Gardner Denver ELECTRA-SAVER Service manual

13
-
21
-
601
Version: 04
August 31, 2015
ELECTRA-SAVER
ELECTRA-SAVER II
STATIONARY BASE-MOUNTED
COMPRESSOR
AirSmart
™Controller
EAH99D - 50 HP
EBH99H - 40, 50 HP
EAM99D, EBM99M - 60, 75 HP
EAP99K, EBP99K - 100 HP
INTERNATIONAL MODELS
EBM99N 60, 75, 100 HP (45, 56, 75 KW)
OPERATING AND
SERVICE MANUAL

13-21-601 Page 1
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER® COMPRESSOR PARTS AND SUPPORT SERVICES
Gardner Denver® Compressor genuine parts, manufactured to design tolerances, are developed for optimum
dependability –specifically for Gardner Denver compressor systems. Design and material innovations are the result
of years of experience with hundreds of different compressor applications. Reliability in materials and quality
assurance is incorporated in our genuine replacement parts.
Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. An AirSmartänetwork of
authorized distributors provides the finest product support in the air compressor industry.
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 rotary screw airends. Most popular model remanufactured
airends are maintained in stock at the factory, for purchase on an exchange basis with liberal core credit
available for the replacement unit.
3. A full line of factory tested AEON™compressor lubricants specifically formulated for use in Gardner Denver
compressors.
4. Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.
Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They
are ready to respond and assist you by providing fast, expert maintenance and repair services.
To Contact Gardner Denver or locate your local distributor:
visit: www.contactgd.com/compressors
or
call: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS/REMANUFACTURED AIRENDS
Whenever an airend requires replacement or repair, Gardner Denver offers an industry unique, factory
remanufactured airend exchange program. From its modern factory, Gardner Denver is committed to supplying you
with the highest quality, factory remanufactured airends that are guaranteed to save you time, aggravation and
money
When ordering parts, specify Compressor MODEL, Method of Cooling, POWER and SERIAL NUMBER (see
nameplate on unit). The Airend Serial Numbers are also stamped on top of the discharge bearing carrier castings.
All orders for Parts should be placed with the nearest authorized distributor.
Where NOT specified, quantity of parts required per compressor or unit is one (1); where more than one is required
per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right-Hand and Left-Hand side of a compressor, stand at the motor end and look toward the
compressor. Right-Hand and Left- Hand are indicated in parenthesis following the part name, i.e. (RH) and (LH),
when appropriate.

13-21-601 Page 2
WARNING –PROHIBITION –MANDATORY LABEL INFORMATION
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled
manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise
care in its operation and maintenance. This book is written to give the operator and maintenance
department essential information for day-to-day operation, maintenance and adjustment. Careful
adherence to these instructions will result in economical operation and minimum downtime.
Boxed text formats are used, within this manual, to alert users of the following
conditions:
Safety Labels are used, within this manual and affixed to the appropriate areas of
the compressor package, to alert users of the following conditions:
Indicates a hazard with a high level of risk, which if not avoided,
WILL
result in death or serious
injury.
Equipment starts automatically
Cutting of Finger or Hand Hazard –Rotating
impeller blade
Cutting of Finger or Hand Hazard –Rotating fan
blade
Health Hazard –Explosive Release of Pressure
High Voltage –Hazard of Shock, Burn, or Death
Present until Electrical Power is Removed
Entanglement of Fingers or Hand/Rotating Shaft

13-21-601 Page 3
Indicates a hazard with a medium level of risk which, if not avoided,
COULD
result in death or
serious injury.
Asphyxiation Hazard –Poisonous Fumes or Toxic Gases in Compressed Air
Indicates a hazard with a low level of risk which, if not avoided,
MAY
result in a minor or
moderate injury.
Burn Hazard –Hot surface
PROHIBITION/MANDATORY ACTION REQUIREMENTS
Do not Operate Compressor with Guard
Removed
Do Not Lift Equipment with Hook –No Lift Point
Handle Package at Forklift Points Only
Lockout Electrical Equipment in De-Energized
State
Loud Noise Hazard –Wear Ear Protection
Read the Operator’s Manual Before Proceeding
with Task

13-21-601 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.
·Keep fingers and clothing away from rotating fan, drive coupling, etc.
·Disconnect the compressor unit from its power source, lockout and tagout before working on the
unit –this machine is automatically controlled and may start at any time.
·Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostatic mixing valve or
break any connections, etc., in the compressor air or oil system until the unit is shut down and
the air pressure has been relieved.
·Electrical shock can and may be fatal.
·Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.
·Open main disconnect switch, lockout and tagout before working on the control, wait 10 minutes
and check for voltage.
Failure to observe these notices could result in damage to equipment.
·Stop the unit if any repairs or adjustments on or around the compressor are required.
·Do not use the air discharge from this unit for breathing –not suitable for human consumption.
·An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).
·Do not exceed the rated maximum pressure values shown on the nameplate.
·Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.

13-21-601 Page 5
TABLE OF CONTENTS
Maintain Compressor Reliability And Performance With Genuine
Gardner Denver Compressor Parts And Support Services.......................................................................1
Instructions For Ordering Repair Parts/Remanufactured Airends..............................................................1
Warning –Prohibition –Mandatory Label Information..............................................................................2
Safety Precautions ..................................................................................................................................4
Index.......................................................................................................................................................6
List Of Illustrations...................................................................................................................................8
Section 1, General Information ................................................................................................................9
Section 2, Installation.............................................................................................................................13
Section 3, Starting & Operating Procedures...........................................................................................23
Section 4, Controls & Instrumentation....................................................................................................28
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator ........................................................................77
Section 6, Air Filter................................................................................................................................96
Section 7, Coupling ...............................................................................................................................98
Section 8, Maintenance Schedule........................................................................................................101
Section 9, Troubleshooting..................................................................................................................103
This book covers the following models:
HP
PSIG
Model
Parts List
Controller Manual
50 100, 125 EAH99D 13-22-500 13-17-600
40, 50 100, 125, 150, 175, 200 EBH99H 13-21-502 13-17-600
75 100, 125 EAM99D 213-9-500 13-17-600
60, 75 100, 125, 150, 175, 200 EBM99M 213-9-501 13-17-600
100 100, 125, 150 EAP99K 213-9-500 13-17-600
100 100, 125, 150, 175, 200 EBP99K 213-9-501 13-17-600

13-21-601 Page 6
INDEX
Addition of Oil Between Changes....................84
Aftercooler Piping...........................................82
Air Filter Element Life.....................................97
Air Filter Vacuum Switch.................................34
Air Filter, Heavy Duty (Standard) ....................96
AIR FILTER, SECTION 6................................96
Air Flow in the Compressor System................. 9
Air-Cooled Units, Location..............................14
AirSmart™Operation.....................................28
Auxiliary Air Receiver......................................17
Blowdown Valve.............................................31
Blowdown Valve Piping ..................................18
Check
Daily...........................................................25
Cold Ambient Operation .................................84
Cold Weather Operation.................................16
Cold Weather Operation, Installation for..........16
Compression Principle..................................... 9
Compressor..................................................... 9
Compressor Capacity Control - Turn Valve Units
Only............................................................36
COMPRESSOR OIL COOLER - WATER-
COOLED HEAT EXCHANGER...................89
Control Devices..............................................28
Control Piping.................................................17
Controller .......................................................28
CONTROLS & INSTRUMENTATION, Section 4
...................................................................28
Cooling, Sealing and Lubrication.....................10
Coupling.........................................................98
Daily Check....................................................25
Discharge Service Line...................................18
Discharge Thermistor .....................................35
Drain
Oil Reservoir...............................................15
Draining and Cleaning Oil System ..................86
Electrical Wiring..............................................21
Emergency Stop Push-Button.........................35
Enclosure.......................................................15
Fan Starter.....................................................35
FILLING OIL RESERVOIR .............................87
Filter Element.................................................96
Foundation.....................................................15
Fuse Blocks....................................................35
GENERAL INFORMATION, Section 1............. 9
Grounding ......................................................21
Heat Exchanger (Oil) Piping............................83
High Temperature Operation..........................78
Inlet Line ........................................................17
Inlet Screen and Tube ....................................97
Inlet Valve......................................................32
Installation for Cold Weather Operation...........16
INSTALLATION, Section 2 .............................13
LIFTING UNIT................................................13
Location .........................................................13
Air-Cooled Units..........................................14
Water-Cooled Units.....................................15
Lubricant
Recommended...........................................77
Lubricant Change Procedure..........................84
Lubrication
Motor..........................................................22
Lubrication, Cooling and Sealing....................10
LUBRICATION, Oil Cooler, Oil Filter &
Separator ...................................................77
Main Starter...................................................35
MAINTENANCE SCHEDULE, SECTION 8...101
Minimum Discharge Pressure Valve...............31
MOISTURE IN THE OIL SYSTEM..................78
Moisture Separator/Trap ................................17
Motor Lubrication...........................................22
Oil Change Interval........................................85
OIL COOLER - RADIATOR TYPE..................89
OIL FILTER....................................................88
Oil Level Gauge.......................................31, 85
Oil Reservoir..................................................92
Oil Reservoir Drain.........................................15
Oil Separator
Compressor (GD Eliminator).......................92
Inspection...................................................93
Oil Carryover..............................................92
Pressure Differential Gauging.....................93
Removal for Inspection or Replacement......94
Oil Specifications ...........................................77
Oil System
Compressor................................................77
Draining and Cleaning................................86
Oil System Check ..........................................94
Air and Oil Discharge Temperature.............94
Oil Cooler Oil Pressure Differential (Air-
Cooled Radiator).....................................95
Oil Cooler Oil Pressure Differential (Water-
Cooled Heat Exchanger).........................95
Oil Cooler Temperature Differential (Air-
Cooled Radiator).....................................95
Oil Cooler Temperature Differential (Water-
Cooled Heat Exchanger).........................95
Oil Cooler Water Pressure Differential (Water-
Cooled Heat Exchanger).........................95
Oil Inlet Pressure........................................94
Oil Inlet Temperature..................................94
Operation
High Temperature.......................................78
Parallel Piping................................................21
Piping
Series.........................................................20
Power Supply.................................................35
Pressure Differential Gauging.........................93
Pressure Regulator........................................33
Prestart-Up Instructions..................................23
Purge Valve...................................................33
Quick Start Guide...........................................26
Relief Valve....................................................29
Remote Mounted Elevated Cooler Assembly..82

13-21-601 Page 7
Reservoir Pressure Transducer ......................34
Reservoir Thermistor......................................35
SAFETY PRECAUTIONS................................ 4
Sealing, Lubrication and Cleaning...................10
Series Piping..................................................20
Service Check List........................................101
Every 1000 Hours Operation.....................101
Every 125 Hours Operation.......................101
Every 8 Hours Operation...........................101
Every 8000 Hours Operation.....................101
Every Year................................................101
Motor Lubrication......................................101
Oil Separator.............................................101
SERVICE CHECK LIST
AIR FILTER..............................................101
Shuttle Valve..................................................33
Solenoid Valves IVC and IVO.........................33
Solenoid Valves TVC and TVO.......................34
STARTING & OPERATING PROCEDURES,
Section 3.....................................................23
Starting the Unit.............................................25
Unit Cold....................................................25
Unit Hot......................................................25
Stopping the Unit ...........................................25
System Pressure Transducer.........................34
Terminal Strip ................................................35
THERMAL CONTROL (THERMOSTATIC
MIXING) VALVE.........................................89
TROUBLESHOOTING, SECTION 9.............103
Turn Valve...............................................10, 34
Turn Valve Actuator.......................................34
WARNING –PROHIBITION –MANDATORY
LABEL INFORMATION ................................2
WATER FLOW CONTROL VALVE FOR HEAT
EXCHANGER.............................................91
Water Piping..................................................19
WATER SHUTOFF VALVE - WATER-COOLED
HEAT EXCHANGER ..................................92
Water-Cooled Units, Location.........................15

13-21-601 Page 8
LIST OF ILLUSTRATIONS
Figure 1-1 –Compression Cycle .............................................................................................................................9
Figure 1-2 –Starter Box........................................................................................................................................10
Figure 1-3 –Control Box.......................................................................................................................................10
Figure 1-4 –Compressor / Motor Side...................................................................................................................11
Figure 1-5 –Cooler / Reservoir Side......................................................................................................................11
Figure 1-6 –Air/Oil Flow Diagram..........................................................................................................................12
Figure 2-1 –Typical Compressor Room.................................................................................................................14
Figure 2-2 –Air Flow Chart ...................................................................................................................................14
Figure 2-3 –ColdWeather Installation...................................................................................................................16
Figure 2-4 –Inlet Line Lengths..............................................................................................................................17
Figure 2 5 –Heat Exchanger (Oil Cooler) Approximate Water Flow........................................................................18
Figure 2-6 –Aftercooler Approximate Water Flow..................................................................................................19
Figure 2-7 –Series Piping.....................................................................................................................................20
Figure 2-8 –Parallel Piping...................................................................................................................................20
Figure 4-1 –Key Pad............................................................................................................................................29
Figure 4-2 –Schematic Tubing Diagram................................................................................................................30
Figure 4-3 –Blowdown Valve................................................................................................................................31
Figure 4-4 –Minimum Discharge Pressure/Check Valve........................................................................................31
Figure 4-5 –Inlet Valve.........................................................................................................................................32
Figure 4-6 –Shuttle Valve.....................................................................................................................................33
Figure 4-7 –Turn Valve –Electra-Saver Only........................................................................................................34
Figure 4-8 –Control Schematic –Compressor Unloaded –Constant Speed Mode..................................................37
Figure 4-9 –Control Schematic –Compressor At Full Load –Constant Speed Mode..............................................38
Figure 4-10 –Control Schematic –Compressor Unloaded –Low Demand Mode Or Auto Mode..............................39
Figure 4-11 –Control Schematic –Compressor At Full Load..................................................................................40
Figure 4-12 –Control Schematic –Compressor Fully Unloaded –Low Demand Mode Switch Off ...........................41
Figure 4-13 –Control Schematic –Compressor Fully Loaded –Low Demand Mode Switch On...............................42
Figure 4-14 –Wiring Diagram –Wye Delta (Air–Cooled / Water–Cooled) - 200, 230, 460 Volt................................43
Figure 4-15 –Wiring Diagram –Wye Delta (Air–Cooled / Water–Cooled) - 575 Volt...............................................45
Figure 4-16 –Wiring Diagram –Full Volt (Air–Cooled / Water–Cooled) –200 & 230 Volt........................................47
Figure 4-17 –Wiring Diagram –Full Volt (Air–Cooled / Water–Cooled) –460 Volt..................................................49
Figure 4-18 –Wiring Diagram –Full Volt (Air–Cooled / Water–Cooled) –575 Volt..................................................51
Figure 4-19 –Wiring Diagram –Less Starter (Air–Cooled / Water–Cooled) –200, 230, 460 Volt ...........................53
Figure 4-20 –Wiring Diagram –Less Starter (Air–Cooled / Water–Cooled) –575 Volt ...........................................55
Figure 4-21 –Wiring Diagram –Wye Delta (Air–Cooled / Water–Cooled) –200/230 Volt .......................................57
Figure 4-22 –Wiring Diagram –Wye Delta (Air–Cooled / Water–Cooled) –380/460 Volt .......................................59
Figure 4-23 –Wiring Diagram –Wye Delta (Air–Cooled / Water–Cooled) –575 Volt..............................................61
Figure 4-24 –Wiring Diagram –Full Volt (Air–Cooled / Water–Cooled) –200 & 230 Volt........................................63
Figure 4-25 –Wiring Diagram –Full Volt (Air–Cooled / Water–Cooled) –380/460 Volt...........................................65
Figure 4-26 –Wiring Diagram –Full Volt (Air–Cooled / Water–Cooled) –575 Volt..................................................69
Figure 4-27 –Wiring Diagram –Less Starter (Air–Cooled / Water–Cooled) –200, 230, 380, 460 Volt....................73
Figure 4-28 –Wiring Diagram –Less Starter (Air–Cooled / Water–Cooled) –575 Volt...........................................75
Figure 5-1 –Dew Point Chart °F............................................................................................................................79
Figure 5-2 –Dew Point Chart °C...........................................................................................................................79
Figure 5-3 –Flow Diagram –Air/Oil System...........................................................................................................80
Figure 5-4 –Oil Flow Diagram –Remote Overhead Mounted Cooler......................................................................81
Figure 5-5 –Cooler Drain Detail............................................................................................................................82
Figure 5-6 –Oil Level Gauge.................................................................................................................................85
Figure 5-7 –Oil Change Interval............................................................................................................................86
Figure 5-8 –Approximate Oil System Capacities....................................................................................................87
Figure 5-9 –Thermostatic Mixing Valve Element....................................................................................................89
Figure 5-10 –Water Control Valve.........................................................................................................................90
Figure 5-11 –Dew Point Temperature VS. Ambient Temperature...........................................................................91
Figure 5-12 –Oil Separator...................................................................................................................................92
Figure 6-1 –Heavy Duty Air Filter..........................................................................................................................96
Figure 7-1 –Installation Of Coupling Cushions.......................................................................................................98

13-21-601 Page 9
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 compression chamber. Single width cylindrical roller
bearings are used at the inlet end of the rotors to carry part of 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) - Compression is accomplished by the main and secondary
rotors synchronously meshing in a one-piece cylinder. The main rotor has four (4) helical lobes 90°apart.
The secondary rotor has six (6) matching helical grooves 60°apart to allow meshing with main rotor
lobes.
The air inlet port is located on top of the compressor cylinder near the drive shaft end. The discharge port
is near the bottom at the opposite end of the compressor cylinder. Figure 1-1 is an inverted view to show
inlet and discharge ports. The compression cycle begins as rotors unmesh at the inlet port and air is
drawn into the cavity between the main rotor lobes and secondary rotor grooves (A). When the rotors
pass the inlet port cutoff, air is trapped in the interlobe cavity and flows axially 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 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-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 5-3, page 80) - Air enters the air filter and passes
through the inlet unloader valve to the compressor. After compression, the air/oil mixture passes into the
oil reservoir where most of the entrained oil is removed by velocity change and impingement and drops
back into the reservoir. The air and remaining oil passes into the separator and separator housing where
the oil is separated and passes through tubing connecting the separator housing and compressor. The
air passes through the minimum pressure valve, discharge check valve and cooler, then to the plant air
lines.

13-21-601 Page 10
LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through
the oil cooler, thermostatic mixing valve, and oil filter and discharges into the compressor main oil gallery.
A portion of the oil is directed through internal passages to the bearings, gears and shaft oil seal. The
balance of the oil is injected directly into the compression chamber to remove heat of compression, seal
internal clearances and lubricate the rotors.
TURN VALVE (ELECTRA-SAVER 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 the inlet passage. This varies the compressor rotor volume to match the
demand for air, thus reducing the part-load power requirement.
Figure 1-2 –STARTER BOX
Figure 1-3 –CONTROL BOX
217ECM797
-
A
(Ref. Drawing)

13-21-601 Page 11
Figure 1-4 –COMPRESSOR / MOTOR SIDE
Figure 1-5 –COOLER / RESERVOIR SIDE
217ECM797
-
A
(Ref. Drawing)

13-21-601 Page 12
Figure 1-6 –AIR/OIL FLOW DIAGRAM
219ECM797
-
A
(Ref. Drawing)

13-21-601 Page 13
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
Do not electric weld on the compressor or base; bearings can be damaged by
passage of current.
LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Lifting slots are
provided in the base for tow motor use. The unit may also be moved into location by rolling on bars.
Lift compressor package by base only. Do not use other places such as
motors, compressors or discharge manifold piping as lifting points.
The eyebolts or lugs provided on the motors are for lifting the motors only and
should not be used to lift any additional weight. All eyebolts must be securely
tightened. When lifting the motors, 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, separator chamber and all piping and tubing may
be at high temperature during and after operation.
LOCATION - The compressor should be installed, whenever possible, in a clean, well-lighted, well-
ventilated area with ample space all around for maintenance. Select a location that provides a cool,
clean, dry source of air. In some cases it may be necessary to install the air filter at some distance from
the compressor to obtain proper air supply.
C
C
C
A
A
A
U
U
U
T
T
T
I
I
I
O
O
O
N
N
N
C
C
C
A
A
A
U
U
U
T
T
T
I
I
I
O
O
O
N
N
N

13-21-601 Page 14
Both the air-cooled and water-cooled units require cooling air as well as air to the compressor inlet.
Proper ventilation MUST be provided; hot air must be exhausted from the compressor operating area. A
typical inlet-outlet air flow arrangement is shown in Figure 2-1.
Figure 2-1 –TYPICAL COMPRESSOR ROOM
Air-Cooled Units - A combination oil/aftercooler is supplied as standard equipment on all air-cooled
units. The air-cooled unit with the standard enclosure requires sufficient flow, Figure 2-2, for the
compressor oil/aftercooling system and for electric motor cooling. Air is drawn into the unit at the motor
side of the enclosure and is exhausted at the oil cooler side. Do not block the air flow to and from the
unit. Allow three and one-half (3-1/2) feet (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 obstruction above and on other sides of unit.
For continuous 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.
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, 75 & 100 HP 12,500 (354) 1,700 (48)
* 80°F (27°C) Inlet Air
Figure 2-2 –AIR FLOW CHART

13-21-601 Page 15
N
N
NO
O
OT
T
TI
I
IC
C
CE
E
E
For aluminum oil coolers, do not use any cleaning solution that is not
compatible with aluminum. Use of improper solution may result in damage to
the cooler.
Water-Cooled Units - The water-cooled unit with the standard enclosure requires sufficient air flow,
Figure 2-2, for electric motor cooling. Air is drawn into the unit at the top of the enclosure and is
exhausted at the motor side. Do not block air flow to and from unit. Allow three and one-half (3-1/2) feet
(1.1 m) to the nearest obstruction on the starter end and control box side of the unit. Allow three (3) feet
(.9 m) to the nearest obstruction above and on other sides of the unit.
FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but
should be mounted on a smooth, solid surface. Whenever possible install the unit near level. Temporary
installation may be made 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 moving vehicles may require the use of mounting bolts
and shims to provide uniform support for the base.
OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the side of the frame.
This drain is approximately 4.50 inches (115 mm) above the floor level. If this is not sufficient to
conveniently drain the oil some other methods of providing drain are:
1. Elevate the compressor unit on a suitable structure 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 drain to a container.
If the compressor unit base is raised above floor level, the space between the
floor and the base bottom must be closed with solid material all around to
prevent recirculation of hot air from the oil cooler end and over temperature
operation.
ENCLOSURE - The compressor, electric motor, oil cooler and aftercooler are mounted inside the
enclosure. Service doors are provided for maintenance access. Be sure to allow enough space around
the 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.
The motor inspection/air filter service panel is held by two latches and lifts away from the enclosure. The
air outlet panel is attached by screws to the enclosure and is not readily removable.
Do not operate the compressor with the fan and coupling guard removed.
Exposed fan and couplings may cause injury to personnel.
C
C
C
A
A
A
U
U
U
T
T
T
I
I
I
O
O
O
N
N
N

13-21-601 Page 16
Figure 2-3 –COLD WEATHER INSTALLATION
INSTALLATION FOR COLD WEATHER OPERATION (Figure 2-3) - 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 advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for an adequate shelter for the unit.
When an outside installation must be made, the precautions required will depend on the severity of the
environment. The following are general guidelines for outside installations:
Cold Weather (Down To +10°F, -12°C)
1. Be sure all drains, traps, and control lines, including pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermostat control is generally satisfactory for this purpose
and can be obtained at various local plumbing or hardware outlets at nominal cost.
2. If an air-cooled aftercooler is to be used, provisions to bypass the aftercooler must be made. Since
cold air contains very little moisture, successful operation can be achieved without the aftercooler.
3. Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow.
4. Use only Gardner Denver AEON 9000 SP lubricant.
5. Monitor the unit carefully during start-up and operation to be sure it is functioning normally.
6. Specify UL TYPE 4 enclosure for electrical devices.

13-21-601 Page 17
Extreme Cold Weather Operation (Down To -10°F, -23°C)
In addition to the above, the following should be provided:
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 provided
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 environments.
3. Some means of providing heat during shutdown. Start-up 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 (-12 C)
environment for coolers, motor and sump. Figure 2-3, page16, 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.
AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and
provides sufficient storage capacity to prevent rapid cycling. When used, an air receiver should be of
adequate size, provided with a relief valve of proper setting, a pressure gauge and a means of draining
condensate.
MOISTURE SEPARATOR/TRAP - Since the unit is equipped with a built-in aftercooler, a combination
moisture separator and trap is furnished with the unit.
CONTROL PIPING - Control piping is not necessary since the Rotary Screw compressor unit is factory
wired and piped for the control system specified.
INLET LINE - Where an inlet line is used between the air filter and the compressor, it must be thoroughly
cleaned on the inside to prevent dirt or scale from entering the compressor. If welded construction is
used, the line must be shot blasted and cleaned to remove welding scale. In either case, the inlet
line must be coated internally by galvanizing or painting with a moisture and oil-proof sealing lacquer. Up
to ten (10) feet (3 meters) in length, the inlet line should be the full size of the inlet opening on the
compressor. If an extra-long line is necessary, the pipe size should be increased according to Inlet Line
Length Chart, Figure 2-4 page -17.
Accessibility for inlet air filter servicing must be considered when relocating the filters from the unit to a
remote location.
INLET LINE LENGTHS
Length of Inlet Line Diameter of Pipe Size
0 to 10 Feet (0 to 3 Meters)
................................
Same as Compressor Inlet Opening
10 to 17 Feet (3 to 5 Meters)
................................
One Size Larger Than Inlet Opening
17 to 38 Feet (5 to 11.5 Meters)
................................
Two Sizes Larger Than Inlet Opening
Figure 2-4 –INLET LINE LENGTHS

13-21-601 Page 18
DISCHARGE SERVICE LINE - The discharge service line connection on both water-cooled and air-
cooled units is made at the right hand corner of the unit, viewed from the opposite end from control panel
side. When manifolding two or more rotary screw units on the same line, each unit is isolated by the
check valve in the unit discharge line. If a rotary screw unit is manifolded to another compressor, be sure
the other compressor has a check valve in the line between the machine and the manifold. If a rotary
screw and a reciprocating compressor are manifolded together, an air receiver must be located between
the two units.
Discharge air used for breathing will cause severe injury or death.
Consult filtration specialists for additional filtration and treatment equipment to
meet health and safety standards.
BLOWDOWN VALVE PIPING - The blowdown valve is piped back into the airend between the inlet valve
and air filter.
HEAT EXCHANGER
Water Temperature to Heat
Exchanger
Gallons/minute
Maximum Water
Flow
Gallons/minute *
ApproximateWater
Pressure Drop @ 90°F
Water Temperature PSI
HP Model 60°F 70°F 80°F 90°F
40 EBH99H 3.4 4.3 5.7 8.6 30.0 1.0
50 EAH99D
EBH99H 4.1 5.1 6.8 10.2 30.0 1.5
60 EAM99D
EBM99M 5.0 6.2 8.3 12.5 40.8 2.0
75 EAM99D
EBM99M 6.0 7.6 10.1 15.1 40.8 1.5
100 EAP99K
EBP99K
8.4
10.5 14.1 21.1 40.8 5.0
* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.
HEAT EXCHANGER (INTERNATIONAL)
Water Temperature to Heat
Exchanger
Liters/seconds
Maximum
Water Flow
Liters per
Second *
ApproximateWater Pressure
Drop @ 32°C Water
Temperature (bar)
KW Model 16
°
C 21
°
C 27
°
C 32
°
C
45 EBM99N .32 .38 .51 .77 2.52 Less than .15 bar for any flow
rate shown in the table
56 EBM99N .44 .53 .72 1.08 2.52
75 EBM99N .57 .70 .94 1.41 2.52
* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.
Figure 2-5 –HEAT EXCHANGER (OIL COOLER) APPROXIMATE WATER FLOW

13-21-601 Page 19
AFTERCOOLER
Water Temperature to Heat
Exchanger
Gallons/minute
Maximum Water
Flow
Gallons/minute *
ApproximateWater
Pressure Drop @ 90°F
Water Temperature PSI
HP Model 60°F 70°F 80°F 90°F
40 EBH99H .5 .7 .9 1.3 26.0
Less than 1 PSI for any
flow rate shown in the table
50 EAH99D
EBH99H .7 .9 1.2 1.8 26.0
60 EAM99D
EBM99M .8 1.0 1.4 2.1 26.0
75 EAM99D
EBM99M 1.2 1.5 2.0 3.0 26.0
100 EAP99K
EBP99K 1.7 2.1 2.8 4.1 26.0
* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.
AFTERCOOLER (INTERNATIONAL)
Water Temperature to Heat
Exchanger
Liters/seconds
Maximum
Water Flow
Liters per
Second *
ApproximateWater Pressure
Drop @ 32°C Water
Temperature (bar)
KW Model 16°C 21°C 27°C 32°C
45 EBM99N .05 .06 .09 .13 3.47 Less than .1 bar for any flow
rate shown in the table
56 EBM99N .08 .09 .13 .19 3.47
75 EBM99N .11 .14 .19 .28 3.47
* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.
Figure-2-6 –AFTERCOOLER APPROXIMATE WATER FLOW
WATER PIPING (Water-Cooled Heat Exchanger Models Only) - On machines equipped with water-
cooled heat exchangers, the water inlet and outlet connections are located in the unit base flange on the
left side of the unit.
It is mandatory that any water cooled unit be install
ed in a shelter heated to
temperatures above freezing (32°F., 0°C).
The water source should be capable of supplying up to the maximum flow shown in Figure 2-5, Page 18,
and Figure-2-6, page19, at a minimum pressure of 40 psig (2.8 bar); maximum allowable water pressure is
150 psig (10.3 bar). The water flow rates shown are approximate and a guide to sizing piping, cooling
tower and other water system equipment.
C
C
C
A
A
A
U
U
U
T
T
T
I
I
I
O
O
O
N
N
N