WD+7-22B Manual en

Wärtsilä id: DBAC790619 -
OPERATION AND MAINTENANCE

INSTRUCTIONS
Air cooled
WD 7-22
Screw Compressor
Version 1.00
This is the original language of the Manual
© 2012 Gardner Denver Oy

Assurance of Compliance with EC Requirements for a Machine
(Directive 2006/42/EC)
Manufacturer's Name: Gardner Denver Oy
Manufacturer's Address: Etu-Hankkionkatu 9

FIN-33700 Tampere
Finland
hereby assures that the manufactured machine Screw Compressor

Type: WD 7-22
with accessories
F005314
meets the EMC-directive 2004/108/EEC
and the machine directive 2006/42/EC
and pressure equipment directive (PED) 97/23/EC
and the enforcing national regulations VNA 400/2008
The machine also complies with the following EC

directives and the corresponding national regulations: 73/23/EEC
The following uniformed standards have been applied in EN 1012-1

the engineering of the machine: Compressors and vacuum pumps-
Safety requirements-Part 1:
Compressors
More technical information available from: Jyrki Mäkiö

Etu-Hankkionkatu 9
FIN-33700 Tampere
Finland
Tampere 11.5.2012
(Place) (Date)
(Signature)
Jyrki Mäkiö, Director of Engineering

(Signer, position in company)
Gardner Denver Oy
P.O.Box 516
FIN-33101 Tampere
Finland
1. Introduction ............................................................................................................................ 1
1.1 Storing the books ......................................................................................................... 1
1.2 Warranty terms............................................................................................................. 1
1.3 Log book....................................................................................................................... 1
1.4 Inquiries........................................................................................................................ 1
2. Safety ...................................................................................................................................... 2
2.1 Safety during installation and preparations for use ...................................................... 2
2.2 Safety during operation ................................................................................................ 2
2.3 Safety during maintenance........................................................................................... 3
2.4 Safety signs.................................................................................................................. 4
3. TECHNICAL DESCRIPTION .................................................................................................. 5

3.1 General......................................................................................................................... 5
3.1.1 WD 7-22 components ......................................................................................... 5
3.2 Control system ............................................................................................................. 6
3.2.1 Alarm signals-set points see Controller manual ................................................... 6
3.2.2 Service Countdown system.................................................................................. 7
3.2.3 Safety functions of the Controller ......................................................................... 7
3.2.4 Remote communication signals ........................................................................... 7
3.3 Limitations in use.......................................................................................................... 8
3.3.1 Limitations ............................................................................................................ 8
3.4 Location conditions....................................................................................................... 8
3.5.1 Air compressing process .................................................................................... 10
3.5.2 Oil circulation and compressed air circulation .................................................... 11
3.5.3 Air output regulating system............................................................................... 12
3.5.4 Compressor control systems.............................................................................. 12
3.5.7 Automatic load/unload....................................................................................... 13
4. INSTALLATION .................................................................................................................... 14
4.1 Installation Hook-up procedure .................................................................................. 14
4.1.1 Pre-installation ................................................................................................... 14
4.1.2 Ventilation of the compressor room.................................................................... 15
4.1.3 Removing the transportation supports ............................................................... 15
4.1.4 Electric connection ............................................................................................. 15
4.1.5 Connection to compressed air network and cooling water connections............. 16
4.2 Handling and transportation procedures .................................................................... 17
4.2.1 Lifting the compressor with lifting slings ............................................................. 17
4.2.2 Lifting the compressor using forklift.................................................................... 18
4.3 Storage and receipt procedures ................................................................................ 18
4.3.1 Storage procedure for compressors................................................................... 18
5. OPERATING INSTRUCTIONS ............................................................................................. 21

5.1 Hazards and protective measures.............................................................................. 21
5.2 Start, normal operation, stop and emergency stop .................................................... 21
5.2.1 Before start-up ................................................................................................... 21
5.2.2 Starting ............................................................................................................... 22
5.2.3 Stopping ............................................................................................................. 22
5.2.4 Emergency Stop................................................................................................. 23
5.2.5 After Emergency Stop ........................................................................................ 23
5.2.6 Operation of the compressor after power failure ................................................ 23
5.2.7 Setting the operating pressure ........................................................................... 24
6. Maintenance programme .................................................................................................... 25

6.1 Routine and periodic maintenance............................................................................. 28
6.1.1 Pre-maintenance procedures ............................................................................. 28

6.1.2 Post-maintenance procedures ........................................................................... 28
6.2 Oil ............................................................................................................................... 29
6.2.1 Oil recommendation for GD compressors ......................................................... 29
6.2.2 Oil specifications ................................................................................................ 29
6.2.4 Changing the oil filter and oil separator.............................................................. 31
6.2.5 Visual check for possible oil leaks...................................................................... 32
6.3 Visual inspection of hoses.......................................................................................... 32
6.4 Change the air filter cartridge ..................................................................................... 33
6.5 Electric box filter change ............................................................................................ 34
6.6 Cleaning the cooler ................................................................................................... 35
6.7 Replacing the belts..................................................................................................... 35
6.8 Removing the pulley and the conical sleeve .............................................................. 36
6.9 Mounting the pulley and the conical sleeve................................................................ 37
6.10 Checking tightness of electrical connections........................................................... 38
6.11 Testing the pressure relief valve .............................................................................. 38
6.12 Testing temperature alarm and shutdown................................................................ 39
6.13 Faultfinding / Troubleshooting .................................................................................. 40
7. Technical Appendixes ......................................................................................................... 43

1. Introduction
1. Introduction
Gardner Denver wishes you welcome among the users of Gardner Denver screw compressors!
This manual gives you instructions on correct and safe operation and maintenance of your screw
compressor.
Read these and other instructions with the compressor carefully before using your screw
compressor. This ensures correct preparations and use from the very beginning.
1.1 Storing the books
All the instructions in this manual have been provided to guarantee a long life and reliable operation of your
screw compressor.
Always keep the manual available near the compressor. Make sure that the compressor is operated and
serviced according to the instructions.
1.2 Warranty terms
Get acquainted with the Gardner Denver warranty terms, which are enclosed with the manuals for the
compressor. Fill in the warranty registration card with care and return it to the seller as instructed.
The warranty becomes void if the terms are not observed or if other than original Gardner Denver spare
parts are used. Use only the recommended AEON oil types in order to ensure undisturbed operation.
All the service and maintenance duties, which are not covered in this manual should be made only by
trained and qualified service personnel authorized by Gardner Denver or its representative.
1.3 Log book
There is a log book enclosed with the manuals for the compressor. Always fill it in after any maintenance or
repair work.
1.4 Inquiries
When making inquiries concerning your screw compressor, always quote the complete type specification
and the serial number as they are given on the data plate of the compressor.
Gardner Denver reserves the right to change the construction and manuals of the compressors without
prior notice.
1
2. Safety
2. Safety
The general safety instructions concerning the compressor are presented in this chapter.
Read also the safety instructions for transportation, installation, operation and maintenance
presented separately in each section of the manual.
Always read the safety instructions before starting to work.
The instructions concerning safety are marked with this symbol.
In addition to these instructions, the local regulations in your country may impose additional requirements
that must be observed.
2.1 Safety during installation and preparations for use
The noise level of the compressor, which is presented in the "Technical data", is determined according to
ISO2151 and ISO3744. The noise level may rise higher if the walls surrounding the installing location
reflect sound. Take this into consideration, when choosing the best location for the compressor.
Observe the local regulations concerning the use of ear protectors.
The intake air for the compressor must be clean and cool. Prevent the used and hot cooling air
circulating back to the cooling air intake. Make sure that foreign objects cannot get into the compressor
with the intake air. The intake air must not contain any explosive or inflammable gases or harmful
substances.
Do not exceed compressor's rated maximum pressure, capacity or rotation speed. For more details see
"Technical data".
Use pneumatic hoses that can hold the working pressure. Pay special attention to the hose mountings.
The pressure in the hoses must be removed before disconnecting. A whipping hose may cause
unpredictable damage.
The pressure vessels in the pressurized air network must be in accordance with the pressure vessel
regulations.
Only authorized and qualified personnel should make the electrical connections. For more information on
electrical connections, see "Electrical drawings".
The condensate water contains oil. It should be disposed of according to the local regulations on waste oil.
2.2 Safety during operation
Do not blow pressurized air against the skin.
Do not use the compressor with its doors open.
2
2. Safety
Use only the recommended AEON oil types. Do not mix different types of oil.
Compressors with remote start-up should be provided with a warning sign that indicates the method of
starting.
Do not use the compressor in explosive environment.
2.3 Safety during maintenance
While doing maintenance, the compressor must always be stopped and disconnected from the electrical
mains connection. The shut-off valve of the pressurized air network must also be closed. Make sure that
there is no pressure in the air/oil receiver before starting maintenance.
Starting of the compressor or compressors with remote control or in multi-compressor installation must be
prevented while maintenance work is in progress.
Use only original Gardner Denver spare parts.
Do not repair the receiver by welding.
All alterations must comply with the pressure vessel regulations PED 97/23/EC.
Do the regular checkups and maintenance of the compressor in order to ensure undisturbed operation.
Maintenance and service operations other than described in this manual must be left to service personnel
authorized by Gardner Denver.
In the frequency converter compressors, the high voltage can cause serious or fatal injury. Frequency
converter and motor connections can remain under high voltage after the main power is switched off.
Service is permitted only by trained and authorized personnel.
Only one safety function is allowed to be disabled at a time for any maintenance or troubleshooting
purposes.
3
2. Safety
2.4 Safety signs
Read User Manual before starting the compressor Wear ear protectors
Warning: hot surface Warning: risk of electric shock
Warning: compressor is remotely controlled and

Warning: moving parts
may start without warning
Warning: risk of hot exhaust fumes/hot air
General meaning of geometric shapes, safety colors and contrast colors for the safety signs
Graphical symbol
Geometric shape Meaning Safety color Contrast color
color
Mandatory action Blue White White

Circle
Warning Yellow Black Black

Equilateral triangle
4
3. TECHNICAL DESCRIPTION
3.1 General
The Gardner Denver compressor is an oil-cooled single stage screw compressor. The
pressurized air is produced with a screw air end driven by an electric motor. Oil is separated
from the compressed air in an oil separation receiver. The pressurized air and the oil are
cooled with separate coolers.
3.1.1 WD 7-22 components
Standard compressor is equipped with enclosure.
Figure 3-1 Air cooled compressor
19
5 13
12
6
4 8 16
7
15
3
18
17
2
10
11 1
No Component Purpose
1 Electric motor Rotates air end
2 Belts Power transmission
3 Air end Compresses air
4 Inlet valve Output control
5 Air filter Cleans intake air
6 Receiver Oil separation
Maintains minimum receiver pressure, non-return
7 Discharge valve
valve
8 Pressure relief valve Protects receiver against over pressure
9 Oil cooler Cools oil
10 After cooler Cools pressurized air
5
11 Fan Circulates air for motor cooling
12 Oil filter Purifies oil
13 Controller Compressor control
15 Control valves Compressor control
16 Main switch Power supply
17 Bolt for lifting the motor Belt change
18 Thermostat valve Maintains correct running temperature
19 Oil separator Oil separation
3.2 Control system
All the compressor settings are made by using the electronic Controller. For detailed
instructions for the controller, please refer to the Controller User's Manual.
The operation of the screw compressor is monitored by a control system comprising of:
1.Pressure transmitters and temperature sensors
2.System controller containing:
•Direct on-line (DOL)/star-delta (Y/D) (option)/frequency control(option).
•Electronic control for delayed automatic standby.
•Fully automatic continious running control.
•The compressor is working continously, loading, idling, modulating (option) and getting into
standby position.
•Full load/off load control.
•Automatic stop/start running control.
•The compressor will start and stop automatically within the defined pressure range. The
number of stops is limited to six to eight per hour (DOL) by a timer, as per recommenda-
tions of the motor supplier.
•Fault Log with the last 50 alarms (including date/time).
3.2.1 Alarm signals-set points see Controller manual
•High running temperature.
•High delivery temperature
•Inlet filter high DP alarm.
6
•Oil separator element high DP alarm.
3.2.2 Service Countdown system
The control system includes service timers for the following items:
•Oil change.
•Oil filter change.
•Oil separator cartridge change.
•Air filter change.
•El. box filter change.
•Motor lubrication interval.
•Intake/discharge valve service.
•Belt drive service
3.2.3 Safety functions of the Controller
The following safety features will cause the compressor to stop:
•High motor temperature, thermistor or thermal relay.
•High internal temperature, shut down at 115° C.
•High internal pressure (1,0 bar/10% above maximum working pressure).
•High delivery temperature, shut-down at 70° C.
•Analogue sensor fault.
•High differential pressure in normal operation.
3.2.4 Remote communication signals
The compressor control system provides the following remote signals:
Output signals:
•Local/Remote signal position(potential free contact).
•Load signal (potential free contact).
•Stand-by signal (potential free contact).
•Emergency stop remote indication signal (potential free contact).
7
•Common alarm signal (potential free contact).
•Delivery pressure (4-20 mA)(grounded).
•Running signal (potential free contact).
Input signals:
•External start/stop signal (2 wire & 3 wire system)(potential free contact).
•Remote emergency stop signal (potential free contact).
•Remote master/slave signal (potential free contact).
•Remote load/unload enable signal (potential free contact).
•Remote load/unload signal (potential free contact).
For further details of the Controller see the Controller User’s Manual.
3.3 Limitations in use
3.3.1 Limitations
The standard rotary screw compressor must never be either installed or used in any
explosive areas.
Secure safe air inlet avoiding any kind of explosive or imflammable and pollution atmosphere
elements.
3.4 Location conditions
The screw compressor unit must be installed on an even surface capable of handling the
weight of the unit as specified in technical specification, see technical appendix for more
information.
Observe the need for drainage for air condensate water.
The condensate water contains oil. Follow local regulations on

waste-oil disposal.
Consult the GA drawing in Technical Appendix for the minimum required distance to walls and
other equipments to reserve sufficient maintenance space.
Ensure the compressor room is properly ventilated.
Use external ventilation and exhaust fan if needed.
8
Ensure that the hot exhaust air from the compressor or other
equipment is not re-circulating to the air intake or to the cooling air
inlet.
Ensure that the air intake for the compressor is kept clean and cool
below maximum allowed ambient temperature.
Ensure that foreign objects cannot get into the compressor through
the air inlet.
Ensure that the intake air does not contain any explosive or
inflammable gases or polluted air.
If the compressor is provided with air ducts, ensure that the

required cooling air volume and the maximum pressure drop of the
fan can be obtained.
The compressor’s noise level, measured in an open space, may rise higher if the installation
is surrounded by walls that reflect sound.
Observe the current local regulations for use of Personal Protective

Equipment (PPE).
Ensure correct cooling water pressure and flow.
Ensure service space around and above the compressor.
9
3.5 FUNCTIONAL DESCRIPTION
3.5.1 Air compressing process
Figure 3-2 Air end process
The compressor air end is driven by an electric motor and compresses the air as shown
Figure 3-2 Air end process.
• At the end of the compression phase air/oil mixture enters the air/oil separator.
• The air end consists of a pair of rotors with a male and a female profile. The air is
compressed between the rotors by decreasing volume from the inlet to the outlet
port.
The air in the compressor and air end unit itself is cooled by oil that is injected into the air
end unit. The oil also lubricates the bearings and seals the clearances between the rotors and
the housing.
10
3.5.2 Oil circulation and compressed air circulation
Air cooled compressor
Figure 3-3 Oil circulation, air cooled compressor
1 Intake air filter Cleans inlet air
2 Intake valve assy Output control
3 Compressor air end Compresses air
4 Oil receiver Separates oil from compressed air, oil sump
5 Oil separator Separates oil from compressed air
6 Discharge valve Maintains min. receiver pressure, non return valve
7 After cooler Cools pressurized air
Prevents pressure flow through inlet valve when the

8 Non return valve
compressor stops
9 Oil thermostat valve Maintains target running temperature
10 Oil cooler Cools oil
11 Oil filter with bypass Purifies oil
12 Oil drain, plug Oil drainage
13 Solenoid valve Controls intake valve and blow down
11
14 Vacuum switch Inlet filter condition indicator
15 Safety/relief valve Protects receiver against over pressure
16 Temperature sensor TT1 Measures air end internal temperature
17 Temperature sensor TT2 Measures air delivery temperature
18 Pressure sensor PT1 Measures internal pressure
19 Pressure sensor PT2 Measures delivery pressure
20 Orifice Shaft seal oil removal
21 Controller Compressor control
Prevents oil leakage

22 Shaft seal
23 Orifice Controls start up flow
Inlet valve control: Allows pressure rise during start

24 Start up valve up
25 Unload pressure valve Inlet valve control: Blow down control
Oil circulation in air cooled compressor
From the compressor air end the mixture of pressurized air and oil mist is ducted into the oil
separating receiver, where oil is separated from the pressurized air. The separating process
has two phases.
Main part of the oil is separated in the cyclone in the receiver, where the centrifugal effect is
utilized. The remainder of the oil is separated by means of one or more oil separating
cartridge (5). The oil separated at the cartridge is led back into circulation.
From the receiver, the hot oil is led through the cooler (10) and the oil filter (11), and
returned to circulation.The thermostat valve (9) directs oil through the oil cooler when the
temperature on air end discharge is increasing.
The forced oil circulation is maintained by the pressure difference between the receiver and
the compressor air end. To quarantee oil circulation whenever the compressor produces
pressurized air, the discharge valve (6) prevents the receiver pressure from dropping below
the set minimum level (5 bar).
3.5.3 Air output regulating system
The purpose of the regulating system is to adjust the pressure and output of the compressed
air according to the air consumption.
12
3.5.4 Compressor control systems
Load/Unload control systems:
A compressor with load/unload control system means that inlet valve is either fully closed or
fully open. When the inlet valve is fully closed, the compressor is not producing air. When the
inlet valve is fully open, the compressor is producing 100% of its capacity.
3.5.5 Compressor running fully loaded
Compressor running loaded means that the intake valve is open and the compressor is
producing compressed air.
As the compressor starts, the solenoid valve (13) of the inlet valve becomes active. A partial
vacuum is formed in the suction line, the inlet valve opens, and the compressor starts
producing compressed air. Minimum pressure valve (6) opens when pressure is 5 bar in the
receiver. Compressor starts to produce air in the network at full capacity.
3.5.6 Compressor running unloaded
Compressor running unloaded means that the inlet valve is closed and the compressor is not
producing compressed air. To decrease power consumption the receiver is blown down.
As soon as the discharge pressure reaches the set maximum, solenoid valve(13) opens the
passage under the inlet valve piston and pressure closes the valve plate.
Simultaneously, solenoid valve (13) opens receiver blow down passage.
3.5.7 Automatic load/unload
• If air consumption stops and the network pressure rises over the unload, the
compressor runs unloaded until the standby run on time.
• If the network pressure drops below the load limit, the compressor will
automatically restart.
13
4. INSTALLATION
4. INSTALLATION
4.1 Installation Hook-up procedure
4.1.1 Pre-installation
Welding can damage electrical parts on the compressor.
Ground current can damage electrical parts.
Do not damage the base frame when installing the compressor.
To secure trouble-free operation ensure that the foundation is strong,

stable and without vibration. This applies to both rigid and flexible
mounted units.
If the compressor is provided with air ducts, ensure that the required
cooling air volume can be obtained and mark also the maximum pressure
loss of the fan.
Make sure that main power voltage is correct and according to the
regulations/standards.
Ensure service space above and around the compressor. Ref. GA drawing.
14
4. INSTALLATION
4.1.2 Ventilation of the compressor room
The drawing below gives an example of how the ventilation of the compressor room should
be arranged.
The compressor minimum

distances from the walls are
shown in the general
arrangement drawing
Figure 4-1 Ventilation of the compressor room
Ensure the exhaust is effective. Use a separate fan if necessary. The

cooling air temperature must not drop below 0° C. Make sure the ducts are
correctly dimensioned.
1. If air duct is mounted, observe the service space needed for cleaning of the
coolers and maintenance.
2. Observe the possibilities for recirculation of cooling air.
Most power input to the motor is transferred back as radiation heat to the
ambient air when running an air cooled compressor.
4.1.3 Removing the transportation supports
Remove the transportation supports and make sure the motor is in its correct position and
belts are correctly tensioned. See item 6.7 “Replacing the belts”.
4.1.4 Electric connection
The electric connection must be made according to IEC stadards. All local
safety regulations must be followed. Only qualified electricians are
allowed to do power supply connections.
Ensure the electric supply voltage is correct in accordance with the technical datasheet.
Maximum acceptable tolerance is +-5%.
Connect the power supply cable to the main switch of the compressor.
15
4. INSTALLATION
Ensure the ground cable is mounted correctly.
Check the power requirement of the compressor package for correct cable
size. Sizing of cables and main fuses must be determined by an authorized
electrical engineering company.
The compressor package must be protected against overload from the

power supply system . For electrical termination details, plese see a
separately provided electrical drawing.
If ambient temperature sensor is misplaced into a warm air flow, the

compressor will run too hot.
4.1.5 Connection to compressed air network and cooling water connections
1 network connection
2 not in use
Figure 4-2 Connection to compressed air network and cooling water connections
Install a shut-off valve between the compressor and the compressed air network for
maintenance purposes.
Note that a non -return valve between the compressor and the network
will cause regulating problems to the compressor.
Ensure the pipe connection is not smaller that the size of the compressor
air outlet size. The pipeline dimension must be designed to avoid pressure
drop. Use the same size of the flexible hose to connect the compressor to
the air network.
16
4. INSTALLATION
If a piston type compressor is connected to the compressed air network ,

an air receiver must be installed between the piston and screw
compressor.
4.2 Handling and transportation procedures
If the compressor needs to be transported in temperature below 0° C,

make sure that the water circuit is empty of water or filled with glycol.
4.2.1 Lifting the compressor with lifting slings
DO NOT STAND OR WALK UNDERNEATH THE LOAD.
When lifting the unit to be aware of the centre of gravity of the

compressor, please see GA drawing of the compressor.
Lifting slings should not press against any compressor part.
• See GA drawing for lifting dimensions.
Figure 4-3 Lifting the compressor with lifting slings
17
4. INSTALLATION
4.2.2 Lifting the compressor using forklift
DO NOT STAND OR WALK UNDERNEATH THE LOAD.
It is important when lifting the unit to be aware of the centre of gravity of

the compressor, please see Dimensional drawings of the compressor.
1. Insert the forks under the compressor in the directions shown in the following
figure.
Figure 4-4 Moving the compressor with a fork lift truck
4.3 Storage and receipt procedures
4.3.1 Storage procedure for compressors
GENERAL STORAGE CONDITIONS
•Storage location: dry with humidity below 60% Rh.
•Storage temperature: above 5° C.
•Protect the compressor against direct sunlight, rain, dust etc.
•Store the compressor in upright position and never stacked.
18
4. INSTALLATION
STORAGE CONDITIONS BELOW 5° C (UNDER 0 ° C)
•Storage location: dry with humidity below 60% Rh.
•Protect the compressor against direct sunlight, rain , dust etc.
•Store the compressor in upright position and never stacked.
•Drain the cooling water system totally to prevent freezing damages on coolers, hoses and
connections. Use compressed air to empty the water circuit.
•Before start up, make sure the temperature in the compressor room is well above 0° C for a
period so there is no ice left in the cooling water system.
•The recommendation is to have the compressor filled with synthetic oil when stored.
ONSHORE STORAGE
General requirements:
•Add 0,5 liters synthetic oil through the air inlet valve to the air end.
•Every 6 months replace anticorrosion inhibitor in the electric cabinet and elsewhere in the
compressor.
•Once a month, manually rotate the compressor drive shaft and electric motor´s shaft a few
revolutions.
Units with belts:
•Slacken the drive belts while the unit is in storage.
ONBOARD STORAGE
•Read storage conditions below 5° C.
•Ensure sufficient rust/corrosion protection of non-painted surfaces.
•Check direction of rotation if the electric power has been disconnected.
•Other points as in onshore storage.
When welding on the vessel/ship, be aware of possibility of ground

current, which can damage electrical components.
Protect the compressor from grinding hazards.
19
4. INSTALLATION
4.3.2 Receipt Procedure
Upon receipt verify that all parts are present as detailed in packing list.
Verify that storage conditions are as detailed in "Location conditions" item 3.4
The compressor will not start if ambient temparature is below 1° C.
20
5. OPERATING INSTRUCTIONS
5.1 Hazards and protective measures
BEWARE OF EXPOSING TO ROTATING PARTS IF OPENING DOORS AND/

OR COVERS.
Beware of high temperature on surfaces.
Beware of high noise level.
5.2 Start, normal operation, stop and emergency stop
5.2.1 Before start-up
The start-up must be made by qualified personnel.
1. For correct oil level check the receiver. For more details, see "Adding/changing oil"
item 6.2.3 and “Oil recommendation for GD compressors” item 6.2.1.
2. Open the network shut-off valve.
3. Add 0,5 l synthetic oil through the air inlet valve to the air end. Rotate the air end
by hand before start up. Note that power must be off.
4. Turn the main switch to ON position. If alarms are shown, press the RESET button
of the controller.
5. See the arrows on the air end for the correct direction of rotation.
6. Before final start up check correct rotation direction of the air end using Motor Jog
Function. For more information on Motor Jog Function, see the Controller manual.
In case of incorrect rotation direction change the supply phase order.
Wrong direction of rotation will damage the air end.
The air end's direction of rotation must be checked every time the supply
or motor cables have been disconnected or reconnected.
7. Check Unload and Load pressures and adjust if needed. See Controller manual for
more details or contact GD technical suppport.
21
8. Start the compressor by pressing the START button.
Do not use the shut-off valve to control the air flow to the compressed air
network. The misuse of the shut-off valve will cause rapid blow down and
oil carryover.
Avoid oil overfilling. When filling oil, do not exceed the top mark on the oil
indicator. See “Adding oil” item 6.2.3.
5.2.2 Starting
1. Ensure that the instructions in "Installation hook-up" item 4.1 have been done .
2. Close the compressor cabinet doors.
BEWARE OF EXPOSING TO ROTATING PARTS IF OPENING DOORS.
Do not open the unit’s cabinet doors when the compressor is running as
this will impact the cooling of the compressor.
3. Turn the main switch to ON position.
4. If there are alarms, press the controller's RESET button until all are confirmed.
5. Press the START button.
The compressor will start and stop automatically in on position.
5.2.3 Stopping
• Press the STOP button and wait until the compressor stops after the fixed idling
time.
It is recommended to leave the main switch turned on for night times and
weekends to prevent moisture from gathering into the electronics. Space
heater in motor will not be active if main switch is turned off.
Do not stop the compressor using emergency stop unless required.
Always turn off the main swich when doing inspection and maintenance.
22
5.2.4 Emergency Stop
IN CASE OF EMERGENCY, THE COMPRESSOR CAN BE STOPPED USING THE

‘EMERGENCY STOP’ DEVICE ON THE CONTROL PANEL.
Use the Emergency Stop only in emergency situations. Constant use

shortens the life time of the compressor.
Use of the Emergency Stop might cause increased oil carryover.
Using the Emergency Stop device causes simultaneously inlet valve to close, blowdown valve
to open and all the motors to stop. In order to restart the compressor, the Emergency Stop
device must be retracted and all the possible fault conditions must be cleared from the
controller.
See the Controller User’s Manual for more details.
The compressor stops instantly, when the Emergency Stop device is pushed.
5.2.5 After Emergency Stop
To restart the compressor:
1. Turn the Emergency Stop device clockwise to release it.
2. Press the controller's RESET button.
3. Press the START button.
Oil mist from intake valve may appear when using emergency stop.
5.2.6 Operation of the compressor after power failure
If the compressor has had a power failure, it needs to be started again manually.
If the automatic start after power failure is activated, the compressor will
start automatically after a set time.
23
In multi-compressor installation, the restart delays must be set in steps in order to avoid
simultaneous starts of compressors that may collapse the electrical supply network.
See the Controller User’s Manual for more details.
5.2.7 Setting the operating pressure
See the Controller User's Manual for more details.
Figure 5-1 Electronic controller
The Load and Unload pressures must be determined before starting the compressor. The
Unload set point pressure controls at which pressure the compressor unloads . The Load set
point pressure controls at which pressure the compressor will start loading. The default value
for Unload pressure is the compressor maximum working pressure. Press the MENU button to
access the Menu structure.
4. The Unload and Load settings are under P01 (User Setup).
5. Adjust the Unload and Load pressure values. See the Controller User’s Manual for more
details.
The recommended pressure difference between the Load and Unload

pressures is 1 bar. If smaller pressure difference is required, please
contact GD.
Too small pressure difference causes foaming of the oil. This increases the
oil consumption and wearing of the components.
The Unload pressure cannot be adjusted higher than the compressor’s

allowed maximum pressure.
24
6. Maintenance programme
It is important to record all service and maintenance activities, please be

sure to fill in the compressor log book.
Do not neglect the regular checkups and maintenance of the compressor.
Always wear PPE (personal protective equipment)where required.
Maintenance and service operations other than those described in this

manual must be left to service personnel authorized by Gardner Denver.
The service chart is presented on the next page.
25
Service chart
Service schedule
1) Daily
2) 200 h
3) 1500 h
4) 3000 h
5) 9000 h
6) 20 000 h
7) 30 000 h
8) Once a year
Operation 1 2 3 4 5 6 7 8
Check controller display for alarms x
Check oil level** x
Check hoses for leakages x
Check running temperature x
Tighten electrical cables x x
Tighten connections and screws x x
Replace oil filter x
Change oil x
Replace oil separator cartridges x
Replace air filter x
Change belts x
Clean cooler inside (water cooled compressors) x
Clean cooler externally (air cooled compressor) x
Check operation of safety valve x
Replace rep. kit inlet valve x
Replace discharge valve x
Change solenoid valve for load function x
Change oil thermostat element x
Check air end and motor pulley x
Replace motor bearings x
Replace air end with factory reconditioned unit x
Lubricate el.motor bearing according to motor manual ***
Replace el. box filters x x
Check contactor´s contacts x
Replace oil and air hoses x
26
* For oil recommendation see User Manual.

** Stop the compressor at least for 10 minutes before checking the oil level. Oil must be
according to oil manufacturer´s specification. See also number 4 in the list below for
more information.
***For amount and type of grease, see motor identificartion plate or manual.
MAINTENANCE OF COMRPESSORS
1. Do not fill oil between oil changes without knowing the reason for the oil
consumption. When oil is needed it is recommended to make log with the
amount and type of oil filled. Never mix oil types.
2. The compressor needs to be started minimum once a week and to run for one
hour to secure that all water condensate in the oil system is evaporated.
3. Before starting the compressor after a week stand still, open the oil drain plug
and check that no water is detected in the oil reservoir. If water is found drain
it out before starting the compressor.
4. The running temperature of the compressor must be minimum 50°C above

the cooling media.
All alarms and service signals from the compressor controller must be
followed.
Always adjust service counter in controller when servicing the
compressor. Different installations, ambient temperature and running
conditions might lead to different service schedule.
Intervals are based on synthetic screw compressor oil ISO VG 46.
To maintain warranty it is essential to only use original spare parts from

GD.
27
6.1 Routine and periodic maintenance
6.1.1 Pre-maintenance procedures
Beware of rotating parts if opening doors.
Certain compressor sections can reach high surface temperature.
1. Stop the compressor and make sure that there is no pressure in the receiver The
blow-down function empties the receiver after stopping, wait for 2 minutes.
2. Turn power off with the main switch and make sure that the compressor cannot
be accidentally started.
Compressors with remote control and/or used in a sequencing mode must

be disabled from the remote control. A “Service in Progress” -sign must be
placed on the starting device and the compressor involved, when the
maintenance personnel is not present.
3. Close the shut-off valve between the network and the compressor.
4. Open the pressure relief valve’s cap with 4 to 5 turns to release the pressure.
Figure 6-1Removing pressure from the space between the discharge valve and the system shut-off valve
The space between the discharge valve and the system shut-off valve
stays under pressure when the compressor is stopped and the shut-off
valve is closed. Release the pressure by loosening the plug (1) on the
disharge pipe until you hear the air coming out.
6.1.2 Post-maintenance procedures
1. Close the pressure relief valve.

2. Open the shut-off valve between the network and the compressor.
28
3. Switch ON main power.

4. Start the compressor.
6.2 Oil
6.2.1 Oil recommendation for GD compressors
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.
6.2.2 Oil specifications
The recommended compressor lubricants are:
• Gardner Denver AEON 3000 (type F 2105).

• Gardner Denver AEON 9000 SP.
Recommended compressor lubricants
AEON 3000 (type F 2105)* AEON 9000 SP

Package size
order number order number
20 liters 033 891 42 897 560 89
209 liters 033 891 43 897 676 89
Specific AEON lubricants are recommended for use in this equipment. Other lubricants will cause:
• shortened life time of oil filter, oil separators and oil

• varnishing and blockage of oil circuit
• increased oil consumption
• excessive oil carryover and compressor damage
Do not mix different types of oil.
Note! If wrong oil type has been used or oil circuit is varnished, please contact an authorized distributor of Gardner
Denver for oil circuit cleaning instructions.
29
Oil and oil filter change:
Oil change must be done at 1500 running hours or at least every second year whichever
occurs first. See service chart.
Do not mix different oil/grease types.
If the oil type is changed, also change oil filter cartridge. Start the
compressor and run the compressor for 2-3 hours, then change oil & filter
again to avoid the mix of different oil types.
6.2.3 Adding/changing oil
Figure 6-2 Adding/changing oil
Adding oil
1. Before starting the maintenance work see “Pre-maintenance procedures” item

6.1.1 for more details.
2. Open the oil filling plug (1) and add new oil . Do not over fill!
3. Close the filling plug (1).
4. Always update the log book with running hours and the amount of oil added.
5. If no other maintenance is to be done, carry out the post maintenance procedure,

see "Post-maintenance procedures" item 6.1.2.
30
Changing oil
Use only the original GD oil filters.
Dispose of used oil according to current local regulations on handling of

waste oil.
1. Run the compressor until the oil temperature is +40...+50°C.
2. Before starting the maintenance work see "Pre-maintenance procedures" item

3. Open the oil filling plug (1) and the drain plug (3), and let oil drain out.
4. Close the drain plug (3) and fill in the oil sump with fresh oil.
5. Close the filling plug (1).
6. Reset the oil exchange time in the controller at the MAINTENANCE ADJUSTMENT
menu. See also "Oil" item 6.2 and "Oil recommendation" item 6.2.2.
7. Run the compressor for 5 minutes, stop and wait for 5 minutes. Check oil level
and add oil if necessary.
8. Always update the log book with running hours and amount of oil changed.

see "Post-maintenance procedures" on item 6.1.2.
If the oil type is changed, please contact an authorized distributor of

Gardner Denver for more details.
6.2.4 Changing the oil filter and oil separator
Dispose of the used filter according to current local regulations on toxic

waste.
Oil filter is mounted directly to the air end.

2. The oil filter/oil separator is mounted on the air end. Use a protective cloth, as
some oil will drain out when the oil filter is removed.
3. To remove the oil filter/oil separator, turn it counter-clockwise.
4. Lubricate the oil filter/oil separator sealing ring with clean oil.
31
5. To install the oil filter/oil separator, tighten it up clockwise by hand.

Figure 6-3 Changing the oil filter (1)and oil separator (2)
6.2.5 Visual check for possible oil leaks

2. Visually check the inside of the compressor for oil leaks, in particular around the
compressor unit, the oil cooler and the oil hoses.

6.3 Visual inspection of hoses
1. Before starting the maintenance work see "Pre-maintenance procedures" ITEM

2. Check all hoses for cracks, blisters, tears, leaks, and stiffness. Replace as required

REMOVE THE PRESSURE IN THE HOSES BEFORE DISCONNECTING.
ALWAYS USE ORIGINAL PNEUMATIC HOSES THAT ARE RATED TO

WITHSTAND THE WORKING PRESSURE AND TEMPERATURE. PAY
PARTICULAR ATTENTION TO THE HOSE MOUNTINGS AS A LOSE HOSE CAN
FLAIL AND CAUSE UNPREDICTABLE DAMAGE.
32
Flexible hose for connection to the onboard network of the vessel is not
included in the standard equipment for the compressor.
6.4 Change the air filter cartridge
Do not reuse the filter cartridge.
Dispose of the used filter according to current local regulations on toxic

waste.

2. Remove the filter frame (1) and the old filter (2).
3. Clean the housing inside.
4. Mount a new filter and filter frame.

Figure 6-4 Replacing air filter
Figure 6-5
33
6.5 Electric box filter change

2. Turn the main switch off.
3. Open the electric cabinet door.
4. Remove the flters.
5. Clean the housing inside.
6. Mount a new filter.

see "Post-maintenance procedures" item 6.1.2
1
1
Figure 6-6 Changing electric box filters
34
6.6 Cleaning the cooler
WEAR FACEMASK WHEN CLEANING THE COOLER TO PROTECT AGAINST

DUST INHALATION.
A clogged cooler increases the discharge temperature and may lead to a

compressor stoppage.
After cleaning check the cooler for internal leakages.
Danger of damage for sealing of surfaces. Do not clean sealing surfaces

with sharp objects. Scores in sealing surfaces may cause leaks.
6.6.1 Cleaning of the cooler in air cooling system
Figure 6-7 Cleaning the cooler
Clean the cooler by directing jets of pressurized air inside. For a more effective cleaning
brush the underside of the cooler.
If the cooler is very dirty, remove it from the compressor and clean up the outside with mild
detergent.
Before reassembly after cleaning work remove old gaskets, clean the sealing surfaces from
gasket residuals, install new gaskets, o-rings must be generally replaced.
6.7 Replacing the belts
The belts are kept always correctly tensioned by the motor weight.

2. Remove the back panel or service hatch (1).
3. Lift the motor up by fastening the bolt (2).
35
4. Change the belts (3).
5. When the bolt loosens the new belts are automatically on right tightness.

Figure 6-8 Replacing the belts
6.8 Removing the pulley and the conical sleeve
1. Remove the two screws and insert one into the removal hole.
2. Tighten the screw evenly until the sleeve comes off the hub.
3. Remove the loose pulley manually from the shaft, taking care not to damage the
shaft (do not hammer).
4. Sleeve comes off with the pulley.
36
6.9 Mounting the pulley and the conical sleeve
1. Remove protective grease from the sleeve and the pulley hub. Fix the sleeve to
the pulley and align the holes.
2. Grease the two fixing screws (1), insert them in the holes shown in the figure,
and tighten lightly. Threads are in the pulley.
3. Clean the shaft, and mount the pulley with the sleeve on it. Note that the sleeve
fastens first, after which the pulley can still be moved a bit in relation to the
sleeve. Bear this in mind when aligning the pulleys.
4. Tighten the screws equal tightness with a spanner.

5. Knock the sleeve lightly with a drift, and retighten the screws. Repeat this a few
times to make sure the sleeve is firmly fixed in place.
6. Check the tightness of the screws from time to time.
7. Fill the extraction holes e.g. with grease to protect them against dirt.
Sleeve Tightening torque Nm
1610 20
2517 49
3020 92
Sleeve type is marked on the end of the sleeve.
37
6.10 Checking tightness of electrical connections
See the correct switch type according to the compressor model from the
Electrical drawings. Check all control voltage connections
Switch off the supply power to the compressor.
While using the compressor, the electronical connections may become loose. During
maintenance it is important to control the tightness of the main cable connections the supply
cables connected to the load break switch and the contactors. Tighten the screws in the load
break switch with torques given in the table below. For correct component type, see the
Electrical drawings.
Tightening torques of the load break switches
Load break switch type Maximum tightening torque
OT 63 2 Nm
6.11 Testing the pressure relief valve
THE COMPRESSOR MUST BE STOPPED AND SECURED FROM AUTOMATIC

RESTART BEFORE ATTEMPTING THIS PROCEDURE.
The opening pressure of the pressure relief valve must be tested in a separate pressurized air
line. The pressure relief valve has been tested at the manufacturer's site before shipping out
the compressor. If the valve has been replaced, it needs to be tested for proper operation.
This procedure can be performed only by a qualified mechanican.The operation of the valve
can be tested by turning the cap (1) counter-clockwise 1 to 2 turns. Always tighten up the
pressure relief valve cap properly to avoid damage caused by vibration.
Figure 6-9 Testing of the pressure relief valve
38
6.12 Testing temperature alarm and shutdown
The water outlet must be left open in order to avoid extreme danger.
The alarms might have a short delay time. ( For example 30 seconds).
Immediate stop will occur at +115 °C.
Air cooled systems:
• Air outlet temperature: Use hot air gun to heat the sensor until alarm is reached at 65°C.
Continue to heat until shutdown is reached at 70°C.
• Block the cooler airflow or open the service doors until internal running temperature
reaches the alarm point of 110°C. Continue until shut down point is reached at 115°C.
39
6.13 Faultfinding / Troubleshooting
Troubleshooting chart
Problem Possible cause Possible cause and repair
Network pressure is • wait, compressor starts

above compressor’s lower automatically when Start button is
pressure limit. pressed
• reset main switch and check the

Main motor is overloaded.
reason for overload
Fuses are blown. • replace fuses and check reason
Emergency Stop button is • release emergency stop button

COMPRESSOR IS pressed.
STOPPED AND FAILS
TO START Temperature sensor has • examine cause of overheating
detected high • allow compressor to cool down and
temperature. restart
Main switch auxiliary • replace auxiliary contact

contact is faulty.
Fault in electric equipment • check electric equipment

e.g. contact fault at • check points
contactor points or • replace
damaged contactor coil.
Oil level is low. • add oil
Thermostat valve • check the function of thermostat

functions incorrectly. valve
Pressure is above rated • adjust pressure to be correct

maximum pressure. • check inlet valve function
COMPRESSOR IS
OVERHEATING • change oil according to oil
recommendation
Wrong oil type. • change oil filter
• flush oil system before filling new
oil
Cooler is dirty. • clean the cooler
40
Oil separator is blocked. • replace separator
Air filter is dirty. • replace filter
The blow-down valve is • check operation of controlling

open when compressor solenoid valve
OUTPUT runs loaded.
INSUFFICIENT Minimum pressure valve • check operation of the valve
is working incorrectly.
Air consumption is too • check network for leaks and air

high. consuming devices
Safety valve is open. • close the valve
• change oil according to oil

Wrong oil type.
recommendations
OIL CONSUMPTION IS Output air temperature is • check ambient temperature

TOO HIGH too high. • check thermostat
Oil separator is blocked. • replace oil separator element
Cycling running. • readjust pressures and inlet valve
Inlet valve is leaking or • check condition of solenoid valve

open. Y1
COMPRESSOR IS Supply voltage is low. • check supply voltage

STARTING SLOWLY • change oil type according to oil
Wrong oil type.
recommendations
Pressure in receiver. • wait
Load/unload pressure • check and readjust the pressure

setting are incorrect.
Pressure setting range is • adjust pressure range wider

too narrow.
COMPRESSOR IS
Water in network. • drain water out
UNLOADING TOO
OFTEN • check valves and treatment
Network volume is too devices
small. • check if the network is correctly
dimensioned
After-filter is clogged up. • replace filter
Pressure settings are in- • readjust

correct. • check the inlet valve
COMPRESSOR IS NOT
Inlet valve is not working. • check operation of valve
RUNNING UNLOADED
Solenoid valve Y1 is • replace the solenoid valve
faulty.
41
Unit’s shaft seal is • replace

NETWORK PRESSURE leaking.
RISES OVER SET • solenoid valve (Y1) is broken,
PRESSURE VALUE Inlet valve is not closing replace
properly. • controller relay output is not
working
Please also refer to the error messages, see Control system.
42

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Wärtsilä id: DBAC790619 -

OPERATION AND MAINTENANCE

This is the original language of the Manual

© 2012 Gardner Denver Oy

Assurance of Compliance with EC Requirements for a Machine

Manufacturer's Name: Gardner Denver Oy

Manufacturer's Address: Etu-Hankkionkatu 9

hereby assures that the manufactured machine Screw Compressor

meets the EMC-directive 2004/108/EEC

and the machine directive 2006/42/EC

and pressure equipment directive (PED) 97/23/EC

and the enforcing national regulations VNA 400/2008

The machine also complies with the following EC

The following uniformed standards have been applied in EN 1012-1

More technical information available from: Jyrki Mäkiö

Jyrki Mäkiö, Director of Engineering

3. TECHNICAL DESCRIPTION .................................................................................................. 5

5. OPERATING INSTRUCTIONS ............................................................................................. 21

6. Maintenance programme .................................................................................................... 25

6.1.1 Pre-maintenance procedures ............................................................................. 28

7. Technical Appendixes ......................................................................................................... 43

1.1 Storing the books

1.2 Warranty terms

1.3 Log book

Always read the safety instructions before starting to work.

The instructions concerning safety are marked with this symbol.

2.1 Safety during installation and preparations for use

Observe the local regulations concerning the use of ear protectors.

2.2 Safety during operation

Do not blow pressurized air against the skin.

Do not use the compressor with its doors open.

Do not use the compressor in explosive environment.

2.3 Safety during maintenance

Use only original Gardner Denver spare parts.

Do not repair the receiver by welding.

2.4 Safety signs

Warning: hot surface Warning: risk of electric shock

Warning: compressor is remotely controlled and

Warning: risk of hot exhaust fumes/hot air

Mandatory action Blue White White

Warning Yellow Black Black

3.1.1 WD 7-22 components

Standard compressor is equipped with enclosure.

Figure 3-1 Air cooled compressor

3.2 Control system

1.Pressure transmitters and temperature sensors

2.System controller containing:

•Direct on-line (DOL)/star-delta (Y/D) (option)/frequency control(option).

•Electronic control for delayed automatic standby.

•Fully automatic continious running control.

•Full load/off load control.

•Automatic stop/start running control.

•Fault Log with the last 50 alarms (including date/time).

3.2.1 Alarm signals-set points see Controller manual

•High running temperature.

•High delivery temperature

•Inlet filter high DP alarm.

•Oil separator element high DP alarm.

3.2.2 Service Countdown system

•Oil filter change.

•Oil separator cartridge change.

•Air filter change.

•El. box filter change.