Gardner Denver ELECTRA-SCREW 40 HP-EDEQH Service manual

Price$5.00
~~
GARDNER-DENVER@ 13-8-601
2nd Edition
ELECTRA-SCREW@
STATIONARY
BASE-MOUNTED
COMPRESSOR
MODELS
40HP - EDEQH
50HP - EDEQJ
u
AINDUSTRIAL MACHINERY
c)puc)g)fi

kmGARDNER-DENVER”
m
Awarranty registration card is provided with each machine. The
card must be completed by the purchaser and mailed (card is
preaddrassad and postage paid) within ten days after machine
start up in ordar to validate this warranty.
Gardner-Denver/l ndustrial Machinery (the “Company”) warrants
to each original retail purchaser (“PU rchaser”) or its products
from tha Company or its authorized distributors that such pro-
ducts will be frea from defects in matarial 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, whichaver 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 ba as warranted within the applicable period.
Purchaser must return, transportation charges prapaid, 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 instructions,
will because for denial of warranty.
ELECTRIC MOTORS
Electric motors, when specified and furnished by the Company,
are warrantad for 12 months from data of initial use or 15 months
from date of shipment to the first purchaser, whichever occurs
first.
The motor manufacturer or authorized service shop will provide
at its option, motor repairs or replacement motor FOB manu-
facturer’s location for any motor which in tha manufacturer’s
judgment proves not to be as warranted within the applicable
~eriod.
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 warrantad within the
applicable period.
GENERAL PROVISIONS AND LIMITATIONS
No warranty is made with respact to:
1. Any product which has been rapaired or altered in such a
way, in the Company’s judement, as to affect the product
adversely.
2. Any product which has, in the Company’s judgment been
subjact to negligence, accident, improper storaga, or im-
proper installation or application.
3.
4.
5.
WARRANTY
ROTARY SCREW COMPRESSORS
EC ELECTRA-SAVER II@
EA ELECTRA-SAVER@
EB, ED ELECTRA-SCREW@
SE, ST PACKAGES
Any product which has not bean opetated or maintained
in accordance with normal practica and with the recom-
mendations of the Company.
Components or accessories manufactured, warranted and
serviced by others, axcept as separately ratad.
Any reconditioned or prior owned product.
Claims for items descibed 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. Tha Company may require the return
of any pert claimed not to be as warranted to one of its facilities
as designated by Company, transportation prapaid by Purchaser,
to establish aclaim under this warranty.
Tha Company will provida labor for repair or replacement of
any product or part thereof which in tha Company’s judgmant
is proved not to be as warranted, by Company representativa up
to the amount specified in the Company’s labor rate schedules,
or up to tha amount the Company determines is reasonable.
Labor costs in excess of the Company rata schedule amounts
or labor provided by unauthorized service personnel is not pro-
vided for by this warranty.
Replacement parts providad 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 thereot.
DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS
EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE
COMPANY 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 AVAIL-
ABLE TO PURCHASER AND IN NOCASE SHALL THECOM-
PANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR
LIABILITIES. UNDER NO CIRCUMSTANCES SHALL THE
COMPANY BE LIABLE FOR SPECIAL, INDIRECT, inciden-
tal OR CONSEQUENTIAL 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 isnotcontainad 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 product is
claimed not to have bean as warranted. Any action for breach
of this warranty must be commencad within one yaar after the
data upon which the cause of action occurred.
Any adjustment mada pursuant to this warranty shall not be
construad as an admission by the Company that any product
was not as werrantad.
13-8-601 Page i

Gardner-Denver@ Electra-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 writter,
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.
ADANGER
FAILURE TO OBSERVE A DANGER NOTICE COULD RESULT IN INJURY TO, OR DEATH OF
PERSONNEL.
,WARNING
A●FAILURE TO OBSERVEA WARNING NOTICE COULD RESULT IN DAMAGE TO EQUIPIENT.
ACAUTION
CAUTION NOTICES SET FORTH GENERAL REl#INDERSOF GOOD SAFETY PRACTICE, OR DIRECT
ATTENTION TO UNSAFE PRACTI’CES.
NOTE:
INFORlfATIONFURNISHED IN A NOTE WILL INCLUDE GENERAL INFORMATION OR THE
HIGHLIGHTS OFA PROCEDURE.
This book covers the following models:
1 I I I
IHP IPSIG IAir Cooled I
40 100 EDEQH
125
100
50 125 EDEQJ
150
TABLE OF CONTENTS
GENERAL INFORMATION .........................................................SECTION 1
INSTALLATION ................................................................SECTION 2
STARTING AND OPERATING PROCEDURES ...........................................SECTION 3
CONTROLS AND INSTRUMENTS ....................................................SECTION 4
LUBRICATION, OIL COOLER, OIL FILTER AND SEPARATOR ...........................SECTION 5
AIR FILTERS .................................................................SECTION 6
V-BELTS .....................................................................SECTION 7
MAINTENANCE SCHEDULE ........................................................SECTION 8
TROUBLESHOOTING .............................................................SECTION 9
REBUILDING DATA .............................................................SECTION 10
13-8-601 Page ii

~
NOTE:Numbers preceding dash are Sect ion Numbers -Numbers fo 1lowing dash are Page Numbers.
Addition of Oil Between Changes ..................5-3
Air Control Components ...........................4-2
AIR FILTERs (sEcTIoN 6) ..........................6-l
Air Flow in the Compressor System. ...............1-1
Auxiliary Air Receiver ......................2-3. 4-5
Belt Tension, Checking ........................ ...7-1
Blowdown Valve ..............................4-2. 4-4
Check Valve ......................................4-6
Cold Ambient Operation ...........................5-3
Cold Weather Operation, Installation for... ......2-2
Compress ion Principle ............................1-1
CONTROLS &INSTRUMENTATION (SECTION 4) ...........4-1
Control System Operation .........................4-6
Daily Check ......................................3-1
Discharge Air Pressure Gauge .....................4-2
Discharge Air Temperature Gauge ..................4-2
Discharge Temperature, Air and Oil. ..............5-8
Discharge Service Line ...........................2-3
Draining and Cleaning Oil System .................5-4
DRIvE(sEcTIoN 7) ................................7-l
Electrical Wiring ................................2-4
Enclosure ........................................2-2
cilling Oil Reservoir ............................5-4
low Diagram -Air-Oil Systems ...................5-l
Foundation .......................................2-2
GENERAL INFORMATION (SECTION 1) ..................1-1
Grease Recotnnendat ions ...........................2-4
Grounding ........................................2-4
High Discharge Temperature Switch. ...............4-1
High Temperature operation .......................5-2
Hourmeter ..............
Inlet Line .............
Inlet Valve ............
INSTALLATION (SECTION 2
Instruments ............
.........................4-6
.........................2-3
.........................4-4
.........................2-1
.........................4-2
Lifting Unit .....................................2-1
Location .........................................2-1
Lubricants .......................................5-2
Lubrication, Cooling and Sealing .................l-l
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5) ..........................5-1
MAINTENANCE scHEDuLE (SECTION 8).. ...............8-1
Minimum Discharge Pressure Valve .................4-5
t40isture inthe Oil System .......................5-3
Moisture Separator/Trap. .........................2-3
Motor Lubrication ................................2-4
Motor Protect ion Devices .........................4-1
Oi1Change Interva 1..............................5-4
Oil Cooler, Compressor ...........................5-5
Oi 1Filter, Compressor ...........................5-4
Oil Inlet Pressure. ..............................5-8
Oil Inlet Temperature ............................5-8
Oil Level Gauge .............................4-2. 5-3
Oil Reservoir ....................................5-6
Oil Reservoir Drain ..............................2-2
Oil Separator ................... .................5-6
Oil Specification ................................5-l
Oi 1System Check .................................5-7
Oil System, Compressor ...........................5-1
Operating Air Pressure Adjustment. ...............4-7
Piloted Unloader Valve ...........................4-3
Pressure Differential Gauging ....................5-6
Prestart-up Instruct ions .........................3-l
Regressing Interval. .............................2-5
Reservoir Pressure Switch ........................4-4
Safety Devices ...................................4-1
Safety Precautions. ..............................1-4
Safety Valve .....................................4-1
Separator Indicator Pressure Button. .............4-2
Service Check List ...............................8-1
Starter/Control Box ..............................4-6
STARTING &OPERATING PROCEDURES
(sEcTIoN 3) ....................................3-l
Stopping Unit ....................................3-1
Subtract ive Pilot ................................4-3
Synthetic Lubricants .............................5-2
Thermal Control Valve ............................5-5
TROUBLESHOOTING (SECTION 9) ......................9-1
Wiring Diagram ...................................4-9
13-8-601 Page iii

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FIGURE 1-1. -COMPRESSION CYCLE
COMPRESSOR - The Gardner-Denver@ “EDE” Electra-Screw@ compressor is a single stage,
positive displacement rotary machine using 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 l-l) -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 the 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 by proprietary means 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 COMPRESSORSYSTEM (Figure 1-5) - Air enters the air filter and passes
through the inlet unloader valve to the compressor. After compression, the air/oil
mixture passes into the oil reservoir where most of the entrained oil is removed by
velocity change and impingement and drops back into the reservoir. The air and
remaining oil then passes through the oil separator, the separated oil is returned to
the system through tubing connecting the separator and compressor. The air passes
through the reservoir discharge manifold, minimum pressure valve and discharge check
valve to the plant air lines.
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
13-8-601 Section 1 Page 1

through internal passages to the bearings and shaft oil seal. The balance of the oil
is injected directly into the compression chamber to remove heat of compression, seal
internal clearances and lubricate the rotors.
13-8-601 Section 1 Page 2

13-8-601 Section 1 Page 3

SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. Al1
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:
AWARNING
FAILURE TO OBSERVE THESE NOTICES COULD RESULT IN DANAGE TO EQUIPMENT.
o STOP THE UNIT IF ANY REPAIRS OR ADJUSTMENTS ON OR AROUND THE COflPRESSORARE
REQUIRED.
o ALL COMPRESSED AIR SUPPLY HOSES EXCEEDING 1/2 INCH INSIDE DIAMETER SHOULD
HAVE AN EXCESS FLOW VALVE. (OSHA REGULATION, SECTION 1518.302)
e DO NOT EXCEED THE RATED flAXIIWMPRESSURE VALUES SHOWN ON THE NAflEPLATE.
●DO NOT OPERATE UNIT IF SAFETY DEVICES ARE NOT OPERATING PROPERLY. CHECK
PERIODICALLY. NEVER BYPASS SAFETY DEVICES.
ADANGER
FAILURE TO OBSERVE THESE NOTICES COULD RESULT IN INJURY TO OR DEATH OF
PERSONNEL.
KEEP FINGERS AND CLOTHING AWAY FROM REVOLVING FAN, DRIVE BELTS, 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 CONNECTIONS, ETC., IN THE
COMPRESSOR AIR OR OIL SYSTEM UNTIL THE UNIT IS SHUT DOWN AND THE AIR
PRESSURE HAS BEEN RELIEVED.
ELECTRICAL SHOCK CAN AND MAY BE FATAL.
COMPRESSOR UNIT MUST REGROUNDED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL
CODE. A GROUND JUMPER EQUAL IN SIZE TO THE EQUIPMENT GROUND CONDUCTOR MUST
BE USED TO CONNECT THE COMPRESSOR MOTOR BASE TO THE UNIT BASE.
OPEN MAIN DISCONNECT SWITCH BEFORE WORKING ON THE CONTROL.
DISCONNECT THE COMPRESSOR UNIT FROM ITS POWER SOURCE BEFORE WORKINGON THE
UNIT - THIS MACHINE IS AUTOMATICALLY CONTROLLED AND MAY START AT ANY TItfE.
13-8-601 Section 1 Page 4

SECTION2
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.
ACAUTION
DO NOT ELECTRIC WELD ON THE COMPRESSOR OR BASE; BEARINGS CANBEDAIYAGED BY
PASSAGE OF CURRENT.
LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent
damage.
ACAUTION
LIFT COMPRESSOR UNIT BY BASE ONLY. DO NOTUSE OTHER PLACES SUCHAS ENCLOSURE,
HOTOR, COMPRESSOR OIL DISCHARGEMANIFOLDANDPIPINGAS LIFTING POINTS.
ADANGER
THE EYEBOLTS OR LVGS PROVIDEDON THE flOTORARE FOR LIFTING THE flOTORONLY AND
SHOULD NOT BE USED TO LIFT ANY ADDITIONAL WEIGHT. ALL EYEBOLTS MUST BE
SECURELY TIGHTEN. WHEN LIFTING THE #lOTORTHE LIFTING ANGLE MUSTNOTEXCEED 15
DEGREES. FAILURE TO OBSERVE THIS NARNING HAY RESULT IN DAMAGE TO EQUIPflENTOR
PERSONAL INJURY.
Lifting slots are provided in the base for towmotor use. Unit may also be moved into
location by rolling on bars.
LOCATION - The compressor should be installed, whenever possible, in 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. A combination oil/aftercooler is supplied as standard
equipment. Sufficient air flow, Figure 2-2, for the compressor oil/after cooling
system and for electric motor cooling is required. Air is drawn into the unit at the
motor end of the enclosure is exhausted at the oil cooler. Do not block the air flow
to and from the unit. Allow two (2) feet to the nearest obstruction on the control
box end of the unit. Allow two (2) feet to the nearest obstruction above enclosure.
LOUVERED
WINDOW .F
EXHAUST FAN
=A LOUVERED
WI NOOW
--- !-AIR AIR ~
IN IN
r1
A75119 -
Minimum Air Flow For Compression
And Cooling (Cubic Feet/Minute)
All Models (Air Cooled) ........6000 cfm
FIGURE 1-2. - TYPICAL COMPRESSOR ROOM FIGURE 2-2,
13-8-601 Section 2 Page 1

FOUNDATION - The 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 20° angle lengthwise or 20° 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. Belt alignment and tension should be checked after installation.
OIL RESERVOIR DRAIN - The oil drain is piped from the bottom of the reservoir to the
side of the frame. This drain is approximately six (6) inches above 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 raising blocks 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.
ENCLOSURE - Service doors are provided for access to the motor and compressor. Be
sure to allow enough space around the unit for the doors to open completely. Both of
the two (2) doors may be removed by opening the door and lifting it up slightly to
disengage the opposite end. The doors can then be removed.
ADANGER
DO NOT OPERATE COMPRESSOR WITH FANANDBELT GUARD REMOVED. EXPOSED FAN AND
BELTS HAY CAUSE INJURY TO PERSONNEL.
INSTALLATION FOR COLD WEATHER OPERATION -It is recommended that whenever possible 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 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 precautions required will depend on how
severe the environment. The following are general guidelines for outside
installations:
Cold Weather (Down To -10° F)
1.
2.
3.
4.
5.
Be sure all control lines, drains and traps are heated to avoid freezing of
condensate. Heat tape with thermostat control is generally satisfactory for this
purpose and can be obtained at various local plumbing or hardware outlets at
nominal cost.
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.
Provide at least some simple shelter such as a plywood windbreak to protect
against drifting snow.
Use only Gardner-Denver@ GD800 lubricant.
Monitor unit carefully during start-up and operation to be sure it is functioning
normally.
13-8-601 Section 2 Page 2

6. Specify NEMA 4 enclosure for electrical devices.
Extreme Cold Weather Operation (Down To -40° F)
In addition to the above, the following should be provided:
1. It will probably be necessary to provide shutters or to block off part 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. Avoid extended periods of unloaded operation in extreme environments.
3. Some means of providing heat to the oil reservoir and cooler during shutdown
should be provided. There are various methods to accomplish this, but since
openings are not provided for sump heaters, the use of radiant heaters is
recommended. The heaters should be sized to provide at least a -10° F environment
for the coolers, motor and sump.
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 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.
MOISTURESEPARATOR/TRAP-A moisture separator/trap should be included downstream of
the aftercooler to drain condensate.
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 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
accordingly:
Len@h of Inlet Line Diameter of Pir)eSize Diameter of Pipe Size
Oto 10 Feet .........................................Same As Compressor Inlet Opening
10 to 17 Feet .......................................One Size Larger Than Inlet Opening
17 to 38 Feet.. ....................................Two Sizes Larger Than Inlet Opening
Accessibility for inlet air filter servicing must be considered when relocating the
filters from the unit to a remote location.
DISCHARGESERVICE LINE - The discharge service line connection is made at the upper
right hand corner of the cooler, viewed from the oil cooler side. A hand operated
valve (air service valve) must be installed between the unit and the customer’s air
system. When manifolding two or more Electra-Screw@ units on the same line, each unit
13-8-601 Section 2 Page 3

is isolated by the check valve in the unit discharge line. If an Electra-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 an Electra-Screw@ and a
reciprocating compressor are manifolded together, an air receiver must be located
between the two units.
ADANGER
DO NOT USE THE AIR DISCHARGED FRON THIS UNIT FOR BREATHING - IT IS NOT
SUITABLE FOR HUIYANCONSUMPTION. USE OF THIS AIR FOR BREATHING iVAYRESULT IN
PERSONAL INJURY OR DEATH.
ELECTRICAL WIRING - The Electra-Screw compressor is factory wired for all starter to
motor and control connections for the voltage specified on the order. It is necessary
only to connect the unit starter to the correct power supply. See Section 4 for
general wiring diagrams. These diagrams are general only - use the wiring diagrams
supplied with the compressor for exact connections. The standard unit is supplied
with an open drip-proof motor, a NEMA 3R starter and control enclosure. See
“Location” paragraph for distance to nearest obstruction on starter/control box side
of the unit.
GROUNDING - Equipment must be grounded in accordance with Table 250-95 of the National
Electrical Code.
MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in
large measure on proper lubrication of the bearings. The following charts show
recommended grease qualities and regressing intervals for ball bearing motors. For
additional information refer to the motor manufacturer’s instructions.
The following procedure should be used in regressing:
1.
2.
3.
4.
5.
6.
7.
Stop the unit.
Disconnect the unit from the power supply.
Remove the relief plug and free hole of hardened grease.
Wipe the lubrication fitting clean and add grease with a hand-operated grease gun.
Leave the relief plug temporarily off. Reconnect unit and run for about 20
minutes to expel the excess grease.
Stop the unit. Replace the relief plug.
Restart the unit.
GREASE RECOMMENDATIONS
Standard High
Service Temperature
Worked Penetration ................................... 265-296 220-240
Oil Viscosity, SSUAt 100° F ........................ 400-550 475-525
Soap Type ............................................ Lithium Lithium
N-H Bomb, Minimum Hours For 20 PSI Drop At 210° F ... 750 1000
Bleeding, Maximum Weight% In 500 Hours 212° F ...... 10 3
Rust Inhibiting ...................................... Yes Yes
13-8-601 Section 2 Page 4

REGRESSING INTERVAL
Relubrication
Type of Service Typical Example Rating Interval
Standard One or Two Shift Operation 150 HP 18 Months
& Below
Severe Continuous Operation 150 HP 9 Months
& Below
Very Severe Dirty Location, High Ambient 150 HP 4 Months
Temperature
13-8-601 Section 2 Page 5

SECTION3
STARTING&OPERATINGPROCEDURES
PRESTART-UP INSTRUCTIONS - A new 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 oil level in the reservoir. Add oil only if the oil level
gauge reads in the red range. Do not mix different type oils. 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 EVERY1000 HOURS.
Initial fill, or filling after a complete draining of the system, may show the oil
level in the yellow range. After start-up, the oil will fall into the green range
as system components are filled. If necessary, add oil to bring the level to the
top of the green range as read when the unit is operating at full load and normal
operating pressure. See Figure 3-5 for oil system capacities.
ADANGER
ALWAYS STOP THE LMIT AND RELEASE AIR PRESSURE BEFORE REIYOVINGOIL FILLER PLUG.
2.
3.
4.
5.
6.
FAILURE TO RELEASE PRESSURE MAY RESULT II PERSONAL INJURY OR DEATH.
During unloaded operation and after shutdown, the system tiill partially drain back
into the oil reservoir and the oil level may 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.
Air Filter - Inspect the air filter to be sure it is clean and tightly assembled.
Refer to Section”6, “Air Filter”, for complete servicing instru~t
the inlet line, if used, is tight and clean.
Alignment - Check all bolts and cap screws for tightness. Check dr
alignment; refer to Section 7, “Drive” for procedure.
Ons. Be sure
ve sheaves for
Piping - Refer to Section 2, “Installation”, and make sure the piping meets all
recommendati ens.
Electrical - Check the wiring diagrams furnished with the unit to be sure it is
properly wired. See Section 4. “Controls and Instruments”, for general wiring
diagrams and Section 2 for installation instructions.
Rotation - Check the motor rotation by momentarily jogging the motor. Compressor
drive shaft rotation is clockwise standing facing the compressor sheave.
A
fWARNING
●DO NOT REPEATEDLY JOG THE MOTOR UILESS ROTATION IS CORRECT. SEVERE COIVPRESSOR
DAIYAGECAN RESULT.
7. System Pressure - Set the inlet valve subtractive pilot and piloted unloader valve
to the desired unload pressure and differential. DO NOT EXCEED MAXIMUM OPERATING
PRESSURE ON COMPRESSOR NAMEPLATE. See Section 4, “Controls and Instruments”, for
procedure.
13-8-601 Section 3 Page 1

8. Operating Mode - Refer to Section 4 for detailed information on the control
system.
9. Enclosure - Check for damaged panels or doors. Check all screws and latches for
tightness. Be sure doors are in place.
STARTING THE UNIT - OBSERVE UNIT COLD OR HOT STARTING PROCEDURES
Unit Cold - Close the air service valve between the main air system and the unit check
valve. Start the unit by pushing the START button. Run for approximately one minute
and then open the air service valve. Since the unit is equipped with a minimum (65
psig) pressure discharge valve, no special procedure to maintain unit reservoir
pressure is required.
Unit Hot - No warm-up period is required. Close the air service valve (furnished by
customer). Start the unit by pushing the START button. Open the air service valve.
DAILY CHECK - Refer to Section 8, “Maintenance Schedule”.
STOPPING THE UNIT - Close the air service valve, allow the unit to build up to full
unload pressure and unload. Wait a short period to allow oil reservoir to blow down.
Push the “STOP” button.
Stopping the unit at a pressure below full unload may cause oil carry-over. Also, the
oil reservoir will continue to blow down after the motor stops.
Open the air service valve.
13-8-601 Section 3 Page 2

SECTION4
CONTROLS& INSTRUMENTATION
GENERAL - The Gardner-Denver@ “EDE” Electra-Screw@ compressor is supplied with a
factory mounted starter and complete controls as standard equipment. The standard
control system consists of both a modulating system to control capacity when system
demand is high, and a load/unload system with reservoir blowdown for maximum economy
when demand is low.
SAFETY DEVICES - All compressors incorporate the following safety devices:
Motor Protection Devices - Overload heaters are furnished for the starter in the
voltage range specified. There are three (3) overloads in the starter of proper size
for the starter and its enclosure. When replacing or changing overloads, be sure to
select them from a 3-overload heater table, since the use of a third overload for a
given enclosure due to the extra heat. An overload from a 2-overload heater table
would be undersize.
The overload heaters have a high-low adjustment off6% determined by the position of
the heater in the overload relay. The high or low position is shown on the overload
heater table inside the starter enclosure. Motor nameplate amperage is used to
determine high-low position.
High Discharge Temperature Switch - The compressor is protected from high discharge
temperature by two independent temperature switches. One switch is located in the
compressor discharge housing to sense compressor discharge air-oil mixture
temperature. The second probe is located on the reservoir cover and senses the
temperature of the air at the oil separator.
These switches are factory set at 225° F. They may be checked by immersing the probe
in an oil bath.
ACAUTION
DO NOT CONTINUE
SHORT PERIOD OF
Pressure Relief Valve -
TO RESET THE CIRCUIT IF THE SAME MALFUNCTION OCCURS WITHIN A
TIil’E.FIND AiVDCORRECT THE TROUBLE BEFORE RESUiVINGOPERATION.
A pressure relief valve is installed in the final discharqe
manifold and set at the factory to approximately 120% of the specified operati~g
pressure for protection against overpressure.
The pressure relief valve should be tested for proper operation at least once every
year, but no more often than once every two months. To test the pressure relief
valve, raise the system operating pressure to 75% of the pressure relief valve set
pressure and manually open the valve with the hand lever. Hold the valve open for a
few seconds and allow it to snap shut.
A
,WARNING
●WHENA PRESSURE RELIEF VALVE OPENS, A STREAA OF HIGH VELOCITY AIR IS RELEASED,
RESULTING INA HIGH NOISE LEVEL AND POSSIBLE DISCHARGE OF ACCUMULATED DIRT OR
OTHER DEBRIS. ALWAYS WEAR EYE AND EAR PROTECTION AND STAID CLEAR OF THE
DISCHARGE PORT WHEN TESTINGA PRESSURE RELIEF VALVE TO PREVENT INJURY.
ACAUTION
NEVER PAINT, LUBRICATE OR ALTER A PRESSURE RELIEF VALVE. DO NOT PLUG VENT OR
RESTRICT DISCHARGE.
13-8-601 Section 4 Page 1

A
,WARNING
●DO NOT OPERATE THE COMPRESSOR WITHOUT THE PROPER PRESSURE RELIEF VALVE.
OVERPRESSURE 0PERAT10NNA% CAUSE SEVERE DAlfAGETO EQUIPIYENT.
Blowdown Valve (Figure 2-1) - The blowdown valve releases pressure from the oil
reservoir. See description under “Air Control Components” in this section for
construction and operation information.
INSTRUMENTS - All units incorporate the following instruments and indicators:
Discharge Air Pressure Gauge (Figure 3-1) - This direct reading air pressure gauge
indicates final discharge air pressure at the discharge manifold. Minimum air
pressure is limited by the minimum discharge pressure valve to 65 psig. Maximum air
pressure is controlled by the subtractive pilot.
Discharge Air Temperature Gauge (Figure 3-1) - This direct reading gauge indicates
compressor discharge air temperature. Normal operating temperature is 170-200° F.
Maximum discharge air temperature is limited to 225” F by the High Discharge
Temperature Switch (see description under “Safety Devices” in this section).
Separator Indicator Pressure Button (Figure 3-1) - This button allows the discharge
air pressure gauge to be used to measure separator differential. See Section 5,
“Lubrication, Oil Cooler, Oil Filter and”Separator” for instructions.
Oi1
the
for
AIR
See
Level Gauge (Figure 3-1) - This float type gauge indicates the level of the oil in
reservoir. See Section 5, “Lubrication, Oil Cooler, Oil Filter and Separator”,
information on how to correctly read this gauge.
CONTROL COMPONENTS - All units incorporate the following air control components.
Figure 1-4 for schematic tubing diagram.
=w 11: I I
011 MAIM I1
FIGURE 1-4. - CONTROL SCHEMATIC
13-8-601 Section 4 Page 2

Subtractive Pilot - The subtractive pilot is an
adjustable, spring-loaded diaphragm valve that controls 110
pressure in relation to the upstream (discharge) ~ 10S
pressure. m
~100
The downstream pressure is maintained equal to the a
n 95
upstream pressure minus a constant which is adjustable. >
$
In the example shown in Figure 2-4, the downstream 90
cc
pressure equals the upstream pressure minus 95 psi. $ ~~
When the upstream pressure rises to 100 psig, the ;
downstream pressure rises to 5 psig. This 1 to 1 psi
rise is constant above the set point. o
05 10 15
Below the set point, the valve seat is closed and the DOWNSTREAM PRESSIJRE
downstream pressure is vented. In the example of Figure
2-4 the downstream pressure is vented below 95 psig. B76681
FIGURE 2-4.
ADJUSTING =“fi /“ENT
SCREW J
SPRING
DIAPHRAGM 1
VALVE
CLOSED w—DOWNSTREAM
/
—
UPSTREAM
LINE
FIGURE 3-4. -
SUBTRACTIVE PILOT (Closed)
ADJUSTING
SCREW
SPRING
DIAPHRAGM UPSTREAM
LINE
LINE OPEN II—
DOWNSTREAM LINE
FIGURE 4-4. -
SUBTRACTIVE PILOT (Opened)
Figure 3-4 shows a schematic cross section of the subtractive pilot with the valve
seat closed and the downstream line vented. Figure 4-4 shows the pilot with the valve
seat open, holding a downstream pressure which is adjustable with the screw. In this
position it is normal for the valve to continually bleed air through the small vent
hole in the bowl. The pilot can be adjusted from 65 to 150 psig.
Moisture, oil and dirt in the control system lines and components can cause the set
point of the subtractive pilot to shift or be erratic. Daily draining of the control
air lines will minimize any problems. The subtractive pilot can be disassembled and
the diaphragm and ports cleaned when necessary.
See “Control System Operation” in this section for a description of how the
subtractive pilot responds during operation. See “Operating Air Pressure Adjustment”
in this section for instructions on adjusting the subtractive pilot.
Piloted Unloader Valve (Figure 5-4) - The piloted unloader valve is a combination
unloader pilot and pilot actuated two-way valve. When the pilot pressure at port 1
exceeds the upper set point, the unloader pilot opens, shifting the two-way valve to
the open position. In this position, port 3 is open to port 2 and port 4 is open to
port 1. As of this printing, port 4 must remain plugged.
13-8-601 Section 4 Page 3

When the pilot pressure at port 1 drops below the lower set point, the un-
closes, shifting the two-way valve to the closed position.
Both load pressure and differential are adjustable. A lockout screw is
keep the valve in the closed position.
See “Control System Operation” in this section for a description of how
oader pilot
provided to
the piloted
unloader responds during operation. See “Operating Air Pressure Adjustment” in this
section for instructions on adjusting the piloted unloader.
LOCKNUT
PORT 4
—.
k
I
LOCKOUTSCREW “A”
(SuppliedWith Optional
Modulating Control System)
MADJUSTING SCREW “B*’
“c’’&i41
ADJUSTING SCREW “D”
II
PORT 2
w
W
IPOiiT 3
—
PORT 1
Eiis
—
202SSE799
FIGURE 5-4. FIGURE 6-4. - INLET VALVE
Inlet Valve (Figure 6-4) - The inlet valve is a pilot-actuated valve that restricts
the inlet to control capacity and closes to unload the compressor. At shutdown the
inlet valve closes to function as a check valve and prevent backflow of air.
As control pressure is increased the valve will begin to close, restricting the inlet
and reducing compressor capacity. Approximately 18 psig of control pressure is
required to close the inlet valve completely. When closed, the inlet valve prevents
the flow of air in either direction. When the control pressure is less than 18 psig,
the inlet valve will modulate to match compressor capacity to system demand.
Blowdown Valve (Figure 2-1) - The blowdown valve is a two-way solenoid valve that is
piped into the oil reservoir discharge manifold ahead of the check valve. When the
solenoid is de-energized, the blowdown valve opens, and the reservoir is blown down.
When thesolenoid is energized, the blowdown valve closes, and allows the reservoir to
pressurize.
Reservoir Pressure Switch (Figure 1-4) - A pressure 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 6 psig 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 one-half (1/2) to one (1)
minute. This switch is set at the factory and is not intended to be adjusted in the
field.
13-8-601 Section 4 Page 4