Gardner Denver ELECTRA-SAVER Service manual

GARDNER DENVER
ELECTRA–SAVER
ELECTRA–SAVER II
STATIONARY BASE–MOUNTED
COMPRESSOR
WITH OPTIONAL ES+ CONTROLLER
DOMESTIC MODELS
40 – 100 HP
EBH, EBM, EBP & EAP
INTERNATIONAL MODELS
EBM_ _B – 60 – 100 HP (45 – 75 KW)
OPERATING AND
SERVICE MANUAL
13–9/10–641 SP
7th Edition
September, 1995

13–9/10–641 SP Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner Denver Compressor genuine parts, engine-
ered to original tolerances, are designed for optimum
dependability–––specificallyforGardnerDenvercom-
pressor systems. Design and material innovations are
theresultofyearsofexperiencewithhundredsofdiffer-
ent compressor applications. Reliability in materials
and quality assurance are incorporated in our genuine
replacement parts.
Your authorized Gardner Denver Compressor distribu-
tor offers all the backup you’ll need. A worldwide net-
workofauthorizeddistributorsprovidesthefinestprod-
uct support in the air compressor industry.Your local
authorized distributor maintains a large inventory of
genuinepartsandheisbackedup foremergencyparts
by direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
Denver air compressor with these services:
1. Trained parts specialists to assist you in selecting
the correct replacement parts.
2. Factory warranted new and remanufactured
rotaryscrewair ends.Most popularmodelreman-
ufacturedairendsaremaintainedinstockatMDC
for purchase on an exchange basis with liberal
core credit available for the replacement unit.
3. AfulllineoffactorytestedAEONtcompressorlu-
bricantsspecifically formulatedfor use inGardner
Denver compressors.
4. Repair and maintenance kits designed with the
necessary parts to simplify servicing your com-
pressor.
Authorized distributor service technicians are factory–
trained and skilled in compressor maintenance and re-
pair. They are ready to respond and assist you by pro-
viding fast, expert maintenance and repair services.
For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages
of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: [phone]
Phone: [phone] Fax: [phone]
(800) 245–4946
Fax: [phone] REMANUFACTURED AIR ENDS
Whenever an air end requires replacement or repair,
Gardner Denver offers an industry unique, factory re-
manufactured air end exchange program. From its
modern Remanufacturing Center in Indianapolis, IN,
GardnerDenver iscommittedto supplyingyou withthe
highest quality, factory remanufactured air ends that
are guaranteed to save you time, aggravation and
money.
Immediately Available
Repair downtime costs you money, which is why there
are over 200 remanufactured units in inventory at all
times, ready for immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average
over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, in-
spected and analyzed. Only those parts that can be
brought back to original factory specifications are re-
manufactured. Everyremanufactured airend receives
anewoverhaulkit: bearings,gears,seals,sleevesand
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
justdon’t do. Magnafluxand ultrasonicinspectionspot
cracked or stressed castings, monochromatic light
analysis exposes oil leaks, and coordinate measure-
ment machine inspects to +/– .0001”, insuring that all
remanufactured air ends meet factory performance
specifications.
Warranty
Gardner Denver backs up every remanufactured air
end with a new warranty . . . 18 months from purchase,
12 months from service.
GardnerDenverremanufacturedairendsdeliver
quali-
ty without question . . . year in and year out.
Call Gardner Denver for information on the air end ex-
change program and the name of your authorized dis-
tributor. Phone Number: 800–245–4946 or
FAX: [phone]

13–9/10–641 SP Page ii
FOREWORD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To
beassuredofreceivingmaximumservicefromthismachinetheownermustexercisecareinitsoperationandmain-
tenance.Thisbookiswrittentogivetheoperatorandmaintenancedepartmentessentialinformationforday–to–day
operation,maintenanceand adjustment.Careful adherenceto theseinstructionswill resultin economicaloperation
and minimum downtime.
Danger is used toindicate the presenceof a hazardwhich will causesevere personal
injury, death, or substantial property damage if the warning is ignored.
Warning isusedto indicatethepresence ofahazard whichcancause severeperson-
al injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
Notice is used tonotify people of installation,operation or maintenanceinformation
which is important but not hazard–related.

13–9/10–641 SP Page iii
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER(see nameplateonunit). The SerialNumber
isalso stampedon topof thecylinder flangeto theright
of the inlet housing.
All orders for Parts should be placed with the nearest
authorized distributor.
Where NOT specified, quantity of parts required per
compressor or unit is one (1); where more than one is
required per unit, quantity is indicated in parenthesis.
SPECIFY EXACTLY THE NUMBER OF PARTS RE-
QUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left Hand side of a
compressor, stand at the motor end and look toward
the compressor. Right Hand and Left Hand are indi-
cated in parenthesis following the part name, i.e. (RH)
& (LH), when appropriate.

13–9/10–641 SP Page iv
TABLE OF CONTENTS
REMANUFACTURED AIR ENDS i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOREWARD ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS FOR ORDERING REPAIR PARTS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF ILLUSTRATIONS ix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1, GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2, INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3, STARTING & OPERATING PROCEDURES 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4, CONTROLS & INSTRUMENTATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5, LUBRICATION, OIL COOLER, OIL FILTER & SEPARATOR 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6, AIR FILTER 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7, COUPLING 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8, MAINTENANCE SCHEDULE 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9, TROUBLE SHOOTING 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10, TROUBLE SHOOTING CONTROLS 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–9/10–641 SP Page v
Actuator, Turn Valve 33. . . . . . . . . . . . . . . . . . . . . . .
Addition of Oil Between Changes 49. . . . . . . . . . . .
Adjustments
Configuration 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Setup 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advisories, Service 20. . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER, SECTION 6 57. . . . . . . . . . . . . . . . . . .
Air Filter Element Life 57. . . . . . . . . . . . . . . . . . . . . .
Air Filter Vacuum Switch 34. . . . . . . . . . . . . . . . . . .
Air Filter, Heavy Duty (Standard) 57. . . . . . . . . . . .
Air Flow in the Compressor System 1. . . . . . . . . . .
Air Receiver, Auxiliary 10. . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Units, Location 8. . . . . . . . . . . . . . . . . .
Alarm Relay 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amp Sensor Failure 21. . . . . . . . . . . . . . . . . . . . . . .
Auto Sentry–ES+ Controller
Programming and Setup 21. . . . . . . . . . . . . . . .
Auto Sentry–ES+ Operation 18. . . . . . . . . . . . . . . .
Automatic Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode 18. . . . . . . . . . . . . . . . . . . .
Low Demand Mode 18. . . . . . . . . . . . . . . . . . . . .
Sequence Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Auto Sentry–ES+ Control Display 20. . . . . . . . . . .
Automatic Mode Operation 19. . . . . . . . . . . . . . . . .
Automatic Rotation 29. . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Air Receiver 10. . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . .
Change Procedure, Lubricant 49. . . . . . . . . . . . . . .
Check, Daily 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Draining Oil System 51. . . . . . . . . . .
Cold Ambient Operation 49. . . . . . . . . . . . . . . . . . . .
Cold Weather Operation 10. . . . . . . . . . . . . . . . . . .
Cold Weather Operation, Installation for 9. . . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor (GD Eliminator) Oil Separator 55. . .
Compressor Capacity Control – Turn Valve
Units Only 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Cooler 52. . . . . . . . . . . . . . . . . . . . .
Compressor Oil Filter 52. . . . . . . . . . . . . . . . . . . . . .
Compressor Oil System 45. . . . . . . . . . . . . . . . . . . .
Compressor Oil System Check 56. . . . . . . . . . . . . .
Configuration Adjustments 24. . . . . . . . . . . . . . . . . .
Connection Failure 21. . . . . . . . . . . . . . . . . . . . . . . .
Connection to Extermal Controls 29. . . . . . . . . . . .
Alarm Relay 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote On / Off 29. . . . . . . . . . . . . . . . . . . . . . . .
Serial Communications 30. . . . . . . . . . . . . . . . . .
Constant Run Mode Operation 18. . . . . . . . . . . . . .
Control Devices, Other 30. . . . . . . . . . . . . . . . . . . . .
Control Features, Other
Auto Restart After Power Failure 26. . . . . . . . .
Current Limiting 26. . . . . . . . . . . . . . . . . . . . . . . .
Modulating – Load/Unload 26. . . . . . . . . . . . . . .
Control Piping 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Schematics 35. . . . . . . . . . . . . . . . . . . . . . . .
Control Transformer 34. . . . . . . . . . . . . . . . . . . . . . .
CONTROLS & INSTRUMENTS,
SECTION 4 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls & Instruments, General Description 18. .
Cooler, Compressor Oil 52. . . . . . . . . . . . . . . . . . . .
Cooling, Sealing and Lubrication 1. . . . . . . . . . . . .
COUPLING, SECTION 7 59. . . . . . . . . . . . . . . . . . .
Coupling 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Cushion Design 59. . . . . . . . . . . . . . .
Daily Check 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 6, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 12. . . . . . . . . . . . . . . . . . . .
Discharge Thermistor 34. . . . . . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 9. . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning Oil System 51. . . . . . . . . . .

INDEX
13–9/10–641 SP Page vi
Electric Motor Grease Recommendations 15. . . .
Electric Motor Regreasing Interval 15. . . . . . . . . . .
Electrical Wiring 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Units 14. . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Air Filter 57. . . . . . . . . . . . . . . . . . . . .
Emergency Stop Push–Button 34. . . . . . . . . . . . . .
Emergency Stop Shutdown 21. . . . . . . . . . . . . . . . .
Enclosure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ES+ Sequence System Operation 28. . . . . . . . . . .
External Device Shutdown 21. . . . . . . . . . . . . . . . . .
Fan Starter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Compressor Oil 52. . . . . . . . . . . . . . . . . . . . . .
Filter Element 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Heavy Duty Air (Standard) 57. . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foundation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Oil Level 31, 50. . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . .
Grease Recommendations, Electric Motor 15. . . .
Grounding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Shutdown 21. . . . . . . . . . . . . . . . . . .
High Temperature Operation 45. . . . . . . . . . . . . . . .
High Temperature Shutdown 20. . . . . . . . . . . . . . . .
Inlet Line 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 58. . . . . . . . . . . . . . . . . . . . .
Inlet Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION, SECTION 2 8. . . . . . . . . . . . . . . .
Installation, General 8. . . . . . . . . . . . . . . . . . . . . . . .
Installation for Cold Weather Operation 9. . . . . . .
Lifting Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 12. . . . . . . . . . . . . . . . . . . .
Line, Inlet 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Units 8. . . . . . . . . . . . . . . . . . . . . . . .
Water–Cooled Units 9. . . . . . . . . . . . . . . . . . . . .
Low Demand Mode Operation 18. . . . . . . . . . . . . .
Low Oil Pressure Shutdown 21. . . . . . . . . . . . . . . .
Lubricant, Recommended 45. . . . . . . . . . . . . . . . . .
Lubricant Change Procedure 49. . . . . . . . . . . . . . .
Lubrication, Motor 14. . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication, Cooling and Sealing 1. . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 45. . . . . . . . . . . . . .
Main Adjustments Menu, Controller 21. . . . . . . . . .
Main Starter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Adjustments 23. . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE, SECTION 8 60. . .
Minimum Discharge Pressure Valve 31. . . . . . . . .
Moisture in the Oil System 50. . . . . . . . . . . . . . . . . .
Moisture Separator/Trap 10. . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 15. . . . . . . . . . .
Motor Lubrication 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Protective Devices 20. . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 15. . . . . . . . . . . . . . . . . .
Oil Change Interval 50. . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Compressor 52. . . . . . . . . . . . . . . . . . . .
Oil Filter, Compressor 52. . . . . . . . . . . . . . . . . . . . . .
Oil Level Gauge 31, 50. . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 9. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator
Compressor (GD Eliminator) 55. . . . . . . . . . . . .
Inspection 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Carryover 55. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal for Inspection or Replacement 56. . .
Oil Specifications 45. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System
Compressor 45. . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning 51. . . . . . . . . . . . . . . . . .
Oil System Check 56. . . . . . . . . . . . . . . . . . . . . . . . .
Air and Oil Discharge Temperature 56. . . . . . .
Compressor Oil Inlet Temperature 56. . . . . . . .

INDEX
13–9/10–641 SP Page vii
Oil Cooler Oil Pressure Differential 56. . . . . . . .
Oil Cooler Temperature Differential 56. . . . . . .
Oil Cooler Water Pressure Differential 56. . . . .
Oil Inlet Pressure 56. . . . . . . . . . . . . . . . . . . . . . .
Operation
Automatic Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Cold Ambient 49. . . . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode 18. . . . . . . . . . . . . . . . . . . .
High Temperature 45. . . . . . . . . . . . . . . . . . . . . .
Low Demand Mode 18. . . . . . . . . . . . . . . . . . . . .
Sequence Mode 19. . . . . . . . . . . . . . . . . . . . . . . .
Operation Adjustments 23. . . . . . . . . . . . . . . . . . . . .
Optional Switches 35. . . . . . . . . . . . . . . . . . . . . . . . .
Other Sequencing Features 29. . . . . . . . . . . . . . . .
Piping, Control 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Failure 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Differential Gauging 55. . . . . . . . . . . . . . .
Pressure Regulator 33. . . . . . . . . . . . . . . . . . . . . . . .
Prestart–Up Instructions 16. . . . . . . . . . . . . . . . . . . .
Air Filter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode 17. . . . . . . . . . . . . . . . . . . . . . . .
Piping 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 17. . . . . . . . . . . . . . . . . . . . . . .
Programming and Setup, Auto Sentry–ES+
Controller 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Controller, Main Adjustments
Menu 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Shutdowns 20. . . . . . . . . . . . . . . . . . . . . .
Purge Valve 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Lubricant 45. . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 15. . . . . . . . . .
Regulator, Pressure 33. . . . . . . . . . . . . . . . . . . . . . .
Relief Valve 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote On/Off 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Ordering Instructions iii. . . . . . . . . . .
Reservoir, Oil 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reservoir Pressure Transducer 34. . . . . . . . . . . . .
Safety Precautions 4–5. . . . . . . . . . . . . . . . . . . . . . .
Sealing, Lubrication and Cleaning 1. . . . . . . . . . . .
Separator, Compressor (GD Eliminator) Oil 55. . .
Separator Differential Pressure Shutdown 21. . . .
Separator/Trap, Moisture 10. . . . . . . . . . . . . . . . . . .
Sequence Adjustments 24. . . . . . . . . . . . . . . . . . . .
Sequence Mode Operation 19. . . . . . . . . . . . . . . . .
Sequenced System Checkout 29. . . . . . . . . . . . . . .
Sequencing Compressors with Auto Sentry–ES+
Compressor System 27. . . . . . . . . . . . . . . . . . . .
Establishing Initial Sequence 28. . . . . . . . . . . . .
General 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequencing Installation 27. . . . . . . . . . . . . . . . .
Serial Communications 30. . . . . . . . . . . . . . . . . . . .
Service Advisories 20. . . . . . . . . . . . . . . . . . . . . . . . .
Service Check List 60. . . . . . . . . . . . . . . . . . . . . . . .
Air Filter 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 1000 Hours Operation 60. . . . . . . . . . . . .
Every 125 Hours Operation 60. . . . . . . . . . . . . .
Every 6000 Hours Operation 60. . . . . . . . . . . . .
Every 8 Hours Operation 60. . . . . . . . . . . . . . . .
Every Year 60. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 60. . . . . . . . . . . . . . . . . . . . . . .
Oil Separator 60. . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdowns
Amp Sensor Failure 21. . . . . . . . . . . . . . . . . . . .
Connection Failure 21. . . . . . . . . . . . . . . . . . . . .
Emergency Stop 21. . . . . . . . . . . . . . . . . . . . . . .
External Device 21. . . . . . . . . . . . . . . . . . . . . . . .
High Pressure 21. . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 20. . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure 21. . . . . . . . . . . . . . . . . . . . . . .
Motor Protective Devices 20. . . . . . . . . . . . . . . .

INDEX
13–9/10–641 SP Page viii
Other 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Failure 21. . . . . . . . . . . . . . . . . . . . . . . . . .
Separator Differential Pressure 21. . . . . . . . . . .
Shuttle Valve 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valves IVC and IVO 33. . . . . . . . . . . . . . .
Solenoid Valves TVC and TVO 34. . . . . . . . . . . . . .
Specifications, Oil 45. . . . . . . . . . . . . . . . . . . . . . . . .
Starter
Fan 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES,
SECTION 3 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Strip, Terminal 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch
Air Filter Vacuum 34. . . . . . . . . . . . . . . . . . . . . . .
Vibration 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switches, Optional 35. . . . . . . . . . . . . . . . . . . . . . . .
System Pressure Transducer 34. . . . . . . . . . . . . . .
System Thermistor 34. . . . . . . . . . . . . . . . . . . . . . . .
Terminal Strip 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor
Discharge 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer
Reservoir Pressure 34. . . . . . . . . . . . . . . . . . . . .
System Pressure 34. . . . . . . . . . . . . . . . . . . . . . .
Transformer, Control 34. . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING, SECTION 9 61. . . . . . . . .
TROUBLE SHOOTING CONTROLS,
SECTION 10 64. . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Shooting Controls
Advisory Troubleshooting 65. . . . . . . . . . . . . . . .
Controls Troubleshooting 69. . . . . . . . . . . . . . . .
Display Modes 64. . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Troubleshooting 66. . . . . . . . . . . . . .
Tube, Inlet 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve 1, 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve Actuator – EAQ Units Only 33. . . . . . .
Unit Setup Adjustments 25. . . . . . . . . . . . . . . . . . . .
Valve
Blowdown 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure 31. . . . . . . . . . . .
Purge 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid IVC and IVO 33. . . . . . . . . . . . . . . . . . .
Solenoid TVC and TVO 34. . . . . . . . . . . . . . . . .
Turn 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Switch 34. . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . .
Water–Cooled Units, Location 9. . . . . . . . . . . . . . .
Wiring, Electrical 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 35. . . . . . . . . . . . . . . . . . . . . . . . . .

13–9/10–641 SP Page ix
LIST OF ILLUSTRATIONS
Figure # Description Page
Figure 1–1 Compression Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 Starter Box 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–3 Package – Controller & Starters 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–4 Package – Drive Motor & Air Filter 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–5 Package – Oil Filter, Oil Level Gauge, Mixing Valve, Minimum Pressure Valve
and Check Valve 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–6 Package – Air/Oil Flow Diagram 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–1 Typical Compressor Room 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Air Flow Chart 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–3 Cold Weather Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–4 Inlet Line Lengths 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–5 Heat Exchanger (Oil Cooler) Approximate Water Flow 11. . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–6 Aftercooler Approximate Water Flow 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–7 Series Piping 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–8 Parallel Piping 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–1 Auto Sentry–ES+ Display 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Flowchart for Set–up Programming, Auto Sentry–ES+ 22. . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Schematic Tubing Diagram 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Blowdown Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Minimum Discharge Pressure Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Inlet Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Shuttle Valve 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–8 Turn Valve – Turn Valve Units Only 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–9 Control Schematic – Compressor Unloaded – Constant Speed Mode,
EBH & EBM Units Only 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–10 Control Schematic – Compressor at Full Load – Constant Speed Mode,
EBH & EBM Units Only 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–11 Control Schematic – Compressor Unloaded – Low Demand Mode or Auto Mode
EBH & EBM Units Only 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–12 Control Schematic – Compressor at Full Load, Turn Valve Units Only 39. . . . . . . . . . . .
Figure 4–13 Control Schematic – Compressor Fully Unload – Low Demand Mode Switch Off,
Turn Valve Units Only 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–14 Control Schematic – Compressor Fully Loaded – Low Demand Mode Switch On,
Turn Valve Units Only 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–15 Wiring Diagram – 214ECP546 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–16 Wiring Diagram – 218ECP546 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–17 Wiring Diagram – 215EAP546 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Flow Diagram 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Oil Flow Diagram – Remote Overhead Mounted 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Cooler Drain Detail 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–4 Oil Level Gauge 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–5 Oil Change Interval 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–6 Approximate Oil System Capacities 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–7 Thermostatic Mixing Valve Element 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–8 Water Control Valve 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–9 Dew Point Temperature vs. Ambient Temperature, (100% Relative Humidity) 54. . . . . .
Figure 5–10 Oil Separator 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy Duty Air Filter (Standard) 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Installation of Coupling Cushions 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–9/10–641 SP Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSION CYCLE
COMPRESSOR – The Gardner Denver Rotary Screw
compressor is a single stage, positive displacement
rotary machine using meshing helical rotors to effect
compression. Both rotors are supported between high
capacity roller bearings located outside the compres-
sion chamber. Single width cylindrical roller bearings
areusedat theinletend oftherotorstocarrypartof the
radial loads. Tapered roller bearings at the discharge
end locate each rotor axially and carry all thrust loads
and the remainder of the radial loads.
COMPRESSION PRINCIPLE (FIGURE 1–1) – Com-
pression is accomplished by the main and secondary
rotors synchronously meshing in a one–piece cylinder.
Themain rotorhas four(4) helical lobes90_apart. The
secondary rotor has six (6) matching helical grooves
60_apart to allow meshing with main rotor lobes.
Theairinletportislocatedontopofthecompressorcyl-
inder 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 ro-
torgrooves (A). Whenthe rotorspass the inletport cut-
off,airistrappedintheinterlobecavityandflowsaxially
with the meshing rotors (B). As meshing continues,
more of the main rotor lobe enters the secondary rotor
groove, normal volume is reduced and pressure in-
creases.
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-
ductionandpressureincreasecontinuesuntiltheair/oil
mixture trapped in the interlobe cavity by the rotors
passesthedischargeportandisreleasedtotheoilres-
ervoir(C). Each rotor cavityfollows the same“fill–com-
press–discharge” cycle in rapid succession to produce
a discharge air flow that is continuous, smooth and
shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM
(FIGURE 5–1, page 46) – Air enters the air filter and
passes through the inlet unloader valve to the com-
pressor. 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
passesintotheseparatorandseparatorhousingwhere
theoilisseparatedandpassesthroughtubingconnect-
ing the separator housing and compressor. The air
passes through the minimum pressure valve, dis-
charge check valve and cooler, then to the plant air
lines.
LUBRICATION, COOLING AND SEALING – Oil is
forcedbyair pressurefromthe oilreservoirthrough the
oil cooler, thermostatic mixing valve, and oil filter and
discharges into the compressor main oil gallery. A por-
tion of the oil is directed through internal passages to
the bearings, gears and shaft oil seal. The balance of
theoilisinjecteddirectlyintothecompressionchamber
to remove heat of compression, seal internal clear-
ances and lubricate the rotors.
TURN VALVE (EAP UNITS ONLY) – The turn valve is
a rotary helical valve located on the discharge side of
the cylinder toward the inlet end. The valve opens and
closes ports in the cylinder which communicates with
theinletpassage.Thisvaries thecompressorrotorvol-
ume to match the demand for air, thus reducing the
part–load power requirement.

13–9/10–641 SP Page 2
FIGURE 1–2 – STARTER BOX
FIGURE 1–3 – PACKAGE – CONTROLLER & STARTERS
FIGURE 1–4 – PACKAGE – DRIVE MOTOR & AIR FILTER

13–9/10–641 SP Page 3
FIGURE 1–5 – PACKAGE – OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE,
MINIMUM PRESSURE VALVE & CHECK VALVE
OIL LEVEL GAUGE
FIGURE 1–6 – PACKAGE – AIR/OIL FLOW DIAGRAM

13–9/10–641 SP Page 4
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:
Failure to observe these notices could result in injury to or death of personnel.
DKeep fingers and clothing away from revolving fan, drive coupling, etc.
DDo not use the air discharge from this unit for breathing – not suitable for hu-
man consumption.
DDonot loosenorremove theoil fillerplug, drainplugs, covers,the thermostat-
icmixingvalve orbreakanyconnections,etc., inthecompressorair oroilsys-
tem until the unit is shut down and the air pressure has been relieved.
DElectrical shock can and may be fatal.
DCompressor unit mustbe grounded inaccordance withthe National Electrical
Code. A ground jumper equal to the size of the equipment ground conductor
must be used to connect the compressor motor base to the unit base.
DFan motors must remain grounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.
DOpen main disconnect switch, tag and lockout before working on the control.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.

13–9/10–641 SP Page 5
Failure to observe these notices could result in damage to equipment.
DStop the unit if any repairs or adjustments on or around the compressor are
required.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.
DAn Excess Flow Valve should be on all compressed air supply hoses ex-
ceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)
DDonot exceed the ratedmaximum pressure values shown on the nameplate.
DDo not operate unit if safety devices are not operating properly. Check peri-
odically. Never bypass safety devices.

13–9/10–641 SP Page 6
DECALS
206EAQ077 212EAQ077
218EAQ077
211EAQ077 207EAQ077

13–9/10–641 SP Page 7
DECALS
216EAQ077
217EAQ077
222EAQ077
221EAQ077 208EAQ077

13–9/10–641 SP Page 8
SECTION 2
INSTALLATION
GENERAL– On receipt of theunit,check for any dam-
agethatmayhavebeenincurredduringtransit. Report
any damage or missing parts as soon as possible.
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
methodsmust beusedto preventdamage. Liftingslots
areprovidedinthebasefortowmotoruse.Theunitmay
also be moved into location by rolling on bars.
Lift compressor unit by base only. Do
not use other places such as motor,
compressor or discharge manifold
piping as lifting points.
The eyebolts or lugs provided on the
motor are for lifting the motor only
and should not be used to lift any
additional weight. All eyebolts must
be securely tightened. When lifting
the motor the lifting angle must not
exceed 15 degrees.Failure to observe
this warning may result in damage to
equipment or personal injury.
Compressor, air/oil reservoir, separa-
tion chamber and all piping and tub-
ingmaybe athightemperatureduring
and after operation.
LOCATION – The compressor should be installed,
wheneverpossible,in aclean,well–lighted,well–venti-
lated area with ample space all around for mainte-
nance.Selectalocationthatprovidesa cool,clean,dry
source of air. In some cases it may be necessary to
install the air filter at some distance from the compres-
sor to obtain proper air supply.
Both the air–cooled and water–cooled units require
coolingairaswellasairtothecompressorinlet.Proper
ventilation MUST be provided; hot air must be ex-
hausted from the compressor operating area. A typical
inlet–outlet air flow arrangement is shown in
FIGURE 2–1.
Air–Cooled Units – A combination oil/aftercooler is
suppliedasstandardequipmentonallair–cooledunits.
The air–cooled unit with the standard enclosure re-
quires sufficient flow, FIGURE 2–2, page 9, for the
compressoroil/aftercoolingsystemandforelectricmo-
tor cooling. Air is drawn into the unit at the motor side
ofthe enclosure andis exhaustedat the oilcooler side.
Do not block the air flow to and from the unit. Allow
three and one–half (3–1/2) feet (1.1 M) to the nearest
obstruction on the starter end and control box end of
the unit. Allow three (3) feet (.9 M) to the nearest ob-
struction above and on other sides of unit. For continu-
ous efficiency, oil cooler cores must be periodically
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.
FIGURE 2–1 – TYPICAL COMPRESSOR ROOM

13–9/10–641 SP Page 9
* 80_F (27_C) Inlet Air
Minimum Air Flow * For Compression
And Cooling – Cubic Feet/Minute
(Cubic Meters/Minute)
HP (KW) Air Cooled Water Cooled
40 & 50 HP 6,500 1,400
60–100 HP 12,500 1,700
(45–75 KW) (354) (48)
FIGURE 2–2 – AIR FLOW CHART
For aluminum oil coolers, do not use
any cleaning solution that is not com-
patible with aluminum.Use ofimprop-
er solution may result in damage to
the cooler.
Water–Cooled Units – The water–cooled unit withthe
standard enclosure requires sufficient air flow,
FIGURE 2–2, for electric motor cooling. Air is drawn
intotheunitatthetopoftheenclosureandisexhausted
atthe motor side. Donot block air flowto and from unit.
Allow three and one–half (3–1/2) feet (1.1 M) to the
nearest obstruction on the starter end and control box
sideoftheunit.Allowthree(3)feet(.9 M)tothenearest
obstruction above and on other sides of the unit.
FOUNDATION – The G–D Rotary Screw compressor
requires no special foundation, but should be mounted
on a smooth, solid surface. Whenever possible install
theunitnearlevel.Temporaryinstallationmaybemade
at a maximum 10_angle lengthwise or 10_sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt, or danger of shifting from outside vibration or mov-
ing 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
thebottomofthereservoirtothe sideoftheframe.This
drainis approximately4.50 inches(115mm) abovethe
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 a suitable struc-
ture to obtain the desired drain height.
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 hotair from
the oil cooler end and over tempera-
ture operation.
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 drain
to a container.
ENCLOSURE – The compressor, electric motor, oil
cooler and aftercooler are mounted inside the enclo-
sure. Service doors are provided for maintenance ac-
cess. Be sure to allow enough space around the unit
for the doors to open completely. Any of the enclosure
doors may be removed by opening the door and lifting
it up slightly to disengage the hinges.
Do not operate the compressor with
the fan and coupling guard removed.
Exposed fan and belts may cause
injury to personnel.
The motor inspection/air filter service panel is held by
two latches and lifts away from the enclosure. The air
outletpanel isattached byscrews to theenclosure and
is not readily removeable.
INSTALLATION FOR COLD WEATHER OPERA-
TION (FIGURE 2–3, page 10) – It is recommended
that the unit be installed inside a shelter that will be
heated to temperatures above freezing (32_F, 0_ C).
This will eliminate many of the problems associated
with operating units in cold 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.Thisheatrecoverycouldeasilypayforanad-
equate shelter for the unit.
When an outside installation must be made, the pre-
cautions required will depend on the severity of the en-
vironment. The following are general guidelines for
outside installations:

13–9/10–641 SP Page 10
FIGURE 2–3 – COLD WEATHER INSTALLATION
(2.4 M)
Cold Weather (Down To +10_F, –12_C)
1. Be sure all drains, traps, and control lines, includ-
ing pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermo-
stat control is generally satisfactory for this pur-
pose and can be obtained at various local plumb-
ing or hardware outlets at nominal cost.
2. If an air–cooled aftercooler is to be used, provi-
sions to bypass the aftercooler must be made.
Since cold air contains very little moisture, suc-
cessful operation can be achieved without the af-
tercooler.
3. Provideatleastsomesimplesheltersuchasaply-
wood windbreak to protect against drifting snow.
4. Use only Gardner DenverRAEONt9000 SP lu-
bricant.
5. Monitor the unit carefully during start–up and op-
eration to be sure it is functioning normally.
6. Specify NEMA 4 enclosure for electrical devices.
Extreme Cold Weather Operation (Down To –40_F,
–40_C)
In addition to the above, the following should be pro-
vided:
1. It will 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. Since shutters are not pro-
vided as a factory option, blocking off a portion of
the cooler with plywood should be satisfactory.
2. Auto operation should not be used in extreme en-
vironments.
3. Some means of providing heat during shutdown
should be provided. There are various methods
toaccomplishthis,butsinceopeningsarenotpro-
videdfor sump heaters, theuse of radiant heaters
is recommended. The heaters should be sized to
provide at least a +10_F (–12_C) environment for
coolers, motor and sump. FIGURE 2–3, page 10,
shows how these might be located in a typical
installation and sizes required.
Remember unsheltered (outside) installations should
be avoided where possible. Installation next to a
heated building 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.
Refer to Engineering Data Sheet 13–9–411, available
from an authorized Gardner Denver distributor, for the
advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for
an adequate shelter for the unit.
AUXILIARYAIR RECEIVER – Anauxiliary airreceiver
isnotrequiredifthepipingsystemislargeandprovides
sufficient storage capacity to prevent rapid cycling.
Whenused,anairreceivershouldbe ofadequatesize,
providedwithareliefvalveofpropersetting,apressure
gauge and a means of draining condensate. A means
of draining condensate will need to be provided for.
MOISTURE SEPARATOR/TRAP – Since the unit is
equipped with a built–in aftercooler, a combination
moisture separator and trap is furnished with the unit.