TM

Translation of the original operating

instructions
Screw compressor

EnviroAire T 75 - 160 V2
EnviroAire TVS 110 - 160 V2

GB ZS1101925 / 06 - August 2015

 TM

Contents

CONTENTS 5.2 Compressed air connection.................... 41

5.3 Cooling water connection........................42
1 Foreword........................................................ 4 5.4 Electrical connection............................... 43
1.1 About these operating instructions............4 5.5 Compressed air connection ejector
compressed air supply............................ 45
1.2 Notes......................................................... 5
1.3 Intended use............................................. 5
6 Commissioning and operating.................. 46
1.4 Intentional misuse..................................... 6
6.1 Initial commissioning............................... 46
1.5 Service...................................................... 6
6.1.1 Cooling water control in a water-cooled
1.6 Nameplate................................................. 7 compressor system................................. 48
6.2 Normal operation.................................... 50
2 Safety conditions.......................................... 8
6.3 Routine commissioning........................... 51
2.1 General safety instructions....................... 8
6.4 Commissioning after a long
2.2 Instructions about particular types of shutdown................................................. 51
danger....................................................... 8
6.5 Commissioning after a fault.................... 51
2.3 Protection and safety equipment.............. 9
2.4 Residual hazards.................................... 10 7 Troubleshooting.......................................... 52
2.5 Identification of safety instructions.......... 10 7.1 Reset safety temperature switch.............55
2.6 Safety sign.............................................. 10
2.7 Transport and positioning....................... 14 8 Maintenance and Service........................... 56
2.8 Normal operation.................................... 14 8.1 General information................................ 56
2.9 Special tasks...........................................15 8.2 Service.................................................... 58
2.10 Conversions and changes to the 8.3 Inspection of protection and safety
machine...................................................16 equipment................................................58
8.4 Routine maintenance.............................. 59
3 Design and function................................... 17
8.5 Maintenance plan....................................60
3.1 General description................................. 17 8.6 Maintenance work...................................64
3.2 Compressor design................................. 18 8.6.1 Accesses................................................. 64
3.3 System scheme air-cooled 8.6.2 Filter mat cooling air inlet........................65
compressor..............................................22
8.6.3 Inlet filter cooling air switch cabinet (VS
3.4 System scheme water-cooled compressors)...........................................65
compressor..............................................25
8.6.4 Condensate drain....................................66
3.5 Air circuit................................................. 29
8.6.5 Lubricating oil..........................................66
3.6 External water circuit.............................. 32
8.6.6 Ejector vent system................................ 68
3.7 Internal water circuit................................34
8.6.7 Cooling system....................................... 71
3.8 Oil circuit................................................. 35
8.6.8 ................................................................ 73
3.9 Ejector vent system................................ 36
8.6.9 Air Filter...................................................74
3.10 Control (automatic operation)................. 36
8.6.10 Control air filter....................................... 74

4 Transport and positioning..........................38 8.6.11 Drive motor / Lubricator.......................... 75

8.6.12 Control system........................................ 76
4.1 Transport................................................. 38
4.2 Storage....................................................38
9 Appendix...................................................... 77
4.3 Positioning...............................................38
9.1 Shutdown................................................ 77

5 Preparations for commissioning............... 41 9.2 Lubricants and additives......................... 77

9.3 Removal.................................................. 77
5.1 Pipelines..................................................41
9.4 Disposal...................................................78

2 / 112 GB July 2015

 TM

Contents

9.5 Limit values of dissolved matter..............79

9.6 Technical Specification............................80
9.6.1 EnviroAire T 75 + T 90, 50Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................80
9.6.2 EnviroAire T 110 + T 132, 50Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................81
9.6.3 EnviroAire T 160, 50Hz, air-cooled "A" and
water-cooled "W" (European version)..... 82
9.6.4 EnviroAire TVS 110, 50Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................84
9.6.5 EnviroAire TVS 132, 50Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................85
9.6.6 EnviroAire TVS 160, 50Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................86
9.6.7 EnviroAire T 75 + T 90, 60Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................88
9.6.8 EnviroAire T 110 + T 132, 60Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................89
9.6.9 EnviroAire T 160, 60Hz, air-cooled "A" and
water-cooled "W" (European version)..... 90
9.6.10 EnviroAire TVS 110, 60Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................92
9.6.11 EnviroAire TVS 132, 60Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................93
9.6.12 EnviroAire TVS 160, 60Hz, air-cooled
"A" and water-cooled "W" (European
version)....................................................94
9.6.13 EnviroAire T 75 + T 90, 60Hz, air-
cooled "A" and water-cooled "W" (USA
version)....................................................96
9.6.14 EnviroAire T 110 + T 132, 60Hz, air-
cooled "A" and water-cooled "W" (USA
version)....................................................97
9.6.15 EnviroAire T 160, 60Hz, air-cooled "A" and
water-cooled "W" (USA version)............. 98
9.6.16 EnviroAire TVS 110, 60Hz, air-cooled "A"
and water-cooled "W" (USA version).... 100
9.6.17 EnviroAire TVS 132, 60Hz, air-cooled "A"
and water-cooled "W" (USA version).... 101
9.6.18 EnviroAire TVS 160, 60Hz, air-cooled "A"
and water-cooled "W" (USA version).... 102
9.7 Installation plan..................................... 104
9.8 Declaration of conformity...................... 110

July 2015 GB 3 /112

 TM

1 Foreword

1 FOREWORD These operating instructions are written for operat-

ing- and maintenance personnel.
Gardner Denver screw compressors are the prod-
uct of years of research and development. This The basis of these operating instructions are the
experience in conjunction with high quality require- master operating instructions ZS1101916 /02,
ments ensures that the manufactured screw com- which are relevant for translations of the operating
pressors are long-lasting, providing guaranteed re- instructions.
liability and economic operation.
These operating instructions are an inherent part
Equally, the stringent requirements for environ- of the compressor. They must be available and ac-
mental protection are also met. cessible near the compressor at all times.

1.1 About these operating These operating instructions provide you with all
instructions the information you need for safe operation and
maintenance of the compressor. This includes:
These operating instructions apply for the follow- Installation and connection of the compressor
ing compressors from Gardner Denver Deutsch-
land GmbH: Commissioning and operation of the compres-
sor
EnviroAire T 75-8A V2
Replacement of wear parts and consumables
EnviroAire T 75-10A V2 such as filters or oil
EnviroAire T 90-8A V2 Identification of faults and rectification of mal-
EnviroAire T 90-10A V2 functions

EnviroAire T 110-8A V2 Carrying out of visual inspections for damage

on a rotational basis
EnviroAire TVS 110-8A V2
Cleaning, maintenance and repair of the com-
EnviroAire T 110-10A V2 pressor
EnviroAire TVS 110-10A V2 The dealer's or manufacturer's workshop, with its
EnviroAire T 132-8A V2 qualified and experienced personnel, is respon-
sible for all maintenance work that goes beyond
EnviroAire TVS 132-8A V2 customary service work and requires specialist
EnviroAire T 132-10A V2 technical knowledge.
EnviroAire TVS 132-10A V2 All pressures given in these operating instructions
are, where not otherwise specified, positive pres-
EnviroAire T 160-10A V2 sures (gauge pressures).
EnviroAire TVS 160-10A V2
Target groups
EnviroAire T 75-8W V2
The target groups for these operating instructions
EnviroAire T 75-10W V2 are operators, maintenance personnel and electri-
EnviroAire T 90-8W V2 cians.

EnviroAire T 90-10W V2 After training, the operator is permitted to start up

and shut down the compressor and activate the
EnviroAire T 110-8W V2 emergency-stop.
EnviroAire TVS 110-8W V2 Maintenance personnel may, in conjunction with
EnviroAire T 110-10W V2 the information in these operating instructions,
maintain the compressor, repair it, start it up and
EnviroAire TVS 110-10W V2 shut it down and activate the emergency-stop.
EnviroAire T 132-8W V2 Electricians may electrically install the compres-
EnviroAire TVS 132-8W V2 sor, carry out direction of rotation checks and carry
out electrical maintenance work.
EnviroAire T 132-10W V2
EnviroAire TVS 132-10W V2 Safety conditions
Alongside all the other details in these operating
EnviroAire T 160-10W V2
instructions, the general safety instructions, in the
EnviroAire TVS 160-10W V2 chapter "Safety Conditions", must be read without
fail.

4 / 112 GB July 2015

 TM

Foreword 1

1.2 Notes Copyright

General information These operating instructions are subject to copy-

right and may only be used for the agreed pur-
The operating instructions must be read and used pose, i.e. as a reference for in-plant purposes.
by every person who is assigned to work with and
on the compressor. Forwarding or reproduction of this document, ex-
ploitation and sharing of its content are forbid-
Irrespective of these operating instructions, the den, insofar as this is not expressly authorised.
laws, regulations, directives and standards applic- Infringements will incur payment of compensa-
able in the place of use must be observed. tion. All rights reserved for the case of granting of
a patent, petty-patent or design registration.
Training
The provision of local operator training is under- Reselling
taken by authorised service technicians. The train- If the compressor is resold, these operating in-
ing documentation comprises these operating in- structions must be handed over to the new oper-
structions and the repair manual, which is only is- ator together with the compressor. If necessary,
sued as part of service training. the operating instructions must be reordered from
These measures ensure that the assigned work Gardner Denver by specification of the order con-
can be reliably carried out. firmation number. The compressor must not under
any circumstances be resold without these operat-
Warranty ing instructions.
Gardner Denver Deutschland GmbH will not be
held liable for the safe functioning of the compres- 1.3 Intended use
sor if it used other than for its normal use or for The compressor conforms to the state of the art
purposes not listed in the operating instructions. and the applicable safety conditions at the time of
Gardner Denver Deutschland GmbH excludes all its bringing to market provided it is used for its in-
warranty and liability in the event of: tended purpose.
Operating errors. From a design point of view, neither intentional
misuse nor all of the residual dangers can be
Use of the compressor for other than the in- avoided, without limiting the intended functionality.
tended purpose.
The compressor is designed for the compression
Damage resulting from deliberate misuse or of atmospheric oil-free air (compressed air for dri-
non-observance of the operating instructions. ving pressure equipment) the compressor is not
Damage or injuries caused by non-OEM com- suitable for the compression of other gases.
ponents.
The compressor is only classed as being used for
Use of spare or wear parts or operating fluids its intended purpose if the following points are also
that do not originate from or are not currently observed:
recommended by or have not been previously
The compressor is used according to these op-
recommended by Gardner Denver Deutschland
erating instructions.
GmbH.
The working steps and standard operating pro-
Inadequate maintenance.
cedures of the operator are followed.
Compressor conversions.
Any other use or use beyond this is defined as
Warranty and liability conditions of the general non-intended use. The manufacturer is not liable
business conditions of Gardner Denver Deutsch- for any resulting damage. The user alone bears
land GmbH are not expanded by the aforesaid in- the risk.
formation. Intended use also includes observation of the op-
erating instructions and adherence to the inspec-
Guarantee
tion and maintenance instructions.
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 retrospec-
tively.

July 2015 GB 5 /112

 TM

1 Foreword

Other conditions 1.4 Intentional misuse

Danger to life and limb of the user or third parties Incorrect use and misuse
can arise from use of the compressor; likewise
damage to the compressor or other material can The following typical reasonably foreseeable mis-
arise if the compressor: uses (incorrect uses) are classed as contrary to
the intended use:
Is not used as intended.
Compression of gases other than atmospheric
Is not operated by trained personnel. air.
Is changed or modified. Operation outside the permissible operating
The safety instructions are not observed. limits, even if the exceeding of the limits is only
temporary or not immediately identifiable.
Alongside these operating instructions, the follow- Operation outside the permissible ambient tem-
ing apply: peratures.
Relevant accident prevention regulation Extraction of non-atmospheric air (overpres-
Generally recognised safety rules sure or vacuum pressure).

Country-specific conditions Use as a breathing air compressor.

Manipulation of sensor signals.
Installation location / installation altitude
Signal modification of sensors.
The compressor is intended for installation in a
suitable compressor room. The compressor is not Operation without protection and safety equip-
suitable for open-air installation! ment.

The permissible installation altitude of the com- Operation with defective, deactivated or ma-
pressor is limited dependent on the operating nipulated protection and safety equipment or
pressure, ambient humidity and ambient tempera- safety valves, or operation with other such
ture at which it is operated. The permissible instal- safety relevant defects.
lation altitude is specified for each individual case Use by private users or users without technical
by consultation between the customer and Gard- training.
ner Denver. Operation outside industrial environments.
Working environment Non-adherence to maintenance intervals.
The illumination in the region of the compressor Omission of maintenance and repair work.
must be ≥ 200 lx during normal operation.
Incorrect execution of maintenance and repair
The illumination for inspection and repair work work.
must be ≥ 500 lx.
Ambient temperature for operation: see "Technical Limitations on use
data". Operation of the compressor is not permitted
Pressure equipment outside the permissible ambient temperatures.
For pressure equipment/systems a pressure re- above the permitted altitude of the installation
lief device (safety valve or similar) dimensioned to location.
match the weakest pressure carrying component on an insufficiently load-bearing substrate.
and conforming to the relevant regulations must
be installed in the compressed air system. in areas with an explosive atmosphere.

1.5 Service
If you have any questions about or problems with
the compressor please contact your responsible
Gardner Denver agency.
The trained specialised personnel will ensure you
receive quick and proper assistance.

6 / 112 GB July 2015

 TM

Foreword 1

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. Specifi-
cation of this data will ensure that you receive the
correct information and/or spare parts.

Your Gardner Denver Deutschland GmbH

agency
Please enter the details of your local Gardner
Denver agency in the following table.
Name:
Contact:
Address:

Phone
Fax
Email:

Chart 1-1: Local Gardner Denver agency

1.6 Nameplate

Fig. 1-2: Nameplate

Fig. 1-1: Nameplate

July 2015 GB 7 /112

 TM

2 Safety conditions

2 SAFETY CONDITIONS The intervals between tests and inspections

must be adhered to.
Any person who is involved with the operation,
maintenance or repair of the compressor, must The operating instructions must be supple-
read and follow the safety conditions. mented with instructions for the observation of
operating peculiarities including monitoring and
Gardner Denver Deutschland GmbH accepts no reporting obligations, e.g. in respect of working
responsibility for material damage or injuries that organisation, working processes, responsibili-
arise from non-observation of safety conditions or ties, etc.
the failure to observe normal levels of care and at-
tention, even where this is not expressly stated in Personnel selection and qualification; funda-
these operating instructions. mental responsibilities
Only reliable and authorised personnel may work
2.1 General safety instructions on the compressor.
Organisational measures
The authorised personnel must:
The following organisational measures contribute be trained by Gardner Denver.
to the safe use of the compressor:
be trained according to its responsibilities, du-
Only appointed personnel may work on the ties and activities and instructed about the
compressor. The personnel have been trained compressor.
and briefed about the compressor.
have the physical and mental capabilities to
Before starting work, the personnel must have fulfil its responsibilities and carry out its duties
read the operating instructions, in particular the and activities on the compressor.
"Safety Conditions" chapter. Don’t leave this
until you start work – it’s too late. This applies have understood the operating instructions in
in particular to personnel who only work on the respect of its responsibilities, duties and activ-
machine occasionally, e.g. to carry out mainte- ities on the compressor and be able to practi-
nance. cally implement this.
The responsibilities of the personnel for oper- 2.2 Instructions about particular
ation, maintenance and repair must be clearly
defined.
types of danger
The safe and hazard-aware working of the per- Electrical energy
sonnel must be checked regularly.
DANGER
Personnel who are to be trained in, taught
about or instructed as part of a general training Electric shock
course, must only work on the compressor un-
Life-threatening electric shock
der the constant supervision of an authorised
person. ➯ When carrying out any work on the
electrical equipment, exercise ex-
If safety-relevant changes are made to com-
treme care.
pressor or arise in its operating behaviour, the
compressor must be immediately shutdown ➯ Before starting the maintenance
and the fault reported to the responsible post/ work, switch the compressor to a
person. voltage-free state and secure to pre-
vent switching back on.
Faults, especially those that could impair
safety, must be immediately rectified. Other- For all work on the electrical equipment of the
wise the compressor must not be operated. compressor the 5 safety rules for working on elec-
All danger signs on and in the surroundings of trical equipment must be observed.
the compressor must be regularly checked for
completeness and legibility. Missing danger
signs must be immediately replaced.

8 / 112 GB July 2015

 TM

Safety conditions 2

Moreover, the following instructions must be ob- Heating connection option

served:
Only a qualified electrician following elec- DANGER
trotechnical regulations may carry out work on Risk of bursting, risk of burns
the electrical equipment of the compressor.
The compressed air outlet temperature
The compressor's electrical equipment must be can be up to 235°C.
checked regularly. Defects such as loose con-
nections or charred cables must be rectified im- ➯ The burst strength of the following
mediately. components of the supply line (cus-
tomer network) must be suitable for
Only original fuses of the specified current rat- these temperatures.
ing may be used.
➯ Secure the supply line to prevent
Only for VS compressors: contact.
Due to the residual voltage on the capacitors, a Legionella formation with water-cooled com-
waiting time of at least 10 minutes must elapse pressors and an open cooling circuit
after switching to a zero volts state (main switch
OFF) before the switch cabinet can be opened. WARNING
Observe the danger sign on the switch cabinet!
See table "Safety signs". Legionella contamination

Noise Health risk with open cooling systems.

The sound pressure level without the sound-proof- ➯ Constant testing of the water quality
ing enclosure is 110 dB(A). Remaining for long pe- in the cooling circuit for the number
riods alongside the compressor without its sound- of microbes.
proofing enclosure can result in irreversible hear-
ing impairment. 2.3 Protection and safety
Only operate the compressor without the sound- equipment
proofing enclosure during test runs. Wear ear de- The compressor is equipped with the protection
fenders! and safety equipment described below.
The sound pressure level with the sound-proofing All protective and safety equipment must be at-
enclosure is approximately: see "Technical data". tached and checked for trouble-free operation be-
During normal operation the compressor may only fore every commissioning, in particular after main-
be operated with a closed acoustic hood. tenance and repair work.
Oils, fats and other chemical substances In addition, the legally prescribed testing frequen-
cies of the country of use must be adhered to.
When handling oils, fats and other chemical sub-
stances, observe the applicable safety conditions!
NOTE
Exercise caution when using hot operating fluids
and additives, there is a risk of burns or scalds! Operation of the compressor is only permitted
with complete and operational protective and
Explosive areas safety equipment.

DANGER Emergency-stop

Risk of explosion The compressor can be rendered safe in danger-

ous situations using the emergency-stop pushbut-
The compressor is not designed for op- ton.
eration in explosive atmospheres.
Emergency-stop pushbuttons are attached:
➯ Operation of the compressor in ex-
plosive atmospheres is forbidden! on the compressor control panel
optionally in a control room (control centre)

July 2015 GB 9 /112

 TM

2 Safety conditions

Using emergency-stop 2.5 Identification of safety

1 Press the <Emergency-stop> pushbutton. instructions
The compressor is placed in a safe condition.
Within the operating instructions, safety instruc-
2 Rectify the fault that was the cause of the tions are used as special warnings with the follow-
Emergency-stop. ing described names and symbols.
See the "Troubleshooting" chapter.
These special warnings are intended to prevent
3 Unlock the <Emergency-stop> pushbutton.
danger and are located close to the possible dan-
Turn the pushbutton anticlockwise.
ger both in terms of space and time:
4 Set the compressor in operation.
on the system close to the danger source
See section "Commissioning after a fault" in the
chapter "Commissioning and operation". in the operating instructions, before a sequence
of actions / activity is described
Safety valves / non-return valve
The compressor is protected against exceeding Structure of safety instructions
of the permissible operating pressure using safety The special warnings in the operating instructions
valves. Open the safety valves at 3.5 bar (1st are structured as follows:
airend) or 11.4 bar (2nd airend).
DANGER WORD
The compressor is secured by a non-return valve
on the pressure side against reverse flow from the Danger (danger sequence)
compressed air network. Description of the danger (danger
Safety sign source)
Protective covers and enclosure panels
Protective measure (danger pre-
The cooling air fans are covered by grilles. vention)
The clutch between the drive and the compressor
is covered by a grille. Parts of safety instructions
The compressor enclosure is designed so that any Danger (danger sequence): The danger se-
broken bits that might fly out are retained in the quence names the type of hazard.
compressor. Description of the danger (danger source): The
The compressor enclosure serves as an acoustic danger source names the cause of the hazard.
hood. Protective measure (danger prevention): Dan-
ger prevention describes the measures for com-
2.4 Residual hazards batting the hazard.
Hot surfaces Danger word: The danger word subdivides the
Some parts of the compressor become very hot in severity of the danger into four steps, graphically
operation (up to 235 °C). A danger warning sign highlighted by different colours. The danger word
on the compressor enclosure warns of the danger. is used in the safety instructions as described be-
low.
Before starting any maintenance and repair work,
the compressor must be sufficiently cooled. DANGER indicates a directly dangerous situa-
tion which, if not protected against, could result in
Personal protective equipment death or serious (irreversible) injuries.
We recommend the wearing of the following per- WARNING indicates a potentially dangerous situa-
sonal protective equipment: tion which, if not protected against, could result in
death or serious (irreversible) injuries.
Safety shoes
CAUTION indicates a potentially dangerous situa-
Safety glasses for all work with compressed air tion which, if not protected against, could result in
and open enclosure minor or less serious (reversible) injuries.
Ear defenders during test runs with an open ATTENTION indicates information or recommen-
acoustic hood dations that directly or indirectly concern the safety
of persons or system protection.
2.6 Safety sign
The following safety signs (danger signs) may be used in the surroundings of the compressor and in the
operating instructions.

10 / 112 GB July 2015

 TM

Safety conditions 2

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.

Pressurised part or sys- Identification of devices or rooms in which there is per-

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

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

Electrical voltage Warning of dangerous, electrical voltage.

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

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

Observe the instruction Identification of operating instructions where additional

manual information is to be found in the operating instructions (of
the manufacturer).
Before the device is operated, the operator (user) must
have read and understood the instruction manual (manu-
facturer's usage instructions).
Wear ear defenders Identification of areas with a heightened sound pressure
level.
Only enter the area wearing suitable ear defenders.

Chart 2-1: Safety sign

July 2015 GB 11 /112

 TM

2 Safety conditions

Safety sign Meaning Use / Behaviour

Warning against indus- Warning of in-plant industrial trucks (e.g. forklifts) trans-
trial trucks porting materials.
Do not carry out any work on traffic ways that cannot
be seen to be clear and are not made safe or blocked
off. Use or crossing of this traffic way can only be imple-
mented with great care.
Warning against sus- Warning of suspended loads being transported.
pended loads No person may remain in the danger area during trans-
port. In particular, do not encroach into the area under
the raised compressor or place your feet beneath it.

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

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

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

start-up automatically at any time. The readiness for operation
of the compressor is indicated by the green LED on the
control panel.
Do not carry out any work on the compressor, if the
green LED illuminates.
Warning of hot surfaces Parts of the compressor become very hot during opera-
tion (up to 235 °C). 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.
Chart 2-1: Safety sign

12 / 112 GB July 2015

 TM

Safety conditions 2

Safety sign Meaning Use / Behaviour

Remaining under the It is not permitted to remain under a suspended load.
load is forbidden The driver is not permitted to drive the industrial truck if
there is a person beneath the load. Moreover, the dri-
ver is obliged to check that persons do not stand or walk
under the load.
The load must only be transported so that it is 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 dri-
ving and load movements.
Lifting point Identification of the lifting points.
Only the indicated lifting points may be used for trans-
port.

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

Check the connecting Warning against loosened connecting terminals. The

terminals and tighten if clamping pressure can be released after some time.
necessary. For additional Regularly check the terminals according to the safety
information see the oper- guidelines and retighten as necessary.
ating instructions.
Electrical voltage Warning of dangerous, electrical voltage.
Residual voltage of the Warning of electrical energy stores in the form of capaci-
capacitors tors. These can conduct a life-threatening electrical volt-
age.
Only open the switch cabinet (VS compressor) 10 min-
utes 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.
Only a qualified electrician following electrotechnical reg-
ulations 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 mainte-
nance personnel.

Chart 2-1: Safety sign

July 2015 GB 13 /112

 TM

2 Safety conditions

Safety sign Meaning Use / Behaviour

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.

2.7 Transport and positioning Check regularly that:

Transport All hoses and pipelines are serviceable and

firmly attached.
A suitable forklift with forks of adequate length
must be used to transport the compressor. Depen- There are no leaks (oil, coolant or cooling wa-
dent on type, the compressor weighs up to 3,800 ter).
kg. The electrical power cables are free from faults.
Only insert the forks at the intended load support The cooling water supply is guaranteed (wa-
points. ter-cooled compressors only).
The compressor must not be transported using a The external compressed air supply for the
crane, even when still in its packaging. ejector system is guaranteed (only for heating
No person may remain in the danger area during connection (HOC) full flow (FF) [no aftercooler
transport. In particular, do not encroach into the in the plant]).
area under the raised compressor or place your Rules for working with compressed air:
feet beneath it.
Forbid all working practices that could pose a
Positioning / installation location risk to safety
The entire surface of the compressor must be Never 'play around' with compressed air.
placed on an even suitable substrate. Never direct compressed air onto the skin or at
The installation location (compressor room) must other people.
be dimensioned so that there is sufficient access Never use compressed air for cleaning cloth-
to the compressor and the necessary cooling is ing.
ensured.
When using compressed air to clean equip-
No inflammable or explosive materials may be ment, proceed with great care and always use
stored in the vicinity of the compressor. eye protection.
2.8 Normal operation Use of the compressed air of the optional heat-
ing connection (HOC) [max. 235°C] in secured
The compressor may only be operated in a techni- useage areas.
cally fault-free condition for its intended use, with
an awareness of safety and hazards while observ- Safety measures
ing the operating instructions. Only operate the compressor with the enclosure
Only operate the compressor if all protective and closed.
safety equipment, sound insulation, ventilation and At least once per shift check the compressor for
extraction equipment and the cooling water supply externally visible damage and defects. Immedi-
(water-cooled compressors only) are present and ately report changes that have occurred (includ-
serviceable. ing in the operating behaviour) to the responsi-
ble post/person. If necessary stop the compressor
immediately and secure. Immediately rectify any
faults.
Do not switch off or remove extraction and ventila-
tion equipment when the compressor is running.

14 / 112 GB July 2015

 TM

Safety conditions 2

Safeguarding of the external compressed air sup- Wait until the residual electrical energy has
ply for the ejector vent system for the option heat- drained from the capacitors.
ing connection (HOC) full flow (FF) [no aftercooler Allow the compressor to cool to room tempera-
in the plant]. ture.
Remote control Cleanliness
If a remote control is available, a sign with the fol- During maintenance and repair work always check
lowing lettering must be clearly visible on the com- for cleanliness. Keep dirt away by covering parts
pressor: "Attention! The compressor is remotely and uncovered openings with a clean cloth, paper
controlled and could start without warning!" or adhesive strips.
In addition safety precautions must be imple- Oil leaks lead to a slippery floor. Thoroughly clean
mented so that nobody works on the compressor the work area after completion of maintenance
when it is under remote control. and repair work.
2.9 Special tasks Cleaning agents
Organisational When cleaning parts, never use solvents or clean-
Adhere to the prescribed maintenance work and ing agents that could chemically attack the materi-
intervals including details about the replacement als.
of parts/part assemblies contained in the operating Take precautions to prevent harmful vapours from
instructions. solvents or cleaning agents.
Maintenance and repair work must only be carried
Weight / lifting gear
out under the supervision of or by a person quali-
fied to carry out this work. When replacing heavy individual parts and assem-
blies carefully attach and secure to the lifting gear
If necessary, cordon off a wide area around the
so that no danger can arise. Use only suitable and
workplace.
technically flawless lifting gear and load handling
Workshop equipment appropriate for the task is equipment with adequate load capacity. Never
essential for carrying out maintenance and repair work or remain under suspended loads.
work.
Spare parts
Safety measures
Use only original spare parts.
Personnel must not have loose long hair nor wear
Spare parts must correspond to the technical re-
loose clothes or jewellery including rings. If the
quirements specified by the manufacturer. This is
compressor is running there is a risk of injury, e.g.
only guaranteed with original spare parts.
by being caught-up or pulled in. Where necessary
or if required by regulations, wear personal protec- Upon completion of maintenance and repair
tive equipment! work
Only carry out maintenance and repair work for Upon completion of maintenance and repair work,
which you are adequately trained and which you ensure that no tools, loose parts or cleaning cloths
feel confident to carry out. have been left in the compressor (especially in the
Do not use machine parts as climbing aids. If car- drive motor or drive train).
rying out maintenance work at heights, provide fall Turn the drive several times to ensure that there is
protection. no mechanical malfunction within the compressor
or the drive train.
Maintenance/Troubleshooting
Tighten up all threaded connectors loosened dur-
Only carry out maintenance and repair work with ing maintenance and repair work. Likewise check
the compressor switched off and mains power all other threaded connectors.
off. Secure the compressor to prevent inadvertent
Before release of the compressor for operation af-
switching on.
ter maintenance and repair work, ensure that the
Before opening the compressor enclosure: operating pressures, temperatures and time set-
tings are correct and that the control and switching
Drain the compressor.
off equipment is fully serviceable.
Wait for automatic pressure discharge to com- If safety and protective equipment must be re-
plete. moved, then it must be immediately replaced af-
ter completion of the work and checked for trou-
ble-free operation.

July 2015 GB 15 /112

 TM

2 Safety conditions

2.10 Conversions and changes to

the machine
Do not make any changes or additions to or re-
build the compressor without prior consultation
with Gardner Denver.
Unauthorised changes to the machine are not au-
thorised for safety reasons.
Genuine parts are designed especially for the ma-
chine. 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 prod-
ucts may therefore impair active and/or passive
safety.
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 ap-
plies for the fitting and adjustment of safety equip-
ment and valves as well as to the welding of load-
bearing or pressure carrying parts.

16 / 112 GB July 2015

 TM

Design and function 3

3 DESIGN AND FUNCTION Compression principle

The airends comprise a main rotor and an auxil-
3.1 General description iary rotor with intermeshing spiral toothing. A syn-
The compressor is an oil-free compressing, two- chronized gearbox in each airend ensures the
stage screw compressor with one sound-proofed contact-free running of the rotors. Compression
enclosure. chambers are delimited by the flanks of the tooth-
The main components are the drive motor, the ing and the compressor casing. The rotation of
airend unit, the cooling and lubrication system and the rotors continuously reduces the volume in the
the electronic control. chambers until the compressed air is pushed out
through the outlet window of the stage casing.
The airend unit comprises the drive gear and the Screw compressors count amongst rotation-dis-
first and second airends. placement compressors without oscillating masses
The parts of the airends through which the air but with a pulsing output.
flows are provided with a special wear-reducing To minimise the power consumption of the airend
and corrosion-resistant coating. unit and to limit the airend temperatures to tech-
Rolling contact bearings and gearbox are oil-lubri- nically permissible values, the compression takes
cated. place in two stages with interstage cooling (in-
The air and oil system are designed so that no oil tercooler). In addition the casing of the stages is
can get into the air circuit. The ejector ventilation cooled by the internal cooling circuit
system produces a defined vacuum pressure in
Electronic control unit
the oil-lubricated area of the airend unit thus pre-
venting any oil from escaping into the surround- The main components of the electronic control
ings. unit are a microprocessor, a touchscreen, film-pro-
tected keys and LEDs.
Detailed description of the operating instructions
for the electronic control unit.

Heat recovery option

The "heat recovery" option is used to exploit a
large part of the compression energy. The ex-
ploitable energy depends on the connected load
and the operating and ambient conditions.
The cooling circuit of the machine is changed so
that on the one hand high water temperatures can
be achieved and on the other hand, sufficient cool-
ing of the machine is ensured.

July 2015 GB 17 /112

 TM

3 Design and function

3.2 Compressor design

Air-cooled

Fig. 3-1: Overview part 1

[1] Condensation trap (intercooler) [10] Silencing baffle with filter mesh
[2] Oil / water cooler [11] Aftercooler (with option heating connection
(HOC) full flow (FF) not fitted)
[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

18 / 112 GB July 2015

 TM

Design and function 3

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 (VS)
[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

July 2015 GB 19 /112

 TM

3 Design and function

Water-cooled

14 13
15 12 11
16
17
18

10

1 9
2 3 8
4
5 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 (with option heating connection
(HOC) full flow (FF) not fitted)
[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)

20 / 112 GB July 2015

 TM

Design and function 3

16 15

18 17
1

14

13

4
HOC
5
8 9
10 11 12 HOC

[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
Normal and hot gas connection (HOC)
[5] Connecting flange, normal and hot gas [14] Switch cabinet cooling air inlet filter
connection (HOC) (speed-controlled system)
[6] Condensate separator [15] Pushbutton <Emergency-stop>
Not fitted with option heating connection
(HOC) full flow (FF)
[7] Condensate connectors [16] Electronic control unit
[8] Condensate trap [17] Switch cabinet
Not fitted with option heating connection
(HOC) full flow (FF)
[9] Solenoid valve (Y3) [18] Fan

July 2015 GB 21 /112

 TM

3 Design and function

3.3 System scheme air-cooled compressor

L
Y1
S18

27
16

17 7 P1.0
26
Y2
14
32

15
25
B0
1 2 6
E1 R7

B1
R0 32 28
5
R1
20
B2
19 3
4 B7

B8
ϑ>
B3 S22
M1_PTC R2

29
ϑ>
30

H S21
R3
B5
E4 E5
B4 31
9 10 11 13 R5
18
8 B6
12
R4

R6 E2
S12
G 21 22 23 24

Y3
B5
(HOC) R5 S5
14(HOC) (FF) (HOC)(FF)
12(HOC)(FF) P1.1

Fig. 3-3: Function scheme

Compressed air Water

Air Oil

Chart 3-1: Cables

22 / 112 GB July 2015

 TM

Design and function 3

Components
No Name No Name No Name
1 Intake air filter 22 Temperature control valve
(oil circuit)
2 Suction regulator 12 Pressure relief valve 23 Heat exchanger
3 First airend 13 Water separator (after- 24 Oil Filter
cooler)
Not fitted with heating
connection (HOC) full
flow (FF)
4 Snubber 14 Safety valve (final pres- 25 Cooler internal cooling
sure) water circuit
Additional with heating
connection (HOC)
5 Intercooler 15 Filter water separator 26 Temperature control valve
(internal cooling water cir-
cuit)
6 Water separator (inter- 16 Shuttle valve 27 Compensating tank
cooler)
7 Safety valve (intermedi- 17 Blow-off silencer 28 Cooling water pump
ate pressure)
8 Second airend 18 Maintenance unit 29 Drive motor
9 Combined silencer and 19 Vacuum generator 30 Speed control (inverter)
snubber
10 Non-return valve 20 Ultra-fine filter 31 Radial fan
11 Aftercooler 21 Oil pump 32 Radial fan
P1.0 Standard compressed P1.1 Heating connection
air connection, with (HOC)
option heating connec-
tion (HOC) full flow (FF)
this connection is not fit-
ted
Chart 3-2: Components

Instrumentation & control technology

No Name No Name No Name
B0 Ambient pressure R2 Outlet temperature first S12 Oil level
absolute airend
B1 Inlet pressure first airend R3 Inlet temperature second S18 Water level
airend
B2 Outlet pressure first R4 Outlet temperature sec- S21 Safety temperature switch
airend ond airend
B3 Inlet pressure second R5 Network temperature S22 Safety temperature switch
airend
B4 Outlet pressure second R6 Oil temperature M1- Drive motor positor
airend PTC
Chart 3-3: Instrumentation & control technology

July 2015 GB 23 /112

 TM

3 Design and function

No Name No Name No Name

B5 Network pressure R7 Water temperature jacket Y1 Solenoid valve suction
cooling inlet regulator
B6 Oil pressure E1 Condensate drain control Y2 Solenoid valve suction
regulator
B7 Water pressure jacket E2 Condensate drain not fit- Y3 Solenoid valve gearbox
cooling inlet ted with heating connec- casing venting
tion (HOC) full flow (FF)
B8 Vacuum in gearbox cas- E4 Motor lubrication system L Balance piston first airend
ing
R0 Ambient temperature E5 Motor lubrication system H Balance piston second
airend
R1 Inlet temperature first S5 Oil filter differential pres-
airend sure
Chart 3-3: Instrumentation & control technology

24 / 112 GB July 2015

 TM

Design and function 3

3.4 System scheme water-cooled compressor

31 L
S18
Y1 R8

27
16 33 R9

17 7
26
Y2
Y4

15
32 25
B0
1 2
6
R7

R0 B1 32
28

R1 E1 5
20
B2
19
3 4 B7 P1.0

B8 B3
M1_PTC R2
29 14
30

H
R3

E4 E5
32 S22 ϑ>
B4
9 10 S21 ϑ>
18
B6 R5
8 11 12
R4
B5
R6
S12 G 22 23 24
21
13
Y3

B5 S5
(HOC) R5 E2
14(HOC) (FF) (HOC)(FF)
12(HOC)(FF) P1.1

Fig. 3-4: Function scheme

Compressed air Water

Air Oil

Cooling water (external)

Chart 3-4: Cables

July 2015 GB 25 /112

 TM

3 Design and function

31 L
S18
Y1 R8

27
16 33 R9

17 7
26
Y2
Y4

15
25
B0
1 2
6
R7

R0 B1 28

R1 E1 5
20
B2
19
3 4 B7

B8 B3 P1.0
M1_PTC R2
14
30 29

H
R3
B5
32
E4 E5
B4
9 10 13 R5
18
B6 11 12
8
R4
R6
S12 G 22 E2
21 23 24

Y3

B5 S5
(HOC) R5
14(HOC) (FF) (HOC)(FF)
12(HOC)(FF) P1.1

Fig. 3-5: Functional schematic of external heat recovery

Compressed air Water

Air Oil

Cooling water (external)

Chart 3-5: Cables

26 / 112 GB July 2015

 TM

Design and function 3

Components
No Designation No Designation No Designation
1 Intake air filter 12 Pressure relief valve 23 Heat exchanger
2 Suction regulator 13 Water separator (after- 24 Oil Filter
cooler)
Not fitted with heating
connection (HOC) full
flow (FF)
3 First airend 14 Safety valve (final pres- 25 Cooler internal cooling
sure) water circuit
Additional with heating
connection (HOC)
4 Snubber 15 Filter water separator 26 Temperature control valve
(internal cooling water cir-
cuit)
5 Interstage cooler 16 Shuttle valve 27 Compensating tank
6 Water separator (inter- 17 Blow-off silencer 28 Cooling water pump
stage cooler)
7 Safety valve (intermedi- 18 Maintenance unit 29 Drive motor
ate pressure)
8 Second airend 19 Vacuum generator 30 Speed control (inverter)
9 Combined silencer and 20 Ultra-fine filter 31 Axial fan
snubber
10 Non-return valve 21 Oil pump 32 Throttle valves external
cooling water circuit
11 Aftercooler 22 Temperature control 33 Strainer sieve
Not fitted with heating valve (oil circuit)
connection (HOC) full
flow (FF)
34 Safety valve (external P1.0 Standard compressed P1.1 Heating connection
water circuit) air connection, with (HOC)
option heating connec-
tion (HOC) full flow (FF)
this connection is not fit-
ted
Chart 3-6: Components

Instrumentation & control technology

No Designation No Designation No Designation
B0 Ambient pressure R3 Inlet temperature second S12 Oil level
absolute airend
B1 Inlet pressure first airend R4 Outlet temperature sec- S18 Water level
ond airend
B2 Outlet pressure first R5 Network temperature S21 Safety temperature switch
airend
Chart 3-7: Instrumentation & control technology

July 2015 GB 27 /112

 TM

3 Design and function

No Designation No Designation No Designation

B3 Inlet pressure second R6 Oil temperature S22 Safety temperature switch
airend
B4 Outlet pressure second R7 Water temperature jacket M1- Drive motor positor
airend cooling inlet PTC
B5 Network pressure R8 Cooling water tempera- Y1 Solenoid valve suction
ture inlet (external) regulator
B6 Oil pressure R9 Cooling water tempera- Y2 Solenoid valve suction
ture outlet (external) regulator
B7 Water pressure jacket E1 Condensate drain control Y3 Solenoid valve gearbox
cooling inlet casing venting
B8 Vacuum in gearbox cas- E2 Condensate drain control Y4 Cooling water solenoid
ing Not fitted with heating valve
connection (HOC) full
flow (FF)
R0 Ambient temperature E4 Motor lubrication system L Balance piston first airend
R1 Inlet temperature first E5 Motor lubrication system H Balance piston second
airend airend
R2 Outlet temperature first S5 Oil filter differential pres- G Gearbox casing
airend sure
Chart 3-7: Instrumentation & control technology

28 / 112 GB July 2015

 TM

Design and function 3

3.5 Air circuit

4
5
3
6
7

10

11

9
2

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

[1] Combined silencer and snubber [7] Blow-off valve
[2] Safety valves [8] Snubber
[3] Aftercooler (with option heating connection [9] Heating connection option (HOC)
(HOC) full flow (FF) not fitted)
[4] Interstage cooler [10] Safety valve heating connection option
(HOC)
[5] Blow-off silencer [11] Safety temperature switch (S21 + S22)
[6] Suction regulator

July 2015 GB 29 /112

 TM

3 Design and function

4
5
6 7
3 11

10

2 8
1

Fig. 3-7: Air cooling circuit (water-cooled)

[1] Combined silencer and snubber [7] Blow-off valve
[2] Safety valve [8] Snubber
[3] Aftercooler (with option heating connection [9] Heating connection option
(HOC) full flow (FF) not fitted)
[4] Interstage cooler [10] Safety valve heating connection option
(HOC)
[5] Blow-off silencer [11] Safety temperature switch (S21 + S22)
[6] Suction regulator

DANGER
Risk of bursting, risk of burns
The compressed air outlet temperature can be up to 235°C.
➯ The burst strength of the following components of the supply line (customer network) must
be suitable for these temperatures.
➯ Secure the supply line to prevent contact.

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.

30 / 112 GB July 2015

 TM

Design and function 3

Compressed air outlet from the compressor system

• Standard system: The compressed air is output to the compressed air network via the aftercooler.
Condensate formed during cooling is separated by an automatic condensate separator.
• Partial flow (PF) heating connection (HOC): The compressed air is output to the compressed air
network via the aftercooler. Condensate formed during cooling is separated by an automatic conden-
sate separator. The second part of the compressed air passes uncooled into the customer's hot gas
system.
• Full flow (FF) heating connection (HOC): The compressed air passes uncooled into the customer's
hot gas system.
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 fluc-
tuations. A combined silencer and snubber after the second airend is used to reduce pressure fluctua-
tions and for sound insulation.
Safety valves are fitted after the intercooler and the aftercooler or the heating connection (HOC) 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 in-
stalled in the pressure line inside the compressor.

July 2015 GB 31 /112

 TM

3 Design and function

3.6 External water circuit

1
3

Fig. 3-8: External water circuit

[1] Water stop valve [3] Strainer (sieve)
[2] Safety valve (external water circuit)

32 / 112 GB July 2015

 TM

Design and function 3

B
B

3
A A

Fig. 3-9: External water cooling circuit with external heat recovery
[1] Water stop valve [3] Strainer (sieve)
[2] Safety valve (external water circuit)

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 ex-
changer (internal water circuit) with cooling water.

Heat recovery option (external)

NOTE
Local site arrangements must be made to ensure heat dissipation is ensured if the heat recovery sys-
tem is switched off.

July 2015 GB 33 /112

 TM

3 Design and function

With this option, the cooling water first enters the cooler of the internal cooling water circuit, thereafter it
passes through the interstage cooler and then through the aftercooler before it exits the machine. This se-
quence guarantees maximum cooling water heating. See also the functional schematic for external heat
recovery.
Dependent on requirements, various cooling water out temperatures can be set by adjusting the cooling
water volume. The cooling water volume is adjusted using the manual valve on the aftercooler.
The cooling water inlet and outlet temperatures can be read off at the electronic control.
You can find instructions on the limit data for cooling water quantities, temperatures and pressure losses
in the appendix to these operating instructions.

3.7 Internal water circuit

A
I
4

W
I
3 O
2

7 6

Fig. 3-10: 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) - cooler
Water/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 fluctu-
ations are compensated by the expansion tank.

34 / 112 GB July 2015

 TM

Design and function 3

3.8 Oil circuit

Fig. 3-11: 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.

July 2015 GB 35 /112

 TM

3 Design and function

3.9 Ejector vent system 3.10 Control (automatic operation)

Preconditions

The following preconditions must be fulfilled for

automatic running:
All preparations for commissioning are fulfilled.
The compressor is correctly connected to the
power supply network.
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 guar-
anteed.
The cooling water supply is guaranteed (wa-
ter-cooled compressors only).
The direction of rotation of the drive motor has
been checked.
All protective and safety equipment is fitted and
Fig. 3-12: Ejector vent system serviceable.
[1] Second stage condensate separator The electronic control unit indicates [Ready to
(aftercooler water separator) Start].
[2] Compressed air connection ejector vent Pressure demand from the compressed air net-
system. An external compressed air work.
supply is necessary with the option hot
gas connection (HOC) full flow (FF) and Operating sequence
external heat recovery (WRG). Switch on the cooling water supply (wa-
[3] Solenoid valve Y3 ter-cooled compressor only).

[4] Maintenance unit (water separator, Press the start button < I > on the control
pressure regulator, pressure gauge) panel.
The compressor is switched on.
[5] Ejector (vacuum generator)
Checking of the start parameters (tempera-
[6] Extract air tures, pressures, sensors, cooling water level)
[7] Ultra-fine filter by the electronic control unit.
[8] Oil return Once the start parameters have been fulfilled,
the cooling water pump and the oil pump are
The ejector ventilation system produces a defined switched on sequentially; the water and oil cir-
vacuum pressure in the oil-lubricated area of the cuit are running.
airend unit thus preventing any oil from escaping Simultaneously, solenoid valve Y3 is actuated
into the surroundings. so that the ejector vent system starts operating.
The ejector vent system uses compressed air from If the water and oil pressure are correct, the
the compressed air network. The air passes via drive motor is started.
the maintenance unit to the vacuum generator.
After running up of the drive motor, solenoid
The air sucked out of the oil system is filtered and valves Y1 and Y2 are switched in a time-de-
output to the atmosphere, the separated oil is re- layed manner, the suction regulator opens. The
turned to the oil sump. two fans are switched on. The compressor is
now in load operation.
The compressor operates under load until the
maximum line pressure [Line Pressure max.] is
reached.

36 / 112 GB July 2015

 TM

Design and function 3

Once maximum line pressure [Line Pressure

max.] is reached, the solenoid valves Y1 and
Y2 are switched to zero volts; the suction reg-
ulator 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.
The compressor runs off-load until the line
pressure has dropped below the minimum line
pressure [Line Pressure min.] or until the pro-
grammed off-load period has elapsed.
– If the line pressure drops below the min-
imum 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 op-
eration.
– 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 sys-
tem 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" (s-
tandby) mode.
If the compressor is switched off, then the cool-
ing water supply can likewise be switched off
(water-cooled compressors only).

July 2015 GB 37 /112

 TM

4 Transport and positioning

4 TRANSPORT AND Transporting the compressor

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

Receipt of goods
Upon receipt of goods check for transport dam-
age.
1 Check the delivery for visible damage. Fig. 4-1: Lifting points

2 Check the completeness of the delivery using 1 Remove the screws from the transport pallet.
the delivery note.
2 Lift the compressor from the transport pallet.
3 Immediately inform the shipper, Gardner Den-
ver and insurance of any missing parts or dam- 3 Transport the compressor to the destination
age. point.
4 Align the compressor and set down.
Weight
Dependent on type, the compressor weighs up 4.2 Storage
to 3,800kg (gross). The weight is stated on the Storage of compressors
nameplate which is visible from the outside.
The compressor should be stored in a dry and,
Transport where possible, heated room. This applies particu-
larly during the winter months.
DANGER
NOTICE
Risk of fatal injury
Material damage
Risk of fatal injury due to toppling or
falling parts Material damage through exceeding of the per-
missible temperature range
➯ A suitable forklift with forks of ade-
quate length must be used to trans- ➯ Where there is a risk that the permissible
port the compressor. 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 trans- Before they leave the factory all compressors are
ported using a crane, even when protected against corrosion during transport and
still in its packaging. short term storage before commissioning. If com-
➯ No person may remain in the dan- pressors are stored for longer than 6 months, ad-
ger area during transport. In partic- ditional precautions must be undertaken.
ular, do not encroach into the area Also compressors that have been taken out of ser-
under the raised compressor or vice for a long period, must be protected against
place your feet beneath it. 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.

38 / 112 GB July 2015

 TM

Transport and positioning 4

The installation location (compressor room) must In the event of unfavourable local conditions, in-
be dimensioned such that the compressor has stall air ducts in which the flow velocity of the cool-
a clearance on all sides of 1m ("A" and "B") and ing air must not exceed 5 m/s. We recommend
above the compressor of 1.50 m. Moreover, ade- a minimum channel cross section of 1.2 m2 (air-
quate access must be provided for maintenance. cooled 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 cool-
ing air flow required by the compressor.
If installing several compressors in one com-
pressor 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 ven-
tilation 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 suffi-
cient size and have adequate ventilation.
The recommended minimum size of the compres-
sor room is 60 m3.
The air inlet and outlet openings should have a
minimum cross section of 1.2 m2 (air-cooled com-
pressor) or 0.45 m2 (water-cooled compressor).
The intake air opening should be positioned as low
as possible. The extract air opening should be po-
sitioned 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 "Tech-
nical data".)

July 2015 GB 39 /112

 TM

4 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 compres-
sor must be placed on an even suit-
able substrate.
➯ The compressor must not be oper-
ated on the transport pallet.
➯ No inflammable or explosive mate-
rials 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)

Heating connection option

DANGER
Risk of bursting, risk of burns
The compressed air outlet temperature
can be up to 235°C.
➯ The burst strength of the following
components of the supply line (cus-
tomer network) must be suitable for
these temperatures.
➯ Secure the supply line to prevent
contact.

40 / 112 GB July 2015

 TM

Preparations for commissioning 5

5 PREPARATIONS FOR 5.2 Compressed air connection

COMMISSIONING
5.1 Pipelines 1

Remove all blank flanges, plugs, caps and des-

iccant containing pouches before fitting the
pipelines.
Manifolds and pipe connections must be of the A
correct size and be suitable for the operating tem- 3
peratures and pressures. 1
4
2
Label compressed air and water pipes according 5
to the local regulations.
Support all pipelines with correctly dimensioned
supports; pipes must not support any loads.
If compressed air hose is used, it must be cor-
rectly dimensioned and be suitable for the oper- Fig. 5-1: Compressed air and condensate connection
ating pressure and temperature. Do not use any
[1] Compressed air connection
abraded, damaged or inferior quality hose.
[A1] Automatic condensate drain, aftercooler
A shut-off valve must be fitted in the supply line
so that the compressor can be isolated for main- [A2] Condensate drain pipe aftercooler via ball
tenance purposes. No additional non-return valve valve (use if there is a malfunction of the
may be installed. The additional non-return valve automatic condensate drain)
would impede the air supply to the vacuum gener- [A3] Automatic condensate drain, intercooler
ator.
[A4] Condensate drain pipe intercooler via ball
If a high level of condensate formation is ex- valve (use if there is a malfunction of the
pected, the compressed air connection for the automatic condensate drain)
ejector vacuum generator must be connected to
[A5] Ejector supply
a condensate-free compressed air supply. Exter-
nal compressed air supply can be carried out via Compressed air supply of the ejector vent
connector [A5]. Please contact Gardner Denver for system
any modification on the ejector line.
The two automatic condensate drains must be DANGER
provided with separate lines that are routed to a
drain or a collecting tank. Risk of bursting
The drains lines leading away from the conden- The compressed air outlet temperature
sate connections must not be designed to rise can be up to 95°C.
more than 5 m! ➯ The burst strength of the following
An air tank with sufficient volume (as a buffer) components of the supply line (cus-
must be installed between the compressor and the tomer network) must be suitable for
compressed air network. As a guide, the tank ca- these temperatures.
pacity should equal 10 % of the delivery quantity,
e.g. a compressor with a delivery quantity of 10 WARNING
m³/min requires a tank volume of 1 m³.
Risk of injury due to hot supply line
The compressed air outlet temperature
can be up to 95°C.
➯ Protect the supply line to prevent
contact with it.

July 2015 GB 41 /112

 TM

5 Preparations for commissioning

5.3 Cooling water connection

WARNING
Risk of injury
If an incorrect connection is made, the
connector could come loose and the free
connection result in severe personal in-
jury.
➯ When connecting the compressor
to the compressed air network, the
connecting flange must be checked 1
in addition to the operating tempera-
tures and pressures. 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
Connecting the compressor to the com- in the cooling circuit for the number
pressed air mains of microbes.
The compressor is completely assembled in the
factory. The connection to the compressed air net- NOTICE
work must be made with a flexible line, e.g. a com-
Material damage
pressed air hose or expansion joint.
Heat recovery option
Use only hose couplings and connections of the
correct type and size. The temperature control valve for the external
water circuit must be completely opened before
1 Ensure that the supply line can be connected
the first start.
free from tension.
Information on the position of the temperature
2 Connect the connection line to the compressed control valve and its setting can be found in the
air connection of the compressor. chapter Commissioning and operation.
3 Secure the hose lines.

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 com-
pressed air hose or expansion joint.
Only use correctly sized connectors.
1 Ensure that the lines can be connected free
from tension.
2 Connect the connecting line with the compres-
sor cooling water inlet and outlet.
3 Shut-off valves must be provided at the cooling
water inlet and outlet.

42 / 112 GB July 2015

 TM

Preparations for commissioning 5

4 Secure the hose lines. min. max.

Water inlet 5 °C 40 °C
Cooling water inlet and cooling water outlet temperature:
• European version: EN 10226-1 Rp 1 1/4 Water outlet 25 ° 90 °C
• USA/CANADA version: 1 1/4 - 11 1/2 NPT temperature:
Water volume flow: 15 l/min. 140 l/min.

Permissible cooling water data Pressure loss from the 0.3 bar 2.5 bar
water circuit:
• Cooling water pressure max.:
8 bar / 115 psi Do not use any operating parameters deviating
• Cooling water inlet temperature min.: from the above values without prior consultation
5 °C / 41 °F with GardnerDenver.
• Cooling water inlet temperature max.:
42 °C / 107 °F
• Cooling water outlet temperature max.:
5.4 Electrical connection
57 °C / 134 °F
NOTICE
Faults in the electrical supply network
Cooling water requirement at maximum power and
(ΔT = 15 K , Δp = 0.7 bar / 13 psi) In low voltage networks, speed-controlled com-
pressor systems (VS) can cause faults. For this
• 75KW = 89 l/min / 23 gal/min reason, this drive system is not intended for use
• 90KW = 111 l/min / 29 gal/min in public low voltage networks that also supply
• 110KW = 132 l/min / 35 gal/min residential areas.
• 132KW = 155 l/min / 41 gal/min The compressor system is executed completely in
• 160KW = 170 l/min / 45 gal/min the factory according to EN 60204 (industrial ma-
chinery).
The compressor power supply must be suitable
ΔT: for industrial equipment and must fulfil all the
Cooling water outlet temperature = requirements of EN60204-1/IEC60204-1. Con-
Cooling water inlet temperature + ΔT tact Gardner Denver if the positioning condi-
tions differ from the conditions as they are de-
Δp: scribed in EN 60204.
Cooling water outlet pressure = Implement the electrical connection and the
Cooling water inlet pressure - Δp protective measures in accordance with VDE,
The values relate to fresh water quality without ad- BS or the appropriate local regulations. In gen-
ditives (e.g. antifreeze). If the cooling water quality eral, the supplementary regulations of the re-
deviates from this, please contact Gardner Den- spective power supply utility must be consid-
ver. ered.
Set the cooling water volume in accordance with A main switch must be fitted on-site upstream
the description "Cooling water control in a wa- of the compressor (DIN EN 1012 - 1) insofar
ter-cooled compressor system". 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
NOTE standard EN 60 204-1 (Electrical equipment of
The cooling water outlet temperature should machines), as well as EN 60947-2 (low voltage
where possible be greater than 57 °C to prevent switchgear).
heightened limescale formation. The compressor must be fused using suitable
backup fuses in accordance with EN 60269-1
Limit values for the option external heat re- (low voltage directives).
covery

July 2015 GB 43 /112

 TM

5 Preparations for commissioning

If third party circuits are retrospectively con- Checking the setting of the fan protection
trolled via the electronic control, e.g. lighting, switch
heating or similar, that cannot be switched off
from the main switch, these excluded circuits DANGER
must be labelled according to EN 60204 and
routed separately. Moreover, warning signs Electric shock
must be attached close to the main switch and Life-threatening electric shock
close to the relevant circuits.
➯ Work on the electrical equipment
Should an electrical connection to an un- must only be carried out by autho-
earthed AC electrical circuit (IT network) be rised electricians or electrical techni-
made, observe the instructions in the supplied cians.
documentation of the frequency converter (only
1 Check the settings of the protection switch of
VS compressors).
the two fan motors, see wiring diagram.
Electrically connecting the compressor 2 Set the safety switch according to the supply
network voltage and frequency.

Check the setting of the control transformer

DANGER
Electric shock
Life-threatening electric shock
➯ Work on the electrical equipment
must only be carried out by autho-
rised electricians or electrical techni-
cians.
➯ With types EnviroAire TVS 110 -160
there is a risk of electric shocks due
to charged capacitors!
Switch the compressor to a zero
Fig. 5-3: Supply line openings volts state and wait 10 minutes be-
[1] Compressed air connection fore touching any electrical parts.

[2] Filter mat cooling air inlet ➯ Checking the DC bus voltage.
[3] Condensate drain The control transformer is set to the rated volt-
[4] Supply line cover panel age ex works.
Experience has shown that the actual supply
DANGER voltage may differ from the rated voltage.

Electric shock To match the local circumstances, the cor-

rect setting of the control transformer must be
Life-threatening electric shock checked when the compressor is under load
➯ Work on the electrical equipment by measuring the control voltages and if neces-
must only be carried out by autho- sary the transformer then reset.
rised electricians or electrical techni- A number of taps are provided for this purpose
cians. (see wiring diagram).
1 Remove the factory-provided cover panel.
2 Insert the customer-provided supply line panel. NOTICE
3 Feed the power supply cable through the open- Material damage
ings in the switch cabinet.
Incorrect setting of the control transformer en-
4 Connect the power supply cable, see the wiring dangers trouble-free operation.
diagram.
➯ Checking of the setting of the control trans-
5 Tighten the cable glands. former forms part of commissioning and pe-
riodic inspection/maintenance, as the mains
voltage conditions may vary.

44 / 112 GB July 2015

 TM

Preparations for commissioning 5

5.5 Compressed air connection

ejector compressed air supply

Fig. 5-4: Compressed air connection ejector com-

pressed air supply
[1] Solenoid valve Y3

NOTICE
Compressed air quality for ejector com-
pressed air supply
The compressed air used (min. 5 [bar] und max.
10 [bar]) must be oil free and must not exceed a
maximum temperature of 60°C.
Faults in the external ejector compressed air
supply
The oil mist extraction from the gearbox housing
is missing. Oil mist can form in the compressor
system.

July 2015 GB 45 /112

 TM

6 Commissioning and operating

6 COMMISSIONING AND 9 Acknowledge faults indicated on the display.

OPERATING – The message [Ready to Start] appears on
the display.
6.1 Initial commissioning
10 Check the factory setting of the pressure set-
NOTICE points (minimum line pressure [Line Pressure
min.] and maximum [Line Pressure max.]) and
Material damage readjust if necessary.
Although every compressor has already under- 11 Ensure the external cooling water supply is ad-
gone a test run in the factory and has undergone equate (water-cooled compressor only).
a careful final inspection in dispatch, the possi- 12 Press the start button < I >.
bility of transport damage cannot be excluded.
13 Check the direction of rotation of the drive mo-
➯ Before commissioning check the compres- tor (not VS compressors) or the fans (VS com-
sor once more for damage and monitor it pressors). See the following descriptions.
during its initial operating hours.
14 Check the output voltages of the control trans-
➯ If the compressor is being connected to a former in load operation.
power supply network and started for the
first time, then dependent on the version, Check the direction of rotation of the drive
the direction of rotation of the drive motor motor (not VS compressors)
and/or fans must be checked.
– Drive motor for non-VS compressors DANGER
– Fans for VS compressors Risk of injury
Preparations The drive motor rotational direction can
only be checked if the clutch cover is de-
Check all electrical and electronic compo- mounted.
nents/devices for water ingress or condensate
formation, in case of complaints, contact Gard- ➯ Before switching on, check that
ner Denver. there is nobody in the danger area!
If the compressor has been in storage for a ➯ Maintain an adequate distance from
substantial period of time (up to 2 years), the rotating machine parts!
main switch must be switched on at least one ➯ Wear ear defenders!
hour prior to starting. This ensures the operabil-
➯ Except for test runs, only operate
ity of the capacitors and prevents any damage
the compressor with the enclosure
from occurring.
closed.
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 Check the external compressed air supply with
the option heating connection (HOC) full flow
(FF).
7 Switch on the main switch.
– All three LEDs on the control panel illumi-
nate.
Fig. 6-1: Check the drive motor rotational direction
8 Set the display language.
[1] Protective cover (removed)

46 / 112 GB July 2015

 TM

Commissioning and operating 6

1 Switch the main switch OFF.

2 Open the enclosure.
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: Immedi-
ately switch the compressor off with the <Emer-
gency-stop>; not the Stop button < O >, as oth-
erwise 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.
Fig. 6-3: Check direction of rotation of fan motor (wa-
Checking the direction of rotation of the fans ter-cooled system)
(for VS compressors) The rotational direction of the fan motors can be
checked with the enclosure still closed.
CAUTION
1 Place a suitable ladder alongside the compres-
Risk of falling sor and use it to climb up.
The rotational direction of the fan motors 2 Check the rotational direction.
can only be checked "from above". The rotational direction arrow can be deter-
mined through the protective cover.
➯ Ensure safe climbing means are
provided. 3 If the rotational direction is incorrect: switch off
the compressor.
4 Switch the main switch OFF.
5 Correct the rotational direction. Change the
compressor rotating field.

Temperature start-up protection

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

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

cooled system)
[1] Rotational direction indicator

July 2015 GB 47 /112

 TM

6 Commissioning and operating

6.1.1 Cooling water control in a water- Cooler, water-cooled compressor system with
cooled compressor system external heat recovery

Cooler, water-cooled compressor system

+
-
- + + -
-
+

Fig. 6-5: Cooler layout external heat recovery

Fig. 6-4: Cooler layout
[A] Hand valve cooling water circuit
[A] Jacket / oil cooling
[B] Interstage cooler
[C] Aftercooler
Not fitted with option heating connection
(HOC) full flow (FF)

48 / 112 GB July 2015

 TM

Commissioning and operating 6

NOTE NOTICE
The cooling water volumes of the individual cool- Material damage
ers are preset in the factory and secured using a
tamper-evident seal. Operating conditions to be adhered to before
the adjustment work

This does not apply for the option external heat ➯ Hand valves A - C completely open before
recovery. system starting.
(A only with the heat recovery option)
Settings of the hand valves without heat re- ➯ Ensure the cooling water supply is ade-
covery quate.
➯ Operate the system for at least 45 minutes
2 at full load.
° Maximum pressure and maximum speed
for speed-controlled systems.
° Maximum pressure for systems without
speed control.

This adjustment work must only be carried out

by trained maintenance personnel.
1 • Slowly close hand valve A (jacket / oil cooler)
until the oil temperature "1" has risen by about
1°C / 1.8°F.
• Slowly close hand valve B (interstage cooler)
until the second stage air inlet temperature "2"
is approximately 9°C / 16.2°F to 10°C / 18°F
above the water inlet temperature.
For water inlet temperatures that are well below
3 4
the ambient temperature, a second stage air in-
let temperature 2" of approximately 5°C / 9°F to
10°C / 18°F above ambient temperature must
Fig. 6-6: Display schematics GD Pilot TS be aimed for (avoidance of condensation).
The hand valves A, B and C are preset. Further • Slowly close hand valve C (aftercooler) until
adjustment is not normally necessary. In the event the temperature difference cooling water out-
that the values given below are not achieved, a let "3" to cooling water inlet "4" is approximately
readjustment can be undertaken. 15°C / 27°F.

The following specified values only apply after

at least 45 minutes operation under full load:
• Oil temperature "1" approximately 25°C / 45°F
above the cooling water inlet temperature "4".
• Second stage air inlet temperature 2" approx-
imately 9°C / 16.2°F to 10°C / 18°F above the
water inlet temperature "4".
• The temperature difference between cool-
ing water outlet "3" and cooling water inlet "4"
equals approximately 15°C / 27°F.

July 2015 GB 49 /112

 TM

6 Commissioning and operating

Settings of the hand valves with heat recov- 6.2 Normal operation
ery
Electronic control unit

1
Fig. 6-8: Control panel
[1] Touchscreen display
[2] Start button < I >.
[3] Stop button < O >
[4] red LED
flashing slowly: warning or maintenance
3 4 flashing rapidly: Fault
[5] yellow LED
Fig. 6-7: Display schematics GD Pilot TS flashing slowly: Maintenance necessary
Hand valve A is not preset. The hand valve must [6] green LED
be completely open before the system is started. lit up permanently: System in operation
Settings should only be made after at least 45 Flashing: System in standby
minutes operation under full load. [7] Pushbutton <Emergency-stop>
Dependent on the desired water outlet tempera-
ture, slowly close the manual valve A. The water
inlet temperature 4 and water outlet temperature 3 DANGER
can be read off on the display.
Risk of injury
The compressor can start automatically
The following limit values must be adhered to at any time when it is in standby mode
• The minimum temperature rise (inlet to outlet) with the green LED flashing.
is 20K. The rise value must not fall below this. ➯ Do not carry out any work on the
• The maximum cooling water outlet temperature compressor, if the green LED is
of 90°C must not be exceed. flashing.

DELCOS XL setting, “WRG option" Switching on

Depending on the water inlet temperature and 1 Press the start button < I > on the control
temperature increase, it may be necessary to ad- panel.
just the parameters of the “line temperature” and – The compressor is switched on.
“intercooler recooling” monitoring in line with the
– The compressor runs automatically (au-
temperatures to be expected.
tomatic operation). See the operating se-
quence description in the section "Operating
These parameters can be found in the factory sequence" in the chapter "Design and func-
settings menu. Please refer to the DELCOS XL tion".
D series operating instructions for more informa-
tion in this regard. 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]

50 / 112 GB July 2015

 TM

Commissioning and operating 6

Partial load operation (on-load operation at re- 6.4 Commissioning after a long
duced speed only VS compressors) [On-Load] shutdown
Off-load [Off-Load]
If commissioning after a long shutdown, contact
Observations during operation Gardner Denver.

During operation the compressor must be regu- 6.5 Commissioning after a fault
larly checked to ensure leak-tightness of the cool-
ing water circuit and oil circuit. NOTICE
Condensate drain Material damage
The condensate drains from the intercooler and af- Avoid switching the compressor on multiple
tercooler are activated under sensor control. times without rectification of the fault as this can
lead to considerable mechanical damage.
Switching off
➯ Only switch the compressor back on after
1 Press the stop button < O > on the control the fault is rectified.
panel.
– The compressor runs on for 30 seconds Re-commissioning after a fault (automatic
(soft stop). switching off)
After this time, drive motor and fan 1 are Faults are displayed in the display menu "Fault
switched off. log".
– Once the drive motor is stationary, oil pump, 1 Switch main switch off and secure to prevent
water pump and fan 2 are switched off. switching back on.
Emergency-stop 2 Rectify the fault.
See the "Troubleshooting" chapter.
The compressor can be rendered safe in danger-
ous situations using the emergency-stop pushbut- 3 Switch on the main switch.
ton. 4 Acknowledge fault in the fault log.
Emergency-stop pushbuttons are attached: 5 After acknowledgement, the message [Ready
to Start] appears on the display, provided no
• on the compressor control panel
other fault exists.
• 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
2 Rectify the fault that was the cause of the
the section "Control (automatic operation)"
Emergency-stop.
in the chapter "Design and function".
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 commis-
sioning after maintenance.
1 Open the shut-off valves between the compres-
sor and compressed air network.
2 Thereafter proceed as described in the section
"Initial commissioning".

July 2015 GB 51 /112

 TM

7 Troubleshooting

7 TROUBLESHOOTING
NOTICE
Troubleshooting instructions
The following tables list possible fault causes and Material damage
remedies. Material damage due to improper/incorrect trou-
The troubleshooting measures listed in these op- bleshooting measures.
erating instructions may only be carried out by ➯ If the remedies listed here are insufficient
specially trained personnel. All work going beyond for rectification of the fault, consult Gardner
this must be carried out by the manufacturer's ser- Denver.
vice personnel! Work on the electrical equipment ➯ For fault and warning messages that are
must only be carried out by authorised electricians output to the display of the electronic control
or electrical technicians. unit, observe the information in the "Trou-
Remedies are described in detail in the repair bleshooting" chapter in the operating in-
manual, which is provided as part of operator structions of the electronic control unit.
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

52 / 112 GB July 2015

 TM

Troubleshooting 7

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) and replace if
necessary.
Safety temperature switch has tripped and must be
reset (both switches: S21 + S22). Check cooling
circuit.
Cooling aftercooler faulty (system switches to off- Check cooling; repair if necessary. Reset mechan-
load via safety temperature switch) ical lock on both safety temperature switches
(S21 + S22).
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, non-
return 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.
Chart 7-6: Troubleshooting upon: Safety valve opens

July 2015 GB 53 /112

 TM

7 Troubleshooting

Possible Cause Remedy

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

Troubleshooting: Lubricator
If faults occur when operating the lubricator, please check the possible causes of error using the following
table.
Fault Possible Cause Remedy
Lubrication system not working Cable incorrectly connected Connect up cable correctly.
No voltage Check voltage at plug.
Cable failure Connect new cable.

Lubrication system signals Setting "VOL" switch Fit full grease cartridges.
“System running” (green LED)
Partially filled grease car-
although the grease cartridges
tridges fitted
are empty.
Lubrication system signalling Line and/or connection parts Clean line and connection parts,
“Fault" (red LED) blocked then switch lubrication system off
Back pressure too high and on again.

Lubrication system signals “End Setting "VOL" switch Fit full grease cartridges.
of dispensing” (red and green
Almost empty grease car-
LED) although the grease car-
tridges replaced with partially
tridges are not empty.
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 elec-
tronic control unit.

54 / 112 GB July 2015

 TM

Troubleshooting 7

7.1 Reset safety temperature

switch

Both safety temperature switches must be reset

again after cooling down and fault resolution/trou-
bleshooting. To do this, unscrew the cover caps
(1) and push the unlock keys (2) to the top end
position (release locks in audibly) using a screw-
driver. Once the screwdriver is removed the un-
lock keys fall back to the bottom end position. Re-
attach the cover caps after unlocking.

July 2015 GB 55 /112

 TM

8 Maintenance and Service

8 MAINTENANCE AND SERVICE

Maintenance and service are decisive for ensur-
ing that the compressor can fulfil the requirements
made of it for fault-free operation and running
time. Therefore the adherence to the prescribed
maintenance schedule and the careful execution
of all maintenance and service work are indispens- 1
able.
Support is available from your responsible Gard-
ner 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
The maintenance work listed in these operating system
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
1
Electric shock
Life-threatening electric shock
➯ When carrying out any work on the
electrical equipment, exercise ex-
treme care.
➯ Before starting the maintenance
work, switch the compressor to a Fig. 8-2: Position bleeder valve water-cooled compres-
voltage-free state and secure to pre- sor system
vent switching back on. [1] Bleeder valve

WARNING Safety with heating connection (HOC) full

flow (FF)
Risk of injury due to hot bleeder valve
Observe the safety instructions in the chapter
The compressed air outlet temperature
Safety conditions.
can be up to 90°C.
➯ Before opening the bleeder valve, WARNING
allow the compressor to cool.
Risk of injury due to hot bleeder valve
➯ Do not carry out any work when the
compressor system is hot The compressed air outlet temperature
can be up to 235°C.
➯ Before opening the bleeder valve,
allow the compressor to cool.
➯ Do not carry out any work when the
compressor system is hot

56 / 112 GB July 2015

 TM

Maintenance and Service 8

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

supply line.
2 Switch the main switch OFF.
3 Open the enclosure, create access.
4 Undo the lock screw on the closed air vent
valve (ball valve at the aftercooler).
1 5 Depressurise the aftercooler by careful opening
2 of the air vent valve.
6 Close the air vent valve and screw in the air
vent valve.
7 Upon completion of maintenance work, open
the shut-off valve in the supply line.

Test run
[1] Safety valve heating connection (HOC)
A test run should be carried out after all main-
[2] Pressure release heating connection
tenance work; this should amongst other things
(HOC), only with heating connection
make possible the detection of any leaks. During
(HOC) full flow (FF)
every test run, the low-noise running of the com-
pressor must also be ensured.
Protection measures for safe maintenance
(safety routine) Electrical components
For all maintenance work, if not expressly stated
elsewhere: DANGER
1 Switch the compressor off and secure to pre- Electric shock
vent switching back on.
Life-threatening electric shock
2 Drain the compressor.
➯ Work on the electrical equipment
3 Wait for automatic pressure discharge to com- must only be carried out by autho-
plete. rised electricians or electrical techni-
4 Connect the (site provided) shut-off valve in the cians.
supply line. ➯ With types EnviroAire TVS 110 -160
5 Wait until the residual electrical energy in the there is a risk of electric shocks due
capacitors has dissipated (only VS compres- to charged capacitors!
sors). Switch the compressor to a zero
volts state and wait 10 minutes be-
6 Allow the compressor to cool to room tempera-
fore touching any electrical parts.
ture.
➯ Checking the DC bus voltage.
7 Wear personal protective equipment.
8 Observe the information about hazardous sub- Check the DC bust voltage of the frequency
stances. converter

Manual pressure relief The DC bus voltage is measured at the mains ter-
minal strip of the frequency converter. The precise
WARNING position of the terminals "DC+" and "DC-" can be
taken from the supplied frequency converter oper-
Pressure components ating instructions.
Even when the compressor is depres- 1 Measure the voltage between the DC+ and
surised, the aftercooler remains under DC- terminals.
pressure. 2 Measure the voltage between the DC+ terminal
➯ Carry out manual pressure dis- and the chassis.
charge before maintenance work is 3 Measure the voltage between the DC- terminal
carried out in the vicinity of the after- and the chassis.
cooler.
The voltage must read zero in all three measure-
ments.

July 2015 GB 57 /112

 TM

8 Maintenance and Service

8.2 Service Functional checking of the safety valves

The global spare parts and customer service net- The functional checking of the safety valves must
work of Gardner Denver is available worldwide. be carried out by a safety specialist. The result of
The local Gardner Denver subsidiary or the re- the functional check must be documented.
sponsible dealer is available for any spare parts 1 Switch the main switch OFF.
requirements. 2 Open the enclosure, create access.
It is important that the model name and the serial 3 Press the start button < I >.
number of the compressor are stated in all mes- Allow the compressor to run under load.
sages.
NOTICE
Spare parts orders
Spare parts orders to: Hearing damage
Gardner Denver Deutschland GmbH Increased sound pressure level when operating
Aftersales without the sound-proofing enclosure.
Im Boorstück 9 ➯ Wear ear defenders.
D-55469 Simmern
Tel.: +49 (0)6761/832-136 WARNING
Fax.: +49 (0)6761/832-411
Fax.: +49 (0)6761/12746 Risk of burns/scalding
e-mail: ersatzteile@compair.com Risk of burns/scalding due to escaping
hot condensate / hot compressed air.
NOTE ➯ Wear suitable protective clothing.
The spare parts order is placed based on the ➯ Slowly screw out the knurled cap.
spare parts list which is available separately.
➯ Do not screw the knurled cap too far
out of the enclosure.
8.3 Inspection of protection and
safety equipment ➯ Tighten the knurled cap as far as it
will go after each functional check.
Protective covers and enclosure panels
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
Heat shield covers for the snubbers and
pipelines
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 Fig. 8-3: Safety valves

The switching function of the contacts can be [1] Safety valve

checked by an electrician. [2] Valve cap

NOTE 4 Turn the valve cap anticlockwise until an audi-

ble blowing off can be heard.
The Emergency-stop function must only be acti-
vated in dangerous situations. Otherwise the re- 5 Turn the valve cap clockwise as far as it will go.
sult could be increased wear or even damage to The valve must completely close again.
the compressor.
An electrician can check the switch function of the
contacts.

58 / 112 GB July 2015

 TM

Maintenance and Service 8

Option heating connection

WARNING
Risk of burns/scalding
Risk of burns/scalding due to escaping
hot condensate / hot compressed air
(max. 235°C).
➯ Only touch valve with suitable pro-
tective clothing.
1 2 ➯ Activate the manual valve for the
function test.

8.4 Routine maintenance

All maintenance work and checks listed in the
maintenance plan must be carried out and docu-
Fig. 8-4: Safety valve heating connection
mented at the specified intervals.
All maintenance, overhauls and repairs to the
[1] Safety valve heating connection (HOC)
compressor must be documented.
[2] Pressure release heating connection
Service and maintenance work must be carried
(HOC), only with heating connection
out by the local Gardner Denver agency.
(HOC) full flow (FF)
Cleanliness
WARNING The compressor room and the compressor sur-
Risk of burns due to hot compressed roundings must always be kept clean.
air The compressor must be checked regularly for
The compressed air outlet temperature damage and excess wear.
can be up to 235°C. Spilt oil must be immediately wiped up. Oil traces
must be removed immediately.
➯ Wear suitable protective clothing

Function check of the safety valve NOTE

The functional checking of the safety valves must Under no circumstances must oil get into the air
be carried out by a safety specialist. The result of inlet, into components or into the pipelines of the
the functional check must be documented. compressed air network.
1 Switch the main switch OFF.
Electrical connections
2 Open the enclosure, create access.
The condition of cables and terminals must be
3 Press the start button < I >. checked regularly.
Allow the compressor to run under load.
Check for loose connections or frayed or worn-
through wires.
NOTICE
All connections must be clean and tight.
Hearing damage
Immediately replace worn-through or damaged
Increased sound pressure level when operating wires.
without the sound-proofing enclosure.
➯ Wear ear defenders. Leak points

WARNING
Risk injury due to high pressure
➯ Do not manually investigate leak
points in the system.
➯ Always use paper or board for this
purpose.

July 2015 GB 59 /112

 TM

8 Maintenance and Service

If leaks are suspected, check the correspond- In the event of accidents or prolonged contact with
ing area for leaks. operating fluids, observe the information in the
Immediately repair or replace damaged or leak- hazardous substance data sheets!
ing pipe or hose connections. Prevent leakage of operating fluids.
Carefully clear up any operating fluids that escape.
Emission or leakage of operating fluids Observe the information in the hazardous sub-
The following operating fluids are used in the com- stance data sheets!
pressor:
Oil carbon deposits in the oil lubrication sys-
Corrosion inhibiting antifreeze coolant Havoline tem
XLC (harmful to health)
High oil temperatures reduce the service life of the
Lubricating oil Renolin AC68 (harmless if han- oil and this can lead to oil carbon deposits in the
dled normally) oil lubrication system. Oil carbon deposits can re-
sult in damage to the bearings and gearboxes.
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 Maintenance personnel
necessary.
Inlet filter cooling air switch Check and replace as neces- Maintenance personnel
cabinet (only VS compres- sary.
sors)
Condensate drain Intercooler, function check. Maintenance personnel
Aftercooler, function check. Maintenance personnel
Lubricating oil Check level and top up as Maintenance personnel
necessary.
Cooling system Check level and top up as Maintenance personnel
necessary.
Electronic control unit Check for displayed mainte- Operator
nance requirements.
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 operat- Operator
ing parameters.
Electronic control unit Check fault statistics. Operator
Air Filter Check air filter and filter car- Maintenance personnel
tridge, replace if necessary.
Hoses and pipelines Check for leaks or as the case Maintenance personnel
may be, damage.
Chart 8-2: Maintenance plan: Service A

60 / 112 GB July 2015

 TM

Maintenance and Service 8

Component Action Necessary qualification Executed

Electrical wiring Check connections and condi- Electrician
tion.
Compressor Maintain the compressor room Operator
and surroundings clean.
Dirt trap (only water-cooled Remove sieve and clean Maintenance personnel
compressors)
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 Trained service person-
airend). nel
Replace diaphragm (2nd Trained service person-
airend). nel
Control air filter Replace control air filter. Maintenance personnel
Maintenance unit Replace filter element. Maintenance personnel
Solenoid valve Y3 (vacuum Replace valve. Maintenance personnel
generator)
Lubricating oil Change the oil. Maintenance personnel
Electronic control unit Test the emergency-stop func- Operator
tion.
Safety temperature switch Replace switch combination Trained service person-
(S21 + S22) nel
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 person-
nel
Replacement solenoid valve Trained service person-
Y1. nel
Replacement solenoid valve Trained service person-
Y2. nel
Replace sealing washers. Trained service person-
nel
Non-return valve Replace complete valve. Trained service person-
nel
Chart 8-4: Maintenance plan: Service C

July 2015 GB 61 /112

 TM

8 Maintenance and Service

Component Action Necessary qualification Carried out

Drive clutch Check for play and replace Trained service person-
inserts if necessary. nel
Snubber (1st airend) Replace seals. Trained service person-
nel
Combined silencer and snub- Replace seals. Trained service person-
ber (2nd airend) nel
Intercooler Replace inlet seal. Trained service person-
nel
Aftercooler Replace inlet seal. Trained service person-
nel
Blow-off silencer Replace silencer. Trained service person-
nel
Condensate trap Replace complete condensate Trained service person-
drain. nel
Chart 8-4: Maintenance plan: Service C

Notes
Operating parameters:The current settings, e.g. maximum line pressure [Line Pressure max.] and mini-
mum line pressure [Line Pressure min.] should be documented in the customer operations log. Implemen-
tation 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 de-
tailed in the following chapter. All other maintenance work must be carried out by trained service person-
nel using the repair manual.
Service cycles: The earliest date always applies; i.e. if the operating hours are reached before the calen-
dar 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 labora-
tory 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
EnviroAire T 75 - 160 V2 CK8135-1-GD
EnviroAire TVS 110 - 160 V2 CK8135VS-1-GD
Chart 8-5: Part numbers for servicing kits

62 / 112 GB July 2015

 TM

Maintenance and Service 8

Model number Figure Service C

EnviroAire T 75 - CK16135-1-GD
TVS160 V2
* = snubber with
fixed insert

A+W *

EnviroAire T 75 - CK16135-2-GD
TVS160 V2
* = snubber with *
loose insert

A+W+HOC - PF
EnviroAire T 75 - CK16135-3-GD
TVS160 V2
* = snubber with *
loose insert

HOC - FF
Operating fluids Article number
Lubricating oil (Renolin AC68) 100014655
Corrosion inhibiting antifreeze coolant Havoline XLC ZS1101248
Chart 8-6: Part numbers for operating fluids

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:

July 2015 GB 63 /112

 TM

8 Maintenance and Service

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 elec-
tronic control unit operating instructions.

8.6 Maintenance work Drive clutch

8.6.1 Accesses Snubber

Access to the components inside the compressor Access 3 provides access to:
system is via the accesses in the enclosure listed Drive motor
below.
Solenoid valve Y3

Fig. 8-5: Accesses 1 - 3

Fig. 8-6: Accesses 4 - 5
[1] Access 1
[2] Access 2 [4] Access 4

[2] Access 3 [5] Access 5

Access 1 provides access to: Access 4 provides access to:

Cooling-water expansion tank Air Filter

Oil level indicator and oil filler neck Aftercooler

Condensation drain 1st airend Non-return valve

Blow-off silencer Access 5 provides access to:

Suction regulator Switch cabinet

Ultra-fine filter
Oil Filter
Balance piston
Maintenance unit
Control air filter
Shuttle valve
Solenoid valves (Y1 and Y2)
Access 2 provides access to:

64 / 112 GB July 2015

 TM

Maintenance and Service 8

8.6.2 Filter mat cooling air inlet 8.6.3 Inlet filter cooling air switch
cabinet (VS compressors)

Fig. 8-7: Silencing baffle with upstream filter mat

[1] Compressed air connection Fig. 8-8: Inlet filter (only VS compressors)
[2] Filter mat cooling air inlet
[3] Condensate drain
[4] Supply line cover panel

The compressor is equipped with a coarse-

meshed filter mat. The filter mat is used to pre-fil-
ter the inlet air.
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.
Fig. 8-9: Opening the inlet filter
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.
6 Attach the fastening screws.

Fig. 8-10: Inlet filter, opened

The switch cabinet is equipped with four inlet fil-
ters.

July 2015 GB 65 /112

 TM

8 Maintenance and Service

The filter pad of the inlet filter cannot be cleaned, Check the condensate drain.
rather must be replaced if it becomes clogged with 1 Switch the main switch OFF.
dust.
2 Open the enclosure, create access.
1 Pivot open the louvred grille of the inlet filter.
3 Switch the main switch ON.
2 Remove the filter pad.
4 Press button <Test>.
3 Check the condition of the filter pad. Condensate flows away.
– If necessary, replace the filter pad.
NOTE
4 Insert the filter pad into the louvred grille.
The soft side ("A") of the filter pad must point With transparent lines, the condensate drain-off
outwards (towards the louvred grille). can be monitored directly, with opaque lines, it
5 Place the louvred grille onto the filter housing. can be checked at the outlet.
– Replace the condensate drain once no conden-
8.6.4 Condensate drain
sate flows away.
Automatic condensate drain
5 Close the enclosure.
Moisture contained in the compressed air network
condenses in the air coolers (intercooler and after- 8.6.5 Lubricating oil
cooler) and is separated by the cyclone separator.
Checking the fill level
The condensate is automatically drained off by the
condensate drain that is attached to the cyclone
separator.

Check the function of the condensate drain

valve

Fig. 8-12: 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.
Fig. 8-11: Condensate drain 2 Open the enclosure, create access.
[1] Condensate separator 3 Check the level at the level indicator.
[2] Condensate trap The fill level must be between the "min." and
"max." markings.
[3] Button <Test>
The oil volume between the "min" and "max"
[4] Connecting screw markings is approximately 3 l.
[5] Electrical connections – Top up with oil if the oil level is too low.

66 / 112 GB July 2015

 TM

Maintenance and Service 8

4 Close the enclosure. Changing the oil

Topping up the oil

Fig. 8-14: Lubricating oil system

Fig. 8-13: Lubricating oil system [1] Oil / water cooler

[2] Oil temperature control valve
[1] Oil / water cooler
[3] Oil Filter
[2] Oil temperature control valve
[4] Oil pump
[3] Oil Filter
[5] Oil filler neck
[4] Oil pump
[6] Oil level indicator
[5] Oil filler neck
[7] Oil sump
[6] Oil level indicator
[8] Oil drain
[7] Oil sump
[8] Oil drain Oil can be drained via the oil drain. Fresh oil is
topped up via the oil filler neck.
NOTE Where possible drain the oil while still warm so
that it can flow out more easily.
Do not mix different oil types together.
Always only top up with the currently used oil. WARNING
1 Switch the main switch OFF.
Risk of scalding
2 Open the enclosure, create access.
Risk of scalding by hot oil.
3 Remove the cap from the oil filler neck.
➯ Only change the oil when the com-
4 Top up the oil in small quantities and wait until pressor is stationary and depres-
the oil has settled in the system. surised.
This prevents over filling.
➯ Caution when draining hot oil.
5 Place the cap on the oil filler neck and close.
6 Close the enclosure. NOTE
Drain used oil as completely as possible, as
used oil greatly reduces the service life of the
new oil charge.

July 2015 GB 67 /112

 TM

8 Maintenance and Service

1 Switch the main switch OFF.

NOTE 2 Open the enclosure, create access.
Catch the used oil, do not allow it to seep into 3 Unscrew the old oil filter and dispose of.
the ground. 4 Apply a thin film of oil to the seal of the new oil
Dispose of according to the regulations! filter.
Do not spill oil! 5 Screw the oil filter on by hand and tighten. Ob-
Ensure leak tightness! serve the instructions on the oil filter!
6 Tighten the oil filter by a further quarter turn.
1 Switch the main switch OFF.
7 Close the enclosure.
2 Open the enclosure, create access.
3 Position a suitable container beneath the oil 8.6.6 Ejector vent system
drain.
Function check / adjust vacuum pressure
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.
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

Fig. 8-16: Ejector vent system, schematic diagram

[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

Included in checking of the ejector vent system is

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

Fig. 8-15: 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 Fil-
ter] is displayed on the electronic control unit.

68 / 112 GB July 2015

 TM

Maintenance and Service 8

7 Adjust the pressure regulator so that -5 mbar is

displayed on the vacuum pressure sensor.
8 Close the enclosure.

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 adjust-
ment is adequate for fault-free operation.

Changing the filter element of the mainte-

nance unit

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

1 Switch the main switch OFF. Fig. 8-18: Ejector vent system
2 Open the enclosure, create access. [1] Suction regulator
3 Switch the main switch ON. [2] Blow-off valve
4 Press the start button < I >. [3] Maintenance unit
Allow the compressor to run under load.
[4] Control air filter
NOTICE [5] Vacuum pressure sensor
Hearing damage [6] Solenoid valve Y1
Increased sound pressure level when operating [7] Solenoid valve Y2
without the sound-proofing enclosure. [8] Shuttle valve
➯ Wear ear defenders. [9] Ultra-fine filter
5 Check whether air from the opening of the vent The filter element of the maintenance unit in the
housing is discharged. ejector vent system must be changed regularly.
No oil film should form on the air outlet!
1 Switch the main switch OFF.
6 Check the vacuum pressure at the display of
2 Open the enclosure, create access.
the vacuum pressure sensor.
3 Unscrew the casing bottom.

July 2015 GB 69 /112

 TM

8 Maintenance and Service

4 Unscrew the filter holder with the filter element. Replacing the ultra-fine filter element
5 Take off the guide plate and housing seal.
6 Take off the filter element.
7 Undo the knurled screw and demount the float
deflector in the casing bottom.
8 Clean the casing bottom and float deflector us-
ing mild cleaning agent and then blow-off with
compressed air.

WARNING
Risk of injury
Risk of injury to the eyes.
➯ Wear safety glasses.
9 Insert the float detector in the casing bottom
and tighten using the knurled screw.
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. 8-19: 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 ultra-fine filter element in the ejector vent sys-

tem must be changed regularly.
1 Switch the main switch OFF.
2 Open the enclosure, create access.
3 Loosen the drainage line at the bottom on the
filter housing.
4 Screw off the filter housing.
5 Unscrew the ultra-fine filter element and dis-
pose of.
6 Apply a thin film of oil to the seal of the new ul-
tra-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.

70 / 112 GB July 2015

 TM

Maintenance and Service 8

Replacing solenoid valve Y3 4 Demount the solenoid coil from the valve body.
5 Demount the valve body.
6 Fit new valve bodies. When doing so use the
existing fittings and seal using thread sealing
paste or tape.
7 Fit the solenoid coil on the valve body.
8 Connect the electrical connections to the sole-
noid valve.
9 Close the enclosure.

8.6.7 Cooling system

Checking the fill level

3
A
I 4

O 5

W
I
3
2
O
Fig. 8-20: Solenoid valve Y3
[1] Second stage condensate separator 1 6

(aftercooler water separator) 7

[2] Compressed air connection

[3] Solenoid valve Y3 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
1 [7] Oil / water cooler

The fill level should be checked approximately 10

minutes after switching the compressor off, then
the cooling water will have settled in the system.
Fig. 8-21: Solenoid valve Y3 with option heating connec-
1 Switch the main switch OFF.
tion (HOC) full flow (FF)
2 Open the enclosure, create access.
[1] Solenoid valve Y3
3 Check the cooling water level at the level indi-
The solenoid valve Y3 in the ejector vent system cator on the expansion tank.
must be changed regularly. The fill level must be between the "min." and
"max." markings.
1 Switch the main switch OFF.
The cooling water volume between the "min"
2 Open the enclosure, create access. and "max" markings is approximately 0.6 l.
3 Undo the electrical connections from the sole- – Top up with cooling water if the cooling wa-
noid valve. ter level is too low.

July 2015 GB 71 /112

 TM

8 Maintenance and Service

4 Close the enclosure. 4 Top up with cooling water until the required fill-
ing level is reached.
Refill cooling water Top up cooling water in small quantities and
wait until the cooling water has settled in the
system. This prevents over filling.
3
A
5 Fit the cap on the expansion tank.
I 4 6 Close the enclosure.
O 5 Changing the cooling water
W
I 3
A
3
2
O I 4

O 5
1 6

W
7
I
3
2
Fig. 8-23: Internal cooling water system O

[A] To the water/air cooler

[B] From the water/air cooler 1 6

[1] Water pump 7

[2] Temperature control valve

[3] Water/air cooler Fig. 8-24: Internal cooling water system
[4] Expansion line [A] To the water/air cooler
[5] Expansion tank with level sensor [B] From the water/air cooler
[6] Cooling water drain [1] Water pump
[7] Oil / water cooler [2] Temperature control valve
[3] Water/air cooler
NOTE [4] Expansion line
The mixing ratio of the cooling water is 33% gly- [5] Expansion tank with level sensor
col (Havoline XLC ethylene glycol (basis)) and [6] Cooling water drain
67% water.
[7] Oil / water cooler
WARNING The cooling water can be drained via the cooling
Risk of scalding water drain. Fresh cooling water is topped up via
the expansion tank.
Risk of scalding due to escaping hot
cooling water. Draining the cooling water
➯ Only open the cap of the expansion 1 Switch the main switch OFF.
tank once the internal cooling water
2 Open the enclosure, create access.
system has cooled sufficiently.
3 Position a suitable container beneath the cool-
➯ Carefully open the cap and let any
ing water drain.
pressure leak out.
4 Open the cap on the expansion tank.
➯ Only then should the cap be com-
pletely opened. 5 Open the drain valve and allow the cooling wa-
ter to flow out completely. Dispose of the cool-
1 Switch the main switch OFF. ing water.
2 Open the enclosure, create access. 6 Close the drain valve.
3 Remove the cap from the expansion tank.

72 / 112 GB July 2015

 TM

Maintenance and Service 8

Filling with cooling water Cleaning the dirt trap

1 Remove the cap from the expansion tank.
WARNING
2 Top up with cooling water until the required fill-
ing level is reached. Risk of scalding
Top up cooling water in small quantities and Risk of scalding due to escaping hot
wait until the cooling water has settled in the cooling water.
system. This prevents over filling.
➯ Only open the cap of the expansion
3 Fit the cap on the expansion tank. tank once the internal cooling water
4 Switch the main switch ON. system has cooled sufficiently.
5 Press the start button < I >. ➯ Carefully open the cap and let any
Let the compressor run for approximately 5 pressure leak out.
minutes under load until the cooling water has
➯ Only then should the cap be com-
been distributed around the system. pletely opened.
6 Press stop button< O >.
7 Check the fill level. WARNING
8 Top up with cooling water, if necessary. Legionella contamination
9 Close panel Health risk with open cooling systems.

Cleaning the dirt trap ➯ Constant testing of the water quality

in the cooling circuit for the number
of microbes.
1
2 1 Switch main switch OFF and secure to prevent
restarting.
3
2 Isolate the cooling water supply and outlet.
3 Open the enclosure, create access.
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.
8 Fit the dirt trap sieve.
9 Close the enclosure.
10 Re-open the cooling water supply and outlet.
11 Check for leaks.

[1] Safety valve

[2] Strainer
[3] Water stop valve

July 2015 GB 73 /112

 TM

8 Maintenance and Service

8.6.9 Air Filter Replace the air filter element

NOTICE
Material damage
Operation of the compressor without air filters,
even briefly, can result in considerable damage
to the compressor.
➯ Never operate the compressor without an
air filter.
➯ No dirt must get into the clean air side of the
air filter!
1 Switch the main switch OFF.
2 Open the enclosure, create access.
3 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

Fig. 8-25: Air Filter
The control air filter removes moisture and solid
[1] Air Filter bodies from the control air system.
[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.
Moreover the air filter must be changed, if the
message [Service due] or [Air Filter] is displayed
on the electronic control unit.

Checking the air filter

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 con-
taminated.
5 Fit the air filter cover.
6 Close the enclosure.

74 / 112 GB July 2015

 TM

Maintenance and Service 8

Replacing the filter element of the control air 10 Screw the casing bottom on hand-tight.
filter 11 Close the enclosure.

8.6.11 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).

Replacing a grease cartridge

[1] Suction regulator

[2] Blow-off valve
[3] Maintenance unit
[4] Control air filter
[5] Vacuum pressure sensor
[6] Solenoid valve Y1 Fig. 8-26: Lubricator
[7] Solenoid valve Y2 [1] Cable with plug
[8] Shuttle valve [2] Lubricator drive
[9] Ultra-fine filter [3] Grease cartridge
1 Switch the main switch OFF. [4] Drive motor
2 Open the enclosure, create access. 1 Switch the main switch OFF.
3 Unscrew the casing bottom. 2 Open the enclosure, create access.
4 Unscrew the filter holder with the filter element. 3 Pull the plug off from the lubricator.
5 Take off the guide plate and housing seal. 4 Unscrew lubricator (grease cartridge with drive
6 Take off the filter element. and cover) from the lubricating point.
7 Clean the casing bottom using mild cleaning 5 Unscrew the cover from the grease cartridge.
agent and then blow-off with compressed air. 6 Remove the drive from the grease cartridge.
WARNING 7 Place the drive on the new grease cartridge.
The toothing of the two parts must intermesh.
Risk of injury 8 Screw the cover on to the grease cartridge and
Risk of injury to the eyes. tighten by hand.
➯ Wear safety glasses. 9 Remove the stopper-plug from the grease car-
tridge.
8 Insert a new filter element.
9 Position the guide plate and casing seal.

July 2015 GB 75 /112

 TM

8 Maintenance and Service

10 Screw lubricators into lubricating point (hand 8.6.12 Control system

tight).
Testing the Emergency-stop pushbutton
11 Insert the plug in the drive.

Function check of the lubricator

[1] Touchscreen display

[2] Start button < I >.
[3] Stop button < O >
[4] red LED
flashing slowly: warning or maintenance
flashing rapidly: Fault
[5] yellow LED
flashing slowly: Maintenance necessary
Fig. 8-27: Lubricator display elements [6] green LED
lit up permanently: System in operation
[1] Function display (2 LEDs)
Flashing: System in standby
[2] "TIME" switch
[7] Pushbutton <Emergency-stop>
[3] Plug connection
[4] "VOL" switch NOTE
1 Check the function using the LEDs. The Emergency-stop function must only be acti-
vated in dangerous situations. Otherwise the re-
LED Signal Explanation
sult could be increased wear or even damage to
Green Continuous signal OK. “System run- the compressor.
ning”.
Only test the Emergency-stop pushbutton when
Red Continuous signal Dispensing the compressor is at a standstill.
< 30 seconds process 1 Press stop button< O >.
Red Continuous signal Error/Fault – The electronic control unit status message
> 30 seconds is [Ready to Start].
Green Continuous signal Grease cartridge 1 Press the <Emergency-stop> pushbutton.
and red empty, change – The electronic control unit displays the fault
Chart 8-7: LEDs 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.

76 / 112 GB July 2015

 TM

Appendix 9

9 APPENDIX 9.3 Removal

9.1 Shutdown WARNING
Routine shutdown
Harmful to health
Routine shutdowns are for example shutdowns for
Risk of damage to health due to operat-
maintenance work.
ing fluids and additives
1 Switch main switch OFF and secure to prevent
Lubricants and additives may cause ir-
switching back on.
reparable damage to the health, trigger
2 Close the shut-off valves between the com- allergies or irritate the mucous mem-
pressor and compressed air network. brane.
3 Depressurise the aftercooler by careful opening ➯ When handling lubricants and ad-
of the air vent valve. ditives, always observe the locally
valid operating instructions/haz-
Shutdown for a longer period ardous substance data sheets.
For shutdowns longer than six months, contact ➯ Avoid direct contact with lubricants
Gardner Denver. and additives. Wear personal pro-
tective equipment!
Final shutdown
➯ Where injuries occur in which lubri-
To prevent restarting of the compressor or misuse
cants and additives are involved,
by unknown parties, the compressor must be ren-
consult a doctor and name the sub-
dered unusable.
stances involved.
The compressor is rendered unusable by removal Have the hazardous substance data
of the electronic control unit. Contact Gardner sheet readily available.
Denver for advice.
CAUTION
9.2 Lubricants and additives
Risk of slipping
The compressor contains approximately 24 litres
of oil for lubricating the gearbox and the bearings Risk of slipping due to escaped operat-
of the airend unit. ing fluid
The drive motor lubricator contains two grease ➯ Immediately clear up any operating
cartridges. fluid that has escaped.
The internal water circuit contains a water-glycol ➯ Avoid direct contact with operat-
mixture (approximately 70% water and 30% gly- ing fluids. Wear personal protective
col). equipment!

Safety data sheets Preconditions

When handling operating fluids and additives, the The compressor is out of service.
corresponding safety data sheets must be ob- – The compressor is switched to a zero volts
served. state.
Lubricating oil: Renolin AC68 – The main switch is switched to OFF and se-
Lubricating grease: MOBIL POLYREX EM cured to prevent switching back on.

Cooler corrosion inhibitor and antifreeze: Havo- – The compressor is depressurised.

line XLC – Liquids and fats are as far as possible re-
moved.

July 2015 GB 77 /112

 TM

9 Appendix

Demounting the power supply 3 Unscrew lubricator (grease cartridge with drive
and cover) from the lubricating point.
DANGER 4 Close the lubricating point.
Electric shock 5 Close the enclosure.
Life-threatening electric shock
Demounting the air filter
➯ Work on the electrical equipment 1 Demount all filter elements and filter mats. Dis-
must only be carried out by autho-
pose of filter elements and filter mats.
rised electricians or electrical techni-
cians. – Air filter cartridge

1 Disconnect the power supply cable, see the – Filter mat

wiring diagram. – Inlet filter cooling air switch cabinet (only VS
2 Remove the power supply cable. compressors)

3 Attach plugs to the power supply cable open- – Control air filter
ings.
9.4 Disposal
Demounting the pipelines General
1 Disconnect the compressed air connection. The compressor must be dismantled and stripped
2 Disconnect the condensate drain pipes. down by specialised personnel. The applicable lo-
3 Allow the condensate to drain away completely. cal safety and environmental protection regula-
tions must be adhered to when doing this.
4 Immediately clear up any condensate that has
escaped. When disposing of substances harmful to health,
the instructions of the corresponding safety data
Draining the cooling water sheets must be observed.
1 Open the enclosure, create access. Packaging material, cleaning agents and used or
residual lubricants must be delivered to a recycling
2 Position a suitable container beneath the cool-
centre in accordance with the regulations valid in
ing water drain.
the place of use.
3 Open the drain valve and allow the cooling wa-
ter to flow out completely. Dispose of the cool- WEEE-Directive
ing water. In accordance with the WEEE directive (2002/96/
4 Close the drain valve. EC), Gardner Denver undertakes to support the
5 Close the enclosure. recovery and reuse of electrical and electronic de-
vices. Contact Gardner Denver for advice.
Draining the lubricating oil
Disposal
1 Open the enclosure, create access.
The compressor should be stripped down into its
2 Position a suitable container beneath the oil component parts to permit disposal "according to
drain. material composition", for example into base met-
3 Open the drain valve and allow the oil to flow als, plastics, textile products.
out completely. Dispose of the lubricating oil. Biodegradable parts should be delivered to normal
4 Close the drain valve. industrial waste disposal processes. Plastics, rub-
5 Close the enclosure. ber or composite materials must not be disposed
of by burning.
Demounting the oil filter All liquid waste substances such as lubricating
1 Demount out all oil filters in the lubricating sys- oil or grease, antifreeze, cooling liquids or corro-
tem. Dispose of the filters. sion inhibitors must be disposed of using specially
approved waste disposal or recycling systems.
– Oil Filter
When doing so, it must be ensured that these sub-
– Ultra-fine filter stances do not get into the sewage system.

Demounting the grease cartridges of the drive The following table provides an overview for the
motor lubricator disposal of substances and materials used.

1 Open the enclosure, create access.

2 Pull the plug off from the lubricating system.

78 / 112 GB July 2015

 TM

Appendix 9

Material / Disposal type

substance
Recycling Landfill Haz-
ardous
waste
Metals x
Cable x
Seals x
Plastics x 1 x
Filters x
Operating x2
fluids
Chart 9-1: Substances and materials used and their dis-
posal
1 Where possible
2 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
Carbonate hardness CaCO3 < 100 mg/l (5.6 °dH) < 50 mg/l (2.8 °dH)
Total hardness < 2 mmol/l < 0,5 mmol/l
< 200 ppm < 50 ppm
< 11.5 °dH < 2.8 °dH
< 20 °fH < 5 °fH
Chloride Cl- < 200 mg/l < 50 mg/l
Sulfate SO42- < 200 mg/l < 50 mg/l
Nitrate NO3- < 100 mg/l < 100 mg/l
Organic materials (KMnO4 absorption) < 25 mg/l < 10 mg/l
free aggressive carbonic acid CO2 < 20 mg/l < 20 mg/l
Silicon dioxide SiO2 < 10 mg/l < 10 mg/l
Free chlorine Cl2 < 4 mg/l < 2 mg/l
Oxygen O2 < 2 mg/l < 2 mg/l
Ammonium NH4+ < 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 S2- 0 0
Chart 9-2: Limit values of dissolved matter

July 2015 GB 79 /112

 TM

9 Appendix

Dissolved matter / specific values Circulating water Through-flow water

Ammonia NH3 0 0
Conductivity > 50 < 800 µS/cm > 50 < 200 µS/cm
Chart 9-2: Limit values of dissolved matter

9.6 Technical Specification

9.6.1 EnviroAire T 75 + T 90, 50Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire T 75 + T 90, EnviroAire T 75 EnviroAire T 90
50Hz, 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] 4,0
Ambient temperature [°C] 2 / 45 2 / 40 2 / 45 2 / 40
Volume flow [m3/min] 12.91 10.63 15.65 13.79
After cooler outlet temperature above ambient "A" [°C] 6 5 7
temperature
Aftercooler outlet temperature above ambient "W" [°C] 5 6 6
temperature
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 [A] 175 199
(400V)
Electric motor 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] 3 x 70 PE35 3 x 95 PE50
Recommended fuse rating (time-delayed) [A] 3 x 200 3 x 250
Cooling air volume flow [m3/min] ("A" = 255) ; ("W" = 85)
Cooling air outlet temperature above ambient [°C] "A" = 19 "A" = 23
temperature
Residual pressure at ambient temperature "A" [Pa] 45 / 20 45 / 35 40 / 15 40 / 30
[35 °C / [35 °C / [35 °C / [35 °C /
45 °C] 40 °C] 40 °C] 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 89 @Δp=0.7 bar 111 @Δp=0.9 bar
Chart 9-3: Technical data; EnviroAire T 75 + T 90, 50Hz, air-cooled "A" and water-cooled "W" (European version)

80 / 112 GB July 2015

 TM

Appendix 9

EnviroAire T 75 + T 90, EnviroAire T 75 EnviroAire T 90

50Hz, air-cooled "A" and water-cooled
"W" (European version)
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Max. cooling water pressure, external [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"= 3023 ; "A"=3223 ;
"W"=3223 "W"=3423
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-3: Technical data; EnviroAire T 75 + T 90, 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.2 EnviroAire T 110 + T 132, 50Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire T 110 + T 132, EnviroAire T 110 EnviroAire T 132
50Hz, 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] 4,0
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 "A" = [°C] 6 6 7 7
temperature
Aftercooler outlet temperature above ambient "W" = [°C] 7 8 7 8
temperature
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 [A] 249 285
(400V)
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)
Chart 9-4: Technical data; EnviroAire T 110 + T 132, 50Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 81 /112

 TM

9 Appendix

EnviroAire T 110 + T 132, EnviroAire T 110 EnviroAire T 132

50Hz, air-cooled "A" and water-cooled
"W" (European version)
Recommended cable cross-section (400V) [mm2] 2 x 3 x 50 PE50 2 x 3 x 70 PE70
Recommended fuse rating (time-delayed) [A] 6 x 160 6 x 200
Cooling air volume flow [m3/min] ("A" = 338) ; ("W" = 85)
Cooling air outlet temperature above ambient [°C] "A" = 22 "A" = 25
temperature
Residual pressure at ambient temperature "A" [Pa] 120 / 40 120 / 85 110 / 25 110 / 80
[35 °C / [35 °C / [35 °C / [35 °C /
45 °C] 40 °C] 45 °C] 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 132 @Δp=1.0 bar 155 @Δp=1.2 bar
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3265 ; "A"=3432 ;
"W"=3465 "W"=3632
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-4: Technical data; EnviroAire T 110 + T 132, 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.3 EnviroAire T 160, 50Hz, air-cooled "A" and water-cooled "W" (European version)
EnviroAire T 160, EnviroAire T 160
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 "A" = [°C] 9
temperature
Aftercooler outlet temperature above ambient "W" = [°C] 9
temperature
Sound pressure level (ISO 2151) "A" [dB(A)] 78
Chart 9-5: Technical data; EnviroAire T 160, 50Hz, air-cooled "A" and water-cooled "W" (European version)

82 / 112 GB July 2015

 TM

Appendix 9

EnviroAire T 160, EnviroAire T 160

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

Sound pressure level (ISO 2151) "W" [dB(A)] 76

Rated output drive motor [kW] 160
Total current consumption during load operation [A] 340
(400V)
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] 6 x 250
Cooling air volume flow [m3/min] ("A" = 338) ; ("W" = 85)
Cooling air outlet temperature above ambient [°C] "A" = 27
temperature
Residual pressure at ambient temperature "A" [Pa] 90 / 50 [35 °C / 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 170 @Δp=1.3 bar
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3644 ; "W"=3844
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-5: Technical data; EnviroAire T 160, 50Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 83 /112

 TM

9 Appendix

9.6.4 EnviroAire TVS 110, 50Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire TVS 110, EnviroAire EnviroAire
50Hz, air-cooled "A" and water-cooled TVS 110 TVS 110
"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 max. min max.
speed speed speed 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 10.51 / 17.37 /
10 10
After cooler outlet temperature above ambient "A" [°C] 4 6
temperature
Aftercooler outlet temperature above ambient "W" [°C] 7 8
temperature
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] 110
Total power consumption during load operation [A] 262 / 249
(380V / 400V)
Electric motor 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 + [mm2] 3 x 95 PE50
400V)
Recommended fuse rating (time-delayed) (380V [A] 3 x 300
+ 400V)
Cooling air volume flow [m3/min] ("A" = 338) ; ("W" = 85)
Cooling air outlet temperature above ambient [°C] "A" = 22
temperature
Residual pressure at ambient temperature "A" [Pa] 120 / 40 [35 120 / 85 [35
°C / 45 °C] °C / 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 132 @Δp=1.0 bar
Chart 9-6: Technical data; EnviroAire TVS 110, 50Hz, air-cooled "A" and water-cooled "W" (European version)

84 / 112 GB July 2015

 TM

Appendix 9

EnviroAire TVS 110, EnviroAire EnviroAire

50Hz, air-cooled "A" and water-cooled TVS 110 TVS 110
"W" (European version)
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3278 ; "W"=3478
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-6: Technical data; EnviroAire TVS 110, 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.5 EnviroAire TVS 132, 50Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire TVS 132, EnviroAire EnviroAire
50Hz, air-cooled "A" and water-cooled TVS 132 TVS 132
"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 max. min max.
speed speed speed 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 10.51 / 20.85 /
10 10
After cooler outlet temperature above ambient "A" = [°C] 10 8
temperature
Aftercooler outlet temperature above ambient "W" = [°C] 7 8
temperature
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] 132
Total power consumption during load operation [A] 269 / 255
(380V / 400V)
Electric motor IP55 (IE3) - IEC
60034-2-1 ECA Qualifying
Rated speed drive motor [rpm] 1550 / 3380 1959 / 3500
Chart 9-7: Technical data; EnviroAire TVS 132, 50Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 85 /112

 TM

9 Appendix

EnviroAire TVS 132, EnviroAire EnviroAire

50Hz, air-cooled "A" and water-cooled TVS 132 TVS 132
"W" (European version)
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 + [mm2] 3 x 120 PE70
400V)
Recommended fuse rating (time-delayed) (380V [A] 3 x 300
+ 400V)
Cooling air volume flow [m3/min] ("A" = 338) ; ("W" = 85)
Cooling air outlet temperature above ambient [°C] "A" = 26
temperature
Residual pressure at ambient temperature "A" [Pa] 110 / 25 [35 110 / 80 [35
°C / 45 °C] °C / 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 155 @Δp=1.2 bar
Cooling water inlet temperature [°C] min. = 5 ; max. = 42
Cooling water outlet temperature [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3476 ; "W"=3676
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-7: Technical data; EnviroAire TVS 132, 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.6 EnviroAire TVS 160, 50Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire TVS 160, EnviroAire TVS 160
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
Chart 9-8: Technical data; EnviroAire TVS 160, 50Hz, air-cooled "A" and water-cooled "W" (European version)

86 / 112 GB July 2015

 TM

Appendix 9

EnviroAire TVS 160, EnviroAire TVS 160

50Hz, air-cooled "A" and water-cooled
"W" (European version)
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 "A" = [°C] 8
temperature
Aftercooler outlet temperature above ambient "W" = [°C] 8
temperature
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] 160
Total power consumption during load operation [A] 304 / 289
(380V / 400V)
Electric motor 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 + [mm2] 3 x 150 PE95
400V)
Recommended fuse rating (time-delayed) (380V [A] 6 x 355
+ 400V)
Cooling air volume flow [m3/min] ("A" = 338) ; ("W" = 85)
Cooling air outlet temperature above ambient [°C] "A" = 26
temperature
Residual pressure at ambient temperature "A" [Pa] 90 / 50 [35 °C / 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 170 @Δp=1.3 bar
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3688 ; "W"=3888
Chart 9-8: Technical data; EnviroAire TVS 160, 50Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 87 /112

 TM

9 Appendix

EnviroAire TVS 160, EnviroAire TVS 160

50Hz, air-cooled "A" and water-cooled
"W" (European version)
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-8: Technical data; EnviroAire TVS 160, 50Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.7 EnviroAire T 75 + T 90, 60Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire T 75 + T 90, EnviroAire T 75 EnviroAire T 90
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] 4,0
Ambient temperature [°C] 2 / 45 2 / 40 2 / 45 2 / 40
Volume flow [m³/min] 12.39 10.85 15.92 13.15
After cooler outlet temperature above ambient "A" [°C] 6 5 7 6
temperature
Aftercooler outlet temperature above ambient "W" [°C] 5 5 6 6
temperature
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] 75 90
Total power consumption during load operation [A] 198 / 152 225 / 173
(380V / 460V)
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 / [mm²] 3 x 95 PE50 / 3 x 95 PE50 /
460V) 3 x 50 PE25 3 x 70 PE35
Recommended fuse rating (time-delayed) (380V [A] 3 x 250 / 3 x 160 3 x 250 / 3 x 200
+ 460V)
Cooling air volume flow [m³/min] ("A" = 225) ; ("W" = 95)
Cooling air outlet temperature above ambient [°C] "A"=19 "A"=23
temperature
Residual pressure at ambient temperature "A" [Pa] 45 / 20 45 / 35 40 / 15 40 / 30
[35 °C / [35°C / [35 °C / [35°C /
45 °C] 45°C] 45 °C] 40°C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 89 @Δp=0.7 bar 111 @Δp=0.9 bar
Chart 9-9: Technical data; EnviroAire T 75 + T 90, 60Hz, air-cooled "A" and water-cooled "W" (European version)

88 / 112 GB July 2015

 TM

Appendix 9

EnviroAire T 75 + T 90, EnviroAire T 75 EnviroAire T 90

60Hz, air-cooled "A" and water-cooled
"W" (European version)
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3023 ; "A"=3223 ;
"W"=3223 "W"=3423
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-9: Technical data; EnviroAire T 75 + T 90, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.8 EnviroAire T 110 + T 132, 60Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire T 110 + T 132, EnviroAire T 110 EnviroAire T 132
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] 4,0
Ambient temperature [°C] 2 / 45 2 / 40 2 / 45 2 / 40
Volume flow [m³/min] 18.99 16.89 22.59 21.00
After cooler outlet temperature above ambient "A" [°C] 6 6 7 7
temperature
Aftercooler outlet temperature above ambient "W" [°C] 7 8 7 8
temperature
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] 110 132
Total power consumption during load operation [A] 291 / 227 331 / 257
(380V / 460V)
Electric motor 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)
Chart 9-10: Technical data; EnviroAire T 110 + T 132, 60Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 89 /112

 TM

9 Appendix

EnviroAire T 110 + T 132, EnviroAire T 110 EnviroAire T 132

60Hz, air-cooled "A" and water-cooled
"W" (European version)
Recommended cable cross-section (380V / [mm²] 2 x 3 x 70 PE70 / 2 x 3 x 70 PE70 /
400V) 2 x 3 x 50 PE50 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 [m³/min] ("A" = 349) ; ("W" = 95)
Cooling air outlet temperature above ambient [°C] "A"=22 "W"=25
temperature
Residual pressure at ambient temperature "A" [Pa] 120 / 40 120 / 85 110 / 25 110 / 80
[35 °C / [35°C / [35°C / [35°C /
45 °C] 40°C] 45°C] 45°C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 132 @Δp=1.0 bar 155 @Δp=1.2 bar
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3265 ; "A"=3432 ;
"W"=3465 "W"=3632
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-10: Technical data; EnviroAire T 110 + T 132, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.9 EnviroAire T 160, 60Hz, air-cooled "A" and water-cooled "W" (European version)
EnviroAire T 160, EnviroAire T 160
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 [m³/min] 22.54
After cooler outlet temperature above ambient "A" [°C] 8
temperature
Aftercooler outlet temperature above ambient "W" [°C] 8
temperature
Sound pressure level (according to ISO 2151) "A" [dB(A)] 78
Chart 9-11: Technical data; EnviroAire T 160, 60Hz, air-cooled "A" and water-cooled "W" (European version)

90 / 112 GB July 2015

 TM

Appendix 9

EnviroAire T 160, EnviroAire T 160

60Hz, air-cooled "A" and water-cooled
"W" (European version)
Sound pressure level (according to ISO 2151) "W" [dB(A)] 78
Rated output electric motor [kW] 160
Total power consumption during load operation [A] 399 / 306
(380V / 460V)
Electric motor IP55 , EISA 2007 (IE3)
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 / [mm²] 2 x 3 x 95 PE95 / 2 x 3 x 70 PE70
460V)
Recommended fuse rating (time-delayed) [A] 6 x 250 / 6 x 200
Cooling air volume flow [m³/min] ("A" = 349) ; ("W" = 95)
Cooling air outlet temperature above ambient [°C] "A"=27
temperature
Residual pressure at ambient temperature "A" [Pa] 90 / 50 [35 °C / 40°C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K [l/min] 170 @Δp=1.3 bar
@Δp=0.7 bar)
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3644 , "W"=3844
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-11: Technical data; EnviroAire T 160, 60Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 91 /112

 TM

9 Appendix

9.6.10 EnviroAire TVS 110, 60Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire TVS 110, EnviroAire EnviroAire
60Hz, air-cooled "A" and water-cooled TVS 110 TVS 110
"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 max. min max.
speed speed speed 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 10.64 / 8 17.47 / 8
Volume flow rate / final pressure [bar] [m³/min] 8.89 / 8 19.32 / 8 10.51 / 17.37 /
10 10
After cooler outlet temperature above ambient "A" [°C] 4 6
temperature
Aftercooler outlet temperature above ambient "W" [°C] 7 8
temperature
Sound pressure level (according to ISO 2151) at "A" [dB(A)] 76 / 78 76 / 78
70% load / 100% load
Sound pressure level (according to ISO 2151) at "W" [dB(A)] 73 / 76 72 / 75
70% load / 100% load
Rated output electric motor [kW] 110
Total power consumption during load operation [A] 264 / 200 264 / 199
(380V / 460V)
Electric motor IP55 , EISA 2007 (IE3)
Rated speed min. / max. [rpm] 1909 / 3600 2417 / 3630
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 + [mm²] 3 x 150 PE95 / 3 x 95 PE95
400V)
Recommended fuse rating (time-delayed) (380V [A] 3 x 315 / 3 x 250
+ 400V)
Cooling air volume flow [m³/min] ("A" = 349) ; ("W" = 95)
Cooling air outlet temperature above ambient [°C] "A"=22
temperature
Residual pressure at ambient temperature "A" [Pa] 120 / 40 [35 120 / 85 [35
°C / 45 °C] °C / 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 132 @Δp=1.0 bar
Chart 9-12: Technical data; EnviroAire TVS 110, 60Hz, air-cooled "A" and water-cooled "W" (European version)

92 / 112 GB July 2015

 TM

Appendix 9

EnviroAire TVS 110, EnviroAire EnviroAire

60Hz, air-cooled "A" and water-cooled TVS 110 TVS 110
"W" (European version)
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3278 ; "W"=3478
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-12: Technical data; EnviroAire TVS 110, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.11 EnviroAire TVS 132, 60Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire TVS 132, EnviroAire EnviroAire
60Hz, air-cooled "A" and water-cooled TVS 132 TVS 132
"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 max. min max.
speed speed speed 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 10.51 / 20.85 /
10 10
After cooler outlet temperature above ambient "A" [°C] 10 8
temperature
Aftercooler outlet temperature above ambient "W" [°C] 7 8
temperature
Sound pressure level (according to ISO 2151) at "A" [dB(A)] 77 / 79 77 / 79
70% load / 100% load
Sound pressure level (ISO 2151) at 70% load / "W" [dB(A)] 74 / 79 72 / 76
100% load
Rated output electric motor [kW] 132
Total power consumption during load operation [A]
302 / 226 302 / 227
(380V / 460V)
Electric motor IP55 , EISA 2007 (IE3)
Chart 9-13: Technical data; EnviroAire TVS 132, 60Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 93 /112

 TM

9 Appendix

EnviroAire TVS 132, EnviroAire EnviroAire

60Hz, air-cooled "A" and water-cooled TVS 132 TVS 132
"W" (European version)
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 + [mm²] 3 x 150 PE95 / 3 x 95 PE95
400V)
Recommended fuse rating (time-delayed) (380V [A] 3 x 315 / 3 x 250
+ 400V)
Cooling air volume flow [m³/min] ("A" = 349) ; ("W" = 95)
Cooling air outlet temperature above ambient [°C] "A"=26
temperature
Residual pressure at ambient temperature "A" [Pa] 110 / 25 [35 110 / 80 [35
°C / 45 °C] °C / 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 155 @Δp=1.2 bar
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Condensate drain 5 x G1/2"
Weight [kg] "A"=3476 ; "W"=3676
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-13: Technical data; EnviroAire TVS 132, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.12 EnviroAire TVS 160, 60Hz, air-cooled "A" and water-cooled "W" (European
version)
EnviroAire TVS 160, EnviroAire TVS 160
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
Chart 9-14: Technical data; EnviroAire TVS 160, 60Hz, air-cooled "A" and water-cooled "W" (European version)

94 / 112 GB July 2015

 TM

Appendix 9

EnviroAire TVS 160, EnviroAire TVS 160

60Hz, air-cooled "A" and water-cooled
"W" (European version)
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 "A" [°C] 8
temperature
Aftercooler outlet temperature above ambient "W" [°C] 8
temperature
Sound pressure level (ISO 2151) at 70% load / "A" [dB(A)] 77 / 79
100% load
Sound pressure level (ISO 2151) at 70% load / "A" [dB(A)] 74 / 79
100% load
Rated output drive motor [kW] 160
Total power consumption during load operation [A] 385 / 258
(380V / 460V)
Electric motor 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 + [mm2] 3 x 185 PE95 / 3 x 150 PE95
460V)
Recommended fuse rating (time-delayed) (380V [A] 3 x 400 / 3 x 315
+ 460V)
Cooling air volume flow [m3/min] ("A" = 349) ; ("W" = 95)
Cooling air outlet temperature above ambient [°C] "A" = 29
temperature
Residual pressure at ambient temperature "A" [Pa] 90 / 50 [35 °C / 40 °C]
Coolant volume, internal [l] "A" = 30 ; "W" = 20
Cooling water volume, external (@ΔT=15K) [l/min] 170 @Δp=1.3 bar
Cooling water inlet temperature, external [°C] min. = 5 ; max. = 42
Cooling water outlet temperature, external [°C] 57
Cooling water pressure [bar] 8
Cooling water connections EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Total oil quantity [l] 24
Compressed air connection Flange EN 1092-1 / 13 /
B1 / DN80x8 / PN16
Chart 9-14: Technical data; EnviroAire TVS 160, 60Hz, air-cooled "A" and water-cooled "W" (European version)

July 2015 GB 95 /112

 TM

9 Appendix

EnviroAire TVS 160, EnviroAire TVS 160

60Hz, air-cooled "A" and water-cooled
"W" (European version)
Condensate drain 5 x G1/2"
Weight [kg] "A"=3688 ; "W"=3888
Dimensions L x B x H [mm] 2597 x 1744 x 2001
Chart 9-14: Technical data; EnviroAire TVS 160, 60Hz, air-cooled "A" and water-cooled "W" (European version)

9.6.13 EnviroAire T 75 + T 90, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
EnviroAire T 75 + T 90, EnviroAire T 75 EnviroAire T 90
60Hz, air-cooled "A" and water-cooled
"W" (USA version)
Maximum operating pressure [psig] 115 145 115 145
Minimum operating pressure [psig] 58
Ambient temperature "W" [°F] 36 / 113 36 / 113 36 / 113 36 / 113
Ambient temperature "A" [°F] 36 / 113 36 / 104 36 / 113 36 / 104
Volume flow [cfm] 438 383 562 464
After cooler outlet temperature above ambient "A" [°F] 11 9 13 11
temperature
Aftercooler outlet temperature above ambient "W" [°F] 9 9 11 11
temperature
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 [A] 152 / 128 173 / 155
(460V / 575V)
Electric motor TEFC IP55 , EISA 2007 (IE3)
Rated speed [rpm] 3560
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 AWG 3/0 / AWG AWG 4/0 / AWG
(460V / 575V) (cable type 167°F/ copper) 2/0 (single supply) 3/0 (single supply)
Recommended fuse rating (time-delayed) [A] 175 / 150 225 / 175
(460V + 575V) (delayed fuse, class J)
Cooling air volume flow [cfm] ("A" = 7946) ; ("W" = 3354)
Cooling air outlet temperature above ambient [°F] "A"=34 "A"=42
temperature
Residual pressure at ambient temperature "A" [Pa] 45 / 20 45 / 35 40 / 15 40 / 30
[95 °F / [95°F / [95 °F / [95°F /
113 °F] 104°F] 113 °F] 104°F]
Chart 9-15: Technical data; EnviroAire T 75 + T 90, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

96 / 112 GB July 2015

 TM

Appendix 9

EnviroAire T 75 + T 90, EnviroAire T 75 EnviroAire T 90

60Hz, air-cooled "A" and water-cooled
"W" (USA version)
Coolant volume, internal [gal] "A" = 8 ; "W" = 5.3
Cooling water volume, external (@ΔT=15K) [gal/min] 23 @Δp=10psi 29 @Δp=13psi
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 1 1/4 - 11 1/2 NPT
Total oil quantity [gal] 6.4
Compressed air connection Flange 3" ANSI B16.5
Condensate drain 5 x 1/2 NPT
Weight [lbs] "A"=6665 ; "A"=7125 ;
"W"=7105 "W"=7546
Dimensions L x B x H [inch] 102.2 x 68.7 x 78.8
Chart 9-15: Technical data; EnviroAire T 75 + T 90, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.14 EnviroAire T 110 + T 132, 60Hz, air-cooled "A" and water-cooled "W" (USA
version)
EnviroAire T 110 + T 132, EnviroAire T 110 EnviroAire T 132
60Hz, air-cooled "A" and water-cooled
"W" (USA version)
Maximum operating pressure [psig] 115 145 115 145
Minimum operating pressure [psig] 58
Ambient temperature "W" [°F] 36 / 113 36 / 113 36 / 113 36 / 113
Ambient temperature "A" [°F] 36 / 113 36 / 104 36 / 113 36 / 104
Volume flow [cfm] 671 596 798 742
After cooler outlet temperature above ambient "A" [°F] 11 11 13 13
temperature
Aftercooler outlet temperature above ambient "W" [°F] 13 14 13 14
temperature
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 [A] 227 / 189 257 / 214
(460V / 575V)
Electric motor TEFC IP55 , EISA 2007 (IE3)
Rated speed [rpm] 3580
Rated output fan motor [hp] {"A" = 2 x 5.3 (IP54)} ;
{"W" = 1 x 2.5 (IP54)}
Chart 9-16: Technical data; EnviroAire T 110 + T 132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

July 2015 GB 97 /112

 TM

9 Appendix

EnviroAire T 110 + T 132, EnviroAire T 110 EnviroAire T 132

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 AWG 2/0 / AWG AWG 3/0 / AWG
(460V / 575V) (cable type 167°F/ copper) 1/0 (double supply) 2/0 (double supply)
Recommended fuse rating (time-delayed) [A] 150 / 125 175 / 150
(460V + 575V) (delayed fuse, class J)
Cooling air volume flow [cfm] ("A" = 12325) ; ("W" = 3354)
Cooling air outlet temperature above ambient [°F] "A"=40 "A"=45
temperature
Residual pressure at ambient temperature "A" [Pa] 120 / 40 120 / 85 110 / 25 110 / 80
[95 °F / [95°F / [95 °F / [95°F /
113 °F] 104°F] 113 °F] 104°F]
Coolant volume, internal [gal] "A" = 8 ; "W" = 5.3
Cooling water volume, external (@ΔT=15K) [gal/min] 35 @Δp=15psi 41 @Δp=18psi
Cooling water inlet temperature [°F] min. = 41 ; max. = 107
Cooling water outlet temperature [°F] 134
Cooling water pressure [psig] 115
Cooling water connections 1 1/4 - 11 1/2 NPT
Total oil quantity [gal] 6.4
Compressed air connection Flange 3" ANSI B16.5
Condensate drain 5 x 1/2 NPT
Weight [lbs] "A"=7198 ; "A"=7566 ;
"W"=7639 "W"=8007
Dimensions L x B x H [inch] 102.2 x 68.7 x 78.8
Chart 9-16: Technical data; EnviroAire T 110 + T 132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.15 EnviroAire T 160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
EnviroAire T 160, EnviroAire T 160
60Hz, air-cooled "A" and water-cooled
"W" (USA version)
Maximum operating pressure [psig] 145
Minimum operating pressure [psig] 58
Ambient temperature "W" [°F] 36 / 113
Ambient temperature "A" [°F] 36 / 104
Volume flow [cfm] 796
After cooler outlet temperature above ambient "A" [°F] 14
temperature
Chart 9-17: Technical data; EnviroAire T 160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

98 / 112 GB July 2015

 TM

Appendix 9

EnviroAire T 160, EnviroAire T 160

60Hz, air-cooled "A" and water-cooled
"W" (USA version)
Aftercooler outlet temperature above ambient "W" [°F] 14
temperature
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 [A] 306 / 258
(460V / 575V)
Electric motor IP55 , EISA 2007 (IE3)
Rated speed [rpm] 3560
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 AWG 4/0 / AWG 3/0 (double supply)
(460V / 575V) (cable type 167°F/ copper)
Recommended fuse rating (time-delayed) [A] 200 / 175
(delayed fuse, class J)
Cooling air volume flow [cfm] ("A" = 12325) ; ("W" = 3354)
Cooling air outlet temperature above ambient [°F] "A"=49
temperature
Residual pressure at ambient temperature "A" [Pa] 90 / 50 [95 °F / 104 °F]
Coolant volume, internal [gal] "A" = 8 ; "W" = 5.3
Cooling water volume, external (@ΔT=15K) [gal/min] 45 @Δp=19psi
Cooling water inlet temperature [°F] min. = 41 ; max. = 107
Cooling water outlet temperature [°F] 134
Cooling water pressure [psig] 115
Cooling water connections 1 1/4 - 11 1/2 NPT
Total oil quantity [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; EnviroAire T 160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

July 2015 GB 99 /112

 TM

9 Appendix

9.6.16 EnviroAire TVS 110, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
EnviroAire TVS 110, EnviroAire EnviroAire
60Hz, air-cooled "A" and water-cooled TVS 110 TVS 110
"W" (USA version)
Maximum operating pressure [psig] 115 145
Minimum operating pressure [psig] 58 58
Ambient temperature [°F] 36 / 113 36 / 104
min max. min max.
speed speed speed speed
Volume flow rate / final pressure [psig] [cfm] 320 / 85 686 / 85 380 / 85 620 / 85
Volume flow rate / final pressure [psig] [cfm] 317 / 100 684 / 100 375 / 115 617 / 115
Volume flow rate / final pressure [psig] [cfm] 314 / 115 682 / 115 371 / 145 613 / 145
After cooler outlet temperature above ambient "A" [°F] 7 11
temperature
Aftercooler outlet temperature above ambient "W" [°F] 13 14
temperature
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] 150
Total current consumption during load operation [A] 200 / 167 199 / 167
(460V + 575V)
Electric motor IP55 , EISA 2007 (IE3)
Rated speed min. / max. [rpm] 1909 / 3600 2417 / 3630
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 MCM 250 (Single Supply) /
(460V + 575V) (cable type 167°F/ copper) AWG 4/0 (Single Supply)
Recommended fuse rating (time-delayed) [A] 225 / 200
(460V + 575V) (delayed fuse, class J)
Cooling air volume flow [cfm] ("A" = 12325) ; ("W" = 3354)
Cooling air outlet temperature above ambient [°F] "A"=47
temperature
Residual pressure at ambient temperature "A" [Pa] 120 / 40 [95 120 / 85 [95
°F / 113 °F] °F / 104 °F]
Coolant volume, internal [gal] "A" = 8 ; "W" = 5.3
Cooling water volume, external (@ΔT=15K) [gal/min] 35 @Δp=15psi
Cooling water inlet temperature, external [°F] min. = 41 ; max. = 107
Cooling water outlet temperature, external [°F] 134
Chart 9-18: Technical data; EnviroAire TVS 110, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

100 / 112 GB July 2015

 TM

Appendix 9

EnviroAire TVS 110, EnviroAire EnviroAire

60Hz, air-cooled "A" and water-cooled TVS 110 TVS 110
"W" (USA version)
Cooling water pressure [psig] 115
Cooling water connections 1 1/4 - 11 1/2 NPT
Total oil quantity [gal] 6.4
Compressed air connection 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; EnviroAire TVS 110, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.17 EnviroAire TVS 132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
EnviroAire TVS 132, EnviroAire EnviroAire
60Hz, air-cooled "A" and water-cooled TVS 132 TVS 132
"W" (USA version)
Maximum operating pressure [psig] 115 145
Minimum operating pressure [psig] 58 58
Ambient temperature "W" [°F] 36 / 113 36 / 113
Ambient temperature "A" [°F] 36 / 113 36 / 104
min max. min max.
speed speed speed speed
Volume flow rate / final pressure [psig] [cfm] 322 / 85 806 / 85 382 / 85 742 / 85
Volume flow rate / final pressure [psig] [cfm] 319 / 100 803 / 100 376 / 115 739 / 115
Volume flow rate / final pressure [psig] [cfm] 316 / 115 801 / 115 371 / 145 736 / 145
After cooler outlet temperature above ambient "A" [°F] 18 15
temperature
Aftercooler outlet temperature above ambient "W" [°F] 13 15
temperature
Sound pressure level (according to ISO 2151) at "A" [dB(A)] 77 / 79
70% load / 100% load
Sound pressure level (according to ISO 2151) at "W" [dB(A)] 74 / 79 73 / 77
70% load / 100% load
Rated output electric motor [hp] 180
Total current consumption during load operation [A] 226 / 189 227 / 189
(460V + 575V)
Electric motor TEFC IP55, EISA 2007 (IE3)
Rated speed min. / max. [rpm] 1550 / 3380 1559 / 3500
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)
Chart 9-19: Technical data; EnviroAire TVS 132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

July 2015 GB 101 /112

 TM

9 Appendix

EnviroAire TVS 132, EnviroAire EnviroAire

60Hz, air-cooled "A" and water-cooled TVS 132 TVS 132
"W" (USA version)
Rated output coolant pump [hp] 1.5 (IP-54)
Recommended cable cross-section MCM 300 (Single Supply) /
(460V + 575V) (cable type 167°F/ copper) MCM 250 (Single supply)
Recommended fuse rating (time-delayed) [A] 250 / 225
(460V + 575V) (delayed fuse, class J)
Cooling air volume flow [cfm] ("A" = 12325) ; ("W" = 3354)
Cooling air outlet temperature above ambient [°F] "A"=47
temperature
Residual pressure at ambient temperature "A" [Pa] 110 / 25 [95 110 / 80 [95
°F / 113 °F] °F / 104 °F]
Coolant volume, internal [gal] "A" = 8 ; "W" = 5.3
Cooling water volume, external (@ΔT=15K) [gal/min] 41 @Δp=18psi
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 1 1/4 - 11 1/2 NPT
Total oil quantity [gal] 6.4
Compressed air connection 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; EnviroAire TVS 132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

9.6.18 EnviroAire TVS 160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
EnviroAire TVS 160, EnviroAire TVS 160
60Hz, air-cooled "A" and water-cooled
"W" (USA version)
Maximum operating pressure [psig] 145
Minimum operating pressure [psig] 58
Ambient temperature "W" [°F] 36 / 113
Ambient temperature "A" [°F] 36 / 104
min speed max. speed
Volume flow rate / final pressure [psig] [cfm] 378 / 85 827 / 85
Volume flow rate / final pressure [psig] [cfm] 373 / 115 823 / 115
Volume flow rate / final pressure [psig] [cfm] 367 / 145 819 / 145
After cooler outlet temperature above ambient "A" [°F] 14
temperature
Chart 9-20: Technical data; EnviroAire TVS 160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

102 / 112 GB July 2015

 TM

Appendix 9

EnviroAire TVS 160, EnviroAire TVS 160

60Hz, air-cooled "A" and water-cooled
"W" (USA version)
Aftercooler outlet temperature above ambient "W" [°F] 14
temperature
Sound pressure level (according to ISO 2151) at "A" [dB(A)] 77 / 79
70% load / 100% load
Sound pressure level (according to ISO 2151) at "W" [dB(A)] 74 / 79
70% load / 100% load
Rated output electric motor [hp] 215
Total current consumption during load operation [A] 258 / 213
(460V + 575V)
Electric motor TEFC 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)
Recommended cable cross-section MCM 400 (Single supply) /
(460V + 575V) (cable type 167°F/ copper) MCM 300 (Single supply)
Recommended fuse rating (time-delayed) [A] 300 / 250
(460V + 575V) (delayed fuse, class J)
Cooling air volume flow [cfm] ("A" = 12325) ; ("W" = 3354)
Cooling air outlet temperature above ambient [°F] "A"=52
temperature
Residual pressure at ambient temperature "A" [Pa] 90 / 50 [95 °F / 104 °F]
Coolant volume, internal [gal] "A" = 8 ; "W" = 5.3
Cooling water volume, external (@ΔT=15K) [gal/min] 45 @Δp=19psi
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 1 1/4 - 11 1/2 NPT
Total oil quantity [gal] 6,4
Compressed air connection 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; EnviroAire TVS 160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)

July 2015 GB 103 /112

 TM

9 Appendix

9.7 Installation plan

EnviroAire
T(VS)75-160-A 141(A) 142(A)
C
HOC

543(D)
685(CG)

2001
320 320 173(D)

390(E)
B

975(B)
320

1002(A)

905(A)
X

HOC
320
D
1210(B)

155(E)
562(D)

170(B)
192
680 910
77
14

220 220 317(B)

105(E) 92(E)
45(A) 1265(CG) X
750(CG)

409(F)
359
324
1578(C)

1744

146
197
83(C)

243(F)

71(C)
C
1390(C)
2599

D
F
B
E

[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]

104 / 112 GB July 2015

 TM

Appendix 9

EnviroAire T(VS)75-160-W 141(A) 142(A)

C HOC

543(D)

685(CG)
320 320 173(D)

390(E)
B

975(B)
320

1002(A)

905(A)
X

HOC
320
D
1210(B)

155(E)
562(D)

170(B)
192
680 910
77
14

220 220 317(B)

105(E) 92(E)
45(A) 1265(CG)
750(CG)

Ø560
477(C)

1744

C
455(C)
2599

243(F)
A
197
146
210(G)

X
409(F)

D
359
324

F
G
143(G)
B
100
E

[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

July 2015 GB 105 /112

 TM

9 Appendix

min. 1000

min. 1000
89
69

9
2
67

8
76
1

7
78
min. 1000

2
69

67

89 9
8

min. 1000

106 / 112 GB July 2015

 TM

Appendix 9

EnviroAire
T(VS)75-160-A 5.6(A) 5.6(A)
C
HOC

21.4(D)

27(CG)
12.6 12.6 6.8(D)

78.8

15.4(E)
B

38.4(B)
12.6

39.5(A)

35.6(A)
X

HOC
12.6
D
43.6(B)

22.1(D)
0.6

26.8 35.8

6.1(E)
6.7(B)
7.6
3

8.7 8.7 12.5(B)

4.1(E) 3.6(E)
1.8(A) 49.8(CG) X
29.5(CG)

16.1(F)
14.1
12.8
62.1(C)

68.7

5.8
3.3(C)

7.8
9.6(F)

2.8(C)
C
54.7(C)
102.3

D
F
B
E

[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]

July 2015 GB 107 /112

 TM

9 Appendix

EnviroAire T(VS)75-160-W 5.6(A) 5.6(A)

C HOC

21.6(D)
27(CG)

78.8
12.6 12.6 6.8(D)

15.4(E)
B

38.4(B)
12.6

39.5(A)

35.6(A)
X

HOC
12.6
D
43.6(B)

22.1(D)
0.6

26.8 35.8

6.1(E)
6.7(B)
7.6
3

8.7 8.7 12.5(B)

4.1(E) 3.6(E)
1.8(A) 49.8(CG) 29.5(CG)

Ø22
18.8(C)

68.7

C
17.9(C)
102.3

9.6(F)
A
7.8
5.8
8.3(G)

X
16.1(F)

D
14.1
12.8

F
G
5.6(G)
B
3.9
E

[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

108 / 112 GB July 2015

 TM

Appendix 9

min. 39.4

min. 39.4
35
.5

27

.4
26

.5
30

31
min. 39.4

.5
27

26

35 . 4
.5

min. 39.4

July 2015 GB 109 /112

 TM

9 Appendix

9.8 Declaration of conformity

1. Declaration of conformity
in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A
2. We, herby declare Gardner Denver Deutschland GmbH
Argenthaler Str. 11
D-55469 Simmern
that the product: Kompressor
type: T75; T90; T110; TVS110; T132; TVS132; T160; TVS160
manufacturer no.:
Herstell-Nr.:
in the form as shipped by us complies with the following relevant provisions:
2009/ 105/ EG ; 2006/ 42/ EG ; 2004/ 108/ EG ; 2006/ 95/ EG
The machine does not fall under the Pressure Equipment Directive due to the reasons for exclu-
sion according to article: 1, paragraphs: 3.3 and 3.6.
3. If the machine is modified in a way not agreed upon with us, this statement will be void.
4. Harmonized standards applied, particularly
EN 1012-1 ; EN ISO 12100 ; EN 60034-1 ; EN6100-6-4 ; EN 29001 ; EN 60204-1 ; EN 6100-6-2
5. National engineering standards and specifications applied
AD-S1/2000 ; BetrSichV ; DIN 3230 ; VDE 0298
6. Recording agency: CompAir Drucklufttechnik - subsidiary of
Gardner Denver Deutschland GmbH
Simmern,
Date: Signature:

110 / 112 GB July 2015

Gardner Denver Compressor Division,
1800 Gardner Expressway, Quincy, Illinois 62305

Telephone: (800) 682-9868

Fax: (217) 224-7814

Gardner Denver Deutschland GmbH

Argenthaler Str. 11
55469 Simmern
Germany

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

Fax ++49 (0)6761 832-409