Gardener Denver Electra-Saver EAU P Series User manual

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13-10-603
13-10-603
1st Edition
Originally Published As
13-9-616 3rd Edition
ELECTRA-SA VERB
STATIONARY SCREW
COMPRESSOR
MODELS
EAU P—200 HP
EA UQ/ —250 HP
EAU_R —.300 HP
SERIAL NUMBER
u
AGARDNER-DENVER@
COOPER
INDUSTRIES

GARDNER-DENVER COMPRESSORS
Awarranty registration card ia provided with each machina
The card must be completed by the purchaser and mailed (card
ispreaddreaaed andpoatage paid) within tendays after machine
atart up in order to validate this warranty.
Gardner-Denver Compressors (the’’ Company’) warrants to each
original retail purchase r(’’Purchaser”) of its products from the
Company or its authorized diatributora that such products will
be free from defects in material and workmanship cauaed by
Company and shall be warranted aa follows
BASIC COMPRESSOR AIR ENDS
Baaic compressor air ends conaiating of all parts within and
including the comprasaor cylinder and gear housing, are war-
ranted for24 months from date of initial uae or27 months from
date of shipment to the first purchaser, whichever occurs first
The Company will furnish at ita option air end repairs are-
manufactured reiiacement air enft or anew replacement air
end, FOB factory for any air end which in ita judgment proved
not to be aa warranted within the applicable period
Purchaser must return, transportation chargea prepaid, any
air end claimed to be not as warranted to aGardner-Denver
factory. Any disassembly or partial disassemblyof the air end
or failure to return the “unopened’ air end per Company im
structions will be cause for denial of warranty.
In addition to proper installation routine maintenance and uae
aa outlined in applicable instruction manuals this warranty
is contingent upon the Purchaaer taking and submitting oil
aamplea in accordance with the schedule and procedure as
outlined in the service instruction manuals
ELECTRIC MOTORS
Electric motor$ when specified and furnished by the Company,
arewarrantedfor12 months from date ofinitialuaeor15 months
from date of shipment tothe firat purchaser, whichever occura
first
The motor manufacturer or authorized service ahop will pro
vide at its option motor repairs or replacement motor FOB
manufacturer’s location for any motor which in the manufa~
turet’s judgment proves not to be as warranted within the
applicable period
ENGINES
Engines are warranted to the extent of the original manufac-
ture% warranty to the Company.
OTHER COMPONENTS
All other componenta are warranted for12 months from date
of initial uae or 15 months from date of shipment to first
purchaaer, whichever occurs firat
The Company will furnish at its option FOB Company location
repaira or replacement parta for any component which in the
Compan)fs judgment proved not to be as warranted within the
applicable period
GENERAL PROVISIONS AND LIMITATIONS
No warranty ia made with respect to:
1. Any product which haa been repaired or altered in such
away, in the CompanYa judgment as to affect the pro
duct adveraely.
2.
3.,
4.
5.
WARRANTY
ROTARY SCREW COMPRESSORS
EC ELECTRA-SAVER II”
EA ELECTRA-SAVEW’
EB, ET ELECTRA-SCREW’
SE, ST PACKAGES
Anyproduct which haS inthe Compan~s judgment been
subject to negtigencq accident improper atoragq or
improper installation or application
Any product which has not been operated or maintained
in accordance with normal practice and with the re-
commendations of the Company.
Components or accessories manufactured, warranted and
serviced by others except as separately rated
Any reconditioned or prior owned product
ClaimSfor itema described in(4) above should resubmitted
directly to the manufacturer.
The Compan~s obligation under this warranty is limited to repair
or replacement, at ita option during normal business hours at
an authorized service facility of the Company, of any part which
in its judgment proved not to be as warranted within the a~
plicable Warranty Period The Company may require the return
of anyparf claimed not to beaawarranted to one of its facilities
asdesignated by Company, transportation prepaid by Purchaser,
to establish aclaim under this warranty.
The Company will provide labor for repair or replacement of
any product or part thereof which in the Compan~s judgment
is proved not to be as warranted by Company repreaentativeup
to the amount specified inthe CompanYs labor rate schedule$
or up to the amount the Company determines ia reasonable
Labor costs in excess of the Company rate schedule amounts
or labor provided by unauthorized service personnel is not
provided for by this warranty.
Replacement parts provided under the terms of the warranty
are warranted for the remainder of the Warranty Period of the
product upon which installed totheaame extent asifsuch parta
were original components thereof.
DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS
EXPRESSLY AGREED THAT, EXCEPT AS TO TITLL THECOM-
PANY MAKES NO OTHER WARRANTIES EXPRESSED, IMPLIED
OR STATUTORY. INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY,
THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE
THE SOLE, EXCLUSIVE AND ONLY REMEDY AVAi LABLE TO
PURCHASER AND IN NO CASE SHALL THE COMPANY BE
SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES
UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE
LIABLE FOR ANY SPECIAL INDIRECT, lNCl DENTAL OR CON-
SEQUENTIAL DAMAGES, EXPENSES LOSSES OR DELAYS
HOWSOEVER CAUSED.
No statement representation, agreement or understandin~
oral or written made by any agent distributor, representative
or employee of the Company which is not contained in this
Warranty will be binding uDon the Company unless made in
writing and executed by an officer of the Company.
This warranty shall not be effective as to any claim which ia
not presented within 30 daya after the date upon which the
product is claimed not to have been as warranted Any action
for breach of this warranty must be commenced within one
year after the date upon which the cause of action occurred
Any adjustment made pursuant to this warranty shall not be
construed aa an admiaaion by the Company that any product
was not ae warranted
?3-10-603 Pagei

GARDNER-DENVER” compressors are the result of advanced engineering and skilled manufacturing. To be assured
of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is
written to give the operator and the maintenance department essential information for day-to-day operation, maintenance and
adjustment. Careful adherence to these instructions will result in economical operation and minimum downtime.
ADANGER —Failure to obses-oe aDANGER
notice could result in injuty to, or death of personnel.
A
,WARN [NG –Failuretoob5emeaWARNING
●notice could result in damage to equipment.
ACAUTION —CAUTION notices set forth general
reminders of good safety practice, or direct attention to
unsafe practices.
NOTE —Information furnished in aNOTE will include
general information or the highlights of aprocedure.
TABLE OF CONTENTS
GENERAL INFORMATION .................................................................................... SECTION 1
INSTALLATION ............................................................................................... SECTION2
STARTING &Operating PROCEDURES .................................................................... SECTION3
CONTROLS &lNSTRUMENTS ............................................................................... SECTION4
LUBRICATION, OIL COOLER, OIL FILTER &SEPARATOR .................................................. SECTION 5
AIR FILTERS ................................................................................................. SECTION6
COUPLING ................................................................................................... SECTION7
MAINTENANCE SCHEDULE .................................................................................. SECTIC)N8
TROUBLESHOOTING ........................................................................................ SECT10N9
COMPRESSOR OVERHAUL ....................................................................... See Manual 13-9-625
13-10-603 Page ii

INDEX
NOTE: Numbers preceding a!ush are Section Numbers —numbers following dush are Page Numbers.
Acoustic Enclosure . . . . .. . . . . . . . . . .. . . . . . . . .. . . . . .. . . . . 2-1
Actuator, Turn Valve ................................... 4-5
Addition of Oil Between Changes ..................... 5-2
Adjustment, Operating Air Pressure ................... 4-7
Adjustment, Turn Valve ................................ 4-7
Aftercooler (Air-Cooled and Water-Cooled
Machines) .......................................... 2-3
Aftercooler, Heat Exchanger Water Piping . . . . .. . . . . .. 2-5
Air Filter ..................................... 3-1, 6-1,8-1
Air Filter Indicator ..................................... 4-5
AIR FILTERS (SECTION 6) ......................... 6-1
Air Filter Service Indicator ............................ 6-3
Air Flow ............................................... 1-1
Air Flow, Minimum ..................................... 2-1
Air and Oil Discharge Temperature ................... 5-7
Air-Oil Systems Flow Diagram ......................... 5-1
Air Pressure Adjustment, Operating ................... 4-7
Air Pressure Gauge ...................................
Air Receiver, Auxiliary 4-5
............................ 2-3, 4-9
Air Temperature Gauge, Discharge . . . . .. . . . . . .. . . . . . . . 4-5
Air Temperature Shutdown, High ...................... 4-3
Alignment, Coupling ................................... 7-1
Automatic Blowdown Valve ....................... 4-3, 5-7
Automatic Start/Timed Stop Control System
With Low Demand Mode ........................... 4-8
Automatic Start/limed Stop Operation . . . .. . . . . .. . . . . . 4-9
Auxiliary Air Receiver ............................. 2-3, 4-9
Bleed Air Valve ........................................ 4-7
Blowdown Valve, Automatic ....................... 4-3, 5-7
Capacities, Oil System ................................ 5-3
Capacity Control, Compressor ......................... 4-5
Capacity and Pressure Adjustments, Compressor . . . . . 4-7
Check Valve (Oil Reservoir) ........................... 4-5
Cold Ambient Operation ............................... 5-2
Compression Cycle .................................... 1-1
Compression Principle ................................. 1-1
Compressor ............................................ 1-1
Compressor Capacity Control ......................... 4-5
Compressor Capacity and Pressure Adjustments ..... 4-7
Compressor Lubricant ................................. 5-2
Compressor Oil ........................................ 3-1
Compressor Oil Cooler (Radiator Type) Module . . . .. . 5-4
Compressor Oil Cooler —Water-Cooled Heat
Exchanger .......................................... 5-5
Compressor 011 Filter .................................. 5-4
Compressor Oil Separator ............................. 5-6
Compressor Oil System ............................... 5-1
Compressor Oil System Check ........................ 5-7
COMPRESSOR OVERHAUL ...............................
................................. Refer to Manual 13-9-625
Constant Speed Control System With Low Demand
Mode ............................................... 4-8
Constant Speed Opeation ............................. 4-9
Control —Check Valve, Flow ......................... 4-9
Control, Compre*or Capacity ..........................4-5
Control, Low Starting Torque (Unloaded Start) . . . . . . . . 4-9
Control Piping ......................................... 2-4
13-10-603
CONTROLS &INSTRUMENTS (SECTION 4) . . . . . . . 4-1
Control System, Automatic Startfllmed Stop With
Low Demand Mode ................................ 4-8
Control System, Constant Speed With Low Demand
Mode ............................................... 4-8
Control System, Low Demand Mode .................. 4-8
Control Valve, Turn Valve Actuator .................... 4-6
Control Valve, Water Flow (For Heat Exchanger) . . . . . 5-5
Control Voltage ........................................ 4-1
Cooler, Compressor Oil (Radiator Type) Module . . . .. . 5-4
Cooler, Compressor Oil –Water-Cooled Heat
Exchanger .......................................... 5-5
Cooler, Oil ............................................. 2-2
Coupling ............................................... 7-1
COUPLING (SECTION7) ............................ 7-1
Daily Check ........................................... 3-1
Differential Gauge, Pressure ...................... 4-5, 5-7
Differential, Oil Cooler Pressure ....................... 5-7
Differential, Oil Cooler Temperature ................... 5-8
Differential, Oil Cooler Water Pressure ............... 5-8
Discharge Air Temperature Gauge .................... 4-5
Discharge Pressure Valve, Minimum .................. 4-5
Discharge Service Line ................................ 2-5
Discharge Temperature, Air and Oil ................... 5-7
Draining and Cleaning Oil System .................... 5-3
Drain, Oil Reservoir .................................... 2-1
Electrical ............................................... 3-1
Electrical Starter ....................................... 2-6
Electrical Wiring . . . . . 2-6, 4-8, 4-9, 4-12, 4-13, 4-14, 4-15
Enclosure, Acoustic .................................... 2-1
Filling Oil Reservoir ................................... 5-3
Filter, Air ..................................... 3-1, 8-1,8-1
Filter, Compressor Oil ................................. 5-4
Filter indicator, Air ..................................... 4-5
Filter indicator, Oil .................................... 4-5
FILTERS, AIR (SECTION 6) ........................ 6-1
Flow Control —Check Valve .......................... 4-9
Flow Diagram —Air-Oil Systems ...................... 5-1
Foundation ............................................ 2-1
Gauge, Air Pressure ................................... 4-5
Gauge, Discharge Air Temperature .................... 4-5
Gauge, Oil Level ...................................... 5-3
Gauge, Pressure Differential ...................... 4-5, 5-7
Gauges and Instruments .............................. 4-4
General (Controls) ..................................... 4-1
GENERAL INFORMATION (SECTION 1) . . . . . . . . . . . 1-1
General (Installation) .................................. 2-1
Grease Recommendations ............................. 2-6
Grounding ............................................. 2-6
Page iii

High Air Temperature ........... .. .................. 4-3
High Discharge Temperature Switch ................ . 4-2
High Temperature Operation .......................... 5-2
Hourmeter ............................................. 4-4
indicator, Air Filter ................. .... .. .. ... . 4-5
Indicator, Air Filter Service ............................ 6-3
indicator, Oil Filter .................................... 4-5
Inlet Line .............................................. 2-4
inlet Pressure, Oil ..................................... 5-7
Inlet Valve ............................................. 4-7
Inlet Valve Subtractive Pilot.... ....................... 4-7
Installation for Cold Weather Operation .............. 2-3
INSTALLATION (SECTION2) ....................... 2-1
INSTRUMENTS &CONTROLS (SECTION 4) . . . . 4-1
instruments and Gauges .............................. 4-4
Lifting Unit ...................... . ................ 2-1
Light Test, Operating .................................. 3-1
Location ............................................... 2-1
Low Demand Mode Control System .................. 4-8
Low Demand Mode Pressure Switch ................. 4-3
Low Demand Mode Switch ............................ 4-2
Low Demand Mode Unloader Solenoid ............... 4-4
Low Oil Pressure Protection, Air-Cooled Oil
Cooler .............................................. 2-2
Low Oil Pressure Shutdown ........................... 4-4
Low Oil Pressure Time Delay Switch ................. 4-4
Low Starting Torque (Unloaded Start) Control ........ 4-9
Lubricant, Compressor ................................. 5-2
Lubricants, Synthetic .................................. 5-2
Lubrication, Cooling and Sealing ...................... 1-1
Lubrication, Motor ................................ 2-6, 8-1
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION5) ....................... 5-1
MAINTENANCE SCHEDULE (SECTION 8) .......... 8-1
Minimum Air Flow ..................................... 2-1
Minimum Discharge Pressure Valve ................... 4-5
Mode, Operating ....................................... 3-1
Moisture inthe Oil System ........................... 5-3
Moisture Separator Trap .............................. 3-1
Motor Lubrication ................................. 2-6, 8-1
Motor Protection Devices ............................. 4-2
Oil, Addition Between Changes ....................... 5-2
Oil and Air Discharge Temperature ................... 5-7
Oil-Air Systems Flow Diagram ......................... 5-1
Oil Change Interval .................................... 5-3
Oil, Compressor ....................................... 3-1
Oil Cooler ............................................. 2-2
Oil Cooler, COfWXC!SSOr —Water-Cooled Heat
Exchanger) ......................................... 5-5
Oil Cooler Module (Air-Cooled) ........................ 2-1
OIL COOLER, OIL FILTER, SEPARATOR &
LUBRICATION (SECTION 5) ..................... 5-1
Oil Cooler Oil Pressure Differential ................... 5-7
Oil Cooler (Radiator Type) Module, Compressor . . . .. . 5-4
Oil Cooler Temperature Differential ................... 5-8
oil cOOb Water Pressure Differential ................ 5-8
Oil Filter, Compressor ................................. 5-4
Oil Filter Indicator ..................................... 4-5
OIL FILTER, SEPARATOR, OIL COOLER &
LUBRICATION (SECTION5) ..................... 5-1
Oil FIOW Diagram –Remote Overhead Mounted Oil
Cooler .............................................. 5-2
Oil Inlet Pressure ...................................... 5-7
Oil Level Gauge ....................................... 5-3
Oil Pressure Differential, Oil Cooler ................... 5-7
Oil pressure Protection, Low (Air-Cooled Oil
Cooler) .............................................. 2-2
Oil Pressure Shutdown, Low .......................... 4-4
Oil Pressure Time Delay Switch, Low ................. 4-4
Oil Reservoir .......................................... 5-6
Oil Reservoir Check Valve ............................ 4-5
Oil Reservoir Drain ............................. . . 2-1
Oil Reservoir, Filling ................................... 5-3
Oil Separator ................. .. ..................... 8-1
Oil Separator, Compressor ............................ 5-6
Oil Specifications ...................................... 5-1
Oil System Capacities ................................. 5-3
Oil System Check, Compressor ....................... 5-7
Oil System, Compressor ............................... 5-1
Oil System, Draining and Cleaning .................... 5-3
On-Off Switch ......................................... 4-2
Operating Air Pressure Adjustment ................... 4-7
Operating Light Test .................................. 3-1
Operating Mode ....................................... 3-1
OPERATING PROCEDURES &STARTING
(sEcTloN 3) ....................................... 3-1
OVERHAUL, COMPRESSOR ..............................
................................. Refer to Manual 13-9-625
Pilot, inlet Valve Subtractive . . . . . . . . . . . . . 4-7
Pilot Light ............................................. 4-2
Pilot, Turn Valve Subtractive .......................... 4-6
Piping ............................................. 2-2, 3-1
Piping, Control ......................................... 2-4
Piping Diagram for Aftercooler and Heat
Exchanger ............... .. . .............. .. ... 2-3
Piping, Water (Water-Cooled Heat Exchanger Models
Only) ................................................ 2-4
Pressure Adjustment, Operating Air ................... 4-7
Pressure Adjustments, Compressor Capacity and . . . . . 4-7
Pressure Differential Gauge ...................... 4-5, 5-7
Pressure Differential, Oil Cooler Oil ................... 5-7
Pressure Differential, Oil Cooler Water ............... 5-8
Pressure Gauge, Air ................................... 4-5
Pressure, Oillnlet ..................................... 5-7
Pressure Protection, Low Oil (Air-Cooled Oil
Cooler) .............................................. 2-2
Pressure Regulator .................................... 4-4
Pressure Shutdown, Low Oil .......................... 4-4
Pressure Switch, Low Demand Mode ................. 4-3
Pressure Switch, Reservoir ...................... 4-4,4-10
Pressure, System ...................................... 3-1
Pressure Time Delay Switch, Low Oil ................. 4-4
Pressure Valve, Minimum Discharge . . . . . . . . .. . . . . .. . . 4-5
Regressing interval .................................... 2-6
Regulator, Pressure ................................... 4-4
Reservoir Check Valve, Oil ............................ 4-5
Reservoir Drain, Oil .................................... 2-1
Reservoir, Oil .......................................... 5-6
Reservoir Pressure Switch ...................... 4-4,4-10
Reset .................................................. 4-1
Rotation ............................................... 3-1
13-10-603 Page iv

Safety Devices ........................................ 4-2
Safety Precautions .................................... 1-3
Safety Valve ........................................... 4-3
Separator, Compressor Oil ............................ 5-6
Separator, Oil .......................................... 8-1
SEPARATOR, OIL COOLER, OIL FILTER &
LUBRICATION (SECTION5) ..................... 5-1
Separator Trap, Moisture .............................. 3-1
Service Check List .................................... 8-1
Service indicator, Air Filter ............................ 6-3
Service Line, Discharge . . . . .. . . . . . . . . . .. . . . . . .. . . . . . . . 2-5
Shutdown, High Air Temperature. ..................... 4-3
Shutdown, Low Oil Pressure .......................... 4-4
Shutoff Valve, Water –Water-Cooled Heat
Exchanger .......................................... 5-6
Solenoid, Low Demand Mode Unloader ............... 4-4
Specifications, Oil ..................................... 5-1
Starter, Electrical ...................................... 2-6
STARTING &OPERATING PROCEDURES
(sEcTloN 3) ....................................... 3-1
Starting the Unit ...................................... 3-1
Start-Stop/Reset Switch ............................... 4-2
Stopping the Unit ..................................... 3-1
Subtractive Piot, inlet Valve ........................... 4-7
Subtractive Pilot, Turn Valve .......................... 4-6
Switch, High Discharge Temperature . . . .. . . . . . .. . . . . . . 4-2
Switch, Low Demand Mode ........................... 4-2
Switch, Low Demand Mode Pressure ................. 4-3
Switch, Low Oil Pressure Time Delay . . . . . . . . . . . . . . . . . 4-4
Switch, On-Off .........................................
Switch, Reservoir Pressure 4-2 ...................... 4-4, 4-10
Switch, Start-Stop/Reset ............................... 4-2
Switch, Vibration ....................................... 4-9
Synthetic Lubricants ................................... 5-2
System Pressure ...................................... 3-1
Temperature, Air and Oil Discharge . . . .. . . . . .. . . . . . . . . 5-7
Temperature, Dew Point vs Ambient .................. 5-5
Temperature Differential, Oil Cooler ................... 5-8
Temperature Gauge, Discharge Air . . . .. . . . . .. . . . . . . . .. 4-5
Thermal Control (Thermostatic Mixing) Valve . . . . . . . . . 5-4
Thermostatic Mixing Valve, Thermal Control . . .. . . . . . . 5-4
Three-Way Valve ....................................... 4-9
Time Delay Switch, Low Oil Pressure ................. 4-4
Turn Valve ........................................ 1-1, 4-5
Turn Valve Actuator ................................... 4-5
Turn Valve Actuator Control Valve .................... 4-6
Turn Valve Adjustment ................................ 4-7
Turn Valve Subtractive Pilot ........................... 4-6
TROUBLE SHOOTING (SECTION 9) ............... 9-1
Unloader Solenoid, Low Demand Mode ............... 4-4
Valve, Actuator Turn ................................... 4-5
Valve, Automatic Blowdown ....................... 4-3, 5-7
Valve, Bleed Air ....................................... 4-7
Valve, Check (Oil Reservoir) ........................... 4-5
Valve, Flow CorNrol —Check ......................... 4-9
Valve, inlet ............................................. 4-7
Valve, Minimum Discharge Pressure .................. 4-5
Valve, Safety ........................................... 4-3
Valve, Thermal Control (Thermostatic Mixing) ......... 5-4
Valve, Three-Way ...................................... 4-9
Valve, Turn ........................................ 1-1, 4-5
Valve, Turn Valve Actuator Control .................... 4-6
Valve, Water Flow Control (For Heat Exchanger) . . . . . 5-5
Valve, Water Shutoff (Water-Cooled Heat
Exchanger) ......................................... 5-6
Ventilation ............................................. 2-1
Ventilation, Air-Cooled Oil Cooler ..................... 2-2
Vibration Switch ....................................... 4-9
Voltage, Control ....................................... 4-1
Warranty ........................................... Pagei
Water Flow ............................................ 2-5
Water Flow Control Valve (For Heat Exchanger) . . . .. . 5-5
Water Piping, Aftercooler —Heat Exchanger ......... 2-5
Water Piping (Water-Cooled Heat Exchanger Models
Only) ................................................ 2-5
Water Pressure Differential, Oil Cooler ............... 5-8
Water Shutoff Valve —Water-Cooled Heat
Exchanger .......................................... 5-6
Wiring Diagrams .. . . . . . . . . . .. . . . . . . 4-12,4-13,4-14,4-15
Wiring, Electrical . . . . 2-6, 4-8, 4-9, 4-12, 4-13, 4-14, 4-15
13-10-603 Page v

SECTION 1
GENERAL INFORMATION
DISCHARGE
COMPRESSOR
compressor is a
DISCHARGE
FIGURE 1-1. –COMPRESSION CYCLE
—The Gardner-Denver” Electra-SaveP
single-stage, positive displacement rotary
machine using meshing helical rotors to effect compression.
The input drive shaft and helical drive gear are supported in
the gear case by high capacity tapered roller bearings. The
drive gear meshes with adriven gear mounted on the main
rotor shaft to drive the rotors. Both rotors are supported
between large capacity antifriction bearings located outside
the compression chamber. Single-width cylindrical roller
bearings are used at the inlet end of the rotors. Early models
used two (2) heavy-duty single-row angular contact ball
bearings at the discharge end locate each rotor axially and
carry all thrust loads; later models use tapered roller bear-
ings in this location.
COMPRESSION PRINCIPLE (Figure l-l) –Compres-
sion is accomplished by the main and secondary rotors
synchronously meshing in aone-piece cylinder. The main
rotor has four (4) helical lobes 90° apart. The secondary
rotor has five (5) matching helical grooves 72° apart to allow
meshing with main rotor lobes.
The air inlet port is located on top of the compressor near
the center. The discharge port is near the bottom at the
opposite end of the compressor cylinder. Figure 1-1 is an
inverted view to show inlet and discharge ports. The compression
cycle begins as rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and
secondary rotor grooves (A). When the rotors pass the inlet
port cutoff, air is trapped in the interlobe cavity and flows
axially with the meshing rotors (B). As the meshing
continues, more of the main rotor lobe enters the secondary
rotor groove, normal volume is reduced and pressure in-
creases. Oil is injected into the cylinder to remove the
heat of compression and seal internal clearances. Volume
DISCHARGE
PORT
K
,.
‘\
‘. ‘,
(-%”, m
\
#-NJ\l ‘
c
reduction and pressure increase continues until the air/oil
mixture trapped in the interlobe cavity by the rotors passes
the discharge port and is released to the oil rese~oir (c).
Each rotor cavity follows the same “fill-compress-discharge”
cycle in rapid succession to produce adischarge air flow that
is continuous, smooth and shock-free.
AIR FLOW (Figures 2-1 &3-1) —Air enters the air filter
and passes through the inlet unloader valve to the compres-
sor. After compression, the air/oil mixture passes into the
oil reservoir where most of the entrained oil is removed by
velocity change and impingement and drops back into the
reservoir. The air and remaining oil then passes through the
oil separatofi the separated oil is returned to the system
through tubing connecting the separator and compressor.
The air passes through the reservoir discharge manifold, dis-
charge check valve, minimum pressure valve and the custom-
er furnished unit shutoff globe valve to the plant air lines.
LUBRICATION, COOLING AND SEALING –Oil is
forced by air pressure from the oil reservoir through the oil
cooler, thermal control (thermostatic mixing) valve and oil
filter and discharges into the compressor main oil gallery. A
portion of the oil is directed through internal passages to
the bearings, gears and shaft oil seal. The balance of the oil
is injected directly into the compression chamber to remove
heat of compression, seal internal clearances and lubricate
the rotors.
TURN VALVE —The turn valve is arotary helical valve
located on the discharge side of the cylinder toward the inlet
end. The valve opens and closes ports in the cylinder which
communicate with the inlet passage. This varies the com-
pressor rotor volume to match the demand for air, thus
reducing the part-load power requirement.
13-10-603 Section 1Page 1

13-10-603 Section 1Page 2

SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot
always be predicted and covered by established rules. Therefore, use your Dast experience. watch out for safety hazards
and be cautious.
Some general safety precautions are given below:
ACAUTION
0STOP THE UNIT IF ANY REPAIRS OR ADJUSTMENTS ON OR AROUND THE
COMPRESSOR ARE REQUIRED.
●ALL COMPRESSED
DIAMETER SHOULD
SECTION 151 8.302)
●DO NOT EXCEED
THE NAME PLATE.
●DO NOT OPERATE
AIR SUPPLY HOSES EXCEEDING 1/2 INCH INSIDE
HAVE AN EXCESS FLOW VALVE. (OSHA REGULATION,
THE RATED MAXIMUM PRESSURE VALUES SHOWN ON
UNIT IF SAFETY DEVICES ARE NOT OPERATING PROP-
ERLY. CHECK PERIODICALLY. NEVER BYPASS SAFETY DEVICES.
ADANGER
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KEEP FINGERS AND CLOTHING AWAY FROM REVOLVING FAN, DRIVE
COUPLING, ETC.
DO NOT USE THE AIR DISCHARGED FROM THIS UNIT FOR BREATHING –
NOT SUITABLE FOR HUMAN CONSUMPTION.
DO NOT LOOSEN OR REMOVE THE OIL FILLER PLUG, DRAIN PLUGS,
COVERS, THE THERMOSTATIC MIXING VALVE OR, BREAK ANY CON-
NECTIONS, ETC. IN THE COMPRESSOR AIR OR OIL SYSTEM UNTIL THE
UNIT IS SHUT DOWN AND THE AIR PRESSURE HAS BEEN RELIEVED.
ELECTRICAL SHOCK CAN AND MAY BE FATAL.
COMPRESSOR UNIT MUST BE GROUNDED IN ACCORDANCE WITH THE
NATIONAL ELECTRICAL CODE.
FAN MOTORS HAVE BEEN AND MUST REMAIN GROUNDED TO THE
MAIN BASE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE.
OPEN MAIN DISCONNECT SWITCH BEFORE WORKING ON THE CONTROL.
DISCONNECT THE COMPRESSOR UNIT FROM ITS POWER SOURCE
BEFORE WORKING ON THE UNIT –THIS MACHINE IS AUTOMATI-
CALLY CONTROLLED AND MAY START AT ANY TIME.
13-10-603 Section 1Page 3

SECTION 2
INSTALLATION
GENERAL —On receipt of the unit, check for any damage
that may have been incurred during transit. Report any
damage or missing parts as soon as possible.
ACAUTION
DO NOT electric weld on the compressor or base; bear-
ings can be damaged by passage of current.
LIFTING UNIT —LIFT UNIT BY BASE ONLY. Do not
use other places such as the motor, compressor or dis-
charge manifold piping as lifting points.
ADANGER
The eyebolts or Lugsprovided on the motor are for ltfling
the motor only and should not be used to lifl any
additional weight. All tyebolts must be securely tightened.
When lzfling the motor the ltj?ing angle must not exceed
15 degrees. Faihsre to obseroe this warning may result
in damage or personal in]”ury.
LOUVERED EXHAUST FAN LOUVERED
A75119
FIGURE 1-2. –TYPICAL COMPRESSOR ROOM
LOCATION —The compressor should be installed in a
clean, well-lighted, well-ventilated area with ample space all
around for maintenance. Select alocation that provides a
cool, clean, dry source of air. In some cases it may be
necessary to install the air filter at some distance from the
compressor to obtain aproper air supply.
The compressor unit requires electric motor cooling air as
well as air to the compressor inlet. Proper ventilation MUST
be provided (Figure 2-2); hot air must be exhausted from
the compressor operating area. Atypical inlet-outlet air flow
arrangement is shown in Figure 1-2.
If the air-cooled oil cooler module is to be installed at a
location remote from the compressor unit, be sure that
adequate ventilation is provided, Figure 2-2. Hot air must
be exhausted from the oil cooler area.
VENTILATION –The unit, whether air or water cooled,
Open Unit
With Oil
Open Cooler Module
Compressor Oil Cooler Discharge In
Size Unit Module Same Room
200 HP 8,000 23,000 31,000
250 HP 9,900 24,000 33,900
300 HP 11,900 24,000 35,900 J
*80° F. Inlet Air
FIGURE 2-2. –MINIMUM AIR* FLOW
FOR COMPRESSION AND COOLING
(Cubic Feet/Minute)
requires sufficient air flow, Figure 2-2, for electric motor
cooling. Air is drawn into the back and front of motor and is
discharged out the sides. Do not block air flow to and from
the unit.
FOUNDATION —The Electra-Savere compressor re-
quires no special foundation but should be mounted on a
smooth, solid surface of sufficient strength to support the
weight of the unit. Whenever possible install the unit near
level. Temporary installation may be made at amaximum
of 10° angle lengthwise or 30° sidewise.
Mounting bolts are not normally required. However, instal-
lation conditions such as piping rigidity, angle of tilt, or
danger of shifting from outside vibrations or moving vehi-
cles may require the use of mounting bolts to the
foundation.
OIL RESERVOIR DRAIN (Figure 3-1 )—The oil reservoir
drain valve is located near the center of the oil reservoir just
below the separator tower. The drain valve is approx-
imately five (5) inches from the floor level. If this height
is not sufficient to conveniently drain the oil, some other
methods of providing oil drain are:
1. Elevate the compressor unit on the foundation to
obtain the desired drain height.
2. Construct an oil sump or trough below the floor
level and pump or bail the drained oil.
3. Pump oil from the reservoir filler opening or reservoir
drain to acontainer.
ACOUSTIC ENCLOSURE —The Electra-Saver unit is
furnished with an acoustic enclosure over the compressor
only, as standard equipment. The enclosure reduces the
normal operating sound of the unit to 90 DBA or below in
free field conditions.
AIR-COOLED OIL COOLER MODULE –The air-
cooled oil cooler is aseparate module and may be mounted
remote to the compressor unit.
13-10-603 Section 2Page 1