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Gardner Denver AirSmart ELECTRA-SAVER Operating And Service Manual

Stationary base-mounted compressor
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ELECTRA-SAVER
ELECTRA-SAVER II
STATIONARY BASE-MOUNTED
AirSmart™ CONTROLLER
DOMESTIC and INTERNATIONAL MODELS
EAQ99W – 125, 150, and 200 HP, 60 HZ
EBQ99R – 125, 150, and 200 HP, 60 HZ
EAU99AB – 200 HP, 60 HZ
EBU99H – 200 HP, 60 HZ
EAQ99W – 100, 125, and 150 HP, 50 HZ
EBQ99R – 125 and 150 HP, (93, 112 KW) 50 HZ
EAU99AB – 200 HP, (150 KW) 50 HZ
EBU99H – 200 HP, (150 KW) 50 HZ
SERVICE MANUAL
COMPRESSOR
(75, 93, 112 KW)
OPERATING AND
13-21-608
Version: 00
September 7, 2018
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Summary of Contents for Gardner Denver AirSmart ELECTRA-SAVER

  • Page 1 13-21-608 Version: 00 September 7, 2018 ELECTRA-SAVER ELECTRA-SAVER II STATIONARY BASE-MOUNTED COMPRESSOR AirSmart™ CONTROLLER DOMESTIC and INTERNATIONAL MODELS EAQ99W – 125, 150, and 200 HP, 60 HZ EBQ99R – 125, 150, and 200 HP, 60 HZ EAU99AB – 200 HP, 60 HZ EBU99H –...

  • Page 2: Maintain Compressor Reliability And Performance With

    3. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.

  • Page 3: Warning - Prohibition - Mandatory Label Information

    WARNING – PROHIBITION – MANDATORY LABEL INFORMATION Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment.
  • Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.

  • Page 5: Safety Precautions

    SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ............1 Instructions For Ordering Repair Parts/Remanufactured Airends.............. 1 Warning – Prohibition – Mandatory Label Information ................2 Safety Precautions ..........................4 Index ............................... 6 List Of Illustrations ...........................

  • Page 7: Index

    Index Addition Of Oil Between Changes ....55 Inlet Screen And Tube ........67 Aftercooler Piping ...........53 Inlet Valve ............33 Air Filter Element Life ........67 Installation For Cold Weather Operation ..16 Air Filter Vacuum Switch .........35 Installation, Section 2 ........13 Air Filter, Heavy Duty (Standard) ....66 Air Filter, Section 6 .........66 Lifting Unit ............
  • Page 8 Parallel Piping ..........22 Every Year ..........71 Piping Motor Lubrication ........71 Series ............21 Oil Separator ..........71 Power Supply ..........36 Service Check List Pressure Differential Gauging ......63 Air Filter ............71 Pressure Regulator .........34 Shuttle Valve ..........34 Prestart-Up Instructions ........24 Solenoid Valves Ivc And Ivo ......

  • Page 9: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ......................9 Figure 1-2 – Starter Box ........................10 Figure 1-3 – Control Box ........................10 Figure 1-4 – Compressor / Motor Side ....................11 Figure 1-5 – Cooler / Reservoir Side ...................... 11 Figure 1-6 –...

  • Page 10: Section 1, General Information

    GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR - The Gardner Denver Rotary Screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads.

  • Page 11: Figure 1-2 - Starter Box

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

  • Page 12: Figure 1-4 - Compressor / Motor Side

    Figure 1-4 – COMPRESSOR / MOTOR SIDE 200EDM797-A (Ref. Drawing) Figure 1-5 – COOLER / RESERVOIR SIDE 13-21-608 Page 11...

  • Page 13: Figure 1-6 - Air/Oil Flow Diagram

    202EDM797 (Ref. Drawing) Figure 1-6 – AIR/OIL FLOW DIAGRAM 13-21-608 Page 12...

  • Page 14: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passage of current.

  • Page 15: Figure 2-1 - Typical Compressor Room

    LOCATION - The compressor should be installed, whenever possible, in a clean, well-lighted, well- ventilated area with ample space all around for maintenance. Select a location that provides a cool, clean, dry source of air. In some cases it may be necessary to install the air filter at some distance from the compressor to obtain proper air supply.
  • Page 16 (.9 m) to the nearest obstruction above and on other sides of the unit. FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be made at a maximum 10°...

  • Page 17: Figure 2-3 - Cold Weather Installation

    Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000 SP lubricant. Monitor the unit carefully during start-up and operation to be sure it is functioning normally.

  • Page 18: Figure 2-4 - Inlet Line Lengths

    Refer to Engineering Data Sheet 13-9-411, available from an authorized Gardner Denver distributor, for the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit.
  • Page 19 When connecting two or more GD rotary screw units on a common manifold, each unit is isolated by the check valve in the unit discharge line. If a Gardner Denver rotary screw unit is connected to another compressor on a common manifold be sure the other compressor has a check valve in the line between the machine and the manifold.

  • Page 20: Figure 2-5 - Heat Exchanger (Oil Cooler) Approximate Water Flow

    HEAT EXCHANGER (INTERNATIONAL) Water Temperature to Heat Exchanger (l/s) Approximate Water Maximum Pressure Drop @ 32° C Water Flow Water Temperature (l/s) * Model 16° C 21° C 27° C 32° C (bar) EAQ99W 0.51 0.64 0.85 1.28 2.52 EAQ99W, 0.68 0.85 1.14...
  • Page 21 WATER PIPING (Water-Cooled Heat Exchanger Models Only) - On machines equipped with water- cooled heat exchangers, the water inlet and outlet connections are located in the unit base flange on the left side of the unit. It is mandatory that any water cooled unit be installed in a shelter heated to temperatures above freezing (32°...

  • Page 22: Figure 2-7 - Series Piping

    305EAQ797-A (Ref. Drawing) Figure 2-7 – SERIES PIPING SERIES PIPING ( ) - Water flow must be through aftercooler first for effective cooling of Figure 2-7 discharge air and is so piped on the standard water-cooled unit. 306EAQ797-A (Ref. Drawing) Figure 2-8 –...
  • Page 23 PARALLEL PIPING ( , page 21) - A separate water control valve is required to control the Figure 2-8 discharge air temperature. If a remote (externally mounted) water-cooled aftercooler is piped in parallel with the heat exchanger, provide a separate water control valve for the aftercooler and pipe separate inlet water lines to both the aftercooler and heat exchanger.
  • Page 24 For additional information refer to the motor manufacturer’s instructions. The following procedure should be used in regreasing: Stop the unit. Disconnect lockout and tagout the unit from the power supply. Remove the relief plug and free hole of hardened grease. Wipe lubrication fitting clean and add grease with a hand-operated grease gun.

  • Page 25: Section 3, Starting & Operating Procedures

    Compressor Oil - Check the oil level in the reservoir. Add oil only if the oil level gauge reads in the red “ADD OIL” range. Do not mix different type oils. Units are shipped filled with Gardner Denver AEON 9000 SP Lubricating Coolant which is suitable for the first 8000 hours under normal operating conditions.
  • Page 26 Piping - Refer to Section 2, “Installation", and make sure piping meets all recommendations. Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See Figure 4-14 and Figure 4-15 pages 44 thru 47 for general wiring diagrams and Section 2, for installation instructions.
  • Page 27 The compressor starts and stops automatically. Automatic restarting can cause injury or death. Open, lockout and tagout main disconnect and any other circuits before servicing the unit. STARTING THE UNIT - Observe the following starting procedures. Unit Cold - If the unit is a water-cooled heat exchanger model, open any manual water inlet valves wide open.
  • Page 28 Quick Start Guide Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run button to start the compressor, no other settings are required. The Target Pressure comes preset to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure setting is desired, the following steps can be used as a guide.
  • Page 29 To change the Target Pressure, press the Enter button to edit the value. OPERATION ADJUSTMENT TARGET PRESSURE 100 PSI (EDIT PARAMETER) A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the Plus and Minus buttons to change its value.

  • Page 30: Section 4, Controls & Instrumentation

    SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver Rotary Screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop air line (and to the appropriate water supply if water-cooled).

  • Page 31: Figure 4-1 - Key Pad

    Figure 4-1 – KEY PAD Relief Valve - A pressure relief valve(s) is (are) installed in the final discharge line and set to approximately 120-125% of the unit’s full load operating pressure for protection against over pressure. Periodic checks should be made to ensure its (their) operation. The relief valve should be tested for proper operation at least once every year.

  • Page 32: Figure 4-2 - Schematic Tubing Diagram

    Operation of the unit with improper relief valve setting can result in severe personal injury or machine damage. Ensure properly set valves are installed and maintained. 204EDM797 (Ref. Drawing) Figure 4-2 – SCHEMATIC TUBING DIAGRAM 13-21-608 Page 31...

  • Page 33: Figure 4-3 - Blowdown Valve

    Figure 4-3 – BLOWDOWN VALVE Blowdown Valve ( Figure 4-3 – BLOWDOWN VALVE ) - This valve normally is used for control functions, but also serves to relieve reservoir pressure following a shutdown. The blowdown valve is a two-way solenoid valve which is piped into the oil reservoir outlet ahead of the minimum pressure valve. When the solenoid is de-energized, the valve opens and the coolant system is blown down.

  • Page 34: Figure 4-5 - Inlet Valve

    To service the valve, make sure all pressure is relieved, disconnect the unit from the power supply, lockout and tagout, then unscrew the valve cap from the body. The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor. 208EDM797-A (Ref.

  • Page 35: Figure 4-6 - Shuttle Valve

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

  • Page 36: Figure 4-7 - Turn Valve - Electra-Saver Only

    213ECM797-A (Ref. Drawing) Figure 4 7 – TURN VALVE – ELECTRA-SAVER ONLY Turn Valve (Electra-Saver only) (Figure 4 7 )- The turn valve is a helical valve which, when rotated, opens and closes a series of ports cast into the compressor cylinder. When these ports are open, they direct some of the air which would otherwise be compressed back to the inlet, reducing both capacity and power consumption.
  • Page 37 Discharge Thermistor - This sensor is located directly in the compressor discharge. Its signal is used to monitor compressor temperature and shut down the compressor if a coolant problem is detected. Reservoir Thermistor - This sensor is located near the separator and is used to monitor temperature and shut down the compressor if high temperatures are detected.
  • Page 38 COMPRESSOR CAPACITY CONTROL - TURN VALVE UNITS ONLY The capacity of the compressor is controlled by the action of the turn valve and the compressor inlet valve. The turn valve controls compressor delivery to match demands of 40% to 100% of the compressor’s maximum capacity.

  • Page 39: Figure 4-8 - Control Schematic - Compressor Unloaded - Constant Speed Mode

    209EDM797-A (Ref. Drawing) Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – CONSTANT SPEED MODE EBQ & EBU UNITS ONLY...

  • Page 40: Figure 4-9 - Control Schematic - Compressor At Full Load - Constant Speed Mode

    211EDM797-A (Ref. Drawing) Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD – CONSTANT SPEED MODE EBQ & EBU UNITS ONLY...

  • Page 41: Figure 4-10 - Control Schematic - Compressor Unloaded - Low Demand Mode Or Auto Mode

    213EDM797-A (Ref. Drawing) Figure 4-10 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – LOW DEMAND MODE OR AUTO MODE EBQ & EBU UNITS ONLY...

  • Page 42: Figure 4-11 - Control Schematic - Compressor At Full Load

    210EDM797-A (Ref. Drawing) Figure 4-11 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD EAQ & EAU UNITS ONLY...

  • Page 43: Figure 4-12 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch Off

    212EDM797-A (Ref. Drawing) Figure 4-12 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF EAQ & EAU UNITS ONLY...

  • Page 44: Figure 4-13- Control Schematic - Compressor Fully Loaded - Low Demand Mode Switch On

    214EDM797-A (Ref. Drawing) Figure 4-13 – CONTROL SCHEMATIC – COMPRESSOR FULLY LOADED – LOW DEMAND MODE SWITCH ON EAQ & EAU UNITS ONLY...

  • Page 45: Figure 4-14 - Wiring Diagram - Wye Delta

    335EAQ546-A (Ref. Drawing) (Page 1 of 2) Figure 4-14 – WIRING DIAGRAM – WYE DELTA...
  • Page 46 335EAQ546-A (Ref. Drawing) (Page 2 of 2)

  • Page 47: Figure 4-15 - Wiring Diagram - Less Starter

    336EAQ546-A (Ref. Drawing) (Page 1 of 3) Figure 4-15 – WIRING DIAGRAM – LESS STARTER...
  • Page 48 336EAQ546-A (Ref. Drawing) Page 2 of 3...
  • Page 49 336EAQ546-A (Ref. Drawing) Page 3 of 3...

  • Page 50: Section 5, Lubrication, Oil Cooler, Oil Filter & Separator

    AEON lubricants are available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000SP lubricating coolant which can be used for year-round operation. AEON 9000SP is a synthetic, extended life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based lubricant.
  • Page 51 HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000 SP lubricating coolant will operate at a sustained discharge temperature up to 210° F (99° C). When unusually high ambient air temperature is encountered, lubricant life will be shortened, see , page 58.

  • Page 52: Figure 5-1 - Dew Point Chart °F

    Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 100 psig 125 psig 150 psig 175 psig Ambient Temp. F Figure 5-1 – DEW POINT CHART °F Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 6.9 bar 8.6 bar 10.4 bar 12.1 bar Ambient Temp.

  • Page 53: Figure 5-3 - Flow Diagram - Air/Oil System

    203EDM797-A (Ref. Drawing) Figure 5-3 – FLOW DIAGRAM – AIR/OIL SYSTEM...

  • Page 54: Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted Cooler

    204EAQ797-A (Ref. Drawing) 205EDM797 (Ref. Drawing) Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED COOLER 13-21-608 Page 53...

  • Page 55: Figure 5-5 - Cooler Drain Detail

    REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be disconnected after test and the vent fan motor connected in its place. The vent fan will be mounted in the enclosure.
  • Page 56 NOTICE When removing the cooling module from the package for remote operation, do not use the flexible coupling (when supplied) between the air/oil separator housing and the minimum pressure/check valve. The discharge piping from the air/oil separator housing should be piped into the minimum pressure/check valve, then into piping to the cooler, with a flexible connection between the minimum pressure/check valve and aftercooler to keep the weight of the piping off of the cooler.
  • Page 57 COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation,” Section 2. ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is in the red range on the gauge as read while the unit is on. To add oil, follow these steps: Be sure the unit is completely off and that no air pressure is in the oil reservoir.

  • Page 58: Figure 5-6 - Oil Level Gauge

    Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis program with AEON lubricants. The first sample from a new unit should be sent in after 100 hours.

  • Page 59: Figure 5-7 - Oil Change Interval

    Discharge AEON 4000 AEON 9000 SP Temperature Change Interval Change Interval 4000 hrs. 8000 hrs. Up to 180° F (82° C) 3000 hrs. 6000 hrs. 180° F to 190° F (82° C to 88° C) 2000 hrs. 4000 hrs. 190° F to 200° F (88° C to 93° C) 1000 hrs.

  • Page 60: Figure 5-8 - Approximate Oil System Capacities

    FILLING OIL RESERVOIR Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, lockout and tagout the power supply to the starter.
  • Page 61 COMPRESSOR OIL FILTER ( , page 52) - This screw on oil filter is a vital part in maintaining a Figure 5-3 trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is integrated into the replaced oil filter element. Improper oil filter maintenance will cause damage to equipment.

  • Page 62: Figure 5-9 - Thermostatic Mixing Valve Element

    Press the filter assembly into the filterstat assembly. Using a 1” socket tighten down the oil filter, until the o-ring seals. Do not overtighten. Run the unit and check for leaks. COMPRESSOR OIL COOLER - RADIATOR TYPE ( , page 11) - The oil cooler motor and fan is Figure 1-5 mounted on the oil cooler module;...

  • Page 63: Figure 5-10 - Water Control Valve

    COMPRESSOR OIL COOLER - WATER-COOLED HEAT EXCHANGER (Figure 5-3, page 52) - The heat exchanger oil cooler is a multiple pass type, with water in the tubes and oil in the shell. The oil temperature is controlled by the thermal (thermostatic mixing) valve. The optional water control valve may be used to conserve water.
  • Page 64 WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) (Figure 5-10, page 62) - The water flow control valve is adjustable to compensate for varying water inlet temperatures and pressures and is to be mounted in the water outlet line after the oil cooler (Figure 5-3, page 52). Use the compressor discharge air temperature gauge on the instrument panel in setting the flow control valve.

  • Page 65: Figure 5-11 - Oil Separator

    Figure 5-11 – OIL SEPARATOR COMPRESSOR (GD ELIMINATOR) OIL SEPARATOR located in a separate housing, consists of a renewable cartridge-type separator element and provides the final removal of oil from the air stream (Figure 5-11). Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity. Oil collected outside the element is returned through tubing to the compressor cylinder.
  • Page 66 Using an oil separator element at excessive pressure differential can cause damage to equipment. Replace the separator when the "Change Separator" advisory appears. NOTICE A sudden drop of zero pressure differential or sudden heavy oil carryover may indicate a ruptured element. Inspection - After removal of separator element, shine a light inside the element to reveal areas of heavy dirt or varnish deposits or breaks (ruptures) in the element media.
  • Page 67 COMPRESSOR OIL SYSTEM CHECK - The following readings are based on ambient temperature of 80° F (27° C) for air-cooled oil cooler and 80° F (27° C) inlet water on water-cooled oil cooler, with the system in good condition. Compressor should be at operating temperature at the time of checks. One- half hour of loaded operation is usually sufficient to reach level-out operating temperatures.

  • Page 68: Section 6, Air Filter

    Filter Element - Service the air filter element when the ”CHANGE AIR FILTER” LED is illuminated. Clean every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor.
  • Page 69 Inspect the element for ruptures or cracks in the pleated media; replace the element if any are found. Inspect the gasket on the bottom (outlet end) of the element; replace the entire element if the gasket is damaged. A spare element will keep down time to a minimum. Allow the element to air dry COMPLETELY.

  • Page 70: Section 7, Coupling

    SECTION 7 COUPLING Figure 7-1 – INSTALLATION OF COUPLING CUSHIONS Rotating machinery can cause personal injury or death. Turn the unit completely off, open the main disconnect, lockout and tagout before servicing the coupling. COUPLING - The motor and compressor are direct connected by a resilient type flexible coupling with a single cushion.
  • Page 71 ASSEMBLY OF COUPLING ONTO THE AIREND AND MOTOR (See Figure 7-1). NOTICE Elements with non-uniform cross sections must be mounted with the rotation arrow on the coupling the same direction as the rotation arrow on the airend. Incorrect rotation will greatly decrease the torque carrying capacity of the coupling.
  • Page 72 3. Apply a light oil or grease film to both sides of the hardened steel washer. This is very important, since it will significantly reduce the rubber stresses around the metal bushings when torquing down the cap screws. Place the supplied hardened washers under the cap screw heads and torque the screws down to the torque rating in the assembly instructions supplied with the coupling.

  • Page 73: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter - Operating conditions determine frequency of service. If the “CHANGE AIR FILTER” message is displayed, air filter requires servicing or changing. See “Air Filter", Section 6. Oil Separator - Operating conditions determine frequency of service. If the “CHANGE SEPARATOR” message is displayed, the oil separator element requires changing.
  • Page 74 MAINTENANCE SCHEDULE Maintenance Action As Indicated by Every Every Every Every AirSmart Every 8 1000 8000 * Year Controller Hours Hours Hours Hours · Change Air Filter ..............· · Change Oil Separator ............· Check Reservoir Oil Level ........... ·...

  • Page 75: Section 9, Troubleshooting

    SECTION 9 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate heaters tripped . cause of overload. Pressure in reservoir. Inspect blowdown valve. Read error message on Take appropriate action.
  • Page 76 SYMPTOM POSSIBLE CAUSE REMEDY Compressor starts too Wye Delta switch time set Contact your Champion slowly too long. distributor. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Compressor is low on Restricted air filter.
  • Page 77 NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13-21-608 Page 76...
  • Page 79 NOTES...
  • Page 80 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2018 Gardner Denver, Inc. Printed in U.S.A.

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