Translation of the original operating

instructions

Screw compressor
ESM55 - ESM75 V4
ESM55e - ESM75e V4
VS55 - VS75 V4

GB ZS1215749 / FA - November 2021

 Contents
TM

CONTENTS

1 Foreword.................................................. 4 6 Commissioning and operating.............. 33

1.1 About these operating instructions......4 6.1 Initial commissioning...........................33
1.2 Notes...................................................4 6.2 Normal operation................................ 35
1.3 Intended use....................................... 5 6.3 Routine commissioning.......................35
1.4 Intentional misuse............................... 6 6.4 Commissioning after a long shutdown 35
1.5 Service................................................ 6 6.5 Commissioning after a fault................ 36
1.6 Nameplate...........................................7
7 Troubleshooting...................................... 37
2 Safety conditions.................................... 8
2.1 General safety instructions................. 8 8 Maintenance and Service....................... 43
2.2 Instructions about particular types of 8.1 General notes..................................... 43
danger................................................. 8 8.2 Inspection of protective and safety
2.3 Protection and safety equipment........ 9 equipment........................................... 44
2.4 Residual hazards................................ 10 8.3 Service................................................ 45
2.5 Identification of safety instructions...... 10 8.4 Routine maintenance.......................... 45
2.6 Safety sign.......................................... 10 8.5 Maintenance plan with 2000 hour
service package.................................. 46
2.7 Transport and installation....................14
8.6 Maintenance plan without 2000-hour
2.8 Normal operation................................ 14
service package.................................. 48
2.9 Special tasks.......................................14
8.7 Maintenance plan (extended
2.10 Conversions and changes to the warranty)............................................. 50
machine...............................................15
8.8 Maintenance work...............................51
8.8.1 Filter mats (air-cooled system)........... 51
3 Design and function............................... 16
8.8.2 Switch cabinet inlet filter..................... 51
3.1 General description.............................16
8.8.3 Oil change...........................................52
3.2 Compressor design.............................17
8.8.4 Oil filter................................................53
3.3 System scheme.................................. 21
8.8.5 Oil fine separator................................ 53
3.3.1 Oil circuit............................................. 22
8.8.6 Air filter................................................54
3.3.2 Oil regulation system.......................... 22
8.8.7 Moisture sensor protective cap........... 55
3.3.3 Air circuit............................................. 23
8.8.8 Connection terminals in the switch
3.3.4 Cooling water circuit (only "-W")......... 23 cabinet / control transformer setting....55
3.3.5 Controller.............................................23 8.8.9 Drive motor / Lubricator...................... 56
3.4 Lubricant system.................................24 8.8.10 Control system.................................... 57
3.5 Heat recovery ESM55 - ESM75..........25 8.8.11 Checking intervals for pressure
vessel and electrical installation..........57
4 Transport and positioning......................27 8.8.12 Maintenance instructions and
4.1 Transport............................................. 27 lubricant recommendations for fixed
compressors........................................57
4.2 Storage................................................28
8.8.13 Testing the temperature sensor.......... 58
4.3 Installation........................................... 28

9 Appendix.................................................. 59
5 Preparations for commissioning........... 30
9.1 Shutdown............................................ 59
5.1 Pipelines..............................................30
9.2 Lubricants and additives..................... 59
5.2 Compressed air connection................ 30
9.3 Removal.............................................. 59
5.3 Electrical connection........................... 30

2 / 76 GB November 2021
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Contents

9.4 Disposal.............................................. 60
9.5 Cooling Water Quality......................... 61
9.6 Technical Specification........................61
9.6.1 ESM55 / ESM55e + ESM75 /
ESM75e, 50Hz, air-cooled "A", water-
cooled "W".......................................... 61
9.6.2 ESM55 / ESM55e + ESM75 /
ESM75e, 60Hz, air-cooled "A", water-
cooled "W".......................................... 63
9.6.3 VS55, 50Hz + 60Hz, air-cooled "A",
water-cooled "W"................................ 65
9.6.4 VS75, 50Hz + 60Hz, air-cooled "A",
water-cooled "W"................................ 66
9.7 Installation plan................................... 69
9.8 Declaration of conformity.................... 72

November 2021 GB 3 / 76
1 Foreword
TM

1 FOREWORD
Gardner Denver screw compressors are the prod- Replacement of wear parts and consumables
uct of years of research and development. This e.g. filters or oil
experience in conjunction with high quality require- Identification of faults and rectification of mal-
ments ensures that the manufactured screw com- functions
pressors are long-lasting, providing guaranteed re-
liability and economic operation. Carrying out of visual inspections for damage
on a rotational basis
Equally, the stringent requirements for environ-
mental protection are also met. Cleaning, maintenance and repair of the com-
pressor
1.1 About these operating The dealer's or manufacturer's workshop, with its
instructions qualified and experienced personnel, is respon-
sible for all maintenance work that goes beyond
These operating instructions apply to Gardner customary service work and requires specialist
Denver Deutschland GmbH compressors of the technical knowledge.
air-cooled (type "A"), water-cooled (type "W") and
speed-controlled (type "VS”) versions: All pressures given in these operating instructions
are, where not otherwise specified, positive pres-
ESM55 7.5 V4 sures (gauge pressures).
ESM55 9 V4
Target groups
ESM55 10 V4
The target groups for these operating instructions
ESM55 13 V4 are operators, maintenance personnel and electri-
ESM75 7.5 V4 cians.

ESM75 9 V4 After training, the operator is permitted to start up

and shut down the compressor and activate the
ESM75 10 V4 emergency-stop.
ESM75 13 V4 Maintenance personnel may, in conjunction with
VS55 10 V4 the information in these operating instructions,
maintain the compressor, repair it, start it up and
VS75 13 V4 shut it down and activate the emergency-stop.
Version e Electricians may electrically install the compres-
sor, carry out direction of rotation checks and carry
ESM55e 7.5 V4 out electrical maintenance work.
ESM55e 10 V4
Safety conditions
ESM75e 7.5 V4
Alongside all the other details in these operating
ESM75e 10 V4 instructions, the general safety instructions, in the
chapter "Safety Conditions", must be read without
These operating instructions are written for operat- fail.
ing- and maintenance personnel.
The basis of these operating instructions are the 1.2 Notes
master operating instructions ZS1215748, which
General information
are relevant for translations of the operating in-
structions. The operating instructions must be read and used
by every person who is assigned to work with and
These operating instructions are an inherent part on the compressor.
of the compressor. They must be available and ac- Irrespective of these operating instructions, the
cessible near the compressor at all times. laws, regulations, directives and standards applic-
These operating instructions provide you with all able in the place of use must be observed.
the information you need for safe operation and
Training
maintenance of the compressor. This includes:
The provision of local operator training is under-
Installation and connection of the compressor
taken by authorised service technicians. The train-
Commissioning and operation of the compres- ing documentation comprises these operating in-
sor structions and the repair manual, which is only is-
sued as part of service training.

4 / 76 GB November 2021
 TM

Foreword 1

These measures ensure that the assigned work Reselling

can be reliably carried out. If the compressor is resold, these operating in-
structions must be handed over to the new oper-
Warranty
ator together with the compressor. If necessary,
Gardner Denver will not be held liable for the safe the operating instructions must be reordered from
functioning of the compressor if it used other than Gardner Denver by specification of the order con-
for its normal use or for purposes not listed in the firmation number. The compressor must not under
operating instructions. any circumstances be resold without these operat-
ing instructions.
Gardner Denver Deutschland GmbH excludes all
warranty and liability in the event of:
1.3 Intended use
Operating errors.
The compressor conforms to the state of the art
Use of the compressor for other than the in- and the applicable safety conditions at the time of
tended purpose. its bringing to market provided it is used for its in-
Damage resulting from deliberate misuse or tended purpose.
non-observance of the operating instructions. From a design point of view, neither intentional
Damage or injuries caused by non-OEM com- misuse nor all of the residual dangers can be
ponents. avoided, without limiting the intended functionality.
Use of spare or wear parts or operating fluids The compressor is designed for the compres-
that do not originate from or are not currently sion of atmospheric air (compressed air for driving
recommended by or have not been previously pressure equipment). The compressor is not suit-
recommended by Gardner Denver Deutschland able for the compression of other gases.
GmbH.
The compressor is only classed as being used for
Inadequate maintenance. its intended purpose if the following points are also
Compressor conversions. observed:
The compressor is used according to these op-
Warranty and liability conditions of the general
erating instructions.
business conditions of Gardner Denver Deutsch-
land GmbH are not expanded by the aforesaid in- The working steps and standard operating pro-
formation. cedures of the operator are followed.
Any other use or use beyond this is defined as
Guarantee
non-intended use. The manufacturer is not liable
The conditions and caveats of Gardner Denver for any resulting damage. The user alone bears
Deutschland GmbH warranty are specified in our the risk.
general terms and conditions, which were supplied
Intended use also includes observation of the op-
with the compressor.. Upon request, an additional
erating instructions and adherence to the inspec-
copy of the document can also be sent retrospec-
tion and maintenance instructions.
tively.
Other conditions
Copyright
These operating instructions are subject to copy- Danger to life and limb of the user or third parties
right and may only be used for the agreed pur- can arise from use of the compressor; likewise
pose, i.e. as a reference for in-plant purposes. damage to the compressor or other material can
arise if the compressor:
Forwarding or reproduction of this document, ex-
ploitation and sharing of its content are forbid- Is not used as intended.
den, insofar as this is not expressly authorised. Is not operated by trained personnel.
Infringements will incur payment of compensa-
tion. All rights reserved for the case of granting of Is changed or modified.
a patent, petty-patent or design registration. The safety instructions are not observed.

Alongside these operating instructions, the follow-

ing apply:
Relevant accident prevention regulation
Generally recognised safety rules
Country-specific conditions

November 2021 GB 5 / 76
1 Foreword
TM

Installation location / installation altitude Operation outside industrial environments.

The compressor is intended for installation in a Non-adherence to maintenance intervals.
suitable compressor room. The compressor is not
Omission of maintenance and repair work.
suitable for open-air installation!
The permissible installation altitude of the com- Incorrect execution of maintenance and repair
pressor is limited dependent on the operating work.
pressure, ambient humidity and ambient tempera-
Limitations on use
ture at which it is operated. The permissible instal-
lation altitude is specified for each individual case Operation of the compressor is not permitted:
by consultation between the customer and Gard-
Outside the permissible ambient temperatures.
ner Denver.
Above the permitted altitude of the installation
Working environment location.
The illumination in the region of the compressor On an insufficiently load-bearing substrate.
must be ≥ 200 lx during normal operation.
In areas with an explosive atmosphere.
The illumination for inspection and repair work
must be ≥ 500 lx. 1.5 Service
Ambient temperature for operation: see "Technical
If you have any questions about or problems with
data".
the compressor please contact your responsible
Pressure equipment Gardner Denver agency.

For pressure equipment/systems a pressure re- The trained specialised personnel will ensure you
lief device (safety valve or similar) dimensioned to receive quick and proper assistance.
match the weakest pressure carrying component
In case of queries
and conforming to the relevant regulations must
be installed in the compressed air network. If you have a query or wish to make a spare parts
order, please specify the identification number and
1.4 Intentional misuse year of manufacture on the name plate. Specifi-
cation of this data will ensure that you receive the
Incorrect use and misuse correct information and/or spare parts.
The following typical reasonably foreseeable mis-
Your Gardner Denver agency
uses (incorrect uses) are classed as contrary to
the intended use: Please enter the details of your local Gardner
Denver agency in the following table.
Compression of gases other than atmospheric
air. Name:
Operation outside the permissible operating Contact:
limits, even if the exceeding of the limits is only
temporary or not immediately identifiable. Address:
Operation outside the permissible ambient tem-
peratures.
Phone
Extraction of non-atmospheric air (overpres-
sure or vacuum pressure). Fax
Use as a breathing air compressor. Email:
Manipulation of sensor signals. Chart 1-1: Local Gardner Denver agency
Signal modification of sensors.
Operation without protection and safety equip-
ment.
Operation with defective, deactivated or ma-
nipulated protection and safety equipment or
safety valves, or operation with other such
safety relevant defects.
Use by private users or users without technical
training.

6 / 76 GB November 2021
 TM

Foreword 1

1.6 Nameplate

Fig. 1-1: Nameplate

November 2021 GB 7 / 76
2 Safety conditions
TM

2 SAFETY CONDITIONS
Any person who is involved with the operation, The intervals between tests and inspections
maintenance or repair of the compressor, must must be adhered to.
read and follow the safety conditions. The operating instructions must be supple-
Gardner Denver accepts no responsibility for ma- mented with instructions for the observation of
terial damage or injuries that arise from non-obser- operating peculiarities including monitoring and
vation of safety conditions or the failure to observe reporting obligations, e.g. in respect of working
normal levels of care and attention, even where organisation, working processes, responsibili-
this is not expressly stated in these operating in- ties, etc.
structions.
Personnel selection and qualification; funda-
2.1 General safety instructions mental responsibilities

Organisational measures Only reliable and authorised personnel may work

on the compressor.
The following organisational measures contribute
to the safe use of the compressor: The authorised personnel must:

Only appointed personnel may work on the be trained by Gardner Denver.

compressor. The personnel have been trained be trained according to its responsibilities, du-
and briefed about the compressor. ties and activities and instructed about the
Before starting work, the personnel must have compressor.
read the operating instructions, in particular the have the physical and mental capabilities to
"Safety Conditions" chapter. Don’t leave this fulfil its responsibilities and carry out its duties
until you start work – it’s too late. This applies and activities on the compressor.
in particular to personnel who only work on the have understood the operating instructions in
machine occasionally, e.g. to carry out mainte- respect of its responsibilities, duties and activ-
nance. ities on the compressor and be able to practi-
The responsibilities of the personnel for oper- cally implement this.
ation, maintenance and repair must be clearly
defined. 2.2 Instructions about particular
The safe and hazard-aware working of the per- types of danger
sonnel must be checked regularly.
Electrical energy
Personnel who are to be trained in, taught
about or instructed as part of a general training DANGER
course, must only work on the compressor un-
der the constant supervision of an authorised Electric shock
person. Life-threatening electric shock
If safety-relevant changes are made to com- ➯ When carrying out any work on the
pressor or arise in its operating behaviour, the electrical equipment, exercise ex-
compressor must be immediately shutdown treme care.
and the fault reported to the responsible post/ ➯ Before starting the maintenance
person. work, switch the compressor to a
Faults, especially those that could impair voltage-free state and secure to pre-
safety, must be immediately rectified. Other- vent switching back on.
wise the compressor must not be operated.
For all work on the electrical equipment of the
All danger signs on and in the surroundings of compressor the 5 safety rules for working on elec-
the compressor must be regularly checked for trical equipment must be observed.
completeness and legibility. Missing danger
signs must be immediately replaced.

8 / 76 GB November 2021
 TM

Safety conditions 2

Moreover, the following instructions must be ob- All protective and safety equipment must be at-
served: tached and checked for trouble-free operation be-
Only a qualified electrician following elec- fore every commissioning, in particular after main-
trotechnical regulations may carry out work on tenance and repair work.
the electrical equipment of the compressor. In addition, the legally prescribed checking inter-
The compressor's electrical equipment must be vals of the country of use must be adhered to.
checked regularly. Defects such as loose con-
nections or charred cables must be rectified im- NOTE
mediately. Operation of the compressor is only permitted
Only original fuses of the specified current rat- with complete and operational protective and
ing may be used. safety equipment.

Only for VS compressors: Emergency-stop

Due to the residual voltage on the capacitors, a The compressor can be rendered safe in danger-
waiting time of at least 10 minutes must elapse af- ous situations using the emergency-stop pushbut-
ter voltage-free switching (main switch OFF) be- ton.
fore the switch cabinet can be opened. Observe
the danger sign on the switch cabinet! See table Emergency-stop pushbuttons are attached:
"Safety signs". on the compressor control panel

Noise optionally in a control room (control centre)

The sound pressure level without the sound-proof- Using emergency-stop

ing enclosure is approx. 95 dB(A). Remaining for
1. Push <Emergency-Stop> button.
long periods alongside the compressor without its
The compressor is placed in a safe condition.
sound-proofing enclosure can result in irreversible
hearing impairment. 2. Rectify the fault that was the cause of the
Only operate the compressor without the sound- emergency-stop.
proofing enclosure during test runs. Wear ear de- See the "Troubleshooting" chapter.
fenders! 3. Unlock <Emergency-Stop> button.
The sound pressure level with the sound-proof- Turn the pushbutton anticlockwise.
ing enclosure is approximately: (See "Technical 4. Start up the compressor.
data".) See section "Commissioning after a fault" in the
During normal operation the compressor may only chapter "Commissioning and operation".
be operated with a closed acoustic hood.
Safety valve / non-return valve
Oils, grease and other chemical substances
The compressor is protected from exceeding the
When handling oils, fats and other chemical sub- permissible operating pressure by a safety valve.
stances, observe the applicable safety conditions! The safety valve opens at 15 bar / 218 psi.
Exercise caution when handling hot lubricants and The compressor is secured by a non-return valve
additives, there is a risk of burns or scalding! on the pressure side against reverse flow from the
compressed air network.
Explosive areas
Protective covers and enclosure panels
DANGER
The cooling air fans are covered by grilles.
Risk of explosion The clutch between the drive and the compressor
The compressor is not designed for op- is covered by a grille.
eration in explosive atmospheres. The compressor enclosure is designed so that any
➯ Operation of the compressor in ex- broken bits that might fly out are retained in the
plosive atmospheres is forbidden! compressor.
The compressor enclosure serves as an acoustic
2.3 Protection and safety hood.
equipment
The compressor is equipped with the protection
and safety equipment described below.

November 2021 GB 9 / 76
2 Safety conditions
TM

2.4 Residual hazards DANGER WORD

Hot surfaces Danger (danger sequence)
Some parts of the compressor become hot in op- Description of the danger (danger
eration (up to 120 °C / 248 °F). A danger warning Safety sign source)
sign on the compressor enclosure warns of the
Protective measure (danger pre-
danger.
vention)
Before starting any maintenance and repair work,
the compressor must be sufficiently cooled. Parts of safety instructions
Personal protective equipment Danger (danger sequence): The danger se-
quence names the type of hazard.
We recommend the wearing of the following per- Description of the danger (danger source): The
sonal protective equipment: danger source names the cause of the hazard.
Safety shoes Protective measure (danger prevention): Dan-
Safety glasses for all work with compressed air ger prevention describes the measures for com-
and open enclosure batting the hazard.
Ear defenders during test runs with an open Danger word: The danger word subdivides the
acoustic hood severity of the danger into four steps, graphically
highlighted by different colours. The danger word
2.5 Identification of safety is used in the safety instructions as described be-
instructions low.
DANGER indicates a directly dangerous situa-
Within the operating instructions, safety instruc-
tion which, if not protected against, could result in
tions are used as special warnings with the follow-
death or serious (irreversible) injuries.
ing described names and symbols.
WARNING indicates a potentially dangerous situa-
These special warnings are intended to prevent tion which, if not protected against, could result in
danger and are located close to the possible dan- death or serious (irreversible) injuries.
ger both in terms of space and time:
CAUTION indicates a potentially dangerous situa-
on the system close to the danger source tion which, if not protected against, could result in
in the operating instructions, before a sequence minor or less serious (reversible) injuries.
of actions / activity is described ATTENTION indicates information or recommen-
dations that directly or indirectly concern the safety
Structure of safety instructions of persons or system protection.
The special warnings in the operating instructions
are structured as follows:

2.6 Safety sign

The following safety signs (danger signs) may be used in the surroundings of the compressor and in the
operating instructions.
Safety sign Meaning Use / Behaviour
General danger Warning of a general danger.
Observe the warning and proceed with the necessary
caution (e.g. protective clothing) or care.

Risk of slipping Warning against the risk of slipping.

Caution during walking, running or climbing.

Chart 2-1: Safety sign

10 / 76 GB November 2021
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Safety conditions 2

Safety sign Meaning Use / Behaviour

Pressurised part or sys- Identification of devices or rooms in which there is per-
tem manently or occasionally a significantly higher air pres-
sure than in the normal atmosphere.
Do not open the devices or rooms before pressure
equalisation has taken place.
Never operate the com- Running the compressor with open doors or loose enclo-
pressor with open doors sure panels is forbidden except during test runs. High
or loose enclosure pan- sound pressure level, risk of injury!
els. Normal operation only with closed enclosure.

Do not breath in any Use of the compressed air produced by this compressor
compressed air from this as breathing air is forbidden. Drawn in substances could
system be harmful to health.
Do not use compressed air as breathing air.

Electrical voltage Warning of dangerous, electrical voltage.

Only a qualified electrician following electrotechnical reg-
ulations may carry out work on the electrical equipment
of the compressor.

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

Observe the instruction Identification of operating instructions where additional

manual information is to be found in the operating instructions (of
the manufacturer).
Before the device is operated, the operator (user) must
have read and understood the instruction manual (manu-
facturer's usage instructions).
To secure against To secure against switching back on when working on
switching on again electrical systems
To secure against switching back on when working on
rotating parts
To secure against switching back on during repair
work
Wear ear defenders Identification of areas with a heightened sound pressure
level.
Only enter the area wearing suitable ear defenders.

Warning against indus- Warning of in-plant industrial trucks (e.g. forklifts) trans-
trial trucks porting materials.
Do not carry out any work on traffic ways that cannot
be seen to be clear and are not made safe or blocked
off. Use or crossing of this traffic way can only be imple-
mented with great care.
Chart 2-1: Safety sign

November 2021 GB 11 / 76
2 Safety conditions
TM

Safety sign Meaning Use / Behaviour

Warning against sus- Warning of suspended loads being transported.
pended loads No person may remain in the danger area during trans-
port. In particular, do not encroach into the area under
the raised compressor or place your feet beneath it.

Warning against moving During maintenance work it is necessary to check some

machine parts functions with an opened enclosure. There is a risk of
injury due to rotating or translational movements.
Maintenance work must only be carried out by specially
trained personnel.
Warning of hand injuries Danger that the hands could be crushed, drawn in or
otherwise injured.
Maintain a safe distance.

Warning of automatic In normal operating mode, the compressor may start up

start-up automatically at any time. The readiness for operation
of the compressor is indicated by the green LED on the
control panel.
Do not carry out any work on the compressor, if the
green LED illuminates.
Warning of hot surfaces Parts of the compressor become very hot during opera-
tion (up to 235 °C / 455 °F). Risk of injury due to hot sur-
faces.
Before starting any maintenance and repair work, the
compressor must be sufficiently cooled.

Warning of suffocation Risk of suffocation due to inadequate ventilation and

extraction in the compressor room.
The operator must provide adequate ventilation of the
compressor room.

Warning of crushing haz- Warning of crushing hazards due to working materials

ards (e.g. a machine) or a structural element (e.g. covers,
enclosure panels, protection devices, boundary fences).
When working on the identified workstations, increased
awareness is necessary.
Remaining under the It is not permitted to remain under a suspended load.
load is forbidden The driver is not permitted to drive the industrial truck if
there is a person beneath the load. Moreover, the dri-
ver is obliged to check that persons do not stand or walk
under the load.
The load must only be transported so that it is suffi-
ciently clear of the ground (max. 0.5 m / 20 in above the
ground). (In Germany, refer to the law BGV D27 "Indus-
trial trucks"). The driver of an industrial truck is responsi-
ble for all driving and load movements.
Chart 2-1: Safety sign

12 / 76 GB November 2021
 TM

Safety conditions 2

Safety sign Meaning Use / Behaviour

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

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

Check the connecting Warning against loosened connecting terminals. The

terminals and tighten if clamping pressure can be released after some time.
necessary. For additional Regularly check the terminals according to the safety
information see the oper- guidelines and retighten as necessary.
ating instructions.
Electrical voltage Life-threatening electric shock.
Residual voltage of the Work on the electrical equipment must only be carried
capacitors out by authorised electricians or electrical technicians.
With the speed-controlled compressors / fans there is a
risk of electric shocks due to charged capacitors!
Switch the compressor voltage-free and wait at least
10 minutes before touching any electrical parts.
Check DC bus voltage at the frequency converter if DC+/
DC- terminals are present. The voltage measured must
be zero.

Spring tension Warning of tensioned spring inside the suction regulator.

Before opening the suction regulator read the repair
manual.

Risk of microbe contami- Warning against legionella contamination of the cooling

nation water if an open cooling circuit is used.
Constant monitoring of the cooling water by the mainte-
nance personnel.

Attention: hot liquid Warning of hot oil or hot cooling liquid.

Before opening coolant circuits, allow the compressor to
cool.

Chart 2-1: Safety sign

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

November 2021 GB 13 / 76
2 Safety conditions
TM

2.7 Transport and installation Safety measures

Transport Only operate the compressor with the enclosure

closed.
A suitable forklift with forks of adequate length
must be used to transport the compressor. De- At least once per shift check the compressor for
pendent on type, the compressor weighs up to externally visible damage and defects. Immedi-
1520 kg / 3350 lbs. ately report changes that have occurred (includ-
ing in the operating behaviour) to the responsi-
Only insert the forks at the intended load support ble post/person. If necessary stop the compressor
points. immediately and secure. Immediately rectify any
The compressor must not be transported using a faults.
crane, even when still in its packaging. Do not switch off or remove extraction and ventila-
No person may remain in the danger area during tion equipment when the compressor is running.
transport. In particular, do not encroach into the
area under the raised compressor or place your Remote control
feet beneath it. If a remote control is available, a sign with the fol-
lowing lettering must be clearly visible on the com-
Positioning / installation location pressor: "Attention! The compressor is remotely
The entire surface of the compressor must be controlled and could start without warning!"
placed on an even suitable substrate. In addition safety precautions must be imple-
The installation location (compressor room) must mented so that nobody works on the compressor
be dimensioned so that there is sufficient access when it is under remote control.
to the compressor and the necessary cooling is
ensured. 2.9 Special tasks
No inflammable or explosive materials may be Organisational
stored in the vicinity of the compressor.
Adhere to the prescribed maintenance work and
intervals including details about the replacement
2.8 Normal operation
of parts/part assemblies contained in the operating
The compressor may only be operated in a techni- instructions.
cally fault-free condition for its intended use, with Maintenance and repair work must only be carried
an awareness of safety and hazards while observ- out under the supervision of or by a person quali-
ing the operating instructions. fied to carry out this work.
Only operate the compressor if all protective and If necessary, cordon off a wide area around the
safety equipment, sound insulation, ventilation and workplace.
extraction equipment is present and serviceable.
Workshop equipment appropriate for the task is
Check regularly that: essential for carrying out maintenance and repair
All hoses and pipelines are serviceable and work.
firmly attached.
Safety measures
There are no leaks.
Personnel must not have loose long hair nor wear
The electrical power cables are free from faults. loose clothes or jewellery including rings. If the
compressor is running there is a risk of injury, e.g.
Rules for working with compressed air: by being caught-up or pulled in. Where necessary
Forbid all working practices that could pose a or if required by regulations, wear personal protec-
risk to safety tive equipment!
Never 'play around' with compressed air. Only carry out maintenance and repair work for
which you are adequately trained and which you
Never direct compressed air onto the skin or at
feel confident to carry out.
other people.
Do not use machine parts as climbing aids. If car-
Never use compressed air for cleaning cloth-
rying out maintenance work at heights, provide fall
ing.
protection.
When using compressed air to clean equip-
ment, proceed with great care and always use
eye protection.

14 / 76 GB November 2021
 TM

Safety conditions 2

Maintenance/Troubleshooting Tighten up all threaded connectors loosened dur-

Only carry out maintenance and repair work with ing maintenance and repair work. Likewise check
the compressor switched off and mains power all other threaded connectors.
off. Secure the compressor to prevent inadvertent Before release of the compressor for operation af-
switching on. ter maintenance and repair work, ensure that the
operating pressures, temperatures and time set-
Before opening the compressor enclosure: tings are correct and that the control and switching
Drain the compressor. off equipment is fully serviceable.
Wait for automatic pressure discharge to com- If safety and protective equipment must be re-
plete. moved, then it must be immediately replaced af-
ter completion of the work and checked for trou-
Wait until the residual electrical energy has
ble-free operation.
drained from the capacitors.
Allow the compressor to cool to room tempera- 2.10 Conversions and changes to
ture. the machine
Cleanliness Do not make any changes or additions to or re-
During maintenance and repair work always check build the compressor without prior consultation
for cleanliness. Keep dirt away by covering parts with Gardner Denver.
and uncovered openings with a clean cloth, paper Unauthorised changes to the machine are not au-
or adhesive strips. thorised for safety reasons.
Oil leaks lead to a slippery floor. Thoroughly clean Genuine parts are designed especially for the ma-
the work area after completion of maintenance chine. We expressly point out that we also do not
and repair work. authorise parts and special equipment that are not
supplied by us. The fitting and/or use of such prod-
Cleaning agents ucts may therefore impair active and/or passive
When cleaning parts, never use solvents or clean- safety.
ing agents that could chemically attack the materi- Any liability on the part of the manufacturer for
als. damage arising from the use of non-original parts
Take precautions to prevent harmful vapours from or special equipment is excluded. The same ap-
solvents or cleaning agents. plies for the fitting and adjustment of safety equip-
ment and valves as well as to the welding of load-
Weight / lifting gear bearing or pressure carrying parts.
When replacing heavy individual parts and assem-
blies carefully attach and secure to the lifting gear
so that no danger can arise. Use only suitable and
technically flawless lifting gear and load handling
equipment with adequate load capacity. Never
work or remain under suspended loads.

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

Upon completion of maintenance and repair

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

November 2021 GB 15 / 76
3 Design and function
TM

3 DESIGN AND FUNCTION

3.1 General description Compression principle

The compressor is an oil-lubricated, compressing, The compressor stages comprise a main rotor and
single-stage screw compressor with one sound- an auxiliary rotor with intermeshing spiral toothing.
proofed enclosure. Compression chambers are delimited by the flanks
of the toothing and the compressor casing. The ro-
The main components are the drive motor, the tation of the rotors continuously reduces the vol-
compressor stage, the oil circuit and the electronic ume in the chambers until the compressed air is
control. pushed out through the outlet window of the stage
Oil is injected into the compressor stage for lubri- casing. Screw compressors count amongst rota-
cation, sealing and cooling. tion-displacement compressors without oscillating
Rolling contact bearings and gearbox are oil-lubri- masses but with a pulsing output.
cated.
Electronic control unit
The main components of the electronic control
unit are a microprocessor, a touchscreen, film-pro-
tected keys and LEDs.
Detailed description of the operating instructions
for the electronic control unit.

16 / 76 GB November 2021
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Design and function 3

3.2 Compressor design

Air-cooled

1
2

7
8
20
9 19
10
18
11
17
12

13

14
16
15

Fig. 3-1: Overview part 1

[1] Switch cabinet [11] Oil level indicator
[2] Electrical connection [12] Oil fill
[3] EMERGENCY-Off button [13] Oil temperature regulator
[4] Control system control panel [14] Oil drain
[5] Moisture sensor [15] Screw compressor
[6] Fine separator, suction [16] Electric motor
[7] Safety valve [17] Line pressure sensor
[8] Final compression pressure sensor [18] Lubricator
[9] Compression temperature sensor [19] Cooling air fan
[10] Oil filter [20] Switch cabinet cooling air inlet

November 2021 GB 17 / 76
3 Design and function
TM

21

30
22

23
24

25

29

26

28

27

Fig. 3-2: Overview part 2

[21] Fan guard [26] Cooling water connection heat recovery
(option)
[22] Fan [27] Openings for lifting tool
[23] Oil cooler [28] Base frame
[24] Air cooler [29] Pressure vessel with internal fine precipitator
[25] Compressed air outlet [30] Suction filter

18 / 76 GB November 2021
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Design and function 3

Water-cooled

20
1
2

7
8
19
9
10
18
11
17
12

13

14
16
15

Fig. 3-3: Overview part 1

[1] Switch cabinet [11] Oil level indicator
[2] Electrical connection [12] Oil fill
[3] EMERGENCY-Off button [13] Oil temperature regulator
[4] Control system control panel [14] Oil drain
[5] Moisture sensor [15] Screw compressor
[6] Fine separator, suction [16] Electric motor
[7] Safety valve [17] Line pressure sensor
[8] Discharge compression pressure sensor [18] Lubricator
[9] Compression temperature sensor [19] Switch cabinet cooling air inlet
[10] Oil filter [20] Cooling air fan

November 2021 GB 19 / 76
3 Design and function
TM

21

22 31

23

30
24

29
25

28

27
26

Fig. 3-4: Overview part 2

[21] Fan guard [27] Base frame
[22] Temperature switch [28] Air cooler throttle valve
[23] Cooling water solenoid valve [29] Oil cooler throttle valve
[24] Compressed air outlet [30] Air cooler
[25] Cooling water connection [31] Oil cooler
[26] Openings for lifting tool

20 / 76 GB November 2021
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Design and function 3

3.3 System scheme

Fig. 3-5: Functional schematic

Compressed air Oil

Control air Cooling water (only -W)

Chart 3-1: Cables

Components
No. Designation No. Designation No. Designation
1 Suction air filter 9 Safety valve 22 Motor temperature moni-
toring (R1)
2 Suction regulator; resid- 10 Oil level indicator 23 3/2-way solenoid valve
ual pressure 1 - 1.5 bar / (regulator valve) (Y1)
15 - 22 psi
Chart 3-2: Components

November 2021 GB 21 / 76
3 Design and function
TM

No. Designation No. Designation No. Designation

2.1 Adjusting cylinder 11 Final compression pres- 24 Air regulator
sure sensor (B2)
2.2 Butterfly valve 12 Pressure-retention and 25 Optical suction filter moni-
non-return valve tor
Opening pressure Switching point 50 mbar /
4.5 bar / 65 psi 20 in H2O
2.3 Valve block 13 Line pressure sensor 26 Intake filter monitoring
(B1) (S7)*)
Switching point 50 mbar /
20 in H2O
2.4 Blow-off valve 14 Aftercooler compressed 27 Fine separator monitoring
air (S6)*)
Switching point 1.2 bar /
17 psi
2.5 Stop valve 15 Oil cooler 28 Oil filter monitoring (S5)*)
3 Electric motor 16 Oil temperature regulator 29 Monitoring of cooling
(optional) or electronic oil water temperature (only -
regulation system W)
4 Screw compressor 17 Moisture sensor**) 30 Cooling water solenoid
valve (Y6) (only -W)
5 Final compression tem- 18 Oil filter 31 Adjustable throttle valve
perature sensor (R2) (only -W)
6 Pressure vessel 19 Cooling air fan 33 Oil suction non-return
valve
7 Fine separator 20 Motor lubrication system 34 Frequency converter
E4/E5
8 Oil drain 21 Non-return valve
Chart 3-2: Components
*) Option
**) Depending on the version

3.3.1 Oil circuit The oil separated in the oil fine separator (7) is
fed back to the compressor through the oil suction
During operation, due to the differential pressure pipe.
in the oil circuit, the oil, whose purpose is to cool,
lubricate and seal the airend, flows from the pres- 3.3.2 Oil regulation system
sure vessel (6) to the injection point of the screw
compressor (4). System variants with an electronic oil regulation
system additionally use a humidity sensor (17) to
At the outlet of the pressure vessel the oil flow di-
determine the dew point and thus the limit below
vides between the oil cooler (15) and the bypass
which condensate formation occurs.
line. A downstream, version-dependent mechani-
cal or electrical thermostatic valve (16) regulates The electronically controlled mixing valve (16**)
the oil injection temperature. If the injection tem- adjusts the temperature level of the system to the
peratures are too low, it will cause the formation optimally efficient value, thus reliably preventing
of condensate in the oil circuit. By contrast, if the condensate formation in the oil circuit.
temperatures are too high, the compressor’s en- You will find more information in the operating in-
ergy efficiency will be impaired and the life of the structions of the compressor control unit.
oil shortened. Prior to injection, the oil is filtered by
an oil filter (18).

22 / 76 GB November 2021
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Design and function 3

3.3.3 Air circuit The compressor draws in a certain quantity

of air via a bypass into the suction regulator.
The air drawn in reaches the screw compressor Pressure builds up in the pressure vessel. The
(4) via the intake filter (1) and the suction regulator stop valve (2.5) closes.
(2). It is cooled by the injected oil during the com-
pression process. The ensuing compressed air-oil Oil is supplied to the screw compressor due to
mixture flows tangentially into the pressure vessel the drop in pressure between the pressure ves-
(6). After the pre-separation and the subsequent sel and the injection point in the screw com-
fine separation in the fine separator (7), the low-oil pressor.
compressed air reaches the load network via the After the motor start-up phase, the solenoid
pressure retention and non-return valve (12) and valve (23(Y1)) switches, as it is now being sup-
the air cooler (14). plied with power.
The air circulated in the system flows through
3.3.4 Cooling water circuit (only "-W")
the solenoid valve (23(Y1)) into the upper con-
The cooling water circuit is used to supply the trol chamber of the adjusting cylinder (2.1). The
oil cooler and the compressed air aftercooler. blow-off valve (2.4) closes.
The cooling water volume is set via the throttle The butterfly valve (2.2) in the suction regulator
valves (31). (2) is opened.
A cooling water solenoid valve (30) is located in At a vessel pressure of 4.5 bar / 65psi, the
the cooling water inlet. pressure retention and non-return valve (12)
Function description of the cooling water solenoid opens.
valve (see "Controller", page 23). The supply of compressed air to the load net-
You can find instructions on the limit data for cool- work begins.
ing water volumes, temperatures and pressure The unit is in on-load operation.
losses in the appendix to these operating instruc-
tions. With speed-controlled systems (VS) the com-
pressor speed is regulated between a minimum
3.3.5 Controller and maximum speed dependent on the require-
ment for compressed air.
(See also the operating instructions for the com-
pressor controller GD Pilot TS) Shutting the unit down

Unit standstill After pressing the OFF key on the control panel
of the GD Pilot TS compressor control, the so-
During unit standstill times, the suction regula- lenoid valve (23(Y1)) is switched to a de-ener-
tor (2) is closed by the residual pressure at the gised state.
adjusting cylinder (2.1).
The upper control space of the adjusting
The solenoid valve (23(Y1)) is de-energised. cylinder (2.1) is vented by the solenoid valve
The pressure vessel is depressurised through (23(Y1)). The pressure spring in the adjusting
the blow-off valve and stop valve (2.4, 2.5) to cylinder causes the butterfly valve (2.2) in the
atmospheric pressure. suction regulator to close. The pressure ves-
sel is depressurised through the blow-off valve
Without power, the cooling water solenoid valve
(2.4) to off-load operation pressure (residual
(30(Y6)) is closed (only "-W").
pressure).
Starting the unit After 30 seconds, the drive motor (3) and the
cooling air fan (19) are shut down. The cooling
Fixed Speed Systems water solenoid valve (30(Y6)) is closed without
– The motor starts up in Y-operation. power (only “-W"). The system is depressurised
via stop valve (2.5) to atmospheric pressure.
Speed-controlled systems (VS)
– The motor accelerates until it reaches minimum
speed.

The cooling water solenoid valve (30(Y6)) is

supplied with power and opens (only “-W").
The suction regulator is shut.

November 2021 GB 23 / 76
3 Design and function
TM

Automatic operation (OPEN-CLOSED opera- An empty grease cartridge or a fault on the lubri-
tion) cator is indicated on the compressor control by
If the pressure at the line pressure sensor (13 means of a message [Warning: mot.lubr. sys] (also
(B1)) reaches the set upper switching point, the refer to the operating instructions for the compres-
solenoid valve (23(Y1)) is de-energised. sor control GD Pilot TS).
The upper control space of the adjusting Structure of the lubricators
cylinder (2.1) is vented by the solenoid valve
(2x per drive motor)
(23(Y1)). The pressure spring in the adjusting
cylinder causes
The pressure vessel is depressurised via
the blow-off valve (2.4) to off-load operation 1
pressure (residual pressure, approx. 1.5 bar /
22 PSI). The butterfly valve (2.2) in the suction 2
regulator to close.
The screw compressor now runs in off-load op-
eration.
The cooling water solenoid valve (30(Y6)) is
opened and closed dependent on the final 3
compression temperature (only “-W").
If the pressure at the line pressure sensor (13
(B1)) does not drop to the set lower switching
point within the set run-on time (e.g. 120 sec- 4
onds), the drive motor (3) and the cooling air
fan (19) are shut down and the system is de-
pressurised to atmospheric pressure via the
stop valve (2.5). The cooling water solenoid
valve (30(Y6)) is closed without power (only "-
W"). [1] Socket for connection cable

The unit is now in stand-by mode and can [2] Lubricator drive
restart at any time once the line pressure drops [3] Grease cartridge (not refillable)
to the set lower switching point (see section “S- [4] Support bracket
tarting the unit”).
If the line pressure drops to the preset lower
switching point within the set motor run-on
time, the solenoid valve (23(Y1)) is supplied
with current again and the blow-off valve (2.4)
is shut.
The unit goes back to on-load operation.

3.4 Lubricant system

The screw compressor unit’s drive motor is fitted
with an automatic motor lubrication system.

Function of the motor lubrication system

The automatic motor lubrication system ensures
that the motor bearing is lubricated at all times.
The installed lubricators are powered (24 VDC)
via the compressor control when the drive motor is
running. The volume of grease set on the lubrica-
tor is dispensed over several cycles depending on
the motor runtime measured.

24 / 76 GB November 2021
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Design and function 3

Function display on lubricator (*) When the lubricator issues this signal, the fol-
lowing message is output on the compressor con-
trol: [Warning: mot.lubr. sys] (also refer to the op-
4 erating instructions for the compressor control
2 GD Pilot TS).
3 If the lubricant pipe is blocked, the drive unit in-
creases the pressure to 6 bar / 87psi. If the max.
pressure is reached, the lubricator switches to a
5 special programme and attempts to open the lubri-
cation duct with three additional lubrications within
48 hours. If this remains unsuccessful, the unit re-
1 ports a fault.
1 Special lubrication
If you push the “SET” key for 10 seconds, a spe-
cial lubrication takes place; e.g. for prefilling or
flushing a soiled lubrication point.

Lubricator operating parameters

The following running time applies for screw com-
pressors with a standard electric motor:
Description Value
Grease cartridge service life approx.
4,000 operat-
[1] Function display (LED) ing hours
[2] Min. lubrication period from the vessel
change and count display of the last 100
3.5 Heat recovery ESM55 - ESM75
operating hours of the lubricant vessel.
WARNING
[3] Lubricant quantity for 100 operating hours
Legionella contamination
[4] Plug connection
Health risk with open cooling systems.
[5] <SET> key
➯ Constant testing of the water quality
The function display is only active if the screw air in the cooling circuit for the number
compressor unit’s drive motor is running. of microbes.
The lubricators are fitted with one red and one
Synthetic oil must be used if heat recovery is be-
green LED. These LEDs indicate the following op-
ing used:
erating conditions or faults to the operator.
LED Signal Explanation
green Continuous OK. “System running”
signal
green Continu- Dispensing process
ous signal
<30sec.
red Continu- Error/Fault
ous signal
>30sec.(*)
red Continuous Grease cartridge empty,
signal (*) please change

November 2021 GB 25 / 76
3 Design and function
TM

Function schematic of heat recovery Switching heat recovery on/off

A
B

3 1
1

2
2
4

[1] Connection from oil cooler

[1] Heat recovery
[2] Connection to compressor
[2] Temperature regulator with switch-off
function [3] Connection from heat exchanger
[3] Heat exchanger [A] Heat recovery switched on
[4] Cooling water connection [B] Heat recovery switched off

Turning the hex screw clockwise to the stop (max.

External connections
torque 3 Nm) switches the heat recovery off. Turn-
ing the hex screw counter-clockwise to the stop
(max. torque 3 Nm) switches the heat recovery on.

[1] Cooling water connection heat recovery

26 / 76 GB November 2021
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Transport and positioning 4

4 TRANSPORT AND POSITIONING

4.1 Transport Transporting the compressor

Delivery
The compressor is screwed onto a transport pallet
and packaged with a film cover.
The centre of gravity and lifting points are marked
on the packaging.

Receipt of goods
Upon receipt of goods check for transport dam-
age.
1. Check the delivery for visible damage.
2. Check the completeness of the delivery using
the delivery note.
3. Immediately inform the shipper, Gardner Den-
ver and insurance of any missing parts or dam-
age.

Weight Fig. 4-1: Lifting points

Dependent on type, the compressor weighs up to
1785 kg + 80 kg wood plate (gross). The weight
is stated on the name plate and is visible from the
outside.
1
Transport

DANGER
Risk of fatal injury 2
Risk of fatal injury due to toppling or
falling parts
➯ A suitable forklift with forks of ade-
quate length must be used to trans-
port the compressor.
➯ Only insert the forks at the intended [1] Wire pin
lifting points. [2] Hinge pin
➯ The compressor must not be trans-
ported using a crane, even when 1. Remove the screws from the transport pallet.
still in its packaging. 2. Pull wire pin
➯ No person may remain in the dan- 3. Remove doors
ger area during transport. In partic-
4. Lift the compressor from the transport pallet.
ular, do not encroach into the area
under the raised compressor or 5. Transport the compressor to the destination
place your feet beneath it. point.
6. Align the compressor and set down.
NOTICE
Weights
Material damage The following values are approximate. They apply
Do not lift up or lash the compressor system by to the screw compressor unit, including oil charge:
its enclosure.
Note fork length of forklift.

November 2021 GB 27 / 76
4 Transport and positioning
TM

Air-cooled systems The installation location (compressor room) must

be dimensioned such that a clearance of 1 m /
Type Weight 39 " on side “A” and 1.5 m / 59 " on side “B” is not
ESM55 / ESM55e 1405 kg / 1405 kg exceeded. The clearance above the compressor
should be at least 1.50 m / 59 ". Moreover, ade-
ESM75 / ESM75e 1495 kg / 1785 kg quate access must be provided for maintenance.
VS55 1430 kg
VS75 1520 kg

Water-cooled systems
Type Weight
ESM55 / ESM55e 1435 kg / 1435 kg
ESM75 / ESM75e 1495 kg / 1785 kg
VS55 1460 kg
VS75 1520 kg

4.2 Storage
Storage of compressors Fig. 4-2: Positioning / clearances

The compressor should be stored in a dry and, Position the compressor so that it is sufficiently
where possible, heated room. This applies particu- accessible and the required cooling is ensured.
larly during the winter months. Do not block the air inlet.
NOTICE Avoid moisture.

Material damage Ventilation

Material damage through exceeding of the per-
missible temperature range DANGER
➯ Where there is a risk that the permissible Risk of suffocation
temperature limits of +2 ...+65 °C / +36 ... Risk of suffocation due to inadequate
+149 °F could be over or undershot, contact ventilation
Gardner Denver.
➯ The operator must provide adequate
Corrosion protection ventilation of the compressor room.

Before they leave the factory all compressors are To be able to dissipate the heat generated during
protected against corrosion during transport and operation, the compressor room must be of suffi-
short term storage before commissioning. If com- cient size and have adequate ventilation.
pressors are stored for longer than 6 months, ad- The recommended minimum size of the compres-
ditional precautions must be undertaken. sor room is 25 m3 / 883 ft³.
Also compressors that have been taken out of ser- The air inlet and outlet openings should have
vice for a long period, must be protected against a minimum cross section of 0.8 m² / 8.8 ft².
corrosion. The intake air opening should be positioned as low
as possible. The extract air opening should be po-
4.3 Installation sitioned as high as possible.
Requirements for the installation location Provide the air openings with sieves to prevent
The entire surface of the compressor must be penetration of dirt into the compressor room.
placed on a sufficiently load bearing substrate. The design of the ventilation facility is primarily
The bearing surface must be level to within 3 mm / based on the required cooling air flow. See "Tech-
0.12 ". nical data”.)
In the event of unfavourable local conditions, in-
stall air ducts in which the flow velocity of the cool-
ing air must not exceed 5 m/s / 16.5 ft..

28 / 76 GB November 2021
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Transport and positioning 4

We recommend a minimum duct cross section of Positioning the compressor

approximately 0.8 m2 / 8.8 ft.2 for air-cooled ver-
sions "A". DANGER
Risk of injury
NOTE
Danger due to incorrect positioning
To ensure effective heat removal, the installed
auxiliary fans must be dimensioned such that ➯ Consider the permissible bearing
their air flow is 15 to 20% greater that the cool- force of the substrate.
ing air flow required by the compressor. ➯ Ensure there is a hard and even
If installing several compressors in one com- substrate.
pressor room, then this applies to the total of the ➯ The entire surface of the compres-
cooling air flows required by all the compressors sor must be placed on an even suit-
present in the compressor room. able substrate.

The following figure shows the recommended ven- ➯ The compressor must not be oper-
tilation requirements. ated on the transport pallet.
➯ No inflammable or explosive mate-
rials may be stored in the vicinity of

1 the compressor.

1. Set down the compressor at the destination

point.
2. Ensure that the support surface is level to
within 3 mm / 0.12 ". (The compressor does not
have any levelling means fitted on it.)

Fig. 4-3: Compressor room ventilation

November 2021 GB 29 / 76
5 Preparations for commissioning
TM

5 PREPARATIONS FOR COMMISSIONING

5.1 Pipelines
WARNING
Remove all blank flanges, plugs, caps and des-
iccant containing pouches before fitting the Risk of injury
pipelines. If an incorrect connection thread is used,
Manifolds and pipe connections must be of the the connector could come loose and the
correct size and be suitable for the operating tem- free connection result in severe personal
peratures and pressures. injury.
Label compressed air and water pipes according ➯ When connecting the compressor
to the local regulations. to the compressed air network, the
connecting thread must in particu-
Support all pipelines with correctly dimensioned
lar be checked in addition to check-
supports; pipes must not support any loads.
ing the operating temperatures and
If compressed air hose is used, it must be cor- pressures.
rectly dimensioned and be suitable for the oper-
➯ When connecting hoses, suitable
ating pressure and temperature. Do not use any
measures must be taken to prevent
abraded, damaged or inferior quality hose.
the dangerous "whipping" of a loose
A shut-off valve must be fitted in the supply line hose end.
so that the compressor can be isolated for mainte-
nance purposes. Checking the connection thread
The drain pipe leading away from the condensate The following connection threads are possible:
connection must not be designed to rise more than
European version: DIN 2999 R 2" (coloured blue)
5 m / 16.4 ft!
An air tank of sufficient volume should be installed Connecting the compressor to the com-
(as a buffer) between the compressor and the pressed air network
compressed air network. As a guide, the tank ca- The compressor is completely assembled in the
pacity should equal 10 % of the delivery quantity, factory. The connection to the compressed air net-
e.g. a compressor with a delivery quantity of 10m³/ work must be made with a flexible line, e.g. a com-
min / 353 ft³/min requires a tank volume of 1 m³ / pressed air hose or expansion joint.
35 ft³.
Use only hose couplings and connections of the
5.2 Compressed air connection correct type and size.
1. Ensure that the supply line can be connected
free from tension.
2. Connect the connection line to the compressed
air connection of the compressor.
3. Secure the hose lines.

5.3 Electrical connection

NOTICE
Faults in the electrical supply network
In low voltage networks, speed-controlled com-
pressor systems (VS) can cause faults. For this
reason, this drive system is not intended for use
in public low voltage networks that also supply
residential areas.

1
Fig. 5-1: Power leads/electrical connection
[1] Compressed air connection

30 / 76 GB November 2021
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Preparations for commissioning 5

The compressor system is executed completely in Electrically connecting the compressor

the factory according to EN 60204 (industrial ma-
chinery).
The compressor power supply must be suitable
for industrial equipment and must fulfil all the
requirements of EN60204-1/IEC60204-1. Con-
tact Gardner Denver if the positioning condi-
tions differ from the conditions as they are de-
scribed in EN 60204.
Implement the electrical connection and the
1
protective measures in accordance with VDE,
BS or the appropriate local regulations. In gen-
eral, the supplementary regulations of the re-
spective power supply utility must be consid-
ered.
A main switch must be fitted on-site upstream
of the compressor (DIN EN 1012 - 1) (insofar Fig. 5-2: Supply line openings
that such a switch has not already been fitted in [1] Power leads/electrical connection
the factory as a special accessory). The main
switch must fulfil the requirements of the safety DANGER
standard EN 60 204-1 (Electrical equipment of
machines), as well as EN 60947-2 (low voltage Electric shock
switchgear). Life-threatening electric shock
The compressor must be fused using suitable ➯ Work on the electrical equipment
backup fuses in accordance with EN 60269-1 must only be carried out by autho-
(low voltage directives). rised electricians or electrical techni-
If third party circuits are retrospectively con- cians.
trolled via the electronic control, e.g. lighting,
heating or similar, that cannot be switched off 1. Feed the power supply cable through the open-
from the main switch, these excluded circuits ings in the switch cabinet.
must be labelled according to EN 60204 and 2. Connect the power supply cable (see circuit di-
routed separately. Moreover, warning signs agram).
must be attached close to the main switch and 3. Tighten the cable glands.
close to the relevant circuits.
Should an electrical connection to an un- Checking the setting of the fan protection
earthed AC electrical circuit (IT network) be switch
made, observe the instructions in the supplied
documentation of the frequency converter (only DANGER
VS compressors). Electric shock
Life-threatening electric shock
➯ Work on the electrical equipment
must only be carried out by autho-
rised electricians or electrical techni-
cians.

1. Check the settings of the safety switch of the

two fan motors (see circuit diagram).
2. Set the safety switch according to the supply
network voltage and frequency, see circuit dia-
gram.

November 2021 GB 31 / 76
5 Preparations for commissioning
TM

Check the setting of the control transformer

DANGER
Electric shock
Life-threatening electric shock
➯ Work on the electrical equipment
must only be carried out by autho-
rised electricians or electrical techni-
cians.
➯ With the speed-controlled compres-
sors / fans there is a risk of electric
shocks due to charged capacitors!
➯ Switch the compressor voltage-free
and wait at least 10 minutes before
touching any electrical parts.
➯ Check DC bus voltage at the fre-
quency converter if DC+/DC- termi-
nals are present. The voltage mea-
sured must be zero.

The control transformer is set to the rated volt-

age ex works.
Experience has shown that the actual supply
voltage may differ from the rated voltage.
To match the local circumstances, the cor-
rect setting of the control transformer must be
checked when the compressor is under load
by measuring the control voltages and if neces-
sary the transformer then reset.
A number of taps are provided for this purpose
(see circuit diagram).

NOTICE
Material damage
Incorrect setting of the control transformer en-
dangers trouble-free operation.
➯ Checking of the setting of the control trans-
former forms part of commissioning and pe-
riodic inspection/maintenance, as the mains
voltage conditions may vary.

32 / 76 GB November 2021
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Commissioning and operating 6

6 COMMISSIONING AND OPERATING

6.1 Initial commissioning 8. Check the factory setting of the pressure set-
points (minimum line pressure [Line Pres-
NOTICE sure min.] and maximum [Line Pressure max.])
and readjust if necessary.
Material damage
9. Press start button < I >.
Although every compressor has already under-
gone a test run in the factory and has undergone 10.Check the direction of rotation of the drive mo-
a careful final inspection in dispatch, the possi- tor (not VS compressors) and of the fan (VS
bility of transport damage cannot be excluded. compressors). See the following descriptions.

➯ Before commissioning check the compres- 11. Check the output voltages of the control trans-
sor once more for damage and monitor it former in load operation.
during its initial operating hours.
Check the drive motor rotational direction
➯ If the compressor is being connected to a ( for non-VS compressors)
power supply network and started for the
first time, then dependent on the version, DANGER
the direction of rotation of the drive motor
and/or fans must be checked. Risk of injury

– Drive motor for non-VS compressors, The drive motor rotational direction can
only be checked if the clutch cover is de-
– Fan for VS compressors mounted.

Preparations ➯ Before switching on, check that

there is nobody in the danger area!
Check all electrical and electronic compo-
nents/devices for water ingress or condensate ➯ Maintain an adequate distance from
formation, in case of complaints, contact Gard- rotating machine parts!
ner Denver. ➯ Wear ear defenders!
If the compressor has been in storage for a ➯ Except for test runs, only operate
substantial period of time (up to 2 years), the the compressor with the enclosure
main switch must be switched on at least one closed.
hour prior to starting. This ensures the operabil-
ity of the capacitors and prevents any damage
from occurring.
If the compressor has been stored for longer
than 2 years, consult Gardner Denver.

Carry out the initial commissioning as follows

1. Check the oil level.
2. Check the settings of the fan motor overload
switch.
3. Check the setting of the control transformer.
2
4. Check all the terminals of the electronic control 1
unit and tighten as necessary.
5. Switch on the main switch.
Fig. 6-1: Check the drive motor rotational direction
– All three LEDs on the control panel illumi-
nate. [1] Enclosure (open)
6. Set the display language. [2] Direction of rotation arrow
7. Acknowledge faults indicated on the display. 1. Switch the main switch OFF.
– The message [Ready to Start] appears on 2. Open the enclosure.
the display.
3. Remove the protective cover from the clutch.
4. Switch the main switch ON.
5. Press start button < I >.

November 2021 GB 33 / 76
6 Commissioning and operating
TM

6. Check the rotational direction.

7. If the direction of rotation is wrong: Immedi-
ately switch the compressor off with the emer- 2
gency-stop pushbutton and not with stop button
< O >; otherwise damage to the compressor
may occur, even if it only operates very briefly.
8. Switch the main switch OFF.
9. Correct the rotational direction. Change the
compressor rotating field. 3
10.Replace the protective cover on the clutch.
11. Shut enclosure.

Check direction of rotation of fan motors (for

VS compressors)

CAUTION
1
Risk of falling
The rotational direction of the fan motors
can only be checked "from above". Fig. 6-3: Check direction of rotation of fan motor (wa-
➯ Ensure safe climbing means are ter-cooled system)
provided. [1] Cooling air inlet
[2] Cooling air outlet
[3] Fan impeller direction of rotation

The rotational direction of the fan motors can be

checked with the enclosure still closed.
1. Place a suitable ladder alongside the compres-
sor and use it to climb up.
2. Check the rotational direction.
3. If the direction of rotation is wrong: Switch off
the compressor.
4. Switch the main switch OFF.
5. Correct the rotational direction. Change the
compressor rotating field.

Temperature start-up protection

The compressor does not start up at ambient tem-
peratures less than + 2 °C / 36 °F.

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

cooled system)
[1] Cooling air inlet
[2] Cooling air outlet
[3] Fan impeller direction of rotation

34 / 76 GB November 2021
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Commissioning and operating 6

6.2 Normal operation Part-load operation (on-load operation at re-

duced speed,, only for VS compressors ) [on-
Electronic control unit load operation]
Off-load [Off-Load]

Observations during operation

During operation the compressor must be regu-
larly checked to ensure leak-tightness of the oil cir-
cuit. With water-cooled systems, this inspection is
extended to the cooling water circuit.

Condensate drain
The condensate drain on the aftercooler is actu-
Fig. 6-4: Control panel ated via sensor control.
[1] Touchscreen display
Switching off
[2] Start button < I >.
1. Press stop button < O > on the control panel.
[3] Stop button < O >
– The compressor runs on for 30 seconds
[4] red LED (soft stop).
flashing slowly: warning or maintenance
flashing rapidly: Fault Emergency-stop
[5] yellow LED The compressor can be rendered safe in danger-
flashing slowly: Maintenance necessary ous situations using the emergency-stop pushbut-
[6] green LED ton.
lit up permanently: System in operation Emergency-stop pushbuttons are attached:
Flashing: System in standby
on the compressor control panel
[7] Pushbutton <Emergency-stop>
optionally in a control room (control centre)

DANGER Using emergency-stop

Risk of injury 1. Press the <Emergency-stop> pushbutton.
The compressor is placed in a safe condition.
The compressor can start automatically
at any time when it is in standby mode 2. Rectify the fault that was the cause of the
with the green LED flashing. Emergency-stop.
See the "Troubleshooting" chapter.
➯ Do not carry out any work on the
compressor, if the green LED is 3. Unlock the <Emergency-stop> pushbutton.
flashing. Turn the pushbutton anticlockwise.
4. Set the compressor in operation.
Switching on See section "Commissioning after a fault" in the
1. Press start button < I > on the control panel. chapter "Commissioning and operation".
– The compressor is switched on.
6.3 Routine commissioning
– The compressor runs automatically (au-
tomatic operation). See the operating se- Routine commissioning is for example commis-
quence description in the section "Operating sioning after maintenance.
sequence" in the chapter "Design and func- 1. Open the shut-off valves between the compres-
tion". sor and compressed air network.
2. Thereafter proceed as described in the section
Operating conditions
"Initial commissioning".
During automatic operation, the compressor can
adopt any of the following operating conditions: 6.4 Commissioning after a long
Ready to start (stand-by) [Ready to Start] shutdown
Operating under load [On-Load] Refer to your local service organisation before
starting.

November 2021 GB 35 / 76
6 Commissioning and operating
TM

6.5 Commissioning after a fault

NOTICE
Material damage
Avoid switching the compressor on multiple
times without rectification of the fault as this can
lead to considerable mechanical damage.
➯ Only switch the compressor back on after
the fault is rectified.

Re-commissioning after a fault (automatic

switching off)
Faults are displayed in the display menu "Fault
log".
1. Switch main switch off and secure to prevent
switching back on.
2. Rectify the fault.
See the "Troubleshooting" chapter.
3. Switch on the main switch.
4. Acknowledge fault in the fault log.
5. After acknowledgement, the message [Ready
to Start] appears on the display, provided no
other fault exists.
6. Press the start button < I > on the control
panel.
– The compressor is switched on.
– The compressor runs in automatic mode.
See the operating sequence description in
the section "Control (automatic operation)"
in the chapter "Design and function".

36 / 76 GB November 2021
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Troubleshooting 7

7 TROUBLESHOOTING
Troubleshooting instructions Remedies are described in detail in the repair
The following tables list possible fault causes and manual, which is provided as part of operator
remedies. training.

The troubleshooting measures listed in these op-

erating instructions may only be carried out by NOTICE
specially trained personnel. All work going beyond Material damage
this must be carried out by the manufacturer's ser-
Material damage due to improper/incorrect trou-
vice personnel! Work on the electrical equipment
bleshooting measures.
must only be carried out by authorised electricians
or electrical technicians. ➯ If the remedies listed here are insufficient
for rectification of the fault, consult Gardner
Denver.
➯ For fault and warning messages that are
output to the display of the electronic control
unit, observe the information in the "Trou-
bleshooting" chapter in the operating in-
structions of the electronic control unit.

Fault: The system will not start

Possible Cause Remedy
Missing operating or control voltage Check fuses, main switch and power cable.
Fault is not acknowledged Acknowledge fault in the electronic control unit.
Pressure vessel not depressurised. Wait for depressurisation. Screw compressor does
not start up when the pressure in the vessel is
greater than the preset value. See factory setting
“Start approval” GD Pilot TS.
Drive motor defective Check connections, winding, etc.
Compressor defective Rotate the compressor by hand, if necessary
replace.
Ambient temperature < +1 °C / 33.8 °F Ensure that the ambient temperature is at least
+1°C / 33.8°F if necessary provide heating when at
a standstill
The remote control/timer control via terminal strip is Deactivate remote control/timer control
activated
Line pressure is above the lower switching point Wait until the line pressure has fallen below the
(compressor without speed control) or nominal switching point / nominal pressure
pressure (compressor with speed control)
Chart 7-1: Troubleshooting upon: The system will not start

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

Possible Cause Remedy
Short-circuit in the compressor Determine the cause of the short-circuit and rectify.
Replace defective fuses.
Terminals loose Check the terminals and tighten if necessary.
Too frequent manual switching on and off results in Avoid frequent manual switching on and off.
exceeding of the maximum motor switching cycles Allow the electric motor to cool.

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

November 2021 GB 37 / 76
7 Troubleshooting
TM

Possible Cause Remedy

Suction regulator does not close completely Provide access to the suction regulator, replace if
necessary.
Check regulator block (2.4).
Chart 7-2: Troubleshooting upon: The system remains stationary during the start-up phase

Fault: System does not reach the set line pressure

Possible Cause Remedy
Line pressure sensor defective Check line pressure sensor, replace if necessary.
Too large air bleed Throttle the air bleed valve or switch on/use further
compressors.
Oil fine separator soiled Replace oil fine separator cartridge
Air filter contaminated Replace air filter cartridge.
Heavy leaks Check compressor. For example:
Check for leaks.
Safety valve defective or open after checking.
Condensate drain set to test function.

Suction regulator does not open completely Provide access to the suction regulator, replace if
necessary.
Check regulator block (2.4).
Chart 7-3: Troubleshooting upon: System does not reach the set line pressure

Fault: System switches off

Possible Cause Remedy
Ambient temperature too high Ventilate the compressor room.
Electric motor defective Check electric motor and posistor.
Fan defective Check fan, replace if necessary.
Sensors, connections or leads defective Check sensors, connections and leads.
Wire cross section of the electrical leads too small Measure current consumption, if necessary replace
leads.
Oil level too low Top up oil in the pressure vessel
Oil injection pressure too low Replace oil filter cartridge. Clean oil system
Oil temperature too high Check oil cooler and fan / check oil temperature
regulator
Compressor defective Replace compressor
Chart 7-4: Troubleshooting upon: System switches off

Fault: Off-load pressure too high

Possible Cause Remedy
Compressor does not discharge Check regulator block (2.4).
Chart 7-5: Troubleshooting upon: Off-load pressure too high

38 / 76 GB November 2021
 TM

Troubleshooting 7

Possible Cause Remedy

Suction regulator does not close completely Provide access to the suction regulator, replace if
necessary.
Check regulator block (2.4).
Chart 7-5: Troubleshooting upon: Off-load pressure too high

Fault: Oil in the air filter

Possible Cause Remedy
Suction regulator non-return function defective Check non-return valve; replace if necessary.
Continuous emergency-off deactivation Emergency-Off may only be used for safety-related
function problems

Fault: Safety valve opens

Possible Cause Remedy
Safety valve defective Replace the safety valve.
Line pressure sensor defective Replace the line pressure sensor.
Final compression pressure sensor defective Replace final compression pressure sensor
Electronic control unit defective Replace the electronic control unit.
Oil fine separator soiled Replace oil fine separator cartridge
Suction regulator does not close completely Check regulator block (2.4).
Provide access to the suction regulator, replace if
necessary.
Chart 7-6: Troubleshooting upon: Safety valve opens

Troubleshooting: Lubricator
If faults occur when operating the lubricator, please check the possible causes of error using the following
table.
Fault Possible Cause Remedy
Lubrication system not dispens- Cable incorrectly connected Check whether the plug icon is
ing, despite voltage being sup- being shown in the display.
Cable failure
plied.

Chart 7-7: Troubleshooting and fault rectification for lubricator

November 2021 GB 39 / 76
7 Troubleshooting
TM

Fault Possible Cause Remedy

Lubrication system not dispens- Drive and LC not screwed to- Screw the drive and LC together
ing, despite voltage being sup- gether properly. until the white triangle on the drive
plied. The plug icon appears on is fully visible.
the display.

Lubrication system is in pressure Counter-pressure to lubrica- Flush lubrication point (man-

cut-off. tion point > 6 bar . ually or special dispensing
PURGE I)
Pressure check if necessary
OL Acknowledge fault by pressing
the SET key.

Lubricant cartridge empty, but no LC unit too small for the drive. Use original LC unit MLS 60 from
“LC” message. Gardner Denver.

Chart 7-7: Troubleshooting and fault rectification for lubricator

40 / 76 GB November 2021
 TM

Troubleshooting 7

Fault Possible Cause Remedy

Message “LC” even though lubri- LC unit too big for the drive. Use original LC unit MLS 60 from
cant cartridge is not completely Gardner Denver
emptied.

LC

Display not working despite volt- Internal drive fault. Replace entire lubrication system
age being supplied.

“Lo” message on the display. Weak backup battery of the drive. Change the CR2450 (3V) backup
battery.
May only be changed by trained
personnel.
Lo

“E” message on the display. Internal drive fault Replace entire lubrication system

Er

Chart 7-7: Troubleshooting and fault rectification for lubricator

November 2021 GB 41 / 76
7 Troubleshooting
TM

NOTE
Observe the fault messages on the operating panel display.
The corresponding measures for fault clearance are described in the operating instructions of the elec-
tronic control unit.

42 / 76 GB November 2021
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Maintenance and Service 8

8 MAINTENANCE AND SERVICE

Maintenance and service are decisive for ensur-
ing that the compressor can fulfil the requirements
made of it for fault-free operation and running
time. Therefore the adherence to the prescribed
maintenance schedule and the careful execution
of all maintenance and service work are indispens-
able.
Support is available from your responsible Gard- 1
ner Denver agency. They will create an individual
maintenance plan for you.

8.1 General notes

Target groups
The maintenance work listed in these operating
instructions may only be carried out by specially
trained personnel.
All work going beyond this must be carried out by
the manufacturer's service personnel!

Safety
Fig. 8-1: Position of air vent valve (air-cooled system)
Observe the safety instructions in the chapter
Safety conditions. [1] Ball valve to aftercooler

DANGER
Electric shock
Life-threatening electric shock
➯ When carrying out any work on the
electrical equipment, exercise ex-
treme care.
➯ Before starting the maintenance
work, switch the compressor to a
voltage-free state and secure to pre-
vent switching back on.

WARNING
Risk of risk of injury due to hot air
vent valve
The compressed air outlet temperature
can be up to 90 °C / 194 °F.
➯ Before opening the air vent valve,
allow the compressor system to
cool.
➯ Do not perform any work when the
compressor system is hot.
1

Fig. 8-2: Position of air vent valve (water-cooled system)

[1] Air vent valve

November 2021 GB 43 / 76
8 Maintenance and Service
TM

Protection measures for safe maintenance Electrical components

(safety routine)
For all maintenance work, if not expressly stated DANGER
elsewhere: Electric shock
1. Switch the compressor off and secure to pre- Life-threatening electric shock
vent switching back on.
➯ Work on the electrical equipment
2. Drain the compressor. must only be carried out by autho-
3. Wait for automatic pressure relief to complete. rised electricians or electrical techni-
cians.
4. Connect the (site provided) shut-off valve in the
supply line. ➯ With the speed-controlled compres-
sors / fans there is a risk of electric
5. Wait until the residual electrical energy in the
shocks due to charged capacitors!
capacitors has dissipated (only VS compres-
sors). ➯ Switch the compressor voltage-free
and wait at least 10 minutes before
6. Allow the compressor to cool to room tempera-
touching any electrical parts.
ture.
➯ Check DC bus voltage at the fre-
7. Wear personal protective equipment.
quency converter if DC+/DC- termi-
8. Observe the information about hazardous sub- nals are present. The voltage mea-
stances. sured must be zero.

Manual pressure relief

8.2 Inspection of protective and
WARNING safety equipment
Pressure components Protective covers and enclosure panels
Even when the compressor is depres- Ensure that all compressor protective covers and
surised, the aftercooler remains under enclosure panels are correctly attached.
pressure. Protective cover of the cooling air fans
➯ Carry out manual pressure dis- Clutch protective cover between drive and
charge before maintenance work is compressor
carried out in the vicinity of the after-
Compressor housing; here in particular the
cooler.
openings (doors)
1. Connect the (site provided) shut-off valve in the Safety valve must be in perfect condition. For ex-
supply line. ample, it must not be blocked by dirt or paint.
2. Switch the main switch OFF. Emergency-Stop pushbutton /Emergency-Stop
3. Open the enclosure, create access. function
4. Undo the lock screw on the closed air vent The switching function of the contacts can be
valve (ball valve at the aftercooler). checked by an electrician.
5. Depressurise the aftercooler by careful opening
of the air vent valve. NOTE
6. Close the air vent valve and screw in the air The Emergency-stop function must only be acti-
vent valve. vated in dangerous situations. Otherwise the re-
sult could be increased wear or even damage to
7. Upon completion of maintenance work, open
the compressor.
the shut-off valve in the supply line.
An electrician can check the switch function of the
Test run contacts.
A test run should be carried out after all main-
tenance work; this should amongst other things Functional checking of the safety valves
make possible the detection of any leaks. During The function check of the safety valve must be
every test run, the low-noise running of the com- carried out by a safety specialist. The result of the
pressor must also be ensured. functional check must be documented.

44 / 76 GB November 2021
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Maintenance and Service 8

1. Switch the main switch OFF. 8.3 Service

2. Open the enclosure, create access. The global spare parts and customer service net-
3. Press start button < I >. work of Gardner Denver is available worldwide.
Allow the compressor to run under load. The local Gardner Denver subsidiary or the re-
sponsible dealer is available for any spare parts
NOTICE requirements.
Hearing damage It is important that the model name and the serial
number of the compressor are stated in all mes-
Increased sound pressure level when operating
sages.
without the sound-proofing enclosure.
➯ Wear ear defenders. Spare parts orders
Spare parts orders to:
WARNING
Germany
Risk of burns/scalding eMail
Risk of burns/scalding due to escaping ersatzteile@compair.com
hot oil (oil mist) / hot compressed air. Tel.: +49 (0)6761/832-136
Fax.: +49 (0)6761/832-411
➯ Wear suitable protective clothing.
International
➯ Slowly screw out the knurled cap. eMail
➯ Do not screw the knurled cap too far Brno.Amt@gardnerdenver.com
out of the enclosure.
➯ Tighten the knurled cap as far as it NOTE
will go after each functional check. The spare parts order is placed based on the
spare parts list which is available separately.

8.4 Routine maintenance

All maintenance work and checks listed in the
maintenance plan must be carried out and docu-
mented at the specified intervals.
All maintenance, overhauls and repairs to the
compressor must be documented.
Service and maintenance work must be carried
out by the local Gardner Denver agency.
1
Cleanliness
2
The compressor room and the compressor sur-
roundings must always be kept clean.
The compressor must be checked regularly for
damage and excess wear.
Spilt oil must be immediately wiped up. Oil traces
must be removed immediately.

Fig. 8-3: Pressure vessel safety valve Electrical connections

[1] Safety valve The condition of cables and terminals must be
[2] Valve cap checked regularly.
Check for loose connections or frayed or worn-
4. Turn the valve cap anticlockwise until an audi- through wires.
ble blowing off can be heard.
All connections must be clean and tight.
5. Turn the valve cap clockwise as far as it will go.
Immediately replace worn-through or damaged
The valve must completely close again.
wires.

November 2021 GB 45 / 76
8 Maintenance and Service
TM

Leak points Compressor oil AEON 3000

Compressor oil AEON S
WARNING
Compressor oil AEON FG 8000
Risk of injury due to high pressure
➯ Do not manually investigate leak In the event of accidents or prolonged contact with
points in the system. operating fluids, observe the information in the
hazardous substance data sheets!
➯ Always use paper or board for this
purpose. Prevent leakage of operating fluids.
Carefully clear up any operating fluids that escape.
If leaks are suspected, check the correspond- Observe the information in the hazardous sub-
ing area for leaks. stance data sheets!
Immediately repair or replace damaged or leak-
Oil carbon deposits in the oil lubrication sys-
ing pipe or hose connections.
tem
Emission or leakage of operating fluids High oil temperatures reduce the service life of the
The following operating fluids are used in the com- oil and this can lead to oil carbon deposits in the
pressor: oil lubrication system. Oil carbon deposits can re-
sult in damage to the bearings and gearboxes.

8.5 Maintenance plan with 2000 hour service package

Maintenance work should be carried out regularly as recommended in the following maintenance plan.
In the majority of cases the maintenance plan is appropriate, however under certain circumstances it is
possible that changes to the details may be necessary. The maintenance plan should always be used as
a guideline. However, if based on experience a change is necessary, then this should be discussed with
Gardner Denver.

Maintenance plan: Maintenance every 8 operating hours

Component Measure Necessary qualification Carried out
Oil tank level check Check and refill if neces- Maintenance personnel
sary
On-load/off-load machine Check and report if nec- Operator
function essary
Pressure and tempera- Check Operator
ture at discharge
Control Panel Check for fault mes- Operator
sages and notify when
necessary
Chart 8-1: Maintenance plan, very 8 operating hours

Maintenance plan: Maintenance every 125 operating hours

Component Measure Necessary qualification Carried out
Cooler / fan Check and clean if nec- Maintenance personnel
essary
Oil tank Drain condensate Maintenance personnel
Chart 8-2: Maintenance plan, very 125 operating hours

Maintenance plan: Service interval A - every 2000 hours run, but no less than annually
Component Measure Necessary qualification Carried out
Filter mats cooling air inlet Check, clean and replace as Maintenance personnel
necessary.
Chart 8-3: Maintenance plan: Service A

46 / 76 GB November 2021
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Maintenance and Service 8

Component Measure Necessary qualification Carried out

Air filter Replace air filter Maintenance personnel
Oil filter Replace oil filter Maintenance personnel
Condensate drain Aftercooler, function check. Maintenance personnel
Electronic control unit Check for displayed mainte- Operator
nance requirements.
Chart 8-3: Maintenance plan: Service A

Maintenance plan: Service interval B – Every 4,000 hours, but no less than annually
Component Measure Necessary qualification Executed
Customer operations log Check and adhere to operat- Operator
ing parameters.
Electronic control unit Check fault statistics. Operator
General Maintenance / cleaning Maintenance personnel
Oil fine separator Replace Maintenance personnel
Switch cabinet cooling air inlet Replace. Maintenance personnel
filter
Frequency converter cooling Replace. Maintenance personnel
air inlet filter (VS)
Compressor oil Replace / check Maintenance personnel
*See oil change interval
Moisture sensor replacement Replace Maintenance personnel
filter cap
Safety valve Function test at least once a Maintenance personnel
year
Hoses and pipelines Check for leaks or as the case Maintenance personnel
may be, damage.
Electrical wiring Check connections and condi- Electrician
tion.
Compressor Maintain the compressor room Operator
and surroundings clean.
Emergency stop switch Function test Maintenance personnel
Temperature sensor Function test Maintenance personnel
Chart 8-4: Maintenance plan: Service B

Maintenance plan: Maintenance interval C – every 8,000 hours, but at least every two years
Component Measure Necessary qualification Executed
Pressure retention valve Replace. Maintenance personnel
Suction regulator non-return Replace. Maintenance personnel
valve
Compressor oil Replace / check Maintenance personnel
*See oil change interval
Chart 8-5: Maintenance plan: Service C

November 2021 GB 47 / 76
8 Maintenance and Service
TM

Inspection every 4 years:

Have electrical installation inspected by an electrician.

Inspection every 5 years:

Internal inspection of the pressure vessel by a competent individual.

Inspection every 10 years:

Strength test of the pressure vessel by appointed body.

Electronic control unit

Information concerning the maintenance points for the electronic control unit can be found in the elec-
tronic control unit operating instructions.

Oil change interval

Operating hours* 4 000 h 8 000 h 16 000 h
Mineral AEON 3000 X
Synthetic AEON S X
Food grade AEON FG 8000 X
Chart 8-6: Oil overview
*4,000 hours, but at least yearly
*8,000 hours, but at least every two years / oil check at 4,000 h
The oil change intervals stated in the maintenance plan must be halved when final compression tempera-
tures are continuously higher than 90 °C / 195 °F.

8.6 Maintenance plan without 2000-hour service package

Maintenance work should be carried out regularly as recommended in the following maintenance plan.
In the majority of cases the maintenance plan is appropriate, however under certain circumstances it is
possible that changes to the details may be necessary. The maintenance plan should always be used as
a guideline. However, if based on experience a change is necessary, then this should be discussed with
Gardner Denver.

Maintenance plan: Maintenance every 8 operating hours

Component Measure Necessary qualification Carried out
Oil tank level check Check and refill if neces- Maintenance personnel
sary
On-load/off-load machine Check and report if nec- Operator
function essary
Pressure and tempera- Check Operator
ture at discharge
Control Panel Check for fault mes- Operator
sages and notify when
necessary
Chart 8-7: Maintenance plan, very 8 operating hours

Maintenance plan: Maintenance every 125 operating hours

Component Measure Necessary qualification Carried out
Cooler / fan Check and clean if nec- Maintenance personnel
essary
Chart 8-8: Maintenance plan, very 125 operating hours

48 / 76 GB November 2021
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Maintenance and Service 8

Component Measure Necessary qualification Carried out

Oil tank Drain condensate Maintenance personnel
Chart 8-8: Maintenance plan, very 125 operating hours

Maintenance plan: Maintenance interval - every 2000 operating hours, but at least every year
Component Measure Necessary qualification Carried out
Filter mats cooling air inlet Check, clean and replace as Maintenance personnel
necessary.
Condensate drain Aftercooler, function check. Maintenance personnel
Electronic control unit Check for displayed mainte- Operator
nance requirements.
Chart 8-9: Maintenance plan: Maintenance every 2000 operating hours

Maintenance plan: Maintenance interval EX every 4,000 hours, but no less than annually
Component Measure Necessary qualification Executed
Customer operations log Check and adhere to operat- Operator
ing parameters.
Electronic control unit Check fault statistics. Operator
General Maintenance / cleaning Maintenance personnel
Premium air filter Replace air filter Maintenance personnel
Premium oil filter Replace oil filter Maintenance personnel
Oil fine separator Replace Maintenance personnel
Frequency converter cooling Replace. Maintenance personnel
air inlet filter (VS)
Compressor oil Replace / check Maintenance personnel
*See oil change interval
Moisture sensor replacement Replace Maintenance personnel
filter cap (VS / e)
Safety valve Function test at least once a Maintenance personnel
year
Hoses and pipelines Check for leaks or as the case Maintenance personnel
may be, damage.
Electrical wiring Check connections and condi- Electrician
tion.
Compressor Maintain the compressor room Operator
and surroundings clean.
Emergency stop switch Function test Maintenance personnel
Temperature sensor Function test Maintenance personnel
Chart 8-10: Maintenance plan: Maintenance EX

Maintenance plan: Maintenance interval C – every 8,000 hours, but at least every two years
Component Measure Necessary qualification Executed
Pressure retention valve Replace. Maintenance personnel
Chart 8-11: Maintenance plan: Service C

November 2021 GB 49 / 76
8 Maintenance and Service
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Component Measure Necessary qualification Executed

Suction regulator non-return Replace. Maintenance personnel
valve
Compressor oil Replace / check Maintenance personnel
*See oil change interval
Chart 8-11: Maintenance plan: Service C

Inspection every 4 years:

Have electrical installation inspected by an electrician.

Inspection every 5 years:

Internal inspection of the pressure vessel by a competent individual.

Inspection every 10 years:

Strength test of the pressure vessel by appointed body.

Electronic control unit

Information concerning the maintenance points for the electronic control unit can be found in the elec-
tronic control unit operating instructions.

Oil change interval

Operating hours* 4 000 h 8 000 h 16 000 h
Mineral AEON 3000 X
Synthetic AEON S X
Food grade AEON FG 8000 X
Chart 8-12: Oil overview
*4,000 hours, but at least yearly
*8,000 hours, but at least every two years / oil check at 4,000 h
The oil change intervals stated in the maintenance plan must be halved when final compression tempera-
tures are continuously higher than 90 °C / 195 °F.

8.7 Maintenance plan (extended warranty)

Other maintenance cycles are required for the expanded warranty. Please take these from the extended
warranty conditions.

Electronic control unit

Information concerning the maintenance points for the electronic control unit can be found in the elec-
tronic control unit operating instructions.

50 / 76 GB November 2021
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Maintenance and Service 8

8.8 Maintenance work 8.8.2 Switch cabinet inlet filter

8.8.1 Filter mats (air-cooled system)

Fig. 8-5: Switch cabinet inlet filter

[1] Speed-controlled compressor switch
cabinet inlet filter
Fig. 8-4: Filter mats
[1] Cooler cooling air inlet
[2] Motor cooling air inlet
[3] Switch cabinet cooling air inlet
[4] Compressed air intake

Replacement times for the filter pad

The operating modes and the quality of the suction
air (e.g. dust content) have a significant impact on
the service life of the filter pad.
The filter pad should be inspected for dust accu-
mulation at least weekly; daily if possible.
In these usage scenarios, shorter replacement in- Fig. 8-6: Louvred grille
tervals are possible.
As soon as one of the filter pads shows a defect, it
must be replaced.

Fig. 8-7: Filter element replacement

November 2021 GB 51 / 76
8 Maintenance and Service
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Change inlet filter

1. Pivot open the louvred grille of the inlet filter. WARNING
2. Remove dirty filter. Risk of scalding
3. Insert new filter. Risk of scalding by hot oil.
4. Close louvred grille. ➯ Only change the oil when the com-
pressor is stationary and depres-
Replacement times for the inlet filter elements surised.
The operating modes and the quality of the suction ➯ Caution when draining hot oil.
air (e.g. dust content) have a significant impact on
the service life of the filter elements. Oil must be changed if the message [Service due]
is displayed on the electronic control unit.
The filter elements should be inspected for dust
accumulation at least weekly; daily if possible. With these compressors, the time for changing oil
is heavily dependent on the degree of soiling of
If usage scenarios transpire with, for example, an
the circulating oil. It is vital you ensure that no oil-
increased rate of dust accumulation, the replace-
harming foreign substances (dust, vapour, gas)
ment intervals must be shortened in relation to the
get into the oil circuit of the compressor system
maintenance plan.
through the air suction filter with the suction air.
Also, high humidity in the suction air and conden-
8.8.3 Oil change
sate build-up within the machine have an impact
on the service life of the lubrication oil, meaning
that shortening of the oil replacement times may
be necessary. The replacement intervals specified
are based on suction air which is normally present
and no large ratios of foreign substances (dust,
vapour, gas) arising.
When changing oil, drain used oil as completely as
possible, as used oil greatly reduces the service
1 3 life of the new oil charge.
5 You must refrain from mixing different lubrica-
tion oils. When changing oil types, the oil must be
4 completely drained from the oil circuit.
You can find the maintenance intervals in the
2 maintenance plan.
6 Replacement times for the lubrication oil
Operating conditions (e.g. cooling medium temper-
atures), the type of operation and the quality of the
suction air (e.g. dust content, content of gaseous
Fig. 8-8: Oil tank foreign substances such as SO2, solvent vapours,
[1] Oil filler neck etc.) have a significant impact on oil change inter-
vals.
[2] Oil drain
In such instances of usage, the permitted duration
[3] Oil level indicator of use of the oil must be checked with the help of
[4] Min. oil level marking an oil analysis.
[5] Max. oil level marking
[6] Oil drain hose NOTE
Catch the used oil, do not allow it to seep into
the ground.
Dispose of according to the regulations! Do not
spill oil! Immediately capture any used oil! En-
sure leak-tightness!

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Maintenance and Service 8

Changing oil The compressor is equipped with one oil filter.

1. Switch main switch OFF and secure to prevent The oil filter element must be changed, if the mes-
switching back on. sage [Service due] or [Air filter] is displayed on
the electronic control unit.
2. Wait for compressor to cool down
3. Open the enclosure, create access. Replacing the oil filter element
4. Open oil filler neck carefully. Allow any resid- 1. Switch main switch OFF and secure to prevent
ual pressure to be released. switching back on.
5. Provide an oil collecting vessel. 2. Wait for compressor to cool down
6. Place oil drain hose over the collecting vessel. 3. Open the enclosure, create access.
7. Open oil drain valve. 4. Release the filter element (for direction of rota-
tion see figure).
8. Drain oil completely.
5. Insert new filter elements.
9. Close oil drain valve.
6. Shut enclosure.
10.Top up with oil until the max. mark is reached.
11. Shut oil filler neck. 8.8.5 Oil fine separator
12.Shut enclosure.
13.Switch on the main switch.
1
14.Switch on screw compressor for approx. 2 min.
15.Switch off screw compressor. 2
16.Switch main switch OFF and secure to prevent
switching back on.
17.Open the enclosure.
18.Check the oil level. If necessary, correct oil
level.
19.Shut enclosure.

8.8.4 Oil filter

Fig. 8-10: Oil fine separator replacement

[1] Vessel cover lifting device
[2] Oil fine separator

The compressor is equipped with an internal oil

fine separator. The oil fine separator separates
compressed air and oil, with the oil then being in-
jected in the airend for lubrication, cooling and
sealing.
Fig. 8-9: Oil filter The oil fine separator must be changed if the mes-
sage [Service due] or [Fine separator] is displayed
WARNING on the electronic control unit.
Risk of scalding
Risk of scalding by hot oil.
➯ Only change the oil when the com-
pressor is stationary and depres-
surised.
➯ Caution when draining hot oil.

November 2021 GB 53 / 76
8 Maintenance and Service
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Changing the oil fine separator 8.8.6 Air filter

WARNING
2
Pressure components
Even when the compressor is depres-
surised, the aftercooler remains under 1
pressure.
➯ Release pressure manually prior to
performing maintenance work in the
aftercooler and pressure-retaining
valve area.

1. Switch main switch OFF and secure to prevent

switching back on.
2. Open the enclosure, create access.
3. Open the aftercooler pressure relief valve.
4. Remove the pressure pipe.
Fig. 8-11: Air filter
5. Remove the pressure retention valve.
6. Remove the suction pipe. [1] Clamp
7. Remove vessel cover screws. [2] Air filter
8. Raise vessel cover using the lifting device (1). The compressor is equipped with an air filter. The
9. Turn vessel cover through 155°. air filter is used to filter the inlet air. The condition
of the air filter must be checked through regular vi-
10.Lift oil fine separator (2) out of the vessel.
sual inspections.
11. Replace sealing rings.
The air filter element must be changed, if the mes-
12.Lift new oil fine separator (2) into the vessel. sage [Service due] or [Air filter] is displayed on
13.Swivel vessel cover into the exit position. the electronic control unit.
14.Unclamp lifting device.
Checking the air filter
15.Attach vessel cover screws
1. Switch main switch OFF and secure to prevent
Screw torque 8.8 – switching back on.
215 Nm ; 158 lbf-ft
2. Open the enclosure, create access.
16.Fit the suction pipe 3. Check the filter element.
17.Fit the pressure retention valve – Replace the filter element if it is heavily con-
18.Fit the pressure pipe. taminated.
19.Close the aftercooler pressure relief valve. 4. Shut enclosure.
20.Shut enclosure.
Replace the air filter element

NOTICE
Material damage
Operation of the compressor without air filters,
even briefly, can result in considerable damage
to the compressor.
➯ Never operate the compressor without an
air filter.
➯ No dirt must get into the clean air side of the
air filter!

1. Switch the main switch OFF.

2. Open the enclosure, create access.
3. Open the clamp.

54 / 76 GB November 2021
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Maintenance and Service 8

4. Change the filter element. Performance of a protective cap change

5. Close the clamp. 1. Switch main switch OFF and secure to prevent
6. Shut enclosure. switching back on.
2. Wait for compressor to cool down
8.8.7 Moisture sensor protective cap 3. Open the enclosure, create access.
4. Remove the protective cap of the moisture sen-
sor.
5. Fit new protective cap (tighten manually).
6. Shut enclosure.
7. Switch on the main switch.

8.8.8 Connection terminals in the switch

cabinet / control transformer set-
ting

DANGER
Electric shock
Life-threatening electric shock
➯ When carrying out any work on the
electrical equipment, exercise ex-
treme care.
1 ➯ Before starting the maintenance
work, switch the compressor to a
voltage-free state and secure to pre-
vent switching back on.

DANGER
Electric shock
Life-threatening electric shock
➯ Work on the electrical equipment
Fig. 8-12: Moisture sensor protective cap must only be carried out by autho-
rised electricians or electrical techni-
[1] Protective cap
cians.
➯ With the speed-controlled compres-
sors / fans there is a risk of electric
shocks due to charged capacitors!
➯ Switch the compressor voltage-free
and wait at least 10 minutes before
NOTICE touching any electrical parts.
➯ Check DC bus voltage at the fre-
Damage due to static charging
quency converter if DC+/DC- termi-
➯ When replacing the protective cap of the nals are present. The voltage mea-
moisture sensor, electronic components sured must be zero.
are uncovered. These components may be
damaged by contact.

The moisture sensor protective cap must be re-

placed every 4000 operating hours. If the safety
valve on the pressure vessel should open, the pro-
tective cap should likewise be replaced.

November 2021 GB 55 / 76
8 Maintenance and Service
TM

8.8.9 Drive motor / Lubricator

NOTICE
Replacing a grease cartridge
Material damage
Incorrect setting of the control transformer en-
dangers trouble-free operation.
1
➯ Checking of the setting of the control trans-
former forms part of commissioning and pe- 2
riodic inspection/maintenance, as the mains
voltage conditions may vary.

Checking the setting of the control transformer

forms part of commissioning and periodic in-
spection/maintenance, as the mains voltage
3
conditions may have changed.
The connection terminals in the switch cabinet are
to be checked during the first commissioning and
thereafter in accordance with the maintenance 4
plan and re-tightened if necessary.

Fig. 8-13: Lubricator

[1] Socket for connection cable
[2] Lubricator drive
[3] Grease cartridge (not refillable)
435V 415V 400V 380V 360V
[4] Support bracket

Changing the grease cartridge

An empty grease cartridge or a fault on the lu-
bricator is indicated on the compressor control
by means of a message [Warning: Mot.Schmier-
sys] (also refer to the operating instructions for the
compressor control GD Pilot TS).
Procedure for changing the grease cartridge:
Check the setting of the control transformer 1. Switch main switch OFF and secure to prevent
as follows: switching back on.
Switch on system as in chapter “Routine com- 2. Open the enclosure, create access.
missioning”.
3. Pull the plug from the lubricator as follows.
In on-load operation check the control trans-
– Completely unscrew union nut.
former’s output voltages. A number of taps are
provided for this purpose (see circuit diagram). – Pull out plug.
4. Release drive union nut from the grease car-
If the output voltage is not correct, check the
tridge fully and lift off.
setting of the control transformer as follows:
5. Release grease cartridge from the support
Switch main switch off and secure to prevent
bracket by turning anticlockwise.
switching back on.
6. Unscrew cap of the new grease cartridge.
With speed-controlled systems or fans (VS),
wait for 10 minutes. This the time it takes the 7. Screw in new grease cartridge into the support
power capacitors to discharge. bracket. (max. torque 2 – 3 Nm / 18 - 27 ft-lbs)
Modify the setting of the control transformer ac- 8. Place the drive on the new grease cartridge.
cordingly (control transformer tap illustration The toothing of the two parts must intermesh.
shows an example of this). 9. Apply drive union nut without tool. (max. torque
Then check setting once more. 2–3 Nm / 18 - 27 ft-lbs)

56 / 76 GB November 2021
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Maintenance and Service 8

– You must ensure that the triangular marks 3. Reset the fault message.
on the drive housing are fully visible. To do this press the button [RESET] on the tab
– If these marks are not fully visible, release "Fault log" in the electronic control unit.
the union nut and put the drive back on – The "Fault log" tab stops flashing.
again.
8.8.11 Checking intervals for pressure
10.Insert plug in the drive and apply union nut
again so it is finger-tight.
vessel and electrical installation
11. Shut enclosure. Pressure vessel
After five years, a person qualified to do so must
8.8.10 Control system check the pressure vessel internally in accordance
Testing the Emergency-stop pushbutton with Pressure Equipment Directive 97/23/EC.
After ten years, an appointed body must subject
the pressure vessel to a strength test in accor-
dance with Pressure Equipment Directive 97/23/
EC.

Electrical installation
After four years, or after each instance of interfer-
ence, the electrical installation is to be subjected
to an inspection by an electrical specialist.
If shorter checking intervals apply in your territory,
please adhere to them.
[1] Touchscreen display
[2] Start button < I >. 8.8.12 Maintenance instructions and lu-
[3] Stop button < O > bricant recommendations for fixed
[4] red LED
compressors
flashing slowly: warning or maintenance Lubricant recommendation
flashing rapidly: Fault Please note that proper lubrication significantly in-
[5] yellow LED creases the service life of your compressor sys-
flashing slowly: Maintenance necessary tem.
[6] green LED In accordance with applicable accident prevention
lit up permanently: System in operation regulations, lubrication oils whose properties meet
Flashing: System in standby the intended operating conditions are to be used.
[7] Pushbutton <Emergency-stop> Please refrain from mixing different lubrication oils.
This also means oil must be completely drained
NOTE from the oil circuit when changing oil types.

The Emergency-stop function must only be acti- The oil change intervals stated in the mainte-
vated in dangerous situations. Otherwise the re- nance plan are to be halved when final compres-
sult could be increased wear or even damage to sion temperatures are continuously higher than
the compressor. 90°C/195°F.
A precise specification of the oil change intervals
Only test the Emergency-stop pushbutton when should be defined according to the operating con-
the compressor is at a standstill. ditions that actually exist by carrying out oil sam-
1. Press stop button< O >. pling and analysis
– The electronic control unit status message
The following types of oil are to be used:
is [Ready to Start].
Mineral: AEON 3000
1. Press the <Emergency-stop> pushbutton.
Synthetic: AEON S
– The electronic control unit displays the fault
message [Emergency Stop Activated]. Food grade: AEON FG 8000
– The tab "Fault log" flashes.
2. Unlock the <Emergency-stop> pushbutton.
Turn the pushbutton anticlockwise.

November 2021 GB 57 / 76
8 Maintenance and Service
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8.8.13 Testing the temperature sensor

WARNING
Risk of scalding!
Caution when draining hot oil.
Carry out temperature sensor testing
only if the compressor is out of service,
depressurised and secured to prevent
switching back on.
The test must only be carried out by
trained technicians.
Pipelines or other parts with a sur-
face temperature of greater than 70 °C
(158 °F must be protected and labelled
in a suitable way to prevent contact.

As part of the annual compressor service, the tem-

perature sensor must be checked twice.
When doing so, the compressor must be shut
down and all necessary safety precautions taken.

Plausibility check of the measured value

Remove the temperature sensor and make
sure that any oil escaping at the oil outlet is col-
lected.
Expose the sensor to ambient temperature dur-
ing approx. 15 minutes. Check whether the
controller indicates the correct ambient temper-
ature.
Once the test is complete, refit the temperature
sensor in the compressor.

Testing automatic deactivation

Unplug the temperature sensor.
Check whether there is a shutdown message
at the regulator in relation to the discharge tem-
perature / temperature sensor.
The temperature sensor must be replaced if it
does not pass one of the tests.

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Appendix 9

9 APPENDIX
9.1 Shutdown 9.3 Removal
Routine shutdown
WARNING
Routine shutdown is e.g. shutdown for mainte-
nance. Harmful to health

1. Switch main switch OFF and secure to prevent Risk of damage to health due to operat-
switching back on. ing fluids and additives

2. Close the shut-off valves between the com- Lubricants and additives may cause ir-
pressor and compressed air network. reparable damage to the health, trigger
allergies or irritate the mucous mem-
3. Depressurise the aftercooler by careful opening brane.
of the air vent valve.
➯ When handling lubricants and ad-
Shutdown for a longer period ditives, always observe the locally
valid operating instructions/haz-
Refer to your local service organisation.
ardous substance data sheets.
Final shutdown ➯ Avoid direct contact with lubricants
To prevent restarting of the compressor or misuse and additives. Wear personal pro-
by unknown parties, the compressor must be ren- tective equipment!
dered unusable. ➯ Where injuries occur in which lubri-
The compressor is rendered unusable by removal cants and additives are involved,
of the electronic control unit. Contact Gardner consult a doctor and name the sub-
Denver for advice. stances involved.
Have the hazardous substance data
9.2 Lubricants and additives sheet readily available.

The compressor contains approximately 41 l of oil.

CAUTION
Safety data sheets Risk of slipping
When handling operating fluids and additives, the Risk of slipping due to escaped operat-
corresponding safety data sheets must be ob- ing fluid
served.
➯ Immediately clear up any operating
Mineral: AEON 3000 fluid that has escaped.
Synthetic: AEON S ➯ Avoid direct contact with operat-
Food grade: AEON FG 8000 ing fluids. Wear personal protective
equipment!

Preconditions
The compressor is out of service.
– The compressor is switched to a zero volts
state.
– The main switch is switched to OFF and se-
cured to prevent switching back on.
– The compressor is depressurised.
– Liquids and grease are as far as possible
removed.

November 2021 GB 59 / 76
9 Appendix
TM

Demounting the power supply When disposing of substances harmful to health,

the instructions of the corresponding safety data
DANGER sheets must be observed.
Electric shock Packaging material, cleaning agents and used or
residual lubricants must be delivered to a recycling
Life-threatening electric shock
centre in accordance with the regulations valid in
➯ Work on the electrical equipment the place of use.
must only be carried out by autho-
rised electricians or electrical techni- WEEE-Directive
cians. In accordance with the WEEE directive (2002/96/
1. Disconnect the power supply cable (see circuit EC), Gardner Denver undertakes to support the
diagram). recovery and reuse of electrical and electronic de-
vices. Contact Gardner Denver for advice.
2. Remove the power supply cable.
3. Attach plugs to the power supply cable open- Disposal
ings. The compressor should be stripped down into its
component parts to permit disposal "according to
Demounting the pipelines material composition", for example into base met-
1. Disconnect the compressed air connection. als, plastics, textile products.
2. Disconnect the condensate drain pipes. Biodegradable parts should be delivered to normal
3. Allow the condensate to drain away completely. industrial waste disposal processes. Plastics, rub-
ber or composite materials must not be disposed
4. Immediately clear up any condensate that has of by burning.
escaped.
All liquid waste substances such as lubricating
Draining the lubricating oil oil or grease, antifreeze, cooling liquids or corro-
sion inhibitors must be disposed of using specially
1. Open the enclosure, create access.
approved waste disposal or recycling systems.
2. Position a suitable container beneath the oil When doing so, it must be ensured that these sub-
drain. stances do not get into the sewage system.
3. Open the drain valve and allow the oil to flow The following table provides an overview for the
out completely. Dispose of the lubricating oil. disposal of substances and materials used.
4. Close the drain valve.
Material / Disposal type
5. Close the enclosure. substance
Recycling Landfill Haz-
Demounting the oil filter ardous
waste
1. Remove the oil filter from the lubrication sys-
tem. Dispose of the filters. Metals x
– Oil filter Cable x
– Oil fine separator
Seals x
Demounting the air filter Plastics x1 x
1. Demount the filter element and filter mats. Dis-
Filters x
pose of filter element and filter mats.
– Air filter cartridge Operating x2
fluids
– Filter mats
Chart 9-1: Substances and materials used and their dis-
– Switch cabinet cooling air inlet filter (only VS
posal
compressors)
1 Where possible
9.4 Disposal 2 Disposal according to the safety data sheet or manu-
General facturer's information

The compressor must be dismantled and stripped

down by specialised personnel. The applicable lo-
cal safety and environmental protection regula-
tions must be adhered to when doing this.

60 / 76 GB November 2021
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Appendix 9

9.5 Cooling Water Quality

NOTE
The following data are guidelines, which may deviate under certain operating conditions. The overall
composition and the operating temperature are always decisive. No guarantee claims can be made
based on the data.

Dissolved matter / specific values Circulating water Through-flow water

pH value (at 25 °C / 77 °F) 6-9 6-9
Carbonate hardness CaCO3 < 100 mg/l (5,6 °dH) < 50 mg/l (2,8 °dH)
Total hardness < 2 mmol/l < 0.5 mmol/l
< 200 ppm < 50 ppm
< 11,5 °dH < 2,8 °dH
< 20 °fH < 5 °fH
Chloride Cl- < 200 mg/l < 50 mg/l
Sulfate SO42- < 200 mg/l < 50 mg/l
Nitrate NO3- < 100 mg/l < 100 mg/l
Organic materials (KMnO4 absorption) < 25 mg/l < 10 mg/l
free aggressive carbonic acid CO2 < 20 mg/l < 20 mg/l
Silicon dioxide SiO2 < 10 mg/l < 10 mg/l
Free chlorine Cl2 < 4 mg/l < 2 mg/l
Oxygen O2 < 2 mg/l < 2 mg/l
Ammonium NH4+ < 1 mg/l < 1 mg/l
Iron Fe < 0.2 mg/l < 0.2 mg/l
Manganese Mn < 0.1 mg/l < 0.1 mg/l
Sulfide S2- 0 0
Ammonia NH3 0 0
Conductivity > 50 < 800 µS/cm > 50 < 200 µS/cm
Chart 9-2: Limit values of dissolved matter

9.6 Technical Specification

9.6.1 ESM55 / ESM55e + ESM75 / ESM75e, 50Hz, air-cooled "A", water-cooled "W"
ESM55 / ESM55e + ESM75 / ESM55 / ESM55e ESM75 / ESM75e
ESM75e
50Hz, air-cooled "A", water-cooled
"W"
Maximum operating pressure [bar] 7.5 10 13 7.5 10 13
Maximum operating pressure (ver- [bar] 7.5 10 - 7.5 10 -
sion e)
Minimum operating pressure [bar] 5.0
Ambient temperature [°C] 1/ 45
Chart 9-3: Technical data; ESM55 / ESM55e + ESM75 / ESM75e, 50Hz, air-cooled "A", water-cooled "W"

November 2021 GB 61 / 76
9 Appendix
TM

ESM55 / ESM55e + ESM75 / ESM55 / ESM55e ESM75 / ESM75e

ESM75e
50Hz, air-cooled "A", water-cooled
"W"
Volume flow *) [m3/min] 10.71 9.50 8.25 13.98 12.54 10.50
Volume flow (version e) *) [m3/min] 10.71 9.50 - 14.80 12.68 -
Total input power without load, fan "A" = [kW] 15.5 13.5 11.7 22.7 19.6 15.5
switched off "W" = [kW] 16.7 14.5 12.5 24.0 20.8 16.7
Aftercooler outlet temperature above "A" = [°C] 5 4 3 7 6 4
ambient temperature "W" = [°C] 2 2 1 4 3 2
Sound pressure level (ISO 2151) **) "A" [dB(A)] 69 72
"W" [dB(A)] 68 71
Sound pressure level (ISO 2151) "A" [dB(A)] 69 - 71 -
(version e) **) "W" [dB(A)] 68 70
Rated speed of drive motor [kW] 55 75
Total current consumption during on- [A] 120 160
load operation at no more than 400V
Electric motor IE3 (IP55)
Electric motor (version e) IE4
Rated speed of drive motor [1/min] 3000
Rated speed of fan motor "A" [kW] 1.27 1.91
"W" [kW] 0.37 0.37
Recommended cable cross-section [mm2] 3x35 PE16 3x50 PE25
at 400V
Recommended fuse rating (time- [A] 3x160 3x200
delayed) at 400V
Cooling air volume flow "A" = [m3/min] 147 201
"W" = [m3/min] 32 32
Size of the cooling air inlet opening "A" = [mm] 890 x 830 890 x 830
"W" = [mm] 424 x 166 424 x 166
Size of the cooling air outlet opening "A" = [mm] 344 x 1206 413 x 1206
"W" = [mm] Ø460 Ø460
Cooling air outlet temperature above "A" [°C] 24 25
ambient temperature (at maximum
capacity)
Residual pressure at ambient temper- "A" [Pa] 100 / 58 / 20 80 / 60 / 0
ature [20 ° / 35 °C / 45 °C] [20 ° / 35 °C / 45 °C]
Cooling water volume "W" [l/min] 77 l/min 82 l/min
ΔT = 12K, Δp = 1.3 bar ΔT = 15K, Δp = 1.4 bar
Cooling water inlet temperature "W" [°C] min. 5 / max. 35 min. 5 / max. 35
Cooling water outlet temperature "W" [°C] max. 55 max. 55
Chart 9-3: Technical data; ESM55 / ESM55e + ESM75 / ESM75e, 50Hz, air-cooled "A", water-cooled "W"

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Appendix 9

ESM55 / ESM55e + ESM75 / ESM55 / ESM55e ESM75 / ESM75e

ESM75e
50Hz, air-cooled "A", water-cooled
"W"
Cooling water pressure "W" [bar] max. 10 max. 10
Cooling water connections "W" EN 10226-1 Rp 1 (DIN 2999-R 1)
Total oil quantity [l] 40
Total oil quantity heat recovery [l] 44
(optional)
Compressed air connection EN 10226-1 R 2 (DIN 2999-R 2)
Weight "A" [kg] 1405 1495
"W" [kg] 1435 1495
Weight (version e) "A" [kg] 1405 - 1785 -
"W" [kg] 1435 1785
Dimensions L x W x H [mm] 1958 x 1138 x 1857
Chart 9-3: Technical data; ESM55 / ESM55e + ESM75 / ESM75e, 50Hz, air-cooled "A", water-cooled "W"
*) Data measurement and specification as per ISO1217 fourth edition, Appendix C & E and under the following con-
ditions:
Air suction pressure: 1 bar a / 14.5 psia
Air suction temperature: 20 °C/68 °F air humidity: 0 % (dry)
**) Measured in an open area as per ISO 2151, tolerance 3 dB(A).

at Gardner Denver, our philosophy is to continually improve our products. We therefore reserve the right to alter
technical data without prior notice.

9.6.2 ESM55 / ESM55e + ESM75 / ESM75e, 60Hz, air-cooled "A", water-cooled "W"
ESM55 / ESM55e + ESM75 / ESM55 / ESM55e ESM75 / ESM75e
ESM75e
60Hz, air-cooled "A", water-cooled
"W"
Maximum operating pressure [bar] 7.5 9 13 7.5 9 13
Maximum operating pressure (ver- [bar] - -
sion e)
Minimum operating pressure [bar] 5.0
Ambient temperature [°C] 1/ 45
Volume flow *) [m3/min] 10.11 10.06 8.20 14.03 12.65 11.21
Volume flow (version e) *) [m3/min] - -
Total input power without load, fan "A" = [kW] 14.6 14.6 11.7 23.0 19.9 17.0
switched off "W" = [kW] 15.8 15.8 12.7 24.5 21.3 18.4
Aftercooler outlet temperature above "A" = [°C] 5 4 3 7 6 4
ambient temperature "W" = [°C] 2 2 1 4 3 2
Sound pressure level (ISO 2151) **) "A" [dB(A)] 72 74
"W" [dB(A)] 71 73
Chart 9-4: Technical data; , 60Hz, air-cooled "A", water-cooled "W"

November 2021 GB 63 / 76
9 Appendix
TM

ESM55 / ESM55e + ESM75 / ESM55 / ESM55e ESM75 / ESM75e

ESM75e
60Hz, air-cooled "A", water-cooled
"W"
Sound pressure level (ISO 2151) "A" [dB(A)]
(version e) **) "W" [dB(A)]
Rated speed of drive motor [kW] 55 75
Total current consumption during on- [A] 124 / 106 173 / 140
load operation at no more than 380V /
460V
Electric motor IE3 (IP55)
Rated speed of drive motor [1/min] 3600
Rated capacity of fan motor at 380V / "A" [kW] 1.35 / 1.42 1.50 / 1.80
460V
"W" [kW] 0.75 / 0.66 0.75 / 0.66
Recommended cable cross-section [mm2] 3x35 PE16 / 3x25 PE16 3x70 PE35 / 3x50 PE25
at 380V / 460V
Recommended fuse rating [A] 3x160 / 3x125 3x200 / 3x160
at 380V / 460V
Cooling air volume flow "A" = [m3/min] 147 201
"W" = [m3/min] 35 35
Size of the cooling air inlet opening "A" = [mm] 890 x 830 890 x 830
"W" = [mm] 424 x 166 424 x 166
Size of the cooling air outlet opening "A" = [mm] 344 x 1206 413 x 1206
"W" = [mm] Ø460 Ø460
Cooling air outlet temperature above "A" [°C] 24 25
ambient temperature (at maximum
capacity)
Residual pressure at ambient temper- "A" [Pa] 100 / 58 / 20 80 / 60 / 0
ature [20 ° / 35 °C / 45 °C] [20 ° / 35 °C / 45 °C]
Cooling water volume "W" [l/min] 77 85
ΔT = 12K, Δp = 1.3 bar ΔT = 15K, Δp = 1.4 bar
Cooling water inlet temperature "W" [°C] min. 5 / max. 35 min. 5 / max. 35
Cooling water outlet temperature "W" [°C] max. 55 max. 55
Cooling water pressure "W" [bar] max. 10 max. 10
Cooling water connections "W" EN 10226-1 Rp 1 (DIN 2999-R 1)
Total oil quantity [l] 40
Total oil quantity heat recovery [l] 44
(optional)
Compressed air connection EN 10226-1 R 2 (DIN 2999-R 2)
Weight "A" [kg] 1405 1495
"W" [kg] 1435 1495
Chart 9-4: Technical data; , 60Hz, air-cooled "A", water-cooled "W"

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Appendix 9

ESM55 / ESM55e + ESM75 / ESM55 / ESM55e ESM75 / ESM75e

ESM75e
60Hz, air-cooled "A", water-cooled
"W"
Dimensions L x W x H [mm] 1958 x 1138 x 1857
Chart 9-4: Technical data; , 60Hz, air-cooled "A", water-cooled "W"
*) Air suction pressure: 1 bar a / 14.5 psia
Air suction temperature: 20 °C/68 °F air humidity: 0 % (dry) Data measurement and specification as per ISO1217
fourth edition, Appendix C & E and under the following conditions:
**) Measured in an open area as per ISO 2151, tolerance 3 dB(A).

at Gardner Denver, our philosophy is to continually improve our products. We therefore reserve the right to alter
technical data without prior notice.

9.6.3 VS55, 50Hz + 60Hz, air-cooled "A", water-cooled "W"

VS55 VS55
50Hz + 60Hz, air-cooled "A", water-cooled "W"
Maximum operating pressure [bar] 10
Minimum operating pressure [bar] 5.0
Ambient temperature [°C] 1/ 45
min speed max. speed
Volume flow rate / discharge pressure [bar] *) [m3/min] 2.58 / 7.5 10.78 / 7.5
[m3/min] 2.56 / 8 10.51 / 8
[m3/min] 2.53 / 9 9.93 / 9
[m3/min] 2.50 / 10 9.41 / 10
Total input power without load, fan switched off "A" = [kW] 4.6
"W" = [kW] 4.2 / 4.4 (50 Hz / 60 Hz)
Aftercooler outlet temperature above ambient "A" = [°C] 4/3
temperature (max. power at 7.5 bar / 10 bar) "W" = [°C] 2/2
Sound pressure (ISO 2151) (7.5 / 10 bar) **) "A" [dB(A)] 72 / 69 (50 Hz) ; 73 / 70 (60 Hz)
"W" [dB(A)] 71 / 67 (50 Hz) ; 72 / 68 (60 Hz)
Rated speed of drive motor [kW] 55
Nominal voltage [tolerance] (frequency) 380 V [+10% -5%]; 400 V [±10%];
460 V [±10%] (50, 60 Hz)
Total current consumption during load operation "A" = [A] 116 / 110 / 96
(380 V / 400 V / 460 V) "W" = [A] 115 / 109 / 95
Electric motor IE3 (IP55)
Rated min./max. speed of drive motor 750 / 3020
Rated capacity of fan motor at "A" [kW] 1.35 / 1.27 / 1.42
380 V (60 Hz) / 400 V (50 Hz) /
"W" [kW] 0.75 / 0.37 / 0.66
460 V (60 Hz)
Recommended cable cross-section [mm2] 3x35 PE16 / 3x35 PE16 / 3x25 PE16
(380 V / 400 V /460V)
Chart 9-5: Technical data; VS55, 50Hz + 60Hz, air-cooled "A", water-cooled "W"

November 2021 GB 65 / 76
9 Appendix
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VS55 VS55
50Hz + 60Hz, air-cooled "A", water-cooled "W"
Recommended fuse rating (time-delayed) [A] 3x160 / 3x160 / 3x125
(380 V / 400 V / 460 V)
Cooling air volume flow "A" = [m3/ 147
min]
"W" = [m3/ 32 / 50 (50 Hz / 60 Hz)
min]
Size of the cooling air inlet opening "A" = [mm] 890 x 830
"W" = [mm] 424 x 166
Size of the cooling air outlet opening "A" = [mm] 344 x 1206
"W" = [mm] Ø460
Cooling air outlet temperature above ambient "A" [°C] 24
temperature (at maximum capacity)
Residual pressure at ambient temperature "A" [Pa] 100 / 58 / 20
[20 °C / 35 °C / 45 °C]
Cooling water volume "W" [l/min] 77
ΔT = 12K, Δp = 1.3 bar
Cooling water inlet temperature "W" [°C] min. 5 / max. 35
Cooling water outlet temperature "W" [°C] max. 55
Cooling water pressure "W" [bar] max. 10
Cooling water connections "W" EN 10226-1 Rp 1 (DIN 2999-R 1)
Total oil quantity [l] 40
Total oil quantity heat recovery (optional) [l] 44
Compressed air connection EN 10226-1 R 2 (DIN 2999-R 2)
Weight "A" [kg] 1430
"W" [kg] 1460
Dimensions L x W x H [mm] 1958 x 1138 x 1857
Chart 9-5: Technical data; VS55, 50Hz + 60Hz, air-cooled "A", water-cooled "W"
*) Data measurement and specification as per ISO1217 fourth edition, Appendix C & E and under the following con-
ditions:
Air suction pressure: 1 bar a / 14.5 psia
Air suction temperature: 20°C / 68°F air humidity: 0% (dry)
**) Measured in an open area as per ISO 2151, tolerance 3 dB(A).

at Gardner Denver, our philosophy is to continually improve our products. We therefore reserve the right to alter
technical data without prior notice.

9.6.4 VS75, 50Hz + 60Hz, air-cooled "A", water-cooled "W"

VS75, VS75
50Hz + 60Hz, air-cooled "A", water-cooled "W"
Maximum operating pressure [bar] 13
Minimum operating pressure [bar] 5.0
Chart 9-6: Technical data; VS75, 50Hz + 60Hz, air-cooled "A", water-cooled "W"

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Appendix 9

VS75, VS75
50Hz + 60Hz, air-cooled "A", water-cooled "W"
Ambient temperature [°C] 1/ 45
min speed max. speed
Volume flow rate / discharge pressure [bar] *) [m3/min] 2.20 / 7.5 13.92 / 7.5
[m3/min] 2.19 / 8 13.58 / 8
[m3/min] 2.16 / 9 12.87 / 9
[m3/min] 2.13 / 10 12.15 / 10
[m3/min] 2.10 / 11 11.67 / 11
[m3/min] 2.94 / 12 11.27 / 12
[m3/min] 3.75 / 13 10.88 / 13
Total input power without load, fan switched off "A" = [kW] 4.2
"W" = [kW] 3.8 / 4.0 (50 Hz / 60 Hz)
Aftercooler outlet temperature above ambient "A" = [°C] 6/5/3
temperature (max. power at 7.5 bar / 10 bar / 13 "W" = [°C] 4/3/2
bar)
Sound pressure level (ISO 2151) (7.5 / 10 bar) **) "A" [dB(A)] 74 / 73 / 72 (50 Hz) ; 75 / 74 / 73 (60 Hz)
"W" [dB(A)] 73 / 71 / 69 (50 Hz) ; 72 / 72 / 70 (60 Hz)
Rated speed of drive motor [kW] 75
Nominal voltage [tolerance] (frequency) 380V[+10% -5%]; 400V[±10%];
460V[±10%] (50, 60 Hz)
Total current consumption during load operation "A" = [A] 156 / 148 / 129
(380 V / 400 V / 460 V) "W" = [A] 153 / 146 / 127
Electric motor IE3 (IP55)
Rated min./max. speed of drive motor 650 / 3930
Rated capacity of fan motor at "A" [kW] 1.50 / 1.91 / 1.80
380 V (60 Hz) / 400 V (50 Hz) /
"W" [kW] 0.75 / 0.37 / 0.66
460 V (60 Hz)
Recommended cable cross-section [mm2] 3x50 PE25 / 3x50 PE25 / 3x35 PE16
(380 V / 400 V /460V)
Recommended fuse rating (time-delayed) [A] 3x200 / 3x200 / 3x160
(380 V / 400 V / 460 V)
Cooling air volume flow "A" = [m3/ 201
min]
"W" = [m3/ 32 / 35 (50 Hz / 60 Hz)
min]
Size of the cooling air inlet opening "A" = [mm] 890 x 830
"W" = [mm] 420 x 166
Size of the cooling air outlet opening "A" = [mm] 413 x 1206
"W" = [mm] Ø460
Chart 9-6: Technical data; VS75, 50Hz + 60Hz, air-cooled "A", water-cooled "W"

November 2021 GB 67 / 76
9 Appendix
TM

VS75, VS75
50Hz + 60Hz, air-cooled "A", water-cooled "W"
Cooling air outlet temperature above ambient "A" [°C] 25
temperature (at maximum capacity)
Residual pressure at ambient temperature "A" [Pa] 80 / 60 / 0
[20 °C / 35 °C / 45 °C]
Cooling water volume "W" [l/min] 82
ΔT = 15K, Δp = 1.4 bar
Cooling water inlet temperature "W" [°C] min. 5 / max. 35
Cooling water outlet temperature "W" [°C] max. 55
Cooling water pressure "W" [bar] max. 10
Cooling water connections "W" EN 10226-1 Rp 1 (DIN 2999-R 1)
Total oil quantity [l] 40
Total oil quantity heat recovery (optional) [l] 44
Compressed air connection EN 10226-1 R 2 (DIN 2999-R 2)
Weight "A" [kg] 1520
"W" [kg] 1520
Dimensions L x W x H [mm] 1958 x 1138 x 1857
Chart 9-6: Technical data; VS75, 50Hz + 60Hz, air-cooled "A", water-cooled "W"
*) Data measurement and specification as per ISO1217 fourth edition, Appendix C & E and under the following con-
ditions:
Air suction pressure: 1 bar a / 14.5 psia
Air suction temperature: 20°C / 68°F air humidity: 0% (dry)
**) Measured in an open area as per ISO 2151, tolerance 3 dB(A).

at Gardner Denver, our philosophy is to continually improve our products. We therefore reserve the right to alter
technical data without prior notice.

68 / 76 GB November 2021
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Appendix 9

9.7 Installation plan

Air-cooled system

[A] Compressed air connection [G] Cooling air inlet motor

[C] Water IN (cold) (optional) [H] Switch cabinet cooling air inlet
[EN] Water OUT (hot) (optional) [J] Cooling air outlet
[E] Compressed air inlet [K] Openings for power supply cable
[F] Cooling air inlet

November 2021 GB 69 / 76
9 Appendix
TM

Water-cooled system

[A] Compressed air connection [H] Switch cabinet cooling air inlet
[C] Cooling water inlet [J] Motor cooling air outlet
[EN] Cooling water outlet [K] Openings for power supply cable
[E] Switch cabinet cooling air inlet [L] Cooling water inlet
[G] Motor cooling air inlet [M] Cooling water outlet

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Appendix 9

Space requirements

73

361 212 760 212 *

1100

1044
750

800

1100

950
750
1044

1100

[*] Openings for forklift transport

November 2021 GB 71 / 76
9 Appendix
TM

9.8 Declaration of conformity

1. EC Declaration of Conformity
Pursuant to the EC Machinery Directive 2006/42/EC, Annex II A
2. We, Gardner Denver Deutschland GmbH
Argenthaler Str. 11
D-55469 Simmern
hereby declare that the product: Compressor
Type: ESM55; ESM75; ESM55e; ESM75e; VS55; VS75
Trade name:
Manufacturer number:
in the design supplied by us conforms with the following relevant regulations:
2014/29/EU (Simple Pressure Vessels Directive); 2014/30/EU (EMC Directive)
The machine does not fall under the Pressure Equipment Directive 2014/68/EU due to the criteria
for exclusion, as per Article: 1, Para.: 2.c, 2.f. and 2.j
3. In the event of the machine undergoing modification without our agreement, this declaration loses its
validity.
4. Harmonised standards applied, especially:
EN 1012-1 ; EN ISO 12100 ; EN 60204-1 ; EN60034-5
EN 60034-30-1 ; EN 61000-6-4 ; EN 6100-6-2
5. National technical standards and specifications applied
AD-S1/2000
6. Documentation provided by: CompAir Drucklufttechnik - subsidiary of
Gardner Denver Deutschland GmbH
Simmern,
Date: Signature:

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November 2021 GB 73 / 76
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November 2021 GB 75 / 76
Gardner Denver Compressor Division,
1800 Gardner Expressway, Quincy, Illinois 62305

Telephone: (800) 682-9868

Fax: (217) 224-7814

Gardner Denver Deutschland GmbH

Argenthaler Str. 11
55469 Simmern
Germany

Tel. ++49 (0)6761 832-0

Fax ++49 (0)6761 832-409