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

control of moisture entering the shop air lines while reducing
the normal low discharge temperature of about 170° F.
at 100 PSIG discharge Pressure to near inlet air temper-
ature
Aftercoolers are available in these classifications
1. Factory installed built-in air-cooled radiator type
2. Factory installed built-in water-cooled shell and tube
type.
3. Externally mounted aftercoolers supplied by user.
Built-In Air Cooled Aftercooler —This radiator-type
aftercooler is mounted at the factory in the same supporting
structure as and adjacent to the unit radiator-type oil
cooler. The unit cooling fan forces air through the after-
cooler and oil cooler. The compressed air is taken from the
oil reservoir manifold passes through the aftercooler and
moisture separator to the final discharge outlet Amoisture
trap is supplied to remove separated moisture mounting of
the trap is at user-selected location for convenience of drairt
ing See Figure 6-2 for moisture trap connection to
separator
Later models of steel air-cooled aftercoolers are coated
internally to resist corrosion Coated aftercoolers have atag
attached to one header with identification and date
Built-In WaterCooled Aftercooler —This shell and tube
type aftercooler is mounted at the factory adjacent to the
unit oil cooling shell and tube-type heat exchanger. The
aftercooler is piped in series with the heat exchanger.
Water is admitted through amagnetic water shutoff valve
to the aftercooler and passes through the aftercooler then
the heat exchanger and finally exits through the water flow
control valve See Section 5for adiscussion of the functions
and setting of the water shutoff and flow control valves The
compressed air is taken from the oil reservoir manifold
OIL IN OIL OUT WATER
CONTROL
‘. VALVE *
WATER
HEAT EXCHANGER OUT
I
1
Ih
r
SEPARATOR AFTERCOOLER
r~
WATER IN
WATER SHUTOFF VALVE *
SERIES PIPING –Water flow must be through after-
cooler first for effective cooling of discharge air.
passes through the aftercooler and moisture separator to the
final discharge outlet Amoisture trap is supplied to remove
separated moisture mounting of the trap is at user-selected
location for convenience of draining
CheCK VALVE
/
B76323
MOISTURE II
SEPARATOR
‘
VENT
SERVICe VALVE vent
-TO DRAIN
FIGURE 6-5. –BUILT-IN AFTERCOOLER UNITS –
INSTALLATION OF SEPARATOR AND TRAP
Externally Mounted Aftercooler —When the aftercooler
is mounted outside the compressor unit it is to be installed
between the final discharge outlet and any auxiliary air
receiver. Figure 5-2 shows awater-cooled aftercooler but
the piping arrangement shown also applies to an air-cooled
type. Amoisture separator is to be mounted directly down
OIL IN OIL 00T
b
WATER
ICONTROL
---- ., VALVE *
IB/
HEAT EXCHANGER =WATER OUT
WATER
IN
G
SEPARATOR AFTERCOOLER “,
!I
LWATER CONTROL VALVE
%
WATER
SHUTOFF
VALVE *
PARALLEL PIPING –Two water control valves required
for temperature control of oil and discharge air temperature.
*FURNISHED BY GARDNER-DENVER
MUST BE ORDERED SEPARATELY
FIGURE 7-2, –PIPING DIAGRAM FOR AFTERCOOLER
13-9-607 Section 2Page 4
AND HEAT EXCHANGER

APPROXIMATE WATER FLOW
stream from the aftercooler and before any auxiliary air
receiver. Asuitable moisture trap should be provided at the
separator to insure adequate draining
CONTROL PIPING —Control piping is not necessary
since the Electra-Screw 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 com
pressor. 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 amoisture and oil-proof sealing lacquer.
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
Length Of Inlet Line Diameter Of Pipe Size
0to 10 Ft Same as Compressor Inlet Opening
10 to 17 Ft .One Size Larger Than Inlet Opening
17 to 38 Ft Two Sizes Larger Than Inlet Opening
Accessibility for inlet air filter servicing must be considered
when relocating the filters from the unit to aremote
location
DISCHARGE SERVICE LINE —The discharge service
line connection is made at the optional globe valve located
at the upper right instrument panel side of the unit When
manifolding two or more ES or ECK units on the same line
each ES or ECK unit is isolated by the check valve in the unit
discharge line If an ES or ECK unit is manifolded to another
compressor, be sure the other compressor has acheck valve
in the line between the machine and the manifold
DA NG ER
donotuse the air discharge from this unit for breathing
it is not suitable for human consumption
BLOWDOWN VALVE PIPING —The blowdown valve is
fitted with amuffler for operation indoors If the installation
requires the muffler may be removed and the blowdown
valve piped to the outside with pipe size the same as the
blowdown valve outlet connection See “Acoustic Enclosure”
for precautions on piping which penetrates the enclosure
WATER PIPING (Watercooled Heat Exchanger Models
Only) —On machines equipped with awater-cooled heat
exchanger, pipe water to the magnetic water shutoff valve
mounted in the water inlet piping to the heat exchanger.
Pipe outlet water from the water flow control valve to a
sump or drain See “Acoustic Enclosure” for precautions on
piping which penetrates the enclosure
The water source should be capable of supplying up to the
maximum flow shown below at aminimum pressure of 40
PSIG maximum allowable water pressure is 150 PSIG
The following water flow rates are approximate and aguide
to sizing piping cooling tower and other water system
equipment
The maximum water flow shown is that allowable through
the heat exchanger.
Model
ESK, ECKSK
ESL ECKSL
ESM, ECKSM
U.S. Gallon#Minute
Water Temperature Max-
To Heat Exchanger imum
Water
60” F. 70” F, 80” F. 90” F. Flow
5,5 6.8 9.1 13.6 40.8
6.9 8.6 11.5 17.3 60.6
9.0 11.2 14.9 22.4 40,8
The heat exchanger system is designed to operate with water
inlet temperatures from 60° F. to 90° F. and awater outlet
temperature not to exceed 11 O“ F. If water cooler than 60°
F. is used high water outlet temperatures (over 110° F.) will
be experienced along with shortened heat exchanger life
caused by tube fouling and corrosion If water warmer than
90° F. is used higher compressor oil inlet temperatures and
high water usage will result
Most water systems will require control of impurities fil-
tration softening or other treatment See “Compressor Oil
Cooler —Water-Cooled Heat Exchanger” for more informa
tion on the water system
Externally Mounted Aftercooler —Heat Exchanger
Water Piping (Figure 7-2) —If an aftercooler is used and
piped in series with the heat exchanger, remove the
magnetic water shutoff valve from the heat exchanger and
relocate in the water inlet line upstream of the aftercooler.
Pipe the aftercooler outlet water to the heat exchanger on
the compressor unit If the aftercooler is piped in parallel
with the heat exchanger, provide aseparate magnetic water
control valve for the aftercooler and pipe separate inlet
water lines to both the aftercooler and the heat exchanger.
See “Acoustic Enclosure" for precautions on piping which
penetrates the enclosure
The water control valve is to be adjusted to maintain oil out
of the heat exchanger within the 1300-140° F. range regard
less of inlet water flow or temperature Maximum allowable
oil temperature is 160° F. See Section 5for adjustment
instructions
ELECTRICAL WIRING —Standard Units —The Electra-
Screw 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 4for wiring diagrams of the
control system on your unit The standard unit is supplied
with an open drip-proof motor, aNEMA Istarter enclosure
and adust resistant control enclosure
Remote Starter— Some low voltage and special application
starters are too large to be mounted within the unit
enclosure and must be mounted outside the enclosure at a
location selected by the user at the time the unit is installed
Alength of flexible conduit must be used from the motor
conduit box to apoint one (1) foot outside the enclosure (on
units without an enclosure to apoint three [3] feet from the
motor conduit box) to maintain effective sound and
vibration isolation Electrical connections to other parts of
the unit (instrument panel fan motor, etc) from the starter
do not require flexible conduit since the compressor and
motor are already isolated from these parts See “Acoustic
Enclosure" for precautions on conduit which penetrates the
enclosure
13-9-607 Section 2Page 5

Grounding —Equipment must be grounded in accordance
with Table 250-95 of the National Electric Code
WARNING
Worked
An equipment ground jumper equal in size to the
equipment ground conductor must be used to connect the
compressor-motor subbase to the main base since the bases
are isolated from each other by vibration mounts The oil
cooler fan and enclosure vent fan motor frame will be
grounded to the main base with agrounding conductor
GREASE RECOMMENDATIONS
Standard
Service
Penetration .......... 265-296
Oil Viscosity, SSU At 100 F. 400-550
Soap Type . . . . . . . . . . . . . . . . . . . . Lithium
N-H Bomb Minimum Hours
For 20 PSI Drop At 210 F... 750
Bleeding Maximum Weight %
ln 500 Hours 212 F. . . . . . . . . 10
Rust Inhibiting . . Yes
High
Temper-
atu re
220-240
475-525
Lithium
1000
3
Yes
compatible with the fan short circuit protection at the
factory..
MOTOR LUBRICATION —The long time satisfactory
operation of an electric motor depends in large measure on
the bearings and timely lubrication The following charts
show the recommended grease csualities and reareasina
intervals for motor equipped w“ith ball
additional information refer to the motor
instructions
The following procedure should be used in
bearings. for
manufacturer’s
regressing
1.
2.
3.
4.
5.
6.
7.
Stop the unit
Disconnect the unit from the power supply.
Remove the relief plug and free the hole of hardened
grease
Wipe the lubrication fitting clean and add grease with
ahand-operated grease gun
Leave the relief plug temporarily off. Reconnect the
unit and run for about 20 minutes to expell the excess
grease
Stop the unit Replace the relief plug
Restart the unit
REGRESSING INTERVAL
Type Of Service Typical Examples Rating Relubrication Interval
150 HP and Below 18 Months
Standard One Or TwoShift Operation Over 150 HP 12 Months
150 HP and Below 9Months
Severe Continuous Operation Over 150 HP 6Months
150 HP and Below 4Months
Very Severe Dirty Locations, High Ambient Temperature Over 150 HP 2Months
13-9-607 Section 2Page 6

SECTION 3
STARTING &OPERATING PROCEDURES
Anew unit as received from the factory has been prepared
for shipping only. Do not attempt to operate the unit until
checked and serviced as follows
1. Compressor Oil —Check oil level in reservoir. Add oil
only if the oil level gauge reads in the red ADD OIL
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 For sustained operation above
+90° F. ambient temperature use Gardner-Denver
GD8000 Lubricating Coolant See Figure 2-5. REPLACE
OIL FILTER ELEMENT EVERY 1000 HOURS.
Initial fill or filling after acomplete draining of the system
may show the oil level beyond the red EXCESS OIL
range After start-uR the oil will fall into the operating
range as system components are filled If necessary,
add oil to bring the level into the center of the RUN
range when the unit is operating (Spread of the RUN
range is shown in Figure 3-5).
,DANGER
ALWAYS STOP THE UNIT AND RELEASE AIR
—
2.
3.
4.
5.
6.
PRESS URE BEFORE REMOVING OIL FILLER
PLUG TO ADD OIL
During unloaded operation and after shutdown the
system will partially drain back into the oil reservoir and
oil level will read higher than when operating on load
DO NOT DRAIN OIL TO CORRECT on the next loaded
cycle or start oil will again fill the system and the gauge
will indicate the operating level
Air Filter —Inspect the air filter to be sure it is clean
and tightly assembled Refer to Section 6“Air Filter” for
complete servicing instructions Be sure the inlet line
if used is tight and clean
Alignment —Check all bolts and cap screws for tight-
ness Check coupling alignment refer to Section 7
“Coupling” for procedure
Piping —Refer to Section 2“Installation” and make
sure the piping meets all recommendations
Moisture Separator Trap —The trap is constructed of
cast iron with side inlet and outlet connections and in-
verted bucket design Astainless steel internal strainer
is used in trap; it should be checked periodically for clog
ging and replaced if necessary. Repair parts are available
for trap cap retainer gasket and strainer. See package
outlines for mounting dimensions of moisture separator
trap The moisture separator trap must be primed by
filling with clean water prior to initial start-up of unit
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
Section 2for installation instructions
7. ‘
8.
9.
Rotation —Check the motor rotation by momentarily
starting the motor. Compressor drive shaft rotation is
counterclockwise standing at the motor end
Operating Light Test –Observe the operating lights
at the ON-OFF switch when jogging the motor in Step
7. Be sure all lamps are operative
System Pressure —Set the constant speed pilot and/or
operating air pressure switch to the desired unload pres-
sure and differential
DANGER
DO NOT EXCEED MAXIMUM OPERATING pres-
10.
11.
SURE ON COMPRESSOR NAMEPLATE
See Section 4“Controls and Instruments’ for procedure
Operating Mode —Refer to Section 4for detailed in-
formation on the control system with which your unit is
equipped (Constant Speed Automatic Start-Stop Dual
or Duomatic).
Acoustic Enclosure —Check for damaged panels or
doors Check all screws and latches for tightness
STARTING UNIT –Constant Speed and Automatic Start-
Stop units require only pressing of ON push button
Duomatic control units require setting of the timer (tom
stant speed set in center of space between 30 and O; auto
matic start-stop set desired time between 2and 30) and
pressing of ON push button Dual control units require
pressing of constant speed (CON) push button or automatic
start-stop (AUTO) push button as desired
~WARNING
On Dual control units when changing from one mode to
the other the OFF button for that mode must bepressed
Omission of this step will result in damage to the switch
operator and replacement will be necessary.
OBSERVE UNIT COLD OR UNIT HOT STARTING PRO
CEDURES.
Unit Cold –If discharging into apressurized air system
close the air service valve between the main air system and
the unit check valve If unit is awater-cooled heat exchanger
model open any manual water inlet valves wide open Start
the unit and allow to reach full pressure and unload Open
the air service valve. Since the unit is equipped with a
minimum (55-65 PSIG) pressure discharge valve no special
procedure to maintain unit reservoir pressure is required
Unit Hot —No warmup period is required Close the air
service valve If the unit is water-cooled heat exchanger
model open any manual water inlet valves wide open Start
unit Open the air service valve.
DAILY CHECK —Refer to Section 8“Maintenance
Schedule”.
13-9-607 Section 3Page 1

STOPPING UNIT
Unit Operating On Constant Speed —Close the air service
valve allow the unit to build up to full unloaded pressure
and press the OFF push button Stopping the unit at apres
sure below full receiver may cause oil carryover. The oil
reservoir will automatically blow down as the motor stops
If the unit is awater-cooled heat exchanger type close any
manual water inlet valves Open the air service valve
Unit Operating On Automatic Start-iStop —If the unit is
operating close the air service valve allow the unit to build
up to full receiver pressure and stop automatically, then
press OFF push button Stopping the unit at apressure
below full receiver may cause oil carry-over. If the unit is
stopped because of full receiver pressure or stopped on
unloaded time cuycle press OFF push button On water-
cooled heat exchanger units close any manual water inlet
valves Open air service valve
13-9-607 Section 3Page 2

SECTION 4
CONTROLS & INSTRUMENTS
GENERAL —The Gardner-Denver Model “ES” or “ECK’
Electra-Screw@ compressor units are available with four
different control systems:
Constant Speed
Automatic Start-Stop
Dual (Selective —Constant Speed or Automatic Start-Stop)
Duomatic (Selective —Constant Speed with Low Unloaded
Horsepower or Automatic Start —Timed Stop)
Unless voltage and starter enclosure size do not permit
mounting of the starter or customer specifications instruct
otherwise, the Electra-Screw@ unit is prewired with the
starter mounted and all starter to motor and control con-
nections for the voltage specified on the order. It is
necessary only to connect the unit to the correct power
supply, to the shop air line and to the shop water line, if the
unit is the heat exchanger type. The standard unit consists
of the compressor, oil reservoir and cooler, air and oil
filters, the control system specified, an open drip-proof
motor, NEMA Istarter enclosure and adust resistant
control enclosure/instrument panel all mounted on asteel
base and enclosed in an acoustic cabinet.
CONTROL VOLTAGE —The control voltage for the
start-stop push button, hourmeter, pressure switch, high
discharge temperature shutdown switch, blowdown valve,
and other electrical control devices is 115 volts regardless of
power supply voltage. Atrasnformer in the control enclo-
sure is connected to change the power supply voltage
to 115 volt control voltage.
ON-OFF SWITCH —The Constant Speed and theAutomatic
Start-Stopunits have an ON-OFF push button with an amber
lighted section to indicate when compressor is running.
The Dual control unit has apush button switch with CON-
OFF and AUTO- OFF sections for the two modes of opera-
tion and an amber lighted center section to indicate when
compressor is running.
The Duomatic control unit has an ON-OFF push button
with an amber lighted section to indicate “On” (com-
pressor running), and agreen lighted section to indicate
“Load” (compressor loaded). The black bar at the bottom of
this switch has no function.
To replace the bulb (Sylvania 120 PSB or equal) in any of
the switches:
1. Turn power off at main breaker panel.
2. Open control panel.
3. Turn slotted locking screw on upper side of switch
body counterclockwise 1/4 turn and remove switch
body from switch operator.
4. Remove old bulb located in stem of switch body and
insert new bulb.
5. Reassemble switch body to operator and lock in place
by turning locking screw 1/4 turn clockwise.
SAFETY DEVICES —All four control systems incorporate
these 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 a3-overload heater
table, since the use of athird overload derates each overload
for agiven enclosure due to the extra heat. An overload
from a2-overload heater table would be undersize.
The overload heaters are in acommon overload block in the
starter and have asingle common percentage adjustment
knob with a90 to 110% range. The knob is set at the
factory on the 100% mark.
High Air Temperature Shutdown —The compressor is
protected against high discharge temperatures by two shut-
down switches. One switch protects against lubrication fail-
ure by sensing the temperature of the compressed air dis-
charged from the compressor itself. The probe for this switch
is located in the discharge manifold between the compressor
and oil reservoir. The other switch protects against high
temperature in the oil separators. The probe for this switch
is located in the discharge air piping on top of the reservoir.
The switches are wired into the motor control circuit and will
shut the unit down if the discharge temperatures exceed
225° F. The switches have amanual reset button lo-
cated on top of the switch boxes and must be reset any
time the unit is shut down due to high air temperature.
Early units were supplied with only the high discharge tem-
perature switch which sensed the temperature of the com-
pressed air from the compressor itself. The location of the
probe and the manual resetting is as previously descibed for
the units with the two shutdown switches.
Circuit Breaker —Some units have aseparate push-to-
reset type circuit breaker for the high discharge temperature
shutdown switch located on the instrument panel (Figures
1-4, 2-4, 3-4, 4-4, 7-4, 8-4, 10-4 and 11-4). If atemperature
failure occurs, the circuit breaker button will pop up
indicating that the safety device has stopped the unit.
~WARNING
DO NOT CONTINUE TO RESET THE MANUAL
RESET (OR THE CIRCUIT BREAKER) IF THE
SAME MALFUNCTION OCCURS WITHIN ASHORT
PERIOD OF TIME. FIND AND CORRECT THE
TROUBLE BEFORE RESUMING OPERA TION.
Automatic Blowdown Valve (Figures 2-1, 5-1 &1-5) —A
solenoid valve piped into the oil reservoir final discharge
manifold between the minimum pressure valve and the
check valve and wired into the motor control circuit, will
release pressure from the oil reservoir each time the
motor stops on constant speed, (continued on page 8)
13-9-607 Section 4Page 1

SEE NOTE “H’~ HINGE -, BACK VIEW OF CONTROL BOX DOCR !FuSE- 250vA TRANSFORMER
BUSS FRN 21/4 OR EQuAL
NOTE
SOME MODEL COMPRESSOR HAVE 24CA41 PANEL MOUNT RESET --
cONNEtTl ONs ANO SCHEMATIC WIRING ARE AS SHOWN BELOW
CONTROL BOX SCHEMATIC WIRING
T
OVER TEMPERATURE
1456
;%’s”=
8*14R,4, 5,6,
8,9,10,11,13
DSA
4+-: 3A +SEE NOTE “C’,
‘E’ ‘“TE’’J’’R’’R’WL’”
:;:::u::: --}- Jl-LL>--------------------___+:_/l+= .~.coci,.
—VOLTS __; ~.L22_______ –––––––_-––––– –-_
_PHASE :\+., J2:YT;, 3
—HZ –L_;-L-3~– -––. .–. .––. __–-–_. .___~:_~,1~3> <~ J
pOWE;OSUPPLY
‘0~“%
,6 LIZ LZ2 L32
~M2
N
)M
G
5’65
L1 L2 L3
COMPRESSOR
POWER SUPPLY
—VOLTS
—PHASE
—HZ
J-<0> “=
SEE NOTE A“
DSAOL3(31
COMP SE P
—x3
NC
OVER TEMPERATuRE
MANUAL RESET BUTTON
ON TEMPERATURE SWITCH
PRESS TO RESET
OFF ON “ON “‘~’ (,
T
7
CONSTANT SPEED CONTROL
~AE 4ccQQL&R4c!S& Q)4-3> ~
‘----LW-VJ’E ‘S:g +-~ ;
13
I
3\
n
12
“L1,L2 c
6
L7
—
&
_MTR
OIL c
COOLER
13
‘<ON “‘@/ 4
,0 APS ,t M3 ,.
A-b !! 12“LcOOLER
Ml
,5 Ml ,6 ~oMp
,!4 BDv
+
@lR AFT-COOLER (IF USED)@&+
L—––– KKL(E 4>ED)-~-_ -.
ISEE NOTES
,“B BF“ k
83.
OFF
-1- ,.’)
b“
~-i____,
1/2<, CDT
5*14R 3,4,11 ,12,13-
REMOVE JUMPERS
~-~aTl~t~__~
F,;-c:T------ ‘1
5~12B L12, L22, L32,16, L2-
4Z14R 2,3,9,11- REMOVE
JUMPER 1215 8 ADD JUMPER
~12B WIRE) BETWEEN LI 0TB ID
-—r—. ———— ——
1FQWE;OSUPPLY
AUTO ST/ST CONTROL
SEE fiPS NOTE
13
AuTO. “ON” ‘ ‘
+0 .,,0:’:
,
,( M3 ,A.
r; ~‘L~E i
,,
CON 12M,OIL cOOLER Ml
40 I
15 16 COMP
APS MUST BE
SET 2-3 PSI 14 BDV
+0
BELOW PNEU
PILOT
IoFF AIR AF7-mOLER [IF USED) -$
F––––––––––––*+
ix+kJ L——.–M—WI~F—u~EW)*J
D75298 DUAL C; NTROL
SEE APS NOTE
FIGURE 1-4.
CONSTANT SPEED, AUTOMATIC START-STOP &DUAL CONTROL
(For Notes See Section 4, Pages 6@7)
—WIRING DIAGRAM —AIR-COOLED UNITS —
13-9-607 Section 4Page 2

.,
HINGE~, BACK VIEW OF CONTROL BOX DOOR
FUSE -250 VA TRANSFORMER
BuSS FRN 2-1/4 OR EOUAL-2 1/4 AMP
750 VA TRANSFORMER
BuSS FRN 0OR EQUAL -8 AMP
[Hj
10 A13
8N 0 10
HI
AUTO ST/ST
NOTE WIRING INSIDE UNITS WITH SEPARATE
..,. n., ,.. ,\,.., T! . . . !. . . . . .,,.
.,....-”.!. i. .,.,, ,.,. ,. . . . . . . .
40-c AMBIENT
IB]
10q A%13
8N10
8N 0II
24CA48
EN 0 10
DUAL
NOTE
SOME MODEL COMPRESSORS HAvE 24CA41 PANEL MOUNT RESET
,“...,,, ”.. . . . ., HFMAT, CW,R,NG &RE AS SHOWN ~~~~w
CONTROL Box
6Y
~7—J-DOOR LOOM- 5*14R 8, 9, 10, 11, 13- ). . . . . .
.0
1
BDV r+~l MWV WIRE *9 IS REMOVED FROM THE LOOM ~3,4, CDT
14 13 ~O_!g [I13 WHEN CONTROL IS AuTO ST/ST OR DUAL 514R [,4,9,11, 13
SCHEMATIC WIRING
OVER TEMPERATuRE
PRESS TO RESET
-—————— —
w
i
c
?21092
//
,-,:;.>_#E NOTE “C”
AFTER COOLER 1L12 ‘“ ‘OTE’’J’’%Rc~ LEDED
POWER SUPPLY –—; –Z––––– ––––––– –––––-- –––––-; }+, X,O--, AFT COOLER
_VOLTS __q 1L22 T2z)’- ~
—PHASE +-–––––– –––––––– ––-–-–––––; ke,la- MTR/
–.; _>zc_... ____________ i____i ~+,x,&33~A
COMPRESSOR
(L1’)
OSA 0L2(31
COMP SEP ,-—1
—x3
FuSE X2 -
POW ERT;UPPLY
m
P
TRANSFORMER
2~CA\59 (250vA) OR
2;2A139 (750vA1
H3 H4
230v 460v 575v
24 CA160 [250vA) OR
2’?~140 (750 VA)
208V 2;; V3;~V
r
—
m
‘1 @,,5, @l.
OVER TEMPERATuRE
MANuAL RESET BUTTON
ON TEMPERATuRE SWITCH
PRESS TO RESET OFF
~
6
L
1
CONSTANT
13
I
ON
6’
MTR ~
=1
cOMP ––L—–—.
~,q’ ~~~
3*1’2B LI’, L2’,16-
4*,4R ,,2,9,,, .REM~”E
JuMPER 12158 ADD JUMPER
@l<B ~lRE) BETWEEN Ll_’~B~5~
T—— FO— —
SEE NOTES
,,B ~ ~
L----- —
VENT FAN –1/2” CDT I
5*,4R 2,3,,,,,2,,3.
REMOVE JUMPERS
~-3a ,i.l, _J
TO
AUTO ST/ST CONTROL
SEE APS NOTE 4
#fi AFT-COOLER (IF uSED) ~-=~
~Myv (IF uSED) ,~,_n _;
[WATER-COOLED AFTERCO’OLER
13
IPOWE~ SU~PLY
FuSE BLOCK MTG DATA-SEE NOTE “DI”
Pi
~-–––
APPROX ARE~-1/2”L X3“ H- 1
MTG CTRS 21, -*29 DRILL( 1360)
TWO HOLES FOR *8 SELF TAPPING (1L12 121 L32 I
SCREWS FuRNISHED WITH FUSE
BLOCK AND FuSES F.:–, /
B
13
II
~~i;t-~ M2 ~
I[:~;. ,2
L2A..~ ,~L2(3)
DS& ???
“’v” ;
L–-––––d
6
LAUTO ‘<ON” ‘ ‘
WI F;W”” ‘AN d
IOFF
LX*,J :AE.FT.CO ~
–––QLJ~(fJ~E%kL +
LM—w~ (LF MsgD! ___ ,’~ ,: __ I
DUAL CONTROL (wATER-COOLED AFTERCOOtER
SEE APS NOTE
D75290
FIGURE 2-4. —WIRING DIAGRAM —WATER-COOLED UNITS —
CONSTANT SPEED, AUTOMATIC START-STOP &DUAL CONTROL
(For Notes See Section 4, Pages 6@7)
13-9-607 Section 4Page 3

SEE NOTE “H”
I<ql
BACK VIEW OF CONTROL BOX DOOR
HINGE
c0N7R0L 00x TIMER
, / \ FUSE -250VA TRANSFORMER
BUSS FRN 21/4 OR EOUAL 2I/4 AMPS
NOTE
SOME MODEL COMPRESSORS HAVE 24CA41 PANEL MOUNT RESE1
CONNECTIONS 4ND SCHEMATIC WIRING ARE AS SHOWN BELOW
BOX
\\\
&
OVER TEMP
PRESS TO RESET
SCHEMATIC WIRING
OVER TEMPERATURE
PRESS TO RESET
.___— — ————
e
6
.. . ..
<’.I4L g.14E~ 1
T1 000R LOO M-6 *14R 8,9, 10, II, 13 a 14 DOOR LOOM F21,92
8*14 R,4,5 ,6,
8,9, 10, II, I3
I
13/4” CDT
2=120 L1, L2
,5=14R 1,4,9,11,13,
AMw” ;H~N“~~~
1S REMOTE MOUNTED
AND WIRED BY
CUSTOMER
/
~-
*#,4~ 2*,4R
G+
5645
HDTS n~~~s
COMP
cNC. C. N.C
DSA
4. ‘–13A~SEE NOTE “C
AFTER COOLER
‘E’ ‘“’’’’’’-’’c””’”
4L’–FJ~Li3_____________ ––––_. _.. –+,–~.l-m FTC~LER
POWER SUPPLY ‘–~
_VOLTS ___l LL~>________________ –––__l–l L~,\~23;~T-R}
_PHASE I
-–l_+:z . . . . _________ –____ i+.,Jz} .,.
Z$’-:%:
TO
POWER SUPPLY
c
12 LI L2 L3
15
N
Ml
1
“J
1??
0Ll[31 T) T2 T3
17
COMP SEP
~HDTS
It!
OL2(3) T12 T22 T32
(=% ~5,,,Esai
COOLER –COMP –I
TIMED DUOMAT1r
SEE APS NOTE
➤–—l–––.7
,,2,, CDT
5*14R 3,4,11 ,12,13-
REMOVE JUMPERS
P-4 a11-12 –d
075299
FIGURE 3-4. –WIRING DIAGRAM —AIR-COOLED UNITS —
TIMED DUOMATIC CONTROL
(For Notes See Section 4, Pages 6@7)
13-9-607 Section 4Page 4
..-

AMP
LMOUNT RESET --
HOWN OELOW
SCHEMATIC WIRING
OVER TEMPERATuRE
PRESS TO RESET
.—— ——— ———
w
*=
+G
3645
HDTS HDTS
COMP SEP
cMC C NC
(
SEE NOTES
TO
POWER SUPPLY
~’ 2*14R 13, 18
#14~.GRD
T
,,B&F, MTR —1–—–—,
vENT FAN =~/27 COT
5*14R 2,3, 11,12,13-
REMOVE JUMPERS
@.~.y.~__ J
,IPowE:Osu~PLY
FuSE BLOCK MTG DATA-SEE NOTE ,01”
P
1
APPROX AREA 21/2” Lx3“ H
MTG CTRS 21’ 29 DRILL [1360]
TwO HOLES FOR 8SELF TAPPING II 12 L22U
SCREWS FURNISHED WITH FuSE
BLOCK AND FuSES
h
13
r--l>:> ~2Y
:, T
I:-12. !2
:~—, -—r
L-.< 0L2(3) ??2
DSA I
‘i:’w ‘
L––––-–J
D75292
13
!
/
DSA
>rTl 2A<SEE NOTE “C”
AFTER COOLER Tir T
POWER SUPPLY —–r”>Li2–- –––––––– —––
~,47FD$. .___-–
3*12B LI’, L2’, !6
4.14R 29,11. REMov E
;POWER SUPPLY
4_—
_VOLTS ..; I_L&Z_______ —–––– ___
—pHASE -——-—— ;:+.) -T2:2YM; ,
1L32
—H? –- JO_,- ––––. __ –____ ___ T94 A
–——––; :+,1.0 >
P
COMPRESSOR
DSA OL2(3) (L1’)
ri ti~~-+’:
CCUP SEP
60Ll[3)l X, —
—x3
k’ ;-. :
TR
c,, y2 ,2 FAN ~
Iclo ,5 CR ,6 ~~~p ,
‘R *M’ Mwv
H
TIMED DUO MATIC CONTROL p~~F Lc–~L11LFA$ED)4:& J
SEE APS NOTE MWV (IF USED) _,,,, _ J
[wATERCOOLED AFT ERCOOLE~)
WIRING DIAGRAM —WATER-COOLED UNITS —
TIMED DUOMATIC CONTROL
(For notes seesection 4,pages 6&7)
13-9-607 section 4Page 5