Gardner Denver ELECTRA-SAVER EAYQ E Service manual

GARDNER DENVER
ELECTRA–SAVER
STATIONARY BASE–MOUNTED
COMPRESSOR
WITH OPTIONAL ES+ CONTROLLER
MODELS
EAYQ_E
EAYS_E
OPERATING AND
SERVICE MANUAL
13–10–613 SP
2nd Edition
December, 1995

13–10–613 SP Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner Denver Compressor genuine parts, engine-
ered to original tolerances, are designed for optimum
dependability–––specificallyforGardnerDenvercom-
pressor systems. Design and material innovations are
theresultofyearsofexperiencewithhundredsofdiffer-
ent compressor applications. Reliability in materials
and quality assurance are incorporated in our genuine
replacement parts.
Your authorized Gardner Denver Compressor distribu-
tor offers all the backup you’ll need. A worldwide net-
workofauthorizeddistributorsprovidesthefinestprod-
uct support in the air compressor industry.Your local
authorized distributor maintains a large inventory of
genuinepartsandheisbackedup foremergencyparts
by direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
Denver air compressor with these services:
1. Trained parts specialists to assist you in selecting
the correct replacement parts.
2. Factory warranted new and remanufactured
rotaryscrewair ends.Most popularmodelreman-
ufacturedairendsaremaintainedinstockatMDC
for purchase on an exchange basis with liberal
core credit available for the replacement unit.
3. AfulllineoffactorytestedAEONtcompressorlu-
bricantsspecifically formulatedfor use inGardner
Denver compressors.
4. Repair and maintenance kits designed with the
necessary parts to simplify servicing your com-
pressor.
Authorized distributor service technicians are factory–
trained and skilled in compressor maintenance and re-
pair. They are ready to respond and assist you by pro-
viding fast, expert maintenance and repair services.
For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow
pages of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: [phone]
Phone: [phone] Fax: [phone]
(800) 245–4946
Fax: [phone] REMANUFACTURED AIR ENDS
Whenever an air end requires replacement or repair,
Gardner Denver offers an industry unique, factory re-
manufactured air end exchange program. From its
modern Remanufacturing Center in Indianapolis, IN,
GardnerDenver iscommittedto supplyingyou withthe
highest quality, factory remanufactured air ends that
are guaranteed to save you time, aggravation and
money.
Immediately Available
Repair downtime costs you money, which is why there
are over 200 remanufactured units in inventory at all
times, ready for immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average
over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, in-
spected and analyzed. Only those parts that can be
brought back to original factory specifications are re-
manufactured. Everyremanufactured airend receives
anewoverhaulkit: bearings,gears,seals,sleevesand
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
justdon’t do. Magnafluxand ultrasonicinspectionspot
cracked or stressed castings, monochromatic light
analysis exposes oil leaks, and coordinate measure-
ment machine inspects to +/– .0001”, insuring that all
remanufactured air ends meet factory performance
specifications.
Warranty
Gardner Denver backs up every remanufactured air
end with a new warranty . . . 18 months from purchase,
12 months from service.
GardnerDenverremanufacturedairendsdeliver
quali-
ty without question . . . year in and year out.
Call Gardner Denver for information on the air end ex-
change program and the name of your authorized dis-
tributor. Phone Number: 800–245–4946 or
FAX: [phone]

13–10–613 SP Page ii
FOREWORD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To
beassuredofreceivingmaximumservicefromthismachinetheownermustexercisecareinitsoperationandmain-
tenance.Thisbookiswrittentogivetheoperatorandmaintenancedepartmentessentialinformationforday–to–day
operation,maintenanceand adjustment.Careful adherenceto theseinstructionswill resultin economicaloperation
and minimum downtime.
Danger is used toindicate the presenceof a hazardwhich will causesevere personal
injury, death, or substantial property damage if the warning is ignored.
Warning isusedto indicatethepresence ofahazard whichcancause severeperson-
al injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
Notice is used tonotify people of installation,operation or maintenanceinformation
which is important but not hazard–related.
This book covers the following models:
HP PSIG Air Cooled Water Cooled Parts List
350 100, 125, 150 EAYQSE EAYSSE 13–10–510 SP
400 100, 125, 150 EAYQTE EAYSTE 13–10–510 SP
500 100, 125, 150 EAYQVE EAYSVE 13–10–510 SP

13–10–613 SP Page iii
TABLE OF CONTENTS
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations ix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1, General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2, Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3, Starting & Operating Procedures 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4, Controls & Instrumentation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6, Air Filter 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7, Coupling 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8, Maintenance Schedule 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9, Trouble Shooting 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 10, Trouble Shooting Controls 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER(see nameplateonunit). The SerialNumber
isalso stampedon topof thecylinder flangeto theright
of the inlet housing.
All orders for Parts should be placed with the nearest
authorized distributor.
Where NOT specified, quantity of parts required per
compressor or unit is one (1); where more than one is
required per unit, quantity is indicated in parenthesis.
SPECIFY EXACTLY THE NUMBER OF PARTS
REQUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left Hand side of a
compressor, stand at the motor end and look toward
the compressor. Right Hand and Left Hand are
indicated in parenthesis following the part name, i.e.
(RH) & (LH), when appropriate.

INDEX
13–10–613 SP Page iv
Actuator, Turn Valve 33. . . . . . . . . . . . . . . . . . . . . . .
Addition of Oil Between Changes 42. . . . . . . . . . . .
Adjustments
Configuration 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Setup 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advisories, Service 20. . . . . . . . . . . . . . . . . . . . . . . .
Aftercooler 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER, SECTION 6 51. . . . . . . . . . . . . . . . . . .
Air Filter 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element Life 51, 52. . . . . . . . . . . . . . . . . .
Air Filter Vacuum Switch 34. . . . . . . . . . . . . . . . . . .
Air Filter, Dust Cap 52. . . . . . . . . . . . . . . . . . . . . . . .
Air Filter, Heavy–Duty – 350 & 400 HP Units 51. .
Air Flow in the Compressor System 1. . . . . . . . . . .
Air Receiver, Auxiliary 11. . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Oil Cooler Module 9. . . . . . . . . . . . . . . .
Amp Sensor Failure 21. . . . . . . . . . . . . . . . . . . . . . .
Auto Sentry–ES Controller
Programming and Setup 21. . . . . . . . . . . . . . . .
Serial Communications 30. . . . . . . . . . . . . . . . . .
Auto Sentry–ES Operation 18. . . . . . . . . . . . . . . . .
Automatic Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode 18. . . . . . . . . . . . . . . . . . . .
Low Demand Mode 19. . . . . . . . . . . . . . . . . . . . .
Sequence Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Auto Sentry–ES+ Control Display 20. . . . . . . . . . .
Automatic Mode Operation 19. . . . . . . . . . . . . . . . .
Automatic Rotation 29. . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . .
Change Procedure, Lubricant 41. . . . . . . . . . . . . . .
Check, Daily 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Draining Oil System 43. . . . . . . . . . .
Cold Ambient Operation 42. . . . . . . . . . . . . . . . . . . .
Cold Weather Operation 12. . . . . . . . . . . . . . . . . . .
Cold Weather Operation, Installation for 12. . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Capacity Control – Turn Valve
Units Only 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Cooler 45. . . . . . . . . . . . . . . . . . . . .
Compressor Oil Filter 44. . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Separator 48. . . . . . . . . . . . . . . . . .
Compressor Oil System 40. . . . . . . . . . . . . . . . . . . .
Compressor Oil System Check 50. . . . . . . . . . . . . .
Configuration Adjustments 24. . . . . . . . . . . . . . . . . .
Connection Failure 21. . . . . . . . . . . . . . . . . . . . . . . .
Connection to Extermal Controls 29. . . . . . . . . . . .
Alarm Relay 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote 0n/Off 29. . . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode Operation 18. . . . . . . . . . . . . .
Control Devices, Other 31. . . . . . . . . . . . . . . . . . . . .
Control Features, Other
Auto Restart After Power Failure 26. . . . . . . . .
Current Limiting 26. . . . . . . . . . . . . . . . . . . . . . . .
Modulating – Load/Unload 26. . . . . . . . . . . . . . .
Control Schematics 35. . . . . . . . . . . . . . . . . . . . . . . .
Control Transformer 34. . . . . . . . . . . . . . . . . . . . . . .
CONTROLS & INSTRUMENTS, SECTION 4 18.
Controls & Instruments, General Description 18. .
Cooler, Compressor Oil 45. . . . . . . . . . . . . . . . . . . .
Cooling, Sealing and Lubrication 1. . . . . . . . . . . . .
COUPLING, SECTION 7 53. . . . . . . . . . . . . . . . . . .
Coupling 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Check 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 6–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagrams, Wiring 35. . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 13. . . . . . . . . . . . . . . . . . . .
Discharge Thermistor 34. . . . . . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 9. . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning Oil System 43. . . . . . . . . . .
Dust Cap 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–10–613 SP Page v
Electric Motor Grease Recommendations 15. . . .
Electric Motor Regreasing Interval 15. . . . . . . . . . .
Electrical Wiring 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Units 14. . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Air Filter 51, 52. . . . . . . . . . . . . . . . .
Emergency Stop Push–Button 34. . . . . . . . . . . . . .
Emergency Stop Shutdown 21. . . . . . . . . . . . . . . . .
Enclosure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ES+ Sequence System Operation 28. . . . . . . . . . .
External Device Shutdown 21. . . . . . . . . . . . . . . . . .
Fan Starter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Oil Reservoir 44. . . . . . . . . . . . . . . . . . . . . . . .
Filter, Compressor Oil 44. . . . . . . . . . . . . . . . . . . . . .
Filter Element 51, 52. . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Air (Standard) 51. . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foundation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Oil Level 31, 42. . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . .
Grease Recommendations, Electric Motor 15. . . .
Grounding 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Shutdown 21. . . . . . . . . . . . . . . . . . .
High Temperature Operation 41. . . . . . . . . . . . . . . .
High Temperature Shutdown 20. . . . . . . . . . . . . . . .
Inlet Line 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 52. . . . . . . . . . . . . . . . . . . . .
Inlet Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION, SECTION 2 8. . . . . . . . . . . . . . . .
Installation, General 8. . . . . . . . . . . . . . . . . . . . . . . .
Installation for Cold Weather Operation 12. . . . . .
Lifting Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 13. . . . . . . . . . . . . . . . . . . .
Line, Inlet 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Demand Mode Operation 19. . . . . . . . . . . . . .
Low Oil Pressure Shutdown 21. . . . . . . . . . . . . . . .
Lubricant, Recommended 40. . . . . . . . . . . . . . . . . .
Lubricant Change Procedure 41. . . . . . . . . . . . . . .
Lubrication, Cooling and Sealing 1. . . . . . . . . . . . .
Lubrication, Motor 15. . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 40. . . . . . . . . . . . . .
Main Adjustments Menu, Controller 21. . . . . . . . . .
Main Starter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Adjustments 23. . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE, SECTION 8 54. . .
Minimum Discharge Pressure Valve 31. . . . . . . . .
Moisture in the Oil System 42. . . . . . . . . . . . . . . . . .
Moisture Separator/Trap 12. . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 15. . . . . . . . . . .
Motor Lubrication 15. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Protective Devices 20. . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 15. . . . . . . . . . . . . . . . . .
Oil Change Interval 43. . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Compressor 45. . . . . . . . . . . . . . . . . . . .
Oil Filter, Compressor 44. . . . . . . . . . . . . . . . . . . . . .
Oil Level Gauge 31, 42. . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 9. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator
Compressor 48. . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Carryover 48. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal for Inspection or Replacement 49. . .
Oil Specifications 40. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System
Compressor 40. . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning 43. . . . . . . . . . . . . . . . . .
Oil System Check 50. . . . . . . . . . . . . . . . . . . . . . . . .
Air and Oil Discharge Temperature 50. . . . . . .
Oil Cooler Oil Pressure Differential 50. . . . . . . .
Oil Cooler Temperature Differential 50. . . . . . .

INDEX
13–10–613 SP Page vi
Oil Cooler Water Pressure Differential 50. . . . .
Oil Inlet Pressure 50. . . . . . . . . . . . . . . . . . . . . . .
Operation
Automatic Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Cold Ambient 42. . . . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode 18. . . . . . . . . . . . . . . . . . . .
High Temperature 41. . . . . . . . . . . . . . . . . . . . . .
Low Demand Mode 19. . . . . . . . . . . . . . . . . . . . .
Sequence Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Operation Adjustments 23. . . . . . . . . . . . . . . . . . . . .
Optional Switches 34. . . . . . . . . . . . . . . . . . . . . . . . .
Other Sequencing Features 29. . . . . . . . . . . . . . . .
Power Failure 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Differential Gauging 49. . . . . . . . . . . . . . .
Pressure Regulator 33. . . . . . . . . . . . . . . . . . . . . . . .
Prestart–Up Instructions 16. . . . . . . . . . . . . . . . . . . .
Air Filter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode 17. . . . . . . . . . . . . . . . . . . . . . . .
Piping 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 17. . . . . . . . . . . . . . . . . . . . . . .
Programming and Setup, Auto Sentry–ES+
Controller 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Controller, Main Adjustments
Menu 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Shutdowns 20. . . . . . . . . . . . . . . . . . . . . .
Purge Valve 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Lubricant 40. . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 15. . . . . . . . . .
Regulator, Pressure 33. . . . . . . . . . . . . . . . . . . . . . .
Relief Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Ordering Instructions iii. . . . . . . . . . .
Reservoir, Oil 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reservoir Pressure Transducer 34. . . . . . . . . . . . .
Safety Precautions 4–5. . . . . . . . . . . . . . . . . . . . . . .
Schematics, Control 35. . . . . . . . . . . . . . . . . . . . . . .
Sealing, Lubrication and Cleaning 1. . . . . . . . . . . .
Separator, Compressor Oil 48. . . . . . . . . . . . . . . . .
Separator Differential Pressure Shutdown 21. . . .
Separator/Trap, Moisture 12. . . . . . . . . . . . . . . . . . .
Sequence Adjustments 24. . . . . . . . . . . . . . . . . . . .
Sequence Mode Operation 19. . . . . . . . . . . . . . . . .
Sequenced System Checkout 29. . . . . . . . . . . . . . .
Sequencing Compressors
Compressor System 27. . . . . . . . . . . . . . . . . . . .
Establishing Initial Sequence 28. . . . . . . . . . . . .
General 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequencing Installation 27. . . . . . . . . . . . . . . . .
Sequencing Compressors with Auto
Sentry–ES+ 26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Communications 30. . . . . . . . . . . . . . . . . . . .
Service Advisories 20. . . . . . . . . . . . . . . . . . . . . . . . .
Service Check List 54. . . . . . . . . . . . . . . . . . . . . . . .
Air Filter 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 1000 Hours Operation 54. . . . . . . . . . . . .
Every 125 Hours Operation 54. . . . . . . . . . . . . .
Every 6000 Hours Operation 54. . . . . . . . . . . . .
Every 8 Hours Operation 54. . . . . . . . . . . . . . . .
Every Year 54. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 54. . . . . . . . . . . . . . . . . . . . . . .
Oil Separator 54. . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdowns
Amp Sensor Failure 21. . . . . . . . . . . . . . . . . . . .
Connection Failure 21. . . . . . . . . . . . . . . . . . . . .
Emergency Stop 21. . . . . . . . . . . . . . . . . . . . . . .
External Device 21. . . . . . . . . . . . . . . . . . . . . . . .
High Pressure 21. . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 20. . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure 21. . . . . . . . . . . . . . . . . . . . . . .
Motor Protective Devices 20. . . . . . . . . . . . . . . .
Other 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Failure 21. . . . . . . . . . . . . . . . . . . . . . . . . .
Separator Differential Pressure 21. . . . . . . . . . .

INDEX
13–10–613 SP Page vii
Shuttle Valve 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valves IVC and IVO 32. . . . . . . . . . . . . . .
Solenoid Valves TVC and TVO 33. . . . . . . . . . . . . .
Specifications, Oil 40. . . . . . . . . . . . . . . . . . . . . . . . .
Starter
Fan 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES,
SECTION 3 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Strip, Terminal 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch
Air Filter Vacuum 34. . . . . . . . . . . . . . . . . . . . . . .
Vibration 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switches, Optional 34. . . . . . . . . . . . . . . . . . . . . . . .
System Pressure Transducer 34. . . . . . . . . . . . . . .
System Thermistor 34. . . . . . . . . . . . . . . . . . . . . . . .
Terminal Strip 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor
Discharge 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer
Reservoir Pressure 34. . . . . . . . . . . . . . . . . . . . .
System Pressure 34. . . . . . . . . . . . . . . . . . . . . . .
Transformer, Control 34. . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING, SECTION 9 55. . . . . . . . .
TROUBLE SHOOTING CONTROLS, SECTION
10 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Shooting Controls
Advisory Troubleshooting 59. . . . . . . . . . . . . . . .
Controls Troubleshooting 63. . . . . . . . . . . . . . . .
Display Modes 58. . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Troubleshooting 60. . . . . . . . . . . . . .
Tube, Inlet 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve 1, 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve Actuator – EAQ Units Only 33. . . . . . .
Unit Setup Adjustments 25. . . . . . . . . . . . . . . . . . . .
Valve
Blowdown 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure 31. . . . . . . . . . . .
Purge 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid IVC and IVO 32. . . . . . . . . . . . . . . . . . .
Solenoid TVC and TVO 33. . . . . . . . . . . . . . . . .
Turn 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Switch 34. . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring, Electrical 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 35. . . . . . . . . . . . . . . . . . . . . . . . . .

13–10–613 SP Page viii
LIST OF ILLUSTRATIONS
Figure # Description Page
Figure 1–1 Compression Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 View of Water Cooled Unit with Aftercooler (less enclosure) – Motor Side 2. . . . . . . . . .
Figure 1–3 View of Water Cooled Unit with Aftercooler (less enclosure) – Motor End 2. . . . . . . . . .
Figure 1–4 View of Water Cooled Unit with Aftercooler (less enclosure) – Reservoir End 3. . . . . . .
Figure 1–5 View of Water Cooled Unit with Aftercooler (less enclosure) – Reservoir Side 3. . . . . .
Figure 2–1 Typical Compressor Room 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Air Flow Chart 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–3 Piping Schematic 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–4 Piping Diagram for Aftercooler and Heat Exchanger 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–5 Cold Weather Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–6 Inlet Line Lengths 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–7 Heat Exchanger (Oil Cooler) Approximate Water Flow 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–8 Aftercooler Approximate Water Flow 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–1 Auto Sentry–ES+ Display 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Flow Chart for Set–Up Programming, Auto–Sentry ES+ 22. . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Schematic Tubing Diagram 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Blowdown Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Minimum Discharge Pressure Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Inlet Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Shuttle Valve 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–8 Turn Valve Control 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–9 Turn Valve Actuator 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–10 Control Schematic – Compressor at Full Load 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–11 Control Schematic – Compressor Fully Unloaded – Constant Speed Mode 37. . . . . . . .
Figure 4–12 Control Schematic – Compressor Fully Unload – Low Demand Mode 38. . . . . . . . . . . .
Figure 4–13 Wiring Diagram 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Flow Diagram – Air / Oil Systems 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Oil Systems Capacities (Approximate) U. S. Gallons 42. . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Oil Change Interval 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–4 Compressor Oil Filter 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–5 Oil Flow Diagram – Remote Overhead Mounted Oil Cooler 45. . . . . . . . . . . . . . . . . . . . .
Figure 5–6 Thermostatic Mixing Valve Element 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–7 Water Control Valve 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–8 Dew Point Temperature vs. Ambient Temperature, (100% Relative Humidity) 47. . . . . .
Figure 5–9 Single Element Oil Separator 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–10 Ambient Temperatures 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy Duty Air Filter 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Installation of Coupling Style “A” 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–2 Installation of Coupling Style “B” 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–10–613 SP Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSION CYCLE
COMPRESSOR– TheGardner Denver Electra–Saver
compressor is a 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 a
drivengearmountedonthemainrotorshafttodrivethe
rotors.Bothrotorsaresupportedbetweenlargecapac-
ity anti–friction bearings located outside the compres-
sion 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 to locate each rotor
axially and carry all thrust loads; later models use ta-
pered roller bearings in this location.
COMPRESSION PRINCIPLE (FIGURE 1–1) – Com-
pression is accomplished by the main and secondary
rotors synchronously meshing in a one–piece cylinder.
Themain rotorhas four(4) helical lobes90_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
.Thecompression cyclebeginsas rotorsunmesh
attheinlet port and air is drawn into the cavitybetween
the main rotor lobes and secondary rotor grooves (A).
Whentherotors pass the inlet port cutoff,air is trapped
intheinterlobecavityandflowsaxiallywiththemeshing
rotors (B). As meshing continues, more of the main ro-
tor lobe enters the secondary rotor groove, normal vol-
ume is reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-
ductionandpressureincreasecontinuesuntiltheair/oil
mixture trapped in the interlobe cavity by the rotors
passesthedischargeportandisreleasedtotheoilres-
ervoir(C). Each rotor cavityfollows the same“fill–com-
press–discharge” cycle in rapid succession to produce
a discharge air flow that is continuous, smooth and
shock free.
AIR FLOW (FIGURE 5–1, page 40) – Air enters the air
filterand passes through the inletunloader valve to the
compressor. After compression, the air/oil mixture
passes into the oil reservoir where most of the en-
trained oil is removed by velocity change and impinge-
ment and drops back into the reservoir. The air and re-
maining oil then passes through the oil separator; 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
customerfurnished unit shutoffglobe valve tothe plant
air lines.
LUBRICATION, COOLING AND SEALING – Oil is
forcedbyair pressurefromthe oilreservoirthrough the
oil cooler, thermostatic mixing valve, and oil filter and
discharges into the compressor main oil gallery. A por-
tion of the oil is directed through internal passages to
the bearings, gears and shaft oil seal. The balance of
theoilisinjecteddirectlyintothecompressionchamber
to remove heat of compression, seal internal clear-
ances and lubricate the rotors.
TURN VALVE – The turn valve is a rotary helical valve
locatedonthedischargesideofthe cylindertowardthe
inletend.Thevalveopensandclosesportsinthecylin-
der which communicates with the inlet passage. This
varies the compressor rotor volume to match the de-
mand for air, thus reducing the part–load power re-
quirement.

13–10–613 SP Page 2
FIGURE 1–2 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – MOTOR SIDE
208EAY797
(Ref. Drawing)
FIGURE 1–3 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) – MOTOR END
208EAY797
(Ref. Drawing)

13–10–613 SP Page 3
FIGURE 1–4 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – RESERVOIR END
208EAY797
(Ref. Drawing)
FIGURE 1–5 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) RESERVOIR SIDE
208EAY797
(Ref. Drawing)

13–10–613 SP Page 4
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 past experience, watch out for
safety hazards and be cautious.
Some general safety precautions are given below:
Failure to observe these notices could result in injury to or death of personnel.
DKeep fingers and clothing away from revolving fan, drive coupling, etc.
DDo not use the air discharge from this unit for breathing – not suitable for hu-
man consumption.
DDonot loosenorremove theoil fillerplug, drainplugs, covers,the thermostat-
icmixingvalve orbreakanyconnections,etc., inthecompressorair oroilsys-
tem until the unit is shut down and the air pressure has been relieved.
DElectrical shock can and may be fatal.
DCompressor unit mustbe grounded inaccordance withthe National Electrical
Code. A ground jumper equal to the size of the equipment ground conductor
must be used to connect the compressor motor base to the unit base.
DFan motors must remain grounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.
DOpen main disconnect switch, tag and lockout before working on the control.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.

13–10–613 SP Page 5
Failure to observe these notices could result in damage to equipment.
DStop the unit if any repairs or adjustments on or around the compressor are
required.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.
DAn Excess Flow Valve should be on all compressed air supply hoses ex-
ceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)
DDonot exceed the ratedmaximum pressure values shown on the nameplate.
DDo not operate unit if safety devices are not operating properly. Check peri-
odically. Never bypass safety devices.

13–10–613 SP Page 6
DECALS
206EAQ077 212EAQ077
218EAQ077
211EAQ077 207EAQ077

13–10–613 SP Page 7
DECALS
216EAQ077
217EAQ077
222EAQ077
221EAQ077 208EAQ077

13–10–613 SP Page 8
SECTION 2
INSTALLATION
GENERAL– On receipt of theunit, check for any dam-
agethatmayhavebeenincurredduringtransit. Report
any damage or missing parts as soon as possible.
Do not electric weld on the compres-
sor or base; bearings can be damaged
by passage of current.
LIFTING UNIT:
Lift compressor unit by base only. Do
not use other places such as motor,
compressor or discharge manifold
piping as lifting points.
The eyebolts or lugs provided on the
motor are for lifting the motor only
and should not be used to lift any
additional weight. All eyebolts must
be securely tightened. When lifting
the motor the lifting angle must not
exceed 15 degrees.Failure to observe
this warning may result in damage to
equipment or personal injury.
Compressor, air/oil reservoir, separa-
tion chamber and all piping and tub-
ingmaybe athightemperatureduring
and after operation.
LOCATION – The compressor should be installed in a
clean, well–lighted, well–ventilated area with ample
space all around for maintenance. Select a location
that provides a cool, clean, dry source of air. In some
casesitmaybenecessarytoinstalltheairfilteratsome
distance from the compressor to obtain proper air sup-
ply.
The compressor unit require electric motor cooling air
aswellasairtothecompressorinlet.Properventilation
MUST be provided (FIGURE 2–2); hot air must be ex-
hausted from the compressor operating area. A typical
inlet–outlet air flow arrangement is shown in
FIGURE 2–1.
FIGURE 2–1 – TYPICAL COMPRESSOR ROOM
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.
Do not block the air flow to and from the unit. Allow
3–1/2 feet to the nearest obstruction on the control box
side of the unit and 3 feet on all other sides.
Open Unit With
Aftercooler Aftercooler & Oil
Open and Cooler Module
Compressor Oil Cooler Discharge in
Size Unit Module Same Room
350 HP 12,600 43,000 55,600
400 HP 14,400 43,000 57,400
500 HP 18,000 43,000 61,000
* 80_F Inlet Air
FIGURE 2–2 – AIR FLOW CHART

13–10–613 SP Page 9
FIGURE 2–3 – PIPING SCHEMATIC
PIPING SCHEMATIC OF COOLER
WITH SCREWED CONNECTIONS. PIPING SCHEMATIC OF COOLER
WITH FLANGED CONNECTIONS.
VENTILATION – The unit, whether air– or water–
cooled, requires sufficient air flow, FIGURE 2–2, for
electric motor cooling. Air is drawn into the back and
front of the motor and is discharged out the sides. Do
not block air flow to and from the unit.
FOUNDATION – The Electra–Saverrcompressor re-
quiresno specialfoundationbut shouldbe mountedon
asmooth, solid surface of sufficientstrengthto support
theweightoftheunit.Wheneverpossibleinstalltheunit
near level. Temporary installation may be made at a
maximum 10_angle lengthwise or 30_sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt,ordanger ofshiftingfrom outsidevibrationsor mov-
ing vehicles may require the use of mounting bolts to
the foundation.
OIL RESERVOIR DRAIN – (FIGURE 1–5, page 3)
The oil reservoir drain valve is located near the center
of the oil reservoir just below the separator tower. The
drainvalveis approximately5inches fromthefloor lev-
el.Ifthisheightisnotsufficienttoconvenientlydrainthe
oil, some other methods of providing oil drain are:
1. Elevate the compressor unit on a suitable struc-
ture 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 drain
to a container.
ACOUSTICENCLOSURE – The Electra–Saver unit is
furnishedwithanacousticenclosureoverthecompres-
sor only, as standard equipment. The enclosure re-
ducesthenormaloperatingsoundoftheunitto90DBA
or below in free field conditions.
AIR–COOLED OIL COOLER MODULE – The air–
cooled oil cooler is a separate module and may be
mounted remote to the compressor unit.
Ventilation – The oil cooler requires adequate cooling
airflow. Proper ventilationMUST beprovided, withhot
air exhausted away from the cooler; take care that hot
air is not recirculated form the exhaust to the inlet side
ofthecooler.Coolingairflowdirectionisfromthemotor
side through the grille side of the oil cooler. Do not ob-
structtheairflowtoorfromthecooler.Allowtwo(2)feet
clearance on all sides of the cooler module. See
FIGURE 2–2, page 8, for cooling air flow require-
ments.
LowOil Pressure Protection –The standardfactory–
installedlowoilpressureshutdownswitchinthecontrol
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
coolermodulecanbemountedinanyofseveralremote
locations; close coupled but not joined to the compres-
sor unit; horizontal remote, located on the same level
as the compressor unit, but some distance away; or
overhead remote, located above level of the compres-
sor unit, as on a roof.

13–10–613 SP Page 10
FIGURE 2–4 – PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER
The machine cannot be run blown
down with remote overhead oil cool-
er. These units require special wiring
diagram – check with factory. Run-
ning the machine blown down with an
overhead cooler could result in dam-
age to compressor.
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
BEFORE INSTALLATION. The design information to
be submitted for approval includes:
1. Locationof oil cooler module –inside or outdoors.
2. Range of operating ambient temperatures at the
oil cooler location.
3. Elevation of the oil cooler above the compressor
unit.
4. Pipe type and size(s) to be used to connect the oil
cooler and the compressor unit. Minimum pipe
size is 2–1/2” NPT.
5. Horizontal and vertical lengths of the pipe run. If
morethanonepipesizeisused,listlengthofeach
size and total length.
6. Number and size of elbows, tees, unions, reduc-
ers, and valves to be used in the pipe run.
7. A dimensional sketch of the proposed piping sys-
tem showing location of the compressor unit, oil
cooler, pipe, and fittings illustrating design in-
formationincluded in numbers3 through 6above.
All remote piping should be of adequate size to insure
a minimum pressure loss. Number 4 above lists the
minimum pipe size to be used. Long runs of pipe and
the use of valves and fittings require larger than the
minimumpipe sizesin thesystem to keepthe pressure
losslow. All pipeand fittings usedin a remote oilcooler
system should be galvanized or treated internally to
prevent rust, and all valves are to be of a nonferrous
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 the motor side
through core) and the prevailing winds are in the same
direction. A baffle should be provided on the exhaust
sideofthecoolerforprotectionagainstoccasionalwind
shifts.
When the oil cooler is mounted above the compressor
unit,acheck valveis tobe mountedonthe compressor
unit in the line to the oil cooler; see FIGURE 5–4, page
45. A pneumatic pilot–operated normally–closed valve
is to be mounted at the oil filter inlet on the compressor
unit line from the oil cooler. The check valve permits oil
flow to the oil cooler during operation, but prevents re-
turn oil flow from the cooler when the unit is shut down.
Thepilotvalveisheldopenbyairpressurefromtheunit
oil reservoir during operation and closes under spring
loadwhentheunitisshutdowntopreventreturnoilflow
from the oil cooler.

13–10–613 SP Page 11
FIGURE 2–5 – COLD WEATHER INSTALLATION
An oil filler stand pipe and plug must be located in the
pipingon theoil cooler modulefor easeof filling ofa re-
mote oil cooler, see FIGURE 5–4, page 45.
Oil Cooler – Installation – Inspect unit upon arrival.
In case of damage, report immediately to transporta-
tioncompany.Before installation, check ratingplate on
motorto verifythatpower inputand motorspecification
requirementsmatch available electricpower atpoint of
installation.
1. Set the unit level on a firm, solid foundation. The
larger oil cooler models have lifting holes to facili-
tate unit hoisting.
2. Allow for linear expansion and contraction of pip-
ing in the direction away from the oil cooler. Use
flexibleconnectorsorsuitable expansionjointson
all oil cooler inlet and outlet piping. See
FIGURE 2–3, page 9, for typical schematics.
3. Select properly tensioned and aligned piping sup-
port clamps or hangers and position them to re-
lieve any piping stress at the oil cooler inlet and
outlet ports. Do not support from flexible connec-
tors.
4. Service – For continuous efficiency, oil cooler
cores must be periodically cleaned with either
vacuum or compressed air. If wet cleaning is re-
quired, shield motor and spray on a mild soap
solution and flush with clear water.
AUXILIARY AIR RECEIVER – The unit requires an
auxiliary air receiver unless the piping system is large
andprovidessufficientstorage capacitytopreventrap-
idcycling.Whenused,anairreceivershouldbeofade-
quatesize,providedwithareliefvalveofpropersetting,
a pressure gauge, and a means of draining conden-
sate.
AFTERCOOLER (FIGURE 1–2 and FIGURE 1–5,
pages 2 and 3) – An aftercooler will provide control of
moisture entering the shop air lines while reducing the
normal low discharge temperature of about 180_F at
100PSIG dischargepressureto nearinlet airtempera-
ture, or cooling water temperature.
Air–Cooled Machines – When an aftercooler is fur-
nished on an air–cooled machine, the aftercooler is
installed on the oil cooler module between the fan and
the oil cooler. The moisture separator is furnished by
GardnerDenver but mustbe mounted by thecustomer
between the aftercooler and the auxiliary air receiver
with a condensate drain provided at the bottom. All air
piping from the compressor discharge to aftercooler to
auxiliary air receiver is to be furnished and mounted by
customer. The design of the aftercooler piping
must be approved by the factory before installa-
tion. Design information to be submitted for approval
includes:
1. Location of aftercooler module – inside or out-
doors.
2. Range of operating ambient temperatures at the
aftercooler location.
3. Pipetype andsize(s)to beused toconnect theaf-
tercooler, separator, and compressor unit – mini-
mum pipe size is 5” NPT.
4. Lengthsof thepiperun. Ifmore thanone pipesize
is used, list length of each size and total length.
5. Number and size of elbows, tees, unions, reduc-
ers, and valves to be used in the pipe run.
6. A dimensional sketch of the proposed piping sys-
tem showing location of the compressor unit, af-
tercooler,separatorandauxiliaryairreceiver,pipe
andfittingsillustratingdesigninformationincluded
in numbers 3 through 5 above.