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Translation of the original operating

instructions
Screw compressor
D75 - D160 V2
D110RS - D160RS V2

GB

ZS1101891 / 02 - August 2013

Contents

CONTENTS

5.2

Compressed air connection.................... 35

5.3

Cooling water connection........................36

5.4

Electrical connection............................... 37

Foreword........................................................ 4

1.1

About these operating instructions............4

1.2

Notes......................................................... 5

1.3

Intended use............................................. 5

1.4

Intentional misuse..................................... 6

1.5

Service...................................................... 6

1.6

Nameplate................................................. 7

Safety conditions.......................................... 8

2.1

General safety instructions....................... 8

2.2

Instructions about particular types of


danger....................................................... 8

2.3

Protection and safety equipment.............. 9

2.4

Residual hazards.................................... 10

2.5

Identification of safety instructions.......... 10

2.6

Safety sign.............................................. 10

2.7

Transport and positioning....................... 14

2.8

Normal operation.................................... 14

2.9
2.10

Commissioning and operating.................. 39

6.1

Initial commissioning............................... 39

6.1.1

Cooling water control in a water-cooled


compressor system................................. 41

6.2

Normal operation.................................... 42

6.3

Routine commissioning........................... 43

6.4

Commissioning after a long


shutdown................................................. 43

6.5

Commissioning after a fault.................... 43

Troubleshooting.......................................... 44

Maintenance and Service........................... 47

8.1

General information................................ 47

8.2

Service.................................................... 48

8.3

Inspection of protection and safety


equipment................................................48

Special tasks...........................................14

8.4

Routine maintenance.............................. 49

Conversions and changes to the


machine...................................................15

8.5

Maintenance plan....................................50

8.6

Maintenance work...................................53

8.6.1

Accesses................................................. 53

8.6.2

Filter mat cooling air inlet........................54

8.6.3

Inlet filter cooling air switch cabinet (RS


compressors )..........................................54

Design and function................................... 16

3.1

General description................................. 16

3.2

Compressor design................................. 17

3.3

System scheme air-cooled


compressor..............................................21

8.6.4

Condensate drain....................................55

3.4

System scheme water-cooled


compressor..............................................23

8.6.5

Lubricating oil..........................................56

8.6.6

Ejector vent system................................ 58

3.5

Air circuit................................................. 25

8.6.7

Cooling system....................................... 61

3.6

External water circuit.............................. 27

8.6.8

................................................................ 62

3.7

Internal water circuit................................28

8.6.9

Air Filter...................................................63

3.8

Oil circuit................................................. 29

3.9

Ejector vent system................................ 30

3.10

Control (automatic operation)................. 30

8.6.11 Drive motor / Lubricator.......................... 65


8.6.12 Control system........................................ 66
9

Transport and positioning..........................32

Appendix...................................................... 67

9.1

Shutdown................................................ 67

9.2

Lubricants and additives......................... 67

9.3

Removal.................................................. 67

9.4

Disposal...................................................68

Preparations for commissioning............... 35

9.5

Limit values of dissolved matter..............69

Pipelines..................................................35

9.6

Technical Specification........................... 70

4.1

Transport................................................. 32

4.2

Storage....................................................32

4.3

Positioning...............................................32

8.6.10 Control air filter....................................... 64

5.1

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August 2013

Contents
9.6.1

D75 + D90, 50Hz, air-cooled "A" and


water-cooled "W" (European version)..... 70

9.6.2

D110 + D132, 50Hz, air-cooled "A" and


water-cooled "W" (European version)..... 71

9.6.3

D160, 50Hz, air-cooled "A" and watercooled "W" (European version)............... 72

9.6.4

D110 RS, 50Hz, air-cooled "A" and watercooled "W" (European version)............... 73

9.6.5

D132 RS, 50Hz, air-cooled "A" and watercooled "W" (European version)............... 75

9.6.6

D160 RS, 50Hz, air-cooled "A" and watercooled "W" (European version)............... 76

9.6.7

D75 + D90, 60Hz, air-cooled "A" and


water-cooled "W" (European version)..... 78

9.6.8

D110 + D132, 60Hz, air-cooled "A" and


water-cooled "W" (European version)..... 79

9.6.9

D160, 60Hz, air-cooled "A" and watercooled "W" (European version)............... 80

9.6.10 D110 RS, 60Hz, air-cooled "A" and watercooled "W" (European version)............... 81
9.6.11 D132 RS, 60Hz, air-cooled "A" and watercooled "W" (European version)............... 83
9.6.12 D160 RS, 60Hz, air-cooled "A" and watercooled "W" (European version)............... 84
9.6.13 D75 + D90, 60Hz, air-cooled "A" and
water-cooled "W" (USA version)............. 86
9.6.14 D110 + D132, 60Hz, air-cooled "A" and
water-cooled "W" (USA version)............. 87
9.6.15 D160, 60Hz, air-cooled "A" and watercooled "W" (USA version)....................... 88
9.6.16 D110 RS, 60Hz, air-cooled "A" and watercooled "W" (USA version)....................... 89
9.6.17 D132 RS, 60Hz, air-cooled "A" and watercooled "W" (USA version)....................... 91
9.6.18 D160 RS, 60Hz, air-cooled "A" and watercooled "W" (USA version)....................... 92
9.7

Installation plan....................................... 94

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Foreword

FOREWORD

These operating instructions are written for operating- and maintenance personnel.

Gardner Denver screw compressors are the product of years of research and development. This
experience in conjunction with high quality requirements ensures that the manufactured screw compressors are long-lasting, providing guaranteed reliability and economic operation.

The basis of these operating instructions are the


master operating instructions ZS1101886 /02,
which are relevant for translations of the operating
instructions.
These operating instructions are an inherent part
of the compressor. They must be available and accessible near the compressor at all times.

Equally, the stringent requirements for environmental protection are also met.

1.1

About these operating


instructions

These operating instructions provide you with all


the information you need for safe operation and
maintenance of the compressor. This includes:

These operating instructions apply for the following compressors from Gardner Denver Deutschland GmbH:

Installation and connection of the compressor


Commissioning and operation of the compressor

D75-8A V2

Replacement of wear parts and consumables


such as filters or oil

D75-10A V2
D90-8A V2

Identification of faults and rectification of malfunctions

D90-10A V2

Carrying out of visual inspections for damage


on a rotational basis

D110-8A V2
D110RS-8A V2

Cleaning, maintenance and repair of the compressor

D110-10A V2
D110RS-10A V2

The dealer's or manufacturer's workshop, with its


qualified and experienced personnel, is responsible for all maintenance work that goes beyond
customary service work and requires specialist
technical knowledge.

D132-8A V2
D132RS-8A V2
D132-10A V2

All pressures given in these operating instructions


are, where not otherwise specified, positive pressures (gauge pressures).

D132RS-10A V2
D160-10A V2
D160RS-10A V2

Target groups

D75-8W V2

The target groups for these operating instructions


are operators, maintenance personnel and electricians.

D75-10W V2
D90-8W V2

After training, the operator is permitted to start up


and shut down the compressor and activate the
emergency-stop.

D90-10W V2
D110-8W V2
D110RS-8W V2

Maintenance personnel may, in conjunction with


the information in these operating instructions,
maintain the compressor, repair it, start it up and
shut it down and activate the emergency-stop.

D110-10W V2
D110RS-10W V2
D132-8W V2

Electricians may electrically install the compressor, carry out direction of rotation checks and carry
out electrical maintenance work.

D132RS-8W V2
D132-10W V2

Safety conditions

D132RS-10W V2

Alongside all the other details in these operating


instructions, the general safety instructions, in the
chapter "Safety Conditions", must be read without
fail.

D160-10W V2
D160RS-10W V2

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Foreword

1.2

Notes

Copyright
These operating instructions are subject to copyright and may only be used for the agreed purpose, i.e. as a reference for in-plant purposes.

General information
The operating instructions must be read and used
by every person who is assigned to work with and
on the compressor.

Forwarding or reproduction of this document, exploitation and sharing of its content are forbidden, insofar as this is not expressly authorised.
Infringements will incur payment of compensation. All rights reserved for the case of granting of
a patent, petty-patent or design registration.

Irrespective of these operating instructions, the


laws, regulations, directives and standards applicable in the place of use must be observed.
Training

Reselling

The provision of local operator training is undertaken by authorised service technicians. The training documentation comprises these operating instructions and the repair manual, which is only issued as part of service training.

If the compressor is resold, these operating instructions must be handed over to the new operator together with the compressor. If necessary,
the operating instructions must be reordered from
Gardner Denver by specification of the order confirmation number. The compressor must not under
any circumstances be resold without these operating instructions.

These measures ensure that the assigned work


can be reliably carried out.
Warranty
Gardner Denver Deutschland GmbH will not be
held liable for the safe functioning of the compressor if it used other than for its normal use or for
purposes not listed in the operating instructions.

1.3

Intended use

The compressor conforms to the state of the art


and the applicable safety conditions at the time of
its bringing to market provided it is used for its intended purpose.

Gardner Denver Deutschland GmbH excludes all


warranty and liability in the event of:

From a design point of view, neither intentional


misuse nor all of the residual dangers can be
avoided, without limiting the intended functionality.

Operating errors.
Use of the compressor for other than the intended purpose.

The compressor is designed for the compression


of atmospheric oil-free air (compressed air for driving pressure equipment) the compressor is not
suitable for the compression of other gases.

Damage resulting from deliberate misuse or


non-observance of the operating instructions.
Damage or injuries caused by non-OEM components.

The compressor is only classed as being used for


its intended purpose if the following points are also
observed:

Use of spare or wear parts or operating fluids


that do not originate from or are not currently
recommended by or have not been previously
recommended by Gardner Denver Deutschland
GmbH.

The compressor is used according to these operating instructions.


The working steps and standard operating procedures of the operator are followed.

Inadequate maintenance.
Compressor conversions.

Any other use or use beyond this is defined as


non-intended use. The manufacturer is not liable
for any resulting damage. The user alone bears
the risk.

Warranty and liability conditions of the general


business conditions of Gardner Denver Deutschland GmbH are not expanded by the aforesaid information.

Intended use also includes observation of the operating instructions and adherence to the inspection and maintenance instructions.

Guarantee
The conditions and caveats of the Gardner Denver
Deutschland GmbH guarantee are specified in our
general terms and conditions, which were supplied
with the compressor. Upon request, an additional
copy of the document can also be sent retrospectively.

Other conditions
Danger to life and limb of the user or third parties
can arise from use of the compressor; likewise
damage to the compressor or other material can
arise if the compressor:
Is not used as intended.

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Foreword
Is not operated by trained personnel.

Manipulation of sensor signals.

Is changed or modified.

Signal modification of sensors.

The safety instructions are not observed.

Operation without protection and safety equipment.

Alongside these operating instructions, the following apply:

Operation with defective, deactivated or manipulated protection and safety equipment or


safety valves, or operation with other such
safety relevant defects.

Relevant accident prevention regulation


Generally recognised safety rules

Use by private users or users without technical


training.

Country-specific conditions
Installation location / installation altitude

Operation outside industrial environments.

The compressor is intended for installation in a


suitable compressor room. The compressor is not
suitable for open-air installation!

Non-adherence to maintenance intervals.


Omission of maintenance and repair work.
Incorrect execution of maintenance and repair
work.

The permissible installation altitude of the compressor is limited dependent on the operating
pressure, ambient humidity and ambient temperature at which it is operated. The permissible installation altitude is specified for each individual case
by consultation between the customer and Gardner Denver.

Limitations on use
Operation of the compressor is not permitted
outside the permissible ambient temperatures.
above the permitted altitude of the installation
location.

Working environment

on an insufficiently load-bearing substrate.

The illumination in the region of the compressor


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

Ambient temperature for operation: see "Technical


data".

If you have any questions about or problems with


the compressor please contact your responsible
Gardner Denver agency.

Pressure equipment

The trained specialised personnel will ensure you


receive quick and proper assistance.

For pressure equipment/systems a pressure relief device (safety valve or similar) dimensioned to
match the weakest pressure carrying component
and conforming to the relevant regulations must
be installed in the compressed air system.

1.4

Service

In case of queries
If you have a query or wish to make a spare parts
order, please specify the identification number and
year of manufacture on the name plate. Specification of this data will ensure that you receive the
correct information and/or spare parts.

Intentional misuse

Incorrect use and misuse


The following typical reasonably foreseeable misuses (incorrect uses) are classed as contrary to
the intended use:

Your Gardner Denver Deutschland GmbH


agency
Please enter the details of your local Gardner
Denver agency in the following table.

Compression of gases other than atmospheric


air.
Operation outside the permissible operating
limits, even if the exceeding of the limits is only
temporary or not immediately identifiable.
Operation outside the permissible ambient temperatures.
Extraction of non-atmospheric air (overpressure or vacuum pressure).
Use as a breathing air compressor.

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August 2013

Foreword

Name:
Gardner Denver , Inc
Quincy, Illinois

Contact:
Address:
1

Phone

Type

Fax

Machine
4

Weight

Email:

Order Mumber
Compression Medium
Voltage / Phase / Frequency
Flow
Stage Pressure
Suction Pressure
Full Load Current
Speed
Installed Motor Capacity

Made in Germany

Airend

Nameplate

Version

COMPRESSOR

kg

Chart 1-1: Local Gardner Denver agency

1.6

Serial Number

Model

8
9
10

Ph

Hz

11
12
13
14
15
16
17

CFM
1

psi g
psi
A
rpm
KW
100016812

Fig. 1-2: Nameplate

Fig. 1-1: Nameplate

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Safety conditions

SAFETY CONDITIONS

The operating instructions must be supplemented with instructions for the observation of
operating peculiarities including monitoring and
reporting obligations, e.g. in respect of working
organisation, working processes, responsibilities, etc.

Any person who is involved with the operation,


maintenance or repair of the compressor, must
read and follow the safety conditions.
Gardner Denver Deutschland GmbH accepts no
responsibility for material damage or injuries that
arise from non-observation of safety conditions or
the failure to observe normal levels of care and attention, even where this is not expressly stated in
these operating instructions.

Personnel selection and qualification; fundamental responsibilities

2.1

The authorised personnel must:

Only reliable and authorised personnel may work


on the compressor.

General safety instructions

be trained by Gardner Denver.

Organisational measures

be trained according to its responsibilities, duties and activities and instructed about the
compressor.

The following organisational measures contribute


to the safe use of the compressor:
Only appointed personnel may work on the
compressor. The personnel have been trained
and briefed about the compressor.

have the physical and mental capabilities to


fulfil its responsibilities and carry out its duties
and activities on the compressor.

Before starting work, the personnel must have


read the operating instructions, in particular the
"Safety Conditions" chapter. Dont leave this
until you start work its too late. This applies
in particular to personnel who only work on the
machine occasionally, e.g. to carry out maintenance.

have understood the operating instructions in


respect of its responsibilities, duties and activities on the compressor and be able to practically implement this.

2.2

The responsibilities of the personnel for operation, maintenance and repair must be clearly
defined.

Instructions about particular


types of danger

Electrical energy

DANGER

The safe and hazard-aware working of the personnel must be checked regularly.

Electric shock

Personnel who are to be trained in, taught


about or instructed as part of a general training
course, must only work on the compressor under the constant supervision of an authorised
person.

Life-threatening electric shock


When carrying out any work on the
electrical equipment, exercise extreme care.
Before starting the maintenance
work, switch the compressor to a
voltage-free state and secure to prevent switching back on.

If safety-relevant changes are made to compressor or arise in its operating behaviour, the
compressor must be immediately shutdown
and the fault reported to the responsible post/
person.

For all work on the electrical equipment of the


compressor the 5 safety rules for working on electrical equipment must be observed.

Faults, especially those that could impair


safety, must be immediately rectified. Otherwise the compressor must not be operated.

Moreover, the following instructions must be observed:

All danger signs on and in the surroundings of


the compressor must be regularly checked for
completeness and legibility. Missing danger
signs must be immediately replaced.

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

The intervals between tests and inspections


must be adhered to.

The compressor's electrical equipment must be


checked regularly. Defects such as loose connections or charred cables must be rectified immediately.
Only original fuses of the specified current rating may be used.

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Safety conditions
Only for RS compressors:

All protective and safety equipment must be attached and checked for trouble-free operation before every commissioning, in particular after maintenance and repair work.

Due to the residual voltage on the capacitors, a


waiting time of at least 10 minutes must elapse
after switching to a zero volts state (main switch
OFF) before the switch cabinet can be opened.
Observe the danger sign on the switch cabinet!
See table "Safety signs".

In addition, the legally prescribed testing frequencies of the country of use must be adhered to.

NOTE

Noise

Operation of the compressor is only permitted


with complete and operational protective and
safety equipment.

The sound pressure level without the sound-proofing enclosure is 110 dB(A). Remaining for long periods alongside the compressor without its soundproofing enclosure can result in irreversible hearing impairment.
Only operate the compressor without the soundproofing enclosure during test runs. Wear ear defenders!

Emergency-stop
The compressor can be rendered safe in dangerous situations using the emergency-stop pushbutton.

The sound pressure level with the sound-proofing


enclosure is approximately: see "Technical data".
During normal operation the compressor may only
be operated with a closed acoustic hood.

Emergency-stop pushbuttons are attached:

Oils, fats and other chemical substances

Using emergency-stop

When handling oils, fats and other chemical substances, observe the applicable safety conditions!

1 Press the <Emergency-stop> pushbutton.


The compressor is placed in a safe condition.

Exercise caution when using hot operating fluids


and additives, there is a risk of burns or scalds!

2 Rectify the fault that was the cause of the


Emergency-stop.
See the "Troubleshooting" chapter.

on the compressor control panel


optionally in a control room (control centre)

Explosive areas

3 Unlock the <Emergency-stop> pushbutton.


Turn the pushbutton anticlockwise.

DANGER

4 Set the compressor in operation.


See section "Commissioning after a fault" in the
chapter "Commissioning and operation".

Risk of explosion
The compressor is not designed for operation in explosive atmospheres.

Safety valves / non-return valve

Operation of the compressor in explosive atmospheres is forbidden!

The compressor is protected against exceeding


of the permissible operating pressure using safety
valves. Open the safety valves at 3.5 bar (1st
airend) or 11.4 bar (2nd airend).

Legionella formation with water-cooled compressors and an open cooling circuit

The compressor is secured by a non-return valve


on the pressure side against reverse flow from the
compressed air network.

WARNING
Legionella contamination

2.3

Health risk with open cooling systems.

Protective covers and enclosure panels

Constant testing of the water quality


in the cooling circuit for the number
of microbes.

The cooling air fans are covered by grilles.

Protection and safety


equipment

The compressor enclosure is designed so that any


broken bits that might fly out are retained in the
compressor.

The clutch between the drive and the compressor


is covered by a grille.

The compressor is equipped with the protection


and safety equipment described below.

August 2013

The compressor enclosure serves as an acoustic


hood.

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Safety conditions

2.4

Residual hazards

DANGER WORD

Hot surfaces

Danger (danger sequence)

Some parts of the compressor become very hot in


operation (up to 235 C). A danger warning sign
on the compressor enclosure warns of the danger.

Safety sign

Protective measure (danger prevention)

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 sequence names the type of hazard.

We recommend the wearing of the following personal protective equipment:

Description of the danger (danger source): The


danger source names the cause of the hazard.

Safety shoes

Protective measure (danger prevention): Danger prevention describes the measures for combatting the hazard.

Safety glasses for all work with compressed air


and open enclosure
Ear defenders during test runs with an open
acoustic hood

2.5

Danger word: The danger word subdivides the


severity of the danger into four steps, graphically
highlighted by different colours. The danger word
is used in the safety instructions as described below.

Identification of safety
instructions

Within the operating instructions, safety instructions are used as special warnings with the following described names and symbols.

DANGER indicates a directly dangerous situation which, if not protected against, could result in
death or serious (irreversible) injuries.

These special warnings are intended to prevent


danger and are located close to the possible danger both in terms of space and time:

WARNING indicates a potentially dangerous situation which, if not protected against, could result in
death or serious (irreversible) injuries.

on the system close to the danger source

CAUTION indicates a potentially dangerous situation which, if not protected against, could result in
minor or less serious (reversible) injuries.

in the operating instructions, before a sequence


of actions / activity is described

ATTENTION indicates information or recommendations that directly or indirectly concern the safety
of persons or system protection.

Structure of safety instructions


The special warnings in the operating instructions
are structured as follows:

2.6

Description of the danger (danger


source)

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

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Safety conditions
Safety sign

Meaning

Use / Behaviour

Pressurised part or system

Identification of devices or rooms in which there is permanently or occasionally a significantly higher air pressure than in the normal atmosphere.

Do not open the devices or rooms before pressure


equalisation has taken place.
Never operate the compressor with open doors
or loose enclosure panels.

Running the compressor with open doors or loose enclosure panels is forbidden except during test runs. High
sound pressure level, risk of injury!
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 regulations 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 compressor is stationary.

Observe the instruction


manual

Identification of operating instructions where additional


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
(manufacturer's usage instructions).

Wear ear defenders

Identification of areas with a heightened sound pressure


level.
Only enter the area wearing suitable ear defenders.

Warning against industrial trucks

Warning of in-plant industrial trucks (e.g. forklifts) transporting 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 implemented with great care.

Warning against suspended loads

Warning of suspended loads being transported.


No person may remain in the danger area during transport. In particular, do not encroach into the area under
the raised compressor or place your feet beneath it.

Chart 2-1: Safety sign

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Safety conditions
Safety sign

Meaning

Use / Behaviour

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
start-up

In normal operating mode, the compressor may 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 operation (up to 235 C). Risk of injury due to hot surfaces.
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
load is forbidden

It is not permitted to remain under a suspended load.


The driver is not permitted to drive the industrial truck if
there is a person beneath the load. Moreover, the driver is obliged to check that persons do not stand or walk
under the load.
The load must only be transported so that it is sufficiently
clear of the ground (max. 0.5 m above the ground). (In
Germany, refer to the law BGV D27 "Industrial trucks").
The driver of an industrial truck is responsible for all driving and load movements.

Lifting point

Identification of the lifting points.


Only the indicated lifting points may be used for transport.

Chart 2-1: Safety sign

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August 2013

Safety conditions
Safety sign

Meaning

Use / Behaviour

Safety valve

Opening pressure of the safety valves (values "xx" see


sticker on the control panel).

Check the connecting


terminals and tighten if
necessary. For additional
information see the operating instructions.

Warning against loosened connecting terminals. The


clamping pressure can be released after some time.

Electrical voltage

Warning of dangerous, electrical voltage.

Residual voltage of the


capacitors

Warning of electrical energy stores in the form of capacitors. These can conduct a life-threatening electrical voltage.

XX bar

Regularly check the terminals according to the safety


guidelines and retighten as necessary.

Only open the switch cabinet (RS compressor) 10 minutes after switching the compressor off (zero volts).
Check the DC bus voltage of the frequency converter at
the mains connection strip of the frequency converter.
The precise position of the terminals "DC+" and "DC-"
can be taken from the supplied frequency converter
operating instructions.

10 min

Only a qualified electrician following electrotechnical regulations may carry out work on the electrical equipment
of the compressor.
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 maintenance personnel.
Attention: hot liquid

Warning against hot oil or hot coolant.


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.

August 2013

GB

13 /100

Safety conditions

2.7

Transport and positioning

When using compressed air to clean equipment, proceed with great care and always use
eye protection.

Transport
A suitable forklift with forks of adequate length
must be used to transport the compressor. Dependent on type, the compressor weighs up to 3,800
kg.

Safety measures
Only operate the compressor with the enclosure
closed.

Only insert the forks at the intended load support


points.

At least once per shift check the compressor for


externally visible damage and defects. Immediately report changes that have occurred (including in the operating behaviour) to the responsible post/person. If necessary stop the compressor
immediately and secure. Immediately rectify any
faults.

The compressor must not be transported using a


crane, even when still in its packaging.
No person may remain in the danger area during
transport. In particular, do not encroach into the
area under the raised compressor or place your
feet beneath it.

Do not switch off or remove extraction and ventilation equipment when the compressor is running.

Positioning / installation location

Remote control

The entire surface of the compressor must be


placed on an even suitable substrate.

If a remote control is available, a sign with the following lettering must be clearly visible on the compressor: "Attention! The compressor is remotely
controlled and could start without warning!"

The installation location (compressor room) must


be dimensioned so that there is sufficient access
to the compressor and the necessary cooling is
ensured.

In addition safety precautions must be implemented so that nobody works on the compressor
when it is under remote control.

No inflammable or explosive materials may be


stored in the vicinity of the compressor.

2.8

2.9

Normal operation

Organisational

The compressor may only be operated in a technically fault-free condition for its intended use, with
an awareness of safety and hazards while observing the operating instructions.

Adhere to the prescribed maintenance work and


intervals including details about the replacement
of parts/part assemblies contained in the operating
instructions.

Only operate the compressor if all protective and


safety equipment, sound insulation, ventilation and
extraction equipment and the cooling water supply
(water-cooled compressors only) are present and
serviceable.

Maintenance and repair work must only be carried


out under the supervision of or by a person qualified to carry out this work.
If necessary, cordon off a wide area around the
workplace.

Check regularly that:

Workshop equipment appropriate for the task is


essential for carrying out maintenance and repair
work.

All hoses and pipelines are serviceable and


firmly attached.
There are no leaks (oil, coolant or cooling water).

Safety measures
Personnel must not have loose long hair nor wear
loose clothes or jewellery including rings. If the
compressor is running there is a risk of injury, e.g.
by being caught-up or pulled in. Where necessary
or if required by regulations, wear personal protective equipment!

The electrical power cables are free from faults.


The cooling water supply is guaranteed (water-cooled compressors only).
Rules for working with compressed air:
Forbid all working practices that could pose a
risk to safety

Only carry out maintenance and repair work for


which you are adequately trained and which you
feel confident to carry out.

Never 'play around' with compressed air.


Never direct compressed air onto the skin or at
other people.

Do not use machine parts as climbing aids. If carrying out maintenance work at heights, provide fall
protection.

Never use compressed air for cleaning clothing.

14 / 100

Special tasks

GB

August 2013

Safety conditions
Maintenance/Troubleshooting

Tighten up all threaded connectors loosened during maintenance and repair work. Likewise check
all other threaded connectors.

Only carry out maintenance and repair work with


the compressor switched off and mains power
off. Secure the compressor to prevent inadvertent
switching on.

Before release of the compressor for operation after maintenance and repair work, ensure that the
operating pressures, temperatures and time settings are correct and that the control and switching
off equipment is fully serviceable.

Before opening the compressor enclosure:


Drain the compressor.

If safety and protective equipment must be removed, then it must be immediately replaced after completion of the work and checked for trouble-free operation.

Wait for automatic pressure discharge to complete.


Wait until the residual electrical energy has
drained from the capacitors.
Allow the compressor to cool to room temperature.

2.10

Cleanliness

Conversions and changes to


the machine

Do not make any changes or additions to or rebuild the compressor without prior consultation
with Gardner Denver.

During maintenance and repair work always check


for cleanliness. Keep dirt away by covering parts
and uncovered openings with a clean cloth, paper
or adhesive strips.

Unauthorised changes to the machine are not authorised for safety reasons.

Oil leaks lead to a slippery floor. Thoroughly clean


the work area after completion of maintenance
and repair work.

Genuine parts are designed especially for the machine. We expressly point out that we also do not
authorise parts and special equipment that are not
supplied by us. The fitting and/or use of such products may therefore impair active and/or passive
safety.

Cleaning agents
When cleaning parts, never use solvents or cleaning agents that could chemically attack the materials.

Any liability on the part of the manufacturer for


damage arising from the use of non-original parts
or special equipment is excluded. The same applies for the fitting and adjustment of safety equipment and valves as well as to the welding of loadbearing or pressure carrying parts.

Take precautions to prevent harmful vapours from


solvents or cleaning agents.
Weight / lifting gear
When replacing heavy individual parts and assemblies 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 requirements 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.

August 2013

GB

15 /100

Design and function

DESIGN AND FUNCTION

3.1

General description

Compression principle
The airends comprise a main rotor and an auxiliary rotor with intermeshing spiral toothing. A synchronized gearbox in each airend ensures the
contact-free running of the rotors. Compression
chambers are delimited by the flanks of the toothing and the compressor casing. The rotation of
the rotors continuously reduces the volume in the
chambers until the compressed air is pushed out
through the outlet window of the stage casing.
Screw compressors count amongst rotation-displacement compressors without oscillating masses
but with a pulsing output.

The compressor is an oil-free compressing, twostage screw compressor with one sound-proofed
enclosure.
The main components are the drive motor, the
airend unit, the cooling and lubrication system and
the electronic control.
The airend unit comprises the drive gear and the
first and second airends.
The parts of the airends through which the air
flows are provided with a special wear-reducing
and corrosion-resistant coating.

To minimise the power consumption of the airend


unit and to limit the airend temperatures to technically permissible values, the compression takes
place in two stages with interstage cooling (intercooler). In addition the casing of the stages is
cooled by the internal cooling circuit

Rolling contact bearings and gearbox are oil-lubricated.


The air and oil system are designed so that no oil
can get into the air circuit. The ejector ventilation
system produces a defined vacuum pressure in
the oil-lubricated area of the airend unit thus preventing any oil from escaping into the surroundings.

Electronic control unit


The main components of the electronic control
unit are a microprocessor, a touchscreen, film-protected keys and LEDs.
Detailed description of the operating instructions
for the electronic control unit.

16 / 100

GB

August 2013

Design and function

3.2

Compressor design

Air-cooled

17

16

15

14

13
12

11

10
1

9
2

Fig. 3-1: Overview part 1

[1]

Condensation trap (intercooler)

[10]

Silencing baffle with filter mesh

[2]

Oil / water cooler

[11]

Aftercooler

[3]

Oil Filter

[12]

Intercooler

[4]

Snubber / silencer

[13]

Water cooler

[5]

Maintenance unit

[14]

Blow-off silencer

[6]

Compressor unit

[15]

Condensate separator (intercooler)

[7]

Control air filter

[16]

Safety valves (intermediate pressure)

[8]

Ultra-fine filter

[17]

Expansion tank (coolant)

[9]

Snubber

August 2013

GB

17 /100

Design and function


18

18

17

16 15

1
2
3
4
5

14
13

10

11

12

Fig. 3-2: Overview part 2

[1]

Suction regulator

[10]

Drive motor

[2]

Motor lubrication system

[11]

Oil pump

[3]

Non-return valve

[12]

Water pump

[4]

Safety valve (line pressure max.)

[13]

Air Filter

[5]

Connection flange

[14]

Switch cabinet cooling air inlet filter (RS)

[6]

Condensate separator

[15]

Pushbutton <Emergency-stop>

[7]

Condensate connectors

[16]

Electronic control unit

[8]

Condensate trap

[17]

Switch cabinet

[9]

Solenoid valve (Y3)

[18]

Fan

18 / 100

GB

August 2013

Design and function

Water-cooled

14
16
18

13

15

12

11

17

10

6 7

[1]

Condensation trap (interstage cooler)

[10]

Silencing baffle with filter mesh

[2]

Oil / water cooler

[11]

Cooling water manifold

[3]

Oil Filter

[12]

Aftercooler

[4]

Snubber / silencer

[13]

Interstage cooler

[5]

Maintenance unit

[14]

Cooler (internal cooling circuit)

[6]

Compressor unit

[15]

Blow-off silencer

[7]

Control air filter

[16]

Condensate separator (interstage cooler)

[8]

Ultra-fine filter

[17]

Safety valve (interstage cooler)

[9]

Snubber

[18]

Expansion tank (coolant)

August 2013

GB

19 /100

Design and function

16
1

15

17

18

2
3

4
5

6
7
14

13
8

10

11

12

[1]

Suction regulator

[10]

Drive motor

[2]

Motor lubrication system

[11]

Oil pump

[3]

Non-return valve

[12]

Water pump

[4]

Safety valve (line pressure max.)

[13]

Air Filter

[5]

Connection flange

[14]

Switch cabinet cooling air inlet filter(speedcontrolled system)

[6]

Condensate separator

[15]

Pushbutton <Emergency-stop>

[7]

Condensate connectors

[16]

Electronic control unit

[8]

Condensate trap

[17]

Switch cabinet

[9]

Solenoid valve (Y3)

[18]

Fan

20 / 100

GB

August 2013

Design and function

3.3

System scheme air-cooled compressor

Fig. 3-3: Function scheme

Compressed air

Water

Air

Oil

Chart 3-1: Cables

August 2013

GB

21 /100

Design and function

Components
No

Name

No

Name

No

Name

Intake air filter

11

Aftercooler

22

Temperature control valve


(oil circuit)

Suction regulator

12

Pressure relief valve

23

Heat exchanger

First airend

13

Water separator (aftercooler)

24

Oil Filter

Snubber

14

Safety valve (final pressure)

25

Cooler internal cooling


water circuit

Intercooler

15

Filter water separator

26

Temperature control valve


(internal cooling water circuit)

Water separator (intercooler)

16

Shuttle valve

27

Compensating tank

Safety valve (intermediate pressure)

17

Blow-off silencer

28

Cooling water pump

Second airend

18

Maintenance unit

29

Drive motor

Combined silencer and


snubber

19

Vacuum generator

30

Speed control (inverter)

10

Non-return valve

20

Ultra-fine filter

31

Radial fan

21

Oil pump

32

Radial fan

Chart 3-2: Components

Instrumentation & control technology


No

Name

No

Name

No

Name

B0

Ambient pressure
absolute

R0

Ambient temperature

S5

Oil filter differential pressure

B1

Inlet pressure first airend R1

Inlet temperature first


airend

S12

Oil level

B2

Outlet pressure first


airend

R2

Outlet temperature first


airend

S18

Water level

B3

Inlet pressure second


airend

R3

Inlet temperature second M1airend


PTC

Drive motor positor

B4

Outlet pressure second


airend

R4

Outlet temperature second airend

Y1

Solenoid valve suction


regulator

B5

Network pressure

R5

Network temperature

Y2

Solenoid valve suction


regulator

B6

Oil pressure

R6

Oil temperature

Y3

Solenoid valve gearbox


casing venting

B7

Water pressure jacket


cooling inlet

R7

Water temperature
jacket cooling inlet

Balance piston first airend

B8

Vacuum in gearbox casing

Balance piston second


airend

Chart 3-3: Instrumentation & control technology

22 / 100

GB

August 2013

Design and function

3.4

System scheme water-cooled compressor

Fig. 3-4: Function scheme

Compressed air

Water

Air

Oil

Cooling water (external)


Chart 3-4: Cables

August 2013

GB

23 /100

Design and function

Components
No

Designation

No

Designation

No

Designation

Intake air filter

12

Pressure relief valve

23

Heat exchanger

Suction regulator

13

Water separator (aftercooler)

24

Oil Filter

First airend

14

Safety valve (final pressure)

25

Cooler internal cooling


water circuit

Snubber

15

Filter water separator

26

Temperature control valve


(internal cooling water circuit)

Interstage cooler

16

Shuttle valve

27

Compensating tank

Water separator (interstage cooler)

17

Blow-off silencer

28

Cooling water pump

Safety valve (intermediate pressure)

18

Maintenance unit

29

Drive motor

Second airend

19

Vacuum generator

30

Speed control (inverter)

Combined silencer and


snubber

20

Ultra-fine filter

31

Radial fan

10

Non-return valve

21

Oil pump

32

Throttle valves external


cooling water circuit

11

Aftercooler

22

Temperature control
valve (oil circuit)

33

Strainer sieve

34

Safety valve (external


water circuit)

Chart 3-5: Components

Instrumentation & control technology


No

Designation

No

Designation

No

Designation

B0

Ambient pressure
absolute

R2

Outlet temperature first


airend

S5

Oil filter differential pressure

B1

Inlet pressure first airend R3

Inlet temperature second S12


airend

Oil level

B2

Outlet pressure first


airend

R4

Outlet temperature second airend

S18

Water level

B3

Inlet pressure second


airend

R5

Network temperature

M1PTC

Drive motor positor

B4

Outlet pressure second


airend

R6

Oil temperature

Y1

Solenoid valve suction


regulator

B5

Network pressure

R7

Water temperature
jacket cooling inlet

Y2

Solenoid valve suction


regulator

B6

Oil pressure

R8

Cooling water temperature inlet (external)

Y3

Solenoid valve gearbox


casing venting

B7

Water pressure jacket


cooling inlet

R9

Cooling water temperature outlet (external)

Y4

Cooling water solenoid


valve

Chart 3-6: Instrumentation & control technology

24 / 100

GB

August 2013

Design and function


No

Designation

No

No

Designation

Designation

B8

Vacuum in gearbox cas- E1


ing

Condensate drain control L

Balance piston first airend

R0

Ambient temperature

E2

Condensate drain control H

Balance piston second


airend

R1

Inlet temperature first


airend

E4

Motor lubrication system G

Gearbox casing

E5

Motor lubrication system

Chart 3-6: Instrumentation & control technology

3.5

Air circuit
3

2
2
6
1

7
8

Fig. 3-5: Air cooling circuit (air-cooled)

[1]

Combined silencer and snubber

[5]

Blow-off silencer

[2]

Safety valves

[6]

Suction regulator

[3]

Aftercooler

[7]

Blow-off valve

[4]

Intercooler

[8]

Snubber

August 2013

GB

25 /100

Design and function

4
5
6

3
7
8
2

1
Fig. 3-6: Air cooling circuit (water-cooled)

[1]

Combined silencer and snubber

[5]

Blow-off silencer

[2]

Safety valve

[6]

Suction regulator

[3]

Aftercooler

[7]

Blow-off valve

[4]

Interstage cooler

[8]

Snubber

The air is sucked in via a suction filter and reaches the first airend via the suction regulator. Here the air
is compressed to the intermediate pressure and then cooled in the intercooler. Compression to the final
compression pressure desired by the customer then takes place in the second stage. The compressed
air is output to the compressed air network via the aftercooler. Condensate formed during cooling is separated by an automatic condensate separator.
If the compressor is operating off-load, the compressed air output from the second stage is discharged via
a blow-off valve to the atmosphere.
A snubber after the first airend ensures a uniform air flow to the second stage and reduces pressure fluctuations. A combined silencer and snubber after the second airend is used to reduce pressure fluctuations and for sound insulation.
Safety valves are fitted after the intercooler and the aftercooler to protect the machine components and
for safety reasons.
To protect the compressor against backflow from the compressed air network, a non-return valve is installed in the pressure line inside the compressor.

26 / 100

GB

August 2013

Design and function

3.6

External water circuit

2
1

Fig. 3-7: External water circuit

[1]

Water stop valve

[2]

Safety valve (external water circuit)

[3]

Strainer (sieve)

WARNING
Risk of scalding
Risk of scalding due to escaping steam and hot cooling water.
The external cooling water circuit is used to supply the interstage cooler, aftercooler and the heat exchanger (internal water circuit) with cooling water.

August 2013

GB

27 /100

Design and function

3.7

Internal water circuit

A
I

4
5

W
3

1
6

Fig. 3-8: Internal water circuit

[A]

Air-cooled system

[4]

Expansion line

[W]

Water-cooled system

[5]

Expansion tank with level sensor

[1]

Water pump

[6]

Cooling water drain

[2]

Temperature control valve

[7]

Oil / water cooler

[3]

Water/air (A) - coolerWater/water (W) cooler

The two airend stages are cooled by the internal cooling water circuit (casing cooling) while the lubricating
oil is cooled in the oil/water cooler.
The water pump pumps the water to the second airend, to the first airend, to the oil/water cooler and then
back to the water/air cooler.
Temperature control is implemented via the cooling water temperature control valve. Water volume fluctuations are compensated by the expansion tank.

28 / 100

GB

August 2013

Design and function

3.8

Oil circuit

5
4
6

Fig. 3-9: Oil circuit

[1]

Oil / water cooler

[5]

Oil filler neck

[2]

Oil temperature control valve

[6]

Oil level indicator

[3]

Oil Filter

[7]

Oil sump

[4]

Oil pump

[8]

Oil drain

The oil circuit lubricates the gearbox and the bearings of the airend unit.
Oil is sucked out of the oil sump then pumped via the oil cooler or bypass (temperature control) through
the oil filter and into the gearbox and bearings of the airend unit. The used oil returns to the oil sump.
Temperature control is implemented via the oil temperature control valve.
The oil is fed to both airends and goes from there directly into the oil sump.

August 2013

GB

29 /100

Design and function

3.9

Ejector vent system

The compressed air connection is correctly


connected to the compressed air network.
The oil and cooling water levels are OK.
Ventilation of the compressor chamber is guaranteed.

6
7

5
4

The cooling water supply is guaranteed (water-cooled compressors only).

The direction of rotation of the drive motor has


been checked.
All protective and safety equipment is fitted and
serviceable.

The electronic control unit indicates [Ready to


Start].

Pressure demand from the compressed air network.

Operating sequence
Switch on the cooling water supply (water-cooled compressor only).

Fig. 3-10: Ejector vent system

[1]

Second stage condensate separator


(aftercooler water separator)

[2]

Compressed air connection ejector vent


system

[3]

Solenoid valve Y3

[4]

Maintenance unit (water separator,


pressure regulator, pressure gauge)

[5]

Ejector (vacuum generator)

[6]

Extract air

[7]

Ultra-fine filter

[8]

Oil return

Press the start button < I > on the control


panel.
The compressor is switched on.
Checking of the start parameters (temperatures, pressures, sensors, cooling water level)
by the electronic control unit.
Once the start parameters have been fulfilled,
the cooling water pump and the oil pump are
switched on sequentially; the water and oil circuit are running.
Simultaneously, solenoid valve Y3 is actuated
so that the ejector vent system starts operating.
If the water and oil pressure are correct, the
drive motor is started.

The ejector ventilation system produces a defined


vacuum pressure in the oil-lubricated area of the
airend unit thus preventing any oil from escaping
into the surroundings.

After running up of the drive motor, solenoid


valves Y1 and Y2 are switched in a time-delayed manner, the suction regulator opens. The
two fans are switched on. The compressor is
now in load operation.

The ejector vent system uses compressed air from


the compressed air network. The air passes via
the maintenance unit to the vacuum generator.

The compressor operates under load until the


maximum line pressure [Line Pressure max.] is
reached.

The air sucked out of the oil system is filtered and


output to the atmosphere, the separated oil is returned to the oil sump.

3.10

Once maximum line pressure [Line Pressure


max.] is reached, the solenoid valves Y1 and
Y2 are switched to zero volts; the suction regulator is closed, the blow-off valve is opened,
the compressor is unloaded. The compressor
is now operating in off-load mode. Fan 2 is
switched off.

Control (automatic operation)

Preconditions
The following preconditions must be fulfilled for
automatic running:

The compressor runs off-load until the line


pressure has dropped below the minimum line
pressure [Line Pressure min.] or until the programmed off-load period has elapsed.

All preparations for commissioning are fulfilled.


The compressor is correctly connected to the
power supply network.

30 / 100

GB

August 2013

Design and function

If the line pressure drops below the minimum line pressure [Line Pressure min.]:
Fan 2 is switched on, solenoid valves
Y1 and Y2 are switched on, the blow-off
valve is closed and the suction regulator is
opened. The compressor operates under
load until the maximum line pressure [Line
Pressure max.] is reached. Automatic operation.
Once the off-load period has elapsed: the
drive motor is switched off, fan 1 runs for 30
seconds longer, solenoid valve Y3 closes
after 30 seconds and the ejector vent system is shutdown.
As soon as the drive motor stops, the oil
and water pumps are switched off.
Press the stop button < O > on the control
panel.
The compressor is switched off.
The compressor enters "Ready to
start" (standby) mode.
If the compressor is switched off, then the cooling water supply can likewise be switched off
(water-cooled compressors only).

August 2013

GB

31 /100

Transport and positioning

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 damage.
1 Check the delivery for visible damage.

Fig. 4-1: Lifting points

2 Check the completeness of the delivery using


the delivery note.

1 Remove the screws from the transport pallet.

3 Immediately inform the shipper, Gardner Denver and insurance of any missing parts or damage.

3 Transport the compressor to the destination


point.

2 Lift the compressor from the transport pallet.

4 Align the compressor and set down.

Weight

4.2

Dependent on type, the compressor weighs up


to 3,800kg (gross). The weight is stated on the
nameplate which is visible from the outside.

Storage

Storage of compressors
The compressor should be stored in a dry and,
where possible, heated room. This applies particularly during the winter months.

Transport

DANGER

NOTICE

Risk of fatal injury

Material damage

Risk of fatal injury due to toppling or


falling parts

Material damage through exceeding of the permissible temperature range

A suitable forklift with forks of adequate length must be used to transport the compressor.

Where there is a risk that the permissible


temperature limits of +2 ...+65 C could be
over or undershot, contact Gardner Denver.

Only insert the forks at the intended


lifting points.

Corrosion protection

The compressor must not be transported using a crane, even when


still in its packaging.

Before they leave the factory all compressors are


protected against corrosion during transport and
short term storage before commissioning. If compressors are stored for longer than 6 months, additional precautions must be undertaken.

No person may remain in the danger area during transport. In particular, do not encroach into the area
under the raised compressor or
place your feet beneath it.

Also compressors that have been taken out of service for a long period, must be protected against
corrosion.

4.3

Positioning

Requirements for the installation location


The entire surface of the compressor must be
placed on a sufficiently load bearing substrate.
The bearing surface must be level to within 3 mm.

32 / 100

GB

August 2013

Transport and positioning


The installation location (compressor room) must
be dimensioned such that the compressor has
a clearance on all sides of 1m ("A" and "B") and
above the compressor of 1.50 m. Moreover, adequate access must be provided for maintenance.

In the event of unfavourable local conditions, install air ducts in which the flow velocity of the cooling air must not exceed 5 m/s. We recommend
a minimum channel cross section of 1.2 m2 (aircooled compressor) and 0.45 m2 (water-cooled
compressor).

NOTE
To ensure effective heat removal, the installed
auxiliary fans must be dimensioned such that
their air flow is 15 to 20% greater that the cooling air flow required by the compressor.
If installing several compressors in one compressor room, then this applies to the total of the
cooling air flows required by all the compressors
present in the compressor room.
The following figure shows the recommended ventilation requirements.
Fig. 4-2: Positioning / clearances

Position the compressor so that it is sufficiently


accessible and the required cooling is ensured.
Do not block the air inlet.
Avoid moisture.
Ventilation

DANGER
Risk of suffocation
Risk of suffocation due to inadequate
ventilation
The operator must provide adequate
ventilation of the compressor room.
To be able to dissipate the heat generated during
operation, the compressor room must be of sufficient size and have adequate ventilation.
The recommended minimum size of the compressor room is 60 m3.
The air inlet and outlet openings should have a
minimum cross section of 1.2 m2 (air-cooled compressor) or 0.45 m2 (water-cooled compressor).
The intake air opening should be positioned as
high as possible. The extract air opening should
be positioned as high as possible.
Provide the air openings with sieves to prevent
penetration of dirt into the compressor room.

Fig. 4-3: Compressor room ventilation

The design of the ventilation facility is primarily


based on the required cooling air flow. (See "Technical data".)

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Transport and positioning

Positioning the compressor

DANGER
Risk of injury
Danger due to incorrect positioning
Consider the permissible bearing
force of the substrate.
Ensure there is a hard and even
substrate.
The entire surface of the compressor must be placed on an even suitable substrate.
The compressor must not be operated on the transport pallet.
No inflammable or explosive materials may be stored in the vicinity of
the compressor.
1 Set down the compressor at the destination
point.
2 Ensure that the bearing surface is even to
within 3mm. (The compressor does not have
any levelling means fitted on it)

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August 2013

Preparations for commissioning

PREPARATIONS FOR
COMMISSIONING

5.1

Pipelines

5.2

Compressed air connection


1

Remove all blank flanges, plugs, caps and desiccant containing pouches before fitting the
pipelines.

Manifolds and pipe connections must be of the


correct size and be suitable for the respective operating pressure.
Label compressed air and water pipes according
to the local regulations.

1
2

Support all pipelines with correctly dimensioned


supports; pipes must not support any loads.
If compressed air hose is used, it must be correctly dimensioned and be suitable for the operating pressure and temperature. Do not use any
abraded, damaged or inferior quality hose.

3
4

Fig. 5-1: Compressed air and condensate connection

[1]

A shut-off valve must be fitted in the supply line


so that the compressor can be isolated for maintenance purposes. No additional non-return valve
may be installed. The additional non-return valve
would impede the air supply to the vacuum generator.

Compressed air connection

[A1] Automatic condensate drain, aftercooler


[A2] Condensate drain pipe aftercooler via ball
valve (use if there is a malfunction of the
automatic condensate drain)
[A3] Automatic condensate drain, intercooler

If a high level of condensate formation is expected, the compressed air connection for the
ejector vacuum generator must be connected to a
condensate-free compressed air supply. In case of
doubt, contact Gardner Denver.

[A4] Condensate drain pipe intercooler via ball


valve (use if there is a malfunction of the
automatic condensate drain)

DANGER

The two automatic condensate drains must be


provided with separate lines that are routed to a
drain or a collecting tank.

Risk of bursting
The compressed air outlet temperature
can be up to 95C.

The drains lines leading away from the condensate connections must not be designed to rise
more than 5 m!

The burst strength of the following


components of the supply line (customer network) must be suitable for
these temperatures.

An air tank with sufficient volume (as a buffer)


must be installed between the compressor and the
compressed air network. As a guide, the tank capacity should equal 10 % of the delivery quantity,
e.g. a compressor with a delivery quantity of 10
m/min requires a tank volume of 1 m.

WARNING
Risk of injury due to hot supply line
The compressed air outlet temperature
can be up to 95C.
Protect the supply line to prevent
contact with it.

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Preparations for commissioning

5.3

WARNING

Cooling water connection

Risk of injury
If an incorrect connection is made, the
connector could come loose and the free
connection result in severe personal injury.
When connecting the compressor
to the compressed air network, the
connecting flange must be checked
in addition to the operating temperatures and pressures.

1
2

When connecting hoses, suitable


measures must be taken to prevent
the dangerous "whipping" of a loose
hose end.

Fig. 5-2: Cooling water connection (1)

Checking the connection flange

[1]

Inlet for external cooling water

The pressure connection comprises a DIN flange.

[2]

Outlet for external cooling water

The connection label is stamped outside on the


flange plate:

WARNING

DN80, PN16

Legionella contamination

1 Read off the connection label.

Health risk with open cooling systems.

2 Ensure that connector and flange match.

Constant testing of the water quality


in the cooling circuit for the number
of microbes.

Connecting the compressor to the compressed air mains


The compressor is completely assembled in the
factory. The connection to the compressed air network must be made with a flexible line, e.g. a compressed air hose or expansion joint.

Connecting the compressor to the cooling


water mains
The compressor is completely assembled in the
factory. The connection to the cooling water mains
must be made with a flexible line, e.g. a compressed air hose or expansion joint.

Only use hose couplings and connections of the


correct type and size.
1 Ensure that the supply line can be connected
free from tension.

Only use correctly sized connectors.


1 Ensure that the lines can be connected free
from tension.

2 Connect the connection line to the compressed


air connection of the compressor.

2 Connect the connecting line with the compressor cooling water inlet and outlet.

3 Secure the hose lines.

3 Shut-off valves must be provided at the cooling


water inlet and outlet.
4 Secure the hose lines.
Cooling water inlet and cooling water outlet
European version: EN 10226-1 Rp 1 1/4
USA/CANADA version: 1 1/4 - 11 1/2 NPT
Permissible cooling water data
Cooling water pressure max.:
8 bar / 115 psi

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August 2013

Preparations for commissioning


Cooling water inlet temperature min.:
5 C / 41 F

The compressor system is executed completely in


the factory according to EN 60204 (industrial machinery).

Cooling water inlet temperature max.:


42 C / 107 F

The compressor power supply must be suitable


for industrial equipment and must fulfil all the
requirements of EN60204-1/IEC60204-1. Contact Gardner Denver if the positioning conditions differ from the conditions as they are described in EN 60204.

Cooling water outlet temperature max.:


57 C / 134 F
Cooling water requirement at maximum power and
(T = 15 K , p = 0.7 bar / 13 psi)

Implement the electrical connection and the


protective measures in accordance with VDE,
BS or the appropriate local regulations. In general, the supplementary regulations of the respective power supply utility must be considered.

75KW = 89 l/min / 23 gal/min


90KW = 111 l/min / 29 gal/min
110KW = 132 l/min / 35 gal/min
132KW = 155 l/min / 41 gal/min

A main switch must be fitted on-site upstream


of the compressor (DIN EN 1012 - 1) insofar
that such a switch has not already been fitted
in the factory as a special accessory. The main
switch must fulfil the requirements of the safety
standard EN 60 204-1 (Electrical equipment of
machines), as well as EN 60947-2 (low voltage
switchgear).

160KW = 170 l/min / 45 gal/min


T:
Cooling water outlet temperature =
Cooling water inlet temperature + T
p:

The compressor must be fused using suitable


backup fuses in accordance with EN 60269-1
(low voltage directives).

Cooling water outlet pressure =


Cooling water inlet pressure - p
The values relate to fresh water quality without additives (e.g. antifreeze). If the cooling water quality
deviates from this, please contact Gardner Denver.

If third party circuits are retrospectively controlled via the electronic control, e.g. lighting,
heating or similar, that cannot be switched off
from the main switch, these excluded circuits
must be labelled according to EN 60204 and
routed separately. Moreover, warning signs
must be attached close to the main switch and
close to the relevant circuits.

Set the cooling water volume in accordance with


the description "Cooling water control in a water-cooled compressor system".

NOTE

Should an electrical connection to an unearthed AC electrical circuit (IT network) be


made, observe the instructions in the supplied
documentation of the frequency converter (only
RS compressors).

The cooling water outlet temperature should


where possible be greater than 57 C to prevent
heightened limescale formation.

5.4

Electrical connection

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

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Preparations for commissioning


2 Set the safety switch according to the supply
network voltage and frequency.

Electrically connecting the compressor

Check the setting of the control transformer


1

DANGER

Electric shock
Life-threatening electric shock

Work on the electrical equipment


must only be carried out by authorised electricians or electrical technicians.

With types D110RS - D160RS there


is a risk of electric shocks due to
charged capacitors!
Switch the compressor to a zero
volts state and wait 10 minutes before touching any electrical parts.

Fig. 5-3: Supply line openings

[1]

Compressed air connection

[2]

Filter mat cooling air inlet

[3]

Condensate drain

[4]

Supply line cover panel

Checking the DC bus voltage.


The control transformer is set to the rated voltage ex works.
Experience has shown that the actual supply
voltage may differ from the rated voltage.

DANGER

To match the local circumstances, the correct setting of the control transformer must be
checked when the compressor is under load
by measuring the control voltages and if necessary the transformer then reset.

Electric shock
Life-threatening electric shock
Work on the electrical equipment
must only be carried out by authorised electricians or electrical technicians.

A number of taps are provided for this purpose


(see wiring diagram).

1 Remove the factory-provided cover panel.

NOTICE

2 Insert the customer-provided supply line panel.


3 Feed the power supply cable through the openings in the switch cabinet.

Material damage
Incorrect setting of the control transformer endangers trouble-free operation.

4 Connect the power supply cable, see the wiring


diagram.

Checking of the setting of the control transformer forms part of commissioning and periodic inspection/maintenance, as the mains
voltage conditions may vary.

5 Tighten the cable glands.


Checking the setting of the fan protection
switch

DANGER
Electric shock
Life-threatening electric shock
Work on the electrical equipment
must only be carried out by authorised electricians or electrical technicians.
1 Check the settings of the protection switch of
the two fan motors, see wiring diagram.

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Commissioning and operating

COMMISSIONING AND
OPERATING

6.1

Initial commissioning

9 Check the factory setting of the pressure setpoints (minimum line pressure [Line Pressure
min.] and maximum [Line Pressure max.]) and
readjust if necessary.

NOTICE

10 Ensure the external cooling water supply is adequate (water-cooled compressor only).

Material damage

11 Press the start button < I >.

Although every compressor has already undergone a test run in the factory and has undergone
a careful final inspection in dispatch, the possibility of transport damage cannot be excluded.

12 Check the direction of rotation of the drive motor (not RS compressors) or the fans (RS compressors ). See the following descriptions.
13 Check the output voltages of the control transformer in load operation.

Before commissioning check the compressor once more for damage and monitor it
during its initial operating hours.

Check the direction of rotation of the drive


motor (not RS compressors )

If the compressor is being connected to a


power supply network and started for the
first time, then dependent on the version,
the direction of rotation of the drive motor
and/or fans must be checked.

DANGER
Risk of injury
The drive motor rotational direction can
only be checked if the clutch cover is demounted.

Drive motor for non-RS compressors


Fans for RS compressors

Before switching on, check that


there is nobody in the danger area!

Preparations
Check all electrical and electronic components/devices for water ingress or condensate
formation, in case of complaints, contact Gardner Denver.

Maintain an adequate distance from


rotating machine parts!
Wear ear defenders!
Except for test runs, only operate
the compressor with the enclosure
closed.

If the compressor has been in storage for a


substantial period of time (up to 2 years), the
main switch must be switched on at least one
hour prior to starting. This ensures the operability 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 cooling water level (internal water
circuit).
2 Check the oil level.
3 Check the settings of the fan motor overload
switch.
4 Check the setting of the control transformer.
5 Check all the terminals of the electronic control
unit and tighten as necessary.

6 Switch on the main switch.


All three LEDs on the control panel illuminate.

Fig. 6-1: Check the drive motor rotational direction

7 Set the display language.

[1]

8 Acknowledge faults indicated on the display.

1 Switch the main switch OFF.

The message [Ready to Start] appears on


the display.

August 2013

Protective cover (removed)

2 Open the enclosure.

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39 /100

Commissioning and operating

3 Remove the protective cover from the clutch.


4 Switch the main switch ON.
5 Press the start button < I >.
6 Check the rotational direction.
7 If the rotational direction is incorrect: Immediately switch the compressor off with the <Emergency-stop>; not the Stop button < O >, as 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.
10 Replace the protective cover on the clutch.
11 Close the enclosure.
Checking the direction of rotation of the fans
(for RS compressors )

Fig. 6-3: Check direction of rotation of fan motor (water-cooled system)

CAUTION

The rotational direction of the fan motors can be


checked with the enclosure still closed.

Risk of falling
The rotational direction of the fan motors
can only be checked "from above".

1 Place a suitable ladder alongside the compressor and use it to climb up.

Ensure safe climbing means are


provided.

2 Check the rotational direction.


The rotational direction arrow can be determined through the protective cover.
3 If the rotational direction is incorrect: switch off
the compressor.

4 Switch the main switch OFF.


1

5 Correct the rotational direction. Change the


compressor rotating field.
Temperature start-up protection
The compressor does not start up at ambient temperatures less than + 2 C.

Fig. 6-2: Check direction of rotation of fan motors (aircooled system)

[1]

Rotational direction indicator

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August 2013

Commissioning and operating


6.1.1

Cooling water control in a watercooled compressor system

NOTE

Cooler, water-cooled compressor system

The cooling water volumes of the individual coolers are preset in the factory and secured using a
tamper-evident seal.
Adjustment of the hand valves

Fig. 6-4: Cooler layout

Fig. 6-5: Display schematics Delcos XL

[A]

Jacket / oil cooling

[B]

Interstage cooler

[C]

Aftercooler

The hand valves A, B and C are preset. Further


adjustment is not normally necessary. In the event
that the values given below are not achieved, a
readjustment can be undertaken.
The following specified values only apply after
at least 45 minutes operation under full load:
Oil temperature "1" approximately 25C / 45F
above the cooling water inlet temperature "4".
Second stage air inlet temperature 2" approximately 9C / 16.2F to 10C / 18F above the
water inlet temperature "4".
The temperature difference between cooling water outlet "3" and cooling water inlet "4"
equals approximately 15C / 27F.

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Commissioning and operating

6.2

NOTICE

Normal operation

Electronic control unit

Material damage
Operating conditions to be adhered to before
the adjustment work
Hand valves A - C completely open before
system starting.
Ensure the cooling water supply is adequate.
Operate the system for at least 45 minutes
at full load.
Maximum pressure and maximum speed
for speed-controlled systems.

Fig. 6-6: Control panel

Maximum pressure for systems without


speed control.
This adjustment work must only be carried out
by trained maintenance personnel.
Slowly close hand valve A (jacket / oil cooler)
until the oil temperature "1" has risen by about
1C / 1.8F.
Slowly close hand valve B (interstage cooler)
until the second stage air inlet temperature "2"
is approximately 9C / 16.2F to 10C / 18F
above the water inlet temperature.
For water inlet temperatures that are well below
the ambient temperature, a second stage air inlet temperature 2" of approximately 5C / 9F to
10C / 18F above ambient temperature must
be aimed for (avoidance of condensation).

[1]

Touchscreen display

[2]

Start button < I >

[3]

Stop button< O >

[4]

Red LED
Slow flashing: Warning
Fast flashing: Fault

[5]

Yellow LED
Slow flashing: Maintenance necessary

[6]

Green LED
Lit up permanently: System in operation
Flashing: System on standby

[7]

Pushbutton <Emergency-stop>

DANGER
Risk of injury
The compressor can start automatically
at any time when it is in standby mode
with the green LED flashing.

Slowly close hand valve C (aftercooler) until


the temperature difference cooling water outlet "3" to cooling water inlet "4" is approximately
15C / 27F.

Do not carry out any work on the


compressor, if the green LED is
flashing.
Switching on
1 Press the start button < I > on the control
panel.
The compressor is switched on.
The compressor runs automatically (automatic operation). See the operating sequence description in the section "Operating
sequence" in the chapter "Design and function".
Operating conditions
During automatic operation, the compressor can
adopt any of the following operating conditions:
Ready to start (standby) [Ready to Start]
Operating under load [On-Load]

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Commissioning and operating

6.4

Partial load operation (on-load operation at reduced speed only RS compressors ) [On-Load]
Off-load [Off-Load]

Commissioning after a long


shutdown

If commissioning after a long shutdown, contact


Gardner Denver.

Observations during operation


During operation the compressor must be regularly checked to ensure leak-tightness of the cooling water circuit and oil circuit.

6.5

Commissioning after a fault

NOTICE

Condensate drain

Material damage

The condensate drains from the intercooler and aftercooler are activated under sensor control.

Avoid switching the compressor on multiple


times without rectification of the fault as this can
lead to considerable mechanical damage.

Switching off

Only switch the compressor back on after


the fault is rectified.

1 Press the stop button < O > on the control


panel.
The compressor runs on for 30 seconds
(soft stop).
After this time, drive motor and fan 1 are
switched off.

Re-commissioning after a fault (automatic


switching off)

Once the drive motor is stationary, oil pump,


water pump and fan 2 are switched off.

1 Switch main switch off and secure to prevent


switching back on.

Faults are displayed in the display menu "Fault


log".

2 Rectify the fault.


See the "Troubleshooting" chapter.

Emergency-stop
The compressor can be rendered safe in dangerous situations using the emergency-stop pushbutton.

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.

Emergency-stop pushbuttons are attached:


on the compressor control panel
optionally in a control room (control centre)

6 Press the start button < I > on the control


panel.

Using emergency-stop

The compressor is switched on.

1 Press the <Emergency-stop> pushbutton.


The compressor is placed in a safe condition.

The compressor runs in automatic mode.


See the operating sequence description in
the section "Control (automatic operation)"
in the chapter "Design and function".

2 Rectify the fault that was the cause of the


Emergency-stop.
See the "Troubleshooting" chapter.
3 Unlock the <Emergency-stop> pushbutton.
Turn the pushbutton anticlockwise.
4 Set the compressor in operation.
See section "Commissioning after a fault" in the
chapter "Commissioning and operation".

6.3

Routine commissioning

Routine commissioning is for example commissioning after maintenance.


1 Open the shut-off valves between the compressor and compressed air network.
2 Thereafter proceed as described in the section
"Initial commissioning".

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Troubleshooting

TROUBLESHOOTING

NOTICE

Troubleshooting instructions

Material damage

The following tables list possible fault causes and


remedies.

Material damage due to improper/incorrect troubleshooting measures.

The troubleshooting measures 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! Work on the electrical equipment
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 "Troubleshooting" chapter in the operating instructions of the electronic control unit.

Remedies are described in detail in the repair


manual, which is provided as part of operator
training.
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.

Drive motor defective

Check connections, winding, etc.

Compressor defective

Rotate the compressor by hand, if necessary


replace.

Ambient temperature < +2 C

Ensure that the ambient temperature is at least +2


C, if necessary provide stationary heating.

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.
Suction regulator does not close completely

Provide access to the suction regulator, replace if


necessary.
Check solenoid valves (Y1 and Y2).

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.

Air filter contaminated

Replace air filter cartridge.

Chart 7-3: Troubleshooting upon: System does not reach the set line pressure

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August 2013

Troubleshooting
Possible Cause

Remedy

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 solenoid valves (Y1 and Y2).

Chart 7-3: Troubleshooting upon: System does not reach the set line pressure

Fault: System switches off


Possible Cause

Remedy

Water inlet temperature too high

Check the cooling water supply.

(only water-cooled compressors)


Ambient temperature too high

Ventilate the compressor room.

Electric motor defective

Check electric motor and positor.

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.

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 suction regulator, blow-off silencer, nonreturn valve and replace if necessary.

Suction regulator does not close completely

Provide access to the suction regulator, replace if


necessary.
Check solenoid valves (Y1 and Y2).

Chart 7-5: Troubleshooting upon: Off-load pressure too high

Fault: Safety valve opens


Possible Cause

Remedy

Safety valve defective

Replace the safety valve.

Line pressure sensor defective

Replace the line pressure sensor.

Electronic control unit defective

Replace the electronic control unit.

Suction regulator does not close completely

Check the diaphragm in the suction regulator.


Check solenoid valves (Y1 and Y2).
Check the shuttle valve upstream of the inlet to the
two solenoid valves.
Check the opening of the blow-off valve.

Chart 7-6: Troubleshooting upon: Safety valve opens

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Troubleshooting

Troubleshooting: Lubricator
If faults occur when operating the lubricator, please check the possible causes of error using the following
table.
Fault
Lubrication system not working

Possible Cause
Cable incorrectly connected

Connect up cable correctly.

No voltage

Check voltage at plug.

Cable failure

Connect new cable.

Lubrication system signals


System running (green LED)
although the grease cartridges
are empty.

Setting "VOL" switch

Lubrication system signalling


Fault" (red LED)

Line and/or connection parts


blocked

Lubrication system signals End


of dispensing (red and green
LED) although the grease cartridges are not empty.

Remedy

Fit full grease cartridges.

Partially filled grease cartridges fitted

Back pressure too high

Clean line and connection parts,


then switch lubrication system off
and on again.

Setting "VOL" switch

Fit full grease cartridges.

Almost empty grease cartridges replaced with partially


filled grease cartridges

Chart 7-7: Troubleshooting and fault rectification for lubricator

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

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Maintenance and Service

MAINTENANCE AND SERVICE

Maintenance and service are decisive for ensuring 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 indispensable.

Support is available from your responsible Gardner Denver agency. They will create an individual
maintenance plan for you.

8.1

General information

Target groups

Fig. 8-1: Position bleeder valve air-cooled compressor


system

The maintenance work listed in these operating


instructions may only be carried out by specially
trained personnel.

[1]

Bleeder valve

All work going beyond this must be carried out by


the manufacturer's service personnel!
Safety
Observe the safety instructions in the chapter
Safety conditions.

DANGER

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

Fig. 8-2: Position bleeder valve water-cooled compressor system

[1]

WARNING

Bleeder valve

Protection measures for safe maintenance


(safety routine)

Risk of injury due to hot bleeder valve

For all maintenance work, if not expressly stated


elsewhere:

The compressed air outlet temperature


can be up to 90C.

1 Switch the compressor off and secure to prevent switching back on.

Before opening the bleeder valve,


allow the compressor to cool.

2 Drain the compressor.

Do not carry out any work when the


compressor system is hot

3 Wait for automatic pressure discharge to complete.


4 Connect the (site provided) shut-off valve in the
supply line.
5 Wait until the residual electrical energy in the
capacitors has dissipated (only RS compressors ).
6 Allow the compressor to cool to room temperature.
7 Wear personal protective equipment.

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Maintenance and Service

8 Observe the information about hazardous substances.

Check the DC bust voltage of the frequency


converter
The DC bus voltage is measured at the mains terminal strip of the frequency converter. The precise
position of the terminals "DC+" and "DC-" can be
taken from the supplied frequency converter operating instructions.

Manual pressure relief

WARNING
Pressure components

1 Measure the voltage between the DC+ and


DC- terminals.

Even when the compressor is depressurised, the aftercooler remains under


pressure.

2 Measure the voltage between the DC+ terminal


and the chassis.

Carry out manual pressure discharge before maintenance work is


carried out in the vicinity of the aftercooler.

3 Measure the voltage between the DC- terminal


and the chassis.
The voltage must read zero in all three measurements.

1 Connect the (site provided) shut-off valve in the


supply line.

8.2

2 Switch the main switch OFF.

Service

The global spare parts and customer service network of Gardner Denver is available worldwide.
The local Gardner Denver subsidiary or the responsible dealer is available for any spare parts
requirements.

3 Open the enclosure, create access.


4 Undo the lock screw on the closed air vent
valve (ball valve at the aftercooler).
5 Depressurise the aftercooler by careful opening
of the air vent valve.
6 Close the air vent valve and screw in the air
vent valve.

It is important that the model name and the serial


number of the compressor are stated in all messages.

7 Upon completion of maintenance work, open


the shut-off valve in the supply line.

Spare parts orders


Spare parts orders to:

Test run

Gardner Denver Deutschland GmbH


Aftersales
Im Boorstck 9
D-55469 Simmern

A test run should be carried out after all maintenance work; this should amongst other things
make possible the detection of any leaks. During
every test run, the low-noise running of the compressor must also be ensured.

Tel.: +49 (0)6761/832-136


Fax.: +49 (0)6761/832-411
Fax.: +49 (0)6761/12746
e-mail: ersatzteile@compair.com

Electrical components

DANGER

NOTE

Electric shock

The spare parts order is placed based on the


spare parts list which is available separately.

Life-threatening electric shock


Work on the electrical equipment
must only be carried out by authorised electricians or electrical technicians.

8.3

Protective covers and enclosure panels

With types D110RS - D160RS there


is a risk of electric shocks due to
charged capacitors!
Switch the compressor to a zero
volts state and wait 10 minutes before touching any electrical parts.

Ensure that all compressor protective covers and


enclosure panels are correctly attached.
Protective cover of the cooling air fans
Clutch protective cover between drive and
compressor

Checking the DC bus voltage.

48 / 100

Inspection of protection and


safety equipment

Heat shield covers for the snubbers and


pipelines

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August 2013

Maintenance and Service


Compressor enclosure; here in particular the
openings (doors)

Safety valves and the suction regulator-blow-off


valve must be operating flawlessly, for example
they must not be blocked by dirt or paint.

Emergency stop pushbutton /Emergency stop


function
The switching function of the contacts can be
checked by an electrician.

NOTE
The Emergency-stop function must only be activated in dangerous situations. Otherwise the result could be increased wear or even damage to
the compressor.

Fig. 8-3: Safety valves

An electrician can check the switch function of the


contacts.

[1]

Safety valve

[2]

Valve cap

Functional checking of the safety valves

4 Turn the valve cap anticlockwise until an audible blowing off can be heard.

The functional checking of the safety valves must


be carried out by a safety specialist. The result of
the functional check must be documented.

5 Turn the valve cap clockwise as far as it will go.


The valve must completely close again.

1 Switch the main switch OFF.

8.4

2 Open the enclosure, create access.

Routine maintenance

All maintenance work and checks listed in the


maintenance plan must be carried out and documented at the specified intervals.

3 Press the start button < I >.


Allow the compressor to run under load.

NOTICE

All maintenance, overhauls and repairs to the


compressor must be documented.

Hearing damage

Service and maintenance work must be carried


out by the local Gardner Denver agency.

Increased sound pressure level when operating


without the sound-proofing enclosure.

Cleanliness

Wear ear defenders.

The compressor room and the compressor surroundings must always be kept clean.

WARNING

The compressor must be checked regularly for


damage and excess wear.

Risk of burns/scalding
Risk of burns/scalding due to escaping
hot condensate / hot compressed air.

Spilt oil must be immediately wiped up. Oil traces


must be removed immediately.

Wear suitable protective clothing.

NOTE

Slowly screw out the knurled cap.

Under no circumstances must oil get into the air


inlet, into components or into the pipelines of the
compressed air network.

Do not screw the knurled cap too far


out of the enclosure.
Tighten the knurled cap as far as it
will go after each functional check.

Electrical connections
The condition of cables and terminals must be
checked regularly.
Check for loose connections or frayed or wornthrough wires.
All connections must be clean and tight.

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49 /100

Maintenance and Service


Immediately replace worn-through or damaged
wires.

Corrosion inhibiting antifreeze coolant Havoline


XLC (harmful to health)
Lubricating oil Renolin AC68 (harmless if handled normally)

Leak points

WARNING

In the event of accidents or prolonged contact with


operating fluids, observe the information in the
hazardous substance data sheets!

Risk injury due to high pressure


Do not manually investigate leak
points in the system.

Prevent leakage of operating fluids.


Carefully clear up any operating fluids that escape.
Observe the information in the hazardous substance data sheets!

Always use paper or board for this


purpose.
If leaks are suspected, check the corresponding area for leaks.

Oil carbon deposits in the oil lubrication system

Immediately repair or replace damaged or leaking pipe or hose connections.

High oil temperatures reduce the service life of the


oil and this can lead to oil carbon deposits in the
oil lubrication system. Oil carbon deposits can result in damage to the bearings and gearboxes.

Emission or leakage of operating fluids


The following operating fluids are used in the compressor:

8.5

Maintenance plan

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: Weekly checks
Component

Action

Necessary qualification Carried out

Filter mat cooling air inlet

Check, clean and replace as


necessary.

Maintenance personnel

Inlet filter cooling air switch


cabinet (only RS compressors)

Check and replace as necessary.

Maintenance personnel

Condensate drain

Intercooler, function check.

Maintenance personnel

Aftercooler, function check.

Maintenance personnel

Lubricating oil

Check level and top up as


necessary.

Maintenance personnel

Cooling system

Check level and top up as


necessary.

Maintenance personnel

Electronic control unit

Check for displayed maintenance requirements.

Operator

Chart 8-1: Maintenance plan: Weekly checks

Maintenance plan: Service A - every 4,000 hours or 6 months, weekly checks plus the following
work:
Component

Action

Necessary qualification Executed

Customer operations log

Check and adhere to operating parameters.

Operator

Chart 8-2: Maintenance plan: Service A

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Maintenance and Service


Component

Action

Necessary qualification Executed

Electronic control unit

Check fault statistics.

Operator

Air Filter

Check air filter and filter cartridge, replace if necessary.

Maintenance personnel

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.

Dirt trap (only water-cooled


compressors)

Remove sieve and clean

Maintenance personnel

Chart 8-2: Maintenance plan: Service A

Maintenance plan: Service B - every 8,000 hours or 12 months, weekly checks plus service A
plus the following work:
Component

Action

Necessary qualification Carried out

Air Filter

Replace filter cartridge.

Maintenance personnel

Oil Filter

Replace oil filter.

Maintenance personnel

Ultra-fine filter

Replace filter element.

Maintenance personnel

Balance piston

Replace diaphragm (1st


airend).

Trained service personnel

Replace diaphragm (2nd


airend).

Trained service personnel

Control air filter

Replace control air filter.

Maintenance personnel

Maintenance unit

Replace filter element.

Maintenance personnel

Solenoid valve Y3 (vacuum


generator)

Replace valve.

Maintenance personnel

Lubricating oil

Change the oil.

Maintenance personnel

Electronic control unit

Test the emergency-stop


function.

Operator

Chart 8-3: Maintenance plan: Service B

Maintenance plan: Service C - every 16,000 hours or 24 months, weekly checks plus service A
and B plus the following work:
Component

Action

Necessary qualification Carried out

Suction regulator

Replace the diaphragm.

Trained service personnel

Replacement solenoid valve


Y1.

Trained service personnel

Replacement solenoid valve


Y2.

Trained service personnel

Replace sealing washers.

Trained service personnel

Chart 8-4: Maintenance plan: Service C

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Maintenance and Service

Component

Action

Necessary qualification Carried out

Non-return valve

Replace complete valve.

Trained service personnel

Drive clutch

Check for play and replace


inserts if necessary.

Trained service personnel

Snubber (1st airend)

Replace seals.

Trained service personnel

Combined silencer and snubber (2nd airend)

Replace seals.

Trained service personnel

Intercooler

Replace inlet seal.

Trained service personnel

Aftercooler

Replace inlet seal.

Trained service personnel

Blow-off silencer

Replace silencer.

Trained service personnel

Condensate trap

Replace complete condensate Trained service persondrain.


nel

Chart 8-4: Maintenance plan: Service C

Notes
Operating parameters:The current settings, e.g. maximum line pressure [Line Pressure max.] and minimum line pressure [Line Pressure min.] should be documented in the customer operations log. Implementation and results of maintenance work and inspections should likewise be logged in this operations log.
In this way Gardner Denver can identify the specific service for your compressor.
Maintenance work:The individual maintenance tasks that the service personnel can carry out, are detailed in the following chapter. All other maintenance work must be carried out by trained service personnel using the repair manual.
Service cycles: The earliest date always applies; i.e. if the operating hours are reached before the calendar date, then the service in question must be carried out.
Oil change periods: The oil change periods can be extended to 16,000 operating hours or 24 months
provided the oil analyses permit this. Oil analyses are carried out during the warranty period in a laboratory appointed by Gardner Denver.
Coolant change: The coolant (cooling liquid) of the internal cooling circuit must be changed every 32,000
operating hours or after 48 months. The mixing ratio is 33 % glycol (Havoline XLC ethylene glycol (base))
and 67 % water.
Servicing kits: To identify the correct servicing kit, see the following table "Part numbers for servicing
kits".
Model number

Service B

Service C

D75 - D160 V2

CK8135-1

CK16135-1

D110RS - D160RS V2

CK8135RS-1

CK16135-1

Chart 8-5: Part numbers for servicing kits

Operating fluids

Article number

Lubricating oil (Renolin AC68)

100014655

Corrosion inhibiting antifreeze coolant Havoline XLC

ZS1101248

Chart 8-6: Part numbers for operating fluids

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GB

August 2013

Maintenance and Service

NOTE
The compressor is supplied with Renolin AC68.
The following oil types can be used instead:
Shell Turbo T68
Mobil Rarus 426
Esso Teresso 68
Castrol Perfecto T68
Pressure accumulator (snubber)
Checking of the pressure accumulator (snubber) must be carried out according to national regulations.
We recommend the following checking intervals for the snubber:
External inspection: 2 years
Internal inspection: 5 years
Strength test: 10 years
Electronic control unit
Information concerning the maintenance points for the electronic control unit can be found in the electronic control unit operating instructions.

8.6

Maintenance work

Blow-off silencer

8.6.1

Accesses

Suction regulator
Ultra-fine filter

Access to the components inside the compressor


system is via the accesses in the enclosure listed
below.

Oil Filter
Balance piston
Maintenance unit
Control air filter

1
2

Shuttle valve

Solenoid valves (Y1 and Y2)


Access 2 provides access to:
Drive clutch
Snubber
Access 3 provides access to:
Drive motor
Solenoid valve Y3

Fig. 8-4: Accesses 1 - 3

[1]

Access 1

[2]

Access 2

[2]

Access 3

Access 1 provides access to:


Cooling-water expansion tank
Oil level indicator and oil filler neck
Condensation drain 1st airend

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53 /100

Maintenance and Service


The condition of the filter mat must be checked by
regular visual inspections.
1 Undo the fastening screws.
2 Remove the filter mat.

3 Check the filter mat condition.


If damaged, replace the filter mat.

4 Clean the filter mat.


Brush off the filter mat.
Wash off the filter mat with a mild cleaning
solution.
Thoroughly rinse the filter mat and allow to
dry.
5 Insert the filter mat.

Fig. 8-5: Accesses 4 - 5

[4]

Access 4

[5]

Access 5

6 Attach the fastening screws.

8.6.3

Access 4 provides access to:

Inlet filter cooling air switch


cabinet (RS compressors )

Air Filter
Aftercooler
Non-return valve
Access 5 provides access to:
Switch cabinet

8.6.2

Filter mat cooling air inlet

1
2
Fig. 8-7: Inlet filter (only RS compressors )

3
4

Fig. 8-6: Silencing baffle with upstream filter mat

[1]

Compressed air connection

[2]

Filter mat cooling air inlet

[3]

Condensate drain

[4]

Supply line cover panel

Fig. 8-8: Opening the inlet filter

The compressor is equipped with a coarsemeshed filter mat. The filter mat is used to pre-filter the inlet air.

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Maintenance and Service

Check the function of the condensate drain


valve

Fig. 8-9: Inlet filter, opened

The switch cabinet is equipped with four inlet filters.


The filter pad of the inlet filter cannot be cleaned,
rather must be replaced if it becomes clogged with
dust.
1 Pivot open the louvred grille of the inlet filter.
2 Remove the filter pad.

Fig. 8-10: Condensate drain

3 Check the condition of the filter pad.

[1]

Condensate separator

[2]

Condensate trap

[3]

Button <Test>

[4]

Connecting screw

5 Place the louvred grille onto the filter housing.

[5]

Electrical connections

8.6.4

Check the condensate drain.

If necessary, replace the filter pad.


4 Insert the filter pad into the louvred grille.
The soft side ("A") of the filter pad must point
outwards (towards the louvred grille).

Condensate drain

1 Switch the main switch OFF.

Automatic condensate drain

2 Open the enclosure, create access.

Moisture contained in the compressed air network


condenses in the air coolers (intercooler and aftercooler) and is separated by the cyclone separator.
The condensate is automatically drained off by the
condensate drain that is attached to the cyclone
separator.

3 Switch the main switch ON.


4 Press button <Test>.
Condensate flows away.

NOTE
With transparent lines, the condensate drain-off
can be monitored directly, with opaque lines, it
can be checked at the outlet.
Replace the condensate drain once no condensate flows away.
5 Close the enclosure.

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55 /100

Maintenance and Service

8.6.5

Lubricating oil

Topping up the oil

Checking the fill level

5
4
6
7
8

3
2
1

Fig. 8-12: Lubricating oil system

Fig. 8-11: Level indicator

The fill level should be checked approximately 30


minutes after switching the compressor off, then
the oil will have settled in the system.
1 Switch the main switch OFF.

[1]

Oil / water cooler

[2]

Oil temperature control valve

[3]

Oil Filter

[4]

Oil pump

[5]

Oil filler neck

[6]

Oil level indicator

[7]

Oil sump

[8]

Oil drain

NOTE

2 Open the enclosure, create access.

Do not mix different oil types together.


Always only top up with the currently used oil.

3 Check the level at the level indicator.


The fill level must be between the "min." and
"max." markings.
The oil volume between the "min" and "max"
markings is approximately 3 l.

1 Switch the main switch OFF.


2 Open the enclosure, create access.
3 Remove the cap from the oil filler neck.

Top up with oil if the oil level is too low.

4 Top up the oil in small quantities and wait until


the oil has settled in the system.
This prevents over filling.

4 Close the enclosure.

5 Place the cap on the oil filler neck and close.


6 Close the enclosure.

56 / 100

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Maintenance and Service


Changing the oil

NOTE
Catch the used oil, do not allow it to seep into
the ground.
Dispose of according to the regulations!
Do not spill oil!

Ensure leak tightness!

1 Switch the main switch OFF.

6
7
8

3
2
1

2 Open the enclosure, create access.


3 Position a suitable container beneath the oil
drain.
4 Remove the cap from the oil filler neck.
5 Open the drain valve and allow the oil to flow
out completely. Dispose of the lubricating oil.
Change the oil filter.

Fig. 8-13: Lubricating oil system

[1]

Oil / water cooler

[2]

Oil temperature control valve

[3]

Oil Filter

[4]

Oil pump

[5]

Oil filler neck

[6]

Oil level indicator

[7]

Oil sump

[8]

Oil drain

6 Close the drain valve.


7 Top up the oil in small quantities and wait until
the oil has settled in the system.
This prevents over filling. Oil capacity: see
"Technical data".
8 Close the oil filler neck.
9 Close the enclosure.
Changing the oil filter

Oil can be drained via the oil drain. Fresh oil is


topped up via the oil filler neck.
Where possible drain the oil while still warm so
that it can flow out more easily.

WARNING
Risk of scalding
Risk of scalding by hot oil.
Only change the oil when the compressor is stationary and depressurised.
Caution when draining hot oil.

NOTE
Drain used oil as completely as possible, as
used oil greatly reduces the service life of the
new oil charge.

Fig. 8-14: Oil Filter

The oil filter must be changed every time the oil


filter is changed. Moreover the oil filter must be
changed, if the message [Service due] or [Oil Filter] is displayed on the electronic control unit.
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Maintenance and Service

1 Switch the main switch OFF.

2 Open the enclosure, create access.

3 Unscrew the old oil filter and dispose of.

6
7
8
9

4 Apply a thin film of oil to the seal of the new oil


filter.
5 Screw the oil filter on by hand and tighten. Observe the instructions on the oil filter!

3
4

6 Tighten the oil filter by a further quarter turn.

7 Close the enclosure.

8.6.6

Ejector vent system

Function check / adjust vacuum pressure

6
7

5
4

Fig. 8-16: Ejector vent system

3
2
1

Fig. 8-15: Ejector vent system, schematic diagram

[1]

Suction regulator

[2]

Blow-off valve

[3]

Maintenance unit

[4]

Control air filter

[5]

Vacuum pressure sensor

[6]

Solenoid valve Y1

[7]

Solenoid valve Y2

[8]

Shuttle valve

[9]

Ultra-fine filter

[1]

Second stage condensate separator


(aftercooler water separator)

[2]

Compressed air connection ejector vent


system

1 Switch the main switch OFF.

[3]

Solenoid valve Y3

[4]

Maintenance unit (water separator,


pressure regulator, pressure gauge)

3 Switch the main switch ON.

[5]

Ejector (vacuum generator)

[6]

Extract air

NOTICE

[7]

Ultra-fine filter

Hearing damage

[8]

Oil return

Increased sound pressure level when operating


without the sound-proofing enclosure.

2 Open the enclosure, create access.


4 Press the start button < I >.
Allow the compressor to run under load.

Included in checking of the ejector vent system is


functional checking of the fine filter and adjustment
of the pressure regulator.

Wear ear defenders.


5 Check whether air from the opening of the vent
housing is discharged.
No oil film should form on the air outlet!
6 Check the vacuum pressure at the display of
the vacuum pressure sensor.

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Maintenance and Service

7 Adjust the pressure regulator so that -5 mbar is


displayed on the vacuum pressure sensor.

4 Unscrew the filter holder with the filter element.

8 Close the enclosure.

6 Take off the filter element.

5 Take off the guide plate and housing seal.


7 Undo the knurled screw and demount the float
deflector in the casing bottom.

NOTE
The vacuum created in the oil system depends
on the flow velocity in the vacuum generator.
Hence the vacuum cannot be exactly preset via
the pressure regulator. The described adjustment is adequate for fault-free operation.

8 Clean the casing bottom and float deflector using mild cleaning agent and then blow-off with
compressed air.

WARNING

Changing the filter element of the maintenance unit

Risk of injury
Risk of injury to the eyes.
Wear safety glasses.

1
2

9 Insert the float detector in the casing bottom


and tighten using the knurled screw.

6
7
8
9

3
4

10 Insert a new filter element.


11 Position the guide plate and casing seal.
12 Screw in filter holder with the filter element.
13 Screw the casing bottom on hand-tight.

14 Close the enclosure.

Fig. 8-17: Ejector vent system

[1]

Suction regulator

[2]

Blow-off valve

[3]

Maintenance unit

[4]

Control air filter

[5]

Vacuum pressure sensor

[6]

Solenoid valve Y1

[7]

Solenoid valve Y2

[8]

Shuttle valve

[9]

Ultra-fine filter

The filter element of the maintenance unit in the


ejector vent system must be changed regularly.
1 Switch the main switch OFF.
2 Open the enclosure, create access.
3 Unscrew the casing bottom.

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59 /100

Maintenance and Service

Replacing the ultra-fine filter element

Replacing solenoid valve Y3

1
2
6
7
8
9

3
4
5

Fig. 8-18: Ejector vent system

Fig. 8-19: Solenoid valve Y3

[1]

Suction regulator

[1]

[2]

Blow-off valve

Second stage condensate separator


(aftercooler water separator)

[3]

Maintenance unit

[2]

Compressed air connection

[4]

Control air filter

[3]

Solenoid valve Y3

[5]

Vacuum pressure sensor

[6]

Solenoid valve Y1

The solenoid valve Y3 in the ejector vent system


must be changed regularly.

[7]

Solenoid valve Y2

1 Switch the main switch OFF.

[8]

Shuttle valve

2 Open the enclosure, create access.

[9]

Ultra-fine filter

3 Undo the electrical connections from the solenoid valve.

The ultra-fine filter element in the ejector vent system must be changed regularly.

4 Demount the solenoid coil from the valve body.


5 Demount the valve body.

1 Switch the main switch OFF.

6 Fit new valve bodies. When doing so use the


existing fittings and seal using thread sealing
paste or tape.

2 Open the enclosure, create access.


3 Loosen the drainage line at the bottom on the
filter housing.

7 Fit the solenoid coil on the valve body.

4 Screw off the filter housing.

8 Connect the electrical connections to the solenoid valve.

5 Unscrew the ultra-fine filter element and dispose of.

9 Close the enclosure.

6 Apply a thin film of oil to the seal of the new ultra-fine filter element.
7 Screw the ultra-fine filter element on by hand.
8 Screw on the filter housing.
9 Connect the drainage line.
10 Close the enclosure.

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August 2013

Maintenance and Service


8.6.7

Cooling system

Refill cooling water

Checking the fill level


3

3
2

I
2

A
I

O
6

1
7

1
7

Fig. 8-21: Internal cooling water system


Fig. 8-20: Internal cooling water system

[A]

To the water/air cooler

[A]

To the water/air cooler

[B]

From the water/air cooler

[B]

From the water/air cooler

[1]

Water pump

[1]

Water pump

[2]

Temperature control valve

[2]

Temperature control valve

[3]

Water/air cooler

[3]

Water/air cooler

[4]

Expansion line

[4]

Expansion line

[5]

Expansion tank with level sensor

[5]

Expansion tank with level sensor

[6]

Cooling water drain

[6]

Cooling water drain

[7]

Oil / water cooler

[7]

Oil / water cooler

NOTE

The fill level should be checked approximately 10


minutes after switching the compressor off, then
the cooling water will have settled in the system.

The mixing ratio of the cooling water is 33% glycol (Havoline XLC ethylene glycol (basis)) and
67% water.

1 Switch the main switch OFF.

WARNING

2 Open the enclosure, create access.


3 Check the cooling water level at the level indicator on the expansion tank.
The fill level must be between the "min." and
"max." markings.
The cooling water volume between the "min"
and "max" markings is approximately 0.6 l.

Risk of scalding
Risk of scalding due to escaping hot
cooling water.
Only open the cap of the expansion
tank once the internal cooling water
system has cooled sufficiently.

Top up with cooling water if the cooling water level is too low.

Carefully open the cap and let any


pressure leak out.

4 Close the enclosure.

Only then should the cap be completely opened.


1 Switch the main switch OFF.
2 Open the enclosure, create access.
3 Remove the cap from the expansion tank.

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Maintenance and Service

4 Top up with cooling water until the required filling level is reached.
Top up cooling water in small quantities and
wait until the cooling water has settled in the
system. This prevents over filling.

Filling with cooling water


1 Remove the cap from the expansion tank.
2 Top up with cooling water until the required filling level is reached.
Top up cooling water in small quantities and
wait until the cooling water has settled in the
system. This prevents over filling.

5 Fit the cap on the expansion tank.


6 Close the enclosure.

3 Fit the cap on the expansion tank.

Changing the cooling water


3

4 Switch the main switch ON.


5 Press the start button < I >.
Let the compressor run for approximately 5
minutes under load until the cooling water has
been distributed around the system.

A
I

6 Press stop button< O >.

7 Check the fill level.


8 Top up with cooling water, if necessary.

3
2

9 Close panel

Cleaning the dirt trap


6

Fig. 8-22: Internal cooling water system

[A]

To the water/air cooler

[B]

From the water/air cooler

[1]

Water pump

[2]

Temperature control valve

[3]

Water/air cooler

[4]

Expansion line

[5]

Expansion tank with level sensor

[6]

Cooling water drain

[7]

Oil / water cooler

The cooling water can be drained via the cooling


water drain. Fresh cooling water is topped up via
the expansion tank.
Draining the cooling water
1 Switch the main switch OFF.

[1]

Safety valve

[2]

Strainer

[3]

Water stop valve

2 Open the enclosure, create access.


3 Position a suitable container beneath the cooling water drain.
4 Open the cap on the expansion tank.
5 Open the drain valve and allow the cooling water to flow out completely. Dispose of the cooling water.
6 Close the drain valve.

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Maintenance and Service


8.6.9

Cleaning the dirt trap

Air Filter

WARNING
Risk of scalding

Risk of scalding due to escaping hot


cooling water.

Only open the cap of the expansion


tank once the internal cooling water
system has cooled sufficiently.

Carefully open the cap and let any


pressure leak out.
Only then should the cap be completely opened.

WARNING
Legionella contamination
Health risk with open cooling systems.
Constant testing of the water quality
in the cooling circuit for the number
of microbes.

Fig. 8-23: Air Filter

1 Switch main switch OFF and secure to prevent


restarting.
2 Isolate the cooling water supply and outlet.
3 Open the enclosure, create access.

[1]

Air Filter

[2]

Air filter cap

[3]

Filter element (fitted)

The compressor is equipped with an air filter. The


air filter is used to filter the inlet air. The condition
of the air filter must be checked by regular visual
inspections.

4 Preposition a capture container.


5 Carefully release the cover of the dirt trap (2).
6 Catch the escaping coolant.
7 Clean the dirt trap sieve.

Moreover the air filter must be changed, if the


message [Service due] or [Air Filter] is displayed
on the electronic control unit.

8 Fit the dirt trap sieve.


9 Close the enclosure.
10 Re-open the cooling water supply and outlet.

Checking the air filter

11 Check for leaks.

1 Switch the main switch OFF.


2 Open the enclosure, create access.
3 Demount the air filter cover.
4 Check the filter element.
Replace the filter element if it is heavily contaminated.
5 Fit the air filter cover.
6 Close the enclosure.

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63 /100

Maintenance and Service

Replace the air filter element

Replacing the filter element of the control air


filter

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.

6
7
8
9

3
4

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 Demount the air filter cover.
4 Change the filter element.
5 Fit the air filter cover.
6 Close the enclosure.

8.6.10

Control air filter

The control air filter removes moisture and solid


bodies from the control air system.
[1]

Suction regulator

[2]

Blow-off valve

[3]

Maintenance unit

[4]

Control air filter

[5]

Vacuum pressure sensor

[6]

Solenoid valve Y1

[7]

Solenoid valve Y2

[8]

Shuttle valve

[9]

Ultra-fine filter

1 Switch the main switch OFF.


2 Open the enclosure, create access.
3 Unscrew the casing bottom.
4 Unscrew the filter holder with the filter element.
5 Take off the guide plate and housing seal.
6 Take off the filter element.
7 Clean the casing bottom using mild cleaning
agent and then blow-off with compressed air.

WARNING
Risk of injury
Risk of injury to the eyes.
Wear safety glasses.
8 Insert a new filter element.
9 Position the guide plate and casing seal.

64 / 100

GB

August 2013

Maintenance and Service


10 Screw the casing bottom on hand-tight.

11 Insert the plug in the drive.

11 Close the enclosure.

8.6.11

Function check of the lubricator

Drive motor / Lubricator

The drive motor is fitted with an automatic motor


lubrication system.
Maintenance of the motor lubrication system is
limited to replacement of the grease cartridges.
Empty grease cartridges or a fault on the lubricator
is indicated on the compressor electronic control
unit by means of a message [Warning: Mot.lubr.
sys] (also refer to the operating instructions of the
electronic control unit).

3
1

Replacing a grease cartridge


1
2
3
4

Fig. 8-25: Lubricator display elements

[1]

Function display (2 LEDs)

[2]

"TIME" switch

[3]

Plug connection

[4]

"VOL" switch

1 Check the function using the LEDs.

Fig. 8-24: Lubricator

[1]

Cable with plug

[2]

Lubricator drive

[3]

Grease cartridge

[4]

Drive motor

1 Switch the main switch OFF.

LED

Signal

Explanation

Green

Continuous signal OK. System running.

Red

Continuous signal Dispensing


< 30 seconds
process

Red

Continuous signal Error/Fault


> 30 seconds

Green
and red

Continuous signal Grease cartridge


empty, change

Chart 8-7: LEDs

2 Open the enclosure, create access.


3 Pull the plug off from the lubricator.
4 Unscrew lubricator (grease cartridge with drive
and cover) from the lubricating point.
5 Unscrew the cover from the grease cartridge.
6 Remove the drive from the grease cartridge.
7 Place the drive on the new grease cartridge.
The toothing of the two parts must intermesh.
8 Screw the cover on to the grease cartridge and
tighten by hand.
9 Remove the stopper-plug from the grease cartridge.
10 Screw lubricators into lubricating point (hand
tight).

August 2013

GB

65 /100

Maintenance and Service

8.6.12

Control system

Testing the Emergency-stop pushbutton

[1]

Touchscreen display

[2]

Start button < I >

[3]

Stop button< O >

[4]

Red LED
Slow flashing: Warning
Fast flashing: Fault

[5]

Yellow LED
Slow flashing: Maintenance necessary

[6]

Green LED
Lit up permanently: System in operation
Flashing: System on standby

[7]

Pushbutton <Emergency-stop>

NOTE
The Emergency-stop function must only be activated in dangerous situations. Otherwise the result could be increased wear or even damage to
the compressor.
Only test the Emergency-stop pushbutton when
the compressor is at a standstill.
1 Press stop button< O >.
The electronic control unit status message
is [Ready to Start].
1 Press the <Emergency-stop> pushbutton.
The electronic control unit displays the fault
message [Emergency Stop Activated].
The tab "Fault log" flashes.
2 Unlock the <Emergency-stop> pushbutton.
Turn the pushbutton anticlockwise.
3 Reset the fault message.
To do this press the button [RESET] on the tab
"Fault log" in the electronic control unit.
The "Fault log" tab stops flashing.

66 / 100

GB

August 2013

Appendix

APPENDIX

9.1

Shutdown

9.3

Harmful to health

Routine shutdowns are for example shutdowns for


maintenance work.

Risk of damage to health due to operating fluids and additives

1 Switch main switch OFF and secure to prevent


switching back on.

Lubricants and additives may cause irreparable damage to the health, trigger
allergies or irritate the mucous membrane.

2 Close the shut-off valves between the compressor and compressed air network.
3 Depressurise the aftercooler by careful opening
of the air vent valve.

When handling lubricants and additives, always observe the locally


valid operating instructions/hazardous substance data sheets.

Shutdown for a longer period


For shutdowns longer than six months, contact
Gardner Denver.

Avoid direct contact with lubricants


and additives. Wear personal protective equipment!

Final shutdown

Where injuries occur in which lubricants and additives are involved,


consult a doctor and name the substances involved.
Have the hazardous substance data
sheet readily available.

To prevent restarting of the compressor or misuse


by unknown parties, the compressor must be rendered unusable.
The compressor is rendered unusable by removal
of the electronic control unit. Contact Gardner
Denver for advice.

CAUTION

Lubricants and additives

Risk of slipping

The compressor contains approximately 20 litres


of oil for lubricating the gearbox and the bearings
of the airend unit.

Risk of slipping due to escaped operating fluid


Immediately clear up any operating
fluid that has escaped.

The drive motor lubricator contains two grease


cartridges.

Avoid direct contact with operating fluids. Wear personal protective


equipment!

The internal water circuit contains a water-glycol


mixture (approximately 70% water and 30% glycol).

Preconditions

Safety data sheets

The compressor is out of service.

When handling operating fluids and additives, the


corresponding safety data sheets must be observed.

The compressor is switched to a zero volts


state.

Lubricating oil: Renolin AC68

The main switch is switched to OFF and secured to prevent switching back on.

Lubricating grease: MOBIL POLYREX EM

The compressor is depressurised.

Cooler corrosion inhibitor and antifreeze: Havoline XLC

August 2013

Removal
WARNING

Routine shutdown

9.2

Liquids and fats are as far as possible removed.

GB

67 /100

Appendix

Demounting the power supply

3 Unscrew lubricator (grease cartridge with drive


and cover) from the lubricating point.

DANGER

4 Close the lubricating point.


5 Close the enclosure.

Electric shock
Life-threatening electric shock

Demounting the air filter

Work on the electrical equipment


must only be carried out by authorised electricians or electrical technicians.

1 Demount all filter elements and filter mats. Dispose of filter elements and filter mats.
Air filter cartridge
Filter mat

1 Disconnect the power supply cable, see the


wiring diagram.

Inlet filter cooling air switch cabinet (only RS


compressors)

2 Remove the power supply cable.

Control air filter

3 Attach plugs to the power supply cable openings.

9.4

Demounting the pipelines

Disposal

General

1 Disconnect the compressed air connection.

The compressor must be dismantled and stripped


down by specialised personnel. The applicable local safety and environmental protection regulations must be adhered to when doing this.

2 Disconnect the condensate drain pipes.


3 Allow the condensate to drain away completely.
4 Immediately clear up any condensate that has
escaped.

When disposing of substances harmful to health,


the instructions of the corresponding safety data
sheets must be observed.

Draining the cooling water

Packaging material, cleaning agents and used or


residual lubricants must be delivered to a recycling
centre in accordance with the regulations valid in
the place of use.

1 Open the enclosure, create access.


2 Position a suitable container beneath the cooling water drain.
3 Open the drain valve and allow the cooling water to flow out completely. Dispose of the cooling water.

WEEE-Directive
In accordance with the WEEE directive (2002/96/
EC), Gardner Denver undertakes to support the
recovery and reuse of electrical and electronic devices. Contact Gardner Denver for advice.

4 Close the drain valve.


5 Close the enclosure.
Draining the lubricating oil

Disposal

1 Open the enclosure, create access.

The compressor should be stripped down into its


component parts to permit disposal "according to
material composition", for example into base metals, plastics, textile products.

2 Position a suitable container beneath the oil


drain.
3 Open the drain valve and allow the oil to flow
out completely. Dispose of the lubricating oil.

Biodegradable parts should be delivered to normal


industrial waste disposal processes. Plastics, rubber or composite materials must not be disposed
of by burning.

4 Close the drain valve.


5 Close the enclosure.
Demounting the oil filter

All liquid waste substances such as lubricating


oil or grease, antifreeze, cooling liquids or corrosion inhibitors must be disposed of using specially
approved waste disposal or recycling systems.
When doing so, it must be ensured that these substances do not get into the sewage system.

1 Demount out all oil filters in the lubricating system. Dispose of the filters.
Oil Filter
Ultra-fine filter

The following table provides an overview for the


disposal of substances and materials used.

Demounting the grease cartridges of the drive


motor lubricator
1 Open the enclosure, create access.
2 Pull the plug off from the lubricating system.
68 / 100

GB

August 2013

Appendix
Material /
substance

Disposal type
Recycling

Metals

Cable

Landfill

Seals

Hazardous
waste

Plastics

Filters

Operating
fluids

x2

Chart 9-1: Substances and materials used and their disposal

1
2

Where possible
Disposal according to the safety data
sheet or manufacturer's information

9.5

Limit values of dissolved matter


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

< 100 mg/l (5.6 dH)

< 50 mg/l (2.8 dH)

< 2 mmol/l
< 200 ppm
< 11.5 dH
< 20 fH

< 0,5 mmol/l


< 50 ppm
< 2.8 dH
< 5 fH

Carbonate hardness

CaCO3

Total hardness

Chloride

Cl-

< 200 mg/l

< 50 mg/l

Sulfate

SO42-

< 200 mg/l

< 50 mg/l

Nitrate

NO3-

< 100 mg/l

< 100 mg/l

< 25 mg/l

< 10 mg/l

Organic materials (KMnO4 absorption)


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+

< 1mg/l

< 1mg/l

Iron

Fe

< 0,2 mg/l

< 0,2 mg/l

Manganese

Mn

< 0.1 mg/l

< 0.1 mg/l

Sulfide

2-

Chart 9-2: Limit values of dissolved matter


August 2013

GB

69 /100

Appendix

Dissolved matter / specific values


Ammonia

NH3

Conductivity

Circulating water

Through-flow water

> 50 < 800 S/cm

> 50 < 200 S/cm

Chart 9-2: Limit values of dissolved matter

9.6

Technical Specification

9.6.1

D75 + D90, 50Hz, air-cooled "A" and water-cooled "W" (European version)

D75 + D90,

D75

D90

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

Minimum operating pressure

[bar]

Ambient temperature

[C]

2 / 45

Volume flow

[m3/min]

12.91

After cooler outlet temperature above ambient


temperature

"A" [C]

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (ISO 2151)

"A" [dB(A)]

75

74

76

75

Sound pressure level (ISO 2151)

"W" [dB(A)]

72

70

73

72

Rated output drive motor

[kW]

75

90

Total current consumption during load operation


(400V)

[A]

175

199

Electric motor

8,0

10,0

8,0

10,0

2 / 40

2 / 45

2 / 40

10.63

15.65

13.79

4,0

IP55 (IE3) - IEC


60034-2-1 ECA Qualifying

Rated speed drive motor

[rpm]

2970

Rated output fan motor

[kW]

{"A" = 2 x 1.25 (IP54)} ;


{"W" = 1 x 1.1 (IP54)}

Rated output oil pump

[kW]

0.55 (IP54)

Rated output cooling water pump

[kW]

0.75 (IP54)

Recommended cable cross-section (400V)

[mm2]

Recommended fuse rating (time-delayed)

[A]

Cooling air volume flow

[m3/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

Cooling water volume, external (@T=15K)

[l/min]

Cooling water inlet temperature, external

[C]

3 x 70 PE35

3 x 95 PE50

3 x 200

3 x 250

("A" = 255) ; ("W" = 85)


"A" = 19
45 / 20
[35 C /
45 C]

45 / 35
[35 C /
40 C]

"A" = 23
40 / 15
[35 C /
40 C]

40 / 30
[35 C /
40 C]

"A" = 30 ; "W" = 20
89 @p=0.7 bar

111 @p=0.9 bar

min. = 5 ; max. = 42

Chart 9-3: Technical data; D75 + D90 , 50Hz, air-cooled "A" and water-cooled "W" (European version)
70 / 100

GB

August 2013

Appendix
D75 + D90,

D75

D90

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Cooling water outlet temperature, external

[C]

57

Max. cooling water pressure, external

[bar]

Cooling water connections


Total oil quantity

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

24

Compressed air connection

Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"= 3023 ;
"W"=3223

"A"=3223 ;
"W"=3423

2597 x 1744 x 2001

Chart 9-3: Technical data; D75 + D90 , 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.2

D110 + D132, 50Hz, air-cooled "A" and water-cooled "W" (European version)

D110 + D132,

D110

D132

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

8,0

10,0

Minimum operating pressure

[bar]

Ambient temperature

[C]

2 / 45

2 / 40

2 / 45

2 / 40

Volume flow

[m3/min]

19.51

17.39

22.39

20.50

After cooler outlet temperature above ambient


temperature

"A" = [C]

11

10

Aftercooler outlet temperature above ambient


temperature

"W" = [C]

Sound pressure level (ISO 2151)

"A" [dB(A)]

77

77

78

78

Sound pressure level (ISO 2151)

"W" [dB(A)]

75

74

77

76

Rated output drive motor

[kW]

110

132

Total current consumption during load operation


(400V)

[A]

249

285

Electric motor

8,0

10,0
4,0

IP55 (IE3) - IEC


60034-2-1 ECA Qualifying

Rated speed drive motor

[rpm]

2970

Rated output fan motor

[kW]

{"A" = 2 x 3.2 (IP54)} ;


{"W" = 1 x 1.1 (IP54)}

Rated output oil pump

[kW]

0.55 (IP54)

Rated output cooling water pump

[kW]

0.75 (IP54)

Recommended cable cross-section (400V)

[mm2]

2 x 3 x 50 PE50

2 x 3 x 70 PE70

Chart 9-4: Technical data; D110 + D132 , 50Hz, air-cooled "A" and water-cooled "W" (European version)

August 2013

GB

71 /100

Appendix

D110 + D132,

D110

D132

6 x 160

6 x 200

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Recommended fuse rating (time-delayed)

[A]

Cooling air volume flow

[m3/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

Cooling water volume, external (@T=15K)

[l/min]

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

("A" = 338) ; ("W" = 85)


"A" = 22
120 / 40
[35 C /
45 C]

"A" = 25

120 / 85
[35 C /
40 C]

110 / 25
[35 C /
45 C]

110 / 80
[35 C /
40 C]

"A" = 30 ; "W" = 20
132 @p=1.0 bar

155 @p=1.2 bar

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3265 ;
"W"=3465

"A"=3432 ;
"W"=3632

2597 x 1744 x 2001

Chart 9-4: Technical data; D110 + D132 , 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.3

D160, 50Hz, air-cooled "A" and water-cooled "W" (European version)

D160 ,

D160

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

10,0

Minimum operating pressure

[bar]

4,0

Ambient temperature

[C]

2 / 40

Volume flow

[m3/min]

22.33

After cooler outlet temperature above ambient


temperature

"A" = [C]

11

Aftercooler outlet temperature above ambient


temperature

"W" = [C]

Sound pressure level (ISO 2151)

"A" [dB(A)]

78

Sound pressure level (ISO 2151)

"W" [dB(A)]

76

Chart 9-5: Technical data; D160 , 50Hz, air-cooled "A" and water-cooled "W" (European version)

72 / 100

GB

August 2013

Appendix
D160 ,

D160

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Rated output drive motor

[kW]

160

Total current consumption during load operation


(400V)

[A]

340

Electric motor

IP55 (IE3) - IEC


60034-2-1 ECA Qualifying

Rated speed drive motor

[rpm]

2970

Rated output fan motor

[kW]

{"A" = 2 x 3.2 (IP54)} ;


{"W" = 1 x 1.1 (IP54)}

Rated output oil pump

[kW]

0.55 (IP54)

Rated output cooling water pump

[kW]

0.75 (IP54)

Recommended cable cross-section (400V)

[mm2]

2 x 3 x 95 PE95

Recommended fuse rating (time-delayed)

[A]

Cooling air volume flow

[m /min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K)

[l/min]

170 @p=1.3 bar

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

6 x 250
("A" = 338) ; ("W" = 85)
"A" = 27
90 / 50 [35 C / 40 C]

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3644 ; "W"=3844
2597 x 1744 x 2001

Chart 9-5: Technical data; D160 , 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.4

D110 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

D110 RS,

D110 RS

D110 RS

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

8,0

10,0

Minimum operating pressure

[bar]

4,0

4,0

Chart 9-6: Technical data; D110 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)
August 2013

GB

73 /100

Appendix

D110 RS,

D110 RS

D110 RS

2 / 45

2 / 40

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Ambient temperature

[C]

min
speed

max.
speed

min
speed

max.
speed

Volume flow rate / final pressure [bar]

[m3/min]

9,06 / 6

19.42 / 6 10.77 / 6 17.58 / 6

Volume flow rate / final pressure [bar]

[m3/min]

8,97 / 7

19.37 / 7 10.764 / 17.47 / 8


8

Volume flow rate / final pressure [bar]

[m3/min]

8.89 / 8

19.32 / 8

After cooler outlet temperature above ambient


temperature

"A" [C]

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (ISO 2151)

"A" [dB(A)]

76 / 78

76 / 78

Sound pressure level (ISO 2151)

"W" [dB(A)]

72 / 75

71 / 74

Rated output drive motor

[kW]

Total power consumption during load operation


(380V / 400V)

[A]

Electric motor

10.51 /
10

17.37 /
10

110
262 / 249
IP55 (IE3) - IEC
60034-2-1 ECA Qualifying

Rated speed drive motor

[rpm]

1909 / 3600

2417 / 3630

Rated output fan motor

[kW]

{"A" = 2 x 3.2 (IP54)} ;


{"W" = 1 x 1.1 (IP54)}

Rated output oil pump

[kW]

0.55 (IP54)

Rated output cooling water pump

[kW]

0.75 (IP54)

Recommended cable cross-section (380V +


400V)

[mm2]

3 x 95 PE50

Recommended fuse rating (time-delayed) (380V


+ 400V)

[A]

Cooling air volume flow

[m3/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K)

[l/min]

132 @p=1.0 bar

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

3 x 300
("A" = 338) ; ("W" = 85)
"A" = 22
120 / 40 [35
C / 45 C]

120 / 85 [35
C / 40 C]

Chart 9-6: Technical data; D110 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

74 / 100

GB

August 2013

Appendix
D110 RS,

D110 RS

D110 RS

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Cooling water connections
Total oil quantity

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

24

Compressed air connection

Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3278 ; "W"=3478
2597 x 1744 x 2001

Chart 9-6: Technical data; D110 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.5

D132 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

D132 RS,

D132 RS

D132 RS

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

8,0

10,0

Minimum operating pressure

[bar]

4,0

4,0

Ambient temperature

[C]

2 / 45

2 / 40

min
speed

max.
speed

min
speed

max.
speed

Volume flow rate / final pressure [bar]

[m3/min]

9.13 / 6

22.82 / 6 10.81 / 6 21.02 / 6

Volume flow rate / final pressure [bar]

[m3/min]

9.03 / 7

22.75 / 7 10.66 / 8 20.93 / 8

Volume flow rate / final pressure [bar]

[m3/min]

8.95 / 8

22.68 / 8

After cooler outlet temperature above ambient


temperature

"A" = [C]

12

10

Aftercooler outlet temperature above ambient


temperature

"W" = [C]

Sound pressure level (ISO 2151)

"A" [dB(A)]

77 / 79

77 / 79

Sound pressure level (ISO 2151)

"W" [dB(A)]

73 / 78

72 / 76

Rated output drive motor

[kW]

Total power consumption during load operation


(380V / 400V)

[A]

Electric motor

10.51 /
10

20.85 /
10

132
269 / 255
IP55 (IE3) - IEC
60034-2-1 ECA Qualifying

Rated speed drive motor

[rpm]

1550 / 3380

1959 / 3500

Rated output fan motor

[kW]

{"A" = 2 x 3.2 (IP54)} ;


{"W" = 1 x 1.1 (IP54)}

Rated output oil pump

[kW]

0.55 (IP54)

Rated output cooling water pump

[kW]

0.75 (IP54)

Chart 9-7: Technical data; D132 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)
August 2013

GB

75 /100

Appendix

D132 RS,

D132 RS

D132 RS

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Recommended cable cross-section (380V +
400V)

[mm2]

Recommended fuse rating (time-delayed) (380V


+ 400V)

[A]

Cooling air volume flow

[m3/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K)

[l/min]

155 @p=1.2 bar

Cooling water inlet temperature

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

3 x 120 PE70
3 x 300
("A" = 338) ; ("W" = 85)
"A" = 26
110 / 25 [35
C / 45 C]

110 / 80 [35
C / 40 C]

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3476 ; "W"=3676
2597 x 1744 x 2001

Chart 9-7: Technical data; D132 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.6

D160 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

D160 RS,

D160 RS

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

10,0

Minimum operating pressure

[bar]

4,0

Ambient temperature

[C]

2 / 40
min speed

max. speed

Volume flow rate / final pressure [bar]

[m3/min]

10.70 / 6

23.41 / 6

Volume flow rate / final pressure [bar]

[m3/min]

10.55 / 8

23.30 / 8

Volume flow rate / final pressure [bar]

[m3/min]

10.40 / 10

23.19 / 10

After cooler outlet temperature above ambient


temperature

"A" = [C]

12

Chart 9-8: Technical data; D160 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

76 / 100

GB

August 2013

Appendix
D160 RS,

D160 RS

50Hz, air-cooled "A" and water-cooled


"W" (European version)
Aftercooler outlet temperature above ambient
temperature

"W" = [C]

Sound pressure level (ISO 2151)

"A" [dB(A)]

77 / 79

Sound pressure level (ISO 2151)

"W" [dB(A)]

73 / 78

Rated output drive motor

[kW]

Total power consumption during load operation


(380V / 400V)

[A]

Electric motor

160
304 / 289
IP55 (IE3) - IEC
60034-2-1 ECA Qualifying

Rated speed drive motor

[rpm]

1687 / 3320

Rated output fan motor

[kW]

{"A" = 2 x 3.2 (IP54)} ;


{"W" = 1 x 1.1 (IP54)}

Rated output oil pump

[kW]

0.55 (IP54)

Rated output cooling water pump

[kW]

0.75 (IP54)

Recommended cable cross-section (380V +


400V)

[mm2]

3 x 150 PE95

Recommended fuse rating (time-delayed) (380V


+ 400V)

[A]

Cooling air volume flow

[m3/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K)

[l/min]

170 @p=1.3 bar

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

6 x 355
("A" = 338) ; ("W" = 85)
"A" = 26
90 / 50 [35 C / 40 C]

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3688 ; "W"=3888
2597 x 1744 x 2001

Chart 9-8: Technical data; D160 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)

August 2013

GB

77 /100

Appendix

9.6.7

D75 + D90, 60Hz, air-cooled "A" and water-cooled "W" (European version)

D75 + D90,

D75

D90

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

8,0

10,0

8,0

10,0

Minimum operating pressure

[bar]

Ambient temperature

[C]

2 / 45

2 / 40

2 / 45

2 / 40

Volume flow

[m/min]

12.39

10.85

15.92

13.15

After cooler outlet temperature above ambient


temperature

"A" [C]

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (according to ISO 2151)

"A" [dB(A)]

76

75

77

76

Sound pressure level (according to ISO 2151)

"W" [dB(A)]

73

71

74

73

Rated output electric motor

[kW]

Total power consumption during load operation


(380V / 460V)

[A]

4,0

75

90

198 / 152

225 / 173

Electric motor

IP55 , EISA 2007 (IE3)

Rated speed

[rpm]

3560

Rated output fan motor

[kW]

{"A" = 2 x 1.4 (IP54)} ;


{"W" = 1 x 1.8 (IP54)}

Rated output oil pump

[kW]

0.66 (IP-54)

Rated output cooling water pump

[kW]

1.1 (IP-54)

Recommended cable cross-section (380V /


460V)

[mm]

Recommended fuse rating (time-delayed) (380V


+ 460V)

[A]

Cooling air volume flow

[m/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

Cooling water volume, external (@T=15K)

[l/min]

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections

3 x 95 PE50 /
3 x 50 PE25

3 x 95 PE50 /
3 x 70 PE35

3 x 250 / 3 x 160

3 x 250 / 3 x 200

("A" = 225) ; ("W" = 95)


"A"=19
45 / 20
[35 C /
45 C]

"A"=23

45 / 35
[35C /
45C]

40 / 15
[35 C /
45 C]

40 / 30
[35C /
40C]

"A" = 30 ; "W" = 20
89 @p=0.7 bar

111 @p=0.9 bar

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)

Chart 9-9: Technical data; D75 + D90, 60Hz, air-cooled "A" and water-cooled "W" (European version)

78 / 100

GB

August 2013

Appendix
D75 + D90,

D75

D90

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Total oil quantity

[l]

24

Compressed air connection

Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3023 ;
"W"=3223

"A"=3223 ;
"W"=3423

2597 x 1744 x 2001

Chart 9-9: Technical data; D75 + D90, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.8

D110 + D132, 60Hz, air-cooled "A" and water-cooled "W" (European version)

D110 + D132,

D110

D132

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

8,0

10,0

Minimum operating pressure

[bar]

Ambient temperature

[C]

2 / 45

2 / 40

2 / 45

2 / 40

Volume flow

[m/min]

18.99

16.89

22.59

21.00

After cooler outlet temperature above ambient


temperature

"A" [C]

11

10

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (according to ISO 2151)

"A" [dB(A)]

78

78

78

78

Sound pressure level (according to ISO 2151)

"W" [dB(A)]

76

75

78

77

Rated output electric motor

[kW]

Total power consumption during load operation


(380V / 460V)

[A]

Electric motor

8,0

10,0
4,0

110

132

291 / 227

331 / 257

IP55 , EISA 2007 (IE3)

Rated speed

[rpm]

3560

Rated output fan motor

[kW]

{"A" = 2 x 3.9 (IP54)} ;


{"W" = 1 x 1.1 (IP54)}

Rated output oil pump

[kW]

0.66 (IP-54)

Rated output coolant pump

[kW]

1.1 (IP-54)

Recommended cable cross-section (380V /


400V)

[mm]

2 x 3 x 70 PE70 /
2 x 3 x 50 PE50

2 x 3 x 70 PE70 /
2 x 3 x 50 PE50

Recommended fuse rating (time-delayed)

[A]

6 x 200 / 6 x 160

6 x 200 / 6 x 160

Cooling air volume flow

[m/min]

("A" = 349) ; ("W" = 95)

Chart 9-10: Technical data; D110 + D132, 60Hz, air-cooled "A" and water-cooled "W" (European version)

August 2013

GB

79 /100

Appendix

D110 + D132,

D110

D132

"A"=22

"W"=25

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Cooling air outlet temperature above ambient
temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

Cooling water volume, external (@T=15K)

[l/min]

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

120 / 40
[35 C /
45 C]

120 / 85
[35C /
40C]

110 / 25
[35C /
45C]

110 / 80
[35C /
45C]

"A" = 30 ; "W" = 20
132 @p=1.0 bar

155 @p=1.2 bar

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3265 ;
"W"=3465

"A"=3432 ;
"W"=3632

2597 x 1744 x 2001

Chart 9-10: Technical data; D110 + D132, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.9

D160, 60Hz, air-cooled "A" and water-cooled "W" (European version)

D160,

D160

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

10,0

Minimum operating pressure

[bar]

4,0

Ambient temperature

[C]

2 / 40

Volume flow

[m/min]

22.54

After cooler outlet temperature above ambient


temperature

"A" [C]

11

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (according to ISO 2151)

"A" [dB(A)]

78

Sound pressure level (according to ISO 2151)

"W" [dB(A)]

78

Rated output electric motor

[kW]

160

Total power consumption during load operation


(380V / 460V)

[A]

Electric motor

399 / 306
IP55 , EISA 2007 (IE3)

Chart 9-11: Technical data; D160, 60Hz, air-cooled "A" and water-cooled "W" (European version)
80 / 100

GB

August 2013

Appendix
D160,

D160

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Rated speed

[rpm]

3560

Rated output fan motor

[kW]

{"A" = 2 x 3.9 (IP54)} ;


{"W" = 1 x 1.8 (IP54)}

Rated output oil pump

[kW]

0.66 (IP-54)

Rated output coolant pump

[kW]

1.1 (IP-54)

Recommended cable cross-section (380V /


460V)

[mm]

2 x 3 x 95 PE95 / 2 x 3 x 70 PE70

Recommended fuse rating (time-delayed)

[A]

Cooling air volume flow

[m/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K


@p=0.7 bar)

[l/min]

170 @p=1.3 bar

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

6 x 250 / 6 x 200
("A" = 349) ; ("W" = 95)
"A"=27
90 / 50 [35 C / 40C]

Cooling water connections


Total oil quantity

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

24

Compressed air connection

Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3644 , "W"=3844
2597 x 1744 x 2001

Chart 9-11: Technical data; D160, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.10

D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

D110 RS,

D110 RS

D110 RS

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

8,0

10,0

Minimum operating pressure

[bar]

4,0

4,0

Ambient temperature

[C]

2 / 45

2 / 40

min
speed
Volume flow rate / final pressure [bar]

[m/min]

9,06 / 6

max.
speed

min
speed

max.
speed

19.42 / 6 10.77 / 6 17.58 / 6

Chart 9-12: Technical data; D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

August 2013

GB

81 /100

Appendix

D110 RS,

D110 RS

D110 RS

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Volume flow rate / final pressure [bar]

[m/min]

8,97 / 7

19.37 / 7 10.64 / 8 17.47 / 8

Volume flow rate / final pressure [bar]

[m/min]

8.89 / 8

19.32 / 8

After cooler outlet temperature above ambient


temperature

"A" [C]

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (according to ISO 2151) at


70% load / 100% load

"A" [dB(A)]

76 / 78

76 / 78

Sound pressure level (according to ISO 2151) at


70% load / 100% load

"W" [dB(A)]

73 / 76

72 / 75

Rated output electric motor

[kW]

Total power consumption during load operation


(380V / 460V)

[A]

Electric motor

10.51 /
10

17.37 /
10

110
264 / 200

264 / 199

IP55 , EISA 2007 (IE3)

Rated speed min. / max.

[rpm]

Rated output fan motor

[kW]

{"A" = 2 x 3.9 (IP54)} ;


{"W" = 1 x 1.8 (IP54)}

Rated output oil pump

[kW]

0.66 (IP-54)

Rated output coolant pump

[kW]

1.1 (IP-54)

Recommended cable cross-section (380V +


400V)

[mm]

3 x 150 PE95 / 3 x 95 PE95

Recommended fuse rating (time-delayed) (380V


+ 400V)

[A]

Cooling air volume flow

[m/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K)

[l/min]

132 @p=1.0 bar

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

1909 / 3600

2417 / 3630

3 x 315 / 3 x 250
("A" = 349) ; ("W" = 95)
"A"=22
120 / 40 [35
C / 45 C]

120 / 85 [35
C / 40 C]

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Chart 9-12: Technical data; D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

82 / 100

GB

August 2013

Appendix
D110 RS,

D110 RS

D110 RS

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3278 ; "W"=3478
2597 x 1744 x 2001

Chart 9-12: Technical data; D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.11

D132 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

D132 RS,

D132 RS

D132 RS

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

8,0

10,0

Minimum operating pressure

[bar]

4,0

4,0

Ambient temperature

[C]

2 / 45

2 / 40

min
speed

max.
speed

min
speed

max.
speed

Volume flow rate / final pressure [bar]

[m/min]

9.13 / 6

22.82 / 6 10.81 / 6 21.02 / 6

Volume flow rate / final pressure [bar]

[m/min]

9.03 / 7

22.75 / 7 10.66 / 8 20.93 / 8

Volume flow rate / final pressure [bar]

[m/min]

8.95 / 8

22.68 / 8

After cooler outlet temperature above ambient


temperature

"A" [C]

12

10

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (according to ISO 2151) at


70% load / 100% load

"A" [dB(A)]

77 / 79

77 / 79

Sound pressure level (ISO 2151) at 70% load /


100% load

"W" [dB(A)]

74 / 79

72 / 76

Rated output electric motor

[kW]

Total power consumption during load operation


(380V / 460V)

[A]

Electric motor

10.51 /
10

20.85 /
10

132
302 / 226

302 / 227

IP55 , EISA 2007 (IE3)

Rated speed min. / max.

[rpm]

1550 / 3380

1959 / 3500

Rated output fan motor

[kW]

{"A" = 2 x 3.9 (IP54)} ;


{"W" = 1 x 1.8 (IP54)}

Rated output oil pump

[kW]

0.66 (IP-54)

Rated output coolant pump

[kW]

1.1 (IP-54)

Recommended cable cross-section (380V +


400V)

[mm]

3 x 150 PE95 / 3 x 95 PE95

Recommended fuse rating (time-delayed) (380V


+ 400V)

[A]

3 x 315 / 3 x 250

Chart 9-13: Technical data; D132 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

August 2013

GB

83 /100

Appendix

D132 RS,

D132 RS

D132 RS

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Cooling air volume flow

[m/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K)

[l/min]

155 @p=1.2 bar

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

("A" = 349) ; ("W" = 95)


"A"=26
110 / 25 [35
C / 45 C]

110 / 80 [35
C / 40 C]

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3476 ; "W"=3676
2597 x 1744 x 2001

Chart 9-13: Technical data; D132 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.12

D160 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

D160 RS,

D160 RS

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Maximum operating pressure

[bar]

10,0

Minimum operating pressure

[bar]

4,0

Ambient temperature

[C]

2 / 40
min speed

max. speed

Volume flow rate / final pressure [bar]

[m3/min]

10.70 / 6

23.41 / 6

Volume flow rate / final pressure [bar]

[m3/min]

10.55 / 8

23.30 / 8

Volume flow rate / final pressure [bar]

[m3/min]

10.40 / 10

23.19 / 10

After cooler outlet temperature above ambient


temperature

"A" [C]

10

Aftercooler outlet temperature above ambient


temperature

"W" [C]

Sound pressure level (ISO 2151) at 70% load /


100% load

"A" [dB(A)]

77 / 79

Chart 9-14: Technical data; D160 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

84 / 100

GB

August 2013

Appendix
D160 RS,

D160 RS

60Hz, air-cooled "A" and water-cooled


"W" (European version)
Sound pressure level (ISO 2151) at 70% load /
100% load

"A" [dB(A)]

Rated output drive motor

[kW]

Total power consumption during load operation


(380V / 460V)

[A]

Electric motor

74 / 79
160
385 / 258
IP55 , EISA 2007 (IE3)

Rated speed drive motor

[rpm]

1687 / 3320

Rated output fan motor

[kW]

{"A" = 2 x 3.9 (IP54)} ;


{"W" = 1 x 1.8 (IP54)}

Rated output oil pump

[kW]

0.66 (IP54)

Rated output cooling water pump

[kW]

1.1 (IP54)

Recommended cable cross-section (380V +


460V)

[mm2]

3 x 185 PE95 / 3 x 150 PE95

Recommended fuse rating (time-delayed) (380V


+ 460V)

[A]

Cooling air volume flow

[m3/min]

Cooling air outlet temperature above ambient


temperature

[C]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[l]

"A" = 30 ; "W" = 20

Cooling water volume, external (@T=15K)

[l/min]

170 @p=1.3 bar

Cooling water inlet temperature, external

[C]

min. = 5 ; max. = 42

Cooling water outlet temperature, external

[C]

57

Cooling water pressure

[bar]

Cooling water connections


Total oil quantity

3 x 400 / 3 x 315
("A" = 349) ; ("W" = 95)
"A" = 29
90 / 50 [35 C / 40 C]

EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[l]

Compressed air connection

24
Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16

Condensate drain

5 x G1/2"

Weight

[kg]

Dimensions L x B x H

[mm]

"A"=3688 ; "W"=3888
2597 x 1744 x 2001

Chart 9-14: Technical data; D160 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)

August 2013

GB

85 /100

Appendix

9.6.13

D75 + D90, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

D75 + D90,

D75

D90

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Maximum operating pressure

[psig]

116

145

116

145

Minimum operating pressure

[psig]

Ambient temperature

[F]

Volume flow

[cfm]

After cooler outlet temperature above ambient


temperature

"A" [F]

Aftercooler outlet temperature above ambient


temperature

"W" [F]

11

13

13

14

Sound pressure level (according to ISO 2151)

"A" [dB(A)]

76

75

77

76

Sound pressure level (according to ISO 2151)

"W" [dB(A)]

73

71

74

73

Rated output electric motor

[hp]

100

125

Total power consumption during load operation


(460V / 575V)

[A]

152 / 128

173 / 155

58
36 / 113

36 / 104

36 / 113

36 / 104

438

383

562

464

13

Electric motor

15

IP55 , EISA 2007 (IE3)

Rated speed

[rpm]

Rated output fan motor

[hp]

{"A" = 2 x 1.9 (IP54)} ;


{"W" = 1 x 2.5 (IP54)}

Rated output oil pump

[hp]

0.9 (IP-54)

Rated output cooling water pump

[hp]

1.5 (IP-54)

Recommended cable cross-section (460V /


575V)

3560

AWG 3/0 / AWG


2/0 (single supply)

AWG 4/0 / AWG


3/0 (single supply)

175 / 150

225 / 175

Recommended fuse rating (time-delayed) (460V


+ 575V)

[A]

Cooling air volume flow

[cfm]

("A" = 7946) ; ("W" = 3354)

Cooling air outlet temperature above ambient


temperature

[F]

"A"=34

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[gal]

Cooling water volume, external (@T=15K)

[gal/min]

Cooling water inlet temperature, external

[F]

min. = 41 ; max. = 107

Cooling water outlet temperature, external

[F]

134

Cooling water pressure

[psig]

115

Cooling water connections


Total oil quantity

45 / 20
[95 F /
113 F]

"A"=42

45 / 35
[95F /
104F]

40 / 15
[95 F /
113 F]

40 / 30
[95F /
104F]

"A" = 8 ; "W" = 5.3


23 @p=10psi

29 @p=13psi

1 1/4 - 11 1/2 NPT


[gal]

6.4

Chart 9-15: Technical data; D75 + D90, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

86 / 100

GB

August 2013

Appendix
D75 + D90,

D75

D90

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Compressed air connection

Flange 3" ANSI B16.5

Condensate drain

5 x 1/2 NPT

Weight

[lbs]

Dimensions L x B x H

[inch]

"A"=6665 ;
"W"=7105

"A"=7125 ;
"W"=7546

102.2 x 68.7 x 78.8

Chart 9-15: Technical data; D75 + D90, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.14

D110 + D132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

D110 + D132,

D110

D132

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Maximum operating pressure

[psig]

Minimum operating pressure

[psig]

Ambient temperature

[F]

Volume flow

[cfm]

After cooler outlet temperature above ambient


temperature

"A" [F]

Aftercooler outlet temperature above ambient


temperature

"W" [F]

13

14

14

14

Sound pressure level (according to ISO 2151)

"A" [dB(A)]

78

78

79

79

Sound pressure level (according to ISO 2151)

"W" [dB(A)]

76

75

78

77

Rated output electric motor

[hp]

150

180

Total power consumption during load operation


(460V / 575V)

[A]

227 / 189

257 / 214

Electric motor

116

145

116

145

58
36 / 113

36 / 104

36 / 113

36 / 104

671

596

798

742

20

18

IP55 , EISA 2007 (IE3)

Rated speed

[rpm]

Rated output fan motor

[hp]

{"A" = 2 x 5.3 (IP54)} ;


{"W" = 1 x 2.5 (IP54)}

Rated output oil pump

[hp]

0.9 (IP-54)

Rated output coolant pump

[hp]

1.5 (IP-54)

Recommended cable cross-section (460V /


575V)

3580

AWG 2/0 / AWG


AWG 3/0 / AWG
1/0 (double supply) 2/0 (double supply)

Recommended fuse rating (time-delayed) (460V


+ 575V)

[A]

150 / 125

175 / 150

Cooling air volume flow

[cfm]

("A" = 12325) ; ("W" = 3354)

Cooling air outlet temperature above ambient


temperature

[F]

"A"=40

"A"=45

Chart 9-16: Technical data; D110 + D132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

August 2013

GB

87 /100

Appendix

D110 + D132,

D110

D132

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[gal]

Cooling water volume, external (@T=15K)

[gal/min]

Cooling water inlet temperature

[F]

min. = 41 ; max. = 107

Cooling water outlet temperature

[F]

134

Cooling water pressure

[psig]

115

Cooling water connections


Total oil quantity

120 / 40
[95 F /
113 F]

120 / 85
[95F /
104F]

110 / 25
[95 F /
113 F]

110 / 80
[95F /
104F]

"A" = 8 ; "W" = 5.3


35 @p=15psi

41 @p=18psi

1 1/4 - 11 1/2 NPT


[gal]

Compressed air connection

6.4
Flange 3" ANSI B16.5

Condensate drain

5 x 1/2 NPT

Weight

[lbs]

Dimensions L x B x H

[inch]

"A"=7198 ;
"W"=7639

"A"=7566 ;
"W"=8007

102.2 x 68.7 x 78.8

Chart 9-16: Technical data; D110 + D132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.15

D160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

D160,

D160

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Maximum operating pressure

[psig]

145

Minimum operating pressure

[psig]

58

Ambient temperature

[F]

Volume flow

[cfm]

796

After cooler outlet temperature above ambient


temperature

"A" [F]

20

Aftercooler outlet temperature above ambient


temperature

"W" [F]

14

Sound pressure level (according to ISO 2151)

"A" [dB(A)]

79

Sound pressure level (according to ISO 2151)

"W" [dB(A)]

78

Rated output electric motor

[hp]

215

Total power consumption during load operation


(460V / 575V)

[A]

306 / 258

Electric motor

36 / 104

IP55 , EISA 2007 (IE3)

Rated speed

[rpm]

Rated output fan motor

[hp]

3560
{"A" = 2 x 5.3 (IP54)} ;
{"W" = 1 x 2.5 (IP54)}

Chart 9-17: Technical data; D160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

88 / 100

GB

August 2013

Appendix
D160,

D160

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Rated output oil pump

[hp]

0.9 (IP-54)

Rated output coolant pump

[hp]

1.5 (IP-54)

Recommended cable cross-section (460V /


575V)

AWG 4/0 / AWG 3/0 (double supply)

Recommended fuse rating (time-delayed)

[A]

200 / 175

Cooling air volume flow

[cfm]

Cooling air outlet temperature above ambient


temperature

[F]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[gal]

Cooling water volume, external (@T=15K)

[gal/min]

Cooling water inlet temperature

[F]

min. = 41 ; max. = 107

Cooling water outlet temperature

[F]

134

Cooling water pressure

[psig]

115

("A" = 12325) ; ("W" = 3354)


"A"=49
90 / 50 [95 F / 104 F]
"A" = 8 ; "W" = 5.3
45 @p=19psi

Cooling water connections


Total oil quantity

1 1/4 - 11 1/2 NPT


[gal]

6.4

Compressed air connection

Flange 3" ANSI B16.5

Condensate drain

5 x 1/2 NPT

Weight

[lbs]

"A"=8034 ; "W"=8475

Dimensions L x B x H

[inch]

102.2 x 68.7 x 78.8

Chart 9-17: Technical data; D160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.16

D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

D110 RS,

D110 RS

D110 RS

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Maximum operating pressure

[psig]

116

145

Minimum operating pressure

[psig]

58

58

Ambient temperature

[F]

36 / 113

36 / 104

min
speed

max.
speed

min
speed

max.
speed

686 / 87

380 / 87

620 / 87

Volume flow rate / final pressure [psig]

[cfm]

320 / 87

Volume flow rate / final pressure [psig]

[cfm]

317 / 102 684 / 102 375 / 116 617 / 116

Volume flow rate / final pressure [psig]

[cfm]

314 / 116 682 / 116 371 / 145 613 / 145

After cooler outlet temperature above ambient


temperature

"A" [F]

14.4

12.6

Chart 9-18: Technical data; D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

August 2013

GB

89 /100

Appendix

D110 RS,

D110 RS

D110 RS

13

14

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Aftercooler outlet temperature above ambient
temperature

"W" [F]

Sound pressure level (according to ISO 2151)

"A" [dB(A)]

76 / 78

76 / 78

Sound pressure level (according to ISO 2151)

"W" [dB(A)]

73 / 76

72 / 75

Rated output electric motor

[hp]

Total current consumption during load operation


(460V)

[A]

Electric motor

150
200

199

IP55 , EISA 2007 (IE3)

Rated speed min. / max.

[rpm]

Rated output fan motor

[hp]

{"A" = 2 x 5.3 (IP54)} ;


{"W" = 1 x 2.5 (IP54)}

Rated output oil pump

[hp]

0.9 (IP-54)

Rated output cooling water pump

[hp]

1.5 (IP-54)

Recommended cable cross-section (380V +


400V)

1909 / 3600

2417 / 3630

MCM 250 (single supply)

Recommended fuse rating (time-delayed) (460V) [A]

225

Cooling air volume flow

[cfm]

Cooling air outlet temperature above ambient


temperature

[F]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[gal]

Cooling water volume, external (@T=15K)

[gal/min]

Cooling water inlet temperature, external

[F]

min. = 41 ; max. = 107

Cooling water outlet temperature, external

[F]

134

Cooling water pressure

[psig]

115

Cooling water connections


Total oil quantity

("A" = 12325) ; ("W" = 3354)


"A"=47
120 / 40 [95
F / 113 F]

120 / 85 [95
F / 104 F]

"A" = 8 ; "W" = 5.3


35 @p=15psi

1 1/4 - 11 1/2 NPT


[gal]

Compressed air connection

6.4
Flange 3" ANSI B16.5

Condensate drain

5 x 1/2 NPT

Weight

[lbs]

"A"=7227 ; "W"=7668

Dimensions L x B x H

[inch]

102.2 x 68.7 x 78.8

Chart 9-18: Technical data; D110 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

90 / 100

GB

August 2013

Appendix
9.6.17

D132 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

D132 RS,

D132 RS

D132 RS

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Maximum operating pressure

[psig]

116

145

Minimum operating pressure

[psig]

58

58

Ambient temperature

[F]

36 / 113

36 / 104

min
speed

max.
speed

min
speed

max.
speed

806 / 87

382 / 87

742 / 87

Volume flow rate / final pressure [psig]

[cfm]

322 / 87

Volume flow rate / final pressure [psig]

[cfm]

319 / 102 803 / 102 376 / 116 739 / 116

Volume flow rate / final pressure [psig]

[cfm]

316 / 116 801 / 116 371 / 145 736 / 145

After cooler outlet temperature above ambient


temperature

"A" [F]

21.5

18

Aftercooler outlet temperature above ambient


temperature

"W" [F]

14

16

Sound pressure level (according to ISO 2151) at


70% load / 100% load

"A" [dB(A)]

Sound pressure level (according to ISO 2151) at


70% load / 100% load

"W" [dB(A)]

Rated output electric motor

[hp]

Total current consumption during load operation


(460V)

[A]

Electric motor

77 / 79
74 / 79

73 / 77
180

226

227

IP55 , EISA 2007 (IE3)

Rated speed min. / max.

[rpm]

Rated output fan motor

[hp]

{"A" = 2 x 5.3 (IP54)} ;


{"W" = 1 x 2.5 (IP54)}

Rated output oil pump

[hp]

0.9 (IP-54)

Rated output coolant pump

[hp]

1.5 (IP-54)

Recommended cable cross-section (380V +


400V)

1550 / 3380

1559 / 3500

MCM 300 (single supply)

Recommended fuse rating (time-delayed) (460V) [A]


Cooling air volume flow

[cfm]

Cooling air outlet temperature above ambient


temperature

[F]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[gal]

Cooling water volume, external (@T=15K)

[gal/min]

Cooling water inlet temperature, external

[F]

250
("A" = 12325) ; ("W" = 3354)
"A"=47
110 / 25 [95
F / 113 F]

110 / 80 [95
F / 104 F]

"A" = 8 ; "W" = 5.3


41 @p=18psi
min. = 41 ; max. = 107

Chart 9-19: Technical data; D132 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

August 2013

GB

91 /100

Appendix

D132 RS,

D132 RS

D132 RS

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Cooling water outlet temperature, external

[F]

134

Cooling water pressure

[psig]

115

Cooling water connections


Total oil quantity

1 1/4 - 11 1/2 NPT


[gal]

Compressed air connection

6.4
Flange 3" ANSI B16.5

Condensate drain

5 x 1/2 NPT

Weight

[lbs]

"A"=7663 ; "W"=8104

Dimensions L x B x H

[inch]

102.2 x 68.7 x 78.8

Chart 9-19: Technical data; D132 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.18

D160 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

D160 RS,

D160 RS

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Maximum operating pressure

[psig]

145

Minimum operating pressure

[psig]

58

Ambient temperature

[F]

36 / 40
min speed

max. speed

Volume flow rate / final pressure [psig]

[cfm]

378 / 87

827 / 87

Volume flow rate / final pressure [psig]

[cfm]

373 / 116

823 / 116

Volume flow rate / final pressure [psig]

[cfm]

367 / 145

819 / 145

After cooler outlet temperature above ambient


temperature

"A" [F]

18

Aftercooler outlet temperature above ambient


temperature

"W" [F]

16

Sound pressure level (according to ISO 2151) at


70% load / 100% load

"A" [dB(A)]

77 / 79

Sound pressure level (according to ISO 2151) at


70% load / 100% load

"W" [dB(A)]

74 / 79

Rated output electric motor

[hp]

215

Total current consumption during load operation


(460V)

[A]

258

Electric motor

IP55 , EISA 2007 (IE3)

Rated speed min. / max.

[rpm]

1687 / 3320

Rated output fan motor

[hp]

{"A" = 2 x 5.3 (IP54)} ;


{"W" = 1 x 2.5 (IP54)}

Rated output oil pump

[hp]

0.9 (IP-54)

Rated output coolant pump

[hp]

1.5 (IP-54)

Chart 9-20: Technical data; D160 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
92 / 100

GB

August 2013

Appendix
D160 RS,

D160 RS

60Hz, air-cooled "A" and water-cooled


"W" (USA version)
Recommended cable cross-section (380V +
400V)

MCM 400 (single supply)

Recommended fuse rating (time-delayed) (460V) [A]

300

Cooling air volume flow

[cfm]

Cooling air outlet temperature above ambient


temperature

[F]

Residual pressure at ambient temperature

"A" [Pa]

Coolant volume, internal

[gal]

Cooling water volume, external (@T=15K)

[gal/min]

Cooling water inlet temperature, external

[F]

min. = 41 ; max. = 107

Cooling water outlet temperature, external

[F]

134

Cooling water pressure

[psig]

115

Cooling water connections


Total oil quantity

("A" = 12325) ; ("W" = 3354)


"A"=52
90 / 50 [95 F / 104 F]
"A" = 8 ; "W" = 5.3
45 @p=19psi

1 1/4 - 11 1/2 NPT


[gal]

Compressed air connection

6,4
Flange 3" ANSI B16.5

Condensate drain

5 x 1/2 NPT

Weight

[lbs]

"A"=8131 ; "W"=8572

Dimensions L x B x H

[inch]

102.2 x 68.7 x 78.8

Chart 9-20: Technical data; D160 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

August 2013

GB

93 /100

Appendix

Installation plan

141(A)

543(D)

1210(B)
317(B)
105(E)

1744

1578(C)
83(C)

146
243(F)

71(C)
1390(C)

155(E)

1265(CG)

220

92(E)

409(F)
359
324

45(A)

192
562(D)

910
220

750(CG)

77
14

680

390(E)
1002(A)

173(D)

320

320 320

975(B)

685(CG)

D75-D160(RS)-A

170(B)

9.7

320
2001

197

C
2599

D
B

[A]

Compressed air connection flange DIN 3"

[E]

Opening for power supply cable

[B]

Cooling air inlet

[F]

Condensate drain female thread G 1/2"

[C]

Cooling air outlet

[CG] Centre of gravity

[D]

Cooling air inlet (speed control) [option]

94 / 100

GB

August 2013

Appendix

D75-D160(RS)-W

141(A)

543(D)

1210(B)
317(B)
105(E)

155(E)

1265(CG)

220

975(B)

320
45(A)

192
562(D)

910
220

92(E)

750(CG)

77
14

680

390(E)
1002(A)

173(D)

320

320 320

170(B)

685(CG)

1744

477(C)

560

C
455(C)
2599

243(F)
197

210(G)

146

409(F)
359
324

143(G)

F
100

D
G

[A]

Compressed air connection flange DIN 3"

[E]

Opening for power supply cable

[B]

Cooling air inlet

[F]

Condensate drain female thread G 1/2"

[C]

Cooling air outlet

[G]

Cooling water connection

[D]

Cooling air inlet (speed control) [option]

[CG] Centre of gravity

August 2013

GB

95 /100

Appendix

min. 1000

89
9

8
69

67
2

min. 1000

76
1

899

67
2

8
69

min. 1000

7
78

min. 1000

96 / 100

GB

August 2013

Appendix

68.7

62.1(C)
3.3(C)

5.8
9.6(F)

2.8(C)
54.7(C)

15.4(E)
39.5(A)
4.1(E)

6.1(E)

38.4(B)

43.6(B)
12.5(B)

6.7(B)

49.8(CG)

8.7

3.6(E)

16.1(F)
14.1
12.8

1.8(A)

35.8
8.7

7.6
22.1(D)

12.6

78.8

6.8(D)
12.6

12.6 12.6

29.5(CG)

3
0.6

26.8

5.6(A)

21.4(D)

27(CG)

D75-D160(RS)-A

7.8

C
102.3

D
B

[A]

Compressed air connection flange 3 NPT

[E]

Opening, power supply cable

[B]

Cooling air inlet

[F]

Condensate drain female thread 1/2 NPT

[C]

Cooling air outlet

[CG] Centre of gravity

[D]

Cooling air inlet (speed control) [option]

August 2013

GB

97 /100

Appendix

D75-D160(RS)-W

5.6(A)

49.8(CG)

15.4(E)
39.5(A)

X
43.6(B)
12.5(B)
4.1(E)

3.6(E)

29.5(CG)

8.7

6.7(B)

1.8(A)

35.8
8.7

7.6
22.1(D)

3
0.6

26.8

38.4(B)

6.8(D)

12.6

12.6 12.6

12.6

78.8

27(CG)

21.6(D)

6.1(E)

68.7

18.8(C)

22

C
17.9(C)
102.3

9.6(F)
7.8

8.3(G)

5.8

16.1(F)
14.1
12.8

5.6(G)

F
3.9

D
G

[A]

Compressed air connection flange 3 NPT

[E]

Opening, power supply cable

[B]

Cooling air inlet

[F]

Condensate drain female thread 1/2 NPT

[C]

Cooling air outlet

[G]

Cooling water connection

[D]

Cooling air inlet (speed control) [option]

[CG] Centre of gravity

98 / 100

GB

August 2013

Appendix

min. 39.4

35
.4

.5
27

26
.5

min. 39.4

30

35.4

26
.5

.5
27

min. 39.4

31

min. 39.4

August 2013

GB

99 /100

Gardner Denver Deutschland GmbH


Argenthaler Str. 11
55469 Simmern
Germany
Tel. ++49 (0)6761 832-0
Homepage: www.compair.com
e-Mail: sales@compair.com

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