Gardner Denver ELECTRA-SCREW 60 HP User manual

139-607
8th Edition
ELECTra- SCREW
STATIONARY
BASE MOUNTED
COMPRESSOR
●60Hp– Models ECK_.K (ESK)
●75 HP –Models ECK_L (ESL)
100 HP –Models ECK_M(ESM)
13-9-607
GARDNER-DENVER
COOPER
INDUSTRIES INDUSTRIAL MACHINERY DIVISION

ELECTRA-SCREW@
Gardner-Denver compressors (the “Company”) warrants its
products only as follows:
GENERAL PROVISIONS AND LIMITATIONS
The Company warrants to each original retail purchaser
(“Purchaser”) of its new products from the Company or its
authorized distributor that such products are, at the time of
delivery to the Purchaser, made with good material and work-
manship, provided that no warranty is made with respect to:
1.
2.
3.
4.
5.
Any product which has been repaired or altered in
such away, in the Company’s judgment, as to affect
the product adversely.
Any product which has, in the Company’s judgment,
been subject to negligence, accident, improper storage,
or improper installation or application.
Any product which has not been operated or main-
tained in accordance with normal practice and with
the recommendations of the Company.
Components or accessories manufactured, warranted
and serviced by others, except as separately rated.
Any reconditioned or prior owned product.
Claims fur items described in (4) above should be submitted
directly to the manufacturer.
The Company’s obligation under this warranty is limited to
furnishing repaired part or, at its option, replacement part,
during normal business hoursat an authorized service facility
of the Company, for any part which in its judgment proved
not to be as warranted within the applicable Warranty Period.
During the first 90 days from initial use, not to exceed 120
days from date of shipment to fust Purchaser, labor forinstal-
lation of such apart will be provided without charge to the
user during normal working hours at an authorized service
facitity of the Company. All costs of transportation of parts
claimed not to be as warranted and ofrepaired or replacement
parts and service personnel from such service facility shall be
borne by the Purchaser. The Company may require the return
of any part claimed not to be as warranted to one of its facil-
ities as designated by Company, transportation prepaid by
Purchaser, to establish aclaim under this warranty.
Replacement parts provided under the terms of this warranty
are warranted for the remainder of the Warranty Period of
the product upon which installed to the same extent as if
such parts were original components thereof.
GARDNER-DENVER
AND ELECTRA-SAVER@ COMPRESSORS
WARRANTY
WARRANTY PERIOD
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 frost Purchaser, whichever
occurs frost.
Electric motors and oil coolers are warranted for 12 months
from &te of initial use or 15 months from date of shipment
to first Purchaser. whichever occurs first.
All other components are warranted for 6months from date
of initial use or 9months from date of shipment to first
Purchaser, whichever occurs first.
DISCLAIMER
THE COMPANY MAKES NO OTHER WARRANTY OF
ANY KIND WHATSOEVER EXPRESSED OR IMPLIED
AND ALL WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR APARTICULAR PURPOSE ARE HERE-
BY DISCLAIMED BY THE COMPANY. THE COMPANY
SHALL IN NO CASE BE SUBJECT TO ANY OTHER
OBLIGATIONS OR LIABILITIES WHATSOEVER WITH
RESPECT TO PRODUCTS OR SERVICES MANUFAC-
TURED OR FURNISHED BY IT OR ANY ACTS OR
OMISSIONS RELATING THERETO. THE REMEDY PRO-
vided UNDER THIS WARRANTY SHALL BE THE
SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE
TO PURCHASER. UNDER NO CIRCUMSTANCES SHALL
THE COMPANY BE LIABLE FOR ANY SPECIAL, IN-
DIRECT, INCIDENTAL OR CONSEQUENTIAL dam-
AGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER
CAUSED.
NO statement, representation, agreement, or understanding,
oral or written, made by any agent, distributor, representative,
or employee of the Company which is not contained in this
Warranty will be binding upon the Company unless made
in writing and executed by
This warranty shall not be
is not presented within 30
the product is claimed not
action for breach of this
within one year after the
action occurred.
an officer of the Company.
effective as to any claim which
days after the date upon which
to have been as warranted. Any
warranty must be commenced
date upon which the cause of
Any adjustment made pursuant to this warranty shall not
be construed as an admission by the Company that any
product was not as warranted.

FOREWORD
GARDNER- denver ELECTRA-SCREw compressors are the result of advanced engineering and skilled manufacturing To be
assured of receiving maximum service from this machinery the owner must exercise care in its operation and maintenance This book
is written to give the operator and the maintenance department essential information for day-to-day operation, maintenance and
adjustment Careful adherence to these instructions will result in economical operation and minimum downtime
THIS BOOK COVERS THE FOLLOWING MODELS
?AIR COOLED WATER COOLED
60 HP ECKQ_D (ESKAE) 100 Psl ECKSK_D (ESKAF) 100 Psl
ECKQK_F (ESKBE) 125 PSI ECKSK_F (ESKBF) 125 PSI
ECKQL_D (ESLAE) 100 Psl ECKSL_D (ESLAF) 100 Psl
75 HP ECKQL_F (ESLBE) 125 PSI ECKSl_F (ESLBF) 125 PSI
ECKQi_H (ESLCE) 150 Psl ECKSL_H (ESLCF) 150 Psl
ECKQM_D (ESMAE) 100 Psl ECKSM_D (ESMAF) 100 Psl
100 HP ECKQM_F (ESMBE) 125 PSI ECKSM_F (ESMBF) 125 PSI
ECKQM_H (ESMCE) 150 Psl ECKSh4H (ESMCF) 150 Psl
INDEX
NOTE Numbers preceding dash are Section Numbers —numbers following dash are Page Numbers
Accessories Auxiliary ............................... .. 2-3
Acoustic Enclosure ............................... 2-2, 3-1
Addition of Oil Between Changes ..................... 5-2
Adjustment Operating Air Pressure
(Auto Start-Stop Control) ........................... 4-10
Adjustment Operating Air Pressure
(Constant Speed Control ........................... 4-9
Adjustment Operating Air Pressure
(Dual Control) ...................................... 4-11
Adjustment Operating Air Pressure
(Duomatic Control) ................................. 4-12
Aftercooler ............................................. 2-3
Aftercooler —Heat Exchanger Water Piping 2-5
Air-Cooled Unit —Location ........................... 2-1
Air Filter ..................................... 3-1, 6-1,8-1
Air Filter (Heavy Dutyj ................................. 6-1
AI RFILTERS(SECTION6) .......................... 6-1
Air Flow . . . . . . . 1-1
Air& Oil Discharge Temperature. . . . . . . . . . . . . . . . . . . . . 5-8
Air-Oil Systems Flow Diagram ......................... 5-1
Air Pressure Adjustment Operating
(Auto Start-Stop Control) . . 4-1o
Air Pressure Adjustment Operating
(Constant Speed Control) ........................ .. 4-9
Air Pressure Adjustment Operating
(Dual Control) . . 4-11
Air Pressure Adjustment Operating
(Duomatic Control) . . . 4-12
Air Pressure Gauge ................................... 4-8
Air Receiver, Auxiliary .2-3
Air Temperature Shutdowq High ...................... 4-1
Air valve Bleed ....................................... 4-9
Alignment Coupling ........ ..................... 3-1, 7-1
Alignment of Compressor& Motor ................... 10-9
Assembly instructions ................................ 10-4
Automatic Blowdown System... ....................... 5-7
Automatic Blowdown Valve ................... ........ 4-1
Automatic Start-Stop Control System . . 4-9
Automatic Start-Stop (Duomatic) ..................... 4-11
Automatic Start-Stop Timed (Duomatic) .4-11
Auxiliary Accessories .................................. 2-3
Auxiliary Air Receiver .................................. 2-3
Bleed Air Valve .............................. .. ...... 4-9
Blowdown system, Automatic ..... ............ ...... 5-7
Blowdown valve, Automatic ........................... 4-1
Blowdown Valve Piping ................................ 2-5
Breaker, Circuit ................. 4-1
Capacities Oil .................................... 5-2
Check List Service .............. . 8-1
Check Valve (Oil Reservoir) ........................... 4-8
Circuit Breaker ........................................ 4-1
Cleaning and Draining Oil System .5-2
Clearance Chart– Unit Cold ........................ 10-6
Clearances Running .......................... . 10-10
Cold Ambient Operation ............................... 5-2
Cold Weather Operation Installation for .2-2
Compression Principle ................................. 1-1
Compressor ............................................ 1-1
Compressor &Motor Alignment.. .................... 10-9
Compressor Lubricants ................ ..... .. ...... 5-1
Compressor Oil ................................. ...... 3-1
Compressor Oil Cooler –Radiator Type 5-3
Compressor Oil Cooler —
Water-Cooled Heat Exchanger .... ................. 5-4
Compressor Oil Filter ................ ................. 5-3
Compressor Oil Inlet Temperature .................... 5-8
Compressor Oil Separator ....... 5-5
Compressor Oil System ............................... 5-1
Compressor Oil System Check.. .............. ....... 5-8
COMPRESSOR OVERHAUL (SECTION 10) .10-1
13-9-607 Page i

Compressor, Sectional View 10-3
Constant Speed Control System . . . . . . . . . . . . . . . . . . . . 4-8
Constant Speed (Duomatic) . . . . . . . . . . . . . . . . . . . . . . . 4-11
Control Piping ............. .... ................. 2-5
CONTROLS &INSTRUMENTS (SECTION 4) 4-1
Control System Automatic Start-Stop . . . . . . . . . . . . 4-9
Control System, Constant Speed... ............4-8
Control System Dual . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Control System Duomatic . . . . . . . . . . . . . . . . . . 4-11
Control Valve Oil Flow
(Duomatic Control Unit Only) . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Control Valve Thermal (Thermostatic Mixing) 5-3
Control Valve, Water Flow . . . . . . . . 5-5
Control Voltage ................... 4-1
COUPLING (SECTION 7) . . . . . . . . . . . 7-1
Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Diagrams Wiring 4-2 thru 4-7
Differential Group Pressure ........................... 5-8
Differential\ Oil Cooler Oil Pressure
(Air-Cooled Radiatorj 5-8
Differential Oil Cooler Oil Pressure
(Water-Cooled Heat Exchanger 5-8
Differential\ Oil Cooler Temperature
(Air-Cooled Radiator 5-8
Differential!, Oil Cooler Temperature
(Water-Cooled Heat Exchanger 5-8
Differential Oil Cooler Water Pressure
(Water-Cooled Heat Exchanger) 5-8
Dimensions 10-10
Disassembly Instructions, ....... 10-1
Discharge Temperature Air &Oil 5-8
Discharge Pressure Valve Minimum 4-8
Discharge Service Line ................... ...... ..... 2-5
Drain Oil Reservoir ....................... ............ 2-2
Draining and Cleaning Oil System .5-2
Dual Control System .............. 4-10
Du,omatic Control System ..,..... 4-11
Dust Cup(Heavy-Duty Air filter) . . . . . . . . . . . . . . . . . . 6-1
Electrical ........................ 3-1
Electrical Wiring . . 4-9thru 4-12
Electrical Wiring Diagrams .4-2 thru 4-7
Electrical Wiring (Standard Units) 2-5
Element life, Filter (Heavy Duty). ..................... 6-2
Enclosure Acoustic ............................... 2-2, 3-1
Filling Oil Reservoir ... 5-3
Filter, Air ............................ 3-1, 6-1,8-1
Filter, Compressor Oil . . 5-3
Filter Element (Heavy Dutyj ........................... 6-1
Filter Element Life (Heavy Duty) . . . . . . . . . . . . . . . . . . . . . . 6-2
Filter, Heavy Duty Air ................... 6-1
FILTERS, AI R(SECTION6) . . . . . . . . . . . . . . . . . . . . . . . 6-1
Fits . .............. 1o-1o
Flow Control Valve Oil
(Duomatic Control Unit Only) ........................ 5-7
Flow Diagram —Air-Oil Systems. . . . . . . . . . . . . . . . . . . . . 5-1
Foundation . . 2-2
Gauge, Air Pressure .............. 4-8
Gauge, Oil Level ......................... ....... .... 5-2
Gauge, Oil Temperature ........... . . 4-8
Gauges& Instruments ................................. 4-8
General (Controls) .......................... .......... 4-1
GENERAL INFORMATION (SECTION 1) ... 1-1
General installation . . . . . . . . . . . . . . . . . . . 2-1
Grease Recommendations ........ 2-6
Grounding .................................... 2-6
Heat Exchanger, Water-Cooled Compressor
Oil Cooler ........... .. ................... . .. 5-4
Heat Exchanger Water Flow Control Valve 5-5
Heat Exchanger Water Shutoff Valve 5-5
Heavy Duty Air Filter ............. 6-1
High Air Temperature Shutdown 4-1
High Temperature Operation ............. . .......... 5-2
Hourmeter ........,..,.. 4-8
INFORMATION, GENERAL (SECTION 1) 1-1
Inlet Line, ...................... .... ..... ......... . 2-5
inlet Pressure Oil ................ 5-8
Inlet Screen &Tube (Heavy Duty Air Filter) 6-2
Inlet Temperature, Compressor Oil . . . . . . . . . . . . . . . . . . 5-8
Inlet Valve (Constant Speed Control 4-9
inlet Valve (Duomatic Control 4-12
Installation for Cold Weather Operation . . . . . . . . . . . . . 2-2
INSTALLATION (SECTION2) 2-1
INSTRUMENTS &CONTROLS
(sEcTloN 4) ........................................ 4-1
Instruments &Gauges ............ 4-8
Lifting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Light test, Operating ............. 3-1
Location (installation) ............. 2-1
Lubricantq Compressor 5-1
Lubricants, Synthetic ........... .... ..... .... ..... 5-1
Lubrications, Cooling &Sealing 1-1
Lubrication Motor..,.. 2-6, 8-1
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION5) .5-1
Maintenance of Air Filters ....... 6-1, 6-2
MAINTENANCE SCHEDULE (SECTION 8) 8-1
Minimum Discharge Pressure Valve 4-8
Mixing Valve, Thermostatic (Thermal Control) 5-3
Mode, Operating ................... ............... ... 3-1
Moisture Separator Trap .. ....................... ... 3-1
Motor &Compressor Alignment . . . 10-9
Motor Lubrication ......................... ....... 2-6, 8-1
Motor Protection Devices 4-1
Oil& Air Discharge Temperature. .5-8
OiF-Air Systems Flow Diagram ......................... 5-1
Oil Capacities .................................... . 5-2
Oil Change Interval .................................... 5-2
oil, Compressor .................................... 3-1
Oil Cooler, Compressor –Radiator Type 5-3
Oil Cooler, Water-Cooled Heat Exchanger 5-4
Oil Cooler Oil Pressure Differential
(Air-Cooled Radiatorj ................................ 5-8
Oil Cooler Oil Pressure Differential
(Water-Cooled Heat Exchanger . . 5-8
Oil Cooler Temperature Differential
(Air-Cooled radiator ................................ 5-8
Oil Cooler Temperature Differential
(Water-Cooled Heat Exchanger) 5-8
Oil Cooler Water Pressure Differential
(Water-Cooled Heat Exchanger) . . 5-8
Oil Filter, Compressor . . . . . 5-3
Oil Flow Control Valve
(Duomatic Control Unit Only) ........................ 5-7
Oil Inlet Pressure ...................................... 5-8
Oil Inlet Temperature Compressor .................... 5-8
13-9-607 Page ii

Oil Level Gauge ..................... .... .... ....... 5-2
Oil Pressure Differential\ Oil Cooler
(Air-Cooled radiator . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Oil Pressure Differential\ Oil Cooler
(Water-Cooled Heat Exchanged 5-8
Oil Reservoir .................................... . .. 5-5
Oil Reservoir Check Valve 4-8
Oil Reservoir Drain ............... 2-2
Oil Reservoir, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Oil Separator, Compressor 5-5, 8-1
Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Oil System Check, Compressor 5-8
Oil System, Compressor . . . . . . . . . . 5-1
Oil system Draining &Cleaning 5-2
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . 4-8
on-off Switch ....... .............. 4-1
Operating Air Pressure Adjustment
(Auto Start- Stop Control) ................ 4-10
Operating Air Pressure Adjustment
(Constant Speed Control) 4-9
Operating Air Pressure Adjustment
(Dual Control) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Operating Air Pressure Adjustment
(Duomatic Control) 4-12
Operating Light Test 3-1
Operating Mode . . . . . . . . . . . . . . . . . . 3-1
OPERATING PROCEDURES& STARTING
(sEcTloN 3) ........................................ 3-1
Operation High Temperature............,,., 5-2
OVERHAUL COMPRESSOR (SECTION 10) 10-1
Pilot Subtractive ................ 4-8
Piping ............................. 3-1
Piping Aftercooler —Heat Exchanger Water 2-5
Piping Blowdown Valve .... .......... .. ............ 2-5
Piping Water (Water-Cooled Heat Exchanger 2-5
Pressure Adjustment Operating Air
(Auto Start-Stop Control) ........................... 4-10
Pressure Adjustment Operating Air
(Constant Speed Control) ............ ............. 4-9
Pressure Adjustment Operating Air
(Dual Control) .4-11
Pressure Adjustment Operating Air
(Duomatic Control) 4-12
Pressure Differential Group 5-8
Pressure Differential\ Oil Cooler Oil
(Air-Cooled Radiator) . . 5-8
Pressure Differential\ Oil Cooler Oil
(Water-Cooled Heat Exchanger . . . . . . . . . . . . . . . . . . . . 5-8
Pressure Differential\ Oil Cooler Water
(Water-Cooled Heat Exchanger .5-8
Pressure Gauge Air . . . . . . . . . . . . . . . . 4-8
Pressure Oillnlet ..................... ............... 5-8
Pressure Switch Reservoir .......................... 4-12
Pressure System ................. 3-1
Pressure Valve Minimum Discharge 4-8
Radiator-Type Compressor Oil Cooler 5-3
Rebulding Data for Gear-Driven Compressors 10-10
Receiver, Auxiliary Air ........ ....... ............ ... 2-3
Regressing interval .................................... 2-6
Remote Starter . . . . . . . . . . . . . . . . . . . . 2-5
Reservoir Check Valve, 0il ............................ 4-8
Reservoir Drain Oil ................ 2-2
Reservoir, Oil .......................................... 5-5
Reservoir Pressure Switch ....... ............... ... 4-12
Rotation .................................. . 3-1
Running Clearances ................................ 10-10
Safety Devices ..... ...... .... ............. .... 4-1
Safety Valve ............. ..... ................ 4-8
Sectional View of Compressor . . . . . . . . . . . . . . . . . . 10-3
Separator, Compressor Oil 5-5, 8-1
Service Checklist .... ... .. ....... .. .... . ...... 8-1
Shutdown High Air Temperature ...................... 4-1
Shutoff Valve, Water —Heat Exchanger 5-5
Specifications, Oil ...... .. ...... ... .. ...... .. 5-1
Starter, Remote ................. 2-5
STARTING &OPERATING PROCEDURES
(sEcTloN 3) ........................................ 3-1
Starting Unit ...................... 3-1
Stopping Unit .................... 3-2
Subtractive Pilot ................ 4-8
Switch, On-Off ...................... 4-1
Switch, Reservoir Pressure . . . . . 4-12
Synthetic Lubricants ............. 5-1
System Pressure 3-1
Temperature Air& Oil Discharge 5-8
Temperature Compressor Oil Inlet ................... 5-8
Temperature Differential\ Oil Cooler
(Air-Cooled Radiator 5-8
Temperature Differential\ Oil Cooler
(Water-Cooled Heat Exchanger) 5-8
Temperature Gauge, Oil .,.,..... 4-8
Temperature Operation, High.5-2
Temperature Shutdown, High Air......,..,..,.. 4-1
Thermal Control (Thermostatic Mixing) Valve 5-3
Timed Automatic Start-Stop (Duomatic Control) 4-11
Torque Recommendations ..... . ................... 10-4
TROUBLE SHOOTING (SECTION 9) 9-1
Valve Automatic Blowdown 4-1
Valve, Bleed Air ............... ................. .. 4-9
Valve Check (Oil Reservoir) .4-8
Valve Inlet (Constant Speed Control) ..... ........... 4-9
Valve lnlet (Duomatic Control) .......... 4-12
Valve Minimum Discharge Pressure 4-8
Valve Oil Flow Control (Duomatic
Control Unit Onlyj ..... ... .. ..... .... ..... ..... 5-7
Valve Piping Blowdown .2-5
Valve Safety ........................... ............... 4-8
Valve Thermal Control (Thermostatic Mixing) 5-3
Valve, Water Flow Control ...... 5-5
Valve Water Shutoff —Heat Exchanger .5-5
Voltage Control .4-1
Water-Cooled Heat Exchanger Compressor
Oil Cooler ....................................... 5-4
Water-Cooled Unit —Location ........................ 2-1
Water Flow Control Valve for Heat
Exchanger ...................... . 5-5
Water Flow Rates ............. ....... ............ 2-5
Water Piping Aftercooler —Heat
Exchanger ........................ 2-5
Water Piping (Water-Cooled Heat Exchanger
Models Only) ..................... ................. 2-5
Water Pressure Differential\ Oil Cooler
(Water-Cooled Heat Exchanger) 5-8
Water Shutoff Valve —Water-Cooled Heat
Exchanger ......................... .......... 5-5
Wiring Diagrams ................ .. ......... 4-2 thru 4-7
Wiring Electrical ........................... 4-9, thru 4-12
Wiring Electrical —Standard Units 2-5
13-9-607 Page iii

SECTION 1
GENERAL INFORMATION
FIGURE 1-1. –COMPRESSION CYCLE
COMPRESSOR —The Gardner-Denver Model “ES" or
“ECK" Electra- Screw compressor is asingle stage positive
displacement rotary machine using meshing helical rotors
to effect compression The input drive shaft and helical
drive gear are supported in the gear case by high capacity
ball bearings the drive gear meshes with adriven gear
mounted on the main rotor shaft to drive the rotors Both
rotors are supported between large capacity antifriction
bearings located outside the compression chamber. Single
width cylindrical roller bearings are used at the inlet end of
the rotors Two heavy-duty single row angular contact ball
bearings at the discharge end locate each rotor axially and
carry all thrust loads
COMPRESSION PRINCIPLE (Figure l-l) —Compression
is accomplished by the main and secondary rotors
synchronously meshing in aone-piece cylinder. The main
rotor has four helical lobes 90° apart The secondary rotor
has six matching helical grooves 60° apart to allow meshing
with main rotor lobes
The air inlet port is located on top of the compressor near
the 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 adischarge air flow that
is continuous smooth and shock-free
AIR FLOW (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 discharge check valve and the unit
shutoff globe valve to the plant air lines
DANGER
!Do not use the air dischargedfrom this unit for breathing
not suitable for human consumption
LUBRICATION, COOLING AND SEALING —Oil is forced
by air pressure from the oil reservoir through the oil cooler,
thermostatic mixing valve (mixing valve is not used with
the water-cooled oil cooler, and oil filter and discharges
into the compressor main oil gallery. Aportion of the oil
is directed through internal passages to the bearings gears
and shaft oil seal The balance of the oil is injected directly
into the compression chamber to remove heat of compres
sion seal internal clearances and lubricate the rotors
13-9-607 Section 1Page 1

13-9-607 Section 1Page 2

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
~WARNING
DO NOT electric weld on the compressor or base,
bearings can be damaged by passage of current
LIFTING UNIT —Early models were furnished with
lifting bails, later models are not so equipped Proper lifting
and/or transporting methods must be used to prevent
damage
CAUTION
Where lifting bail is not supplied liftcompressor unit
by base only. Do not use other places such as enclosure
motor, compressor oil discharge manifold and piping as
lifting points
DANGER
The eyebolts or lugs provided on the motor are forlifting
the motor only and should not be used to lift any addi-
tional weight All eyebpolts must be securely tightened
When lifting the motor the lifting angle on the eyebolts
must not exceed 15 degrees. failure to observe this
warning may result in damage or personal injury.
Physical size and weight of unit Figure 1-2, may allow use
of tow motors Unit may also be moved into location by
rolling on bars Acoustic enclosure if supplied may easily
be removed if deemed necessary for weight or size reduction
‘.OUVERED
,,, !., mn,,, EXHAUST FAN LOUVERE-
,.,,.,--,.
AIR OUT M
Dimensions
Approx
Model HP Weight H’ HL* Lw w
ESK ECL_K 60 3800 60 56 76 70 54 48
ESL ECK_L 75 4000 60 56 76 70 54 46
ESM ECK_M 100 4600 60 56 76 70 54 48
t
FIGURE 1-2.
13-9-607 Section 2
A75119
FIGURE 2-2. –TYPICAL COMPRESSOR ROOM
LOCATION— The compressor should be installed where
ever possible in aclean well-lighted well ventilated area with
ample space all around for maintenance Select alocation
that provides acool clean dry source of air. In some cases
it may be necessary to install the air filter at some distance
from the compressor to obtain proper air supply.
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 Atypical inlet-outlet air flow
arrangement is shown in Figure 2-2.
Air Cooled Unit —The air-cooled unit with the standard
acoustic enclosure requires sufficient air flow, Figure 3-2,
for the compressor oil cooling system and for electric motor
coolin”g Air is drawn into the unit around the base of
the enclosure and is exhausted vertically. Do not block
the air flow to and from the unit Allow two (2) feet
to the nearest obstruction on all sides and above the
unit When the air-cooled unit is used without an
enclosure all of the above ventilating and cooling air
requirements also apply.
IMinimum Air Flow For Compression
And Cooling (Cubic Feet/Minute) I
Model
ESK ECK_K
ESL ECK_L
ESM, ECK_M
Air Cooled Water Cooled
8400 cfm I2400 cfm I
8000 cfm I2400 cfm
*80° F. Inlet Air
FIGURE 3-2.
WaterCooled Unit —The water-cooled unit with the
standard acoustic enclosure requires sufficient air
flow, Figure 3-2, for electric motor (Main drive and
Page 1

enclosure vent fan) cooling Air is drawn into the unit
around the base of the enclosure and is exhausted vertically.
Do not block air flow to and from the unit Allow two (2)
feet to the nearest obstruction on all sides and above the
unit Lubricate the vent fan motor every 8000 hours of
operation with two (2) drops of SAE 20 oil When the water-
cooled unit is used without an acoustic enclosure all of the
above ventilation and cooling air requirements also apply.
FOUNDATION —The Electra-Screw compressor requires
no special foundation but should be mounted on asmooth
solid surface. Whenever possible install the unit near level
Temporary installation may be made at amaximum 10°
angle lengthwise or 30° sidewise.
Mounting bolts are not normally required However, in-
stallation conditions such as piping rigidity, angle of tilt or
danger of shifting from outside vibration or moving vehicles
may require the use of mounting bolts to the foundation
Coupling alignment must be checked after installation
OIL RESERVOIR DRAIN —The oil reservoir drain valve
is located behind the reservoir foot at the instrument panel
end of the unit On all models the drain valve is approximately
six(6) inches from the floor level If this height is not sufficient
to conveniently drain the oil some other methods of pro
vialing oil drain are:
1. Elevate the compressor unit on raising blocks to ob
tain 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
acontainer.
ACOUSTIC ENCLOSURE —The Electra- Screw unit is
furnished with an acoustic enclosure as standard equipment
The enclosure reduces the normal operating sound of the
unit to alevel below 80 DBA in free field conditions
In order to maintain the sound reduction ability of the
cabinet only the final discharge air line penetrates the em
closure At the time of installation other openings for
electrical conduit oil drain piping and water piping are to
be cut into the enclosure at convenient positions for con-
nection to external wiring and piping All openings should
be no larger than necessary for conduit or pipe diameter
the conduit or pipe should not touch the enclosure When
all conduit pipes are in place the open space between them
and the enclosure panel should be sealed with arubber
grommet or elastic caulk
S’ervice doors are provided for access to the instrument
panel and controls the oil and air filters and the starter
enclosure Be sure to allow enough room above the unit for
panel and separator removal
The air for the compressor and for enclosure is drawn in
around the base and is exhausted from the top of the
enclosure Do not block this air flow or allow the floor area
near the enclosure to accumulate dirt
~WARNING
DO not operate unit with access doors removed Doors
must be in place and closed to direct cooling air over
motor and coolers
DANGER
Do not open service doors while compressor is operating
Open doors will expose rotating fan and coupling
INSTALLATION FOR COLD WEATHER OPERATION –
It is recommended that whenever possible the unit be in-
stalled inside ashelter that will be heated to temperatures
above freezing (32° F., 0° C.). This will eliminate many of
the problems associated with operating the units outside
in cold climates where freezing rain, drifting snow, freezing
condensate and bitter cold temperatures are encountered
When an outside installation must be made the precautions
required will depend on how severe the environment will
get The following are general guidelines for outside in-
stallations
Cold Weather (Down To +10° F.)
1. Be sure all control lines drains and traps are heated
“- ‘“
I~. ‘F’’::k:!:”(::”:::x:-’’’”’”’
&RH400 WITH (2) RH4502
1— I()l? ELEMENTS —2REQ’D.
3,2oO WATTS EACH .
8FT. PLYWOOD “FENCE”
\4FT.
VI IIh WE LLMAN RADIANT 2-ELEMENT
HEATER (OR EQUAL)
*’E;:’’’;’” r~h: }
/
~- [111
\
AWAV FROM PREVAILING WIND
TOP VIEW 8FT. PLVWOOD “FENCE” ELEVATION VIEW
FIGURE 4-2.
13-9-607 Section 2Page 2

SUPPLY LINES MUST DRAIN &WAY
FROM RECEIVER. PROVIDE DRAINS
As 5H0w N AND AT LOWER END.
wATER MuST BE PIPED
ABOVE TOP OF
AFT ERcoOLER TO
INSURE COMPLETE ‘- ““
IMMERSION OF TUBES
AIR
DISC HARGF -
5ERv1CE VALVF
2.
3.
4.
5.
6.
COMPRESSOR
.OIL RESERVOIR
./ .. ..
!
/
&
WATER FLOW
CONTROL ____
REGULATOR
WHEN ORWRED
BYPASS VALVE
FOR INITIAL
FILLING
ADJuSTABLE
MINIMUM
BYPASS VALVE
\
WATER TO HEAT
EXChANGER OIL
COO1. EQ OR JRAIN
MAGNETIC
~
WATER SHUT
OFF VALVE
WHEN O,ROERED
\
UL
MOISTURE ___
SE PA RATC6 ‘-
FLOAT TRAP
WHEN ORDERED
“\
[
\%
!4$
To DRAIN-— --
\’ —,
FIGURE 5-2. –AUXILIARY
to avoid freezing of condensate Heat tape with thermo-
stat control is generally satisfactory for this purpose
and can be obtained at various local plumbing or hard
ware 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.
Specify NEMA 4enclosure for electrical devices
Extreme Cold Weather Operation (Down To i40° 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 aportion of the cooler with
plywood should be satisfactory.
3. Lo Demand operation should be used in extreme en-
vironments
SAFETY VALVE I
,/“ –---A
‘T
~~ II
.—
/
(@
b
AIR RECEIVER
,GAUGE
OUTLET
3/ 411
1$
“~
DROP
LEGS
i
),
#
\,RAIN/
VALVES
THIS TYPE CONNECTION
PREVENTS CONDENSATE
FROM BEING CARRIED
OVER WITH AIR
w
D75120
ACCESSORIES
4. 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 leasta+10° F.
environment for the coolers motor and sump Figure
4-2 shows how these might be located in atypical in-
stallation and sizes required
Remember unsheltered (outside) installations should be
avoided where possible Installation next to aheated building
where enough heat can be used to keep the compressor
room above freezing will save many 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 —Constant speed control
units do not normally use an auxiliary air receiver. Auto-
matic start-stop dual and duomatic control units require an
auxiliary air receiver unless the piping system is large and
provides sufficient storage capacity to prevent rapid cycling
When used an air receiver should be of adequate size pro
vialed with arelief valve of proper setting apressure gauge
and ameans of draining condensate Figure 4-2 shows a
typical air receiver and auxiliary accessories
AFTERCOOLER (Figure 5-2) —An aftercooler will provide
13-9-607 Section 2Page 3