High Pressure Air Compressor

Smarter Compressor Technology
HIGH PRESSURE SOLUTIONS
NITROGEN
HYDRO
PET
CNG
Operating & Maintenance Manual

V290M-WN Compressor Assembly
Sales Order No. 2334137
Publication No. 98407.4815
TABLE OF CONTENTS
Section 1
Compressor Manual
Section 2
Motor Manual
Section 3
Drawings
Section 1
Compressor Manual
V290M-WN
Compressor
Table of contents
V290M-WN Compressor Manual
Introduction .....................................................................................................................................4
Chapter 1 - Technical Data and Description ....................................................................................7
1.1
Data and Compressor Description.....................................................................................8
1.2
Technical Data ..................................................................................................................9
1.3
Technical Description of the Compressor ........................................................................16
Chapter 2 - Safety Information.......................................................................................................21

2.1
Safety Policy ...................................................................................................................22
Chapter 3 - Installation and Commissioning ..................................................................................27

3.1
Safety Precautions ..........................................................................................................28
3.2
Installation Requirements ................................................................................................28
3.3
Handling and Unpacking .................................................................................................34
3.4
Installation Procedure......................................................................................................36
3.5
Preparation for Commissioning .......................................................................................38
3.6
Commissioning the Compressor .....................................................................................40
Chapter 4 - Operating Instructions .................................................................................................43

4.1
Controls and Indicators ...................................................................................................44
4.2
Preparation for Starting ...................................................................................................45
4.3
Starting the Compressor .................................................................................................45
4.4
Running...........................................................................................................................45
4.5
Stopping the Compressor ................................................................................................46
4.6
Fault Indications ..............................................................................................................46
Chapter 5 - Compressor Maintenance ...........................................................................................51

5.1
Preventive Maintenance ..................................................................................................52
5.2
Approved Lubricants .......................................................................................................55
5.3
Maintenance Instructions ................................................................................................56
JOB No: 1 - Crankcase Oil Change ...........................................................................................57

JOB No: 2 - Fit Piston Rod Clamps ............................................................................................59
JOB No: 3 - Cylinder Top Covers - Remove and Re-fit ..............................................................60
JOB No: 4 - Piston rings - Remove and Re-fit ............................................................................64
Issue 1
01/2015
Page 1
V290M-WN
Compressor
JOB No: 5 - Piston/Cylinder End (Bumping) Clearances ............................................................66
JOB No: 6 - Packing Assembly - Remove and Re-fit..................................................................69
JOB No: 7 - Packing Assembly - Overhaul .................................................................................73
JOB No: 8 - Packing Assembly - Remove and Re-fit..................................................................75
JOB No: 9 - Oil Scraper Gland - Remove and Re-fit ..................................................................77
JOB No: 10 - Suction and Delivery Valves - Remove and Re-fit.................................................79
JOB No: 11 - Suction and Delivery Valves - Overhaul................................................................82
JOB No: 12 - Suction and Delivery Valves - Remove and Re-fit.................................................84
JOB No: 13 - Oil Filter - Remove and Re-fit ...............................................................................86
JOB No: 14 - Oil Pressure Relief Valve - Adjustment .................................................................87
JOB No: 15 - Lubricating Oil Pump and Drive - Inspect and Overhaul........................................88
JOB No: 16 - Intercooler - Inspection and Overhaul ...................................................................89
5.4
Lists of Tools ...................................................................................................................90
5.5
Waste Products ...............................................................................................................90
Chapter 6 - Spare Parts.................................................................................................................91

6.1
Spare Parts .....................................................................................................................92
6.2
Ordering Spares and Spares Stock .................................................................................92
6.3
Spares List ......................................................................................................................93
6.4
Drawings .........................................................................................................................95
1. V290M-WN GENERAL ARRANGEMENT ..........................................................................96

2. 2-77-2202 P&ID DRAWING FOR V290 ..............................................................................97
3. CC1034293 LOWER PARTS ASSY ...................................................................................98
4. CC1069291 CYLINDER ASSY CELL-V290 ......................................................................100
5. CC1069292 INTERSTAGE ASSY CELL-V290 .................................................................102
6. CC1069293 FINAL ASSY CELL-V290..............................................................................103
7. CC1039053 ANCILLAIRES ..............................................................................................105
8. CC1071471 ANCILLARY ASSY CELL .............................................................................106
9. CC1042024 INSTRUMENTATION UNLOADER PIPEWORK ASSY ................................107
10. CC1039413 COOLING WATER PIPEWORK .................................................................108
11. CC1039027 AFTERCOOLER ASSY ..............................................................................110
Issue 1
01/2015
Page 2
V290M-WN
Compressor
Issue 1
01/2015
Page 3
V290M-WN
Compressor
Introduction
Important
This Instruction Manual covers Installation & Commissioning, Operation and Maintenance of the
Gardner Denver Industrial range of compressors.
It is ESSENTIAL that this document is read and understood by everyone who will work with this
equipment, as failure to do so may result in death, injury or damage to the compressor or its
associated equipment.
Disclaimer
While every care was taken in the preparation of these instructions, it cannot be guaranteed that
every aspect has been covered. Gardner Denver Belliss & Morcom cannot, therefore, accept
liability for direct or consequential damage that may arise resulting from non-conformity with this
Manual, from repairs carried out improperly, from using other than original spare parts, and from
non-observance of good operating and maintenance engineering practices. Should there be any
doubt whatsoever, or should any further information or explanation be required, Gardner Denver
Belliss & Morcom must be contacted.
This information is given in good faith, no warranty or representation is given concerning such
information, which must not be taken as establishing any contractual or other commitment binding
upon Gardner Denver Belliss & Morcom .
Gardner Denver Belliss & Morcom reserve the right to make changes to any information
contained within this manual without prior notice.
Warranty Statement
The compressor(s) and ancillary equipment supplied by Gardner Denver Belliss & Morcom are
covered under Warranty for the period agreed in the Supply Contract.
The equipment provided is well designed to afford many years of trouble free service. However,
should the need arise to implement a warranty claim then this can be done using Warranty Claim
Form obtainable from Gardner Denver Belliss & Morcom Service Department. A copy of this
form is provided in Appendices located at the end of this manual.
It should be noted that consumable parts that require replacement during normal compressor
operations are not normally covered under Warranty. Similarly, the Warranty does not cover
running adjustments.
Gardner Denver Belliss & Morcom are well known in the market place for the design,
manufacture and supply of high-quality air compressor equipment. These compressors are
constructed from the highest quality materials and are designed and built according to the latest
manufacturing techniques. The compressor design will give good service providing that it is
operated and maintained in accordance with the information contained within this Manual.
The information and notes presented in the 'Ancillary Devices Instruction Manuals will provide
operational and maintenance information for the control and instrumentation system, motor/drive
unit and where appropriate, any other device associated with the compressor package.
Targeted Personnel
Issue 1
01/2015
Page 4
V290M-WN
Compressor
This document is designed to provide competent operatives, who are fully conversant with
compressor operating and maintenance techniques, with an understanding of the compressor
elements and their operation and subsequent maintenance. It should be noted that the term
'competent' implies that the operative is a compressor engineer suitably trained in the installation,
operation and maintenance of the Gardner Denver Belliss & Morcom product.
This Instruction manual is not intended to supersede or take the place of the Gardner Denver
Belliss & Morcom product-training course. For further information regarding training courses or to
book a place, please contact Gardner Denver Belliss & Morcom Service Department. The
address, telephone/facsimile number is provided at the start of this documentation.
How to Use this Instruction Manual

The Instruction Manual is designed to enable speedy location of relevant information. To this end
the document is divided into six chapters, each of which covers an individual topic. Cross
references between topics and illustrations are identified within the text using bold characters i.e.
(Refer to Chap 2 Section 4.1) or see Fig 3.
At appropriate locations within this document you will see 'Information Boxes'. It is VERY
IMPORTANT that the information contained within these boxes is adhered to, as failure to do so
may result in death, injury or damage to the compressor or its associated equipment. The following
outlines the philosophy applied to each of the three levels of boxed notation.
WARNING !
THIS PICTOGRAM WITH THE REMARK "WARNING!" IDENTIFIES A
POTENTIAL DANGEROUS HAZARD. NON-COMPLIANCE WILL PUT THE
OPERATOR OR A THIRD PARTY AT RISK OF DEATH OR INJURY.
CAUTION!
THIS PICTOGRAM WITH THE REMARK CAUTION! IDENTIFIES THE
POSSIBILITY THAT IF NON-COMPLIANT THE COMPRESSOR AND/OR ITS
ASSOCIATED EQUIPMENT CAN BE DAMAGED.
THIS PICTOGRAM MARKS IMPORTANT NOTES, WHICH IDENTIFIES

SUPPLEMENTARY INFORMATION FOR THE COMPETENT AND ECONOMIC
USE/OPERATION OF THIS COMPRESSOR PACKAGE.
Documentation Storage
Always store this Instruction Manual near the compressor so that it is available for reference at all
times. If the instruction manual is lost, Gardner Denver can supply a new copy for a small fee.
When requesting new or additional copies, of this document, please include your compressor
details with your order.
Issue 1
01/2015
Page 5
V290M-WN
Compressor
Point of Contact
For sales, service or spare parts enquiries, please contact :
Address :
Gardner Denver Ltd

Claybrook Drive,
Redditch,
B98 0DS,
England
Telephone :
+44 (0)1527 838600
Fax :
+44 (0)1527 838630
E-mail :
highpressure@gardnerdenver.com
Website :
www.gardnerdenver.com
Comments and Suggestions

We would welcome comments and suggestions for improvements to this Instruction Manual. If you
would like to comment, please make a copy of the page or pages concerned and add your
comments. Then send your response to Gardner Denver. Please do not forget to include your
name and the name of your company, your company address and your telephone and facsimile
numbers.
Issue 1
01/2015
Page 6
V290M-WN
Compressor
Chapter 1 - Technical Data and Description
Issue 1
01/2015
Page 7
V290M-WN
Compressor
1.1 Data and Compressor Description

The information contained in this section is intended for the use of the engineer responsible for the
operation and maintenance of the plant. It is essential that any necessary adjustments, servicing or
overhaul work should be carried out by competent persons who are familiar with the installation,
operation and maintenance of this product and who have the appropriate authorisation.
When communicating with Gardner Denver on matters relating to the compressor always quote the
compressor type and serial number (e.g.V660M-WN Serial No. C00xxxx).
Standards and Legislation

The compressor is manufactured in accordance with the European Economic Community
Directive: BS EN 1012-1: 1997, and is tested in accordance with British Standard: BS 1571 Part 2.
Issue 1
01/2015
Page 8
V290M-WN
Compressor
1.2 Technical Data

a)
Operating Data
Table 1-1: Operating Data
Compressor
Model
V290M-WN
Number of Stages
Inlet Pressure
Atmospheric
Cylinder Type
Double Acting - Non Lubricated
Direction of Rotation
Clockwise looking on Drive-end

Metric
Flow
Imperial
290
m3/hr
171
ft3/min
Stage 1
bar.g
58
lb/in2
Stage 2
20.7
bar.g
300.55
lb/in2
Delivery
90
bar.g
1350
lb/in2
Stage 1
4.4
bar.g
63.8
lb/in2
Stage 2
22.8
bar.g
330.6
lb/in2
Stage 3
99
bar.g
1435.5
lb/in2
Oil Pressure *
3.0 - 4.8
bar.g
43.5 - 69.6
lb/in2
Stage Pressures
Safety Valve Settings
Oil Pump Pressure
bar.g
lb/in2
Sump Capacity
35
litres
9.8
11.8
UKgal
USgal
Compressor Speed (Max)
985
rpm
985
rpm
Vibration
2.5
mm/s
0.01
ft/s 2
Sound Pressure Level
90
db(A)
90
db(A)
Sound Power Level
115
db(A)
115
db(A)
Weight (Without Motor)
4565
kg
10065
lb
Weight (With Motor)
5375
kg
11850
lb
Max Maintenance Lift
1000
kg
2204
lb
Normal Pressure
bar.g
87
lb/in2
Maximum Pressure
10
bar.g
145
lb/in2
Instrument Air
Issue 1
01/2015
Page 9
V290M-WN
Compressor
Table 1-1: Operating Data (Continued)
Cooling
Design Ambient
0 - 35
32 - 113
Cooling Water Flow **
153
l/min
34
41
UKgal/min
USgal/min
Cooling Water Pressure
4-7
bar.g
58 - 102
lb/in2
Water Pressure Drop
bar.g
lb/in2
Water Temperature Rise
14
Compressor
Radiated Heat
kW
27321
Btu/h
Motor Rated Power
110
kW
148
hp
Absorbed Power at Full

Load
76.5
kW
103
hp
Body
Motor
*Oil pressure will fluctuate with ambient conditions, compressor loading and with the type
and viscosity of the oil being used. Also; oil pressure peaks during start-up before settling
back as the oil reaches operating temperature.
** Cooling Water Flow rates are design estimates and may have to be adjusted to suit
ambient site conditions.
This machine is fitted with over-temperature monitoring safety switches for final air from
both the third stage cylinder and the aftercooler. Details of the settings for these devices
are given in Table 1-4:Protection device settings on page 7
b)
Compressor Data
Figures are quoted for new parts. The upper and lower limits arise due to accumulated
effect of manufacturing tolerances. All butt gaps are measured with the piston ring in the
cylinder.
Issue 1
01/2015
Page 10
V290M-WN
Compressor
c)
Mechanical Data
Table 1-2: Piston and Cylinder Data
Piston Data
Metric
Piston Stroke
Imperial
104
mm
253.06
253.00
mm
Stage 1 Cylinder Line

Cylinder Bore
Diametrical Clearance Piston Body in Cyl. Bore
3.34
3.04
mm
Piston Ring
Radial Thickness
11.5
11.4
mm
Axial Clearance in Groove
0.65
0.50
mm
Gap at ring Butt joint
7.1
6.4
mm
Diametrical Clearance in
Cylinder bore
1.68
1.40
mm
Radial Thickness
9.00
8.95
mm
0.55
0.40
mm
Standout
body
1.22
1.20
mm
Bearer Ring
from
piston
Gap at joint
N/A
Bumping Clearance
Piston Top to Top Cover
3.5
mm
Piston Bottom to Cyl.
2.3
mm
196.047
196.000
mm
4.04
4.00
mm

Cylinder Bore
Diametrical Clearance Piston Body in Cyl. Bore
Issue 1
01/2015
Page 11
4.09
in
V290M-WN
Compressor
Table 1-2: Piston and Cylinder Data (Continued)
Piston Ring
Radial Thickness
12.00
11.82
mm
0.35
0.20
mm
6.4
5.8
mm
Cylinder bore
2.52
2.50
mm
Radial Thickness
8.0
7.9
mm
in
0.72
0.58
mm
piston
N/A
mm
Bearer Ring
Axial
Groove
Clearance
Standout
body
from
N/A
Gap at joint
Bumping Clearance
N/A
mm
Piston Bottom to Cyl
2.0
mm
78.03
78.00
mm
1.76
1.70
mm
11.00
10.82
mm
in
0.35
0.20
mm

(Each Gap)
1.2
1.1
mm
0.96
0.95
mm

Cylinder Bore
Diametrical
Clearance
Piston Body in Cyl. Bore
Piston Ring
Radial Thickness
Axial
Groove
Clearance
Bearer Ring
Cylinder bore
Issue 1
01/2015
Page 12
V290M-WN
Compressor
Table 1-2: Piston and Cylinder Data (Continued)
6.00
5.95
mm
in
1.70
1.50
mm
piston
1.60
1.50
mm
N/A
mm
N/A
mm
Piston Bottom to Cyl
2.1
mm
Radial Thickness
Axial
Clearance
Groove
Standout
body
from
Gap at joint
Bumping Clearance
d)
Crankcase Components Clearances

The clearances for new components given are between the limits indicated - the upper
and lower limits arise due to accumulated effect of manufacturing tolerances. The
corresponding maximum figure is the point where renewal of the component is required.
No maximum figure is given against parts which, are not expected to wear to any
significant extent in service.
Metric
Crankshaft
(radial clearance)
Connecting
End Bearing
Rod
Bearings
Imperial
0.031 - 0.076
mm
0.0012 0.003
in
0.10 - 0.15
mm
0.004 - 0.006
in
0.20
mm
0.008
in
0.07 - 0.10
mm
0.003 - 0.004
in
0.107 - 0.293
mm
0.004 - 0.011
in
0.4
mm
0.016
in
Bottom
New
Maximum
Connecting Rod Top End

Bearing
New
Crosshead to Main Guide

Slide
New
Maximum
Issue 1
01/2015
Page 13
V290M-WN
Compressor
Table 1-4: Protection device settings
High air temperature (3rd St Delivery)
250 C (482F) (rising)
High air temperature (After Separator)
65 C (149F) (rising)*
Low lubricating oil pressure
1.8 BarG (26.1 psi) (falling)
Low cooling water flow
75% m3/hr of normal flow (falling)
* Switch is factory set to 65 C. for temperate (UK type) climates. The switch may be
adjusted up to a maximum of 75 C. to suit tropical climates during or after installation.
However, adjustments MUST only be performed by a competent, authorised person.
e)
Tightening Torques (Dry Threads)

CAUTION!
OVER-TIGHTENING OF THE FASTENERS CAN LEAD TO DAMAGE TO
THE FASTENERS AND/OR THE COMPONENTS.
Table 1-6: Component tightening Torques
Component
Thread Size
Torque Nm
Crankcase Components:
Bearing End Cover
M20
128 140
Flywheel End Cover
M16
98 108
Oil Pump to End Cover
M8
15 20
Crankcase Access Covers
M10
25 30
Scraper Support Plate
M10
45 55
Scraper Gland Fasteners
M12
45 55
Crosshead Guide Fasteners
M20
128 140
Flywheel Retaining
M42
375 - 400
Distance Piece to Crankcase
M20
200 220
Cylinder to Distance Piece
M24
200 - 220
Distance Piece Access Cover
M6
10 - 15
Distance Piece Components:
Issue 1
01/2015
Page 14
V290M-WN
Compressor
Table 1-6: Component tightening Torques (Continued)
Thread
Size
Component
Torque Nm
1st Stage Cylinder Components:

Cylinder/Top Cover
M20
190 - 210
Valve Covers
M12
29 - 32
1st Stage Valve Nuts
M16
90 - 110
Inlet Flange
M20
190 - 210
Outlet Flange
M16
98 - 108
Packing Gland Fasteners
M20
128 - 140
Cylinder to Cylinder
M24
200 - 220
Valve Covers
M20
190 - 210
Valve Nuts
M16
90 - 100
Inlet/Outlet Flange
M24
200 - 210
Packing Gland Fasteners
M20
128 - 140
CylinderTop Cap to Piston
M8
16 - 18
3rd Stage to 2nd Stage piston assembly

bolts
M16
Valve Covers
M20
190 - 210
Valve Nuts
M16
90 - 100
Inlet / Outlet Flange
M20
190 - 210
Crosshead Nut to Crosshead
1 5/8 BSF
555 - 610
Piston Nut to Piston
1 3/8 BSF
510 - 560
Crankshaft Lock-nut
M160
1750
2nd Stage Cylinder Components:
3rd Stage Cylinder Components:
134 - 140
Motion Work Components:
Issue 1
01/2015
Page 15
V290M-WN
Compressor
1.3 Technical Description of the Compressor

a)
Purpose of the Equipment

The compressor provides a constant supply of compressed air, at a regulated pressure.
The compressed air can then be used as part of an industrial process.
b)
Compressor Identification
All Gardner Denver compressors have a rating plate located on the crankcase. The
information stamped onto this plate identifies the compressor type, capacity and serial
number. The compressor designation indicates the following:
V - Denotes cylinder configuration
290 - Denotes nominal capacity in m3/hr
M - Denotes medium pressure three stage
W - Denotes water-cooled
N - Denotes oil free cylinder operation
3rd
Stage
Cylinder
Aftercooler
Inlet Filter & Silencer
1st Stage
Cylinder
2nd
Stage
Cylinder
Distance Piece
Access Cover
Seperator
Distance
Piece
Access Cover
Lubricating Oil
Pump &Filter
Intercooler
Illustration 1-1 : External View of typical 3 stage Compressor
Issue 1
01/2015
Page 16
V290M-WN
Compressor
c)
Compressor Operation
The compressor operates by drawing air from atmosphere via an efficient air filter and
silencer system into the first stage cylinder where it is compressed to approximately 4 Bar
G. The heat, generated by compressing air, is dissipated by passing through the watercooled intercooler. The cooled air then flows through the 2nd stage suction separator,
which removes any free moisture, condensed during cooling.
Air then passes to the 2nd stage cylinder where the air is further compressed to
approximately 21 Bar G. The heat generated by compressing the air is dissipated in the
second stage intercoler. Air then flows through the 3 rd stage suction separator, which
removes any moisture condensed during second stage cooling.
The air then passes to the 3rd stage cylinder where the air is further compressed to its
final delivery pressure of 90 Bar G (max). The heat from compression is dissipated in the
watercooled aftercooler positioned after the 3rd stage cylinder. The final delivery
separator removes any moisture condensed during cooling. The compressed air is then
discharged into the delivery pipework.
d)
Crankcase and Lower Motion Work

1 - Crankcase
The crankcase is a heavily-ribbed iron casting with integral mounting feet and cylinder
mounting flanges. Also integral within the crankcase are housings for the two crankshaft
driveend bearings. There are machined faces for the flange mounted motor, bearing end
cover, crankcase and main guide doors. The bolt-on bearing end cover incorporates the
housing for the third crankshaft bearing.
The crankcase forms the lubricating oil sump, and is complete with tapped holes for the oil
level window nut, the oil pump suction feed pipe, the crankcase drain plug and the oil
cooler. Oil retention in the crankcase is made possible by a lip seal fitted at the drive-end
of the crankshaft and by scraper rings fitted around the piston rods. Immediately beneath
the drive-end crankshaft seal housing is an integral oil return passage.
2 - Crankshaft
The single throw, cast high-tensile iron, crankshaft has integral design counter-balanced
weights. The standard throw is 52.00 mm, giving a piston stroke of 104.00 mm. The
crankshaft is supported by three self-aligning, double-race spherical roller bearings, two at
the driving end and one at the oil-pump end. Endwise location is by clamping the outer
drive-end main bearing (in the oil seal holding cover) against a machined shoulder in the
crankcase. The driving end has a tapered shaft, which is keyed to accommodate the rotor
of a direct mounted motor. The oil pump end of the crankshaft has internal oil passages to
the crankpin.
3 - Oil Pump
The gear type oil pump is mounted on the crankshaft bearing end cover and is driven via
a coupling off the non-drive end of the crankshaft. Oil is drawn by the pump from the
crankcase sump through a wire mesh strainer and external pipe. The oil is delivered
through a full-flow fine-mesh cartridge filter to the oil ways in the crankshaft. Any excess
Issue 1
01/2015
Page 17
V290M-WN
Compressor
oil output is by-passed back to the sump by a spring-loaded pressure relief valve mounted
on the crankcase main bearing housing.
All the bearing surfaces in the crankcase are lubricated by the oil passing through the
bore of the crankshaft and connecting rods. The main roller bearings are splash lubricated
by the oil from the crosshead, and also by the general oil mist in the crankcase.
4 - Connecting Rods
The connecting rods have detachable bottom end caps to enble removal of the rods and
rods have split-shell bottom end bearings and bush type top end bearings. The bottom
end bearing shells are steel backed copper-lead, lead-tin plated. The pressed-in top end
bushes are lead bronze.
An oil passage connects the top and bottom bearings allowing oil under pressure (from
the oil pump via passages in the crankshaft) to lubricate both. Oil is sprayed, from an
annular groove around the top end bush and through two small holes, onto both slides of
the crosshead guide.
5 - Crossheads
The crossheads run in the main guides which are bolted to the cylinder mounting flange of
the crankcase. The crossheads are attached to the top of the connecting rods by gudgeon
pins (which are retained themselves by circlips). The top face of the crosshead is drilled
and tapped for reception of the piston rod. The piston rod is retained by a securing pin
which passes through the side of the crosshead into the slot in the end of the piston rod.
The piston rod is then clamped by a nut, which is tightened down against the top of the
crosshead. The securing pin is prevented from coming loose by a retaining plate.
e)
Cylinders, Pistons and Piston Rod Packings

1 - Cylinders
The double-jacketed cylinders are cast complete with mounting base, valve chambers and
a housing for the piston rod packing assembly. They have machined faces for the top
cover, lower mating flange, valve covers, distance rings and valves and the air and water
inlets and outlets. The inner jacket of the cylinder is for the cooling water, the outer jacket
is divided into air valve chambers.
The first and second stage cylinders are cast with integral valve chambers, cooling water
passages and air chambers. The third stage cylinder and top cover is a combined casting.
The cylinders all have machined faces for the cylinder joint, valve covers, distance rings
and valves.
The cylinders are non-lubricated, the piston rings being made of low friction material, and
are spaced off the crankcase by distance pieces. This is to help prevent oil from the
crankcase sump getting into the cylinders. Cooling is provided by passing water first
through the compressor intercoolers, and then, via a series of flexible pipes, around the
cylinder water jackets and cylinder top covers.
2 - Pistons and Rings
The pistons are of a two-piece hollow construction, with machined piston-ring grooves.
The centre body is drilled and recessed to take the piston rod. The pistons are made from
Issue 1
01/2015
Page 18
V290M-WN
Compressor
aluminium and the piston rings are made from composite material. Compression rings are
jointed to assist with replacement during servicing. Bearer rings are solid (un-cut) and are
located on the pistons between the piston upper and lower halves.
3 - Piston Rods and Packings
The piston rods are threaded at both ends. The piston rod bottom end has a cruciform slot
to accommodate a securing pin (to prevent rotation of the rod in the crosshead) and is
held in the crosshead by a locknut. The top end of the rod is shouldered and waisted
inside the piston. A self-locking nut secures the piston to the rod.
The piston/cylinder end clearances at the top and bottom are governed by the distance
the piston rod is screwed into the crosshead.
The oil-free cylinder compressor has separate packing gland assemblies. The packing
comprises multiple sets of sealing rings, each set of rings being housed in a container and
held against the piston rod by a garter spring. The containers are assembled to a base by
long studs and nuts, and the assembly held in its housing in the base of the cylinder by
studs and nuts. A soft iron ring is recessed into the top surface of the upper container to
prevent air leakage around the packing.
The separate scraper assembly is housed in the crosshead-guide loose plate and
comprises a number of segmented rings in a split casing, each ring is held in contact with
the piston rod by a garter spring.
An oil shedder is also fitted to the piston rod between the packing and the scraper
assemblies to prevent any oil-creep along the rod.
f)
Valves
Suction and delivery valves are similar in construction but differ in detail. Care must
always be taken when servicing the compressor to ensure that the correct valve is fitted
into the correct valve chamber.
All suction valves are controlled by plate depressors (or unloaders), their location being
identified by the presence of actuators on the valve covers. The actuators have small bore
instrument air pipes connected to them.
The valve assemblies are held in their seats by valve cages. The cages have 'O' rings
recessed into their upper circumference to prevent leakage of air. The first and second
valve covers have an additional 'O' ring seal between them and their cages. The valve
covers are the 'raised face' type.
To unload a working compressor, the suction valves are rendered inoperative by the valve
plates being pressed off their seats. This is accomplished by plate depressors (unloaders)
being operated by load control actuators.
A plate depressor is basically an inverted cup-shaped body with fingers protruding from its
rim, assembled with a spring-loaded central guide surmounted by a cylindrical cap. The
fingers operate through slots in the suction valve seat directly onto the valve plate.
Issue 1
01/2015
Page 19
V290M-WN
Compressor
In action the plate is depressed, against its spring, by the pneumatically operated
actuator. Compressed air fed to the load control actuator, by the load control solenoid
valve, acts on a multi-layer diaphragm, which is sandwiched between the two halves of
the actuator body. The diaphragm is in contact with the head of the spring loaded plunger
immediately under the disk. The plunger, guided in the lower half of the actuator body, has
its stem end in contact with the cap of the plate depressors. When the control air is
exhausted by the solenoid valve, springs return the plunger away from the valve plate.
g)
Coolers, Separators and Drains

The standard intercooler stack is made up of multiple copper tubes soldered into a brass
fixed end plate and a brass expansion end plate. The tubes have internal copper coil
secondary surfaces. The fixed end plate is sandwiched between the cooler body inlet
flange and the cylinder air delivery adaptor; the expansion end plate is free to move axially
in rubber 'O' ring seals at the outlet end.
The stack is contained either in a cast iron body or mild steel fabricated body with cast
iron adaptors at either end. The body has water inlet and outlet connections and internal
brass baffle plates to guide the cooling water over the tubes.
If an aftercooler is fitted it is of similar construction. Separators are fitted after each cooler
and have drains fitted.
h)
Motor and Couplings

The compressor can be supplied with a flange mounted motor with a direct in-line drive
through a flexible coupling, or indirect drive through a vee belt pulley wheel.
For a flexible coupling drive, a flywheel is keyed on to the crankshaft, and for a vee belt
drive the heavy crankshaft mounted pulley provides the flywheel effect.
The standard motor is a brush-less cage rotor type, with a power output suited to the
delivery requirements of the compressor.
i)
Control Panel and Controls

The compressor can be supplied with or without a starter system. The standard starter
system is housed in a two-compartment dust and damp proof wall or floor mounted sheet
steel cubicle. The control panel is an integral part of the front of the cubicle and the
controls and gauges are divided between the upper and lower compartments. (For full
details of the controls their operation and functions refer to the supplementary information
provided with your compressor).
Issue 1
01/2015
Page 20
V290M-WN
Compressor
Chapter 2 - Safety Information
Issue 1
01/2015
Page 21
V290M-WN
Compressor
2.1 Safety Policy

The compressor and its associated equipment are to be operated in accordance with
current Statutory Health & Safety Policies (and any such regulations applicable in the
country of installation). It is the responsibility of the operative to familiarise him/her self
with these policies/regulations.
Any work practices that may pose a potential health and safety hazard or any
faulty/suspect equipment associated with the safe operation or maintenance of the
compressor package must be brought to the immediate attention of the supervisor or
supervising authority.
Always wear appropriate personal protective equipment (PPE) when operating or
maintaining this equipment. PPE should include, but not limited to:
Ear Defenders
Safety Glasses.
Industrial Boots.
Safety Headwear
Appropriate Hand Protection (gloves and/or barrier cream).
Any other safety item identified under Risk or COSHH Assessments.

Loose fitting or frayed/ripped clothing MUST NOT be worn while operating or maintaining
this equipment.
a)
Commonplace Hazards
If a hazard is identified that is not identified within the Operating Authority 'Standing Safety
Instructions' a separate Risk Assessment must be made. Similarly If a hazard in the form
of a hazardous substance (Substance identified under COSHH regulations in the UK) is
identified, steps must be taken to assess the risk of injury to staff.
The compressor and its associated equipment are to be operated in accordance with
current statutory Health & Safety at Work policies. It is the responsibility of the operative to
familiarise him/herself with these policies. Any work practices that may pose a potential
health and safety hazard or any faulty/suspect equipment associated with the safe
operation and maintenance of the compressor must be brought to the attention of the
supervisor or supervising authority.
b)
Proper Use
The compressor is built to stringent manufacturing guidelines to guarantee safe operation.
However, using compressed air can be linked to dangerous occurrences if compressed air
is not properly handled. Proper use also includes the following:
Issue 1
01/2015
Follow the guideline laid down within this instruction manual, observing all pertinent
regulations and notes for the compressor.
Maintaining the equipment at the mandatory inspection and maintenance intervals.
Correct repair of the compressor equipment.
Operation of the compressor in accordance with the original design parameters.
Operation is carried out in accordance with the relevant environmental and operating
regulations.
Page 22
V290M-WN
Compressor
c)
Organisational Measures
It is the customers responsibility to ensure that the operating manual is adequately
supplemented with internal regulations regarding supervision and notification duties, work
organisation, and personnel qualification etc.
No modifications may be carried out on the compressor or its peripheral devices without
the written consent of Gardner Denver. Unauthorised Modification of the equipment will
invalidate the WARRANTY.
When renewing compressor components, use only original spare parts and accessories
supplied by Gardner Denver.
d)
General Safety Precautions for Compressors

Electrical System - Before performing work on the electrical system the compressor and
the peripheral devices must be isolated from the mains and secured against accidental
switch-on. Work on the electrical system must only be carried out by qualified staff who
are aware of the risk involved with the task. All electrical work must be carried out in
accordance with local laws relating to electrical working.
Pressure Relief Valves - These MUST be Full Compressor Capacity relief valves
connected directly to the flow pipework to relieve any excess pressure that may build-up
between the cylinder discharge flange and in line equipment (e.g., stop valve, non-return
valve, cooler, etc).
There must be no restriction of any kind between the relief valve position and the
preceding cylinder. Relief valves must be directly mounted with no isolating valves
interposed between the relief valve and the pressure sensing point. The exhaust from the
relief valves must only discharge into designated safe areas. The setting of relief valves
must be checked regularly as required by statutory codes and regulations.
Pressure vessels must be fitted with a full capacity pressure relief valve. Vessels must not
be operated above their stated operation rating and must be checked regularly as
required by codes and regulations.
WARNING !
THIS COMPRESSOR MUST NOT BE OPERATED UNLESS RELIEF
VALVES ARE IN A FULLY OPERATIONAL CONDITION AND ARE
CORRECTLY SET TO THE CORRECT RELIEF PRESSURE.
Protection Equipment - All protection, control switches and circuits must be regularly
checked for correct operation. Switches can be tested by checking in calibration rigs, or by
carefully controlled simulation of fault conditions at the actual machine. Circuits can be
checked by mechanically operating the switches.
Frost Protection - Where, due to its location, the compressor could be exposed to frost,
then adequate precautions must be taken to prevent freezing of the water system.
Guards - All guards and covers must be in position and secure before start-up.
Issue 1
01/2015
Page 23
V290M-WN
Compressor
Operating Records - It is IMPORTANT that a regular log sheet be kept for the
compressor recording operating pressures, temperatures and oil pressure (a copy of a
Log Sheet is provided within the Appendices located at the end of this manual). Variances
from normal running performance should be brought to the immediate attention of the
Supervisor responsible for consideration and action.
Lifting Equipment - Before using any lifting equipment, it is IMPORTANT that the crane,
gantry, hoist or chain block and any slings employed must be certified capable of lifting
the weight of the compressor (or motor/compressor assembly). Any such lifting equipment
MUST have a current CITB Test Certificate (or an equivalent certificate applicable to the
country of installation).
e)
Installation, Commissioning and Operation

In all matters of safety regarding the Installation, Commissioning and Operation of the
compressor or package, the reader's attention is directed to the full implementation of the
requirements of the Health & Safety at Work Act (and any such regulation applicable in
the country of installation). Gardner Denver may be consulted should any doubt exist
regarding matters of safety related to their product.
f)
Maintenance
In addition to the General Safety Precautions, the following safety precautions MUST be
observed when maintaining your machine.
Issue 1
01/2015
Before commencing any maintenance work on the compressor or its driving unit or
any ancillary, the driving unit must be rendered incapable of being started whilst
maintenance and adjustment work is in progress. In the case of an electric motor for
example, the machine must be isolated from the main electricity supply, the isolator
locked off and/or the fuses withdrawn. This is particularly important with auto
start/stop machines where the machine could be started automatically.
ii
Affix "NOT TO BE USED" boards to the compressor and control cabinet.
iii
Isolate the compressor from the discharge main and the instrument air. Where a
compressor is isolated from the delivery of other machines by a non-return valve,
the non-return valve must not be used as the only source of isolation. The
compressor must also be positively isolated from the delivery by closure of an
isolating valve.
iv
Before opening up the machine, all pressurised compartments MUST be

depressurised down to atmospheric pressure in a safe and controlled manner.
Isolate the compressor from the cooling water supply and drain all relevant water
containing compartments.
vi
If the compressor motion work or rotational parts are to be worked on then piston
rod clamps MUST be fitted to prevent accidental movement. Also chocking the
crankshaft should be considered where necessary.
vii
ALL lifting equipment MUST be correctly rated for the loads being applied and
MUST be certified as being in good working condition. Always ensure that when
lifting equipment is used, only specified lifting or slinging points are used.
viii.
Always refer to the applicable procedure when undertaking maintenance and

overhaul procedures.
ix.
Bolts and nuts must not be under or over tightened. Refer to the appropriate torque
values given in Table 1-6.
Page 24
V290M-WN
Compressor
Issue 1
01/2015
x.
Ensure that ALL tools and spare parts are accounted for after reassembly, since
any items left on or within the compressor may cause serious damage upon
restarting.
xi.
DO NOT place the electrical isolating switch to the 'ON' position until all work has
been completed by all personnel working on the equipment. The site supervisor
must inspect and approve the work carried out before re-connecting the equipment
to the electrical supply.
xiii.
Before starting the compressor, bar over the machine by hand where possible to
ensure free rotation and that no metallic 'knocking' noise is evident. If any solid
resistance to rotation is found, investigate the cause.
Page 25
V290M-WN
Compressor
INTENTIONALLY BLANK
Issue 1
01/2015
Page 26
V290M-WN
Compressor
Chapter 3 - Installation and Commissioning
Issue 1
01/2015
Page 27
V290M-WN
Compressor
3.1 Safety Precautions

Before carrying out any work related to this Section, it is a requirement that you read and
work in accordance with, the Safety Precautions given in Chapter 2 of this manual. For
your own protection, be sure to read and obey the WARNING and CAUTION notices you
find in this Section and any associated literature.
WARNING!
IF THE COMPRESSOR IS TO BE SUPPORTED ON ANTIVIBRATION
MOUNTINGS, AIR, WATER AND ELECTRICAL SERVICES ARE TO
BE MADE WITH NON-RIGID (FLEXIBLE) CONNECTIONS.
DUE TO POSSIBLE ELECTRICAL INSULATION EFFECTS OF PIPE
GASKET MATERIAL AND ANTI-VIBRATION MOUNTINGS, THE
MACHINE MUST BE PROVIDED WITH A PERMANENT EARTH
CONTINUITY CONNECTION OF A NON-RIGID (FLEXIBLE) TYPE,
WHICH SHOULD COMPLY WITH LOCAL REGULATIONS AND
SAFETY REQUIREMENTS.
3.2 Installation Requirements

The installation of the compressor, and its associated pipework, should be the subject of
careful consideration before undertaking the actual task. This section of the manual
provides the necessary information for the installation engineer to locate and to install the
compressor to the best advantage.
a)
Location
The compressor should be located in a clean, well-lit, well-ventilated area with ample
space all around it to facilitate inspection and maintenance. Sufficient room must be
allowed for the removal of pistons and cylinders, crankshaft and motor, and as the
compressor and many of its components are heavy, there must be headroom sufficient to
permit the operation of a crane or hoist, which must be certified capable of lifting safely
the weight.
Statutory regulations and local by-laws governing the operation of heavy machinery must
be complied with, this may have some influence on the choice of location.
b)
Ventilation
Approximately 10% of the energy consumed by a compressor is lost as heat. This is the
heat generated by the motor, the mechanical losses of the compressor and straightforward heat radiation from the air manifolds.
For example, a 365kW water-cooled compressor would require some 486 m3/min of
ambient air circulation to limit the compressor room temperature rise to 6C. Natural
convection is normally adequate with the outlet vents at a high level to prevent the
temperature building down from the roof.
c)
Issue 1
01/2015
Foundations
For vibration isolator mounted compressors, all that is required is a floor of sufficient
strength to carry the weight of the compressor, motor and ancillaries. For solidly mounted
compressors the foundation dimensions must be determined for each installation,
consideration being given to the nature of the subsoil and local surroundings.
Page 28
V290M-WN
Compressor
WARNING!
THE FLOOR MUST BE LEVEL AND FLAT.
Foundation depth must be such that the subsoil reached is, in the opinion of an expert,
capable of taking the load of the working compressor and preventing the transmission of
vibration. Unless the foundation rests on bed-rock or hard-pan, a sub-footing should be
made of such a size and design as to provide a solid bottom. In extreme cases of poor
subsoil, piling may be required, and in such circumstances a competent foundation
engineer should be consulted.
If the compressor is to be mounted on a metal floor, it can be either bolted direct to the
floor, or beam or skid mounted. The beams or skids may be bolted or welded to the floor,
with due consideration being given to structural vibrations and floor strength.
A foundation plan (for good subsoil conditions) is furnished in advance of the shipment of
the compressor, and the foundation used must not be less than given in the plan.
When installing a solidly mounted compressor, it must be ensured that the crankcase feet
are ALL flat down and fully supported BEFORE tightening the "Holding Down" fasteners.
A detailed foundation drawing is available (on request) from Gardner Denver
d)
Pipework Installation
These paragraphs give recommendations with regard to delivery pipework and will help
the plant engineer plan the best possible installation.
Pipes must not be fixed inflexibly such that heavy thrust can act back onto the compressor
otherwise serious damage could result, examine carefully the anchoring point locations
and pipework support arrangements.
WARNING!
ALL INLET AND OUTLET CONNECTIONS TO COMPRESSORS
MOUNTED ON VIBRATION ISOLATORS MUST USE SUITABLE
FLEXIBLE PIPES. ALL FLEXIBLE PIPES MUST BE INSTALLED IN
ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS
1 - Inlet System
An efficient air intake filtration system is essential to ensure that debris is removed from
the air flow to the compressor thereby prolonging the life of the machine.
Standard Gardner Denver practice is to fit a machine mounted, combined filter/silencer,
however, in hot or dirty locations, or in the presence of difficult combinations (e.g. fumes,
alumina or cement dust), filtration may be improved by mounted the intake remotely and
ducting the air to the compressor. Special filter/silencer arrangements are available for
this type of installation.
Only dry type filters must be used with oil-free compressors.
Noise regulations should be taken into account when deciding silencer requirements and
locations.
2 - Delivery System
Issue 1
01/2015
Page 29
V290M-WN
Compressor
The flexible delivery pipe connects the aftercooler to the receiver (where fitted). It must be
of the correct specification for the pressure and temperature and nature of the medium
being compressed, and not smaller than the size specified below.
The pipe must be well supported to avoid strain on the compressor cylinders, and it's
configuration be such that any expansion effect, due to the air/gas temperature rise for
whatever reason, can adequately be dissipated within the natural elasticity of the pipework
leading from the compressor and cannot act back on the cylinder.
At the junction with the receiver, or pipe main, a shut-off valve should be fitted to isolate
the compressor as required. On automatic and multi-machine installations, non-return
valves should also be fitted to isolate standby units from system pressure.
A safety valve must be fitted, close to the compressor, in the delivery pipe. The valve must
be fitted before any shut-off valve, non-return valve or aftercooler to prevent damage in
the event of the compressor being run with the shut-off valve closed. The valve should be
a springloaded type and of sufficient size to pass safely the maximum compressor output.
A small blow-down valve should be fitted between the compressor and shut-off valve to
relieve residual pressure when required for maintenance purposes.
3 - Air Receiver
An air receiver of suficient capacity is required for use with this equipment. The receiver
should have a capacity equal to a one minute supply of compressed air (neglecting
temperature rise).
The air receivers should, ideally, be located in the coldest place possible, to ensure that
as much condensate as possible is precipitated from the air in the receiver. This means
that the receiver must be drained frequently, either by fitting an adequate drain or an
automatic drain trap.
To facilitate servicing of the drain trap whilst the receiver is in commission, a by-pass
should also be incorporated.
4 - Distribution Piping (air systems)
Water collectors of an automatic discharge type should be fitted at suitable points in the
pipe system. They should be fitted with three-way cocks (either in connection with the
traps or separately) so that pipes may be blown through to disperse condensation.
Delivery pipework must be arranged to prevent condensation running back from the
aftercooler or receiver into the compressor cylinders.
The pipe system for air distribution should be carefully considered if optimum results are
to be obtained. Moisture-laden air can cause rusting in low-lying parts of the pipe system
so, ideally, all distribution pipework should be internally galvanized and angled slightly
towards the drain points.
An effective way of eliminating possible water damage is to install a refrigerative air dryer
or, for dryer air, an adsorption dryer.
5 - Load Control Piping
Connect (with similar size piping) the load control system on the compressor to the control
air take-off points on the compressor panel, the connections on the compressor will
indicate the size.
Issue 1
01/2015
Page 30
V290M-WN
Compressor
Connect (with similar size piping) the compressor panel control air inlet point to the
compressed air/instrument air main - any isolating valve fitted here must be of the
lockable open type.
6 - Drain Valves & Drain Valve Piping
It is important that the drain pipes from the water separator drain traps are run individually
to open ends (e.g., over OPEN containers). They must NOT be piped together as there
would then be a risk of "blow-back" along adjacent pipes in the event of a trap
malfunctioning.
Drain valves are fitted to the separators of each compression stage. These valves exhaust
the collected moisture at high pressure and must be piped away to a safe area using solid
pipework.
MOST IMPORTANT - if the exhausts of any vent valves are piped away, it is essential
that these have direct outlets to atmosphere, they must NOT be connected into any other
pipe. It is also recommended that a silencer is fitted to the exhaust in order to reduce
noise levels.
e)
Cooling Water
An adequate source of clean, cool water for the compressor cylinders, intercoolers and
aftercooler should be provided.
Cooling water must be as free as possible from scale forming salts, with (if the water is not
clean) an efficient filter(s) placed in the intake pipeline. A Duplex type arrangement is
recommended as this will allow one filter to be cleaned whilst the other is in service.
The temperature of the cooling water supply to the compressor (NOT aftercooler) should
not be less than the ambient temperature. The methods of achieving this depend on the
cooling system employed:
The temperature of the cooling water supply should be in the range 20C to 35C
In situations where the ambient temperature is in excess of 35C., advice should be
sought from Gardner Denver.
The pressure in the cooling water pipeline at the compressor must be sufficient to promote
the flow required by the size and duty of the machine. This should take into consideration
all the friction losses in the overall pipework and valves and across the heat exchanger
units (as may be installed) as well as across the compressor.
Except for compressors made to special customer requirements, water pressure in the
jackets must not exceed 7 Bar g. It is recommended that thermometer pockets are fitted to
the water inlet and outlet pipes to the compressor and, the aftercooler. Temperature
differentials between these points will give a good indication of sufficient water flow, 10 to
12C being usual.
CAUTION!
FAILURE OF WATER FLOW IS A CAUSE OF MAJOR DAMAGE
AND MUST BE AVOIDED. ENSURE THAT COOLING WATER PIPES
TO AND FROM THE COMPRESSOR ARE CONSTRUCTED TO
AVOID THE FORMATION OF AIR LOCK
Issue 1
01/2015
Page 31
V290M-WN
Compressor
For compressors operating in cold environments, drain points are present on the cylinders
to empty the water jackets of the machine (when out of service) to prevent damage in the
case of frost. Open air vent cocks at the tops of the cylinders at the time of water
drainage. Certain water pipe connections should afterwards be disconnected to
completely drain the system.
CAUTION!
EXPOSURE TO FROST CONDITIONS WILL DAMAGE YOUR
MACHINE UNLESS THE PROPER FROST PRECAUTIONS ARE
TAKEN. IF ADVICE IS REQUIRED, PLEASE CONTACT GARDNER
DENVER.
f)
Electric Cabling
The electric cabling to the motor must be run such that small amounts of movement at the
motor terminals can be safely absorbed within inherent flexibility of the type of cabling
used.
Check that the motor nameplate details agree with those of the electricity supply on which
the motor is to be used.
Connect motor in accordance with the instruction supplied. Use cables of adequate size to
carry the full load current and also large enough to carry the starting current without
excessive voltage drop.
Ensure that the motor frame is properly earthed.
Electrical Suppy
Voltage - Steady state voltage with 90% to 110% of nominal value. Frequency Variations should be no lower than 99% or higher than 101% of the nominal frequency for
continual operation. Exceptionally limits can be extended to 98% to 102% for short
periods.
g)
Harmonics - Harmonic distortion not to exceed 10% of the total r.m.s. voltage between
live conductors for the sum of the second through to the fifth harmonic. An additional 2%
of the harmonic is permissible.
Voltage imbalance - Neither the voltage of the negative sequence component nor the
voltage of the zero sequence component shall exceed 2% of the positive sequence
component.
Voltage interruption - Supply interrupted or at zero voltage for not more than 3 s at any
random time in the supply cycle. There shall be more than 1 s between successive
interruptions.
Voltage dips - Voltage dips shall not exceed 20% of the peak voltage of the supply for
more than one cycle. There shall be more than 1 s between successive dips.
h)
Motor Starters
1 - Motor Protection Equipment
The following has been prepared to describe the minimum protection requirements for
motors used on the compressor.
Protection of the motor should consist of as a minimum the following :
Issue 1
01/2015
Thermal motor overload by monitoring motor current

Motor overheating using PTC thermistor probes
Page 32
V290M-WN
Compressor
Phase imbalance
Phase failure
Gardner Denver reccomend the Group Schnieder (Telemecanique) thermal overload
motor protection relay. This provides the above levels of protection.
2 - Basic Starter Equipment Requirements
Equipment supplied within a starter control panel should as a minimum consist of the
following :
Mains Isolator
Star Delta Starter complete with thermal overload motor protection relay (above)
PTC thermistor protection relay
Soft start unit (optional)
Soft start by pass contactor ( for by pass after run up time)
Thermal overload motor protection relay (as above)
Motor short circuit protection (either fuses or mccb) should be provided by the
customer, unless otherwise specified.
3 - General
All equipment shall be selected for use on AC 3 phase circuits up to 600 Volts.
Control circuits may generally be either 110 Volts AC or 24 Volts DC. Check that
solenoids and other equipment fitted on the compressor are designed to operate at the
supplied control voltage.
All motor starting equipment should be rated for AC3 motor starting duties and be
selected in accordance with the motor rating information provided. All equipment should
conform to the latest ISO standards.
All thermal overload motor protection relays must be set at the phase current. (rated
current of the motor divided by 1.732).
i)
Drive Motor
The motor used to drive the compressor must comply with the following specification :
1 - Application
Motors should be designed, manufactured and tested in accordance with the following
standards:-BS
EN 60034 - Rotating electrical machines
BS 4999 - General requirements for rotating electrical machines
BS EN 50347 - General purpose three phase induction motors
The design of the motor should take into account the irregular turning effort required for
this application. The motor design should also take into account the rotor inertia needed to
meet the requirements of this type of load. The motor should be capable of continuous
operation (S1 duty) and be able to be started with electronic "soft start" equipment or a
start/delta starter.
Issue 1
01/2015
Page 33
V290M-WN
Compressor
The motor may be subjected to a maximum of three (3) starts in a one (1) hour period.
The compressor can be loaded and unloaded several times a minute via a two (2) or three
(3) step control.
2 - Rating
The motor shall be rated as follows:Power rating and speed as shown in Technical Data, Chapter 1
Drip protected (IP21S) to IEC 60034-6, suitable for 40C ambient, a maximum altitude of
1000 metres above sea level and limited to class F temperature rise. Maximum voltage
variation permissible shall be within 90% and 110% of nominal value. Whilst the motor will
be rated for operation at supply voltage, its insulation standard should be for 1000 volts
which includes consideration in respect of the winding inter-turn insulation. The dielectric
strength of the insulation should be rated for a voltage waveform with a rise time of not
less than 3 kV/ sec.
Direction of rotation - Motor to drive the compressor clockwise looking from the motor end.
Insulation class F.
3.3 Handling and Unpacking

a)
Stability
Due consideration must be given to maintaining the compressor's stability during all lifting
procedures. The compressor is only in a stable condition when standing on a suitable,
level floor surface with all four crankcase feet firmly down. It MUST be noted that the
Centre of Gravity (C of G) for each machine will change depending on whether the
compressor is 'bareshaft' or fitted with a 'drive unit'.
WARNING!
THE CRANE, GANTRY, HOIST OR CHAIN BLOCK OR ANY SLINGS
EMPLOYED MUST BE CERTIFIED CAPABLE OF LIFTING THE
WEIGHT OF THE COMPRESSOR (OR MOTOR/ COMPRESSOR
ASSEMBLY).
Issue 1
01/2015
Page 34
V290M-WN
Compressor
Compressor Slinging Diagram (Typical)

b)
Slinging Instructions
On all compressors two cradle slings are positioned, one under each of the two outer
cylinder crankcase flanges. A third sling is used to balance the compressor.
1
In the case of a compressor fitted with a flange mounted motor, a cradle sling is
passed under the motor, taking care to keep it clear of the fan housing.
If the compressor is fitted with a flywheel, a balancing sling is passed around the
shaft.
WARNING!
UNDER NO CIRCUMSTANCES USE THE MOTOR LIFTING HOLE
FOR BALANCING THE WEIGHT (THIS LIFTING POINT IS FOR THE
MOTOR ONLY WHEN DETACHED OR DETACHING FROM THE
COMPRESSOR).
Care MUST be taken to ensure that no small bore pipes or other components are trapped
by slings.
c)
Lifting Instructions
Because the type of lifting equipment for each installation will be different the following
instructions have been written with the intent of being a general guide rather than specific
instructions.
Issue 1
01/2015
Page 35
V290M-WN
Compressor
1
d)
Whatever your equipment or conditions, good safety procedures must be

practiced, i.e.:
Establish the actual weight of the load.
Check whether the lift will be a straight lift, or will an angle rig be needed.
These factors will affect the lifting capacity required.
The slings must be free of kinks, knots, broken strands or loose connections
etc, and meet the regulation requirements.
Check the clearance available to make sure the lift can be carried out safely.
To prevent damage to the machine's finish or the edges of the machine from
cutting into the slings, use proper blocking and padding.
When involved in the lifting of heavy loads, we suggest you protect yourself by
wearing approved protective gear such as: safety helmets, steel toe cap safety
shoes, gloves, eye protection, etc.
Prepare the installation area before moving the machine.
Refer to the machine installation drawings and note the location of the machine
support points. Review all machine installation requirements carefully before
positioning the machine.
Unpacking
No special unpacking instructions can be given here as the compressors may be
transported fully boxed, crated, or on open bases, depending on destination and mode of
transportation. Boxed compressors have directions for lifting and opening on or with the
boxes. Some of the cylinder valves will have been replaced with silica-gel bags. The
displaced valves and the accessories are packed in a separate container, which should be
located and safeguarded until after the installation of the compressor.
3.4 Installation Procedure

a)
Safety Precautions
The following additional safety precautions should be observed before installing the
compressor onto its foundation.
Personnel must be a safe distance from the compressor during positioning, guide ropes
may be used to assist, but not 'hands-on'. The compressor must be lowered slowly, in
small stages with no sudden jerks whilst observing for any indications of potential
problems. Once in position the compressor must be properly secured with suitable
foundation bolts or antivibration mounts (AVM's).
If the floor is to be drilled for foundation bolts, the compressor must be moved away whilst
work proceeds.
Each time the compressor is moved check for stability and correct sling placement.
DO NOT apply load tension to the slings if the compressor is held to the floor.
Issue 1
01/2015
Page 36
V290M-WN
Compressor
b)
Mounting Arrangements - Anti-Vibration Mounts

A flat and level floor of sufficient strength to support the combined weight of the motor,
compressor and ancillaries should be prepared in advance of the compressor delivery.
The procedure should then be as follows:
1
Ensure that the underfaces of the compressor feet are clean.
Bolt the anti-vibration mountings on to the compressor feet.
Move the compressor into position and mark on the floor the position of the holding
down bolt holes in the anti-vibration mounting plate.
Remove the compressor and attached mounts and drill the floor for appropriate
size holes for the Rawl-bolt shells.
Insert shells, reposition compressor and bolt onto floor by means of the mounting
holding down bolts.
OR:
The anti-vibration mountings may be held down by bolts or anchors of a similar
diameter to the holes in the mounting plate. Use of these will eliminate the need to
move the compressor to drill the floor holes. The appropriate instructions supplied
with the bolts should be followed precisely.
c)
Finally, check the bolts holding the compressor onto the anti-vibration mountings
and use these bolts to finish levelling the compressor (See Levelling and
Alignment).
Levelling and Alignment - Flange Mounted Motors

Compressors with flange mounted motors are completely assembled and lined-up before
shipping, it is therefore only necessary to set the machine on the foundations and level it
in both directions as follows:
Issue 1
01/2015
Adjust the pressure within the pneumatic AVM's around the machine until the
desired level is achieved. Do not inflate AVM's unless the static weight of the
compressor is placed on them.
Ensure that the final levelled height of each mount is within the makers limits and
that each mount is levelled until it carries its correct proportion of the overall
machine weight.
If any mount is compressed solid, levelling must be carried out on the free mounts
to redistribute the load.
Using a spirit level on any horizontal surface, check that the compressor is level in
both planes (i.e. parallel to and at right angles to the crankshaft).
If NOT, then adjust again until satisfied.
Page 37
V290M-WN
Compressor
3.5 Preparation for Commissioning

a)
Cleaning the Compressor

The compressor must be thoroughly cleaned before preparing for commissioning.
Care should be taken when making connections to see that no grit or impurities of any
kind are allowed to enter while the compressor is being piped up and prepared for work.
b)
Preparing the Compressor

After works testing, the compressor is prepared for shipment. Before use therefore, the
compressor will require to be prepared for use as follows:
Issue 1
01/2015
Remove the 'mouldable' wrapping from around the piston rods and clean the rod
surfaces.
Remove control piping from cylinder valve covers marked with adhesive labels and
remove the covers.
Extract the silica gel bags from the valve chambers; ensuring that where more than
one bag is present, ALL bags are removed.
Using a plastic or soft metal scraper, remove rust resistant paint from the seating
in the valve chambers.
Remove the valve assemblies from their wrappings.
Fit components in their correct order, ensuring that suction and delivery valves are
fitted in the correct valve chambers. Where plate lifters are fitted to suction valves,
care must be taken to ensure correct assembly.
Tighten the valve covers and refit the control air pipes
Remove and store the adhesive labels and warning plates with the silica gel bags.
Check that all gauges and small-bore pipework are undamaged, and are properly
connected.
10
Ensure that all external nuts and bolts on the compressor and its ancillary
equipment are tight, including all holding down bolts and bolts of all pipework
flanges and supports.
11
Remove the crankcase access covers (and wooden blocks where fitted), and
crosshead access aperture covers, and check to ensure that the interior of the
crankcase is clean and free of foreign matter.
12
Ensure free movement of compressor motion by turning the crankshaft round a

number of times in the correct direction of rotation.
13
Fill the oil sump (in the bottom of the crankcase) with the recommended grade of
lubricant to level indicated by the window nut on the front of the crankcase. Initially
fill to near the top of the window, the level will fall towards the bottom of the
window when the compressor is started, rising to about half-way when the oil has
reached its sustained running temperature.
Page 38
V290M-WN
Compressor
c)
14
Wearing suitable (oil resistant) protective gloves, liberally coat clean oil onto all the
main guide slides - turning the crank to different positions to achieve full face
coverage (keep hands out of the crankcase when the shaft is being turned).
15
As the compressor may have been in transit/storage for some time, prime the
suction side of the lubricating oil pump by disconnecting the suction pipe top fitting.
Then using the recommended grade of lubricant pump oil 'in' to 'wet' the gears and
fill partially the suction side of the pump body. This promotes a quick pick up of oil
pressure on start up of the compressor.
16
Refit the crankcase and crosshead access covers.
17
Ensure that the compressor pressure instrument isolating cocks are open.
18
Ensure that the pipes of the rubber filling plugs are removed to vent the gauge
cases and allow correct gauge indication.
19
Ensure that the pressure signal pipelines of the load control system are open (i.e.,
make certain that any isolating valves are fixed open).
20
Fill slowly and carefully (to avoid trapping air) in the cooling water spaces of the
compressor - do not rush this operation. Open the air vent cocks, at the tops of the
cylinder covers to rid the system of trapped air. The operation is carried out in
association with any other water-cooled ancillary items in the overall cooling water
system of the installation.
Preparing the Motor

Check the driving motor insulation resistance (IR) using a 500 volt megohmeter taking
note that the insulation resistance in mega-ohms, measured between any terminal and the
frame with the machine cool, is infinity.
If the windings have become damp and the insulation resistance is low, then the windings
must be thoroughly dried out and re-tested for satisfactory condition before
commissioning.
CAUTION!
BEFORE USING THE INSULATION TESTER DISCONNECT THE
SUPPLY LEADS AT THE MOTOR TERMINALS SO THAT ONLY THE
MOTOR WINDINGS ARE TESTED. THIS WILL AVOID THE
POSSIBILITY OF THE
TEST INSTRUMENT POTENTIAL
DESTROYING ANY ELECTRONIC EQUIPMENT THAT MAY BE IN
ANCILLARY CIRCUITS.
Issue 1
01/2015
Page 39
V290M-WN
Compressor
d)
Motor Rotation Check

The compressor is designed to rotate in a clockwise direction when viewed from the drive
end.
CAUTION!
RUNNING THE COMPRESSOR WITH INCORRECT ROTATION WILL
RESULT IN SERIOUS DAMAGE.
After checking it is safe to do so, switch on the electricity supply to the compressor control
panel. Prepare the compressor for an 'unloaded' start and perform a flick test (Start then
quickly stop the compressor motor). Check motor is rotating in the correct direction
(indicated on motor end). In the event of wrong direction of rotation, isolate the machine
immediately. A qualified electrician must rectify the problem before rechecking.
3.6 Commissioning the Compressor

Before commissioning the compressor, read and fully understand Part 3 "Operation" and
any associated literature regarding the control panel and any other ancillary equipment.
a)
Trial Run
When commissioning, the trial run must include certain vital checks, and these should be
carried out as follows:
Issue 1
01/2015
Ensure that the factory delivery mains and air using equipment are safe to
pressurise - and all delivery isolating valves in the system are open.
Ensure that the load control sensing pipework is open to the compressed air main.
Ensure that the isolating cocks of all pressure gauges are open.
Ensure that the by-pass valves situated at the drain traps are closed.
Start compressor in the unloaded condition and allow to run up to full speed,
observe oil pressure is quickly established (this will be high with a cold machine)
and observe compressor running generally.
Page 40
V290M-WN
Compressor
6
After a 3 minute run, stop and electrically isolate the compressor. Remove the
crankcase main doors and check the temperatures of the motion work bearings
and guides. This should be done using a thermometer fitted with a suitable surface
probe.
WARNING!
TAKE CARE DURING EXAMINATION, AS SOME OF THE
PARTS WILL HAVE BECOME HEATED.
All should be cool except the bottom end bearings, which can be a little warmer
than other bearings - also one side (the 'working face' side) of main guides may be
slightly warmer than the opposite side.
Refit the crankcase main doors and reconnect the compressor.
Run the compressor for a further 10 minutes and repeat checks as in step 6.
When satisfied that all is in order, restart the compressor. When the compressor
has settled on speed place the load control to the load condition whereupon the
compressor will commence compressing.
10
Observe compressor operation and the build up of pressure.
The load control must be set for no higher pressure than that for which the compressor is
supplied. (See Section 1.1.1 Technical Data).
During the first commissioning run on load, make careful observation of the general
operation of the compressor.
Observe the compressor gauges, until the desired unloading set-point (as set on the load
control pressure switches) is reached, at this point the compressor will unload
automatically as described in Load Control System.
Check that the loading/unloading sequence is in accordance with requirements - adjust
the control as necessary.
b)
Issue 1
01/2015
Completion of Commissioning
1
Run the compressor until it attains operational temperature and check that the oil
pressure settles at a satisfactory level, approx. 3.5 Bar or above; this will depend
upon ambient temperature, oil viscosity at running temperature, and on-load/offload running pattern.
After a settled period of running (approx. 24 hours) check the tightness of all
external bolts and nuts - particularly cylinder and valve cover fasteners, also
compressor and compressor driver fixings.
During this run adjust the cooling water flow control valve to achieve the required
temperature rise. When on sustained full load, the optimum temperature rise is
about 10 to 12 C.
Page 41
V290M-WN
Compressor
INTENTIONALLY BLANK
Issue 1
01/2015
Page 42
V290M-WN
Compressor
Chapter 4 - Operating Instructions
Issue 1
01/2015
Page 43
V290M-WN
Compressor
These instructions are designed to providing experienced operatives, who are fully conversant with
compressor operating techniques, with operational information for the Gardner Denver range of
compressors.
NOTE: THE FOLLOWING OPERATING INFORMATION ASSUMES THAT THE
COMPRESSOR IS FITTED WITH A STANDARD GARDNER DENVER
CONTROL SYSTEM. HOWEVER, IF THE CONTROL EQUIPMENT IS OF
DIFFERENT MANUFACTURE, THE COMPRESSOR MUST BE OPERATED IN
ACCORDANCE WITH THE SUPPLEMENTARY OPERATING INFORMATION
SUPPLIED WITH THE CONTROL SYSTEM.
The compressor is designed and built for continuous running and will provide long term reliable
operation if regular periodic checks and servicing are carried out in accordance with the
information provided within Chapter 5 of this Instruction Manual.
CAUTION!
PROLONGED UNLOADED RUNNING OF THE MACHINE SHOULD BE
AVOIDED NOT ONLY BECAUSE OF POWER WASTAGE, BUT
UNNECESSARY COMPONENT WEAR CAN RESULT.
It is the customer's responsibility to:
1
Maintain the inlet filter system and air blast cooler in a clean condition as dictated by site
conditions.
Ensure that the specified, clean lubricant is added to ensure the correct crankcase oil
level is maintained
Report promptly to Gardner Denver Service Department any operating abnormalities

faults defects or malfunctions of the compressor and/or associated ancillary equipment.
Such reports must be forwarded in writing by facsimile transmission. Oral reporting shall
be deemed to be acceptable if confirmed in writing within 48 hours.
4.1 Controls and Indicators

a)
Starter System
Where the starter system has been supplied by Gardner Denver details are provided in
the supplementary material at the rear of this manual. Where the control system is
provided by others, details will be supplied by the manufacturer.
b)
Load Control System Functions

All of the suction valves in the compressor have actuators, which cause the valve plate to
be held off its seat whenever a pneumatic signal is applied. When the plate is held open
no compression can take place. If all suction valves are held open then the compressor is
'OFF LOAD'. On removal of the pneumatic signal the plate returns to its seat and
compression can then recommence. The unloader is pushed back by the valve plate
springs and the unloader return spring.
Two-Step Load Control means that the compressor is either on:1
FULL LOAD (compression taking place) - all suction valves being in service
or
2
OFF LOAD (no compression taking place) - all suction valves being held open.
Issue 1
01/2015
Page 44
V290M-WN
Compressor
4.2 Preparation for Starting

NOTE: THE FOLLOWING OPERATING INFORMATION ASSUMES THAT THE
COMPRESSOR IS FITTED WITH A STANDARD GARDNER DENVER
CONTROL SYSTEM. HOWEVER, IF THE CONTROL EQUIPMENT IS OF
DIFFERENT MANUFACTURE, THE COMPRESSOR MUST BE OPERATED IN
ACCORDANCE WITH THE SUPPLEMENTARY OPERATING INFORMATION
SUPPLIED WITH THE CONTROL SYSTEM.
a)
Before Operating the Machine (Pre-Start Checks)

1
Establish that it is safe to discharge high-pressure air into the delivery lines.
2
Ensure that all machine guards are correctly fitted to the machine and auxiliary
equipment. It is IMPORTANT that any loose, missing or damaged guards are
correctly fitted before attempting to operating the compressor.
3
Check that access ways around the machine are clear and free from tripping or
slipping hazards. Remove any obstacles and neutralise any fluid spillage such as
oils or greases, using an absorbent material. Allow spillage to be absorbed for a
short time before thoroughly cleaning the spillage area.
4
Ensure that all of the fault warning, annunciators are extinguished and that the
compressor is safe to start.
5
Check oil level in sump. Correct level is halfway up window nut in front face of
crankcase.
6
If the machine has been standing idle for some time it may be necessary to prime
the oil pump.
7
Ensure that the cooling water supply valve is open promoting water circulation
through the compressor jackets, intercoolers, aftercooler and oil cooler.
8
Ensure that the air pressure sensing pipeline from the air main to the pressure
switches and solenoid valves in the control panel is locked open.
9
Ensure that the main air-isolating valve is OPEN.
4.3 Starting the Compressor

a)
b)
Under Normal Conditions

Refer to the control panel manual for details of starting and operation.
After An Emergency Stop
Rectify fault condition and restart.
4.4 Running
a)
Issue 1
01/2015
Running Checks
1
Allow the compressor to run up to full speed and then close the small drain cocks.
2
Check the oil pressure. This will fall initially as the oil temperature rises, but should
steady at between 3.0 to 4.0 BarG even in a hot environment.
3
Check the cooling water is flowing at the visible outlet or flow indicator. On multicompressor installations balance the flows in the parallel systems of the
compressors (including intercooler) to give equal water temperature rise across
both - ideally 11C.
4
Check all automatic drain traps for unusual discharge.
5
Check all temperatures and pressures periodically.
6
Check for undue noise, vibration or heat. If present, report immediately.
Page 45
V290M-WN
Compressor
b)
7
It is good practice to carry out these checks regularly and log the results.
Automatic Operation
Before Automatic Operation is selected, the compressor must be prepared for starting as
described in (Before Operating the Machine (Pre-Start Checks).
For details of operation, refer to the control panel manufacturers literature.
c)
Faults/Hazards
Should a fault develop, this will be detected by the appropriate sensing switch
4.5 Stopping the Compressor

a)
Normal Stopping
Refer to the control panel manufacturers literature for details of the stopping procedure.
b)
Emergency Stopping
Pressing the 'EMERGENCY STOP' mushroom button stops the machine instantly in
whatever mode of operation it is operating
CAUTION!
THIS IS NOT RECOMMENDED FOR ROUTINE STOPPING AND
SHOULD ONLY BE USED IN THE CASE OF AN EMERGENCY
WHERE NORMAL STOPPING IS NOT POSSIBLE.
4.6 Fault Indications

The following is a list of indications of possible faults which could arise in service; periodic
surveillance of pressures and temperatures, etc, will establish the normally experienced
levels applicable to the site and load conditions.
Variation from these due to a fault arising may be slow to occur - the early effect of a fault
(with the robust reciprocating type machine) being, usually very gradual. It is IMPORTANT
therefore, to retain a simple daily record sheet of pressures and temperatures.
Comparison with previous readings will then warn if there is an untoward trend arising when reference to the following fault indication's list will indicate the probable cause and
remedial action to take. A copy of a typical log sheet is provided in the Appendices located
at the end of this manual.
The running performance of the compressor can also indicate when it is necessary to
renew a particular part: Generally, wear or malfunction of valves or piston rings will be
indicated by variations (other than those due to suction or delivery conditions) in the
interstage or final delivery pressure and temperature.
Progressive crankcase bearing wear will slowly give rise to a gradual lowering of the lube
oil pressure; if low oil pressure does occur and cannot be traced to any other cause listed,
then connecting rod bottom end bearings should be inspected.
a)
Issue 1
01/2015
Fault Finding
Page 46
V290M-WN
Compressor
Minor variations in pressure and temperature readings may occur, due to possible small
changes in the suction or delivery conditions. These factors should be considered when
checking and assessing instrument readings.
Table 4-1: Fault Finding
Possible Cause
Remedial Action
1.
Leaking or broken suction valve plate in

first stage.
Replace valve plate -examine seat for damage.
2.
One or more 1st stage suction valve

depressor(s) sticking in "offload" position.
Remove, clean and refit depressor(s) - examine

valve for damage.
1.
Fouling of inlet filter.
Renew filter elements.
2.
Leaking or broken delivery valve plate in

first stage.
Replace valve plate - examine seat for damage.
3.
Worn, broken or malfunctioning piston

rings in first stage.
Renew rings - clean grooves.
1.

second stage.
Replace valve plate - examine seat for damage
2.
Second stage suction valve depressor

sticking in "off-load" position.
Examine, clean, and refit valve plate

depressor, also examine valve for
Damage
3.

rings in third or second stage cylinders.
1.
Cooling water flow through first stage

intercooler restricted or ceased by
blockage.
Examine and clean air side of intercooler tubes.

(both on air and water sides).
1.

second stage.
Replace valve plate -examine seat for damage.
2.

rings in third stage.
3.
First stage intercooler tubes blocked on

air side.
4.
Relief valve defective.
Repair or fit new valve.
1.

second stage.
Replace valve plate examine seat for damage.
2.
Second stage suction valve depressor

Remove, clean and refit depressor, also examine

valve for damage.
1.
Leaking or broken delivery plate in second

stage.
2.

rings in second stage.
High second stage delivery air

pressure and temperature.
1.

third stage.
High second stage air delivery

temperature after intercooler.
1.
Cooling water flow through second stage

intercooler restricted or ceased blockage.
Examine and clean intercooler cooler tubes (both

on air and by water sides).
1.
Leaking or broken suction valve or

delivery valve plate in third stage.
2.
Third stage suction valve


valve for damage.
3.
Second stage intercooler tubes blocked

on air side.
4.
Fault
Low first stage delivery pressure
(normal or low first stage air
delivery temperature).
Low first stage delivery pressure

(high first stage air delivery
temperature).
High
first
stage
delivery
pressure (normal or high first
stage temperature). delivery
High first stage air delivery

temperature after cooler.
First stage pressure

delivery valve blowing.
relief
Low second stage delivery

pressure (normal) or low second
stage delivery temperature).
Low second stage delivery

pressure (high second valve
stage delivery temperature).
Second stage delivery pressure

relief valve blowing.
Issue 1
01/2015
Page 47
depressor

Repair or replace valve.
V290M-WN
Compressor
Fault
Low
third
pressure.
stage
delivery
Possible Cause
Remedial Action
1.
Demand of end using equipmen thas

overtaken capacity of compressor.
If none of the previous faults are present ,i.e.

compressor running normally, no remedial action
possible.
2.
Low setting of load controller.
When demand reduces, the pressure will rise to

normal level (as set by the load controller).
3.
Malfunction of load controller.
Adjust to required pressure.

Repair/replace pressure controller.
High third
temperature.
stage
delivery
1.

third stage.
2.

third stage.
3.
Third stage suction valve

sticking in "off-load" position
4.

rings in third stage.
depressor

valve for damage.
Renew rings and clean piston ring grooves.
High third stage delivery

pressure (relief valve blowing).
High final air temperature from

aftercooler.
Low lubricating oil pressure.
Loss of oil pressure.
Issue 1
01/2015
1.
Isolating valve between compressor and

delivery main closed or partially closed.
Open valve.
2.
Incorrect setting or malfunction of load

controller.
Adjust to required pressure or repair/replace

pressure controller.
3.
Restriction or blockage of control signal to

compressor unloader system.
Remove restriction.
4.
Aftercooler tubes blocked restricted on air

side.
Examine and clean air side of aftercooler tubes.
5.
Seized closed, or partially closed nonreturn valve in delivery main (if fitted).
6.
1.
Cooling water flow through aftercooler is

restricted or ceased by maladjustment of
hand valves.
Check and adjust hand valve openings.
2.
Aftercooler tubes partially blocked on

airside, or waterside of tubes is fouled.
Examine and clean air and water sides of tubes.
1.
Crankcase oil level is low.
2.
Air leakage into suction side of pumping

system.
3.
Partially blocked oil pump suction strainer

in crankcase.
4.
Oil relief valve set too low or valve sticking

open.
Remove, check and reset.
5.
Failure or wear of big end or small end

bearings.
Renew bearing(s). Check crankshaft for damage.
6.
Partially blocked oil pump delivery filter

element.
Replace element.
1.
Compressor rotation incorrect (first trial

run, or after a rebuild).
Change compressor rotation and recheck.
2.
Crankcase oil level very low.
3.
Serious air leakage into oil pump section

pipe or complete disconnection.
4.
Complete blockage of oil pump suction

strainer.
5.
Oil pump drive failure.
Page 48
Repair valve.
Repair or fit new valve.
Check oil level, add oil as required.

Check oil level. Check connecting unions on
suction pipe to pump.
Remove, clean and refit.

Check suction pipe and unions to pump.
Check and clean oil sump. Remove, clean and
refit strainer. Change oil as necessary.
V290M-WN
Compressor
Fault
Possible Cause
Remedial Action
6.
Examine drive coupling, ascertain cause
Oil pump seizure.
of failure and rectify.

Replace pump. Check drive coupling.
No condensate from drain trap

of interstage moisture separator
or
aftercooler
moisture
separator.
1.
Compressor rotation incorrect (first trial

run, or after a rebuild).
Change compressor rotation and recheck.
2.
Crankcase oil level very low.
3.
Serious air leakage into oil pump section

pipe or complete disconnection.
Check suction pipe and unions to pump.
4.
Complete blockage of oil pump suction

strainer.
Check and clean oil sump. Remove, clean and

refit strainer. Change oil as necessary.
5.
Oil pump drive failure.
Examine drive coupling, ascertain cause of failure

and rectify.
6.
Oil pump seizure.
1.
Drain trap blocked
2.
Separator drain pipe trap blocked.
3.
Dry atmospheric conditions.
1.
This suggests that there is an internal

leakage from the cooling water spaces
into the air spaces of the compressor (low
pressure stage).
Replace pump. Check drive coupling.
No condensate from drain trap

of interstage moisture separator
or
aftercooler
moisture
separator.
Large quantity of condensate

emitted from drain trap.
Dismantle, clean and refit.

Dismantle, clean and refit.
Applies to 1st stage only.
Trace the fault and rectify as necessary.
NOTE: WATER EMITTED FROM THE TRAPS IS USUALLY IN THE FORM OF

A TRICKLE (INTERMITTENT OR STEADY) - DEPENDING ON THE HUMIDITY
OF THE AIR TAKEN IN BY THE COMPRESSOR - OR NIL IN THE CASE OF
VERY DRY ATMOSPHERIC CONDITIONS.
Issue 1
01/2015
Page 49
V290M-WN
Compressor
INTENTIONALLY BLANK
Issue 1
01/2015
Page 50
V290M-WN
Compressor
Chapter 5 - Compressor Maintenance
Issue 1
01/2015
Page 51
V290M-WN
Compressor
5.1 Preventive Maintenance

This schedule of maintenance, in general terms, is a preventive maintenance guide and
running service necessary for our range of reciprocating compressors. However, it does
not cover for any eventualities, which could occur from neglect or incorrect operation by
the customer or adverse environmental conditions.
Before carrying out any preventive maintenance work related to this equipment it is a
requirement that you read and work in accordance with the Safety Precautions given in
Chapter 2 - Safety Information of this Instruction Manual. Also, for your own protection,
be sure to read and obey WARNING and CAUTION notices and observe any special
notes you find in this Chapter and any associated literature.
When working on the compressors rotational parts you MUST fit piston rod clamps to
prevent possible uncontrolled movement of the crankshaft and motion work. Refer to
Maintenance Procedure JOB No: 2 - Fit Piston Rod Clamps.
On plants with two or more compressors the opportunity should be taken during the early
weeks of running, following commissioning, to vary the service hours of the compressors
so that no two machines reach their maintenance interval at the same time. A gap of
about 200 hours between machine running times is recommended.
When 'running-in' a new compressor the crankcase oil MUST be renewed after the first
500 hours of operation and thereafter change in accordance with the intervals laid down in
the following maintenance schedule.
a)
Maintenance Schedule
The following schedule, lists recommended maintenance tasks which are designed to
both prevent unplanned machine breakdowns and to help the maintenance teams to plan
maintenance activities. Where a maintenance activity requires greater explanation than
that given in the schedule a reference to the relevant associated maintenance instruction
is given.
All materials used for scheduled maintenance and repair MUST COMPLY with Gardner
Denver standards and the standards laid down by associated equipment manufacturers.
Only approved spares may be used.
When a system component associated with a mechanical or electrical device is changed
or renewed, the system must undergo a functional test before the equipment is returned to
service.
Gardner Denver are not responsible for premature failures of parts which are caused by
neglect, inappropriate servicing, use of none Gardner Denver parts, or any other similar
conditions over which we have no control.
Issue 1
01/2015
Page 52
V290M-WN
Compressor
b)
Each Day or Shift
A shutdown of the compressor is not normally required for a Shift inspection.

Tasks
Supplementary Information
Check all temperature and pressure gauge

readings are normal.
Report immediately any abnormality.
Check operation of moisture trap drains.
Moisture should be regularly draining from

the base of the drain trap.
Check for undue noise, oil leakage, vibration

or heat.
Report immediately any abnormality.
Ensure that load control equipment is

operating correctly.
Check that the compressor loads and

unloads in response to demand by the air
supply system.
Test protection circuits annunciator lamps.

All lamps MUST illuminate
The 'Test' push-button is normally located

on the compressor control panel. If a lamp
fails, renew the bulb. If the new bulb does
not illuminate report failure to the
Supervisor.
Check the crankcase oil level. Oil level

should be halfway up the window nut.
Use the breather aperture in the top of the

crankcase to top-up the oil. Refer to the
table of lubricants for oil type.
Any aspect of the Shift inspection requiring further attention MUST be reported for action as
required.
c)
Monthly Inspection
A shutdown of the compressor is not normally required for a Shift inspection.

Tasks
Carry out a running examination to ensure

satisfactory operation of all compressor and
ancillary equipment
Record all temperatures, pressures and hours

run on compressor log sheet.
Check air inlet filter element cleanliness - renew if

necessary.
Check the cleanliness and ensure correct
operation of drain traps on compressor and
ancillary equipment where applicable
Clean drains and renew worn or damaged parts,

as required.
Check all external bolts and nuts on the

compressor including the holding down nuts for
tightness.
Re-tighten or renew any missing nuts and bolts.

Tighten nuts to appropriate torque.
Check air pressure supplied to compressor

unloaders and note pressure drop.
Pressure should be 7 bar minimum at unloader.
Where vee belts are fitted check tension and

adjust if necessary.
Refer to drive belt manufacturers instructions for

details of tensioning
Any aspect of the Monthly inspection requiring further attention MUST be reported for action as
required.
Issue 1
01/2015
Page 53
V290M-WN
Compressor
d)
Six Monthly Service
The compressor is required to be shutdown for two days to perform this service schedule
Tasks
Carry out a running examination to ensure

satisfactory operation of all compressor and
ancillary equipment.
Record all temperatures, pressures and hours

run on compressor log sheet. A copy of this form
is provided in Appendices located at the end of
this manual. Check cooling water flow rate (If flow
recorder is fitted).
Check the cleanliness and ensure correct

operation of drain traps on compressor and
ancillary equipment where applicable.
Strip and clean drains and renew worn or

damaged parts, as required.
Check all external bolts and nuts on the

compressor including the holding down nuts for
tightness.
Re-tighten or renew any missing nuts and bolts.

Tighten nuts to appropriate torque.
Visually examine (through the valve pockets) the

general surface condition of cylinder bores for
evidence of ring wear or scoring.
Replace worn or damaged parts, as required
Check
valve
unloaders,
actuators
&
interconnecting small bore pipework for defects.
Clean and service as necessary. Replace worn

or damaged parts as required.
Examine piston rods along gland travel to ensure

no scoring is present.
Clean and service as necessary. Renew worn or

damaged parts as required.
Check that inlet filter is clean
Clean and service as necessary.
Check that inter and aftercooler moisture drains

are operational and that the diffusers on the
blowdown valves are clear and clean..
Clean and service as necessary
Check one suction and one delivery valve from

each stage for cleanliness or fouling.

Renew third stage piston rod packing, piston

rings and rider rings.
Renew worn or damaged parts as required.
Check integrity of all flexible air and water pipes.
Record condition. Renew worn or damaged parts as

required.
CRANKCASE INSPECTION
Examine crossheads and main guide slipper
paths, condition and clearances.

Check connecting rod bottom end bolts are

pinned.
Rectify as required.
Check that lubrication oil suction strainer is clean

and all pipework to main pump is in good order
and that unions are tight.
Clean and service as necessary. Tighten unions

and renew worn or damaged parts as required.
Check that crankcase oil is clean and no foreign

particles are present. Ensure that oil delivery filter
is clean and that oil pressure is satisfactory.
Check for any oil leaks. Wherever possible fix
theleak.
If dirty renew crankcase oil and delivery filter

element. If necessary investigate source of any
foreign particles. Refer to table of lubricants for
oil type and quantity. The crankcase oil and the
delivery filter are renewed as a matter of course
during the Annual Service.
Any aspect of the Six Monthly service requiring further attention MUST be reported for action as required. On
completion of the service, re-commission the compressor and recording all operating pressures and
temperatures. Ensure that the working area is left in a clean and tidy condition.
Issue 1
01/2015
Page 54
V290M-WN
Compressor
e)
Annual Service - (or as stipulated by local regulations)
The compressor is required to be shutdown for five days to perform this service schedule. All Six
Monthly tasks are to be undertaken as part of this schedule.
Tasks
Remove all air valves and replace with factory

refurbished units.
Where possible use factory re-conditioned valve

units. Where this is not possible. all valves reconditioned on site must be leak tested before refitting.
Renew crankcase oil and delivery filter element.
Refer to table of lubricants for oil type and

quantity.
Inspect connecting rod bottom end shells,

crankpin, top end bearing and gudgeon pin.
Check motion work clearances.

Withdraw pistons and piston rods and examine

wear. Gauge cylinder bores and piston rods for
wear and record readings.
Renew piston rings, piston rod packings, and

piston rod scrapers.
Check condition of water jacket spacers for

fouling from lime deposits.
Report condition.
Check cleanliness of motor ventilation fan and

that air flow paths are clean. Carry out an
insulation resistance check on motor windings
and record readings.

Check all system protection devices and circuits

for correct operation.
Use a calibrated test rig to test the protection

devices. Alternatively the devices can be tested
by simulation of fault conditions at the machine.
Any aspect of the Annual service requiring further attention MUST be reported for action as required. On
completion of the service close compressor using new gaskets and 'O' rings. Recommission the compressor
and recording all operating pressures and temperatures. Ensure that the working area is left in a clean and
tidy condition.
5.2 Approved Lubricants

Lubricant
Crankcase Oil
Issue 1
01/2015
Recommended Lubricant SAE 30 oil (ISO VG 100)

(Ambient temperature 0oC to 45oC)
Approved Brands:BP Vanellus M30
Esso Essolube HDX 30
Mobil Delvac 1330
Shell Rimula X30
Alternatively:- The oil MUST be a good quality mineral oil having a
flash point (open test) of not less than 210o C and within a viscosity
range (Centistokes) of 110 at 40o C to 12.5 at 100o C, the oil should
also contain rust and oxidation inhibitors and anti-foam additives.
If the site is particularly hot (over 45 oC) then use an SAE 40 oil (ISO
VG 150).
Consult with Gardner Denver for advice on the correct oil for use in
high ambient temperature locations.
Page 55
V290M-WN
Compressor
5.3 Maintenance Instructions

The following procedures are intended for the use of the technician responsible for the
maintenance of the compressor. It is essential that any necessary adjustments, servicing or
overhaul work should only be carried out by competent persons who are familiar with the
compressor installation and who have the appropriate authority (Permit to Work). To avoid possible
warranty invalidation the following instructions should be read before attempting to maintain the
machine.
WARNING !
WHEN WORKING ON COMPRESSOR ROTATIONAL PARTS YOU MUST FIT
PISTON ROD CLAMPS TO PREVENT POSSIBLE UNCONTROLLED
MOVEMENT OF THE CRANKSHAFT AND MOTION WORK. THIS COULD
RESULT IN INJURY OR LOSS OF LIFE.
REFER TO JOB NO. 002
Issue 1
01/2015
Page 56
V290M-WN
Compressor
JOB No: 1 - Crankcase Oil Change

List of Special Tools
27mm (1-1/16) Spanner (no more than 10 mm thick)
List of Consumables
Crankcase Oil (see page 5-6 for reccommended oils)
A/R
Industrial cleaning fluid (White Spirit) & lint free cloth
A/R
WARNING!
TO AVOID SCALDING FROM HOT OIL, ALLOW THE COMPRESSOR TO COOL
BEFORE BEGINNING WORK.
Isolate mains power and display appropriate warning signs.
2
3
Remove the crankcase doors, taking care not to damage the oil seals.
Wipe any excess oil off the doors using an industrial cleaning fluid and a lint free cloth. Place
the door in a clean location to avoid oil contamination when refitting.
Empty the oil sump using suitable pumping equipment and clean out the crankcase sump
(use lint-free cloths, to avoid fouling of the oil strainer).
Once all oil has been removed from the sump, remove the oil strainer. Use a thin spanner,
on the strainer body hexagon to unscrew the strainer whilst holding the external hexagon
fitting to prevent turning. This fitting is not screwed into the crankcase - it passes through a
clear hole. Re-fit the oil strainer, make sure that all sealing washers are fitted in the correct
locations.
4
5
Illustration 5-1 : Crankcase Oil Strainer Arrangement
Issue 1
01/2015
Page 57
V290M-WN
Compressor
Check that all tools and cleaning cloths have been removed from the crankcase sump.
Refill the crankcase sump with the required quantity of clean, new oil.
Refit the crankcase doors after checking, and if necessary replacing, the door seals.
Test run the compressor and check for oil leaks around the strainer seal and crankcase
doors. If all is satisfactory, return the machine to service.
Illustration 5-2 : Lubrication System
Lub. Oil Pressure

Relief Valve
Oil Pump
Lub. Oil to Cooler
Return Pipe
Oil Suction
Hose
Oil Level Sight

Glass
Oil Filter
Cooling Water
Outlet
Lub. Oil to Cooler

Delivery Pipe
Issue 1
01/2015
Oil Cooler
Page 58
Cooling Water
Inlet
V290M-WN
Compressor
JOB No: 2 - Fit Piston Rod Clamps

Piston Rod Clamps
1 set
List of Consumables
1.
A/R
Before starting this operation, carry out the following safety steps :
a)
b)
Ensure that all pressure is vented from the compressor.
c)
Carefully open the vent valves on the third stage cylinder to check de-pressurising has
been completed successfully.
d)
Ensure that the compressor is isolated from the delivery system and that the
compressor is positively isolated from the delivery non-return valve.
e)
Vent air pressure from the unloader system.
f)
Post signs instructing personnel that the machine MUST NOT be used.
2.
Remove the distance piece access covers from the line of motion works NOT being worked
on. Wipe any excess oil off the covers using an industrial cleaning fluid and a lint free cloth.
Place the cover in a clean location to avoid oil contamination.
3.
Mark the position of the oil shedder on the piston rod and remove shedder.
4.
Loosely assemble the piston rod clamps onto the piston rod.
5.
Manually 'bar-over' the compressor to the desired position and hold steady.
6.
Whilst one person holds the crankshaft bar in position, the other must tighten the one piston
rod clamp firmly against the packing gland box and the other firmly against the scraper gland
box.
7.
Only when both clamps are tight in place can the crankshaft bar be carefully released and
safe work or inspection take place.
WARNING!
WHEN MAINTENANCE WORK HAS BEEN COMPLETED THE PISTON ROD CLAMP
MUST BE REMOVED.
8.
When returning the compressor to service, check that all above steps have been reversed,
all clamps and fittings have been removed and that the compressor is safe to run.
Issue 1
01/2015
Page 59
V290M-WN
Compressor
JOB No: 3 - Cylinder Top Covers - Remove and Re-fit

Lifting Eye-Bolt
1 set
Slings, Lifting Equipment
A/R
List of Consumables
a)
A/R
Removal top cover - First Stage Cylinder

1.
a)
b)
c)
Carefully open the vent valves on the third stage cylinder to check depressurising has been completed successfully.
d)
e)
f)
Isolate and drain the cooling water from the compressor cylinders.
Remove cooling water pipes from the top cover and fit blanking plugs to prevent dirt
ingress.
Disconnect and remove all unloader pipes from the top cover unloaders.
Loosen and remove the top cover securing nuts from the cylinder fixing studs. (sixteen
normal plus six dome nuts with washers)
Remove four of the valve cage nuts and attach suitable eye nuts. The lifting eye
locations should be arranged so that when the cylinder head is lifted, with slings, from
these points, the natural hanging angle will be 45 Deg.
Attach a suitable sling to the eye-bolts, and using lifting equipment, take up the slack in
the sling.
Slowly lift and guide the top cover from the cylinder studs. Adjust the position of the
slings so that the head cover will not swing when lifted clear of the cylinder studs.
Lower the top cover onto a suitable, clean work-surface taking care not to damage the
machined face.
10
Clean the top cover using an industrial cleaning fluid and a lint free cloth.
11
Ensure that the piston and cylinder is clean and dry. Ensure that all liquid and loose
material is removed from the top of the cylinder and piston.
Issue 1
01/2015
Page 60
V290M-WN
Compressor
b)
Re-fitting Top Cover - First Stage Cylinder

If any maintenance has been carried out on the motion work which may affect the piston to
cylinder (bumping) clearances, check the clearances are correct before refitting the top
cover.
c)
1.
Ensure that the cylinder top cover and cylinder top mating faces are clean.
2.
Check the condition of the cylinder top cover gasket. Renew if necessary.
3.
Ensure that all old gasket material is removed from the top cover and cylinder mating
faces. Fit a new gasket over the cylinder studs and onto the cylinder mating face.
4.
Attach a suitable sling to the eye-nuts fitted for cylinder head removal (See section a.
above), and using suitable overhead lifting equipment, raise and position the top cover
over the cylinder.
5.
Slowly lower and guide the top cover onto the cylinder, ensuring the correct positioning
of the cooling water and gas pockets.
6.
When in position, remove the sling and lightly secure the top cover to the cylinder with
the fixing nuts.
7.
Tighten the cylinder cover nuts (six centre nuts first), tighten the nuts down evenly and
progressively. Centre nuts are dome type and must have a copper washer fitted
underneath them. Nuts to be torque tightened to the appropriate torque figure.
8.
Remove the eye-bolts from the top cover and re-fit valve cage fasteners.
9.
Refit all pipes.
10.
Secure the supply lines to the cylinder top cover with their fasteners.
11.
Re-establish water and electrical supplies to the compressor.
12.
Bleed off any trapped air in the cooling system using the plugs in the cylinder water
jacket.
13.
Test run the compressor and check for correct operation and freedom from leaks
around any of the disturbed components.
Removal - 3rd Stage Top Cover

1.
a)
b)
c)
d)
e)
f)
2.
Isolate and drain the cooling water from the compressor cylinders.
3.
Remove cooling water pipes from the top cover/cylinder and fit blanking plugs to
prevent dirt ingress.
4.
Disconnect and remove all unloader pipes that connect to the top cover unloaders.
Issue 1
01/2015
Page 61
V290M-WN
Compressor
d)
5.
Remove cooling water pipes from the top cover and fit blanking plugs to prevent dirt
ingress.
6.
Check that there are no supply pipes or hoses fastened to the top cover.
7.
Disconnect and remove as necessary the 3rd stage delivery and suction pipes using
suitable lifting equipment.
8.
Loosen and remove the third stage top-cover fasteners (10 x M20 nuts).
9.
Pass a sling around the top cover inlet and delivery flanges and lift the top cover clear
of the 3rd stage cylinder and studs.
10.
Lower the 3rd stage top-cover onto a clean work surface taking care not to damage the
machined face.
11.
The third stage bearer and piston rings can now be accessed and removed.
To remove the third stage cylinder - Access the second stage piston
To gain access to the top of the second stage piston, carry out the operations described for
removing the third stage head then proceed as follows :
e)
Remove two of the uppermost studs from the 3rd stage cylinder and fit eye-bolts.
Attach a lifting sling to the eyebolts.
Loosen and remove the third stage cylinder fasteners (18 x M20 Nuts).
If possible remove the third stage bearer and piston rings at this point.
Carefully lift and guide the third stage cylinder clear of the studs and, if the third stage
rings could not be removed in the previous step, the third stage piston assembly.
With the third stage cylinder removed the third stage piston can be removed and
access gained to the top of the second stage piston and piston nut.
To re-fit the third stage cylinder

Before re-fitting the third stage cylinder, ensure that the third stage ring carrier and bearer
ring unit have been removed from the third stage piston base. Ensure also that the second
stage piston, piston rod and third stage piston base are correctly fitted.
1
Fit lifting eyes in the locations shown in the photo above on the 3rd stage cylinder
block.
Ensure that all old gasket material has been removed from the cylinder/cylinder face.
Fit a new gasket in the correct location over the cylinder studs.
Lift the third stage cylinder in to position and carefully lower and guide the third stage
cylinder onto the studs and over the third stage piston base. Ensure that the third stage
piston base passes easily into the cylinder bore and is not damaged by jamming.
Ensure that the third stage cylinder is fully down on the second stage and loosely fit the
fasteners.
Remove the lifting eye-bolts and re-fit the studs from the eye-bolt locations.
Tighten the cylinder/cylinder nuts down evenly and progressively. Tighten to the
appropriate torque figure.
Fit the third stage pressure and bearer rings. Refer to JOB No: 4 - Piston rings
Remove and Re-fit.
Issue 1
01/2015
Page 62
V290M-WN
Compressor
f)
To Refit- 3rd Stage Top Cover

If any maintenance has been carried out on the motion work which may affect the piston to
cylinder (bumping) clearances, check the clearances are correct before refitting the top
cover. Refer to Job No. 005.
1
Ensure that the 3rd stage cylinder and top cover mating faces are clean. Ensure that
the cylinder face O ring is in good condition. If necessary replace the O ring.
Attach a suitable sling over the top cover suction and delivery flanges and using
suitable lifting equipment, raise and position over the cylinder. Lower the top cover so
that it passes over the studs.
When in position, remove the sling and lightly secure the top cover fasteners. (10 x
M20 Nuts)
Tighten the top cover nuts down evenly and progressively. Tighten to the appropriate
torque figure.
Re-make all unloader pipework.
Re-fit the suction and delivery pipework.
Re-establish water and electrical supplies to the compressor. Bleed off any trapped air
in the cooling system using the plugs in the cylinder water jacket.
Test run the compressor and check for correct operation and freedom from leaks
around any of the disturbed joints.
Issue 1
01/2015
Page 63
V290M-WN
Compressor
JOB No: 4 - Piston rings - Remove and Re-fit

Piston-rod Bullet
1 set
List of Consumables
a)
A/R
To Remove
Piston removal procedure is detailed as part of Job No.013 Piston Rod - Remove/Refit.
b)
Examination
Piston Pressure Rings For piston pressure ring dimensions refer to Chapter 1 Technical
Data. The pressure rings MUST be replaced with new ones when the radial thickness at any
point has worn to 65% or less of the original thickness.
Piston Bearer Rings For piston bearer ring dimensions refer to Chapter 1 Technical
Data. The bearer rings MUST be replaced by new ones, when the standout at any point has
worn to 0.5mm or less.
c)
Piston Rings Renew

1
Remove and discard the old piston and bearer rings. The old bearer rings may require
cutting in order to remove them; ensure that the piston is not damaged when cutting
rings. Carefully clean piston ring grooves.
Insert the new piston ring squarely into the cylinder bore and check that the ring gap is
correct. Refer to Chapter 1 Technical Data.
Fit bearer rings using an appropriate method. Some rings will require heating in order
to allow them to be fitted over.
4.
Fit the new piston rings by carefully springing them over the piston body.
5.
Fit new bearer rings. The first stage bearer ring is split and can be sprung over the
body of the piston in the same way as the piston rings. The second and third stage
bearer rings must be fitted by the following procedure.
Issue 1
01/2015
a.
Remove the second stage piston rod and piston from the compressor. See JOB
No: 13 - Piston Rods - Remove and Re-fit
b.
Split the piston and remove the old bearer ring. Carefully cut the old bearer ring if
necessary for removal. Ensure that the bearer ring groove is clean and smooth.
c.
Heat the new bearer ring for two hours at 200oC.
d.
Once heating is completed, fit the bearer ring over the bearer ring groove and
carefully tap into position. Ensure that the ring is not damaged or bruised when
fitting.
e.
Re-assemble the piston and re-fit.
Page 64
V290M-WN
Compressor
6.
Ensure that the rings are correctly seated in the piston groove and that all ring gaps are
staggered.
7.
If the cylinder bore is cored or very lightly polished with no signs of honing marks it may
be necessary to re-hone the bore. (In some cases a flexi-hone can be used).
Illustration 5-3 : Typical Piston Ring Configuration
Issue 1
01/2015
Page 65
V290M-WN
Compressor
JOB No: 5 - Piston/Cylinder End (Bumping) Clearances

List of Consumables
Sealing Gasket (between 0.8mm - 1.0mm thick)
A/R
A/R
There are two ways of measuring the piston Top-Dead-Centre (TDC) clearance: Method 1 is used
when the cylinder top covers are removed and Method 2 is by removing the valves and checking
the clearance through the valve pockets. The Bottom-Dead-Centre (BDC) clearance is checked
using Method 2. For the second stage, only the bottom clearance is measured, for the third stage,
only the top clearance is measured.
Illustration 5-4 : Piston features
a)
Job Set Up
1.
Issue 1
01/2015
a)
b)
c)
d)
e)
f)
Page 66
V290M-WN
Compressor
b)
c)
Method 1
1
Remove the cylinder top cover refer to Job No.3.
2.
Place a sealing gasket of between 0.8mm - 1.0mm on to the cylinder mating face.
3.
Place the machined straight-edge across the top of the gasket on the cylinder.
4.
Bar over the compressor to place the piston exactly at TDC.
5.
Measure the clearance between the straight edge and the piston crown. Ensure that
the straight edge is held firmly against the gasket when measuring clearance. record
the with a feeler (thickness) gauge. The required clearances are detailed (Refer to
Crankase Component Clearances.) If the clearances are out side of the tolerance
band the clearance MUST be adjusted (see later in this procedure).
Method 2
1.
Remove either a suction or delivery valve from a top cylinder pocket (if measuring TDC
clearance) or a bottom cylinder pocket (if measuring BDC clearance).
2.
With the piston exactly at TDC or BDC, insert a feeler gauge through the valve pocket
and measure the clearance. Record the end ("bumping") clearances with the piston at
the top (Top-Dead-Centre) and bottom (Bottom-Dead-Centre) of its stroke. The
clearances are detailed in . If the clearances are outside of the tolerance band the
clearance MUST be adjusted (see later in this procedure).
CAUTION!
FEELER GAUGES MUST NOT BE INSERTED INTO THE VALVE
POCKET WHILST TURNING THE MACHINE OVER BECAUSE IF
TRAPPED, THE MACHINE COMPONENTS COULD BE STRAINED
OR DAMAGED.
d)
Piston/Cylinder End Clearances Adjustment

The end ("bumping") clearance is adjusted by screwing the piston rod into, or out of, the
crosshead. To adjust the piston to cylinder end clearances proceed as follows:
1.
Remove the crosshead access cover and gasket from the crankcase.
2.
Bar over the crankshaft to reveal the crosshead locknut and the piston rod securing
pin.
3.
Bend back the locking plate tab retaining the securing pin and remove the pin. Ensure
that the securing pin is removed before slackening the crosshead nut. Otherwise, if the
piston rod turns in the crosshead while the securing pin is in position, the pin will distort
making it extremely difficult to remove
4.
Slacken the crosshead locknut.
5.
The piston rod has a slotted end at the crosshead (through which the securing pin fits)
it can only be turned in 90o steps, one step represents a linear movement of 0.8mm,
(the screwed end of the rod having 8 threads per inch, equivalent to 1 thread every
3.175mm).
6.
To adjust the top end clearance, screw the piston rod into or out of the crosshead.
Ensure that the top and bottom clearances are as close to equal as is possible. If equal
clearances are not obtainable then always, on final setting, make the TOP clearance
the larger of the two (by an amount equal to no more than one quarter turn only of the
piston rod in the crosshead i.e., by no more than 0.8mm).
Issue 1
01/2015
Page 67
V290M-WN
Compressor
7
Fully tighten the crosshead locknut.
Recheck that the piston rod slots are correctly aligned for clearance of the piston rod
securing pin.
Fit a new locking plate to the securing pin before fitting and fully tighten the pin.
10
Bend over the locking plate tab to prevent the securing pin from rotating.
11
Inspect the crosshead access cover gasket. Renew if necessary.
12.
Refit the access cover.
Issue 1
01/2015
Page 68
V290M-WN
Compressor
JOB No: 6 - Packing Assembly - Remove and Re-fit

List of Consumables
A/R
Due to their construction, these packing glands can only be satisfactorily examined and repaired
when they are removed from the compressor and disassembled on a suitable workbench.
a)
Job Set Up
1.
b)
c)
a)
b)
c)
d)
e)
f)
To Remove Packing Assemblies

1
Fit piston rod clamps to prevent possible uncontrolled movement of the crankshaft and
motion works. Refer to Job No:2.
Mark the position of the oil shedder on the rod surface and remove shedder with its two
clamping screws.
Remove the nuts from the small diameter gland assembly tie studs.
Remove the securing nuts from the gland cover and lower the cover down the piston
rod until it is resting on the oil scraper gland assembly.
Slide each container assembly down the piston rod until it is clear of the gland.
Slide the container a little way back up the piston rod to expose the packing rings and
in turn, unhook the garter springs and remove the packing ring segments.
Reassemble and carefully store each ring of segments and garter spring, immediately
on removal. Repeat this step until all of the packing rings have been removed.
Observe that each ring is marked with matching numbers and letters for use in
reassembly. Also the lowermost ring has a peg which locates into a hole in the
uppermost ring to form a container pair. The rings can be re-used depending upon
condition after inspection.
To Refit Packing Assemblies

CAUTION!
THE RINGS AND GLANDS REFITTED COMPLETELY WITHOUT OIL
(THE COMPRESSOR BEING AN OIL-FREE CYLINDER MACHINE) ON NO ACCOUNT INTRODUCE OIL OR GREASE INTO THE
GLAND. IF REFITTING "USED" RINGS FIRST ENSURE THAT
THERE IS NO DIRT OR GRIT EMBEDDED.
Issue 1
01/2015
Page 69
V290M-WN
Compressor
If the piston rod is out of the compressor, the gland can be assembled on the work-bench, then
fitted into place as a finished unit. If the rod is in place, the rings and their springs are assembled
around the rod by working through the distance piece apertures.
1
Check the piston rod surface for wearing or any sign of scoring. If evidence of wearing
or scoring is heavy the piston rod should be replaced.
Assemble each ring onto the piston rod with its garter spring.
Fit the rings as pairs into their respective containers (ensure peg is pointing upwards).
Slide each container assembly up the piston rod in turn, finally clamping the completed
gland assembly with the tie rod nuts.Refit and tighten the packing nuts and secure the
gland assembly to the cylinder bottom.
Refit the oil shedder to the piston rod in the position marked during removal and secure
with its clamping screws.
Remove piston rod clamps.
Inspect the crosshead access cover gasket. Renew if necessary.
Refit the access cover.
Issue 1
01/2015
Page 70
V290M-WN
Compressor
Illustration 5-5 : 1st Stage Packing
1st Stage Packing Assembly
1st Stage Packing Rings
Issue 1
01/2015
Page 71
V290M-WN
Compressor
Illustration 5-6 : 2nd Stage Packing Parts
2nd Stage Packing Assembly
2nd Stage Packing Rings
Issue 1
01/2015
Page 72
V290M-WN
Compressor
JOB No: 7 - Packing Assembly - Overhaul

Wear Check Tool
Thread Guard Cap
List of Consumables
A/R
Due to their construction, these packing glands can only be satisfactorily examined and repaired
when they are removed from the compressor and disassembled on a suitable workbench. To
remove the packing gland completely from the compressor, the piston rod must first be removed.
a)
b)
To Disassemble
1
Remove the nuts from the small diameter gland tie studs and separate and
disassemble the containers. As each container ring is lifted off the assembly, take
meticulous care of the precision ground and lapped faces between the containers and
the plates.
Observe carefully that the ring containers and the plates between them are staggered
sequentially, with number 1 being the top container ring.
Observe that the tie studs are unequally spaced to ensure the correct orientation of the
internal water passageways is maintained.
Observe and carefully record the construction and sequence of assembly for the rings,
noting that each ring of segments is marked with matching numbers and letters. In
addition note that there is a peg and hole location in the segmented ring set in the
containers with the peg pointing upwards.
As each container is lifted off the assembly, remove and store the packing rings
Observe the condition of the soft metal sealing ring in the top face of the uppermost
gland ring ensure that it is not damaged during handling and storage.
Unscrew the small diameter tie studs from the uppermost container ring.
To Inspect
1
The packing rings are checked for wear by re-assembling, with garter spring, squarely
around the piston rod, or on the Wear Check Tool and examining the butt clearances.
When parts are new the butts are each approx. 3mm wide; discard the ring when the
butts reduce to 0.5mm.
Examine the soft metal sealing ring on the top-most container of the gland ring to
ensure this is in good condition.
Issue 1
01/2015
Page 73
V290M-WN
Compressor
c)
To Reassemble
Scrupulous cleanliness of all parts is required on assembly, particularly of the lapped faces
between the containers and plates.
1
Identify and layout the gland components in sequential order in preparation for
reassembly.
Place piston rod/piston assembly onto a clean work-bench resting on the piston crown
with the piston rod pointing upwards so that the rod can be used as an assembly tool.
Thoroughly clean the rod surface and fit the thread guard cap to the rod end.
Thread the packing gland cover plate over the piston rod to rest on the piston.
Progressively build up the gland assembly in the correct numbered sequence of the
plates and containers refitting packing rings and O rings in their correct positions as
noted during dismantling. Refer to Illustration 5-6 : Stage Packing Assemblies for
guidance.
Firmly screw the tie studs back into their original positions in the top gland ring.
Carefully thread the tie rods back through the gland assembly until the top gland ring
rests squarely onto the top container.
Whilst clamping the assembly firmly to prevent, separation or misalignment, lift the
assembly sufficiently to fit the nuts to the tie studs.
Progressively tighten the nuts evenly to clamp the assembly.
10
Refit the gland assembly as described in JOB No: 6 - Packing Assembly - Remove
and Re-fit.
Issue 1
01/2015
Page 74
V290M-WN
Compressor
JOB No: 8 - Packing Assembly - Remove and Re-fit

List of Consumables
A/R
The piston rod oil shedder is clamped in halves to the piston rod by socket head screws. The
shedder is fitted so as to run clear of the packing gland and the scraper gland covers. If the
shedder becomes damaged renew as follows:
The oil shedder should only be fitted onto the piston rod when both the oil scraper gland and
packing gland are fully fitted in place.
Illustration 5-7 : Piston-rod Oil Shedder in situ.
Oil Shedder
a)
Job Set Up
1.
b)
a)
b)
c)
d)
e)
f)
To Remove
1
Issue 1
01/2015
motion works. Refer to JOB No: 2 - Fit Piston Rod Clamps
Page 75
V290M-WN
Compressor
2
c)
Mark the position of the oil shedder on the rod surface and remove shedder with its two
clamping screws.
To Refit
1
Place the piston in BDC position and assemble the shedder onto the piston rod with the
hollowed side placed downwards.
Position the shedder 2.5mm above the top face of the scraper gland and lightly but
firmly tighten the two screws.
Turn over the compressor to ensure that the oil shedder does not foul either the upper
packing gland or the lower scraper gland.
When adjustment is satisfactory, fully tighten the shedder clamping screws.
Refit the access cover to the cylinder distance piece.
Two small diameter washers of the required thickness placed either side on top of the
scraper gland are helpful in setting the shedder position - remove the washers
immediately afterwards.
Issue 1
01/2015
Page 76
V290M-WN
Compressor
JOB No: 9 - Oil Scraper Gland - Remove and Re-fit

Wear Check Tool
List of Consumables
a)
A/R
Job Set Up
1.
a)
b)
c)
d)
e)
f)
Illustration 5-8 : Oil Shedder and Scraper Assembly
b)
To Remove
1
Issue 1
01/2015
motion works. Refer to JOB No: 2 - Fit Piston Rod Clamps.
Page 77
V290M-WN
Compressor
c)
d)
2.
Lift the plate and slide the upper pair of scrapers up the rod.
3.
Unhook the garter springs and remove the scraper ring segments.
4.
Re-assemble and carefully store each ring of segments immediately upon removal.
5.
The segments are marked relative to each other, the lower ring pair having a peg and
locating hole arrangement for correct re-assembly. The rings can be re-used
depending upon condition.
6.
Lift the container and slide the lower pair of scrapers up the rod.
7.
Re-assemble and carefully store each ring of segments immediately upon removal.
Oil Scraper Gland - Inspection

1.
The oil scraper rings are checked for wear by re-assembly, with garter spring, squarely
around the piston rod, or on the wear check tool and examining the butt clearances in
the case of ring W1 and W2.
2.
When parts are new the butts of W1 and W2 are each 0.8mm (0.032") wide.
3.
Discard the rings and their sealing rings when the butts reduce to 0.12mm (0.005")
each or a total of 0.36mm (0.015") or less, and replace with a new pair.
4.
The segments of the sealing ring have angle cut contact faces - there are no butt
clearances.
To Refit
1.
Ensure that the correct relationship is maintained between the rings.
2.
There are oil drain slots cast in the bottom of the housing. Should the housing need to
be removed it must be refitted with these slots (in the case of the inclined cylinders)
positioned lower-must. "TOP" is staggered on the housing.
3.
Remove piston rod clamps.
4.
Bar over the compressor a couple of turns to check for correct operation.
5.
Refit the access covers to the cylinder distance piece.
Issue 1
01/2015
Page 78
V290M-WN
Compressor
JOB No: 10 - Suction and Delivery Valves - Remove and Re-fit

List of Consumables
A/R
Grinding Paste
A/R
Each valve is installed in an individual pocket. They are fitted with metal-to-metal contact (i.e. no
gasket material) to the seat face in the cylinders.
a)
Job Set Up
1.
b)
a)
b)
c)
d)
e)
f)
To Remove
CAUTION!
SERIOUS DAMAGE COULD RESULT FROM SUCTION VALVES
AND THEIR ASSOCIATED COMPONENTS, BEING FITTED IN
DELIVERY VALVE POCKETS OR VICE-VERSA. THEREFORE,
ENSURE VALVES ARE CORRECTLY IDENTIFIED WITH THEIR
POCKETS.
1
Remove the securing bolts from the valve cover.
Remove the valve cover/cage complete with 'O' ring.
Remove the valve from its pocket (using a valve extraction tool where necessary).
Issue 1
01/2015
Page 79
V290M-WN
Compressor
c)
To Refit
CAUTION!
IT IS IMPORTANT AFTER FITTING VALVES (OR AFTER WORK OF
ANY KIND WHICH HAS BEEN DONE INSIDE THE CYLINDERS) TO
ENSURE THAT ALL IS CLEAR IN THE CYLINDERS BY BARRING
OVER THE CRANKSHAFT TWO OR THREE REVOLUTIONS.
1
Ensure that there are no bruises or burrs on the valve seat or pocket seat. A light
grinding-in operation may be needed, it is important to ensure that no grinding paste
enters the cylinder and that all is clean after completion.
The diametric clearance between the valve seat and the seating in the cylinder is small,
therefore the valve has to be fitted very carefully to ensure that it fits squarely on to its
seat. It is essential that the valve is squarely fitted on its seat and metal to metal
contact established.
Check that 'O' rings are in good condition and that their associate grooves are clean
before final assembly of valve cover/cage. Renew if necessary.
Refit the valve cage and the valve cover.
Refit the cover securing bolts and tighten evenly and squarely to the correct torque.
Issue 1
01/2015
Page 80
V290M-WN
Compressor
Issue 1
01/2015
Page 81
V290M-WN
Compressor
JOB No: 11 - Suction and Delivery Valves - Overhaul

Valve Holding Tool
List of Consumables
A/R
Gardner Denver are able to offer a valve exchange service, whereby re-furbished valves are
supplied in exchange for valves returned by customers. The refurbished valves supplied by
Gardner Denver are factory reconditioned and all parts are guaranteed . Use of this service may be
more cost effective than stripping and cleaning valves on customers own site. Please contact
Gardner Denver service department for details.
a)
To Remove
1
b)
Remove the suction delivery valve in accordance with JOB No: 10 -Suction and
Delivery Valves - Remove and Re-fit
To Inspect
CAUTION!
THE CORRECT HOLDING TOOL MUST BE USED WHEN
DISMANTLING AND ASSEMBLING VALVES. THE VALVES
THEMSELVES MUST NEVER BE GRIPPED IN A VICE.
1
Inspect the 'O' ring for each valve cover/cage. Renew if necessary.
Disassemble the valves.
There are locating pegs in all valve seats; these ensure correct relationship between
various components, except the valve coil springs.
Thoroughly clean all parts and examine for signs of fatigue or wear.
Check for distortion or damage to the sealing faces of valve seats, examine also the
guards.
Check for distortion, wear, cracks or breakage of valve plates.
Compare the height of displaced springs, with new spares, to determine any
deterioration in spring loading.
Replace any part, which is found to be defective.
Issue 1
01/2015
Page 82
V290M-WN
Compressor
c)
To Overhaul
CAUTION!
CARE MUST BE TAKEN WHEN REASSEMBLING OVERHAULED
VALVE
COMPONENTS.
THE
COMPONENTS
MUST
BE
ASSEMBLED CORRECTLY. AN INCORRECTLY ASSEMBLED
VALVE WILL QUICKLY DETERIORATE IN SERVICE AND
CONSEQUENTLY MAY DAMAGE OTHER PARTS OR AFFECT THE
COMPRESSOR PERFORMANCE. PARTICULAR CARE MUST BE
TAKEN WHEN ASSEMBLING VALVES TO ENSURE THAT THE
SPRINGS REMAIN CORRECTLY IN THEIR LOCATIONS.
1
The valves have locating pins, which ensure that the various components are correctly
related radially. The pins are of differing diameters which ensures that the valve seat,
valve plate, valve damper plates, and valve guard are correctly fitted, one to the other.
If new locating pins are fitted to an old seat it is essential that they are of the correct
sizes and positioned exactly as on original valve seats, with correct standout height
above the valve seat top surface.
Lift Washers - when not of identical thickness - should be fitted with the thinner one
next to the valve seat (this thinner one is referred to as the lower lift washer).
Conical type springs are fitted with the large diameter end located in the holes in the
valve guard.
Torque the centre bolt nut to the correct value.
Issue 1
01/2015
Page 83
V290M-WN
Compressor
JOB No: 12 - Suction and Delivery Valves - Remove and Re-fit

List of Consumables
a)
Job Set Up
1.
b)
c)
A/R
a)
b)
c)
d)
e)
f)
To Inspect
1
Check that the small vent hole in the side of the lower half case is clear (if this
becomes blocked then the diaphragm cannot deflect properly due to pressure buildup).
Under normal circumstances actuators give long and trouble free service. If there is
deterioration of any part, it is recommended that the complete actuator is replaced.
To Refit
1
Ensure that the suction valve is fitted correctly and that its securing cover is fully
tightened down squarely.
It is essential that the correct gap is present between the actuator and the valve,
otherwise the suction valve may not open or close fully.
Carefully screw the actuator (with its locknut screwed back) until the spindle just
contacts the valve unloader.
The unloader is spring loaded so take care to just contact it and NOT depress it.
Screw back the actuator about 1.5mm and pinch tighten the locknut.
Insert a hard wood dowel/rod through the control air connection hole in the top of the
actuator casing until it just touches the top of the diaphragm.
With the dowel/rod in position, mark it accurately in line with the actuator cover plate
top.
Using the dowel/rod depress the actuator (against the action of the spindle return
spring) until it just contacts the unloader, but do not depress it.
While holding the dowel/rod in position, mark it accurately again in line with the
actuator cover plate top. Then release the dowel/rod (it will rise under the action of the
actuator spindle return spring).
Issue 1
01/2015
Page 84
V290M-WN
Compressor
10
Remove the dowel/rod and measure the distance between the marks. If it is NOT
between 1.4mm and 1.6mm then adjust the actuator position, by screwing it in or, out
of the cover plate, as required.
11
When the gap is set correctly, tighten the locknut to the correct torque.
12
When all the actuators on the compressor are correctly set, fit the end fittings to the
actuators; reconnect the control air pipework to the actuators and to the associated
vent vale and test the compressor for correct operation.
Issue 1
01/2015
Page 85
V290M-WN
Compressor
JOB No: 13 - Oil Filter - Remove and Re-fit

List of Consumables
a)
A/R
To Remove
1
To open the filter body undo the bottom bolt (using a clean bucket to catch spilled oil),
the filter body and element draw off vertically downwards.
Discard the old element and clean out the body.
When replacing the assembly (with a new filter pack) care should be taken that the seal
ring gasket at the top and the washer at the bottom are in their correct positions. A new
seal ring gasket is supplied as part of the filter element spare.
There is a spring fitted internally onto the bolt - this is installed to hold the filter element
up against the top cover and so form the seal; it also provides the automatic safety filter
bypass (for use should the element become heavily fouled).
Before assembly of the filter body to its cover, fill the body with clean compressor
lubricating oil.
Issue 1
01/2015
Page 86
V290M-WN
Compressor
JOB No: 14 - Oil Pressure Relief Valve - Adjustment

List of Consumables
a)
A/R
To Adjust
1
Remove the valve cap.
Slacken the locknut on the adjusting screw and adjust to obtain the required oil
pressure (screw IN to raise the pressure, screw OUT to decrease the pressure).
Tighten the locknut and refit the cap.
Normally adjustment is not necessary after initial setting by the manufacturer. If a fault
should occur and adjustment has no noticeable effect, the trouble could be a particle of
foreign matter trapped under the valve. Dismantling, cleaning and re-assembly is then
required (first noting the valve adjusting screw setting).
Issue 1
01/2015
Page 87
V290M-WN
Compressor
JOB No: 15 - Lubricating Oil Pump and Drive - Inspect and

Overhaul
List of Consumables
a)
A/R
To Overhaul
1
Disconnect all pipes connected to the oil pump.
Remove the cap screws securing the oil pump to bearing housing and carefully
withdraw the pump, together with the filter body attached, its drive coupling can then be
inspected.
Wear on the coupling is expected to be negligible but if excessive wear is present

investigate the cause, remove, and fit a new drive coupling.
When refitting the oil pump renew the gasket if the old one has deteriorated.
Prime the suction side of the pump with oil.
Refit the pipework to the oil pump.
Issue 1
01/2015
Page 88
V290M-WN
Compressor
JOB No: 16 - Intercooler - Inspection and Overhaul

List of Consumables
a)
To Inspect
1
b)
A/R
The cooler MUST be removed completely in order for a complete examination to be

performed. Internal and external inspection, to check for fouling or damage, is annual.
This period will, however, vary depending on site conditions (being extended with good
clean water circulating).
To Overhaul
1
It is not expected that the inside (i.e., tube internals) will foul. Any untoward
accumulation of soft deposits at the tube entrance may be removed by blowing
backwards with compressed air, the cooler being off the compressor for this purpose.
If hard carbonaceous deposits have accumulated, specialist attention may be required.
Should the cooling water side become fouled then use a proprietary procedure as
recommended by local water treatment specialists - this to be compatible with the
materials of construction (see Chapter 1 - Technical Data and Description).
When refitting (after cleaning) all joints must be in good condition.
Issue 1
01/2015
Page 89
V290M-WN
Compressor
5.4 Lists of Tools

a)
Commercially Available Tools List
The following is the recommended list of tools required to perform maintenance tasks on this compressor:
Tool
Standard tool box tools including:A range of open-jaw, ring, and socket type
spanners
Various job locations
A set of hexagonal section Allen keys

(Metric)
Torque wrench
Tightening range 0 to 1500 Nm
Circlip pliers
For removal and refitting crosshead gudgeon pin retaining

circlips.
Eyebolts
Fitters tools
M16 x 2.0 male thread for cylinder top cover lifting
Long-nosed pliers
M12 x 1.75 (for piston rod lifting).
b)
Specialist Service Tools
Specialist service tools (which can be manufactured locally) or purchased direct from Gardner
Denver, can be used to aid compressor maintenance work. Contact Gardner Denver service
department for advice on special tools.
5.5 Waste Products

There are very few waste products associated with air compressors: old lubricating oil and oil filter
elements and condensate. On closed loop systems, coolant may also be considered.
a)
Oil - After Oil Changes

When handling and disposing of sump oil after an oil change several important points need
to be followed:
1
Avoid contact with the skin and wash off any contamination immediately.
Dispose of old oil and filter elements in accordance with local regulations.
For further details contact your local oil company representative, or local government
department dealing with factory wastes.
b)
Coolant
Coolant from closed loop systems ie. water with anti-freeze added, should be disposed of in a safe
manner. For further advice contact the local Water Authority.
Issue 1
01/2015
Page 90
V290M-WN
Compressor
Chapter 6 - Spare Parts
Issue 1
01/2015
Page 91
V290M-WN
Compressor
6.1 Spare Parts

This document provides information regarding the recommended spare parts policy for this
equipment.
Items not identified as a spare can be found within the drawings and parts list for the compressor.
These items, under normal operating conditions, will last for the designed lifetime of the equipment.
Fasteners used on this equipment, such as screws, nuts, washers, bolts and clips etc; have not
been included within the Spare Lists. For details regarding the fastener refer to the Illustrated Parts
List for this equipment
WARNING!
ALWAYS USE THE SPECIFIED FASTENER. ON NO ACCOUNT SHOULD A
LOWER SPECIFICATION FASTENER BE USED
6.2 Ordering Spares and Spares Stock

IMPORTANT - When ordering spare parts please quote the following details:
Compressor Serial Number
Compressor Type
Description of Part required.
Part Number (if available)
Quantity required
We recommend that users of our compressors should hold in stock a complete set of spares.
The spares stock should be maintained at the original level, replacements being ordered in good
time to ensure availability when required. Parts must be kept in good order with appropriate
preservation precautions to meet the climatic conditions.
The quantities given within the lists are the recommended minimum holding.
For spare parts associated with the control console, drive system etc; reference should be made to
the spares information and recommendations provided with these items.
Issue 1
01/2015
Page 92
V290M-WN
Compressor
6.3 Spares List

V290M-WN SPARE PARTS 4000 HOUR SERVICE KIT
COMPRESSOR SPARE PARTS
Item
Description
Qty
Part No.
Bonded Seal
44286/6
Bonded Seal
44286/4
Bonded Seal
44286/5
2nd Stage Top Cover Gasket
CC1033383
3rd Stage Piston Ring
CC1035906
3rd Stage Rider Ring
CC1035907
2nd Stg Piston Rod Pkg Wrg Part
PSB032-024
Piston Rod Scraper Wr Part
PSB032-012
Scraper Box Gasket
PSB008-057
V290M-WN SPARE PARTS 8000 HOUR SERVICE KIT

VALVE ASSEMBLIES
Item
Description
Qty
Part No.
1st Stage Suction Valve
CC1035982
1st Stage Delivery Valve
CC1035983
2nd Stage Suction Valve
CC1033537
2nd Stage Delivery Valve
CC1033593
3rd Stage Suction Valve
CC1033818
3rd Stage Delivery Valve
CC1033819
Issue 1
01/2015
Page 93
V290M-WN
Compressor
V290M-WN SPARE PARTS 8000 HOUR SERVICE KIT-COMPRESSOR SPARE PARTS
Item
Description
Qty
Part No.
1st Stage Top Cover Gasket
PSB008-085
2nd Stage Top Cover Gasket
CC1033383
Crankcase Door Gasket
PSB008-055
Crankcase/ Guide Gasket
PSB008-056
Cylinder Gasket
PSB008-049
1st Stage Valve Cage O-Ring
CC1036040
2nd Stage Valve Cage O-Ring
CC1026966
2nd Stage Valve Cage O-Ring
CC1026967
3rd Stage Suc Valve Cage O-Ring
2-70-216-02
10
3rd Stage Del Valve Cage O-Ring
CC1036016
11
Actuator Diaphragm
PSB028-003
12
1st Stg Piston Rod Pkg Wrg Part
PSB032-014
13
2nd Stg Piston Rod Pkg Wrg Part
PSB032-024
14
Piston Rod Scraper Wr Part
PSB032-012
15
1st Stage Piston Ring
CC1036124
16
1st Stage Rider Ring
CC1036126
17
2nd Stage Piston Ring
CC1035904
18
2nd Stage Rider Ring
CC1035905
19
3rd Stage Piston Ring
CC1035906
20
3rd Stage Rider Ring
CC1035907
21
Piston Rod Nut
PSB002-011
22
Oil Suction Strainer
PSB025-001
23
Oil Filter Element
PSB025-003
24
Oil Filter Element 'O' Ring
PSB025-006
25
Air Inlet Filter Element
ASB511-018
26
Scraper Box Gasket
PSB008-057
27
Big End Bearing
PSB014-012
28
Cotter Pin
MB075-39
29
1st Stage Flange Gasket
43445/13
30
2nd Stage Inlet Gasket
43445/35
31
Intercooler Gasket
CC1033287
32
Intercooler Gasket
43445/28
33
Bonded Seal
44286/4
34
Bonded Seal
44286/5
35
Bonded Seal
44286/6
Issue 1
01/2015
Page 94
V290M-WN
Compressor
6.4 Drawings
The following drawings contain all items used in the construction of the compressor.
Drawing Ref
Description
V290M-WN
GENERAL ARRANGEMENT
2-77-2202
P&ID DRAWING
CC1034293
LOWER PARTS ASSY
CC1069291
CYLINDER ASSY CELL-V290
CC1069292
INTERSTAGE ASSY CELL-V290
CC1069293
FINAL ASSY CELL-V290
CC1039053
ANCILLAIRES
CC1071471
ANCILLARY ASSY CELL
CC1042024
INSTRUMENTATION UNLOADER PIPEWORK ASSY
10
CC1039413
COOLING WATER PIPEWORK
11
CC1039027
AFTERCOOLER ASSY
Issue 1
01/2015
Page 95
V290M-WN
Compressor
1. V290M-WN GENERAL ARRANGEMENT
Issue 1
01/2015
Page 96
V290M-WN
Compressor
2. 2-77-2202 P&ID DRAWING FOR V290
Issue 1
01/2015
Page 97
V290M-WN
Compressor
3. CC1034293 LOWER PARTS ASSY
Issue 1
01/2015
Page 98
V290M-WN
Compressor
Issue 1
01/2015
Page 99
V290M-WN
Compressor
4. CC1069291 CYLINDER ASSY CELL-V290
Issue 1
01/2015
Page 100
V290M-WN
Compressor
Issue 1
01/2015
Page 101
V290M-WN
Compressor
5. CC1069292 INTERSTAGE ASSY CELL-V290
Issue 1
01/2015
Page 102
V290M-WN
Compressor
6. CC1069293 FINAL ASSY CELL-V290
Issue 1
01/2015
Page 103
V290M-WN
Compressor
Issue 1
01/2015
Page 104
V290M-WN
Compressor
7. CC1039053 ANCILLAIRES
Issue 1
01/2015
Page 105
V290M-WN
Compressor
8. CC1071471 ANCILLARY ASSY CELL
Issue 1
01/2015
Page 106
V290M-WN
Compressor
9. CC1042024 INSTRUMENTATION UNLOADER PIPEWORK ASSY
Issue 1
01/2015
Page 107
V290M-WN
Compressor
10. CC1039413 COOLING WATER PIPEWORK
Issue 1
01/2015
Page 108
V290M-WN
Compressor
Issue 1
01/2015
Page 109
V290M-WN
Compressor
11. CC1039027 AFTERCOOLER ASSY
Issue 1
01/2015
Page 110
Section 2
Motor Manual
Motors | Automation | Energy | Transmission & Distribution | Coatings
Low and high voltage electric motors
Instructions manual for installation, operation and maintenance of electric motors
Motores eltricos de baixa e alta tenso

Manual de instalao, operao e manuteno de motores eltricos
Motores Elctricos de baja y alta tensin

Manual de instalacin, operacin y mantenimiento de motores elctricos
Nieder- und Hochspannungsmotoren

Installations-, Betriebs- und Wartungsanleitung fr Asynchronmotoren
Moteurs lectriques basse et haute tension
Consignes de scurit pour linstallation, lutilisation et la maintenance de moteurs

lectriques

Elektrische motoren van lage en hoge spanning
Veiligheidsinstructies voor installatie, bediening en onderhoud van elektrische motoren
Motori elettrici di bassa e alta tensione

Manuale di installazione, gestione e manutenzione di motori elettrici
ENGLISH
TABLE OF CONTENTS
1. FOREWORD ................................................................................................................. 3
2. SHIPMENT, STORAGE AND HANDLING . .................................................................. 3
3. INSTALLATION...... ....................................................................................................... 4
4. OPERATION.................................................................................................................. 5
5. MAINTENANCE ............................................................................................................ 5
6. ADDITIONAL INFORMATION ...................................................................................... 5
7. EC DECLARATION OF CONFORMITY ....................................................................... 5
8. WARRANTY TERM ...................................................................................................... 6
1. FOREWORD
The installation, operation and maintenance of the motor must be always performed by qualied personnel
using proper tools and methods and following the instructions contained in the documents supplied with the
motor.
The instructions presented in this document are valid for WEG motors with the following characteristics:
Three-phase and single-phase induction motors (squirrel cage rotor);
Three-phase permanent magnet motors;
Three-phase hybrid motors (squirrel cage rotor + permanent magnets);
J
J
J
The objective of this manual is to provide important information, which must be considered during the shipment,
storage, installation, operation and maintenance of WEG motors. Therefore, we advise to make a careful and detailed
study of the instructions contained herein before performing any procedures on the motor. The noncompliance
with the instructions informed in this manual and others mentioned on the website www.weg.net voids the product
warranty and may cause serious personal injuries and material damages.
Electric motors have energized circuits and exposed rotating parts which may cause injuries to people.
2. SHIPMENT, STORAGE AND HANDLING

Check the conditions of the motor immediately upon receipt. When any damage is noticed, this must be reported in
writing to the transportation company, and immediately communicated to the insurance company and to WEG. In
this case, no installation job can be started before the detected problem has been solved.
Check if the nameplate data matches the invoice data and the environmental conditions in which the motor will be
installed. If the motor is not immediately installed, it must be stored in a clean and dry room protected against dust,
vibrations, gases and corrosive agents, and with relative humidity not exceeding 60%.
In order to prevent water condensation within the motor during the storage period, it is recommended to keep the
space heater ON (where provided). In order to prevent oxidation of the bearings and ensure an even distribution of
the lubricant, rotate the motor shaft at least once a month (at least ve turns), always leaving it in a different position.
For bearings with oil mist lubrication systems, the motor must be stored horizontally, independently from the
mounting conguration, with ISO VG 68 oil in the bearing, (the amount is indicated in the motor manual available on
the website www.weg.net) and the shaft must be turned weekly. If the motors are stored for more than two years,
it is recommended to change the bearings, or to remove, wash, inspect and relubricate them before the motor is
started. After this storage period, it is also recommended to change the start capacitors of single-phase motors
since they loss their operating characteristics.
Handle the motor always carefully in order to prevent impacts and damages to the bearings and
always install the shaft transportation/locking device (if supplied) when transporting the motor.
Use only the eyebolts to lift the motor. However these eyebolts are designed for the motor
weight only. Thus never use these eyebolts to lift the motor with additional loads coupled to it. The
lifting eyebolts of the terminal box, fan cover, etc., are intended to handle only these parts when
disassembled from the motor. Additional information regarding the maximum allowable angle-ofinclination is indicated in the general manual available on the website www.weg.net.
Low and High Voltage Electric Motors | 3
Periodically and mainly before the initial star-up, measure the insulation resistance of the motor winding.
Check the recommended values and the measuring procedures in the website.
3. INSTALLATION
During the installation, the motors must be protected against accidental energization.
Check the motor direction of rotation, turning it without load before it is coupled to the
load.
Remove the transportation devices and shaft locking device (if supplied) before starting the motor installation.
Motors must be only installed in places compatible with their mounting features and in applications and
environments for which they are intended.
Those motors with feet must be installed on bases duly planned in order to prevent vibrations and assure perfect
alignment. The motor shaft must be properly aligned with the shaft of the driven machine. Incorrect alignment,
as well as improper belt tension, will certainly damage the bearings, resulting in excessive vibrations and even
causing the shaft to rupture. The admissible shaft radial and axial loads indicated in the general manual of the
website must be respected. Use exible coupling whenever possible.
When motors are tted with oil lubricated bearings or oil mist lubrication systems, connect the cooling and
lubrication tubes (where provided). Only remove the corrosion protection grease from the shaft end and ange
immediately before the motor installation.
Unless specied otherwise in the purchase order, WEG motors are dynamically balanced with half key and
without load (uncoupled). The driving elements, such as pulleys, couplings, etc., must be balanced with half key
before they are mounted on the shaft of the motors.
Observe the correct assembly position of the drains as indicated in the manual on the website www.weg.net.
Do not cover and block the motor ventilation openings. Ensure a minimum clearance of
(25%) of the diameter of the air intake of the fan cover from the walls. The air used for
cooling the motor must be at ambient temperature, limited to the temperature indicated on
the motor nameplate.
Motors installed outdoors or in the vertical position require the use of additional shelter to protect
them from water; for instance, use of a drip cover.
To prevent accidents, ensure that the grounding connection has been performed according to the
applicable standards and that the shaft key has been securely fastened before the motor is started.
Connect the motor properly to the power supply by means of safe and permanent contacts, always
considering the data informed on the nameplate, such as rated voltage, wiring diagram, etc.
For power cables, switching and protection devices dimensioning, consider the rated motor current, the
service factor, and the cable length, among others. For motors without terminal block, insulate the motor
terminal cables by using insulating materials that are compatible with the insulation class informed on the
nameplate. The minimum insulation distance between the non-insulated live parts themselves and between
live parts and the grounding must be: 5.5 mm for rated voltage up to 690 V; 8 mm for voltages up to 1.1 kV;
45 mm for voltages up to 6.9 kV; 70 mm for voltages up to 11 kV and 105 mm for voltages up to 16.5 kV.
In order to assure the degree of protection, unused cable inlet holes in the terminal
box must be properly closed with blanking plugs having and equal or higher degree of
protection to that indicated on the motor nameplate.
The motor must be installed with overload protection devices. When motor is tted with temperaturemonitoring devices, they must be connected during the operation and even during tests.
Ensure the correct operation of the accessories (brake, encoder, thermal protection, forced ventilation, etc.)
installed on the motor before it is started.
Motors tted with Automatic Thermal Protectors will reset automatically as soon as
the motor cools down. Thus, do not use motors with Automatic Thermal Protection in
applications where the auto-reseting of this device may cause injuries to people or damage
to equipment. Motors tted with Manual Thermal Protectors require manual reset after they trip. If
the Automatic Thermal Protector or the Manual Thermal Protector trip, disconnect the motor from
4 | Low and High Voltage Electric Motors
the power supply and investigate the cause of the thermal protector tripping. Wmagnet
motors must be driven by WEG variable frequency drives only.
For more information about the use of variable frequency drives, follow the instructions in the motor manual
on the website www.weg.net and in the manual of the variable frequency drive.
4. OPERATION
During operation, do not touch the non-insulated energized parts and never touch or stay
too close to rotating parts.
Ensure that the space heater is always OFF during the motor operation.
The rated performance values and the operating conditions are specied on the motor nameplate. The
voltage and frequency variations of the power supply should never exceed the limits established in the
applicable standards.
Occasional different behavior during the normal operation (actuation of thermal protections, noise level,
vibration level, temperature and current increase) must always be assessed by qualied personnel. In case
of doubt, turn off the motor immediately and contact the nearest WEG service center.
Do not use roller bearings for direct coupling. Motors tted with roller bearings require radial load to ensure
their proper operation.
For motors tted with oil lubrication or oil mist systems, the cooling system must be ON even after the
machine is OFF and until the machine is at complete standstill.
After complete standstill, the cooling and lubrication systems (if any exist) must be switched OFF and the
space heaters must be switched ON.
5. MAINTENANCE
Before any service is performed, ensure that motor is at standstill, disconnected from
the power supply and protected against accidental energization. Even when the motor is
stopped, dangerous voltages may be present in space heater terminals.
If motors are tted with capacitors, discharge them before any handling or service is performed.
Motor disassembly during the warranty period must be performed by a WEG authorized service
center only.
For motors with permanent magnet rotor (lines WQuattro and Wmagnet), the motor assembly and
disassembly require the use of proper devices due to the attracting or repelling forces that occur
between metallic parts. This work must only be performed by a WEG Authorized service center
specically trained for such an operation. People with pacemakers cannot handle these motors.
The permanent magnets can also cause disturbances or damages to other electric equipment and
components during maintenance.
Regularly inspect the operation of the motor, according to its application, and ensure a free air ow. Inspect
the seals, the fastening bolts, the bearings, the vibration and noise levels, the drain operation, etc.
6. ADDITIONAL INFORMATION
For further information about shipment, storage, handling, installation, operation and maintenance of electric
motors, access the website www.weg.net.
For special applications and operating conditions (for example, smoke extraction motors, totally enclosed
air over (TEAO), motors for high thrust applications, motors with brake) refer to the applicable manual on the
website www.weg.net or contact WEG.
When contacting WEG, please, have the full description of the motor at hand, as well as the serial number
and manufacturing date, indicated on the motor nameplate.
7. EC DECLARATION OF CONFORMITY
WEG Equipamentos Eltricos S/A
Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaragu do Sul SC Brazil,
and its authorised representative established in the European Community,
Low and High Voltage Electric Motors | 5
WEGeuro Industria Electrica SA

Rua Eng Frederico Ulrich, Apartado 6074
4476-908 Maia Porto Portugal
hereby declare that the products:
WEG induction motors and components for using in these motors:
Three-phase
IEC frames 63 to 630
Nema frames 42, 48, 56 and 143 to 9610
Single-phase
IEC frames 63 to 132
Nema frames 42, 48, 56 and 143 to 215
when installed, maintained and used in applications for which they were designed, and in compliance with
the relevant installation standards and manufacturers instructions, comply with the requirements of the
following European Directives and standards where applicable:
Directives:
Low Voltage Directive 2006/95/EC
Regulation (CE) No 640/2009
Directive 2009/125/EC
EMC Directive 2004/108/EC (induction motors are considered inherently benign in terms of
electromagnetic compatibility)
Standards:
EN 60034-1/2-1/5/6/7/8/9/11/12/14/30 and 60204-1
From 29/12/2009 on low voltage electric motors are no longer considered under the scope of the current
Machinery Directive 2006/42/EC.
CE marking in: 1996
Milton Oscar Castella
Engineering Director
Jaragu do Sul, May 30th, 2011
8. WARRANTY TERM
WEG Equipamentos Eltricos S/A, Motor Unit, offers warranty against defects in workmanship and materials for their
products for a period of 18 months from the invoice issue date by factory or distributor / dealer, limited to 24 months from
date of manufacture. Motors of the HGF Line are covered for a period of 12 months from the invoice issue date by the
factory or distributor / dealer, limited to 18 months from the date of manufacture.
The paragraph above contains the legal warranty periods. If a warranty period is dened in a different way in the commercial,
technical proposal of a particular sale, that will override the time limits set out above.
The periods above are independent of installation date and provided that the following requirements are met: proper
transportation, handling and storage; correct installation in specied environmental conditions free of aggressive agents;
operation within the capacity limits and observation of the Installation, Operation and Maintenance Manual; execution of
regular preventive maintenance; execution of repairs and/or changes only by personnel with WEGs written authorization;
in the occurrence of an anomaly, the product must be available to the supplier for the minimum period necessary to identify
the cause of the anomaly and to repair it properly; the buyer must immediately notify WEG of any defects occurred and
they must be later conrmed as manufacturing defects by WEG. The warranty does not include assembly and disassembly
services at the buyers premises, costs of product transportation, as well as travel, lodging and meals expenses for the
technical assistance staff when requested by the customer. The warranty service will be provided exclusively at a WEG
authorized Technical Assistance or at the plant.
Components, parts and materials whose useful life is usually less than 12 (twelve) months are not covered by the warranty.
Under no circumstance will warranty services extend the warranty period of the equipment. However, new warranty
equivalent to the original one will be due only to the components repaired or replaced by WEG.
The present warranty is limited to the product supplied. WEG will not be liable for damages to people, third parties, other
equipment and facilities, loss of prots or other incidental or consequential damages.
6 | Low and High Voltage Electric Motors
Section 3
Drawings
HIGH PRESSURE SOLUTIONS
Gardner Denver Ltd

Claybrook Drive, Redditch, Worcestershire B98 0DS UK
T: +44 (0) 1527 838 600, F: +44 (0) 1527 838 630
E: highpressure@gardnerdenver.com
W: www.gdhighpressure.com

High Pressure Air Compressor

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

High Pressure Air Compressor

Enviado por

Direitos autorais:

Formatos disponíveis

Smarter Compressor Technology

HIGH PRESSURE SOLUTIONS

Operating & Maintenance Manual

Data and Compressor Description.....................................................................................8

Technical Data ..................................................................................................................9

Technical Description of the Compressor ........................................................................16

Chapter 2 - Safety Information.......................................................................................................21

Safety Policy ...................................................................................................................22

Chapter 3 - Installation and Commissioning ..................................................................................27

Safety Precautions ..........................................................................................................28

Installation Requirements ................................................................................................28

Handling and Unpacking .................................................................................................34

Preparation for Commissioning .......................................................................................38

Commissioning the Compressor .....................................................................................40

Chapter 4 - Operating Instructions .................................................................................................43

Controls and Indicators ...................................................................................................44

Preparation for Starting ...................................................................................................45

Starting the Compressor .................................................................................................45

Stopping the Compressor ................................................................................................46

Fault Indications ..............................................................................................................46

Chapter 5 - Compressor Maintenance ...........................................................................................51

Preventive Maintenance ..................................................................................................52

Approved Lubricants .......................................................................................................55

Maintenance Instructions ................................................................................................56

JOB No: 1 - Crankcase Oil Change ...........................................................................................57

Lists of Tools ...................................................................................................................90

Waste Products ...............................................................................................................90

Chapter 6 - Spare Parts.................................................................................................................91

Spare Parts .....................................................................................................................92

Ordering Spares and Spares Stock .................................................................................92

Spares List ......................................................................................................................93

1. V290M-WN GENERAL ARRANGEMENT ..........................................................................96

How to Use this Instruction Manual

THIS PICTOGRAM MARKS IMPORTANT NOTES, WHICH IDENTIFIES

Gardner Denver Ltd

+44 (0)1527 838600

+44 (0)1527 838630

Comments and Suggestions

Chapter 1 - Technical Data and Description

1.1 Data and Compressor Description

Standards and Legislation

1.2 Technical Data

Double Acting - Non Lubricated

Clockwise looking on Drive-end

Safety Valve Settings

Oil Pump Pressure

Compressor Speed (Max)

Sound Pressure Level

Sound Power Level

Weight (Without Motor)

Weight (With Motor)

Max Maintenance Lift

Cooling Water Flow **

Cooling Water Pressure

Water Pressure Drop

Water Temperature Rise

Motor Rated Power

Absorbed Power at Full

Stage 1 Cylinder Line

Axial Clearance in Groove

Gap at ring Butt joint

Axial Clearance in Groove

Piston Bottom to Cyl.