Gardner Denver ELECTRA-SAVER ESMF Service manual

Price $5.00
~=
GARDNER-DENVER@
ELECTRA- SAVE~
STATIONARY
BASE MOUNTED
COMPRESSOR
ESM, &
ESNF,
ESOF
MODELS
100 HP
EAQPM, EAQQM, EAQSM
125 HP
EAQPN, EAQQN, EAQSN
150 HP
EAQPO, EAQQO, EAQSO
L
A
COOPER
INDUSTRIES
13-10-601
2nd Edition
INDUSTRIAL MACHINERY

c1
dGARDNER-DENVER@
COOPER
INDUSTRIES
Awarrantyregistrationcard isprovidedwith eachmachine. The
card must be completed by the purchaser and mailed (card is
preaddressed and postage paid) within ten days after machine
start up in order to validate this warranty.
Gardner-Danver/lndustrial Machinery Division (the “Company”)
warrants to each original retail purchaser (“Purchaser”) of its
products from the Company or its authorized distributors that
such products will “be free from defects in material and workman-
ship caused by Company and shall be warranted as follows:
BASIC COMPRESSOR AIR ENDS
Basic compressor air ends, consisting of all parts within and
including the compressor cylinder and gear housing, are war-
ranted for 24 months from date of inital use or 27 months from
date of shipment to the first purchaser, whichever occurs’ first.
The Company will furnish, at Its option air end repairs, are-
manufactured replacement air end, or anew replacement air
end, FOB factory for any air end which in its judgment proved
not to be as warrented within the applicable period.
Purchaser must return, transportation charges prepaid, any air
end claimed to be not as warranted to aGardner-Denver factory.
Any disassembly or partial disassembly of the air end, or failure
to return the “unopened” air end per Company instructions,
will because for denial of warranty.
ELECTRIC MOTORS
Electric motors, when specified and furnished by the Company,
are warranted for12months from data of initial use or 15 months
from date of shipment to the first purchaser, whichever occurs
first.
The motor manufacturer or authorized service shop will provide
at its option, motor repairs or replacement motor FOB manu-
facturer’s location for any motor which in the manufacturer’s
judgment proves not to be as warranted within the applicable
period.
ENGINES
Engines are warranted to the extent of the original manufac-
turer’s warranty to the Company.
OTHER COMPONENTS
All other components arewarranted for 12 months from date of
initial use or 15 months from data of shipment to first purchaser,
whichever occurs first.
The Company will furnish at its option FOB Company location
repairs or replacement parts for any component which in the
Company’s judgment proved not to be as warranted within the
applicable period.
GENERAL PROVISIONS AND LIMITATIONS
No warranty is made with respect to:
1. Any product which has been repaired or altered in such a
way, in the Company’s judgement, as to affect the product
adversely.
2. Any product which has, in the Company’s judgment been
subject to negligence, accident, improper storage, or im-
proper installation or application.
3.
4.
5.
WARRANTY
ROTARY SCREW COMPRESSORS
EC ELECTRA-SAVER Il@
EA ELECTRA-SAVER@
EB, ET ELECTRA-SCREW
SE, ST PACKAGES
Any product which has not been operated or maintained
in accordance with normal practice and with the recom-
mendations of the Company.
Components or accessories manufactured, warranted and
serviced by others, axcept as separately rated.
Any reconditioned or prior owned product.
Claims for items descibed in (4) above should be submitted
directly to the manufacturer.
The Company’s obligation under this warranty is limited to repair
or replacement, at its 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 ap
plicable Warranty Period. The Company may require the return
of any pert claimed not to be as warranted to one of its facilities
as designated 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 Company’s judgment
is proved not to be as warranted, by Company representative up
to the amount specified in the Company’s labor rate schedules,
or up to the amount the Company determines is reasonable.
Labor costs in excess of the Company rate schedule amounts
or labor provided by unauthorized service personnel is not pro-
vided 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 installad to the same extent as if such parts
were original components thereof.
DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS
EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE
COMPANY 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 AVAIL-
ABLE TO PURCHASER AND IN NO CASE SHALL THE COM-
PANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR
LIABILITIES. UNDER NO CIRCUMSTANCES SHALL THE
COMPANY BE LIABLE FOR SPECIAL, INDIRECT, inciden-
tal OR CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES
OR DE LAYS’ HOWSOEVER CAUSED.
No statement, representation, agreement, or understanding, oral
or written, made by any agent, distributor, representative, or
employee of the Company which is not contained in this Warranty
will be binding upon 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 is not
presented within 30 days after the date upon which 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 as an admission by the Company that any product
was not es warranted.
13-10-601 Page i

GARDNER-DENVER@ ELECTRA-SAVER@ 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 DA Y-TO-DAY OPERATION,
MAINTENANCE AND ADJUSTMENT. CAREFUL ADHERENCE TO THESE INSTRUCTIONS WILL RESULT IN
ECONOMICAL OPERATION AND MINIMUM DOWNTIME.
ADANGER
FAILURE TO OBSERVE ADANGER NOTICE COULD RESULT IN
INJURY TO, OR DEATH OF PERSONNEL.
AWARNING
FAILLURE TO OBSERVE AWARNING 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 ................................................................. SECTION 2
STARTING &OPERATING PROCEDURES ............................................. SECTION 3
CONTROLS &lNSTRUMENTS ...................................................... SECTION 4
LUBRICATION, OIL COOLER, OIL FILTER &SEPARATOR ................................ SECTION 5
AIR FILTERS .................................................................. SECTION 6
COUPLING ..................................................................... SECTION 7
MAINTENANCE SCHEDULE ........................................................ SECTION 8
TROUBLE SHOOTING ............................................................ SECTION 9
COMPRESSOR Overhaul ............................................ SERVICE MANUAL 13-10-602
13-10-601 Page ii

INDEX
NOTE Numbers preceding dash are Section Numbers —numbers following dash are Page Numbers.
Acoustic Enclosure .................................. 2-1
Actuator, Turn Valve ............................ 4-5, 4-6
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-Cooled Oil Cooler Module ....................... 2-2
Air Filter ................................... 3-1, 6-1,8-1
Alr Filter indicator ................................... 4-5
AIR FILTERS (SECTION 6) ........................ 6-1
Air Filter Service Indicator .......................... 6-1
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 ................................. 4-4
Air Receiver Auxiliary .......................... 2-3, 4-8
Air Temperature Gauge, Discharge . . . . . . . . . . . . . . . . . . 4-4
Air Temperature Shutdown High .................... 4-2
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/Timed Stop Operation .............. 4-8
Auxiliary Air Receiver ........................... 2-3, 4-8
Bleed Air Valve ...................................... 4-6
Blowdown Valve Automatic ..................... 4-3, 5-7
Blowdown Valve Piping .............................. 2-5
Capacities Oil System .............................. 5-3
Capacity Control Compressor ....................... 4-5
Capacity and Pressure Adjustments Compressor ... 4-7
Check Valve Flow Control .......................... 4-9
Check Valve (Oil Reservoir) ......................... 4-5
Cold Ambient Operation ............................. 5-2
Cold Weather Operation ............................. 2-2
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 Oil Filter ................................ 5-3
Compressor Oil Separator ........................... 5-6
Compressor Oil System ............................. 5-1
Compressor Oil System Check ...................... 5-7
Compressor OverhauI ............................... 1-1
Constant Speed Control System With Low Demand
Mode ............................................. 4-8
Constant Speed Operation .......................... 4-8
Control Compressor Capacity ....................... 4-5
Control Low Starting Torque (Unloaded Start) ...... 4-8
Control Piping ....................................... 2-5
13-10-601
CONTROLS &INSTRUMENTS (SECTION 4) . . . . . . 4-1
Control System Automatic Start/Timed 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 (Thermostatic Mixing) Valve Thermal ....... 5-4
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 (SECTION 7) ........................... 7-1
Daily Check ......................................... 3-1
Differential Gauge, Pressure .................... 4-5, 5-7
Differential Oil Cooler Oil Pressure (Water-Cooled
Heat Exchanger) .................................. 5-8
Differential Oil Cooler Pressure (Air-Cooled
Radiator .......................................... 5-8
Differential Oil Cooler Temperature ................. 5-8
Differential Oil Cooler Water Pressure (Water-Cooled
Heat Exchanger) .................................. 5-8
Discharge Air Temperature Gauge .................. 4-4
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 .................................... 2-5
Electrical Wiring .........................................
............ 2-5, 4-87, 4-11, 4-12, 4-13, 4-14, 4-15, 4-16
Enclosure Acoustic .................................. 2-1
Filling Oil Reservoir ................................. 5-3
Filter, Air ................................... 3-1, 6-1,8-1
Filter, Compressor Oil ............................... 5-3
Filter indicator, Air .................................. 4-5
Filter indicator, Oil .................................. 4-5
FILTERS, AIR (SECTION 6) ........................ 6-1
Filter Service lndicator Air...... .................... 6-1
Flow Control-Check Valve ........................... 4-9
Flow Diagram —Air-Oil Systems .................... 5-1
Foundation .......................................... 2-1
Gauge Air Pressure ................................. 4-4
Gaug,e Discharge Air Temperature .................. 4-4
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 ........................................... 2-5
Page iii

High Air Temperature Shutdown .................... 4-2
High Discharge Temperature Switch ................ 4-2
High Temperature Operation ........................ 5-2
Hourmeter ........................................... 4-4
Indicator, Air Filter .................................. 4-5
indicator, Air Filter Service .......................... 6-1
Indicator, Oil Filter .................................. 4-5
Inlet Line ............................................ 2-5
Inlet Pressure Oil ................................... 5-8
Inlet Valve ........................................... 4-6
inlet Valve Subtractive Pilot ......................... 4-7
Installation for Cold Weather Operation ............ 2-2
INSTALLATION (SECTION 2) ...................... 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 ............. 4-3
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 ...... 4-8
Lubricant Compressor .............................. 5-2
Lubricants Synthetic ................................ 5-2
Lubrication Cooling and Sealing .................... 1-1
Lubrication Motor .............................. 2-5, 8-1
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5) ...................... 5-1
MAINTENANCE SCHEDULE (SECTION 8) ........ 8-1
Minimum Air Flow ................................... 2-1
Minimum Discharge Pressure Valve ................. 4-5
Minimum Operating Pressure ....................... 4-8
Mode, Operating ..................................... 3-1
Moisture lnThe Oil System ......................... 5-3
Moisture Separator Trap ............................ 3-1
Motor Lubrication ............................... 2-5, 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, Compressor –Water-Cooled Heat
Exchanger ........................................ 5-5
Oil Cooler Module (Air-Cooled) ...................... 2-2
OIL COOLER, OIL FILTER, SEPARATOR &
LUBRICATION (SECTION 5) .................... 5-1
Oil Cooler Oil Pressure Differential (Water-Cooled
Heat Exchanger) .................................. 5-8
Oil Cooler Pressure Differential (Air-Cooled
Radiator) .......................................... 5-8
Oil Cooler (Radiator Type) Module, Compressor .... 5-4
Oil Cooler Temperature Differential ................. 5-8
Oil Cooler Water Pressure Differential (Watercooled
Heat Exchanger) .................................. 5-8
Oil Filter, Compressor ............................... 5-3
Oil Filter Indicator ................................... 4-5
OIL FILTER, SEPARATOR, OIL COOLER &
LUBRICATION (SECTION 5) .................... 5-1
Oil Flow Diagram –Remote Overhead Mounted Oil
Cooler ............................................ 5-2
Oil Inlet Pressure ................................... 5-8
Oil Level Gauge ..................................... 5-3
Oil Pressure Differential Oil Cooler ................. 5-8
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 ........................................ 5-8
Oil Reservoir Check Valve .......................... 4-5
Oil Resevoir Drain .................................. 2-1
Oil Reservoir Filling ................................. 5-3
Oil Separator ........................................ 8-1
Oil Separator, Compressor .......................... 5-8
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
O* Off Switch ........................................ 4-2
Operating Air Pressure Adjustment ................. 4-7
Operating Light Test ................................ 3-1
Operating Mode ..................................... 3-1
Operating Pressure Minimum ....................... 4-8
OPERATING PROCEDURES &STARTING
(SECTION 3) ............................... 3-1
Operation High Temperature ....................... . 5-2
Overhaul Compressor ............................... 1-1
Pilot, Inlet Valve Subtractive ........................ 4-7
Pilot Light ........................................... 4-1
Pilot, Turn Valve Subtractive ........................ 4-6
Piping ................................................ 3-1
Piping Blowdown Valve ............................. 2-5
Piping Control ....................................... 2-5
Piping Diagram for Aftercooler &Heat Exchanger ...... 2-4
Piping Water (Water-Cooled Heat Exchanger Models
Only) .............................................. 2-5
Pressure Adjustment Operating Air ................. 4-7
Pressure Adjustments Compressor Capacity and . . . 4-7
Pressure Differential Gauge .................... 4-5, 5-7
Pressure Differential Oil Cooler (Air-Cooled
Radiator) ......................................... 5-8
Pressure Differential Oil Cooler Oil (Watercooled
Heat Exchanger) .................................. 5-8
Pressure Differential Oil Cooler Water (Watercooled
Heat Exchanger) .................................. 5-8
Pressure Gauge, Air ................................. 4-4
Pressure, Minimum Operating ....................... 4-8
Pressure Oil Inlet ................................... 5-8
Pressure Protection Low Oil (Air-Cooled Oil
Cooler) ............................................ 2-2
Pressure Regulator .................................. 4-3
Pressure Shutdown, Low Oil ........................ 4-4
Pressure Switch, Low Demand Mode ............... 4-3
Pressure Switch, Reservoir ..................... 4-4, 4-9
Pressure System .................................... 3-1
Pressure Time Delay Switch, Low Oil ............... 4-4
Pressure Valve, Minimum Discharge ................ 4-5
13-10-601 Page iv

Regressing lnterval .................................. 2-6
Regulator, Pressure ................................. 4-3
Resevoir Check Valve, Oil .......................... 4-5
Reservoir Drain, Oil ................................. 2-1
Resevoir, Oil ........................................ 5-6
Reservoir Pressure Switch ...................... 4-4, 4-9
Reset ................................................ 4-1
Rotation ............................................. 3-1
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 (SECTION 5) .................... 5-1
Service Checklist .................................. 8-1
Service lndicator, Air Filter .......................... 6-1
Service Line Discharge ............................. 2-5
Shutdown High Air Temperature .................... 4-2
Shutdown Low Oil Pressure ........................ 4-4
Shutoff Valve, Water –Water-Cooled Heat
Exchanger ........................................ 5-6
Solenoid, Low Demand Mode Unloader ............. 4-3
Starter, Electrical .................................... 2-5
STARTING &OPERATING PROCEDURES
(SECTION 3) ..................................... 3-1
Starting the Unit .................................... 3-1
Stopping the Unit ................................... 3-1
Subtractive Pilot 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 ....................................... 4-2
Switch, On-Off-Reset ................................ 4-1
Switch, Resevoir Pressure ..................... 4-4, 4-9
Switch, Start-Stop/ Reset ............................ 4-1
Switch, Vibration ..................................... 4-8
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 .................. 4-4
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
Trap Moisture Separator ............................ 3-1
Turn Valve ...................................... 1-1, 4-6
Turn Valve Actuator ............................. 4-5, 4-6
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 ............. 4-3
Valve Actuator Turn ............................ 4-5, 4-6
Valve Automatic Blowdown ..................... 4-3, 5-7
Valve Bleed Air ..................................... 4-6
Valve Check (Oil Reservoir) ......................... 4-5
Valve Flow Control-Check ........................... 4-9
Valve Inlet .......................................... 4-6
Valve Minimum Discharge Pressure ................ 4-5
Valve Piping Blowdown ............................. 2-5
Valve Safety ......................................... 4-3
Valve Thermal Control (Thermostatic Mixing) ....... 5-4
Valve Three-Way .................................... 4-9
Valve Turn ...................................... 1-1, 4-6
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 ..................................... 4-8
Voltage Control ..................................... 4-1
Water Flow .......................................... 2-4
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 (Water-Cooled
Heat Exchanger) .................................. 5-8
Water Shutoff Valve —Water-Cooled Heat
Exchanger ........................................ 5-6
Wiring Diagrams . . . . . 4-11, 4-12, 4-13, 4-14, 4-15, 4-16
Wiring Electrical .........................................
............. 2-5, 4-8, 4-11, 4-12, 4-13, 4-14, 4-15, 4-16
13-10-601 Page v

SECTION 1
GENERAL INFORMATION
FIGURE 1-1. –COMPRESSION CYCLE
COMPRESSOR –The Gardner-Denver@ Electra-Saver@
compressor is asingle 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
bearings 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 six (6) matching heiical grooves 60” 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 compres-
sion 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 second-
ary rotor groove normal volume is reduced and pressure
increases Oil is injected into the cylinder to remove the
heat of compression and seal internal clearances Volume
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 reservoir (C).
Each rotor cavity follows the sam 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 inlet unloader valve to compressor.
After compression the air/oil mixture passes into oil reser-
voir where most of the entrained oil is removed by velocity
change and impingement and drops back into reservoir. The
air and remaining oil then passes through the oii separator,
the separated oil is returned to the system through tubing
connecting the separator and compressor. The air passes
through the reservoir discharge manifold discharge check
valve, minimum pressure valve and the customer 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 gal-
Iery. Aportion 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
compressor rotor volume to match the demand for air, thus
reducing the part-load power requirement
COMPRESSOR OVERHAUL –For compressor overhaul
procedures and rebuilding data including dimensions run-
ningclearances and fits, see Service Manual 13-9-623.
13-10-601 Section 1Page 1

SAFETY PRECAUTIONS
Safety iseverybody’s businessand 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:
,WARNING
A●
FAILURE TO OBSERVE THESE NOTICES COULD RESULT IN DAMAGE TO EQUIPMENT
oSTOP THE UNIT IF ANY REPAIRS OR ADJUSTMENTS ON OR AROUND THE COMPRESSOR ARE
REQUIRED.
oALL COMPRESSED AIR SUPPLY HOSES EXCEEDING 1/2INCH INSIDE DIAMETER SHOULD HAVE
AN EXCESS FLOW VALVE. (OSHA REGULATION, SECTION 1518.302)
oDO NOT EXCEED THE RATED MAXIMUM PRESSURE VALUES SHOWN ON THE NAMEPLATE.
oDO NOT OPERATE UNIT IF SAFETY DEVICES ARE NOT OPERATING PROPERLY. CHECK
PERIODICALLY. NEVER BYPASS SAFETY DEVICES.
ADANGER
FAILURE TO OBSERVE THESE NOTICES COULD RESULT IN INJUR YTO OR DEATH OF PERSONNEL.
o
0
0
0
0
0
0
0
KEEP FINGERS AND CLOTHING AWAY FROM REVOLVING FAN, DRIVE COUPLING, ETC.
DO NOT USE THE AIR DISCHARGE FROM THIS UNIT FOR BREATHING –NOT SUITABLE FOR
HUMAN CONSUMPTION.
DO NOT LOOSEN OR REMOVE THE OIL FILLER PLUG, DRAIN PLUGS, COVERS, THE THER-
MOSTATIC MIXING VALVE OR, BREAK ANY CONNECTIONS, ETC. IN THE COMPRESSOR AIR OR
OIL SYSTEM UNTIL THE UNIT IS SHUTDOWN 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. AGROUND JUMPER EQUAL IN SIZE TO THE EQUIPMENT GROUND CONDUCTOR MUST
BE USED TO CONNECT THE COMPRESSOR MOTOR BASE TO THE UNIT BASE.
FAN MOTORS HAVE BEEN AND MUST REMAIN GROUNDED TO THE MAIN BASE THROUGH THE
STARTER MOUNTING PANEL 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 AUTOMATICALLY CONTROLLED AND MAY START ATANY TIME.
13-10-601 Section 1Page3

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.
~CAUTION
~DO NOT ELECTRIC WELD ON THE COMPRESSOR OR
BASE; BEARINGS CAN BE DAMAGED BY PASSAGE
OF CURRENT.
LIFTING UNIT —Proper lifting and/or transporting methods
must be used to prevent damage.
ACAUTION
LIFT COMPRESSOR UNIT BY BASE ONLY. DO NOT
USE OTHER PLACES SUCH AS ENCLOSURE, MOTOR,
COMPRESSOR OIL DISCHARGE MANIFOLD AND
PIPING AS LIFTING POINTS.
ADANGER
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
OR PERSONAL INJURY.
Physical size and weight of unit may allow use of tow
motors. Unit may also be moved into location by rolling
on bars.
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
acool, 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
rOpen Unit
Open With
Compressor Oil Cooler Oil Cooler
Size Unit Module Module
100 HP 3600 17500 21100
I125 HP I4400 I19300 I23700 I
150 HP 5200 19300 I24500
●800 F. inlet Air
FIGURE 2-2. –MINIMUM AIR* FLOW
FOR COMPRESSION AND COOLING
(Cubic Feet/Minute)
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 motor and
is discharged out the sides Do not block air flow to and
from the unit
FOUNDATION –The Electra-Saver 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 in-
stallation conditions such as piping rigidity, angle of tilt,
or danger of shifting from outside vibrations or moving
vehicles may require the use of mounting bolts to the
foundation
OIL RESERVOIR DRAIN (Figure 3-1) –The oil res-
ervoir drain valve is located near the center of the oil
reservoir just below the separator tower. The drain valve
is approximately 4-1/2 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 Ievel
and pump or bail the drained oil
3. Pump oil from the reservoir filler opening or res-
ervoir drain to acontainer,
ACOUSTIC ENCLOSURE –The Electra-Saver unit is
furnished with an acoustic enclosure over the compressor
13-10-601 Section 2Page 1

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
Ventilation —The oil cooler requires adequate cooling air
flow. Proper ventilation MUST be provided, with hot air
exhausted away from the cooler, 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 Prsssure 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 pres-
sure is not established or maintained due to malfunction
in the oil cooler system
0il Cooler –The oil cooler module can be mounted in
any of several remote locations close coupled but not
joined to the compressor unit horizontal remote, located
on the same level as the compressor unit but some dis-
tance away, or overhead remote located above level of the
compressor unit, as on aroof.
AWARNING
/~\ THE LOW DEMAND MODE SWITCH CANNOT BE USED
WITH REMOTE OVERHEAD OIL COOLER. THESE
UNITS REQUIRE SPECIAL WIRING DIAGRAM –
CHECK WITH FACTOR Y. USE OF LOW DEMAND
SWITCH WITH AN OVERHEAD COOLER COULD
RESULT IN DAMAGE 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.
2.
3.
4.
5.
6.
7.
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 oil cooler
and 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
Number and size of elbows tees, unions, reducers
and valves to be used in the pipe run
Adimensioned sketch of the proposed piping system
showing location of the compressor unit, oil cooler
and pipe fittings of 3through 6above.
All remote piping should be of adequate size to insure the
minimum pressure Ioss Design point 4above Iists 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 pre-
vent rust and all valves are to be of anonferrous con-
struction to prevent corrosion and fouling
The remote cooler should be placed so that the fan airflow
through the cooler (air flow is from motor side through
core) and the prevailing winds are in the same direction
Abaffle should be provided on the exhaust aide 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 cooler 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
cooler 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 cooler see Figure 2-5.
INSTALLATION FOR COLD WEATHER OPERATION
–It is recommended that whenever possible the unit be
installed inside ashelter that will be heated to temperatures
above freezing (32” F., O“ C.). This will eliminate many of
the problems associated with operating the units outside
in cold climates where freezing rain drifting snow, freezing
condensate and bitter cold temperatures are encountered
When an outside installation must be madqe the precau-
tions required will depend on how severe the environment
will get The following are general guidelines for outside
installations
Cold Weather (Down To –10° F.)
1.
2.
3.
4.
5.
6.
Be sure all control Iines drains and traps are heated
to avoid freezing of condensate Heat tape with ther-
mostat control is generally satisfactory for this pur-
pose. This is not afactory option but 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 (Plywood wind-
break etc) to protect against drifting snow.
Use only Gurdner-Denver “GD800 Lubricating
Coolant”.
Monitor unit carefully during start- up and operation
to be sure it is functioning normally.
When the coolers are mounted horizontally use
weather protected enclosure for the unit
13-10-601 Section 2Page 2

7.
f:
. .
1
\
Use
OIL COOLER
v
/
WELLMAN RADIANT 2-ELEMENT
HEATER (OR EQUAL)
RH400 WITH (2) RH4502
ELEMENTS —2REQ’D.
3,200 WATTS EACH 8FT. PLYWOOD “FENCE”
3FT.
\OIL RESERVOIR “\ /
\’- AwAY FROM PREVAILING WIND
WELLMAN RADIANT 2-ELEMENT 74FT.
HEATER (OR EQUAL)
RH7000 WITH (2) RH7502
ELEMENTS —2REQ’D.
F,
P
‘._
6,200 WATTS EACH \-T! /
TOP VIEW \8FT. PLYWOOD “FENCE” ELEVATION VIEW
FIGURE 3-2.
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.
2.
3.
4.
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.
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
Coolers should be located as close to unit as possible.
Long lines to and from the cooler only further com-
plicates the circulation of oil flow on cold starts
Lo-Demand or Duomatic operation cannot be used
in extreme environments Heat tape and insulation
may be required 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
4-2 shows how these might be located in atypical
installation and sizes required
Remember unsheltered (outside) installations should be
avoided where possible Installation 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
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 apres-
sure gauge and ameans of draining condensate
AFTERCOOLER (Figures 2-1, 3-1 &4-2) –An aftercooler
will provide control of moisture entering the shop air lines
while reducing the normal low discharge temperature of
about 179° F. at 100 PSIG discharge pressure to near
inlet air temperature
Air-Cooled Machines –When an aftercooler is furnished
on an air-cooled machine the aftercooler is installed on
the oil cooler module between the fan and the oil cooler.
Later models of steel air-cooled aftercoolers are coated
internally to resist corrosion Coated aftercoolers have a
tag attached to one header with identification and date.
The moisture separator is furnished by Gardner-Denver
Compressors but must be mounted by the customer be-
tween the aftercooler and the auxiliary air receiver with
acondensate 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 installation The design information to be
submitted for approval includes
1.
2.
3.
4.
5.
6.
13-10-601 Section 2
Location of aftercooler module —inside or outdoors
Range of operating ambient temperatures at the
aftercooler location
Pipe type and size(s) to be used to connect the after-
cooler, separator and compressor unit —minimum
pipe size is 2“ IPS
Lengths of the pipe run If more than one pipe size
is used list length of each size and total length
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 aftercooler,
separator and auxiliary air receiver, pipe and fittings
Page 3

OIL WATER
CONTROL
OIL OUT
IN
HEAT EXCHANGER \
WATER
ISEPARATOR
\
SHUTOFF
VALVE d
SERIES PIPING WATER FLOW MUST BE
THROUGH AFTERCOOLER FIRST FOR
EFFECTIVE COOLING OF DISCHARGE AIR.
Size
100 HP
125 HP
dMUST BE
OIL WATER
OIL OUT CONTROL
IN VALVE d
_WATER
HEAT EXCHANGER Dx OUT
I
II
MANUAL VALVE TO
BALANCE WATER FLOW
L‘+
G
SEPARATOR
=
AFTERCOOLER
WATER lN—
WA;ER
SHUTOFF
VALVE d
WATER
~N
PARALLEL PIPING WATER CONTROL
VALVE REQUIRED FOR TEMPERATURE CONTROL
OF OIL
ORDERED SEPARATELY.
FIGURE 4-2. –PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER
ST5853
Approximate
Water Pressure
Rated Water Temperature To Heat Exchanger Maximum Drop @
Pressure Water Maximum Flow
PSIG 80° F. 70° F. 80” F. 90° F. Flow (Psi)
ALL 11.0 13.5 17.5 26.0 40 18
ALL 12.0 15.5 20.5 32.0 60 20
I11
ALL I15.5 ]19.0 I25.5 I37.5 I60 I20 ]150 HP
The Maximum Water Flow Shown Is That Allowable Through The Heat Exchanger.
FIGURE 5-2. –HEAT EXCHANGER (OIL COOLER) APPROXIMATE WATER FLOW
(U.S Gallons/Minute)
III
Approximate
Water Pressure
Rated Water Temperature To Aftercooler Maximum Drop @
Pressure Water Maximum Flow
Size PSIG 80” F. 70° F. 80° F. 90° F. Flow (PSI)
100 HP ALL 2.4 3.0 4.0 6.0 30.0 2.5
125 HP ALL 2.8 3.5 4.7 7.0 30.0 2.5
150 HP ALL 4.0 5.0 8.7 10.0 30.0 2.5
Water flow rates (gpm) are based on 110° F. water temperature out of cooler. Maximum water flow shown is the maximum
allowable flow through aftercooler.
FIGURE 6-2. –AFTERCOOLER APPROXI MATE WATER FLOW
(US Gallons/ Minute)
13-10-801 Section 2Page 4

of 3through 5above The water source should be capable of supplying up to
the maximum flow shown in Figure 5-2 at aminimum pres-
sure of 40 PSIG maximum allowable water pressure is
150 PSIG The water flow rates shown in Figure 5-2 are
approximate and aguide to sizing piping cooling tower
and other water system equipment
Water-Coolod Machlnes (Figure 4-2) –On watercooled
machines with aftercooler the moisture separator and COn-
densate drain are shipped loose and must be installed by
customer. Customer must furnish and install all water
piping required 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
CONTROL PIPING –Control piping is not necessary
since the Electra-Saver unit is factoy-wired and piped
for the control system specified
INLET LINE –Where an inlet line is used between an
outside air filter and the compressor, or to connect the
unit mounted air filter to an outside source of air it must
be thoroughly cleaned on the inside to prevent dirt or
scale from entering the compressor. If welded construc-
tion Is used, the line must be shot blasted and cleaned
to remove welding scale. In either case the inlet line
must be coated internally by galvanizing or painting with a
moisture and oil-proof sealing lacquer. The inlet line
should be the full size of the inlet opening on the com-
pressor. If an extra-long line is necessary, the pipe size
should be increased accordingly
Most water systems will require control of impurities
filtration softening or other treatment See “Compressor
Oil Cooler –Water-Cooled Heat Exchanger for more
information on the water system
Aftercooler– Heat Exchanger Water Plping( Figure 4-2)
—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
exchanger water inlet on the compressor unit
Length Of Inlet Line Diameter Of Pipe Size
Oto l0 ft....... Same As Compressor Inlet Opening
10to17 Ft...... One Size Larger Than Inlet Opening
17 to38 Ft ..... Two Sizes Larger Than Inlet Opening If the aftercooler is piped in parallel with the heat ex-
changer, provide amanual valve between the aftercooler
outlet and the heat exchanger outlet after the water control
valve to adjust aftercooler water flow for discharge temper-
ature required and most economical water use separate
water inlet lines are piped to the aftercooler and heat
exchanger.
Accessability for inlet air filter servicing must be consid-
ered 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 minimum pressure valve located behind the instrument
panel When manifolding two or more E/ectra &Saver units
on the same line each unit is isolated by the check valve in
the unit discharge line If an E/ectra &.Saver unit is mani-
folded to another compressor, be sure the other compres-
sor 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 between the two units
~CAUTION
ALLOWEDBY THE AFTERCOOLER, APARALLEL
WATER PIPING SYSTEM MUST BE USED.
If the standard factory built-in aftercooler is used the
maximum allowable water flow through the aftercooler is
30 gallons per minute and the maximum water inlet pres-
sure is 150 PSIG If another aftercooler is used consult the
manufacturer for operating limits
ADANGER
~DO NOT USE THE AIR DISCHARGED FROM
THIS UNIT FOR BREATHING —IT IS NOT
SUITABLE FOR HUMAN CONSUMPTION. The water control valve MUST be used to maintain dis-
charge temperatures approximately 10 Pover the dew
point for expected ambient (Figure 8-5). See Section 5for
adjustment instructions and maximum allowable oil tem-
perature
BLOWDOWN VALVE PIPING –The blowdown valve
is fitted with amuffler for operation indoors If the in
stallation requires the muffler may be removed and the
blowdown valve piped to the outside with pipe the same
size as the blowdown valve outlet connection
ELECTRICAL WIRING –The Electra &Saver unit is
furnished with the compressor motor enclosure as spec-
ified by the user. If the 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 spec-
ified by the user. Allow 42” deep by 30” wide clear space
to nearest obstruction over control enclosure in accord-
ante with Article 110-16 (4 National Electrical Code
WATER PIPING (Water-Cooled Heat Exchanger Models
Only) –On machines equipped with awater-cooled heat
exchanger pipe water to the inlet or 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
is inserted in the heat exchanger oil outlet Iine refer to
the unit outline drawing for location
It is necessary to connect the compressor unit (and oil
cooler, If used to amain starter of the correct size power
characteristic and enclosure for the application See
13-10-601 Section 2Page 5

Section 4for typical wiring diagrams however, use only the
wiring diagrams supplied with the unit for final connections
Starter —The main starter is to be mounted at alocation
selected by the user at the time of installation The first
three (3) 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
Grounding –Equipment must be grounded in accordance
with Table 250-95 of the National Electrical Code
AWARNING
AN EQUIPMENT GROUND JUMPER, EQUAL IN SIZE
TO THE EQUIPMENT GROUND CONDUCTOR, MUST
BE USED TO CONNECT THE COMPRESSOR-MOTOR
SUBBASE TO THE MAIN BASE. SINCE THE BASES
ARE ISOLATED FROM EACH OTHER BY VIBRATION
MOUNTS. THE OIL COOLER FAN AND ENCLOSURE
VENT FAN MOTOR FRAME WILL BE GROUNDED TO
THE MAIN BASE WITH AGROUNDING CONDUCTOR
COMPATIBLE WITH THE FAN SHORT CIRCUIT PRO-
TECTION AT THE FACTORY. FAILURE TO PROP-
ERLY GROUND EQUIPMENT COULD RES-ULT ‘IN
ELECTRICAL SHOCK.
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
The
1.
2.
3.
4.
5.
6.
7.
refer to the motor manufacturer’s instructions
following procedure should be used in regressing
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 expell the excess
grease
Stop the unit Replace the relief plug
Restart the unit
Worked Penetration ..............................................................
Oil Viscosity, SSU At 100° F. ...................................................
Soap Type ........................................................................
N-H Bomb Minimum Hours For 20 PSI Drop At 210” F. ........................
Bleeding Maximum Weight %In 500 Hours 212° F. ...........................
Rust inhibiting ....................................................................
Standard
Service
265-296
400-550
Lithium
750
10
Yes
High
Temperature
220-240
475-525
Lithium
1000
3
Yes
REGRESSING INTERVAL
Type Of Service Typical Examples Rating Relubrication Interval
150 HP and Below 18 Months
Standard One Or Two-Shift Operation Over 1’50 HP 12 Months
150 HP and Below
Severe 9Months
Continuous Operation Over 150 HP 6Months
150 HP and Below 4Months
Very Severe Dirty Locations High Ambient Temperature Over 150 HP 2Months
13-10-601 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 0il –Check the oil level in the oil
resevoir. 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 Gardner Denver
GD800 Lubricating Coolant which is suitable for the
first 2000 hours under normal operating 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 011range 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
AL WAYS STOP THE UNIT AND RELEASE AIR
PRESSURE BEFORE REMOVING OIL FILLER
PLUG TO ADD OIL
2.
3.
4.
5.
6.
During unloaded operation 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 Iine
if used is tight and clean
Plplng –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 Astainless steel internal
strainer is used in trap it should be checked period
ically for clogglng and replaced if necessary. Repair
parts are available for trap cap retainer gasket and
strainer. See package outlines for mounting dimen
sions of moisture separator trap
The moisture trap must be primed by filling with
clean water prior to initial start-up of unit
Electrlcal -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 2for
installation Instructions
Rotatlon -Check the motor rotation by momen
tarlly starting the motor. Compressor drive shaft rote
tion is counterclockwise standing at the motor end
7. Operating Light Test –Observe the operating lights
on the ON-OFF switch when jogging the motor in
Step 6. Be sure all lamps are operative
8. System Pressure —Set the turn valve pilot inlet pilot
and operating air pressure switch to the desired
unload pressure and differential DO NOT EXCEED
MAXIMUM OPERATING PRESSURE ON THE
COMPRESSOR NAME PLATE EXCEPT AS SPEC-
IFIED UNDER “CONTROL ADJUSTMENTS’ SEC
TION 4.
9. Operating Mode –Refer to Section 4for detailed
information on the control system
STARTING 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
OBSERVE UNIT COLD OR UNIT HOT STARTING PRO
CEDURES
Unit Cold —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 special procedure to maintain unit reser-
voir pressure is required
ACAUTION
ON AUTOMATIC START-TIMED STOP MODE, IT IS
IMPORTANT TO OPEN THE SERVICE VALVE AFTER
STARTING AND BEFORE THE SET DISCHARGE
PRESSURE IS REACHED TO PREVENT THE ALMOST
IMMEDIATE SHUTDOWN OF THE UNIT FOLLOWED
BY ARESTART WHICH MA YCAUSE MOTOR OVER-
LOAD HEATERS TO OVERHEAT AND BLOW.
Unit Hot –No warm-up period is required Close the air
service valve (furnished by customer). If the unit is awater-
cooled heat exchanger model open any manual water inlet
valves wide open Start the unit Open the air service valve
DAILY CHECK –Refer to Section 8“Maintenance
Scheduled.
STOPPING THE UNIT –Close the air service valve
(furnished by customer), allow the unit to build up to
full unloaded pressure and press the OFF push button
Stopping the unit at apressure below full receiver may
cause oil Carry-over. The oil reservoir will automatically
blow down as the motor stops If the unit is awatercooled
heat exchanger type close any manual water inlet valves
Open the air service valve
13-10-601 Section 3Page 1

SECTION 4
CONTROLS &INSTRUMENTS
GENERAL –The Gardner-Denver Electra-Saver com-
pressor units are available with two (2) different control
systems
Constant Speed With Low Demand Mode
Automatic Start/Timed Stop With Low Demand Mode
The standard Electra-Saver unit consists of the compres
sor, 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 spec
ified 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
start-stop push button hourmeter, pressure switch high
discharge temperature shutdown switch and other elec-
trical control devices is 115 volts regardless of power
supply voltage On standard units the transformer in the
control enclosure is connected to change the specified
user’s power supply voltage to 115 volt control voltage
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
ADANGER
/~j 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 OPERATION.
FAILURE TO CORRECT THE PROBLEM MAY RE-
SULT IN DAMAGE TO EQUIPMENT OR PERSONAL
INJURY.
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
13-10-601 Section 4Page 1

two-probe high discharge temperature switch have an
Indicatlng 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 maybe stopped with the amber light
ON indicating power on The blue lighted LOAD in
dicates 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
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 Start/
Timed 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 swltch when turned to the ON posi
tion wIII blow the reservoir down when the compressor
unloads When switch is turned to OFF, unit will retain
pressure in reservoir when unloaded
,WARNING
A●THE LOW DEMAND MODE SWITCH CANNOT BE USED
WITH REMOTE ELEVATED OIL COOLERS. THESE
UNITS REQUIRE SPECIAL WIRING DIAGRAMS –
CHECK WITH FACTOR Y. IMPROPER INSTALLATION
OR USE OF LOW DEMAND MODE MA YRESULT IN
DAMAGE TO EQUIPMENT
SAFETY DEVICES –
these safety devices Both control systems incorporate
Motor Protection Devices —Overload heaters are fur-
nished 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 re-
placing 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 adjust-
ment 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 pro-
vide 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 Starf/Stop(On-Off switch then the Start
(On) button to restart the unit
ADANGER
THIS ADJUSTABLE SWITCH DIAL MUST NOT BE SET
HIGHER THAN 225° F
DO NOT CONTINUE TO RESET CIRCUIT IF THE SAME
MALFUNCTION OCCURS WITHIN ASHORT PERIOD
OF TIME. FIND AND CORRECT THE TROUBLE BE-
FORE RESUMING OPERATION. FAILURE TO COR-
RECT THE PROBLEM MAY RESULT IN DAMAGE TO
EQUIPMENT OR PERSONAL INJUR Y.
In addition to protecting the unit from damage or failure
resulting from high air temperature the switch also in-
corporate four (4) indicator lights which show the point
of high temperature and/or the condition of the tempera-
ture probes This information is shown on the decal inside
the control box and in Figure 2-4.
The High Air Temperature Switch may be 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
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 Alr Temperature Shutdown -Early Models —
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
13-10-601 Section 4Page 2

ADANGER
THIS ADJUSTABLE SWITCH DIAL MUST NOT BE SET
HIGHER THAN 225° F.
DO NOT CONTINUE TO RESET CIRCUIT IF THE SAME
MALFUNCTION OCCURS WITHIN ASHORT PERIOD
OF TIME. FIND AND CORRECT THE TROUBLE BE-
FORE RESUMING OPERATION. FAILURE TO COR-
RECT THE PROBLEM MAY RESULT IN DAMAGE TO
EQUIPMENT OR PERSONAL INJUR Y.
This switch should be checked periodically to assure
proper operation To check with unit running reset switch
to the discharge temperature indicated by the discharge
temperature 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 re
Iease 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 Iine is equipped with amuf
fler 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 reenergize the low
demand mode solenoid valve when discharge pressure
reaches the set point This switch should be set approx-
imately 5PSI above full load pressure with a8-12 PSI
differential
Low Demand Mode Unloader Solenoid (Figure 1-4) -
The low demand mode solenoid valve when energized
supplies an air signal to close the blowdown valve When
de-energized it supplies an air signal to close compressor
inlet valve and exhausts air to open the blowdown valve
Pressure Regulator (Figure 1-4) –The pressure regulator
[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
“x o
,*C o0
\
,,BI!o
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/
SEPARATOR PROBE OPEN RED OFF OFF ORANGE
COMPRESSOR PROBE OPEN/
SEPARATOR PROBE SHORTED RED OFF OFF ORANGE
FIGURE 2-4.
13-10-601 Section 4Page 3

must be set 15-20 PSIG to prevent inlet valve “slam.
Reservolr Pressure $wltch (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 reservoir. 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
[~ \ DO NOT SET THE SWITCH HIGHER THAN 5PSIG
OR RENDER THE SWITCH INOPERATIVE; SEVERE
DAMAGE TO THE MOTOR CAN OCCUR IF STAR TED
WITH PRESSURE IN THE OIL RESERVOIR.
Low 0il Pressure Shutdown (Figure 1-4) –Units are
provided 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. 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
2. 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 move
ment of the screw reduces the differential counter-
clockwise increases differential Note differential
range (1-1 8PSI) 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 Start/Timed Stop control is an auto-
matic starting type areset relay is used as a positive means
to interrupt the circuit on either alow oil pressure shut-
down or high discharge air temperature shutdown to re
start these units press the black bar marked RESET and
then press the ON button
ADANGER
DO NOT CONTINUE TO RESTART THE UNIT IF THE
SAME MALFUNCTION OCCURS WITHIN ASHORT
PERIOD OF TIME. FIND AND CORRECT TROUBLE
BEFORE RESUMING OPERATION. FAILURE TO
CORRECT PROBLEM MAY RESULT IN DAMAGE TO
EQUIPMENT OR PERSONAL INJURY.
This switch should be checked periodically to assure prop
er operation To check disconnect the timed-opening
inatantaneous-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 relay after
checking
Low 0il 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
MANUALOPERATORTAB 1~N.c. TIMING CONTACT
MOVEABLE iNSTAN-
TANEOUS CONTACT
CARRIER -00 NOT
uSE AS A MANUAL
OPERATOR
TIME SETTING ADJUSTING SCREW JA75852
FIGURE 3-4. –LOW OIL PRESSURE
TIME DELAY SWITCH
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 FACTORY SET AT10 SECONDS. NEVER
ATTEMPT TO ADJUST TIMING RELAY FOR MORE
THAN 15 SECONDS DELA Y–SERIOUS COMPRESSOR
DAMAGE MAY RESULT FROM OPERATION WITHOUT
LUBRICATION FOR EVEN ASHORT PERIOD.
~CAUTION
~NEVER DISCONNECT SAFETY DEVICES THAT PRO-
TECT 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
Air Pressure Gauge —Adirect reading air pressure gauge
indicates the final discharge air pressure at the discharge
manifold
Discharge Air Temperature Gauge —Adirect reading
13-10-601 Section 4Page 4