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
●
●
●
●
●
●
●
●
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

ELB0w —
PIPING SCHEMATIC OF COOLER
WITH SCREWED CONNECTIONS
FIGURE
Ventilation —The oil cooler requires adequate cooling air
flow. Proper ventilation MUST be provided, with hot air
exhausted away from the coole~ take care that hot air is not
recirculated from the exhaust to the inlet side of the cooler.
Cooling air flow direction is from the motor side through
the grille side of the oil cooler. Do not obstruct the air flow
to or from the cooler. Allow two (2) feet clearance on all
sides of the cooler module. See Figure 2-2 for cooling air
flow requirements.
Low Oil Pressure Protection —The standard factory-
installed low oil pressure shutdown switch in the control
box will prevent start-up or shut the unit down if oil
pressure is not established or maintained due to mal-
function in the oil cooler system.
Oil Cooler -Location and General Piping -The oil cooler
module can be mounted in any of several remote locations
close coupled but not joined to the compressor unit; hor-
izontal remote, located on the same level as the compressor
unit, but some distance away or overhead remote, located
above level of the compressor unit, as on aroof.
~WARNING
~The low demand mode switch CANNOT be wed with
remote overhead oil cooler. These units require special
wiring diagram —check with factoy.
All piping and wiring between the compressor unit and the
remote oil cooler is to be supplied by the user. THE
DESIGN OF THE REMOTE OIL COOLER MODULE
SYSTEM MUST BE APPROVED BY THE FACTORY BE-
FORE INSTALLATION. The design information to be sub-
mitted for approval includes
1.
2.
3.
4.
5.
Location of oil cooler module —inside or outdoors.
Range of operating ambient temperatures at the oil
cooler location.
Elevation of the oil cooler above the compressor unit.
Pipe type and size(s) to be used to connect the oil
cooler and the compressor unit. Minimum pipe size is
2“ IPs.
Horizontal and vertical lengths of the pipe run. If
more than one pipe size is used, list length of each
size and total length.
3-2.
6.
7.
ir–~$.
Ui==$=
PIPING SCHEMATIC OF COOLER
WITH FLANGED CONNECTIONS
Number and size of elbows, tees, unions, reducers
and valves to be used in the pipe run.
Adimensional sketch of the proposed piping system
showing location of the compressor unit, oil cooler
and pipe and fittings of 3through 6above.
All remote piping should be of adequate size to insure the
minimum pressure loss. Design point 4above lists the pipe
size at the compressor unit oil inlet and outlet connections
and is the minimum pipe size to be used. Long runs of pipe
and the use of valves and fittings require larger than the
minimum pipe sizes in the system to keep the pressure loss
low, All pipe and fittings used in aremote oil cooler system
should be galvanized or treated internally to prevent rust,
and all valves are to be of anonferrous construction to
prevent corrosion and fouling.
The remote cooler should be placed so that the fan air flow
through the cooler (air flow is from motor side through
core) and the prevailing winds are in the same direction. A
baffle should be provided on the exhaust side of the cooler
for protection against occasional wind shifts.
When the oil cooler is mounted above the compressor unit,
acheck valve is to be mounted on the compressor unit in
the line to the oil coole~ see Figure 2-5. Apneumatic pilot-
operated normally-closed valve is to be mounted at the oil
filter inlet on the compressor unit line from the oil coolec
see Figure 2-5. The check valve permits oil flow to the oil
cooler during operation, but prevents return oil flow from
the cooler when the unit is shut down. The pilot valve is
held open by air pressure from the unit oil reservoir during
operation and closes under spring load when the unit is
shut down to prevent return oil flow from the oil cooler.
An oil filler stand pipe and plug must be located in the
piping on the oil cooler module for ease of filling of a
remote oil coole~ see Figure 2-5.
Oil Cooler —Installation –Inspect unit upon arrival. In
case of damage, report immediately to transportation com-
pany. Before installation, check rating plate on motor to
verify that power input and motor specification require-
ments match available electric power at point of installation.
1.
2.
13-10-603 Section 2
Set the unit level on afirm solid foundation, The
larger oil cooler models have lifting holes to facilitate
unit hoisting.
Allow for linear expansion and contraction of piping
Page 2

-.. WATER
OIL
IN
I
OIL WATER
CONTROL
OUT
&------ [VALVE’
t
SHUTOFF
VALVE d
17
iSEPARATOR IAFTERCOOLER I
I I 1---- wAT,, ,N
II
SERIES PIPING -WATER FLOW MUST BE
THROUGH AFT ERCOOLER FIRST FOR
EFFECTIVE COOLING OF DISCHARGE AIR.
OIL
IN
UIL
OIJT
!
CONTROL
VALVE d
.
1------\
+/ WATER
HEAT EXCHANGER TOUT
)WATER
MANUAL VALVE TO SHUTOFF
BALANCE WATER FLOW..__ VALVE d
WATER
1IN
ISEPARATOR IAFTERCOOLER II
L-.--JLw*TER N-.-1
PARALLEL PIPING WATER CONTROL
VALVE REQUIRED FOR TEMPERATURE CONTROL
OF OIL
dMUST BE ORDERED SEPARATELY. B75853
FIGURE 4-2. –PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER
in the direction away from the oil cooler. Use flexible
connectors or suitable expansion joints on all oil
cooler inlet and outlet piping. See Figure 3-2 for
typical schematics.
3. Select properly tensioned and aligned piping support
clamps or hangers and position them to relieve any
piping stress at the oil cooler inlet and outlet ports. Do
not support from flexible connectors.
4. Service —For continuous efficiency, oil cooler cores
must be periodically cleaned with either vacuum or
compressed air. If wet cleaning is required, shield
motor and spray on amild soap solution and flush
with clear water.
ACAUTION
Forahsminum oil coolers, DO NOT use any cleaning
solution that is not compatible with aluminum.
AUXILIARY AIR RECEIVER —The unit requires an
auxiliary air receiver unless the piping system is large and
provides sufficient storage capacity to prevent rapid cycling.
When used, an air receiver should be of adequate size,
provided with arelief valve of proper setting, apressure
gauge and ameans of draining condensate.
AFTERCOOLER (Figures 2-1 &3-1) –An aftercooler will
provide control of moisture entering the shop air lines while
reducing the normal low discharge temperature of about
180” F. at 100 PSIG discharge pressure to near inlet air
temperature, or cooling water temperature.
Air-Cooled Machines —When an aftercooler is furnished
on an air-cooied machine, the aftercooier is instaiied on the
oil cooier module between the fan and the oii cooler. The
moisture separator is furnished by Gardner-Denver but
must be mounted by the customer between the after-
cooier and the auxiiiary air receiver with acondensate
drain provided at the bottom. All air piping from the com-
pressor discharge to aftercooler to auxiiiary air receiver is to
be furnished and mounted by customer. The design of the
aflercoolerpiping mmt be a@roved @thefacto~ before installation.
Design information to be submitted for approvai inciudes:
1.
2.
3.
4.
5.
6.
Location of aftercooler module —inside or outdoors.
Range of operating ambient temperatures at the after-
cooier location.
Pipe type and size(s) to be used to connect the after-
cooier, separator and compressor unit —minimum
pipe size is 3“ iPS.
Lengths of the pipe run. If more than one pipe size is
used, iist length of each size and totai iength.
Number and size of elbows, tees, unions, reducers
and vaives to be used in the pipe run.
Adimensional sketch of the proposed piping system
showing location of the compressor unit, aftercooier,
separator and auxiiiary air receiver, pipe and fittings
of 3through 5above.
Water-Cooied Machines (Figure 4-2) —On water-cooied
machines with aftercooler, the moisture separator and con-
densate drain are shipped loose and must be installed by
customer. Customer must furnish and instail ail water
piping required,
iNSTALLATION FOR COLD WEATHER OPERATiON –
it is recommended that whenever possibie the unit be
instaiied inside ashelter that wiii be heated to temperatures
above the freezing (32° F., O“C.). This wili eiiminate many of
the probiems associated with operating the units outside
in coid climates where freezing rain, drifting snow, freezing
condensate and bitter coid temperatures are encountered.
When an outside installation must be made, the precautions
13-10-603 Section 2Page 3

F
/’
,-
\
L
wELLMAN RADIANT 2-ELEMENT
HEATER (OR EQUAL)
RH400 WITH (2) RH4502
ELEMENTS —2REQ’D.
3,200 WATTS EACH
---
R‘i
‘J./‘u
IIk WE LLMAN RADIANT
HEATER (OR EQUAL)
RH7000 WITH (2) RH7502
++_ o:=J=jjJEQ’D”
2-ELEMENT \4FT.
II
\c AWAY FROM PREVAILING WIND
TOP VIEW \8FT. PLYWOOD “FENCE”
FIGURE 5-2.
required will depend on how severe the environment will
get. Following are general guidelines for outside installations:
Cold Weether (Down To -10° F.)
1.
2.
3.
4.
5.
6.
Be sure all control lines, drains and traps are heated
to avoid freezing of condensate. Heat tape with ther-
mostat control is generally satisfactory for this pur-
pose and can be obtained at various local plumbing
or hardware outlets.
If an air-cooled aftercooler is to be used, provisions
to bypass the aftercooler should be made. Since cold
air contains very little moisture, successful operation
can be achieved without the aftercooler. Successful
operation down to +15° F. can be accomplished by
reversing fan flow, but cooler bypass should still be
provided should it be required.
Provide at least some simple shelter such as a plywood
windbreak to protect against drifting snow.
Use only Gardner-Denverm “GD800” Lubricating
Coolant”.
Monitor unit carefully during start-up and operation
to be sure it is functioning normally.
Use NEMA 4enclosure for electrical devices.
Extreme Cold Weather Operation (Down To -40° F.)
In addition to recommendations for –10° F. installations,
the following should be provided:
1. Atemperature switch to control the fan should be
provided for better starting and quicker warm-up.
This switch can be provided from the factory and
will delay fan start-up until discharge temperature
reaches approximately 150-160° F.
2. It will probably be necessary to provide shutters or
to block off part of the cooler in some manner since
the cooler is greatly oversized for operation in these
low temperatures. Shutters are not afactory option.
3.
4.
8FT. PLYWOOD “FENCE”
N51”
ELEVATION VIEW
Coolers should be located as close to unit as ~ossible.
Long lines to and from the cooler only further com-
liCate the circulation of oil flow on cold starts.
Lo-Demand operation cannot be used in extreme
environments. Heat tape and insulation may be re-
quired on oil lines.
Some means of providing heat to the oil reservoir
and cooler during shutdown should be provided.
There are various methods to accomplish this, but
since openings are not provided for sump heaters,
the use of radiant heaters is recommended. The
heaters should be sized to provide at least a–10° F.
environment for the coolers, motor and sump. Figure
5-2 shows how these might be located in atypical
installation and sizes required.
Remember unsheltered (outside) installations should be
avoided where possible. 1nstallation next to aheated build-
ing where enough heat can be used to keep the compressor
room above freezing will save many complications in the
operation and installation of the unit.
CONTROL PIPING —Control piping is not necessary
since the Electra-Savera unit is factory-wired and piped for
the control system specified.
INLET LINE —Where an inlet line is used between the
air filter and the compressor, it must be thoroughly cleaned
on the inside to prevent dirt or scale from entering the
compressor. If welded construction is used, the line
must be shot blaated and cleaned to remove welding
scale. In either case, the inlet line must be coated inter-
nally by galvanizing or painting with amoisture and oil-
proof sealing lacquer. The inlet line should be the full size
of the inlet opening on the compressor. If an extra-long
line is necessary, the pipe size should be increased
accordingly:
Length Of Inlet Line Diameter Of Pipe Size
Otol OFt. ........ Same As Compressor Inlet Opening
10t017 Ft. ........ One Size Larger Than Inlet Opening
17t038 Ft. . . . . . . . Two Sizes Larger Than Inlet Opening
13-10-603 Section 2Page 4

Water Temperature To Heat Exchanger
Rated
Pressure
Size PSIG 60° F. 70° F. 80° F. 90° F.
200 HP ALL 19 24 32 48
250 HP ALL 24 30 40 60
300 HP ALL 29 36 48 . . .
Maximum
Water
Flow
Approximate
Water Pressure
Drop @
Maximum Flow
(Psi)
60 21.0
60 23.0
I
60 I25.0
The maximum water flow shown is that allowable through the heat exchanger.
FIGURE 6-2 –HEAT EXCHANGER (OIL COOLER) APPROXIMATE WATER FLOW
(U.S. Gallons/Minute)
Water Temperature To Aftercooler
Rated Maximum
Pressure
Size PSIG 60° F. Water 70° F. 80° F. 90” F. Flow
200 HP ALL 4.7 5.8 7.8 11.6 37.0
250 HP ALL 6.4 8.0 10.6 16.0 37.0
300 HP ALL 7.9 9.9 13.2 19.7 50.0
J
Approximate
Water Pressure
Drop @
Maximum Flow
(Psi)
++ ,
Water flow rates (gpm) are based on 11O“ F. water temperature out of cooler. Maximum water flow shown is the maximum
allowable flow through aftercooler.
FIGURE 7-2 –AFTERCOOLER APPROXIMATE W,4TER FLOW
(U.S. Gallons/Minute)
Accessibility for inlet air filter servicing must be considered
when relocating the filters from the unit to aremote
location.
DISCHARGE SERVICE LINE —The discharge service
line connection on water-cooled units with aftercooler is
made at the moisture separator. On air-cooled units and
water-cooled without aftercooler, the connection is made at
the Pipe nipple located behind the instrument panel. When
manifolding two or more Electra-SaveP units on the same
line, each unit is isolated by the check valve in the unit
discharge line.
[f an Electra-Saver unit is manifolded to another com-
pressor, be sure the other compressor has acheck valve in
the line between the machine and the manifold.
If an Electra-Saver and areciprocating compressor are
manifolded together, an air receiver must be located be-
tween the two units.
ADANGER
/&/ DO NOT USE THE AIR DISCHARGED FROM
THIS UNIT FOR BREA THING —IT IS NOT
SUITABLE FOR HUMAN CONSUMPTION.
WATER PIPING (Water-Cooled Heat Exchanger Models
Only) –On machines equipped with awater-cooled heat
exchanger, pipe water to the inlet or the water flow control
valve mounted in the water inlet piping to the heat ex-
changer. Pipe outlet water from the outlet or magnetic
water shutoff valve to asump or drain. The thermal bulb
of the water flow control valve is inserted in the heat ex-
changer oil outlet line; refer to the unit outline drawing
for location.
The water source should be capable of supplying up to the
maximum flow shown in Figure 6-2 at aminimum pressure
of 40 PSIG; maximum allowable water pressure is 150 P.SIG.
The water flow rates shown in Figure 6-2 are approximate
and aguide to sizing piping, cooling tower and other water
system equipment.
The heat exchanger is designed to operate with water inlet
temperatures from 60° F. to 90° F., and awater outlet
temperature not to exceed 110° F. If water cooler than 60°
F. is used, high water outlet temperatures (over 110° F.) will
be experienced along with shortened heat exchanger life
caused by tube fouling and corrosion. If water warmer than
90° F. is used, higher compressor oil temperatures and high
water usage will result.
Most water systems will require control of impurities:
filtration, sofening or other treatment. See “Compressor
Oil Cooler —Water-Cooled Heat Exchanger” for more
information on the water system.
Aftercooler —Heat Exchanger Water Piping (Figures 4-2,
6-2 and 7-2) —If an aftercooler is used and piped in series
with the heat exchanger, install the water flow control valve
and magnetic water shutoff valve, if used, downstream of
the exchanger. Pipe the aftercooler water outlet to the heat
13-10-603 Section 2Page 5

Grounding —Equipment must be grounded in accordance
with Table 250-95 of the National Electric Code.
exchanger water inlet on the compressor unit.
If the aftercooler is piped in parallel with the heat
exchanger, provide amanual valve between aftercooler
outlet and heat exchanger outlet after the water control
valve to adjust aftercooler water flow for discharge
temperature required and most economical water use;
separate water inlet lines are piped to the aftercooler and
heat exchanger.
~WARNING
An equipment ground @roper, equal in size to the
equipment ground conductor, must be used to connect the
compressor-motor subbase to the rnuin base, since the bases
are isolatedjom each other by vibration mounts. The oil
cooler fan and enclosure vint fan motor frame will be
grounded to the main bme with agrounding conductor
compatible with the fan short circuit protection at the
&ctory.
If the standard factory built-in aftercooler is used, the
maximum allowable water flow through the aftercooler is
37 gallons per minute on 200 and 250 HP units, 50 gallons
per minute on 300 HP units and the maximum water inlet
pressure is 150 PSIG. If another aftercooler is used, consult
the manufacturer for operating limits. MOTOR LUBRICATION —Long time satisfactory opera-
tion of an electric motor depends in large measure on the
bearings and timely lubrication. The following charts show
recommended grease qualities and regressing intervals for
motor supplied with ball bearings. For additional informa-
tion refer to the motor manufacturers instructions.
~CAiJTlON
&\ When an afiercooler is piped in series with the oil
COO1O,the maximum allowable water jlow rate through
the oil/a$ercooler system is the maximum allowed
@the afi%rcooler. If the oil cooler requires more water
flow than the muximum allowed ly the afler-
cooler, aparallel water piping system must be used.
The following procedure should be used in regressing:
1.
2.
3.
4.
5.
6.
7.
Stop the unit.
Disconnect the unit from the power supply.
Remove the relief plug and free the hole of hardened
grease.
Wipe the lubrication fitting clean and add grease with
ahand-operated grease gun.
Leave the relief plug temporarily off. Reconnect the
unit and run for about 20 minutes to expeli the excess
The water control valve MUST be used to maintain dis-
charge temperatures approximately 10 F“ over the dew
point for expected ambient (Figure 8-5). See Section 5for
adjustment instructions and maximum allowable oil tem-
perature. grease.
Stop the unit. Replace
Restart the unit.
ELECTRICAL WIRING —The Electra-Saver” unit is fur-
nished with the compressor motor enclosure as specified by
the user. If unit has an air-cooled oil cooler, this fan motor
is atotally enclosed “air-over” or “fan-cooled type” and is
complete with starter and enclosure as specified by the user.
Allow 42 deep by 30 wide clear space to nearest
obstruction over control enclosure in accordance with
Article 11 O-16(a) National Electrical Code.
the relief plug.
GREASE RECOMMENDATIONS
High
Temper-
ature
220-240
475-525
It is necessaw to connect the compressor unit (and oil
cooler, if used) to amain starter of the cprrect size, power
characteristics and enclosure for the application. See
Section 4for typical wiring diagrams; however, use only
the wiring diagrams supplied with the unit for final con-
nections.
Standard
Service
265-296
400-550
Worked Penetration ...........
Oil Viscosity, SSU Atl 00° F. . . . .
Sterter —The main starter is to be mounted at alocation
selected by the user at the time of installation. The first three
feet of line from the motor conduit box to the starter must
be of flexible conduit to maintain effective vibration
isolation. Electrical connections to other parts of the unit
(instrument panel, fan motor, etc.) from the starter do not
require flexible conduit since the compressor and motor are
already isolated from these parts. See Table 11O-16(a)
National Electrical Code for correct working clearance.
Lithium
Soap Type ..................... Lithium
N-H Bomb, Minimum Hours
For 20 PSI Drop At 210° F. . . 750 1000
Bleeding, Maximum Weight %
ln500Hours212° F......... 10 3
Yes
Rust Inhibiting ................ Yes
REGRESSING INTERVAL
Type of Service Typical Examples Rating Relubrication Interval
Standard One- Or Two-Shift Operation Over 150 HP 12 Months
Severe Continuous Operation Over 150 HP 6Months
Very Severe Dirty Locations, High Ambient Temperature Over 150 HP 2Months
13-10-603 Section 2Page 6

SECTION 3
STARTING &OPERATING PROCEDURES
Anew unit as received from the factory has been prepared
for shipping only. Do not attempt to operate the unit until
checked and serviced as follows:
1. Compressor Oil —Check the oil level in the oil
reservoir. Add oil only if the oil level gauge reads in
the red ADD OIL range. Do not mix different types of
oils. The unit is shipped filled with GM specification
“Dexron 11” automatic transmission fluid which is
suitable for the first 2000 hours under normal operat-
ing conditions. REPLACE OIL FILTER ELEMENT
EVERY 1000 HOURS.
Initial fill, or filling after acomplete draining of the
system, may show the oil level beyond the red EX-
CESS oil range. After start-up, oil will fall into the
operating range as system components are filled. If
necessary, add oil to bring level into the center of the
RUN range when unit is operating on load; see Figure
4-5 for quantity of oil required.
ADANGER
ALWAYS STOP THE UNIT AND RELEASE AIR
2.
3.
4.
5.
6.
PRESSURE BEFORE REMOVING OIL FILLER
PLUG TO ADD OIL.
During unloaded operating and after shutdown, the
system will partially drain back into the oil reservoir
and oil level will read higher than when operating on
load. DO NOT DRAIN OIL TO CORRECT on the
next loaded cycle or start, oil will again fill the system
and the gauge will indicate the operating level.
Air Filter —Inspect the air filter to be sure it is clean
and tightly assembled. Refer to Section 6“Air Filter”
for complete servicing instructions. Be sure inlet line,
if used, is tight and clean.
Piping —Refer to Section 2“installation” and make
sure the piping meets all requirements.
Moisture Separator Trap —The trap is constructed
of cast iron with side inlet and outlet connections and
inverted bucket design. Astainiess steel internai
strainer is used in trap; it should be checked period-
ically for clogging and replaced if necessary. Repair
parts are available for trap cap, retainer gasket
and strainer. See package outiines for mounting
dimensions of moisture separator trap.
The moisture trap must be primed by filling with
clean water prior to initial start-up of unit.
Electrical —Check the unit and user-installed wiring
with the wiring diagrams furnished to be sure it is
properly wired. See Section 4“Controls and instru-
ments” for general wiring diagrams and Section 2
for installation instructions.
Rotation -Check the motor rotation by momentarily
7.
8.
9.
starting the motor. Compressor drive shaft rotation is
counterclockwise standing at the motor end.
Operating Light Test –Observe the operating lights
on the ON-OFF switch when jogging the motor in
Step 5. Be sure all lamps are operative.
System Pressure —Set the turn-valve pilot, inlet
piiot and operating air pressure switch to the desired
unload pressure and differential. DO NOT EXCEED
MAXIMUM OPERATiNG PRESSURE ON THE
COMPRESSOR NAMEPLATE EXCEPT AS SPEC-
IFIED UNDER “CONTROL ADJUSTMENTS” SEC-
TION 4.
Operating Mode —Refer to Section 4for detaiied
information on the control systems.
START;NG THE UNiT –The Constant Speed with Low
Demand Mode Unit requires only pressing of the OFF/
RESET and then the ON push button.
The Automatic Start/Timed Stop with Low Demand Mode
Units require selecting the desired mode of operation (see
Section 4) and then pressing first the RESET and then the
ON push button.
~WARNING
~Unit mat not be started with pressure in oil reservoir –
dticharge pressure gauge on panel mmt read zero PSI or
darnuge to motor muy result.
OBSERVE UNiT COLD OR UNiT HOT STARTING
PROCEDURES.
Unit Coid —Close the air service valve (furnished by cus-
tomer) between the main air system and the unit check
valve. if the unit is awater-cooled heat exchanger model,
open any manual water inlet wide open. Start the unit and
run for one minute. Open the air service valve. Since the
unit is equipped with aminimum (65 PSiG) pressure dis-
charge valve, no speciai procedure to maintain unit
reservoir pressure is required.
Unit Hot –No warm-up period is required. Close the air
service valve (furnished by customer). if the unit is awater-
cooled hea) exchanger modei, open any manual water iniet
vaives wide open. Start the unit. Open the air sewice valve.
DAILY CHECK –Refer to Section 8“Maintenance
Schedule”.
STOPPING THE UNiT’ –Close the air service valve (fur-
nished by customer), allow the unit to build up to fuil
unloaded pressure and press the OFF push button.
Stopping the unit at apressure below full receiver may
cause oil carry-over. The oil reservoir wiii automatically
blow down as the motor stops. if the unit is awater-cooled
heat exchanger type, close any manual water inlet valves.
Open the air sewice vaive.
13-10-603 Section 3Page 1

SECTION 4
CONTROLS &INSTRUMENTS
GENERAL —The Gardner-Denver” Electra-Saver” compres- start-stop push button, hourmeter, pressure switch, high
sor units are available with two different control systems: discharge temperature shutdown switch, and other elec-
trical control devices is 115 volts regardless of power supply
Constant Speed With Low Demand Mode voltage. On standard units, the transformer in the control
enclosure is connected to change the specified user’s power
Automatic Start/Timed Stop With Low Demand Mode supply voltage to 115 volt control voltage.
The standard Electra-Saver unit consists of the compressor,
oil reservoir and cooler, air and oil filters, the control system
specified, an open drip-proof motor, and adust resistant
control enclosure/instrument panel all mounted on asteel
base. The compressor is isolated in an acoustic enclosure.
The unit is factory wired for the voltage specified; electrical
connection to amain starter, connection to the shop air
line, shop water line or oil lines to air-cooled oil cooler are
to be made by the user.
CONTROL VOLTAGE —The control voltage for the
RESET —The Reset Button must be pushed whenever
power is interrupted or turned off. For circuit interruption,
see paragraph below relating to the specific safety device.
ACAUTION
DO NOT CONTINUE TO RESET THE MANUAL
RESET IF THE SAME MALFUNCTION OCCURS
WITHIN ASHORT PERIOD OF TIME. FIND AND
CORRECT THE TROUBLE BEFORE RESUMING
OPERA TION.
13-10-603 Section 4Page 1

Start-Stop/Reset Switch –Later model Constant Speed
units with Low Demand switch that use the two-probe high
discharge temperature switch have atwo-button Start-
Stop/Reset switch in the control box door. The indicating
pilot light is separately mounted adjacent to the switch.
On-Off-Reset Switch –Later model Automatic Start/
Timed Stop units with Low Demand switch that use the
two-probe high discharge temperature switch have athree-
button On-Off-Reset switch in the control box door. The
indicating pilot light is separately mounted adjacent to
the switch.
Pilot Light —Later model units with either Constant Speed
or Automatic Start/Timed Stop control system and the
two-probe high discharge temperature switch have an
indicating pilot light mounted in the control box door. The
amber lighted ON indicates compressor running under
Constant Speed Control. Under Automatic Start/Timed
Stop, the compressor may be stopped with the amber light
ON indicating power on. The blue lighted LOAD indicates
compressor is loaded.
To replace the bulbs in the pilot light (replacement bulb
number is Sylvania 120 PSB or equal):
1. Turn power off at main breaker panel.
2. Open control panel.
3. Turn slotted locking screw on upper side of pilot
light body counterclockwise 1/4 turn and remove the
body from the lens holder.
4. Remove old bulb located in the body and insert the
new bulb.
5. Reassemble body to lens holder and secure by turn-
ing locking screw 1/4 turn clockwise.
ON-OFF SWITCH (Figure 2-1) –Early model Constant
Speed units with Low Demand Mode switch and the units
with Automatic Start/Timed Stop with Low Demand Mode
have an ON-OFF push button with an amber lighted section
to indicate ON (compressor running) and agreen lighted
section to indicate LOAD (compressor loaded). The red bar
on the bottom of the ON-OFF switch is the OFF and RESET
on the Constant Speed unit with Low Demand Mode. The
black bar on the bottom of the Automatic Startflimed Stop
ON-OFF switch is the RESET.
To replace the bulb (Sylvania 120 PSB or equal) in any of the
switches:
1.
2.
3.
4.
5.
Turn the power off at the main breaker panel.
Open the control panel.
Turn the slotted locking screw on the upper side of
the switch body counterclockwise 1/4 turn and re-
move the switch body from the switch operator.
Remove the old bulb located in the stem of the switch
body and insert the new bulb.
Reassemble the switch body to the operator and lock
in place by turning the locking screw 1/4 turn clock-
wise.
LOW DEMAND MODE SWITCH (Figure 2-1) –The low
demand mode switch, when turned to the ON position, will
blow the reservoir down when the compressor unloads.
When switch is turned to OFF, unit will retain pressure in
reservoir when unloaded.
~WARNING
=The low demand mode switch CANNOT be used with
remote ele-oated oil coolers. These units require special
wiring diagrams —check with factory.
SAFETY DEVICES –Both control systems incorporate
these safety devices
Motor Protection Devices —Overload heaters are furnish-
ed for the air-cooled oil cooler fan motor starter in the
voltage range specified. There are three (3) overloads of
proper size for the starter and its enclosure, When replacing
or changing overloads, be sure to select them from a3-
overload heater table, since the use of athird overload
derates each overload for agiven enclosure due to the extra
heat. An overload from a2-overload heater table would be
undersize.
The overload heaters are in acommon overload block in the
starter and have asingle common percentage adjustment
knob with a 90 to 11O% range. The knob is set at the factory
on the 100% mark.
Main unit starter should be adequately fused and provided
with overload heaters suitable for the application to provide
protection for the unit drive motor.
High Discharge Temperature Switch —Later Models
—Later models of the compressor unit are protected from
high discharge temperature by atwo-probe adjustable
switch. One probe is located in the discharge pipe between
the compressor and the oil reservoir to sense compressor
discharge air/oil mixture temperature. The second probe
is located in the final discharge manifold and senses the
temperature of the air at the oil separators. The switch is
located inside the control box (Figure 2-1 ); the shutdown
temperature is set on the adjustable dial. If the temper-
ature of the air at either of the probes exceeds the tem-
perature set on the dial, the switch will stop the unit. Press
reset button of the Start/Stop (On-Off) switch, then the Start
(On) button to restart the unit.
ACAUTION
This a#ustable switch dial must not be set higher
than 225° F.
Do not continue to reset the circuit t~ the same mal-
jlsnction occurs within ashort period of time. Find
and correct the trouble before resuming operation.
In addition to protecting the unit from damage or failure
resulting from high air temperature, the
corporate four (4) indicator lights which
of high temperature andlor the condition
ture probes. This information is shown on
the control box and in Figure 2-4.
The High Air Temperature Switch may be
switch also in-
show the point
of the tempera-
te decal inside
checked period-
ically to assure proper operation. To check with the unit
running, turn the dial on the switch to the temperature in-
dicated by the discharge temperature gauge. Unit should
13-10-603 Section 4Page 2

HIGH DISCHARGE TEMPERATURE SWITCH CONDITION CHART
“A” indicates Temperature Condition at Compressor Discharge.
“B’ indicates Temperature Condition at Oil Separator.
“C indicates Probe Condition.
o
POWER
“~ o
“c’ o0
\
“p~
CONDITION POWER ON “A “B’ “c
POWER OFF OFF OFF OFF OFF
NORMAL TEMPERATURE RED RED RED OFF
COMPRESSOR HIGH TEMPERATURE RED OFF RED OFF
SEPARATOR HIGH TEMPERATURE RED RED OFF OFF
COMPRESSOR PROBE OPEN RED OFF RED GREEN
SEPARATOR PROBE OPEN RED RED OFF GREEN
COMPRESSOR PROBE SHORTED RED OFF RED RED
SEPARATOR PROBE SHORTED RED RED OFF RED
COMPRESSOR PROBE SHORTED/
SE~ARATOR PROBE OPEN RED OFF OFF ORANGE
COMPRESSOR PROBE OPEN/
SEPARATOR PROBE SHORTED RED OFF OFF ORANGE
FIGURE
shutdown. If it does not, check the temperature gauge
accuracy and indicator lights —refer to the condition decal
on the control box door for the malfunction. After opera-
tional check, always reset switch dial to the proper setting
(225° F.).
High Air Temperature Shutdown —Early hilodela —
Early Models of the compressor were protected from high
discharge temperature by atemperature switch, with a
single probe located in the discharge pipe between the
compressor discharge and the oil reservoir. This switch is
wired into the motor control circuit and will shut the unit
down if the discharge temperature exceeds 225” F. The
reset button must be pressed any time unit is shut down
due to high air discharge temperature.
ACAUTION
This a@sstable switch MUST NOT be set higher than
225” F.
DO NOT CONTINUE TO RESET THE CIRCUIT IF
THE SAME MALFUNCTION OCCURS WITHIN A
SHORT PERIOD OF TIME. FIND AND CORRECT
THE TROUBLE BEFORE RESUMING OPERA TION.
This switch should be checked periodically to assure proper
2-4.
operation. To check with unit running, reset switch io the
discharge temperature indicated by the discharge temper-
ature gauge. Unit should shut down —if not, switch is
inoperative and should be replaced. Always reset switch to
proper setting after check (225° F.)
Automatic Blowdown Valve —Apilot operated valve
piped into the oil reservoir final discharge manifold ahead
of the check valve and connected to the unloader solenoid
valve which is wired into the motor control circuit, will
release pressure from the oil reservoir each time the unit is
unloaded with low demand mode switch ON or when unit
is shut down. The blowdown line is equipped with amuffler
to reduce air discharge noise.
Safety Valve (Figures 2-1 &3-1) —Apressure relief valve is
installed in the final discharge manifold and set at the
factory to approximately 120% of the specified operating
pressure for protection against overpressure. Periodic
checks should be made to insure its proper operation.
Never operate the unit without aproper safety valve setting.
Low Demand Mode Pressure switch (Figure 1-4) –The
low demand mode switch when turned ON will cause the
low demand mode pressure switch to de-energize the low
demand mode solenoid valve when the discharge pressure
reaches the set point. This switch should be set approx-
13-10-603 Section 4Page 3

imately 5PSI above full load pressure with an 8-12 PSI
differential.
Low Demand Mode Unloader Solenoid (Figure 1-4) –
The low demand mode solenoid valve when energized
supplies an air signal to close blowdown valve. When de-
energized, it supplies an air signal to close compressor inlet
valve and exhausts air to open blowdown valve.
Pressure Regulator (Figure 1-4) –The pressure regulator
must be set 15-20 PSIG to prevent inlet valve “slam”.
Resemoir Pressure Switch (Figure 1-4) —Apressure
switch is connected to the discharge manifold and wired
to the motor control circuit to prevent attempted starting
of the unit when there is more than 5PSIG pressure in the
oil resewoir. This protects the unit from starting against
load when the oil reservoir has not had enough time to
blow down. Blowdown time is usually about 45 seconds.
~WARNING
l~\ DO not set the switch higher than 5PSIG or render the
switch inoperative; severe damage to the motor can
occur t~ started with pressure in the oil reserooir.
Low Oil Pressure Shutdown (Figure 1-4) –Units are pro-
vided with apressure switch piped to the compressor oil
sump and wired into the motor control circuit to protect
the unit against operation at too low an oil pressure and
against complete lubrication failure due to an oil line re-
striction or sudden loss of oil pressure. The pressure switch
is set 10-15 PSIG and will stop the unit if the oil pressure
falls below this pressure any time during operation, and will
prevent the unit being started if the oil pressure does not
rise to 10-15 PSIG within 10 seconds of starting.
The pressure switch is set at 10-15 PSIG at the factory. If
resetting is necessary
1.
2.
Adjust the upper limit pressure to 15 PSIG by turning
the slotted screw (pressure) near the top of the switch.
Clockwise movement of the screw raises the pressure;
counterclockwise lowers the pressure. Note approx-
imate pressure setting is indicated on the range scale
on left face of switch.
Adjust the lower limit pressure to 10 PSIG by turning
the slotted screw (differential) near the bottom of the
switch until the cam-shaped calibrated dial under the
pressure setting screw indicates about 1/4 of full scale
reading from lowest setting. Clockwise movement of
the screw reduces the differential; counterclockwise
increases differential. Note differential range (1-1 8
PSI) is indicated by marks on the cam-shaped dial.
If aunit with Constant Speed with Low Demand Mode
Switch shuts down from low oil pressure, pressing the ON
button will restart the unit. Since the Automatic Startflmed
Stop control is an automatic starting type, areset relay is
used as a positive means to interrupt the circuit on either
alow oil pressure shutdown or high discharge air temperature
shutdown; to restart these units, press the black bar marked
RESET and then press the ON button.
~CAIJTION
~DO not continue to restart the unit if the same mal-
fisnctwn occurs within ashort pm”od of time. Find and
correct the trouble before resuming operation.
This switch should be checked periodically to assure proper
operation. To check, disconnect the timed-opening instan-
taneous-closing time delay relay from the system at point 10
(see wiring diagram). Try to start unit –unit should not run
—if it does, switch is inoperative and should be replaced.
Be sure to reconnect the time delay after checking.
M/i NuAL OPERATOR TAB 1~N.C. TIMING CONTACT
MOVEABLE iNSTAN-
TANEOUS CONTACT
cARR IER -00 NOT
USE AS A MANUAL
OPERATOR
TIME SETTING ADJUSTING SCREW JA75852
FIGURE 3-4. –LOW OIL PRESSURE
TIME DELAY SWITCH
Low Oil Pressure Time Delay Switch (Figures 1-4 &3-4)
located in the control panel enclosure, is wired into the
control circuit to provide the 10-second delay required for
the compressor oil pressure to rise to 10-15 PSIG and
energize the low oil pressure switch circuit.
To check the time delay switch setting:
1.
2.
3.
4.
Pull main breaker switch.
Move black timer tab located on the left half of relay
block to the ON position and hold. Timer will begin
to run for set time.
Observe the action of the right hand set of contacts
on the right half of the relay block the contacts will
open when the preset time runs out.
Adjustment of time delay setting is made by turning
screw on lower right face of relay block to afaster (F)
or slower (S) setting. Recheck setting of relay as in No.
2and 3above each time screw is turned.
~WARNING
=Timer is $ictoy set at 10 seconds. NEVER ATTEMPT
TO ADJUST THE TIMING RELAY FOR MORE
T~N 15 SECONDS DELAY —serious compressor
damage may result ji-om operation without lubrication
@r even ashort period.
~CAU1’10N
&NEVER DISCONNECT SAFETY DEVICES THAT
PROTECT THE UNIT.
INSTRUMENTS &GAUGES (Figures 3-1 &1-4) -Both
control system instrument panels incorporate the following:
Hourmeter —Acontinuous reading (nonreset) type hour-
meter displays the accumulated operating time of the unit
and provides aconvenient means for scheduling changes of
oil supply and servicing of filters, separators and other
devices.
13-10-603 Section 4Page 4