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