Gardner Denver ELECTRA-SAVER II User manual

13-9-630
13-9-630
1st Edition
ELECTRA-SAVERII
STATIONARY
BASE MOUNTED
COMPRESSOR
Models
125 HP
ECQQN, ECQSN
150 HP
ECQQO, ECQSO
r~ 141GARDNER-DENVER COMPRESSORS
~1 COOPER
INDUSTRIES I

GARDNER-DENVER COMPRESSORS
Awarranty registration card is provided with each machine
The card must be completed by the purchaser and mailed (card
ispreaddressed andpostage pai@ within tendays after machine
start up in order to validate this warranty.
Gardner-Denver Compressors (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 workmanship 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 initial 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 warranted 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 in
structions, will be cause for denial of warranty.
In addition to proper installation routine maintenance and use
as outlined in applicable instruction manuals, this warranty
is contingent upon the Purchaser tsking and submitting oil
samples in accordance with the schedule and procedure as
outlined in the service instruction manuals
ELECTRIC MOTORS
Electric motors, when specified and furnished by the Company,
are warranted for 12 months from date of initial use or15 months
from date of shipment to the first purchaser, whichever occurs
first
The motor manufacturer or authorized service shop will pro
vide at its option motor repairs or replacement motor FOB
manufacturet’s location for any motor which in the manufac
turers 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 are warranted for 12 months from date
of initial use or 15 months from date 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
away, in the Company's judgment as to affect the pro
duct adversely.
2.
3.
4.
5.
WARRANTY
ROTARY SCREW COMPRESSORS
EB, EC, ET ELECTRA-SCREW=
EA ELECTRA- SAVER
SE, ST PACKAGES
ALL BARE AIR ENDS
Any product which has, in the Company's judgment been
subject to negligience accident improper storage or
improper installation or application.
Any product which has not been operated or maintained
in accordance with normal practice and with the re
commendations of the Company.
Components or accessories manufactured warranted and
serviced by others, except as separately rated
Any reconditioned or prior owned product
ClaiMS fOr iteMS described 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 part 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
provided 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 installed 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 COm-
PANY 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 AVAILABLE TO
PURCHASER AND IN NO CASE SHALL THE COMPANY BE
SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES
UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE
LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CON-
SEQUENTIAL DAMAGES, EXPENSES LOSSES OR DELAYS
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 the
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 as warranted
13-9-630 Page i

GARDNER- DENVEr ELECTRA-SAVER II 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 day to day operation
maintenance and adjustment Careful adherence to these instructions will result in economical operation and minimum downtime
DAN GE R –Failure to observe aDANGER
notice could result in injury to, or death of personnel
WARNING _Failuretoobserve.WARNING
●notice could result in damage to equipment
CAU TION -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 lNFORMATION .................................................................................... SECTION 1
INSTALLATION ............................................................................................... SECT10N 2
STARTING &OPERATING PROCEDURES .................................................................... SECTi0N 3
CONTROLS&INSTRUMENTS ............................................................................... .SECTi0N 4
LUBRICATION, OIL COOLER OIL FILTER &SEPARATOR .................................................. SECTION5
AIR FILTERS ................................................................................................. SEcTi0N 6
COUPLING ................................................................................................... SEcTiON 7
MAINTENANCE SCHEDULE .................................................................................. SECTi0N 8
TROUBLE SHOOTING ........................................................................................ SEcTi0N 9
COMPRESSOR OVERHAUL ...................................................................... See Manual 13-10-602
13-10-630 Page ii

INDEX
NOTE Numbers preceding dash are Section Numbers —numbers following dash are Page Numbers
Acoustic Enclosure ....................................2-1
Addition of Oil Between Changes. ....................5-2
Adjustment Operating Air Pressure. ..................4-6
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
Air Filter Indicator ....................................4-4
AIR FILTERS (SECTION 6)....... ...................6-1
Air Filter Service Indicator ............................6-1
Air Flow ...............................................
Air Flow, Minimum .............. 1-1
.......................2-1
Air and Oil Discharge Temperature. ..................5-7
Air-Oil Systems Flow Diagram.. .......................5-1
Air Pressure Adjustment Operating. ..................4-6
Air Pressure Gauge ...................................4-4
Air Receiver, Auxilliary ............................2-3.4-7
Air Temperature Gauge Discharge. ...................4-4
Air Temperature Shutdown High ......................4-2
Alignment Coupling ...................................7-1
Automatic Blowdown Valve .......................4-2.5-7
Automatic StarVTimed Stop Control System With
Low Demand Mode ...............................4-6
Automatic Start/Timed Stop Operation. ...............4-6
Auxilliary Air Receiver ............................2-3.4-7
Bleed Air Valve ........................................4-5
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 Adjustment Compressor.. ...4-5
Check Valve Flow Control ............................4-7
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 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 Overhaul .................................1-1
Constant Speed Control System With Low Demand
Mode ..............................................4-6
Constant Speed Operation ............................4-6
Control Low Starting Torque (Unloaded Start .......4-7
Control Piping .........................................2-5
CONTROLS &INSTRUMENTS (SECTION 4) ........4-1
Control System Automatic StarVTimed Stop With
Low Demand Mode ...............................4-6
Control System Constand Speed With Low Demand
Mode ..............................................4-6
Control System Low Demand Mode.. ................4-6
Control (Thermostatic Mixing) valve Thermal .........5-4
Control Valve, Water Flow (For Heat Exchanger .....5-5
Control Voltage ........................................4-1
Cooler, Compressor Oil (Radiator Type) Module ......5-4
13-9-630
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\ 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 Minim um ..................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-I
Electrical Starter ......................................2-5
Electrical Wiring ..........................................
................2-5, 4-7, 4-9, 4-10, 4-11, 4-12, 4-13, 4-14
Enclosure Acoustic ...................................2-1
Filling Oil Reservoir ...................................5-3
Fiiter, Air .....................................3-1.6-1.8-1
Filter Compressor Oil .................................5-3
Filter lndicator Air ....................................4-4
Filter indicator, Oil ....................................4-4
FILTERS, AI RESECTION 6) ..........................6-1
Filter Service indicator, Air..... .......................6-1
Flow Control- Check Valve .............................4-7
Flow Diagram —Air-Oil Systems. .....................5-1
Foundation ............................................2-1
Gauge Air Pressure ...................................4-4
Gauge Discharge Air Temperature. ...................4-4
Gauge Oil Level ......................................5-3
Gauge Pressure Differential .....................4-4, 5-7
General (Controls) .....................................4-1
GENERAL INFORMATION (SECTION 1) ............1-1
General (installation) ..................................2-1
Grease Recommendations ............................2-6
Grounding .............................................2-5
High Air Temperature Shutdown ......................4-2
High Discharge Temperature Switch. .................4-2
High Temperature Operation. .........................5-2
Hourmeter .............................................4-4
indicator, Air Filter ....................................4-4
indicator, Air Filter Service ............................6-1
lndicator Oil Filter ....................................4-4
Inlet Line ..............................................2-5
inlet Pressure Oil .....................................5-8
Inlet Valve .............................................4-5
Inlet Valve Subtractive Pilot ...........................4-5
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
Page iii

Location ...............................................2-1
Low Demand Mode Control System ..................4-6
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 ...........................4-3
Low Oil Pressure Time Delay Switch .................4-4
Low Starting Torque (Unloaded Start) Control ........4-7
Lubricant Compressor ................................5-2
Lubricants Synthetic ..................................5-2
Lubrication, Cooling and Sealing ...................... I-l
Lubrication, Motor ................................2-5.8-l
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 .........................4-6
Mode Operating ......................................3-l
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.l
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 (Water-Cooled
Heat Exchanger ..................................5-8
Oil Filter, Compressor .................................5-3
Oil Filter Indicator .....................................4-4
OIL FILTER, SEPARATOR, OIL COOLER &
LUBRICATION (SECTION 5).... .................5-1
Oil Flow Diagram –Remote Overhead Mounted Oil
Cooler .............................................5-2
Oillnlet 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 Shutdowm Low ..........................4.3
Oil Pressure Time Delay Switch Low.. ...............4-4
Oil Reservoir ..........................................5-6
Oil Reservoir Check Valve ............................4-5
Oil Reservoir Drain ....................................2-1
Oil Reservoir, Filling ...................................5-3
Oil Separator ..........................................8-1
Oil Separator, Compressor ............................5-6
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
OmOff Switch .........................................4-2
Operating Air Pressure Adjustment ...................4-6
Operating Light Test ..................................3-1
Operating Mode .......................................3-1
Operating Pressure Minimum .........................4-6
OPERATING PROCEDURES &STARTING
(sEcTloN 3) .....................................3-l
Operation, High Temperature .........................5-2
Overhau\ Compressor .................................1-1
Pilot inlet Valve Subtractive ..........................4-5
Pilot Light .............................................4-1
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 ...................4-6
Pressure Adjustments Compressor Capacity and .....4-5
Pressure Differential Gauge ......................4-4. 5-7
Pressure Differential Oil Cooler (Air-Cooled
Radiator) ..........................................5-8
Pressure Differential Oil Cooler Oil (Water-Cooled
Heat ExchangeO ..................................5-8
Pressure Differential Oil Cooler Water (Water-Cooled
Heat Exchanger ..................................5-8
Pressure Gauge, Air ...................................4-4
Pressure, Minimum Operating .........................4-6
Pressure, Oillnlet .....................................5-8
Pressure Protection Low Oil (Air-Cooled Oil
Cooled ............................................2-2
Pressure Regulator ....................................4-3
Pressure Shutdown Low Oil ..........................4-3
Pressure Switch Low Demand Mode. ................4-3
Pressure, System ......................................3-1
Pressure Time Delay Switch Low Oil .................4-4
Pressure Valve Minimum Discharge ..................4-5
Regressing interval ....................................2-6
Regulator, Pressure ...................................4-3
Reservoir Check Valve Oil ............................4-5
Reservoir Drain Oil ...................................2-1
Reservoir, Oil ..........................................5-6
Reservoir Pressure Switch .......................4-3.4-7
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 Check List ....................................8-1
Service indicator, Air Filter ............................6-1
Service Line Discharge ...............................2-5
Shutdown Low Oil Pressure ..........................4-3
Shutoff Valve Water –Water-Cooled Heat
Exchanger .........................................5-6
Solenoid Low Demand Mode Unloader ...............4-3
Starter, Electrical ......................................2.5
STARTING &OPERATING PROCEDURES
(sEcTloN 3) .....................................3-l
Starting the Unit ......................................3-1
Stopping the Unit .....................................3-1
Subtractive Pilot inlet Valve ..........................4-5
Switch High Discharge Temperature .................4-2
Switch Low Demand Mode ...........................4-2
13-9-630 Page iv

Switch Low Demand Mode Pressure .................4-3
Switch Low Oil Pressure Time Delay .................4-4
Switch On-Off .........................................4-2
Switch OmOff-Reset ..................................4-l
SwitchStart-Stop/ Reset ..............................4-1
Switch Vibration .......................................4.7
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..............4-4
Thermal Control (Thermostatic Mixing) Valve . . . . . . ...5-4
Thermostatic Mixing Valve Thermal Control ..........5-4
Three Way Valve. ......................................4-7
Time Delay Switch LOW Oil Pressure .................4-4
Trap Moisture Separator ..............................3-1
TROUBLE SHOOTING (SECTION 9) .................9-1
Unloader Solenoid Low Demand Mode ...............4-3
Valve Automatic Blowdowm ......................4-2.5-7
Valve Bleed Air .......................................4-5
Valve Check (Oil Reservoir ...........................4-5
Valve Flow ControFCheck ............................4-7
Valve Inlet ............................................4-5
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 ......................................4-7
Valve Water Flow Control (For Heat Exchanger .....5-5
Valve Water Shutoff (Water-Cooled Heat
Exchange . ...................... .................5-6
Ventilation .............................................2-1
Ventilation Air-Cooled Oil Cooler .....................2-2
Vibration Switch .......................................4-7
Voltage Control ........................................4-l
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
Onlfi ..............................................2.5
Water Pressure Differential\ Oil Cooler (Water- Cooled
Heat Exchanger) ..................................5-8
Water Shutoff Valve —Water-Cooled Heat
Exchanger .........................................5-6
Wiring Diagrams ........4-9, 4-10, 4-11, 4-12, 4-13, 4-14
Wiring Electrical ..........................................
................2-5, 4-7, 4-9, 4-10, 4-11, 4-12, 4-13, 4-14
13-9-630 Page v

SECTION 1
GENERAL INFORMATION
FIGURE 1-1. –COMPRESSION CYCLE
COMPRESSOR –The Gardner- DenveP Electra-Saver 1P
compressor is asingle stagei 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 outaide
the compression chamber. SingIe-width cylindrical roller
bearings are used at the inlet end of the rotors Heavy duty
tapered roller bearings at the discharge end locate the
rotors axially and carry all thrust loads
COMPRESSION PRINCIPLE (Figure l-l) –Compres
sion is accomplished by the main and secondary rotors
synchronously meshing in aonepiece 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 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 same “fill-compress-discharg&
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 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 reservoir. The air and remaining oil then passes
through the oil separator and 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 by proprietary means to remove heat of com
pression seal internal clearances and lubricate the rotors
COMPRESSOR OVERHAUL –For compressor overhaul
procedures and rebuilding data including dimensions run
ing clearances and fits see Service Manual 13-10-602.
13-9-630 Section 1Page 1

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
●
●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 151 8.302)
●DO NOT EXCEED THE RATED MAXIMUM PRESSURE VALUES SHOWN ON
THE NAME PLATE
●DO NOT OPERATE UNIT IF SAFETY DEVICES ARE NOT OPERATING PROP-
ERLY. CHECK PERIODICALLY. NEVER BYPASS SAFETY DEVICES
DANGER
●
●
●
●
●
●
●
●
KEEP FINGERS AND CLOTHING AWAY FROM REVOLVING FAN, DRIVE
COUPLING, ETC.
DO NOT USE THE AIR DISCHARGED FROM THIS UNIT FOR BREATHING –
NOT SUITABLE FOR HUMAN CONSUMPTION.
DO NOT LOOSEN OR REMOVE THE OIL FILLER PLUG, DRAIN PLUGS
COVERS THE THERMOSTATIC MIXING VALVE or BREAK ANY CON-
NECTIONS 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 ELECTRICAL CODE
FAN MOTORS HAVE BEEN AND MUST REMAIN GROUNDED TO THE
MAIN BASE 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 AUTOMATI-
CALLY CONTROLLED AND MAY START AT ANY TIME
13-9-630 Section 1Page 3

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 bear-
ings can be damaged by passage of current
LIFTING UNIT —Proper lifting and/or transporting
methods must be used to prevent damage
~CAUTION
lift compressor unit by base only 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 areforlifting
the motor only and should not be used to lift any addi
tional weight All eyebolts must be securely tightened
When lifting the motor the lifting angle must not ex-
ceed 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
WINDOW
EXHAUST FAN
.m.
ILOUVERED
,L,,., rim,,
COMPRESSOR
UNIT ~%
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
Open Unit
Open With
Compressor Oil Cooler Oil Cooler
Size Unit Module Module
125 HP 4400 19300 23700
150 HP 5200 19300 24500 ~
*80” 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 II 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 level
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 1P unit is
furnished with an acoustic enclosure over the compressor
13-9-630 Section 2Page 1

only, as standard equipment The enclosure reduces the
normal operating sound of the unit to 90 DBA or below
in free field conditions
AIR-COOLED OIL COOLER MODULE —The air-
cooled oil cooler is aseparate module and may be mounted
remote to the compressor unit
Ventilation —The oil cooler requires adequate cooling air
flow. Proper ventilation MUST be provided with hot air
exhausted away from the cooler take care that hot air is
not recirculated from the exhaust to the inlet side of the
cooler. Cooling air flow direction is from the motor side
through the grille side of the oil cooler. Do not obstruct
the air flow to or from the cooler. Allow two (2) feet
clearance on all sides of the cooler module See Figure 2-2
for cooling air flow requirements
Low Oil Pressure Protection —The standard factory
installed low oil pressure shutdown switch in the control
box will prevent start-up or shut the unit down if oil pres
sure is not established or maintained due to malfunction
in the oil cooler system
Oil Cooler —The oil cooler module can be mounted in
any of several remote locations close coupled but not
joined to the compressor unit horizontal remote, located
on the same level as the compressor unit but some dis
tance away or overhead remote located above level of the
compressor unit as on aroof.
~WARNING
The low demand mode switch CANNOT be used with
remote overhead oil cooler These units require special
wiring diagram —check with factory.
All piping and wiring between the compressor unit and the
remote oil cooler is to be supplied by the user. THE
DESIGN OF THE REMOTE OIL COOLER MODULE
SYSTEM MUST BE APPROVED BY THE FACTORY
BEFORE INSTALLATION. The design information to be
submitted for approval includes
1. Location of oil cooler module —inside or outdoors
2. Range of operating ambient temperatures at the oil
cooler location
3. Elevation of the oil cooler above the compressor unit
4. Pipe type and size(s) to be used to connect oil cooler
and compressor unit Minimum pipe size is 2“ IPS
5. Horizontal and vertical lengths of the pipe run If
more than one pipe size is used list length of each
size and total length.
6. Number and size of elbows tee% unions reducers
and valves to be used in the pipe run
7. Adimensioned sketch of the proposed piping system
showing location of the compressor unit oil cooler
and pipe fittings of 3through 6above
All remote piping should be of adequate size to insure the
minimum pressure loss Design point4 above lists the pipe
size at the compressor unit oil inlet and outlet connections
and is the minimum pipe size to be used Long runs of pipe
and the use of valves and fittings require larger than the
minimum pipe sizes in the system to keep the pressure
loss low. All pipe and fittings used in aremote oil cooler
system should be galvanized or treated internally to pre
vent rust and all valves are to be of anonferrous con
struction to prevent corrosion and fouling
The remote cooler should be placed so that the fan air flow
through the cooler (air flow is from motor side through
core) and the prevailing winds are in the same direction
Abaffle should be provided on the exhaust side of the
cooler for protection against occasional wind shifts
When the oil cooler is mounted above the compressor unit
acheck valve is to be mounted on the compressor unit in
the line to the oil cooler see Figure 2-5. Apneumatic pilot-
operated normal-closed valve is to be mounted at the
oil filter inlet on the compressor unit line from the oil
cooler see Figure 2-5. The check valve permits oil flow to
the oil cooler during operation, but prevents return oil
flow from the cooler when the unit is shut down The pilot
valve is held open by air pressure from the unit oil reservoir
during operation and closes under spring load when the
unit is shut down to prevent return oil flow from the oil
cooler.
An oil filler stand pipe and plug must be located in the
piping on the oil cooler module for ease of filling of a
remote oil cooler see Figure 2-5.
INSTALLATION FOR COLD WEATHER OPERATION
—It is recommended that whenever possible the unit be
installed inside ashelter that will be heated to temperatures
above freezing (32” F., 0° C.). This will eliminate many of
the problems associated with operating the units outside
in cold climates where freezing rain, drifting snow, freezing
condensate and bitter cold temperatures are encountered
When an outside installation must be made the precau-
tions required will depend on how severe the environment
will get The following are general guidelines for outside
installations
Cold Weather (Down To –10° F.)
1.
2.
3.
4.
5.
6.
13-9-630 Section 2
Be sure all control Iines drains and traps are heated
to avoid freezing of condensate Heat tape with ther-
mostat control is generally satisfactory for this pur-
pose. This is not afactory option but can be obtained
at various local plumbing or hardware outlets
If an air-cooled aftercooler is to be used provisions to
bypass the aftercooler should be made Since cold air
contains very little moisture successful operation can
be achieved without the aftercooler. Successful
operation down to +15° F. can be accomplished by
reversing fan flow, but cooler bypass should still be
provided should it be required
Provide at least some simple shelter (Plywood wind
break etc) to protect against drifting snow.
Use only Gardner- Denver “GD800 Lubricating
Coolant’.
Monitor unit carefully during start-up and operation
to be sure it is functioning normally.
When the coolers are mounted horizontally use
weather protected enclosure for the unit
Page 2

OIL COOLER
e
t
3FT.
\\
/
WE LLMAN RADIANT 2-ELEMENT
HEATER (OR EQUAL)
RH400 WITH (2) RH4502
ELEMENTS —2REQ’D.
3,2oO WATTS EACH 8FT. PLYWOOD ‘, FENCE,’
aELLMAN RADIANT 2-ELEMENT \4FT.
HEATER (OR EQUAL)
RH7000 WITH (2) RH7502
ELEMENTS —2REQ’D.
‘t-6,200 WATTS EACH
OIL RESERVOIR
\-- AWAY FROM PREvAILING WIND
TOP VIEW \8FT. PLYWOOD “FENCE”
FIGURE
7. Use NEMA 4enclosure for electrical devices
Extreme Cold Weather Operation (Down To 40° F.)
In addition to recommendations for –10° F. installation
the following should be provided
1.
2.
3.
4.
Atemperature switch to control the fan should be
provided for better starting and quicker warm-up
This switch can be provided from the factory and
will delay fan start- up until discharge temperature
reaches approximately 150-160” F.
It will probably be necessary to provide shutters or
to block off part of the cooler in some manner since
the cooler is greatly oversized for operation in these
low temperatures Shutters are not afactory option
Coolers should be located as close to unit as possible
Long lines to and from the cooler only further com-
plicates the circulation of oil flow on cold starts
Lo Demand or Duomatic operation cannot be used
in extreme environments Heat tape and insulation
may be required on oil lines
Some means of providing heat to the oil reservoir
and cooler during shutdown should be provided
There are various methods to accomplish this but
since openings are not provided for sump heaters
the use of radiant heaters is recommended The
heaters should be sized to provide at least a-10” F.
environment for the coolers motor and sump Figure
4-2 shows how these might be located in atypical
installation and sizes required.
Remember unsheltered (outside) installations should be
avoided where possible Installation next to aheated build
ing where enough heat can be used to keep the compressor
room above freezing will save many complications in the
operation and installation of the unit
AUXILIARY AIR RECEIVER —The unit requires an
auxiliary air receiver unless the piping system is large
and provides sufficient storage capacity to prevent rapid
ELEVATION VIEW
3-2.
cycling. When used an air receiver should be of adequate
size, provided with arelief valve of proper setting, apres
sure gauge and ameans of draining condensate
AFTERCOOLER (Figures 2-1, 3-1 &4-2) —An aftercooler
will provide control of moisture entering the shop air lines
while reducing the normal low discharge temperature of
about 179° F. at 100 PSIG discharge pressure to near
inlet air temperature.
Air Cooled Machines —When an aftercooler is furnished
on an air-cooled machine, the aftercooler is installed on
the oil cooler module between the fan and the oil cooler.
Later models of steel air-cooled aftercoolers are coated
internally to resist corrosion Coated aftercoolers have a
tag attached to one header with identification and date
The moisture separator is furnished by Gardner-Denver
Compressors but must be mounted by the customer be
tween the aftercooler and the auxiliary air receiver with
acondensate drain provided at the bottom All air piping
from the compressor discharge to aftercooler to auxiliary
air receiver is to be furnished and mounted by customer.
The design of the aftercooler piping must be approved by the
factory before installation The design information to be
submitted for approval includes
1. Location of aftercooler module —inside or outdoors
2. Range of operating ambient temperatures at the
aftercooler location
3. PiPe tyPe and size(s) to be used to connect the after-
cooler, separator and compressor unit —minimum
pipe size is 2“ IPS.
4. Lengths of the pipe run If more than one pipe size
is used list length of each size and total length.
5. Number and size of elbows tees unions reducers
and valves to be used in the pipe run
6. Adimensional sketch of the proposed piping system
showing location of the compressor unit aftercooler,
separator and auxiliary air receiver, pipe and fittings
13-9-630 Section 2Page 3

OIL
IN
OIL WATER
CONTROL
OUT
h------ /v”L”E’
II#
1~~
WATER
HEAT EXCHANGER OUT
\
t“\
WATER
tSHUTOFF
VALVE d
u~Ir
SEPARATOR AFTERCOOLER
tL.
SERIES P~G WATER FLOW MUST BE
THROUGH AFTERCOOLER FIRST FOR
EFFECTIVE COOLING OF DISCHARGE AIR.
OIL WATER
CONTROL
OIL OUT
IN VALVE d
-&)
HEAT EXCHANGER
MANUAL VALVE TO SHUTOFF
BALANCE WATER FLOW~ ~
IN
ul_-J-l r-
5EPARATOR AFTERCOOLER
c~
I
L
WATER lN—
L
PARALLEL PIPING WATER CONTROL
VALVE REQUIRED FOR TEMPERATURE CONTROL
OF OIL
MUST BE ORDERED SEPARATELY.
FIGURE 4-2. –PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER
B75853
Approximate
Water Pressure
Rated Water Temperature To Heat Exchanger Maximum Drop @
Pressure
Size Water Maximum Flow
PSIG 60° F. 70° F. 80° F. 90° F. Flow (Psi)
125 HP ALL 12.0 15.5 20.5 32.0 60 20
150 HP ALL 15.5 19.0 25.5 37.5 60 20
The Maximum Water Flow Shown IsThatAllowable Through The Heat Exchanger.
FIGURE 5-2. –HEAT EXCHANGER (OIL COOLER) APPROXIMATE WATER FLOW
(U.S Gallons/Minute)
Approximate
Water Pressure
Rated Water Temperature To Aftercooler Maximum Drop @
Pressure Water
Size Maximum Flow PSIG 60° F. 70° F. 80° F. 90° F. Flow (Psi)
125 HP ALL 2.8 3.5 4.7 7.0 30.0 2.5
150 HP ALL 4.0 5.0 6.7 10.0 30.0 2.5
Water flow rates (gpm) are based on 110° F. water temperature out of cooler. Maximum water flow shown is the maximum
allowable flow through aftercooler.
FIGURE 6-2. –AFTERCOOLER APPROXIMATE WATER FLOW
(U. SGallons/Minute)
13-9-630 Section 2Page 4

of 3through 5above
Water Cooled Machines (Figure 4-2) —On water-cooled
machines with aftercooler, the moisture separator and con
densate drain are shipped loose and must be installed by
customer. Customer must furnish and install all water
piping required
CONTROL PIPING –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 an
outside air filter and the compressor, or to connect the
unit mounted air filter to an outside source of air, it must
be thoroughly cleaned on the inside to prevent dirt or
scale from entering the compressor. If welded construc-
tion is used, the line must be shot blasted and cleaned
to remove welding scale. In either case the inlet line
must be coated internally by galvanizing or painting with a
moisture and oil proof sealing lacquer. The inlet line
should be the full size of the inlet opening on the com-
pressor. If an extra-long line is necessary, the pipe size
should be increased accordingly
Length Of Inlet Line Diameter Of Pipe Size
0to 10 Ft ....... Same As Compressor Inlet Opening
10 to 17 Ft . . One Size Larger Than Inlet Opening
17 to 38 Ft ..... Two Sizes Larger Than Inlet Opening
Accessibility for inlet air filter servicing must be consid
ered when relocating the filters from the unit to aremote
location
DISCHARGE SERVICE LINE –The discharge service
line connection on water-cooled units with aftercooler is
made at the moisture separator. On air-cooled units and
water-cooled without aftercooler, the connection is made at
the minimum pressure valve located behind the instrument
panel When manifolding two or more Electra-Saver II units
on the same Iine each unit is isolated by the check valve in
the unit discharge line If an Electra-Saver II unit is mani
folded to another compressor, be sure the other compres
sor has acheck valve in the line between the machine and
the manifold If an Electra-Saver II and areciprocating
compressor are manifolded together, an air receiver must
be located between the two units
DANGER
DO NOT USE THE AIR DISCHARGED FROM
THIS UNIT FOR BREA THING —IT IS NOT
SUITABLE FOR HUMAN CONSUMPTION.
BLOWDOWN VALVE PIPING —The biowdown valve
is fitted with amuffler, for operation indoors If the in
stallation requires the muffler may be removed and the
biowdown valve piped to the outside with pipe the same
size as the blowdown valve outlet connection
WATER PIPING (Watercooled Heat Exchanger Models
Onlyj –On machines equipped with awater-cooled heat
exchanger, pipe water to the inlet or water flow control
valve mounted in the water inlet piping to the heat ex-
changer. Pipe outlet water from the outlet or magnetic
water shutoff valve to asump or drain The thermal bulb
is inserted in the heat exchanger oil outlet line refer to
the unit outline drawing for location
The water source should be capable of supplying up to
the maximum flow shown in Figure 5-2 at aminimum pres
sure of 40 PSIG maximum allowable water pressure is
150 PSIG The water flow rates shown in Figure 5-2 are
approximate and aguide to sizing piping cooling tower
and other water system equipment
The heat exchanger is designed to operate with water inlet
temperatures from 60° F. to 90° F., and awater outlet
temperature not to exceed 110° F. If water cooler than
60° F. is used high water outlet temperatures (overl 10° F.)
will be experienced along with shortened heat exchanger
life caused by tube fouling and corrosion If water warmer
than 90° F. is used higher compressor oil temperatures
and high water usage will result
Most water systems will require control of impurities
filtration, softening or other treatment See “Compressor
Oil Cooler —Water-Cooled Heat Exchanger” for more
information on the water system.
Aftercooler —Heat Exchanger Water Piping (Figure4-2)
—If an aftercooler is used and piped in series with the
heat exchanger, install the water flow control valve and
magnetic water shutoff valve, if used downstream of the
exchanger. PiPe the aftercooler water outlet to the heat
exchanger water inlet on the compressor unit
If the aftercooler is piped in parallel with the heat ex-
changer, provide amanual valve between the aftercooler
outlet and the heat exchanger outlet after the water control
valve to adjust aftercooler water flow for discharge temper-
ature required and most economical water use separate
water inlet lines are piped to the aftercooler and heat
exchanger.
~CAUTION
When an ajtercooler is piped in series with the oil
cooler the maximum allowable waterflow rate through
the oil/aftercooler system is the maximum allowed
by the aftercooler. If the oil cooler requires more
water flow than the maximum allowed by the after-
cooler aparallel water piping system must be used
If the standard factory built-in aftercooler is used the
maximum allowable water flow through the aftercooler is
30 gallons per minute and the maximum water inlet pres
sure is 150 PSIG. If another aftercooler is used consult the
manufacturer for operating limits
The water control valve MUST be used to maintain dis
charge temperatures approximately 10 F* over the dew
point for expected ambient (Figure 8-5). See Section 5for
adjustment instructions and maximum allowable oil tent
perature
ELECTRICAL WIRING —The Electra-Saver II unit is
furnished with the compressor motor enclosure as spec
ified by the user. If the unit has an air-cooled oil cooler,
this fan motor is atotally enclosed “air-over” or fan-cooled
type and is complete with starter and enclosure as spec
ified by the user. Allow 42” deep by 30” wide clear space
to nearest obstruction over control enclosure in accord
ante with Article 110-16 (a) National Electrical Code
it is necessary to connect the compressor unit (and oil
cooler, if used) to amain starter of the correct size power
characteristics and enclosure for the application See
13-9-630 Section 2Page 5

Section 4for typical wiring diagrams however, use only the
wiring diagrams supplied with the unit for final connections
Starter —The main starter is to be mounted at alocation
selected by the user at the time of installation The first
three (3) feet of line from the motor conduit box to the
starter must be of flexible conduit to maintain effective
vibration isolation Electrical connections to other parts of
the unit (instrument panel fan motor, etc) from the starter
do not require flexible conduit since the compressor and
motor are already isolated from these parts See Table
110-16 (a) National Electrical Code for correct working
clearance
Grounding —Equipment must be grounded in accordance
with Table 250-95 of the National Electrical Code.
AWARNING
An equipment ground jumper equal in size to the
equipment ground conductor must be used to connect
the compressor motor to the main base since they are
isolated from the base by vibration mounts~ The oil
cooler fan motor frame will be grounded to the main
base with agrounding conductor compatible with the
fan short circuit protection at the factory.
MOTOR LUBRICATION –Long time satisfactory opera-
tion of an electric motor depends in large measure on the
bearings and timely lubrication. The following charts show
recommended grease qualities and regressing intervals for
motor supplied with ball bearings For additional informa
tion refer to the motor manufacturers 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 the hole of hardened
grease.
Wipe the lubrication fitting clean and add grease with
ahand-operated grease gun.
Leave the relief plug temporarily off. Reconnect the
unit and run for about 20
grease,
Stop the unit Replace
Restart the unit
GREASE RECOMMENDATIONS
.
Worked Penetration ..............................................................
Oil Viscosity, SSU AtlOOO F. ...................................................
Soap Type ........................................................................
N-H Bomb Minimum Hours For20 PSl Drop At210° F. ........................
Bleeding Maximum Weight% ln500Hours 212” F. ...........................
Rust Inhibiting ....................................................................
REGRESSING INTERVAL
minutes to expell the excess
the relief plug.
Standard
Service
265-296
400-550
Lithium
750
10
Yes
High
Temperature
220-240
475-525
Lithium
1000
3
Yes
Type Of Service Typical Examples Rating Relubrication Interval
150 HP and Below 18 Months
Standard One Or two-shift Operation Over 150 HP 12 Months
150 HP and Below 9Months
Severe Continuous Operation Over 150 HP 6Months
150 HP and Below 4Months
Very Severe Dirty Locations High Ambient Temperature Over 150 HP 2Months
13-9-630 Section 2Page 6

SECTION 3
.
STARTING &OPERATING PROCEDURES
Anew unit as received from the factory has been prepared
for shipping only. Do not attempt to operate the unit until
checked and serviced as follows
1. Compressor Oil —Check the oil level in the oil
reservoir. Add oil only if the oil level gauge reads in
the red ADD OIL range. Do not mix different types
of oils The unit is shipped filled with Gardner-Denver
GD800 Lubricating Coolant which is suitable for the
first 2000 hours under normal operating conditions
REPLACE OIL FILTER ELEMENT EVERY 1000
HOURS.
Initial fill or filling after acomplete draining of the
system, may show the oil level beyond the red EX-
CESS oil range After start-uD oil will fall into the
operating range as system components are filled If
necessary, add oil to bring level into the center of
the RUN range when unit is operating on load see
Figure 4-5 for quantity of oil required
DANGER
ALWAYS STOP THE
PRESSURE BEFORE
PLUG TO ADD OIL
UNIT AND RELEASE AIR
REMOVING OIL FILLER
During unloaded operation and after shutdown the
system will partially drain back into the oil reservoir
and oil level will read higher than when operating on
load. DO NOT DRAIN OIL TO CORRECT on the
next loaded cycle or start oil will again fill the system
and the gauge will indicate the operating level
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 inlet line,
if used, is tight and clean
3. piping —Refer to Section 2“installation” and make
sure the piping meets all requirements
4. Moisture Separator Trap —The trap is constructed
of cast iron with side inlet and outlet connections and
inverted bucket design Astainless steel internal
strainer is used in trap it should be checked period
ically for clogging and replaced if necessary. Repair
parts are available for trap cap retainer gasket and
strainer. See package outlines for mounting dimen
sions of moisture separator trap
The moisture trap must be primed by filling with
clean water prior to initial start-up of unit
5. Electrical —Check the unit and user-installed wiring
with the wiring diagrams furnished to be sure it is
properly wired See Section 4“Controls and instru
ments’ for general wiring diagrams and Section 2for
installation instructions
6. Rotation —Check the motor rotation by momen
tarily starting the motor. Compressor drive shaft rota-
13-9-630 Section
tion is counterclockwise standing at the motor end
7. Operating Light Test– Observe the operating lights
on the ON-OFF switch when jogging the motor in
Step 6. Be sure all lamps are operative
8. System Pressure– Set the turn-valve pilot inlet pilot
and operating air pressure switch to the desired
unload pressure and differential DO NOT EXCEED
MAXIMUM OPERATING PRESSURE ON THE
COMPRESSOR NAME PLATE EXCEPT AS spec
IFIED UNDER “CONTROL ADJUSTMENTS’ SEC-
TION 4.
9. Operating Mode —Refer to Section 4for detailed
information on the control system.
STARTING THE UNIT —The Constant Speed with Low
Demand Mode Unit requires only pressing of the OFF/
RESET and then the ON push button
The Automatic StarVTimed Stop with Low Demand Mode
Units require selecting the desired mode of operation (see
sectiOn 4) and then pressing first the RESET and then the
ON push button
OBSERVE UNIT COLD OR UNIT HOT STARTING PRO
CEDURES
Unit Cold —Close the air service valve (furnished by cus
tomer) between the main air system and the unit check
valve if the unit is awater-cooled heat exchanger model
open any manual water inlet wide open. Start the unit and
run for one minute. Open the air service valve Since the
unit is equipped with aminimum (65 PSIG) pressure dis
charge valve, no special procedure to maintain unit reser-
voir pressure is required
CAUTION
On Automatic Start- Timed stop Mode it is important
to open the service valve after ‘starting and before the
set discharge pressure is reached to prevent the almost
immediate shutdown of the unit followed by arestart
which may cause motor overload heaters to overheat
and blow.
Unit Hot —No warmup period is required Close the air
service valve (furnished by customerj. If the unit is awater-
cooled heat exchanger model open any manual water inlet
valves wide open Start the unit Open the air service valve.
DAILY CHECK —Refer to Section 8“Maintenance
Schedule”.
STOPPING THE UNIT —Close the air service valve
(furnished by customer, allow the unit to build up to
full unloaded pressure and press the OFF push button
Stopping the unit at apressure below full receiver may
cause oil carryover. 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
3Page 1

SECTION 4
CONTROLS &INSTRUMENTS
GENERAL –The Gardner- Denver Electra-Saver II com-
pressor units are available with two (2) different control
systems
Constant Speed With Low Demand Mode
Automatic Start/Timed Stop With Low Demand Mode
The standard Electra-Saver II unit consists of the compres
sor, oil reservoir and cooler, air and oil filters the control
system specified an open drip-proof motor, and adust
resistant control enclosure/instrument panel all mounted
on asteel base The compressor is isolated in an acoustic
enclosure. The unit is factory wired for the voltage spec
ified electrical connection to amain starter, connection
to the shop air line shop water line or oil lines to air-cooled
oil cooler are to be made by the user.
CONTROL VOLTAGE –The control voltage for the
start-stop push button hourmeter, pressure switch high
discharge temperature shutdown switch and other elec
trical control devices is 115 volts regardless of power
supply voltage On standard units the transformer in the
control enclosure is connected to change the specified
user’s power supply voltage to 115 volt control voltage.
RESET —The Reset Button must be pushed whenever
power is interrupted or turned off. For circuit interruption
see paragraph below relating to the specific safety device.
CAUTION
DO NOT CONTINUE TO RESET THE MANUAL
RESET IF THE SAME MALFUNCTION OCCURS
WITHIN ASHORT PERIOD OF TIME FIND
AND CORRECT THE TROUBLE BEFORE RE-
SUMING OPERA TION.
start-Stop/Reset Switch –Later model constant Speed
units with Low Demand switch that use the two-probe high
discharge temperature switch have atw0-button Start-
Stop/Reset switch in the control box door. The indicating
pilot light is separately mounted adjacent to the switch
On-Off- Reset Switch –Later model Automatic StarV
Timed Stop units with Low Demand switch that use the
two probe high discharge temperature switch have athree
button On-Off-Reset switch in the control box door. The
indicating pilot light is separately mounted adjacent to
the switch.
Pilot Light —Later model units with either Constant Speed
or Automatic Start/Timed Stop control system and the
13-9-630 Section 4Page 1

two-probe high discharge temperature switch have an
indicating pilot light mounted in the control box door. The
amber lighted ON indicates compressor running under
Constant Speed Control Under Automatic Start/Timed
stop the compressor may be stopped with the amber light
ON indicating power on The blue lighted LOAD indicates
compressor is loaded
To replace the bulbs in the pilot light (replacement bulb
number is Sylvania 120 PSB or equal
1. Turn power off at main breaker panel
2. Open control panel
3. Turn slotted locking screw on upper side of pilot
light body counterclockwise 1/4 turn and remove
the body from the lens holder.
4. Remove old bulb located in the body and insert
new bulb
5. Reassemble body to lens holder and secure by turn-
ing locking screw 1/4 turn clockwise
ON-OFF SWITCH (Figure 2-1) –Early model Constant
Speed units with Low Demand Mode switch and the units
with Automatic Start/Timed Stop with Low Demand Mode
have an ON-OFF push button with an amber lighted section
to indicate ON (compressor running) and agreen lighted
section to indicate LOAD (compressor loaded). The red
bar on the bottom of the ON-OFF switch is the OFF and
RESET on the Constant Speed unit with Low Demand
Mode The black bar on the bottom of the Automatic Start/
Timed Stop ON-OFF switch is the RESET.
To replace the bulb (Sylvania 120 PSB or equal in any of
the switches
1. Turn the power off at the main breaker panel
2. Open the control panel.
3. Turn the slotted locking screw on the upper side of
the switch body counterclockwise 1/4 turn and re
move the switch body from the switch operator.
4. Remove the old bulb located in the stem of the switch
body and insert the new bulb
5. Reassemble the switch body to the operator and lock
in place by turning the locking screw 1/4 turn clock-
wise.
LOW DEMAND MODE SWITCH (Figure 2-1) –The
low demand mode switch when turned to the ON POSi
tion will blow the reservoir down when the compressor
unloads When switch is turned to OFF, unit will retain
pressure in reservoir when unloaded
~WARNING
The low demand mode switch CANNOT be used with
remote elevated oil coolers These units require special
wiring diagrams —check with factory.
SAFETY DEVICES –
these safety device% Both control systems incorporate
Motor Protection Devices —Overload heaters are fur-
nished for the air-cooled oil cooler fan motor starter in
the voltage range specified There are three (3) overloads
of proper size for the starter and its enclosure. When re
placing or changing overloads be sure to select them from
a3-overload heater table since the use of athird overload
derates each overload for agiven enclosure due to the
extra heat An overload from a2-overload heater table
would be undersize
The overload heaters are in acommon overload block in
the starter and have asingle common percentage adjust-
ment knob with a 90 to 110% range. The knob is set at the
factory on the 100% mark
Main unit starter should be adequately fused and provided
with overload heaters suitable for the application to pro
vide protection for the unit drive motor.
High Discharge Temperature Switch —Later Models
—Later models of the compressor unit are protected from
high discharge temperature by atwo-probe adjustable
switch. One probe is located in the discharge pipe between
the compressor and the oil reservoir to sense compressor
discharge air/oil mixture temperature. The second probe
is located in the final discharge manifold and senses the
temperature of the air at the oil separators The switch is
located inside the control box (Figure 2-l); the shutdown
temperature is set on the adjustable dial If the temper-
ature of the air at either of the probes exceeds the tem-
perature set on the dial the switch will stop the unit Press
reset button of the Start/ Stop(On-Off) switch then the Start
(On) button to restart the unit
CAuTION
This adjustable switch dial must not be set higher
than 225° F.
DO not continue to reset the circuit if the same mal-
function occurs within ashort period of time Find
and correct the trouble before resuming operation
In addition to protecting the unit from damage or failure
resulting from high air temperature, the switch also in
corporate four (4) indicator lights which show the point
of high temperature and/or the condition of the tempera
ture probes This information is shown on the decal inside
the control box and in Figure 2-4.
The High Air Temperature Switch may be checked period
ically to assure proper operation To check with the unit
running turn the dial on the switch to the temperature in-
dicated by the discharge temperature gauge. Unit should
shutdown If it doea not check the temperature gauge
accuracy and indicator lights— refer to the condition decal
on the control box door for the malfunction After opera-
tional check always reset switch dial to the proper setting
(225° F.).
Automatic Blowdown Valve —Apilot-operated valve
piped into the oil reservoir final discharge manifold ahead
of the check valve and connected to the unloader solenoid
valve which is wired into the motor control circuit will
release pressure from the oil reservoir each time the unit is
unloaded with low demand mode switch ON or when unit is
shut down. The blowdown line is equipped with amuffler to
reduce air discharge noise.
13-9-630 Section 4Page 2

Safety Valve (Figures 2-1 &3-1) -Apressure relief valve is
installed in the final discharge manifold and set at the
factory to approximately 120% of the specified operating
pressure for protection against overpressure. Periodic
checks should be made to insure its proper operation
Never operate the unit without aproper safety valve setting
Low Demand Mode Pressure Switch (Figure 1-4) -The
low demand mode switch when turned ON will cause the
low demand mode pressure switch to reenergize the low
demand mode solenoid valve when discharge pressure
reaches the set point This switch should be set approx-
imately 5PSI above full load pressure with a8-12 PSI
differential
Low Demand Mode Unloader Solenoid (Figure 1-4) -The
low demand mode solenoid valve when energized supplies
an air signal to close the blowdown valve. When de
energized it supplies an air signal to close compressor inlet
valve and exhausts air to open the blowdown valve
Pressure Regulator (Figure 1-4) -The pressure regulator
must be set 25-30 PSIG to prevent inlet valve “slam”.
Reservoir Pressure Switch (Figure 1-4) -Apressure switch
is connected to the discharge manifold and wired to the
motor control circuit to prevent attempted starting of the
unit when there is more than 5PSIG pressure in the oil
reservoir. This protects the unit from starting against load
when the oil reservoir has not had enough time to blow
down Blowdown time is usually about 45 seconds
,WARNING
Do not set the switch higher than 5PSIG or render the
switch inoperative severe damage to the motor can
occur if started with pressure in the oil reservoir
Low Oil Pressure Shutdown (Figure 1-4) -Units are
provided with apressure switch piped to the compressor oil
sump and wired into the motor control circuit to protect the
unit against operation at too low an oil pressure and against
complete lubrication failure due to an oil line restriction or
sudden loss of oil pressure. The pressure switch is set 10-
15 PSIG and will stop the unit if the oil pressure falls below
this pressure any time during operation, and will prevent
the unit being started if the oil pressure does not rise to 10-
15 PSIG within 10 seconds of starting.
The pressure switch is set at 10-15 PSIG athe factory. If
resetting is necessary
HIGH DISCHARGE TEMPERATURE SWITCH CONDITION CHART
“A indicates Temperature Condition at Compressor Discharge.
“B’ indicates Temperature Condition at Oil Separator.
“C indicates Probe Condition.
o
POWER
“A” o
“c o0
\
“B
o
CONDITION POWER ON “A “B’ “c”
POWER OFF OFF OFF OFF OFF
NORMAL TEMPERATURE RED RED RED OFF
COMPRESSOR HIGH TEMPERATURE RED OFF RED OFF
SEPARATOR HIGH TEMPERATURE RED RED OFF OFF
COMPRESSOR PROBE OPEN RED OFF RED GREEN
SEPARATOR PROBE OPEN RED RED OFF GREEN
COMPRESSOR PROBE SHORTED RED OFF RED RED
SEPARATOR PROBE SHORTED RED RED OFF RED
COMPRESSOR PROBE SHORTED/
separator PROBE OPEN RED OFF OFF ORANGE
COMPRESSOR PROBE OPEN/
SEPARATOR PROBE SHORTED RED OFF OFF ORANGE
FIGURE 2-4
13-9-630 Section 4Page 3

1.
2.
Adjust the upper limit pressure to 15 PSIG by turning
the slotted screw (pressure) near the top of the switch
Clockwise movement of the screw raises the pressure
counterclockwise lowers the pressure Note approx-
imate pressure setting is indicated on the range scale
on left face of switch
Adjust the lower limit pressure to 10 PSIG by turning
the slotted screw (differential) near the bottom of the
switch until the cam-shaped calibrated dial under the
pressure setting screw indicates about 1/4 of full scale
reading from lowest setting Clockwise movement of
the screw reduces the differential counterclockwise
increaaes differential Note differential range (1 -18
PSI) is indicated by marks on the cam-shaped dial
If aunit with Constant Speed with Low Demand Mode
Switch shuts down from low oil pressure pressing the
ON button will restart the unit
Since the Automatic Start/Timed Stop control is an
automatic starting type areset relay is used as a positive
means to interrupt the circuit o’n either alow oil pressure
shutdown or high discharge air temperature shut-down to
restart these units press the black bar marked RESET and
then press the ON button
CAUTION
Do not continue to restart the unit if the same
malfunction occurs within ashort period of time Find
and correct the trouble before resuming operation
This switch should be checked periodically to assure
proper operation To check disconnect the timed-opening
instantaneous closing time delay relay from the system at
point 10 (see wiring diagram). Try to start unit —unit should
not run —if it does switch is inoperative and should be
replaced Be sure to reconnect the time delay relay after
checking
Low Oil Pressure Time Delay Switch (Figures 1-4 &3-4)
located in the control panel enclosure is wired into the
control circuit to provide the 10-second delay required for
the compressor oil pressure to rise to 10-15 PSIG and
energize the low oil pressure switch circuit
MANUAL OPERATOR TAB 1~N.C. TIMING CONTACT
MOVEABLE INSTAN. 1
TANEOUS CONTACT
CARRIER -DO NOTL
uSE AS A MANUAL
OPERATOR I
TIME SETTING AOJUSTING XREW JA75852
FIGURE 3-4 –LOW OIL PRESSURE
TIME DELAY SWITCH
To check the time delay switch setting
1. Pull main breaker switch
2. Move black timer tab located on the left half of relay
block to the ON position and hold Timer will begin to
run for set time
the right half of the relay block the contacts will open
when the preset time runs out
4. Adjustment of time delay setting is made by turning
screw on lower right face of relay block to afaster(F) or
slower (S) setting. Recheck setting of relay as in No. 2
and 3above each time screw is turned
,WARNING
●Timer isfactory set at 10 seconds NEVER ATTEMPT
TO ADJUST THE TIMING RELAY FOR MORE
THAN 15 SECONDS DELAY —serious compressor
damage may result from operation without lubrication
for even ashort period
~CAUTION
INSTRUMENTS &GAUGES (Figures 3-1 &1-4) -Both
control system instrument panels incorporate the following:
Hourmeter -Acontinuous reading (nonreset) type hour-
meter displays the accumulated operating time of the unit
and provides aconvenient means for scheduling changes
of oil supply and servicing of filters separators and other
devices
Air Pressure Geuge -Adirect reading air pressure gauge
indicates the final discharge air pressure at the discharge
manifold
Discharge Air Temperature Gauge -Adirect reading
temperature gauge indicates the compressor discharge air
temperature
Pressure Differential Gauge -This gauge reads the
pressure differential across the oil separators providing a
continuous monitoring of their condition and indicates
when changing of the elements is required
Air Filter Indicator- An air filter indicator is located on the
instrument panel and indicates when the air filter requires
servicing
Oil Filter Indicator- An oil filter indicator is located on the
head of the oil filter and indicates when oil filter needs
servicing
a- ADJUSTING SCREW
RETAINING RING ~SPRING
AIR
IN
B75121 w/ \
3. Observe the action of the right hand set of contacts on FIGURE 4-4 –MINIMUM DISCHARGE
PRESSURE VALVE
13-9-630 Section 4Page 4