where:
Y = 6 bits representing year 0
- 63
M = 4 bits representing
month 1 - 12, unsigned long
11009 Real Time Stamp Read Only
T = 5 bits representing date 1 (32 bits)
- 31,
H = 5 bits representing hour
0 - 23,
N = 6 bits representing
minute 0 - 59,
D = 6 bits representing day of
week 1 - 7.

13-17-604 Page 69
Address Parameter Units/Range Data Type Access
Use the following
masks to isolate
status bits:

0x0001 = READY
0x0002 = RUNNING
0x0004 = COMMAND FWD
0x0008 = ROTATE FWD
0x0010 = ACCELERATING
0x0020 = DECELERATING
0x0040 = ALARM unsigned short
11011 V1 Status Read Only
(16 bits)
0x0080 = FAULT
0x0100 = AT FREQUENCY
0x0200 = WARNING
0x0400 = NOT USED
0x0800 = NOT USED
0x1000 = DIN1 BIT
0x2000 = DIN2 BIT
0x4000 = NOT USED
0x8000 = NOT USED

V1 Actual Units: 1/100 Hz


signed short
11012 Actual motor operating Read Only
Frequency (16 bits)
frequency.
Units: RPM signed short
11013 V1 Motor Speed Read Only
(16 bits)
Units: 1/10 Amp signed short
11014 V1 Current Read Only
(16 bits)
V1 Heat Sink Units: Deg. C signed short
11015 Read Only
Temperature (16 bits)
V1 DC Bus Units: Volts signed short
11016 Read Only
Voltage (16 bits)
unsigned short
11017 Not Used Read Only
(16 bits)
11018 - Shutdown Data Same a Shutdown #1
structure above Read Only
11035 Structure #2
11036 - Shutdown Data Same a Shutdown #1
structure above Read Only
11053 Structure #3
11054 - Shutdown Data Same a Shutdown #1
structure above Read Only
11071 Structure #4
11072 - Shutdown Data Same a Shutdown #1
structure above Read Only
11089 Structure #5
11090 - Shutdown Data Same a Shutdown #1
structure above Read Only
11107 Structure #6

13-17-604 Page 70
Address Parameter Units/Range Data Type Access
111108 Shutdown Data Same a Shutdown #1
structure above Read Only
- 11125 Structure #7
11126 - Shutdown Data Same a Shutdown #1
structure above Read Only
11143 Structure #8
11144 - Shutdown Data Same a Shutdown #1
structure above Read Only
11161 Structure #9
11162 - Shutdown Data Same a Shutdown #1
structure above Read Only
11179 Structure #10
11180 - Advisory Data Same a Shutdown #1
structure above Read Only
11197 Structure #1
11198 - Advisory Data Same a Shutdown #1
structure above Read Only
11215 Structure #2
11216 - Advisory Data Same a Shutdown #1
structure above Read Only
11233 Structure #3
11234 - Advisory Data Same a Shutdown #1
structure above Read Only
11251 Structure #4
11252 - Advisory Data Same a Shutdown #1
structure above Read Only
11269 Structure #5
11270 - Advisory Data Same a Shutdown #1
structure above Read Only
11287 Structure #6
11288 - Advisory Data Same a Shutdown #1
structure above Read Only
11305 Structure #7
11306 - Advisory Data Same a Shutdown #1
structure above Read Only
11323 Structure #8
11324 - Advisory Data Same a Shutdown #1
structure above Read Only
11341 Structure #9
11342 - Advisory Data Same a Shutdown #1
structure above Read Only
11359 Structure #10

13-17-604 Page 71
For additional information contact your local representative or
Gardner Denver Compressor Division,
1800 Gardner Expressway, Quincy, Illinois 62305

Telephone: (800) 682-9868


FAX: (217) 224-7814

Visit our Web Site: www.gardnerdenver.com


Sales and Service in all major cities.

13-17-604 Page 72
CONTRATO MARCO DE INGENIERIA No. 4610006355
DESARROLLO INTEGRADO DE PIEDEMONTE
INGENIERIA DE DETALLE ETAPA 2

SELLER ASERVIN – GARDNER DENVER


PACKAGE
INSTRUMENT AND UTILITY AIR COMPRESSOR
DESC.
EQPT Nos. 63-K-301 / 302
)81&7,21$/ 3(5)250$1&(7(67352&('85(

SDRL
P.O. NUMBER DATE REV. NO.
CAT.
 129  3

<1253_050 >

SELLER DOCUMENT REVIEW

PERMISSION TO PROCEED DOES NOT CONSTITUTE ACCEPTANCE


OF DESIGN DETAILS, CALCULATIONS, TEST METHODS OR MATERIALS
DEVELOPED OR SELECTED BY SELLER AND DOES NOT RELIEVE
SELLER FROM FULL COMPLIANCE WITH CONTRACTURAL OR OTHER
OBLIGATIONS NOR DETRACT FROM ANY OTHER BUYER’S RIGHTS.

REVIEWED AND ACCEPTED. NO FURTHER REVIEW


REQUIRED.

REVISE AND RESUBMIT. WORK MAY PROCEED


SUBJECT TO INCORPORATION OF CHANGES
INDICATED.

REVISE AND RESUBMIT. WORK MAY NOT


PROCEED.

; FOR INFORMATION ONLY.

BUYER’S $5(675(32',&
SIGNATURE............................................... DATE...................................................
'RF7LSLHO)5')0(4073
CONTRATO MARCO DE INGENIERIA No. 4610006355
DESARROLLO INTEGRADO DE PIEDEMONTE
INGENIERIA DE DETALLE ETAPA 2

SELLER ASERVIN – GARDNER DENVER


PACKAGE
INSTRUMENT AND UTILITY AIR COMPRESSOR
DESC.
EQPT Nos. 63-K-301 / 302
67$5783352&('85(

SDRL
P.O. NUMBER DATE REV. NO.
CAT.

 129  3

<1253_050 >

SELLER DOCUMENT REVIEW

PERMISSION TO PROCEED DOES NOT CONSTITUTE ACCEPTANCE


OF DESIGN DETAILS, CALCULATIONS, TEST METHODS OR MATERIALS
DEVELOPED OR SELECTED BY SELLER AND DOES NOT RELIEVE
SELLER FROM FULL COMPLIANCE WITH CONTRACTURAL OR OTHER
OBLIGATIONS NOR DETRACT FROM ANY OTHER BUYER’S RIGHTS.

REVIEWED AND ACCEPTED. NO FURTHER REVIEW


REQUIRED.

REVISE AND RESUBMIT. WORK MAY PROCEED


SUBJECT TO INCORPORATION OF CHANGES
INDICATED.

REVISE AND RESUBMIT. WORK MAY NOT


PROCEED.

; FOR INFORMATION ONLY.

BUYER’S $5(675(32129
SIGNATURE............................................... DATE...................................................