Gardner Denver ELECTRA-SAVER II Service manual

/I)Price $5.00
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GARDNER-DENVER@ 13-9-642
1st Edition
ELECTRA-SAVERII@
STATIONARY
BASE-MOUNTED
COMPRESSOR
MODELS
40 &50 HP
ECH
INDUSTRIAL MACHINERY
ICOOPER
INDUSTRIES

FOREWARD
Gardner-Denver Electra-Saver Il” 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 maintenance department essential information for
day-to-day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical
operation and minimum downtime.
DANGER
Failure to observe aDANGER notice could result in injury to, or death of personnel.
WARNING
Failure to observe aWARNING notice could result in damage to equipment.
CAUTION
CAUTION notices set forth general reminders of good safety practice, or direct
attention to unsafe practices.
NOT E
Information furnished in aNOTE will include general information or the highlights of
aprocedure.
This book covers the following models:
HP PSIG Air Cooled Water Cooled
40 100, 125 ECHQLE ECHSLE
50 100, 125 ECHQME ECHSME
150
TABLE OF CONTENTS
GENERAL INFORMATION .............................................................................................................................SECTlON 1
INSTALLATION ...............................................................................................................................................SECTlON 2
STARTING AND OPERATING PROCEDURES ..............................................................................................SECTlON 3
CONTROLS AND instruments .................................................................................................................SECTlON 4
LUBRICATION, OIL COOLER, OIL FILTER AND SEPARATOR ....................................................................SECTlON 5
AIR FILTERS ...................................................................................................................................................SECTlON 6
COUPLING ......................................................................................................................................................SECTlON 7
MAINTENANCE SCHEDULE ..........................................................................................................................SECTlON 8
TROUBLE SHOOTING ...................................................................................................................................SECTlON 9
13-9-642 Page i

INDEX
NOTE: Numbers preceding dash are Section Numbers -- Numbers following dash are Page Numbers
Addition of Oil Between Changes ..........................5-1
Adjustments .............................................................4.5
Air Control Components .........................................4-1
Air Filter Vacuum Switch .........................................4-3
AIR FILTERS (SECTION 6) .....................................6-1
Air Flow in the Compressor System .......................1-1
Auxiliary Accessories ..............................................2-3
Auxilia~ Air Receiver ...............................................2.3
Blowdown Valve ...............................................4.l. 4-3
Blowdown Valve Piping ..........................................2-4
Check Valve .............................................................4.2
Cold Ambient Operation .........................................5-1
Cold Weather Operation, Installation for ................2-2
Compression Principle ............................................1-1
Control Piping .........................................................2.3
CONTROLS &INSTRUMENTS (SECTION 4) ........4-1
Control Schematics ..................................4-6 thru 4-8
Control System Operation ......................................4-4
COUPLING (SECTION 7) .......................................7-1
Daily Check .............................................................3.l
Discharge Pressure Transducer ..............................4.3
Discharge Temperature, Air and Oil .......................5-4
Display, Controller ....................................................4.5
Draining and Cleaning Oil System .........................5-3
Electrical Wiring .......................................................2.5
Enclosure ................................................................2.2
Emergency Stop Button ........................................ 4-1
Filling Oil Reservoir .................................................5.3
Flow Diagram -- Air/Oil Systems ..............5-2. 5-3, 5-4
Foundation ..............................................................2.2
GENERAL INFORMATION (SECTION 1) ...............1-1
Grease Recommendations ....................................2-5
Grounding ...............................................................2.5
High Discharge Temperature .................................4-1
High Temperature Operation ..................................5-1
Inlet Line .................................................................2.4
Inlet Valve ...............................................................4.l
INSTALLATION (SECTION 2) .................................2-1
Lifting Unit ...............................................................2.l
Location ...................................................................2.l
Lubricant ..................................................................5.l
Lubrication, Cooling and Sealing ...........................1-1
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5) ..................................5-1
MAINTENANCE SCHEDULE (SECTION 8) ...........8-1
Minimum Discharge Pressure Valve ......................4-2
13-9-642
Moisture in the Oil System .....................................5-4
Moisture Separator/Trap ........................................2-3
Motor Lubrication ...................................................2.5
Motor Protection Devices .......................................4-1
Oil Change Interval .................................................5.4
Oil Cooler, Compressor -Radiator Type ...............5-5
Oil Cooler, Compressor -Water Cooled .................5-6
Oil Cooler Oil Pressure Differential .............. . ..... 5-7
Oil Cooler Temperature Differential ...................... 5-7
Oil Cooler Water Pressure Differential ..................5-7
Oil Filter, Compressor ............................................5-5
Oil Inlet Pressure .................................................... 5-7
Oil Inlet Temperature ............................................. 5-7
Oil Level Gauge ......................................................5.4
Oil Separator (G-D Eliminator) ...............................5-7
Oil Specifications ....................................................5-1
Oil System Check .................................................. 5-7
Oil System, Compressor ........................................5-1
Pressure Differential Gauging ................................5-7
Pressure Regulator .................................................4.3
Prestart-up Instructions ..........................................3-1
Programmable Controller ...................................... 4-4
Programmable Controller Operation .....................4-4
Protective Devices and Shutdown .........................4-1
Purge Air Valve .......................................................4.2
Regressing Interval .................................................2.5
Relief Valve ..............................................................4.l
Reservoir Pressure Switch .....................................4-6
Safety Precautions .................................................. 1-4
Service Check List ..................................................8-1
Shuttle Valve ...........................................................4.3
Solenoid Valves -lVCand IVO ................................4-3
Solenoid Valves -TVCand TVO ..............................4-3
Starter/Control Panel ..............................................4-4
STARTING &OPERATING PROCEDURES
(SECTION 3) .......................................................3.l
Stopping Unit ..........................................................3-2
Synthetic Lubricants ...............................................5-l
System Pressure Transducer .................................4-3
Thermal Control Valve ............................................5-5
TROUBLE SHOOTING (SECTION 9) .....................9-1
Vibration Switch .......................................................4.3
Water Flow Control Valve for Heat Exchanger ......5-6
Water Piping ............................................................2.4
Water Shutoff Valve .................................................5.7
Wiring Diagrams .....................................................4.9
Page ii

SECTION 1
GENERAL INFORMATION
v
FIGURE 1-1 -COMPRESSION CYCLE
COMPRESSOR -The Gardner-Denver@ Electra-
Saver II compressor isasingle stage, positive displace-
ment rotary machine using meshing helical rotors to
effect compression. Both rotors are supported between
high capacity roller bearings located outside the com-
pression chamber. Single width cylindrical roller bear-
ings are used at the inlet end of the rotors to carry part
of the radial loads. Tapered roller bearings at the dis-
charge end locate each rotor axially and carry all thrust
loads and the remainder of the radial loads.
COMPRESSION PRINCIPLE (Figure 1-1) - Compres-
sion is accomplished by the main and secondary rotors
synchronously meshin in aone-piece cylinder. The
main rotor has four (4 helical lobes 90 apart. The
secondary rotor has six (6) matching helical grooves 60°
apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor
cylinder near the drive shaft end. The discharge port is
near the bottom at the opposite end of the compressor
cylinder. Figure 1-1 is an inverted view to show inlet and
discharge ports. The compression cycle begins as
rotors unmesh at the inlet port and air is drawn into the
cavity between the main rotor lobes and secondary rotor
grooves (A). When the rotors pass the inlet port cutoff,
air istrapped inthe interlobe cavity and flows axially with
the meshing rotors (B). As meshing continues, more of
the main rotor lobe enters the secondary rotor grove,
normal volume is reduced and pressure increases.
v
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 interiobe cavity by the
rotors passes the discharge port and is released to the
oil reservoir (C). Each rotor cavity follows the same
“fill-compress-discharge” cycle in rapid succession to
produce adischarge airflow that is continuous, smooth
and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure
1-5) -Air enters the air filter and passes through the inlet
unloader valve to the compressor. After compression,
the air/oil mixture passes into the oil reservoir where
most of the entrained oil is removed by velocity change
and impingement and drops back into the reservoir. The
air and remaining oil then passes through the separator
where most of the oil isremoved. The air passes through
the discharge check valve, minimum pressure valve and
aftercooler, then to the plant air lines.
LUBRICATION, COOLING AND SEALING -Oil is
forced by air pressure from the oil resetvoir through the
oil cooler, thermostatic mixing valve, and oil filter and
discharge intothe compressor main oil gallery. 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.
13-9-642 Section 1Page 1

.
STARTER
CONTROL
BOX
o
.-EMERGENCY STOP
EMERGENCY STOP
\
‘“E”D”cONTROLpANEL1\
CONTROL TRANSFORMER
\ \ \
FIGURE 2-1
DRIVE MOTOR 7
~__ —---
0
FIGURE 3-1
—MAIN MOTOR
STARTER
‘FAN MOTOR
STARTER
FIGURE 4-1
13-9-642 Sectionl Page2

MINIMUM
PRESSURE
CHECK VALVE
DISCHARGE -7
VALVE \\
““NG‘ALvE\\\ To”“’TER
OIL CO OLERm
FIGURE 5-1
INLET VALVE 1
COMPRESSOR ~
(L
.—.--.—.-—
—COUPLING GUARD
-OIL LEVEL GAUGE
4
I
I
I
J
FIGURE 6-1
13-9-642 Section 1Page 3

SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances
cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for
safety hazards and be cautious.
Some general safety precautions are given below:
WARNING
Failure to observe these notices could result in damage to equipment.
.Stop the unit if any repairs or adjustments on or around the compressor are
required.
●All compressed air supply hoses exceeding 1/2 inch inside diameter should
have an excess flow valve. (OSHA Regulation, Section 1518.302)
.Do not exceed the rated maximum pressure values shown on the nameplate.
.Do not operate unit if safety devices are not operating properly. Check
periodically. Never bypass safety devices.
DANGER
Failure to observe these notices could result in injury to or death of personnel.
.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 thermo-
static mixing valve or break any connections, etc. in the compressor air or
oil system until the unit is shut down and the air pressure has been relieved.
.Electrical shock can and may be fatal.
.Compressor unit must be grounded in accordance with the National Electri-
cal 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 at any time.
13-9-642 Section 1Page 4

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 pos-
sible.
CAUT ION I
Do not electric weld on the compres-
sor or base; bearings can be damaged
by passage of current.
LIFTING UNIT -Proper lifting and/or transporting
methods must be used to prevent damage. -
CAUTION
Liftcompressor unit by base onl .Do
not use other places such as
enclosure, motor, compressor oil dis-
charge manifold and piping as lifting
points.
DANGER
The eyebolts or lugs provided on the
motor are for Iifting the motor only and
should not be use to lift any additional
weight. All eyebolts must be securely
tightened. when
lifting the motor the
Iifting angle must not exceed 15
degrees. failure to observe this warn-
ing may result in damage to equipment
or personal injury.
Lifting slots are provided in the base for towmotor use.
Unit may also be moved into location by rolling on bars.
LOCATION -The compressor should be installed,
whenever possible, in aclean, well-lighted, well-venti-
lated 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
proper air supply.
Both the air-cooled and water-cooled units require cool-
ing air as well as air to the compressor inlet. Proper
ventilation MUST be provided; hot air must be exhausted
from the compressor operating area. Atypical inlet-out-
let air flow arrangement is shown in Figure 1-2.
AIR-COOLED UNIT -Acombination oiI/aftercooler is
supplied as standard equipment on all air-cooled units.
The air-cooled unit with the standard enclosure requires
sufficient flow, Figure 2-2, for the compressor oil/after-
cooling system and for electric motor cooling. Air is
drawn into the unit at the motor side of the enclosure
and is exhausted at the oil cooler side. Do not block the
air flow to and from the unit. Allow three and one-half
(3-1/2) feet to the nearest obstruction on the starter end
and control box end of the unit. Allow three (3) feet to
the nearest obstruction above and on other sides of unit.
For continuous efficiency, oil cooler cores must be pe-
riodically cleaned with either vacuum or compressed air.
If wet cleaning is required, shield motor and spray on a
mild soap solution and flush with clean water.
WARNING
For aluminum oil coolers, do not use
any cleaning solution that is not com-
patible with aluminum. Use of im-
proper solution may result in damage
to cooler.
WATER-COOLED UNITS -The water-cooled unit with
the standard enclosure requires sufficient air flow, Figure
2-2, for electric motor cooling. Air is drawn into the unit
at the top ofthe enclosure and is exhausted at the motor
side. Do not block air flow to and from unit. Allow three
and one-half (3-1/2) feet to the nearest obstruction on
the starter end and control box side of the unit. Allow
three (3) feet to the nearest obstruction above and on
other sides of the unit.
FOUNDATION -The Electra-Saver II@compressor re-
LOUVERED EXHAUST FAN LOUVEREO
wINDOW WINOOW
Ik~”’ “
.: ...‘,,>....
:\I I
tSIR OUT
14
,,
...’....+ .4 . .. .. .. . . . ,
A75119
FIGURE 1-2- TYPICAL COMPRESSOR ROOM
IMinimum Air Flow* For Compressor
And Cooling (Cubic Feet/Minute) I
Air Cooled Water Cooled
All Models 6000 cfm 1700 cfm
1II1
*60”F inlet air.
FIGURE 2-2
13-9-642 Section 2Page 1

MO TORm ~COMPRESSOR r8FT PLYWOOD “FENCE- 8FT. PLYWOOD ““FENCE’”
-WFLLMAN RADIANT 2–ELEMENT
(OR EOUAL)
:;;c ‘:’?:!:sO’ b4FT.
r-./ HEATER (
RH4m WI
ELEMENT
3.200 WA, ,, .n~n
‘-\ /
P
rr
‘+_
OIL RI SERVOIR \
\
LAWAY fROM PREVAILING WINOS L~~~~~~~ ~*o,A~T 2-~L~~~~~
HEATER (OR EOUAL) ELEVATION VIEW
RH7W WITH [2) RH7502
ELEMENTS -2REOO.
6.200 WATTS EACH
FIGURE 3-2- COLD WEATHER INSTALLATION
quires no special foundation, but should be mounted on
asmooth, solid surface. Whenever possible install the
unit near level. Temporary installation may be made at
amaximum 10° angle lengthwise or 10° sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt, ordangerof shiftingfrom outside vibration or moving
vehicles may require the use of mounting bolts and
shims to provide uniform support for the base.
OIL RESERVOIR DRAIN -The oil drain is piped from
the bottom of the reservoir to the side of the frame. This
drain is approximately 4.5o inches above the floor level.
If this is not sufficient to conveniently drain the oil some
other methods of providing drain are:
1. Elevate the compressor unit on raised blocks to
obtain the desired drain height.
CAUTION
If the compressor unit base is raised
above floor level, the space between
the floor and the base bottom must be
closed with solid material all around to
prevent recirculation of hot air from the
oil cooler end and over temperature
operation.
2. Construct an oil sum or trough below the floor
P
level and pump or bai the drained oil.
3. Pump oil from the reservoir filler opening or drain
to acontainer.
ENCLOSURE -The compressor, electric motor, oil
cooler and aftercooler are mounted inside the
enclosure.
Service doors are provided for maintenance access. Be
sure to allow enough space around the unitfor the doors
to open completely.
Any ofthe enclosure doors maybe removed by opening
the door and lifting itup slightly to disengage the hinges.
The motor inspection/air filter service panel is held by
two latches and lifts away from the enclosure. The air
outlet panel is attached by screws to the enclosure and
is not readily removable.
INSTALLATION FOR COLD WEATHER OPERATION
-It is recommended that whenever possible the unit be
installed inside ashelter that will be heated to tempera-
tures above freezing (32”F, O“C). This will eliminate
many of the problems associated with operating the
unitsoutside incold climates where freezing rain, drifting
snow, freezing condensate and bitter cold temperatures
are encountered.
Refer to Engineering Data Sheet 13-9-411 for the ad-
vantages of using the heat recovered from rotary com-
pressors. This heat recovery could easily pay for an
adequate shelter for the unit.
When an outside installation must be made, the precau-
tions required will depend on how severe the environ-
ment. The following are general guidelines for outside
installations:
Cold Weather (Down To -10”F)
1. Be sure all control lines, drains and traps are heated
to avoid freezing of condensate. Heat tape with
thermostat control is generally satisfactory for this
purpose and can be obtained at various local
plumbing or hardware outlets at nominal cost.
2. Ifan air-cooled aftercooler isto 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.
3. Provide at least some simple shelter such as a
plywood windbreak to protect against drifting
snow.
4. Use only Gardner-Denver@ AEON ‘M 9000
lubricant.
13-9-642 Section 2Page 2

5. Monitor unit carefully during start-up and operation
to be sure it is functioning normally.
6. Specify NEMA 4enclosure for electrical devices.
Extreme Cold Weather Operation (Down To -40*F)
In addition to the above, the following should be
provided:
1. It will probably be necessary to provide shutters or
to block off part ofthe cooler in some manner since
the cooler isgreatly oversized for operation inthese
low temperatures. Since shutters are not provided
as a factory option, blocking off aortion of the
P
cooler with plywood should be satis actory.
2. Lo-Demand operation should not be used in ex-
treme environments.
3. 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-1O“F
environment for coolers motor and sump. Figure
3-2 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
building where enough heat can be used to keep the
compressor room above freezing will save many com-
plications in the operation and installation of the unit.
Refer to Engineering Data Sheet 13-9-411 for the ad-
vantages of using the heat recovered from rotary com-
pressors. This heat recovery could easily pay for an
adequate shelter for the unit.
AUXILIARY AIR RECEIVER -An auxiliary air receiver is
not required if the piping system is large and provides
sufficient storage capacity to preveni rapid cycling.
When used, an air receiver should be of adequate size,
provided with arelief valve of proper setting, apressure
gauge and ameans of draining condensate.
MOISTURE SEPARATOR/TRAP -Since unit is
equipped with abuilt-in aftercooler, acombination mois-
ture separator and trap is furnished with the unit.
CONTROL PIPING -External control piping is not
necessary since the Electra-Saver II unit is factory
wired and piped for the control system specified.
INLET LINE -Where an inlet line is used between the air
filter and the compressor, it must be thoroughly cleaned
on the inside to prevent dirt or scale from entering the
compressor. If welded construction is used, the line
must be shot blasted and cleaned to remove welding
scale. In either case, the inlet line must be coated
internally by galvanizing or painting with amoisture and
oil-proof sealing lacquer. Up to ten (1O) feet in length,
the inlet line should be the full size of the inlet opening
on the compressor. If an extra-long line is necessary,
the pipe size should be increased according to Inlet Line
Chart below.
INLET LINE LENGTHS
Length of Inlet Line Diameter of Pipe Size
Oto 10 Feet ...........................................................................................................Same as Compressor Inlet Opening
10t017 Feet ...........................................................................................................One Size Larger Than Inlet Opening
17 to 38 Feet. ........................................................................................................Two Sizes Larger Than Inlet Opening
-- OIL COOLER
Water Temperature To Heat Exchanger Maximum
Water
HP Model 60”F70”F80° F90”FFlow
40 ECHSKE 3.4 4.3 5.7 8.6 30.0
50 ECHSLE 4.1 5.1 6.8 10.2 30.0 =
Approximate Water
Pressure Drop 090”F
Water Flow (PSI)
1.0
1.5
IAFTERCOOLER I
Water Temperature To Heat Exchanger Maximum
Al1owable
HP Model 6o°F70”F80”F90”FFlow (GPM)
40 ECHSKE 0.5 0.7 0.9 1.3 26.0
50 ECHSLE 0.7 0.9 1.2 1.8 26.0
Approximate
Water Pressure
drop
flow ratesare based on 110*F maximum allowable outlet water temperature. Higher water outlet temperatures
can lead to heat exchanger malfunction by causing fouling in the last water pass.
FIGURE 4-2- HEAT EXCHANGER (OIL COOLER-AFTERCOOLER)
APPROXIMATE WATER FLOW -U.S. GALLONS/MINUTE
13-9-642 Section 2Page 3

OIL o;~
OUT
-, ;Y:;R’”:::,::E
:/
I
am WATER
HEAT ExCHAWER WT
[AFTERCOOLEQ v#.TER C76682
AIR
IN
‘-s LPARATOR/T2LP
*(OPTIONAL) WATER CONTROL VALVE AND WATER
FIGURE 5-2 -SERIES PIPING
Accessibility for inlet air filter servicing must be con-
sidered when relocating the filters from the unit to a
remote location.
DISCHARGE SERVICE LINE -The discharge service
line connection on both water-cooled and air-cooled
units is made at the right hand corner of the unit, viewed
from the opposite end from control panel side. When
manifolding two or more Electra-Saver II Runits on the
same line, each unit is isolated by the check valve inthe
unit discharge line. If an Electra-Saver II unit is
manifolded to another compressor, be sure the other
compressor has acheck valve in the line between the
machine and the manifold. If an Electra-Saver II and a
reciprocating compressor are manifolded toaether, an
air-r’eceiver must be located between the two-units.
DANGER
Discharge air used for breathing will
cause severe injury or death.
Consult filtration specialists for addi-
tional filtration and treatment equi -
P
ment to meet health and safe y
standards.
BLOWDOWN VALVE PIPING -The blowdown valve is
fitted with amuffler for operation indoors. Ifthe installa-
tion requires, the muffler may be removed and the blow-
down valve piped to the outside with apipe sizethe same
as the blowdown valve outlet connection.
WATER PIPING (Water-Cooled Heat Exchanger
Models Only) -On machines equipped with water-
cooled heat exchangers, the water inlet and outlet con-
nections are located in the unit base flange on the left
side of the unit.
The water source should be capable of supplying up to
C76663
OIL IYJT OIL IN
t
~
“= rHER MOSTAT IC ~
MfxING vUVE 1
41----— ~‘wATER CWTROLVALVE
————--
WATER YUTOFF WVE
A‘wATER
HEAT EXCHANGER OUT
WATEQ
OUT ‘—~- 1L
*WT ER
*wA.TEP S~UIOff VALVEJ IN
v--,
-4 At
*’#AT CRC~T ROL VALVE
I
AiR~:~
IN ‘- 5EPARATOR/TRAP
SHUTOFF VALVE MUST BE ORDERED SEPARATELY.
FIGURE 6-2 -PARALLEL PIPING
the maximum flow shown in Figure 5-2 at aminimum
pressure 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.
The heat exchanger system isdesigned to operate with
water inlet temperatures from 60”F to 90°F and awater
outlet temperature not to exceed 11O“F. If water cooler
than 60”F is used, high water outlet temperatures (over
11O“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
inlet temperatures and high water usage will result.
Most water systems will require control of impurities:
filtration, softening or other treatment. See “Compres-
sor Oil Cooler -Water-Cooled Heat Exchanger” for more
information on the water system.
SERIES PIPING (Figure 5-2) -Water flow must be
through aftercooler first for effective cooling of dis-
charge air and isso piped on the standard water-cooled
unit.
PARALLEL PIPING (Figure 6-2) -Aseparate water
control valve is required to control the discharge air
temperature. If aremote (externally mounted) water-
cooled aftercooler is piped in parallel with the heat
exchanger, provide aseparate water control valve for
the aftercoolerand pipe separate inletwaterlines to both
the aftercooler and heat exchanger.
The water control valve isto be adjusted to maintain oil
out ofthe heat exchanger within the 140° to 150° Frange
regardless of inlet water flow and temperature as long
as a minimum flow for agiven temperature (Figure 4-2)
is met. See Section 5for adjustment instructions and
maximum oil temperatures.
ELECTrlCAL WIRING -Standard Units -The Electra-
Saver II compressor is factory wired for all starter to
motor and control connections for the voltage specified
13-9-642 Section 2Page 4

on the order. It is necessary only to connect the unit
starter to the correct power supply. The standard unit is
supplied with an open drip-proof motor, aNEMA 12
starter and control enclosure. See “Location” paragraph
for distance to nearest obstruction on starter and control
box sides of the unit.
Lower operating voltages (200/208) starter, if not suP-
plied with the compressor unit, the starter isto be asize
6full voltage non-reversing type in NEMA (CEMA)
enclosure suitable for the environment, with two (2)
rejection type control circuit fuses (size according to
motor starter manufacturer’s standard), a 200 (208) volt
coil, and three (3) overload heaters for 200 (208) volt 40
or 50 HP, 1.15 service factor motor. The overload
heaters are to be selected according to starter
manufacturer’s tables based on motor nameplate full
load amperage.
WARNING
Electrical shock can cause injury or
death. open main disconnect switch
before working on starter/control box.
GROUNDING -Equipment must be grounded in ac-
cordance with Table 250-95 of the National Electrical
Code.
MOTOR LUBRICATION -Long time satisfactory opera-
tion of an electric motor depends in large measure on
proper lubrication of the bearings. The following charts
show recommended grease qualities and regressing
intervals for ball bearing motors. For additional informa-
tion refer to the motor manufacturer’s instructions. The
following procedure should be used in regressing:
1.
2.
3.
4.
5.
6.
7.
Stop the unit.
Disconnect the unit from the power supply.
Remove the relief plug and free hole of hardened
grease.
Wipe lubrication fitting clean and add grease with
ahand-operated grease gun.
Leave the relief plug temporarily off. Reconnect
unit and run for about 20 minutes to expell the
excess grease.
Stop the unit. Replace the relief plug.
Restart the unit.
IWARNING I
~
Rotatin machinery can cause injury
before working on electric motor.
GREASE RECOMMENDATIONS
Standard
Service
Worked Penetration ................................................. . ... ............................ 265-296
Oil Viscosity, SSU At 100”F............................................. ............................ 400-550
Soap Type .................................................................................................... Lithium
N-H Bomb, Minimum Hours For20 PSI Drop at 21O”F.................................. 750
Bleeding, Maximum Weight % In 500 Hours 212°F. ...................................... 10
Rust Inhibiting. .................................................................................................. Yes
REGRESSING INTERVAL
High
Temperature
220-240
475-525
Lithium
1000
3
Yes
Type of Service Typical Examples Rating Relubrication Interval
Standard One- or Two-Shift Operation 150 HP &Below 18 Months
Severe Continuous Operation 150 HP &Below 9Months
Very Severe Dirty Locations, High 150 HP &Below 4Months
Ambient Temperature
13-9-642 Section 2Page 5

SECTION 3
STARTING &OPERATING PROCEDURES
PRESTART-UP INSTRUCTIONS -Anew unit as
received from the factory has been prepared for ship-
ping only. Do not attempt to operate the unit until
checked and serviced as follows:
1. Compressor Oil -Check oil level in the reservoir.
Add oil only if the oil level gauge reads in the red
“ADD OIL” range. Do not mix different tpe oils
D
Unit is shipped filled with Gardner- enver
AEON ‘M9000 Lubricating Coolant which issuitable
for the first 8000 hours under normal operating
conditions.
REPIACE OIL FILTER EVERY 1000 HOURS.
Initial fill, or filling after acomplete draining of the
system, may show the oil level in the yellow “EX-
CESS OIL” range. After start-up, the oilwill fall into
the reen operating range as system components
are filled. If necessary, add oil to bring the level to
the top of the green range as read when the unit is
operating at full load and normal pressure. See
Figure 3-5.
NOT ICE
Regular maintenance and replace-
ment at required intervals of the oil
filter, air filter and air-oil separator is
necessary to achieve maximum ser-
vice and extended drain intervals of
AEON 9000 synthetic lubricant. Use
only genuine Gardner-Denver filters
designed and specified for this com-
pressor.
DANGER
Always stop the unit and release air
pressure before removing oil filler
plug. Failure to release pressure may
result in personal injury or death.
During unloaded operation and after shutdown, the
system will partially drain back into the oil reservoir
and the oil level ma read hi her than when operat.
ing 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 operat-
ing level.
2. 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
the inlet line, if used, istight and clean.
3. Coupling -Check all bolts and cap screws for
tightness. See Section 7.
4. Piping -Refer to Section 2, “installation,”and make
sure piping meets all recommendations.
5. Electrical -Check the wiring diagrams furnished
with the unit to be sure it is properly wired. See
Section 4, “Controls and Instruments,” for general
wiring diagrams and Section 2for installation in-
structions.
6. Rotation -Check for correct motor rotation using
“JOG MODE.” Compressor drive shaft rotation
must be clockwise standing facing the compressor
sheave.
WARNING
Operation with incorrect motor rota-
tion can damage equipment and cause
oil eruption from the compressor inlet.
When checking motor rotation, induce
minimum rotation (less than one
revolution if possible). Never allow
motor to reach full speed.
7. System Pressure -Set the controls to the desired
load pressure. DO NOT EXCEED MAXIMUM
OPERATING PRESSURE ON COMPRESSOR
NAMEPLATE. See Section 4, “Controls and Instru-
merits,”for procedure.
WARNING
Operation at excessive discharge air
pressure can cause personal injury or
dama eto equipment. Do not adjust
the fulI discharge air pressure above
the maximum stamped on the unit
nameplate.
8. Operating Mode -Refer to Section 4for detailed
information on the control system.
9. Enclosure -Check for dama ed panels or doors.
Check all screws and latches or tightness. Be sure
doors are closed and latched.
STARTING THE UNIT- OBSERVE UNIT COLD OR HOT
STARTING PROCEDURES
Unit Cold -Close the air service valve (furnished by
customer) between the main air system and the unit
check valve. Ifthe unit isawater-cooled heat exchanger
model, open any manual water inlet valves wide open.
Start the unit by pushing either the “CONSTANT RUN”
button or one of the “AUTO” buttons. Run for ap-
proximately one minute and then open the air service
valve. Since the unit is equipped with aminimum (65
psig) pressure discharge valve, no special procedure to
maintain unit reservoir pressure is required.
13-9-642 Section 3Page 1

Unit Hot -No warm-up period is required. Close the air
service valve (furnished by customer). If the unit is a
water-cooled heat exchanger model, open any manual
water inlet valves wide open. Start the unit by pushing
either the “CONSTANT RUN” button or one of the
“AUTO” buttons. Open the air service valve.
DAILY CHECK -Refer to Section 8, “Maintenance
Schedule.”
STOPPING THE UNIT -Close the air service valve
(furnished by customer), allow the unit to build up to full
unloaded pressure and unload. Wait ashort period to
allow the oil reservoir to blow down. Press “STOP-
RESET” button.
Stopping the unit at apressure below full unloaded may
cause oil carry-over. The oil reservoir will automatically
blow down as the motor stops. If the unit is awater-
cooled heat exchanger type, close any manual water
inlet valves. Open the air service valve.
13-9-642 Section 3Page 2

SECTION 4- ECH UNITS WITH AUTO SENTRY ES’M
CONTROLS &INSTRUMENTS
geNERAL DESCRIPTION -The ECH Electra-Saver
II Rcompressor is prewired with all controls, motor and
wiring, and standard wye-delta starter for the voltage
and horsepower specified at the time of the order. It is
necessary only to connect the compressor unit to the
correct power supply, to the shop air line, and to the
shop water line, if the compressor is watercooled. A
standard compressor unit consists of the compressor,
oil reservoir, oil cooling system and oil filters, motor
enclosure specified, NEMA 12 starter/control box, and
controls as described below.
This compressor features the programmable control,
which integrates all the control functions under
microprocessor control. Its functions include safety and
shutdown, compressor regulation, operator control, and
advisory/maintenance indicators. The keypad and dis-
play provide the operator with alogical and easily
operated control of the compressor and indication of its
condition.
PROTECTIVE DEVICES AND SHUTDOWN -The
programmable controller will shut down the unit follow-
ing any fault detected inthe following devices. Following
ashutdown, amessage will be displayed to indicate the
cause. To resume operation, the cause of shutdown
must be corrected and the controller reset by pressing
the “STOP/RESET” key.
Motor Protection Devices -Overload heaters are fur-
nished for the starter in the voltage range specified.
There are three (3) overloads inthe starter of proper size
for the starter and its enclosure. Note that motor
nameplate current must by multiplied by .577 for wye-
delta starters. Proper starter coil and contact action is
also monitored to ensure proper operation.
High Temperature -The compressor is protected from
high discharge and separator temperature by two inde-
pendent thermistor probes. One probe is located in the
discharge housing to sense compressor discharge air-
oil mixture temperature. The second probe islocated at
the separator discharge and senses the temperature of
the air at the oil separator. The programmable controller
will shut the compressor down iftemperature sensed at
either location exceeds 225°F. Shutdown will also occur
if shorted or open probes are detected.
CAUT ION
Machine damage will occur if com-
hressor is repeatedly restarted after
igh temperature stops operation.
Find and correct themalfunction
before resuming operation.
Separator Differential Pressure -The separator dif-
ferential pressure is continually monitored by the
programmable controller. At adifferential pressure of
approximately 15 psi, the unit will be shut down.
High Pressure -The programmable controller will shut
down the unit ifexcessive pressures are detected in the
reservoir or system. Shut down will occur if adefective
transducer is detected.
Relief Valve -Apressure relief valve(s) is (are) installed
inthe final discharge line and set to approximately 120%
of the unit’s full load operating pressure for protection
aaainst overpressure. Periodic checks should be made
toinsure its (their) proper operation,
WARNING
Operation of unit with improper relief
valve setting can result in severe per-
sonal injury or machine damage.
Ensure properly set valves are in-
stalled and maintained.
Low Oil Pressure -The programmable controller will
shut down the unit if inadequate oil pressure to the
compressor is detected.
Emergency Stop -Pressing the emergency stop button
will shut down the unit and the controller. To restart, pull
the button out to its normal position and reset the
controller.
Power Failure -Following power interruptions, the con-
troller will remain in ashutdown state.
High Vibration (optional) -This optional feature will
shut down the unit if abnormally high vibration is
detected.
Blowdown Valve -The blowdown solenoid valve
releases pressure from the oil reservoir during any shut-
down condition, and during some operatin conditions.
See Figure 2-4 and description under “Air ontrol Com-
ponents” in this section for construction and operation
information.
GAUGES AND DISPLAYS
Oil Level -The oil level gauge is located on the side of
the reservoir. See Section 5, “Lubrication, Oil Cooler, Oil
Filter and Separator” for information on how to correctly
read the gauge. All other instruments are part of the
programmable controller.
AIR CONTROL COMPONENTS -Refer to Figures 1-4,
6-4, 7-4 and 8-4 for schematic tubing diagrams.
Inlet Valve (Figure 3-4) -The inlet valve restricts the inlet
to control capacity and closes to unload the compres-
sor. At shutdown, the inlet valve closes to prevent back-
flow of air.
The inletvalve position iscontrolled,by air pressure in its
piston cylinder, which is controlled by the program-
mable controller through solenoid valves IVC and IVO.
As pressure to the piston is increased, the valve closes
to restrict air flow and compressor delivery.
13-9-642 Section 4Page 1

~MU$f LER
PuRGE VALVE
MINIMUM PRESSURE VALVE
m
081Comcm .
,’ ,twoo,,,
~
OIL
SEPARATOR —
SOLFNOIO VALVE
~VACUUM SWITCH
7TRANSK[R
FIGURE 1-4- SCHEMATIC TUBING DIAGRAM
Minimum Discharge Pressure Valve (Figures 5-1 and
4-4) -An internal spring-loaded minimum pressure valve
is used in the final discharge line to provide apositive
pressure on the oil system of the compressor even when
the air service valve is fully open.
Avalve incorporates an orifice which, when air isflowing
through it, maintains approximately 65 psig in the oil
reservoir. Aspring-loaded piston valve senses air pres-
sure on the upstream (oil reservoir side) of the valve.
When the system pressure rises above 65 psig, the
spring is overridden and the valve opens to full porting.
The valve does not require maintenance or adjustment.
Ifthe valve fails to function, check the valve stem O-ring
for sealing, valve orifices for restriction, or valve and
valve seat for burrs and dirt.
The valve isadjustable within asmall range. It isadjusted
by ascrew on the side of the valve body. The minimum
pressure can be adjusted as follows:
/
1. Start the compressor.
2. Reduce pressure downstream of minimum pres-
sure valve to below desired minimum pressure. DO
NOT REDUCE UPSTREAM PRESSURE OR AD-
JUST VALVE BELOW 65 PSIG.
3. Loosen locknut on adjusting screw.
4. Turn set screws into increase, or out to decrease
minimum pressure to be held.
5. Hold set screw at desired point and tighten locknut.
FIGURE 2-4- BLOWDOWN VALVE
Check Valve (Oil Reservoir) -Arenewable seat swing
type check valve inthe final discharge manifold prevents
backflow of air from the shop airline when the unitstops,
unloads or is shut down.
Purge Air Valve -The purge valve is anormally closed
two-way air actuated valve that admits purge airfrom the
final discharge manifold to the compressor to counter-
act the oilknock which occurs in oil-flooded rotary screw
13-9-642 Section 4Page 2

KVALVE
ICE
DOtilN VALVE
PUR
NOID VALVE
TOR
TO JL
~SEPARATOR
AFTERCOOLER HOUSING
TO
TRANSDUCER
FIGURE 3-4 -INLET VALVE
compressors when they are completely unloaded with
pressure in the oil reservoir. This valve is controlled by
the same control pressure which controls the inletvalve.
Solenoid Valves IVC and IVO -These valves control
position of the inlet valve in response to signals from the
programmable controller. With both valves de-ener-
gized, the normally open IVC valve allows control pres-
sure to the inletvalve piston to close the valve. IfIVC only
isenergized, the inlet valve is held in itscurrent position.
If both valves are energized, control pressure is relieved
from the inlet valve piston to allow the valve to open.
Pressure Regulator -The pressure regulator senses
and maintains aconstant downstream pressure. The
pressure regulator is used to supply aconstant and low
control pressure to prevent damage to the inlet valve
from “slamming.” The regulator should be set for 15-20
psig.
Shuttle Valve -(Figure 5-4) Also known as a double
check valve, the shuttle valve is adevice which will take
two (2) supply signals and allow the one with the highest
pressure to pass through. The shuttle valve is used to
provide control air pressure from either the reservoir or
plant air system, as required during different operating
conditions.
Blowdown Valve -(Figure 2-4) The blowdown valve is
atwo-way solenoid valve which is piped into the oil
reservoir outlet but ahead of the check valve. When the
solenoid is de-energized, the valve opens and the oil
system is blown down. When the solenoid is energized,
the valve closes to allow the oil system to pressurize. A
control air check valve isprovided to ensure that the inlet
valve closes during blowdown. See Figure 6-4.
System Pressure Transducer -This transducer is con-
nected after the minimum pressure valve and discharge
check valve. It converts the pressure in the plant a!r
AIR IN
~~
FIGURE 4-4 -MINIMUM DISCHARGE PRESSURE VALVE
system to an electrical signal for use by the program-
mable controller for modulation and control.
Discharge Pressure Transducer -This transducer is
connected to the oil reservoir. Its signal is used to
prevent loaded starts, monitor oil pressure, and for
separator differential.
Air Filter Vacuum Switch -This switch is used to
monitor air filter condition and alert the user ifthe filter
requires service or replacement.
Vibration Switch (Optional Equipment) -The optional
vibration shutdown switch, mounted on the compressor
coupling cover, detects an increase in vibration that
could bean indication of impending damage to the unit.
The switch actuates when the selected level of vibration
is exceeded.
The switch MUST BE ADJUSTED when the unit is first
13-9-642 Section 4Page 3

FIGURE 5-4- shuttle VALVE
installed. Refer to switch manufacturer’s instruction
manual for complete details.
STARTER/CONTROL PANEL
The following items are located in the electrical
enclosure and provide the main control of the compres-
sor unit and switching of the motor(s). Refer to Figure
3-1.
Programmable Control -The programmable
microprocessor controller is located on the upper sec-
tion of the panel. It provides all the control of the motors
and control devices for safe and efficient operation of
the compressor unit. Its display provides all gauging
functions, shutdown causes, and maintenance recom-
mendations. The keypad provides the user with selec-
tion of operating modes and adjustment to tune the
controls for the application. It is connected to other
devices inside the panel and external devices through
the terminal strip. The microprocessor controller re-
quires no maintenance.
Emergency Stop -This isamaintained pushbutton, and
removes power from the controller outputs regardless
of controller status. It is located on the upper section of
the panel, next to the keypad.
WARNING
Automatic restarting or electrical
shock can cause injury or death. Open
and lock main disconnect and any
other circuits before servicing unit.
Control Transformer -This changes the incoming
power voltage to 110/120 volts for use by all unit control
devices. Two primary and one secondary fuse are
provided. Refer to the adjacent Iabelling for replacement
information.
Terminal Strip -This provides connections for all
110/120 volt devices not contained within the control
panel.
Fan Starter -(where applicable) The starter is used to
provide control and overload protection for the cooling
fan on air-cooled units and ventilation fans of water-
cooled unitswith enclosure. Overload heaters should be
selected based on the nameplate current of the fan
motor. Three fuses are provided. Refer to adjacent
Iabelling for replacement information.
Main Starter -This starter isused to provide control and
overload protection for the main drive motor. For wye-
delta starters, overload heaters should be selected
based on the motor nameplate current times .577 for
proper protection. Wye-delta starters employ three con-
tractorswhich are controlled sequentially to provide low
current starting. Optional full-voltage starters employ a
single contactor; overload selection should be based on
the full load current of the motor.
OPERATION
Operation of the programmable controller is dependent
on selection of an operating mode from the controller
keypad. Prior to starting, the “STOP/RESET” key must
be pressed to place the programmable control in its
ready state. Operation may then be started by selecting
an operating mode from the controller keypad. Once
operating, the operating mode may be changed at any
time. The STOP/RESET key may be pressed at anytime
to stop the compressor under normal conditions. NOTE:
an optional control may be wired to the control to
interrupt and restart the unitbased on controls by others.
T
WARNING
Automatic restarting or electrical
shock can cause injury or death. Open
and lock main disconnect and any
other circuits before servicing unit.
In any mode, the compressor will start only if reservoir
pressure is below 5psig. The controls will keep the
compressor unloaded until the start cycle has been
completed.
Constant Run Mode Operation -This mode is best
used in applications where there are no long periods of
unloaded operation. The compressor unit will start and
run continuously, using itsmodulation controls to match
delivery to demand.
As demand falls below the compressor capacity, the
pressure will riseto the setpoint of the control. When the
pressure reaches the setpoint the programmable con-
troller operates the solenoid valves to pass pressure to
the inlet valve piston and the inlet valve closes enough
to match air system demand. See Figure 6-4.
As demand increases, the controller will modulate the
inlet valve by passing pressure with the solenoid valves
as required to provide the most economical means of
matching delivery to demand. See Figure 7-4.
Low Demand Mode Operation -The Iowdemand mode
reduces power consumption by relieving pressure inthe
reservoir during unloaded operation. Under loaded con..
ditions, it will operate identically to the constant-run
mode described above.
During low demand periods, the controller will open the
blowdown valve and fully close the inlet valve to mini-
13-9-642 Section 4Page 4

mize the motor load. See Figure 8-4. Atimer is started
when this occurs. While inthis state, control air pressure
is supplied from the plant air system. When system air
pressure drops due to increased demand, the blow-
down valve recloses and the controls resume their nor-
mal modulation sequence.
Subsequent blowdown periods are not allowed untilthe
timer has completed its cycle. This cycle eliminates the
problems of oil foaming and carryover which can occur
ifthe oil reservoir of an oil-flooded compressor is blown
down too often. The timer is adjustable from 10 to 20
minutes.
Automatic Mode Operation -This mode provides auto-
matic start and timed stop, and is best used in applica-
tions with long unloaded periods. Operation during
periods of demand or moderately long unloaded periods
IS identical to the low demand mode.
The Auto time delay isadustable from 10 to 20 minutes.
If the controller operates unloaded for this period with
no demand, the compressor drive motor is halted to
eliminate its power consumption. The controls will
remain in this state until demand isagain indicated by a
drop in pressure.
Sequence Mode Operation -This mode provides for
communication between controllers, operating only as
many as are required for economical operation. The lead
unit operates identically to the automatic mode; opera-
tion will be automatically staged for each lag unit.
Communication between controllers is achieved by in-
terconnection of acommunications link to circuit board
connectors DB9A &DB9B. An address must be as-
signed to each unit to operate inthis mode (see “Adjust-
ments” in this section).
CONTROLLER DISPlAY
The display above the keypad is used to provide operat-
ing information to the user. If ashutdown has occurred,
the display will indicate the cause as noted above.
During normal operation the display will show the opera-
tion mode, system pressure, compressor discharge
temperature, and total running hours. Alternate displays
are available by pressing keypad cursor keys, and will
be identified on the display. These include reservoir
pressure, separator differential pressure, reservoir
temperature, system pressure, and compressor dis-
charge temperature. If no keys are pressed for 5
seconds, the display will return to its normal mode.
The display isalso used as a service reminder for normal
maintenance items. These include the separator, air
filter, and oilfilter change intervals. Allintervals are based
on recommended parts as noted in the maintenance
section of this manual. Oil change intervals are also
automatically calculated, based on actual operating
conditions. This allows maximum utilization of AEON
9000 oil. Messages willalso be displayed ifoperation has
occurred during low ambient temperatures, or if high
temperature operation has occurred.
To reset these messages, press the STOP/RESET key
to stop operation of the compressor. Disconnect power
and service the unit as required. Following service, re-
store power to the unit, press STOP/RESET to clear the
controller, and press ENTER to display the messages.
Pressing ENTER repeatedly will clear the messa es.
after messages have been cleared, press STOP/ResET
and select an operating mode to resume operation.
ADJUSTMENTS
All operating adjustments are made through the keypad
while compressor oeration is stopped. If the unit is
8operating, press ST P/RESET to enter the ready state.
Then press ENTER to begin adjustments. Service mes-
sages, if present, will be displa ed first (see above). In
o
all of the following, pressing ST P/RESTORE will return
to the ready state, pressing the +(INCREASE) or -
(DECREASE) keys will modify the value, and pressing
ENTER will retain the value as displayed and move to
the next step.
Operating Sequence Address -This isused for multiple
compressor sequence only; the controller must be con-
nected to other units prior to selecting its address. The
address number will be displayed, and maybe changed
by pressing the +or -keys. Avalue of Oremoves the
controller from sequence operation; any other value
may be selected which is different from the other units.
Once selected, press ENTER.
Blowdown Time -This sets the time delay allowed
between blowdowns to prevent oil foaming.
Auto Time -This adjusts the time delay for unloaded
running before the motor is halted in Automatic modes.
Start Time -This adjusts the time that the motor starter
will remain in the start mode on wyedelta starters.
Following the above adjustments, the controller and
display will normally return to the ready state. Setup
adjustments may also be performed if enabled by the
setup switch. To enable, turn off power to the compres-
sor unit. On the upper left corner of the circuit board, a
switch will be found. Move the switch to the left. The
switch may be left inthis position to allow further adjust-
ment, or moved back after the following adjustments are
completed. Restore power to the unit and step through
the adjustments noted above. Following Start Time ad-
justment, the following will be available for adjustment.
Pressure Setpoint -This adjusts the pressure at which
the controller will maintain pressure by modulation.
Oil Filter Interval -The service interval in hours maybe
adjusted to shorter times as required for severe applica-
tions.
Oil Change Interval -The service interval in hours may
be adjusted to shorter times as required for severe
applications. The hours shown are for operation at 180°
F; the advisory message will appear sooner if high
temperature operation occurs.
High Temperature Limit -This is normally set for 225°
F. It may be temporarily set lower to test operation ofthe
high temperature protection, ifdesired.
This completes controller adjustment. Press the
STOP/RESET key to return to operating modes.
NOTE: Schematic Control Drawings, Fi ures 6-4, 7-4,
8-4, and General Wiring Diagram 200Ec P546, Figure
10-4, follow this section on pages 6through 8&10.
13-9-642 Section 4Page 5

SERVICE
VALVE
“R’F’CE7fcHE7:;ficE B
PRE
A. FULL OIL PRESSURE
B. FULL AIR PRESSURE
C. CONTROL AIR PRESSURE
D. ATMOSPHERIC PRESSURE
MINIMUM DISC HARGi
PRESSURE CHECK
VALVE VALVE
c
rB
(15-20 PSI)
OR EXHAUSTING
OIL
RESERVOIR
c
A
wSYSTEM
PRESSURE
TRANSDUCER
—RESERVOIR
PRESSURE
TRANSDUCER
‘AIR FILTER
VACUUM SWITCH
AIR INLET CLOSED
B
REAR VIEW OF COMPRESSOR
FIGURE6-4 -CONTROL SCHEMATIC -COMPRESSOR UNLOADED -
CONSTANT SPEED MODE