Screw air compressor Gardner Denver ESM4 RSCGD020606

Description Screw air compressor Gardner Denver ESM4 RSCGD020606

Screw Air Compressors Gardner Denver ESM Series

The Gardner Denver ESM series screw air compressors represent an advanced solution for small and medium-sized manufacturing enterprises that require a reliable and cost-effective source of compressed air. With a power range from 2.2 to 7.5 kW, these compressors are an ideal choice for a wide range of industrial applications, from small workshops to automotive repair shops and production lines.

Gardner Denver, with years of experience in the compressor equipment industry, has created the ESM series as an embodiment of the best engineering solutions and innovative technologies. These compressors combine compactness, energy efficiency, and exceptional reliability, making them an optimal choice for businesses that value equipment quality and durability.

Model Range and Specifications

Overview of ESM Series Models

The ESM series includes six main models, each designed to meet specific production needs:

• ESM02 - the most compact model with a power of 2.2 kW, delivering a capacity of 0.18-0.21 m³/min at 10 bar pressure. This model is ideal for small workshops, dental clinics, and laboratories where a quiet and reliable compressor with minimal space requirements is needed.
• ESM03 - a 3 kW model with a capacity of 0.35 m³/min, providing an optimal balance between energy consumption and performance for small production operations and service centers.
• ESM04 - a 4 kW compressor with a capacity of 0.45 m³/min, equipped with a star-delta starter for smooth starting and reduced electrical network load. This model is highly popular in automotive repair shops and small industrial enterprises.
• ESM05 - a model with a 5.5 kW motor, delivering 0.66 m³/min of compressed air. It includes an additional air cooler to optimize air quality and minimize the size of additional equipment required.
• ESM06 - the most powerful model in the series with a 7.5 kW motor and a capacity of 0.89 m³/min, designed for intensive industrial use with increased demands for compressed air volume.

Basic Technical Parameters

All ESM series models operate at a maximum pressure of 10 bar (145 psi), which is standard for most industrial pneumatic equipment. Noise levels range from 63 to 70 dB(A) depending on the model, making them some of the quietest in their class. The weight of the base models ranges from 151 to 179 kg, ensuring operational stability with minimal vibrations.

Compressor Element Design

Screw Pair and Its Features

The heart of every ESM compressor is the screw block, manufactured by Gardner Denver. The use of state-of-the-art CNC equipment for rotor grinding, combined with online laser quality control technology, ensures exceptional manufacturing precision and screw pair durability.

The screw block consists of two rotors – a driving and a driven rotor, rotating in opposite directions. The special screw profile ensures optimal air compression with minimal energy losses. Precision machining of rotor surfaces reduces internal leakages and increases the compressor’s volumetric efficiency.

Operating Principle

The operating principle of a screw compressor is based on the gradual reduction of air volume between the rotors during their rotation. Air is drawn in through an inlet filter, enters the compression chamber, where it mixes with compressor oil for cooling and sealing. After compression, the air-oil mixture passes through a separator, where the oil is separated from the compressed air.

Rotor Rotation and Efficiency

Optimized rotor rotation speed ensures maximum efficiency with minimal component wear. An automatic rotation control system protects the compressor from operating in the wrong direction, which could lead to serious equipment damage.

Lubrication System

Engineering Advantage of Lubricated Compressors

The ESM series lubricated screw compressors use special compressor oil that performs several critical functions. Firstly, the oil creates a seal between the rotors and the housing, significantly improving compression efficiency. Secondly, it dissipates heat generated during compression, maintaining an optimal operating temperature. Thirdly, the oil lubricates bearings and other moving parts, extending their service life.

Oil Circulation

The oil circulation system in ESM compressors is designed to ensure consistent and even distribution of lubricant to all critical points. Oil is supplied under pressure directly to the compression zone and rotor bearings. After passing through the compressor block, the oil is separated from the compressed air in the separator and returned to the system through a cooler and filter.

Filtration and Cooling

A multi-stage filtration system ensures oil purity throughout its service life. The oil filter traps wear particles and contaminants, maintaining the oil in optimal condition. The oil cooler keeps the oil temperature within the operating range, which is critical for preserving lubrication properties and preventing thermal degradation.

Electrical Components

Reliable Electric Motor

All ESM series models are equipped with high-quality electric motors with IP55 protection class and F insulation class. This ensures reliable operation even in high humidity and dusty conditions. The motors meet the IE3 energy efficiency class, guaranteeing minimal energy consumption with maximum performance.

Starter Options

The ESM02 and ESM03 models are equipped with direct-on-line (DOL) starting, ensuring simplicity and reliability. Starting from the ESM04 model, compressors are standardly equipped with star-delta starters, which reduce starting current by 33% compared to direct starting, crucial for preserving the electrical network and motor lifespan.

Efficiency Classes and Consumption

The use of IE3 class motors provides up to 5% energy savings compared to previous-generation motors. Optionally, IE4 class motors are available, offering even higher energy efficiency – the highest standard for motor efficiency today.

Air Path

Inlet Air Filtration

Effective inlet air filtration is critical for compressor longevity. A high-quality air filter traps dust and other contaminants, preventing their entry into the compressor block. Regular replacement of the air filter, as per manufacturer recommendations, ensures optimal performance and extends compressor lifespan.

Compressed Air Cooling

The ESM05 and ESM06 models are standardly equipped with an additional air cooler (aftercooler), which reduces the temperature of the compressed air at the compressor outlet. This not only improves air quality but also reduces the load on downstream air preparation systems.

Oil Separation

A high-efficiency oil separator ensures residual oil content in the compressed air of 2-3 mg/m³. The separator uses a combination of centrifugal force and coalescent filtration for maximum oil separation efficiency.

C-Pro1.0+ Control System

Controller Functions

The new C-Pro1.0+ controller is standard equipment for all ESM series models. It provides comprehensive monitoring and control of compressor operation. The display shows information on pressure, oil temperature, and compressor status (loaded/unloaded). An intuitive interface allows easy configuration of operating parameters and equipment status monitoring.

Parameter Monitoring

The system continuously monitors key compressor operating parameters, including outlet pressure, oil temperature, motor temperature, and rotation direction. If any parameter exceeds permissible limits, the system automatically takes protective measures, including operator warnings or emergency shutdown.

Customization Options

The controller allows easy adjustment of operating pressure, unloading timers for DOL and Star-Delta modes, and automatic restart parameters after power outages. The system is password-protected to prevent unauthorized changes to settings.

Communication Capabilities

A built-in RS485 port with Modbus protocol support enables compressor integration into centralized control and monitoring systems. An integrated sequencer allows control of two compressors for optimized operation and even load distribution.

Configuration Options

Base Configuration

Base ESM compressor models are supplied without a receiver and occupy a minimal footprint – only 62 x 60 cm. Compact dimensions (600 x 650 x 1100 mm) allow installation in confined spaces. The base configuration is ideal for integration into existing pneumatic systems with a centralized receiver.

Receiver-Mounted Configuration

Compressors mounted on a receiver provide a ready-to-use solution for small productions. Options with 270 and 500-liter receivers are available (for ESM04-ESM06 models). High-quality receivers, manufactured in accordance with the EN87/404 (AD2000) standard, ensure stable system pressure under variable air consumption.

Full Station (Airstation)

The Airstation is a comprehensive solution that includes a compressor, air dryer, and receiver in a single compact unit. The dryer provides a pressure dew point of +3°C in accordance with ISO 7183, Class A. The use of environmentally friendly R134a refrigerant and an intelligent control system ensures low pressure losses and energy-efficient operation.

Energy Efficiency and Savings

Cost Distribution Over Lifecycle

An analysis of the total cost of ownership shows that approximately 82% of costs are attributed to electricity, 10% to maintenance, and only 8% to initial investment. This underscores the critical importance of energy efficiency when selecting compressor equipment.

Efficiency Enhancement Options

Gardner Denver offers several options to maximize energy efficiency. E-models with an enlarged screw block provide a 6% efficiency increase compared to standard sizes. The option to install IE4 class motors further reduces energy consumption.

Comparison with Competitors

ESM series compressors demonstrate some of the best specific energy consumption figures in their power class. The modern screw block design and optimized control system ensure minimal energy losses across all operating modes.

Noise and Vibration Levels

Design Solutions for Noise Reduction

A specially designed housing with sound-insulating materials ensures low noise levels – from 63 dB(A) for smaller models to 70 dB(A) for the ESM06. This allows compressors to be installed directly in work areas without causing discomfort to personnel.

Vibration Reduction Measures

A robust frame and proper balancing of rotating parts minimize vibrations during operation. Anti-vibration mounts further reduce vibration transmission to the foundation, which is particularly important when installed on upper floors of buildings.

Maintenance and Service

Maintenance Schedule

Gardner Denver has developed a clear maintenance schedule to ensure maximum equipment reliability and durability. Regular replacement of the air filter (every 1000 hours), oil filter (every 2000 hours), and separator (every 4000 hours) keeps the compressor in optimal condition.

Component Accessibility for Maintenance

The new housing design provides quick and easy access to all components requiring maintenance. This minimizes downtime and simplifies routine maintenance tasks. All consumables are readily available through Gardner Denver’s authorized dealer network.

Warranty Conditions

Gardner Denver offers an extended Protect 5 warranty, covering up to 44,000 hours of operation or 6 years for the compressor package and 10 years for the screw block. This reflects the manufacturer’s high confidence in the quality and reliability of its products.

Operational Safety

Built-in Safety Systems

ESM series compressors are equipped with a comprehensive safety system, including motor and compressor overheat sensors, rotation direction control, and overpressure protection. All safety systems are integrated into the C-Pro1.0+ controller for centralized monitoring and control.

Compliance with Safety Standards

All models comply with European safety standards and bear the CE marking. Design and manufacturing adhere to EU directives on machinery, pressure equipment, and electromagnetic compatibility.

Personnel Protection

The enclosed housing design prevents accidental contact with moving parts. An automatic shutdown upon opening service doors further protects maintenance personnel. All hot surfaces are properly insulated to prevent burns.

Optional Equipment

Additional Filters

To enhance compressed air quality, combinations of pre-filters and microfilters are available. These provide additional air purification from solid particles, oil mist, and moisture, which is critical for sensitive pneumatic equipment.

Condensate Removal Systems

Optional timer or float drains for receivers and dryers ensure automatic condensate removal without compressed air loss. This is particularly important for maintaining air quality and protecting pneumatic equipment from corrosion.

Heat Recovery Systems

The heat recovery option allows up to 94% of the thermal energy generated during compressor operation to be utilized. This heat can be used for water heating, space heating, or industrial processes, significantly improving overall plant energy efficiency.

Applications

Industrial Manufacturing

ESM series compressors are widely used in various industries: metalworking, woodworking, food processing, and textile production. Their reliability and stable performance make them an ideal choice for ensuring continuous production processes.

Automotive Repair Shops and Workshops

Compact dimensions and low noise levels make ESM models a popular choice for automotive repair shops and workshops. They provide sufficient air volume for operating pneumatic tools, lifts, and painting equipment.

Medical and Laboratory Facilities

High-quality compressed air with low oil content is suitable for use in medical facilities and laboratories (with additional purification systems to meet medical air quality standards).

Integration into Control Systems

Connection to Centralized Systems

The availability of an RS485 port with Modbus protocol support enables easy integration of ESM compressors into building management systems (BMS) or production control systems. This provides remote monitoring and control, as well as data collection for efficiency analysis.

Operation within Compressor Stations

The built-in sequencer allows the combination of two compressors for optimal load distribution and redundancy. The system automatically alternates compressor operation for even wear and can activate both compressors during peak loads.

Environmental Aspects

Use of Eco-Friendly Materials

Gardner Denver pays special attention to the environmental aspects of its products. The use of environmentally friendly materials, including R134a refrigerant in dryers, minimizes environmental impact.

Energy Efficiency as an Environmental Contribution

Highly energy-efficient ESM series compressors consume less electricity, reducing CO2 emissions from power plants. Over its lifetime, a single compressor can save tens of tons of CO2 emissions compared to less efficient models.

Recycling Opportunities

The compressor design allows for easy recycling at the end of its service life. Most components are made from recyclable materials, including metals, plastics, and oil.

Conclusions

Gardner Denver ESM series screw compressors represent an optimal solution for small and medium-sized enterprises seeking a reliable, energy-efficient, and cost-effective source of compressed air. The wide model range from 2.2 to 7.5 kW allows for selecting the perfect solution for any need.

Key advantages of the ESM series include:

• Exceptional reliability due to the use of proprietary screw blocks.
• Low operating costs thanks to high energy efficiency and simple maintenance.
• Configuration flexibility with options for base, receiver-mounted, or full station setups.
• Modern control system with integration capabilities into centralized systems.

When selecting a specific model, it is recommended to consider not only current compressed air needs but also future production expansion. A power reserve of 20-30% ensures scalability without the need for compressor replacement. It is also important to consider energy efficiency options, especially if the compressor will operate under high loads.

Investing in high-quality Gardner Denver compressor equipment is an investment in the stability and efficiency of your production for years to come. With an extended warranty and support from a global network of service centers, you can be confident in the uninterrupted operation of your equipment.