Gardner Denver ELECTRA-SAVER ETY99A User manual

GARDNER DENVER
ELECTRA–SAVER
TWO–STAGE
STATIONARY BASE–MOUNTED
COMPRESSOR
AUTO SENTRY–ES+ CONTROLS
MODEL
ETY99A – 350 HP – 500 HP
OPERATING AND
SERVICE MANUAL
13–13–600
1st Edition
January, 1998

13–13–600 Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner Denver Compressor genuine parts, engine-
ered to original tolerances, are designed for optimum
dependability–––specificallyforGardnerDenvercom-
pressor systems. Design and material innovations are
theresultofyearsofexperiencewithhundredsofdiffer-
ent compressor applications. Reliability in materials
and quality assurance are incorporated in our genuine
replacement parts.
Your authorized Gardner Denver Compressor distribu-
tor offers all the backup you’ll need. A worldwide net-
workofauthorizeddistributorsprovidesthefinestprod-
uct support in the air compressor industry.Your local
authorized distributor maintains a large inventory of
genuinepartsandheisbackedup foremergencyparts
by direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
Denver air compressor with these services:
1. Trained parts specialists to assist you in selecting
the correct replacement parts.
2. Factory warranted new and remanufactured
rotaryscrewair ends.Most popularmodelreman-
ufacturedairendsaremaintainedinstockatMDC
for purchase on an exchange basis with liberal
core credit available for the replacement unit.
3. AfulllineoffactorytestedAEONtcompressorlu-
bricantsspecifically formulatedfor use inGardner
Denver compressors.
4. Repair and maintenance kits designed with the
necessary parts to simplify servicing your com-
pressor.
Authorized distributor service technicians are factory–
trained and skilled in compressor maintenance and re-
pair. They are ready to respond and assist you by pro-
viding fast, expert maintenance and repair services.
For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow
pages of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: [phone]
Phone: [phone] Fax: [phone]
(800) 245–4946
Fax: [phone]
REMANUFACTURED AIR ENDS
Whenever an air end requires replacement or repair,
Gardner Denver offers an industry unique, factory re-
manufactured air end exchange program. From its
modern Remanufacturing Center in Indianapolis, IN,
GardnerDenver iscommitted tosupplying youwith the
highest quality, factory remanufactured air ends that
are guaranteed to save you time, aggravation and
money.
Immediately Available
Repair downtime costs you money, which is why there
are over 200 remanufactured units in inventory at all
times, ready for immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average
over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, in-
spected and analyzed. Only those parts that can be
brought back to original factory specifications are re-
manufactured. Everyremanufactured airend receives
anewoverhaulkit: bearings,gears,seals,sleevesand
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
justdon’t do. Magnafluxand ultrasonicinspectionspot
cracked or stressed castings, monochromatic light
analysis exposes oil leaks, and coordinate measure-
ment machine inspects to +/– .0001”, insuring that all
remanufactured air ends meet factory performance
specifications.
Warranty
Gardner Denver backs up every remanufactured air
end with a new warranty . . . 18 months from purchase,
12 months from service.
GardnerDenverremanufacturedairendsdeliver
quali-
ty without question . . . year in and year out.
Call Gardner Denver for information on the air end ex-
change program and the name of your authorized dis-
tributor. Phone Number: 800–245–4946 or
FAX: [phone]

13–13–600 Page ii
FOREWORD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To
beassuredofreceivingmaximumservicefromthismachinetheownermustexercisecareinitsoperationandmain-
tenance.Thisbookiswrittentogivetheoperatorandmaintenancedepartmentessentialinformationforday–to–day
operation,maintenance andadjustment.Careful adherenceto theseinstructions willresult ineconomical operation
and minimum downtime.
Danger is used toindicate the presenceof a hazard whichwill cause severepersonal
injury, death, or substantial property damage if the warning is ignored.
Warningisused toindicatethe presenceof ahazardwhich cancausesevere person-
al injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
Notice is used tonotify people of installation, operationor maintenance information
which is important but not hazard–related.
This book covers the following models:
Controller
HP PSIG Air Cooled Water Cooled Parts List Manual
350 100 & 125 ETY99A ETY99A 13–13–500 13–9/10–647
400 100, 125, 150 ETY99A ETY99A 13–13–500 13–9/10–647
500 100, 125, 150 ETY99A ETY99A 13–13–500 13–9/10–647

13–13–600 Page iii
TABLE OF CONTENTS
Maintain Compressor Reliability and Performance With Genuine Gardner Denver Compressor Parts
and Support Services i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1, General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2, Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3, Starting & Operating Procedures 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4, Controls & Instrumentation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6, Air Filter 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7, Coupling 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8, Maintenance Schedule 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9, Trouble Shooting 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER(see nameplateonunit). The SerialNumber
isalso stampedon topof thecylinder flangeto theright
of the inlet housing.
All orders for Parts should be placed with the nearest
authorized distributor.
Where NOT specified, quantity of parts required per
compressor or unit is one (1); where more than one is
required per unit, quantity is indicated in parenthesis.
SPECIFY EXACTLY THE NUMBER OF PARTS
REQUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left Hand side of a
compressor, stand at the motor end and look toward
the compressor. Right Hand and Left Hand are
indicated in parenthesis following the part name, i.e.
(RH) & (LH), when appropriate.

INDEX
13–13–600 Page iv
Actuator, Turn Valve 24. . . . . . . . . . . . . . . . . . . . . . .
Addition of Oil Between Changes 33. . . . . . . . . . . .
Aftercooler 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER, SECTION 6 42. . . . . . . . . . . . . . . . . . .
Air Filter Element Life 42. . . . . . . . . . . . . . . . . . . . . .
Air Filter Vacuum Switch 24. . . . . . . . . . . . . . . . . . .
Air Flow in the Compressor System 1. . . . . . . . . . .
Air Receiver, Auxiliary 11. . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Oil Cooler Module 9. . . . . . . . . . . . . . . .
Ventilation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Sentry Operation 20. . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 22, 23. . . . . . . . . . . . . . . . . . . . . .
Change Procedure, Lubricant 33. . . . . . . . . . . . . . .
Check, Daily 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Draining Oil System 34. . . . . . . . . . .
Cold Ambient Operation 33. . . . . . . . . . . . . . . . . . . .
Cold Weather Operation 13. . . . . . . . . . . . . . . . . . .
Cold Weather Operation, Installation for 12. . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor (GD Eliminator) Oil Separator 39. . .
Compressor Oil Cooler 36. . . . . . . . . . . . . . . . . . . . .
Compressor Oil Cooler – Water–Cooled Heat
Exchanger 38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Filter 35. . . . . . . . . . . . . . . . . . . . . .
Compressor Oil System 30. . . . . . . . . . . . . . . . . . . .
Compressor Oil System Check 41. . . . . . . . . . . . . .
Control Devices 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Transformer 25. . . . . . . . . . . . . . . . . . . . . . .
Controller 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS & INSTRUMENTS, SECTION 4 20.
Controls & Instruments, General Description 20. .
Cooler, Compressor Oil 36. . . . . . . . . . . . . . . . . . . .
Cooling, Sealing and Lubrication 1. . . . . . . . . . . . .
COUPLING, SECTION 7 44. . . . . . . . . . . . . . . . . . .
Coupling 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Cushion Design 44. . . . . . . . . . . . . . .
Daily Check 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 6, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 13. . . . . . . . . . . . . . . . . . . .
Discharge Thermistor 24. . . . . . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 9. . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning Oil System 34. . . . . . . . . . .
Electric Motor Grease Recommendations 17. . . .
Electric Motor Regreasing Interval 17. . . . . . . . . . .
Electrical Wiring 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Air Filter 42. . . . . . . . . . . . . . . . . . . . .
Emergency Stop Push–Button 24. . . . . . . . . . . . . .
Enclosure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Starter 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Oil Reservoir 35. . . . . . . . . . . . . . . . . . . . . . . .
Filter, Compressor Oil 35. . . . . . . . . . . . . . . . . . . . . .
Filter Element 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Heavy Duty Air (Standard) 42. . . . . . . . . . . .
Foundation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Oil Level 22, 34. . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . .
Grease Recommendations, Electric Motor 17. . . .
Grounding 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature Operation 30. . . . . . . . . . . . . . . .
Inlet Line 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 43. . . . . . . . . . . . . . . . . . . . .
Inlet Valve 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION, SECTION 2 8. . . . . . . . . . . . . . . .
Installation, General 8. . . . . . . . . . . . . . . . . . . . . . . .
Installation for Cold Weather Operation 12. . . . . .
Lifting Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 13. . . . . . . . . . . . . . . . . . . .
Line, Inlet 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure Protection 9. . . . . . . . . . . . . . . . .
Lubricant, Recommended 30. . . . . . . . . . . . . . . . . .

INDEX
13–13–600 Page v
Lubricant Change Procedure 33. . . . . . . . . . . . . . .
Lubrication, Cooling and Sealing 1. . . . . . . . . . . . .
Lubrication, Motor 16. . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 30. . . . . . . . . . . . . .
Main Starter 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE, SECTION 8 45. . .
Minimum Discharge Pressure Valve 22. . . . . . . . .
Moisture in the Oil System 34. . . . . . . . . . . . . . . . . .
Moisture Separator/Trap 13. . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 17. . . . . . . . . . .
Motor Lubrication 16. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 17. . . . . . . . . . . . . . . . . .
Oil Change Interval 34. . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Compressor 36. . . . . . . . . . . . . . . . . . . .
Oil Cooler – Installation 11. . . . . . . . . . . . . . . . . . . .
Oil Cooler – Location and General Piping 10. . . . .
Oil Filter, Compressor 35. . . . . . . . . . . . . . . . . . . . . .
Oil Level Gauge, 22, 34
Oil Reservoir 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir, Filling 35. . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 9. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator
Compressor (GD Eliminator) 39. . . . . . . . . . . . .
Inspection 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Carryover 40. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal for Inspection or Replacement 40. . .
Oil Specifications 30. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System
Compressor 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning 34. . . . . . . . . . . . . . . . . .
Oil System Check 41. . . . . . . . . . . . . . . . . . . . . . . . .
Air and Oil Discharge Temperature 41. . . . . . .
Compressor Oil Inlet Temperature 41. . . . . . . .
Oil Cooler Oil Pressure Differential 41. . . . . . . .
Oil Cooler Temperature Differential 41. . . . . . .
Oil Cooler Water Pressure Differential 41. . . . .
Oil Inlet Pressure 41. . . . . . . . . . . . . . . . . . . . . . .
Operation
Cold Ambient 33. . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 30. . . . . . . . . . . . . . . . . . . . . .
Optional Switches 24. . . . . . . . . . . . . . . . . . . . . . . . .
Piping, Water 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Differential Gauging 40. . . . . . . . . . . . . . .
Pressure Regulator 22. . . . . . . . . . . . . . . . . . . . . . . .
Prestart–Up Instructions 18. . . . . . . . . . . . . . . . . . . .
Air Filter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil 18. . . . . . . . . . . . . . . . . . . . . . . .
Coupling 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Piping 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 19. . . . . . . . . . . . . . . . . . . . . . .
Purge Air Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Lubricant 30. . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 17. . . . . . . . . .
Regulator, Pressure 22. . . . . . . . . . . . . . . . . . . . . . .
Relief Valve 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Ordering Instructions iii. . . . . . . . . . .
Reservoir, Oil 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reservoir Pressure Transducer 24. . . . . . . . . . . . .
Safety Precautions 4, 5. . . . . . . . . . . . . . . . . . . . . . .
Sealing, Lubrication and Cleaning 1. . . . . . . . . . . .
Separator, Compressor (GD Eliminator) Oil 39. . .
Separator/Trap, Moisture 13. . . . . . . . . . . . . . . . . . .
SERVICE CHECK LIST, AIR FILTER 45. . . . . . . .
Service Check List 45. . . . . . . . . . . . . . . . . . . . . . . .
Every 1000 Hours Operation 45. . . . . . . . . . . . .
Every 125 Hours Operation 45. . . . . . . . . . . . . .
Every 6000 Hours Operation 45. . . . . . . . . . . . .
Every 8 Hours Operation 45. . . . . . . . . . . . . . . .

INDEX
13–13–600 Page vi
Every Year 45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 45. . . . . . . . . . . . . . . . . . . . . . .
Oil Separator 45. . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valves IVC and IVO 22. . . . . . . . . . . . . . .
Solenoid Valves TVC and TVO 24. . . . . . . . . . . . . .
Specifications, Oil 30. . . . . . . . . . . . . . . . . . . . . . . . .
Starter
Fan 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES,
SECTION 3 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Unit 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Strip, Terminal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Air Filter Vacuum 24. . . . . . . . . . . . . . . . . . .
Switches, Optional 24. . . . . . . . . . . . . . . . . . . . . . . .
System Pressure Transducer 24. . . . . . . . . . . . . . .
System Thermistor 24. . . . . . . . . . . . . . . . . . . . . . . .
Terminal Strip 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal Control (Thermostatic Mixing) Valve 37.
Thermistor
Discharge 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer
Reservoir Pressure 24. . . . . . . . . . . . . . . . . . . . .
System Pressure 24. . . . . . . . . . . . . . . . . . . . . . .
Transformer, Control 25. . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING, SECTION 9 46. . . . . . . . .
Tube, Inlet 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve 2, 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve Actuator 24. . . . . . . . . . . . . . . . . . . . . . . .
Valve
Blowdown 22, 23. . . . . . . . . . . . . . . . . . . . . . . . .
Inlet 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure 22. . . . . . . . . . . .
Purge Air 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid IVC and IVO 22. . . . . . . . . . . . . . . . . . .
Solenoid TVC and TVO 24. . . . . . . . . . . . . . . . .
Thermal Control (Thermostatic Mixing) 37. . . .
Turn 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Flow Control 38. . . . . . . . . . . . . . . . . . . . .
Water Shutoff 39. . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Flow Control Valve for Heat Exchanger 38.
Water Piping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Shutoff Valve – Water–Cooled Heat Ex-
changer 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring, Electrical 15. . . . . . . . . . . . . . . . . . . . . . . . . .

13–13–600 Page vii
LIST OF ILLUSTRATIONS
Figure # Description Page
Figure 1–1 Compression Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 Air Cooled Unit – Less Enclosure – 1st Stage Compressor Side 2. . . . . . . . . . . . . . . . . . . . . .
Figure 1–3 Air Cooled Unit – Less Enclosure – 2nd Stage Compressor Side 2. . . . . . . . . . . . . . . . . . . . .
Figure 1–4 Air Cooled Unit – Less Enclosure – Control Box End 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–5 Air Cooled Unit – Less Enclosure – Oil Reservoir End 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–1 Typical Compressor Room 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Air Flow Chart 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–3 Piping Schematic 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–4 Piping Diagram for Aftercooler and Heat Exchanger 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–5 Cooler Drain Detail 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–6 Cold Weather Installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–7 Inlet Line Lengths 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–8 Heat Exchanger (Oil Cooler) Approximate Water Flow 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–9 Aftercooler Approximate Water Flow 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–10 Ampacity, Fuse and Breaker Sizes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–1 Schematic Tubing Diagram 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Blowdown Valve 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Minimum Discharge Pressure Valve 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Inlet Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Shuttle Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Turn Valve Control 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Turn Valve Actuator 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–8 Control Schematic – Compressor at Full Load 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–9 Control Schematic – Compressor Fully Unloaded – Constant Speed Mode 27. . . . . . . . . . .
Figure 4–10 Control Schematic – Compressor Fully Unloaded – Low Demand Mode or Auto Mode 28.
Figure 4–11 Wiring Diagram – 212EAP546 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Flow Diagram 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Oil Flow Diagram – Remote Overhead Mounted 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Oil Change Interval 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–4 Approximate Oil System Capacities 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–5 Water Control Valve 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–6 Dew Point Temperature vs. Ambient Temperature, (100% Relative Humidity) 39. . . . . . . . .
Figure 5–7 Single Element Oil Separator 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy Duty Air Filter (Standard) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Installation of Coupling Cushions 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–13–600 Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSION CYCLE
COMPRESSOR – The Gardner Denver Electra–Sav-
erRcompressor is a single stage, positive displace-
mentrotarymachineusing meshinghelicalrotorsto ef-
fect compression. The input drive shaft and helical
drive gear are supported in the gear case by high ca-
pacity tapered roller bearings. The drive gear meshes
with a driven gear mounted on the main rotor shaft to
drive the rotors. Both rotors are supported between
largecapacityanti–frictionbearingslocatedoutsidethe
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 to locate
each rotor axially and carry all thrust loads; later mod-
els use tapered roller bearings in this location.
COMPRESSION PRINCIPLE (FIGURE 1–1) – Com-
pression is accomplished by the main and secondary
rotors synchronously meshing in a one–piece cylinder.
Themain rotorhas four (4)helical lobes90_apart. The
secondary rotor has five (5) matching helical grooves
72_apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor
near the center. The discharge port is near the bottom
at the opposite end of the compressor cylinder.
Figure
1–1 is an inverted view to show inlet and discharge
ports
.Thecompression cyclebeginsas rotorsunmesh
attheinlet port and air is drawn into the cavitybetween
the main rotor lobes and secondary rotor grooves (A).
When the rotors pass the inlet port cutoff, air is trapped
intheinterlobecavityandflowsaxiallywiththemeshing
rotors (B). As meshing continues, more of the main ro-
tor lobe enters the secondary rotor groove, normal vol-
ume is reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-
ductionandpressureincreasecontinuesuntiltheair/oil
mixture trapped in the interlobe cavity by the rotors
passesthedischargeportandisreleasedtotheoilres-
ervoir(C). Each rotor cavity followsthe same “fill–com-
press–discharge” cycle in rapid succession to produce
a discharge air flow that is continuous, smooth and
shock free.
AIR FLOW (FIGURE 5–1, page 31) – Air enters the air
filterand passes through the inletunloader valve to the
first stage compressor. After first stage compression,
the air/oil mixture passes through the interstage man-
ifold where coolant is injected. The air/oil mixture then
iscompressedtothefinaldischargepressureinthese-
cond stage compressor. After compression, the air/oil
mixture passes into the oil reservoir where most of the
entrained oil is removed by velocity change and im-
pingement and drops back into the reservoir. The air
andremainingoilthenpassesthroughtheoilseparator,
theseparated oil is returned tothe system through tub-
ing connecting the separator and the first stage com-
pressor. The air passes through the reservoir dis-
charge manifold, minimum pressure/discharge check
valve, and the customer furnished unit shutoff valve if
aftercooled. If water cooled, the aftercooler and mois-
tureseparator are between the minimum pressure/dis-
charge check valve and the customer supplied shutoff
valve.
LUBRICATION, COOLING AND SEALING – Oil is
forcedbyair pressurefromthe oilreservoirthrough the
oil cooler, thermostatic mixing valve/oil filter assembly
and is piped to the first stage compressor, second
stage compressor and the interstage manifold. A por-
tionof the oil to the compressors isdirected through in-
ternal passages to the bearings, gears and shaft oil
seals. Thebalance of theoil is injected directlyinto the

13–13–600 Page 2
compressionchamber toremove heat ofcompression,
seal internal clearances and lubricate the rotors.
TURN VALVE – The turn valve is a rotary helical valve
locatedonthedischargesideofthe cylindertowardthe
inletend.Thevalveopensandclosesportsinthecylin-
der which communicates with the inlet passage. This
varies the compressor rotor volume to match the de-
mand for air, thus reducing the part–load power re-
quirement.
FIGURE 1–2 – AIR COOLED UNIT – LESS ENCLOSURE – 1ST STAGE COMPRESSOR SIDE
300ETY797
(Ref. Drawing)
FIGURE 1–3 – AIR COOLED UNIT – LESS ENCLOSURE – 2ND STAGE COMPRESSOR SIDE
300ETY797
(Ref. Drawing)