Gardner Denver Electra-Screw EDEQHF Service manual

GARDNER DENVER@ 13-8-610
3rd Edition
January, 1994
ELECTRA-SCREW@ STATIONARY
BASE-MOUNTED COMPRESSORS
MODELS
EDEQHF -40 HP
EDEQJF -50 HP
60 HZ
OPERATING AND
SERVICE MANUAL

MAfNTAfNCOMPRESSOR RELIABILITYAND PERFORMANCE WfTH
GENUINE GARDNER DENVER AND JOY COMPRESSOR
PARTSAND SUPPORT SERVICES
Gardner Denver and Joy Compressor genuine parts,
engineered to original tolerances, are designed for op-
timum dependability --- specifically for Gardner-Denver
and Joy compressor systems. Design and material in-
novations are the result of years of experience with
hundreds of different compressor applications.
Reliability in materials and quality assurance are incor-
porated in our genuine replacement parts.
Your authorized Gardner Denver and Joy Compres-
sor distributor offers all the backup you’ll need. A
worldwide network of authorized distributors provides
the finest product support inthe air compressor industry.
Your local authorized distributor maintains alarge inven-
tory of genuine parts and he is backed up for emergency
parts by direct access to the Gardner Denver Machinery
Inc. Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
Denver or Joy air compressor with these services:
1.
2.
3.
4.
Trained parts specialists to assist you in selecting
the correct replacement parts.
Factory warranted new and remanufactured rotary
screw air ends. Most popular model remanufac-
tured air ends are maintained in stock at MDC for
purchase on an exchange basic with liberal core
credit available for the replacement unit.
Afull line of factory tested AEON ‘M compressor
lubricants specifically formulated for use inGardner
Denver and Joy compressors.
Repair and maintenance kits designed with the
necessary parts to simplify servicing Your compres-
sor.
Authorized distributor service technicians are fac-
tory-trained and skilled in compressor maintenance
and repair. They are ready to respond and assist you
by providing fast, expett maintenance and repair
services.
For the location of your local authorized Gardner-Denver and Joy Air Compressor distributor refer to the yellow
pages of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: [phone]
Phone: [phone] Fax: [phone]
Fax: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, required per unit, quantity is indicated in parenthesis.
Method of Cooling, HORSEPOWER and SERIAL NUM- SPECIFY EXACTLY THE NUMBER OF PARTS RE-
BER (see nameplate on unit). Serial Number is also QUIRED.
stamped on top of the cylinder flange to the right of the
inlet housing. DO NOT ORDER BY SETS OR GROUPS.
All orders for Parts should be placed with the nearest
authorized distributor. To determine the Right Hand and Left Hand side of a
compressor, stand at the motor end and look toward the
Where NOT specified, quantity of parts required per compressor. Right Hand and Left Hand are indicated in
compressor or unit is one (l); where more than one is parenthesis following the part name, i.e. (RH) &(LH).
AIR ENDS
NOTE: Factory warranted new and rebuilt air ends are available from your authorized Gardner Denver and Joy
Compressor Distributor.

FOREWARD
Gardner Denver Electra-Screw@ compressors are the result of advanced engineering and skilled manufacturing. To
be assured of receiving maximum service from this machine the owner must exercise care in its operation and
maintenance. This book is written to give the operator and maintenance department essential information for
day-to-day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical
operation and minimum downtime.
~DANGER
IDanger is used to indicate the presence of ahazard which will cause severe personal
injury, death, or substantial propery damage if the warning is ignored. I
II
~WARNING
IWarning is used to indicate the presence of ahazard which can cause severe personal
injury, death, or substantial propery damage if the warning is ignored. I
~CAUTION
Caution is used to indicate the presence of ahazard which will or can cause minor
personal injury or propery damage if the warning is ignored.
NOTICE
INotice is used to notify people of installation, operation or maintenance information
which is important but not hazard-related. I
This book covers the following models:
HP PSIG Air Cooled Parts List
40 100, 125, 150, 175 EDEQHF 13-8-510
50 100, 125, 150, 175 EDEQJF 13-8-510
TABLE OF CONTENTS
GENERAL INFORMATION ............................................................................................................................. SECTION 1
INSTALLATION ............................................................................................................................................... SECTION 2
STARTING AND OPERATING PROCEDURES ............................................................................................. SECTION 3
CONTROLS AND INSTRUMENTS ................................................................................................................. SECTION 4
LUBRICATION, OIL COOLER, OIL FILTER AND SEPARATOR ................................................................... SECTION 5
AIR FILTERS ................................................................................................................................................... SECTION 6
BELT DRIVE ................................................................................................................................................... SECTION 7
MAINTENANCE SCHEDULE ......................................................................................................................... SECTION 8
TROUBLE SHOOTING ................................................................................................................................... SECTION 9
13-8-610 Page i

INDEX
NOTE: Numbers preceding dash are Section Numbers -- Numbers following dash are Page Numbers
Addition of Oil Between Changes ...............................5-2
Air Control Components .............................................4-2
Air Cooled Unit installation ..........................................2.l
Air Filter Element, Heavy Duty ....................................6-1
Air Filter Element, Standard Duty................................6-2
Air Filter Element Life, Heavy Duty..............................6-l
Air Filter Element Life, Standard Duty.........................6-2
Air Filter Element Servicing Instructions .............6-1, 6-2
AIR FILTER (SECTION 6) .. . .......................................6-1
Air Flow in the Compressor System ...........................l-l
Air Receiver, Auxiliay ..................................................2.3
AUTO-LAG Button with LED........................................4-3
AUTO-LEAD Button with LED .....................................4-3
Auto Sentry S-Auto Lag Button .................................4-3
Auto Sentry S-Auto Lead Button...............................4-3
Auto Sentry S-Constant Run Button .........................4-3
Auto Sentry S-Control Pad Diagram .........................4-8
Auto Sentry S-Controller with Keypad ......................4-3
Auto Sentry S-Emergency Stop Pushbutton ............4-3
Auto Sentry S-Hourmeter ..........................................4.3
Auto Sentry S-Lead-Lag operation ...........................4-6
Auto Sentry S-Programming and Set-Up
instructions ..........................................................4.4
Auto Sentry S-Stop/Reset Button .............................4-3
Auxiliay Air Receiver ...................................................2.3
Basic information .........................................................l.l
BELT DRIVE (SECTION 7) ..........................................7-1
Belt Tension, ChecMng ................................................7.l
Blowdown Valve ..........................................................4.2
Blowdown Valve Piping ...............................................2.4
CHANGE AIR FILTER LED ..........................................4-4
CHANGE SEPARATOR LED .......................................4-4
Check, Daily .................................................................3.2
Check, Pre-Start-Up ....................................................3.l
Cold Ambient Operation ..............................................5-2
Cold Weather Operation ..............................................2.2
Compression Principal ................................................l.l
Compressor Oil Cooler ................................................5.5
Compressor Oil Filter ..................................................5.4
Compressor Oil System ..............................................5-1
Compressor System, Air Flow ....................................l-l
CONSTANT RUN Button with LED .............................4-3
Control Piping ..............................................................2.3
CONTROLS AND INSTRUMENTS (SECTION 4) .......4-1
Control System Operation ...........................................4.3
AUTO LAG Button with LED................................4-3
13-8-610
AUTO LEAD Button with LED .............................4-3
CHANGE AIR FILTER LED..................................4-4
CHANGE SEPARATOR LED...............................4-4
CONSTANT RUN Button with LED.....................4-3
HIGH AIR TEMPERATURE LED .........................4-3
MOTOR OVERLOAD LED...................................4-4
Pressure and Temperature Digital Readouts .....4-4
STOP/RESET Button with LED ...........................4-3
Cooler, Compressor Oil ..............................................5.5
Cooling, Lubrication and Sealing ...............................1-1
Daily Check ..................................................................3-2
Decals ...................................................................l.7. 1-8
Definitions of Error Messages .....................................4.4
Discharge Service tine ...............................................2.3
Drain, Oil Resewoir .....................................................2.2
Draining and Cleaning The Oil System ......................5-3
Electrical Wiring...........................................................2.4
Element, Air Filter .................................................6.l. 6-2
Emergency Stop Pushbutton .....................................4-3
Enclosure ....................................................................2.2
Error Messages -Definitions.......................................4.4
Extreme Cold Weather Operation, Installation...........2-3
Filling Oil Reservoir ....................................................5.3
Filter, Nr ................................................................6.l. 6-2
Filter, Compressor Oil .................................................5.4
Filter Element ........................................................6.l. 6-2
Filter Element tife .................................................6.l. 6-2
Foundation .................................................................2.l
Gauge, Oil Sight ...................................................4.2. 5-3
GENERAL INFORMATION (SECTION 1) ..................1-1
Grease Recommendations, Electric Motor ................2-4
Grounding ....................................................................2.4
Heavy Duty Air Filter....................................................6.l
HIGH AIR TEMPERATURE LED..................................4-3
High Discharge Temperature Shutdown ....................4-l
High Temperature Operation .....................................5-1
Hourmeter ....................................................................4.3
Inlet Line ....................................................................2.3
Inlet Line Lengths ........................................................2.3
Inlet Tube, Air Filter .....................................................6.l
Inlet Valve ...................................................................4.2
INSTALLATION (SECTION 2) ....................................2-1
Page ii

INDEX (Continued)
NOTE: Numbers preceding dash are Section Numbers -- Numbers following dash are Page Numbers
installation, Air Cooled Unit.........................................2-l
installation for Cold Weather Operation. ....................2-2
instruments ..................................................................4.2
Lead-Lag Operation of TWOCompressors .................4-6
LED -Change Air Filter................................................4.4
LED -Change Separator .............................................4.4
LED -High Air Temperature ........................................4.3
LED -Motor Overload ..................................................4.3
Lifting Unit ...................................................................2.1
Load-Unload Pressure Setpoints, Programming .......4-4
Location .......................................................................2.l
Lubricant, Addition of Oil Between Changes ..............5-2
Lubricant, Changing Type of Oil .. ............................5-1
Lubricant, Draining and Cleaning System ..................5-3
Lubricant, Oil Specifications .......................................5-1
Lubricant, Recommended.. .........................................5-1
Lubricant Change lntewal ...........................................5.3
Lubricant Change Procedure ......................................5-1
Lubrication, Cooling and Sealing ................................l-l
Lubrication, Motor .......................................................2.4
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5).. ...............................5-1
MAINTENANCE SCHEDULE (SECTION 8) ...............8-1
Minimum Pressure/Check Valve ................................4-3
Moisture in the Oil System .........................................5-3
Moisture Separator/Trap .............................................2-3
Motor Grease Recommendations ...............................2.4
Motor Lubrication .......................................................2.4
MOTOR OVERLOAD LED ...........................................4-4
Motor Regressing lntewal ...........................................2.5
Motor Protection Devices ...........................................4-1
Oil Change lntewal ......................................................5.3
Oil Cooler, Compressor ...............................................5.5
Oil FiIter........................................................................5.4
Oil Level Gauge ..........................................................5.3
Oil Pressure Differential Gauging, Oil Cooler .............5-6
Oil Resewoir .................................................................5.5
Oil Reservoir Drain.......................................................2.2
Oil Reservoir, Filling.....................................................5.3
Oil Separator ................................................................5.5
Oil Separator -Inspection ...........................................5-6
Oil Separator -Pressure Differential Gauging ............5-5
Oil Separator- Removal ..............................................5.6
Oil Sight Gauge ....................................................4-2, 5-3
13-8-610
Oil Specifications .........................................................5.l
Oil System Check ...................................................... 5-6
Air and Oil Discharge Temperature ....................5-6
Compressor Oil Inlet Temperature .....................5-6
Oil Cooler Oil Pressure Differential
(Air-Cooled Radiator) .....................................5-6
Oil Cooler Temperature Differential
(Air-Cooled Radiator) .....................................5-6
Oil Inlet Pressure .................................................5.6
Oil System, Compressor .............................................5.l
Oil System, Draining &Cleaning ................................5-3
Operating Alr Pressure Adjustment ............................4-7
Operation
Cold Weather ......................................................2.2
Extreme Cold Weather ........................................2-3
High Temperature ...............................................5-l
Optional Motor Protective Devices
Wye Delta Stafler ................................................4.l
Ordering Instructions, Repair Parts ............................... ii
Outline Drawings ...........................................l.2. 1-3, 1-4
Piping, Blowdown Valve..............................................2.4
Piping, Control.............................................................2.3
Precautions, Safety ..............................................l.5. 1-6
Pressure and Temperature Digital Readouts .............4-4
Pressure Differential, Oil Cooler Oil............................5-6
Pressure, Oil inlet ........................................................5.6
Pressure, Separator Differential..................................4-l
Prestart-Up Instructions ..............................................3-1
Prestarting Check
Air Filter ...............................................................3.l
Compressor Oil ...................................................3.l
Electrical ..............................................................3.l
Enclosure ............................................................3.2
Grounding ...........................................................3.l
Operating Mode ..................................................3.2
Piping...................................................................3.l
Rotation ...............................................................3.l
System Pressure .................................................3.l
Programming Load-Unload Pressure Setpoints ........4-4
Protective Devices.......................................................4.l
Protective Devices
Blowdown Valve ..................................................4.2
Motor Protective Devices....................................4-l
Relief Valve ..........................................................4.l
Receiver. Auxiliay Mr..................................................2.3
Recommended Lubricant ...........................................5-1
Page iii

INDEX (Continued)
NOTE: Numbers preceding dash are Section Numbers -- Numbers following dash are Page Numbers
Regressing Interval, Electric Motor .............................2-5
Relief Valve ....... .
...........................................................4-l
Reservoir, Oil................................................................5.5
Safety Precautions .............................................. 1-5, 1-6
Sealing, Lubrication and Cooling ................................l-l
Separator Differential Pressure Shutdown .................4-1
Separator/Trap, Moisture ............................................2-3
Service Check tist .......................................................8.l
Air Filter................................................................8.l
Every Year ...........................................................8-1
Motor Lubrication ................................................8.l
Oil Separator ........................................................8.l
8Hours Operation ...............................................8-l
125 Hours Operation ...........................................8-1
1000 Hours Operation .........................................8-1
4000 Hours Operation .........................................8-1
6000 Hours Operation .........................................8-1
Service Line, Discharge ...............................................2.3
Shutdowns
High Discharge Temperature ..............................4.l
Separator Differential Pressure ...........................4-l
Specifications, Oil ........................................................5.l
Starter/Control Box (Components) .............................4-3
AUTO IAG Button with LED................................4-3
AUTO LEAD Button with LED .............................4-3
Auto Sentry “S”Controller with Keypad ..............4-3
CHANGE AIR FILTER LED ..................................4-4
CHANGE SEPARATOR LED ...............................4-4
CONSTANT RUN Button with LED .....................4-3
Emergency Stop Pushbutton ..............................4.3
HIGH AIR TEMPERATURE LED..........................4-3
Hourmeter ...........................................................4.3
MOTOR OVERLOAD LED...................................4-4
Pressure and Temperature Digital Readouts .....4-4
STOP/RESET Button with LED ...........................4-3
Starter, Wye-Delta (Optional) .....................................4-l
STARTING &OPERATING PROCEDURES
(SECTION 3) ..........................................................3.l
Starting The Unit, Cold ................................................3.2
Starting The Unit, Hot..................................................3.2
Stop, Emergency (Pushbutton) ..................................4-3
STOP/RESET Button with LED ...................................4-3
Stopping The Unit ......................................................3-2
Subtractive Pilot ..........................................................4.7
Temperature Differential, Oil Cooler ...........................5-6
Temperature, Air& Oil Discharge ...............................5-6
Temperature, Compressor Oil inlet ............................5-6
Thermostatic Mixing Valve .........................................5-5
TROUBLE SHOOTING (SECTION 9) ........................9-1
Tube, Inlet....................................................................6.l
Unload-Load Pressure Setpoints, Programming .......4-4
Valve, Blowdown .........................................................4.2
Valve, Inlet ...................................................................4.2
Valve, Minimum Pressure/Check ................................4-3
Valve, Relief .................................................................4.l
Wiring Diagram ............................................................4.9
Wiring, Electrical..........................................................2.4
Wye.Delta Statier ........................................................4.l
13-8-610 Page iv

ILLUSTRATIONS
No. Description Page
1-1
1-2
1-3
1-4
2-1
2-2
2-3
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-1o
5-1
5-2
5-3
5-4
5-5
6-1
6-2
7-1
Compression Cycle................................................................................................................................. 1-1
Package -Minimum Pressure/Check Valve, Mixing Valve &Oil Filter.................................................. 1-2
Package -Oil Level Gauge, Separator &Air Filter................................................................................. 1-3
Package -Controller& Starter Box........................................................................................................ 1-4
Typical Compressor Room .....................................................................................................................2-1
Minimum Air Flow Chafl .........................................................................................................................2.l
Cold Weather installation........................................................................................................................2.2
Control Schematic .................................................................................................................................. 4-1
Inlet Valve ................................................................................................................................................4.2
Minimum Pressure/Check Valve.............................................................................................................4.2
Definitions of Error Messages ................................................................................................................4.4
Pressure Chati ........................................................................................................................................ 4-6
Subtractive Pilot (Closed) .......................................................................................................................4.6
Subtractive Pilot (Opened) .....................................................................................................................4.6
Maximum Setpoints for Auto-Sentry SController, PSIG .......................................................................4.8
Auto-Sentry SSolid State Control Touch Pad .......................................................................................4.8
Wiring Diagram ....................................................................................................................................... 4-9
Flow Diagram -Air-Oil System ...............................................................................................................5-1
Approximate Oil System Capacities .......................................................................................................5.2
Thermostatic Mixing Valve......................................................................................................................5-3
Dew Point Temperature vs. Ambient Temperature Chati .....................................................................5-5
Oil Separator ........................................................................................................................................... 5-5
Standard Air Filter ................................................................................................................................... 6-1
Heavy Duty Air Filter (Optional) ..............................................................................................................6-1
Belt Tension 5VX Belts............................................................................................................................ 7-1
13-8-610 Page v

SECTION 1
GENERAL INFORMATION
FIGURE 1-1 -COMPRESSION CYCLE
COMPRESSOR -The Gardner Denver@ compressor
is asingle stage, positive displacement rotary machine
using meshing helical rotors to effect compression. Both
rotors are supported between high capacity roller bear-
ings located outside the compression chamber. Single
width cylindrical roller bearings are used at the inlet end
of the rotors to carry part of the radial loads. Tapered
roller bearings at the discharge end locate each rotor
axially and carry allthrust loads and the remainder ofthe
radial loads.
COMPRESSION PRINCIPLE (Figure 1-1) -Compres-
sion isaccomplished by the main and secondary rotors
synchronously meshing in aone-piece cIinder. The
main rotor has four (4) helical lobes 90 apart. The
secondary rotor has six (6) matching helical grooves 60°
apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor
cylinder near the drive shaft end. The discharge port is
near the bottom at the opposite end of the compressor
cylinder. Figure 1-1is an inverted view to show inlet and
discharge ports. The compression cycle begins as the
rotors unmesh at the inlet port and air is drawn into the
cavity between the main rotor lobes and the secondary
rotor grooves (A). When the rotors pass the inlet port
cutoff, air is trapped in the interlobe cavity and flows
axially with the meshing rotors (B). As meshing con-
tinues, more ofthe main rotor lobe enters the secondary
rotor grove, 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 airflow that iscontinuous, smooth
and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure
5-1, page 1, Section 5) -Airenters the airfilterand passes
through the inlet unloader valve and on into the com-
pression chamber where oil is injected into the air. After
compression, the air/oil mixture passes intothe oil reser-
voir 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 piping and the air/oil separator. The air then
passes through the minimum pressure/check valve, the
aftercooler and the moisture separator and intothe plant
air lines.
LUBRICATION, COOLING AND SEALING -Oil is
forced by air pressure from the oil reservoir through the
oil cooler, thermostatic mixing valve, and oil filter and
discharged into the compressor main oil gallery. Apor-
tion of the oil is directed through internal passages to
the bearings, gears and shaft oil seal. The balance ofthe
oil is injected directly into the compression chamber to
remove heat of compression, seal internal clearances
and lubricate the rotors.
13-8-610 Section 1Page 1

\
PRESSURERELIEFVALVE MOISTURESEPERATOR
TMINIMUMPRESSUREICHECKVALVE 1
MA=‘r --
III II;F’T’F’RI
A1111111111
AUu “’’’’’’’’’11111
IIIIl“i’l”l-i’~pflLF!
1111111111 III
o
IL co0LER
I,,, ,,, , !!, ,,, ,,
OIL RESERVOIR 1[
By_pAss pipING
OIL FILTER THERMALCONTROL
(MIXING)VALVE
FIGURE 1-2- PACKAGE-MINIMUMPRESSURE/CHECKVALVE,MIXINGVALVE&OILFILTER
13-8-610 Section 1Page 2

AIR/OIL SEPERATOR
OIL FILLER PLUG
AIR FILTER
I
1\
—
OIL LEVEL FLOAT GAUGE
RESERVOIROIL DRAIN
FIGURE 1-3 -PACKAGE-OIL LEVELGAUGE,SEPARATOR& AIR FILTER
13-8-610 Section 1Page 3

STARTER/CONTROL BOX=
CONTROL PANEL
HOURMETER
-EMERGENCY STOP BUTTON
FIGURE 1-4- PACXAGE- CONTROLLER&STARTER BOX
13-8-610 Sectionl Page4

SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances
cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for
safety hazards and be cautious. Some general safety precautions are given below:
DANGER
Failure to observe these notices could result in injury to or death of personnel.
.KeeP finGers and clothinG awav from revolving fan, drive coupling, etc.
●Do not use the air discharae from this unit for breathing -not suitable for
human consumption.
●Do not loosen or remove the oil filler plug, drain plugs, covers, the thermo-
static mixing valve or break any connections, etc. in the compressor air or
oil system until the unit is shut down and the air pressure has been relieved.
●Electrical shock can and may be fatal.
●coMPresso runit must be arounded in accordance with the National Electri-
cal Code. Aground jumper equal in size to the equipment ground conductor
must be used to connect the compressor motor base to the unit base.
.Fan motors and must remain arounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.
.OPen main disconnect switch, tag and lockout before working on the control.
●Disconnect the compressor unit from its power source, tag and lockout
before working on the unit-this machine is automatically controlled and may
start at anytime.
13-8-610 Section 1Page 5

WARNING
Failure to observe these notices could result in damage to equipment.
●StoP the unit if any repairs or adjustments on or around the compressor are
required.
.Disconnect the compressor unit from its power source, tag and lockout before
working on the unit -this machine is automatically controlled and may start at
any time.
.An Excess Flow Valve should be on all compressed air supply hoses exceed-
ing 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)
.Do not exceed the rated maximum Pressure values shown on the nameplate.
●Do not ope rate unit if safety devices we not operating properly. Check
periodically. Never bypass safety devices.
13-8-610 Section 1Page 6

DECALS
DISCHARGE AIR USED FOR
BREATHING WILL CAUSE
SEVERE INJURY OR DEATH.
CONSULT FILTRATION
SPECIALI ST FOR
ADDITIONAL FILTRATION
AND TREATMENT EQUIPMENT
TO MEET HEALTH AND
SAFETY REGULATIONS. -
206EAQ077
HIGH vOLTAGE.
ROTATING MACHINERY.
AIR ANo OIL
UNDER PRESSURE,
IMPROPER MODIFICATION
OF EQUIPMENT WILL
CAUSE SEVERE PERSONAL
INJURY OR DEATH.
—
ROTATING MACHINERY CAH
CAUSE 1NJUR% OR DEATH.
KEEP ALL GUAROS AND
SAFETY DEVICES IN
PLACE.
a-
211EAQ077
AIR AND OIL UNOER PRESSURE
WILL CAUSE SEVERE PERSONAL
NJURY OR DEATH.
HUTDOWN COMPRESSOR ANO
ELIEVE SYSTEM OF ALL
PRESSURE BEFORE REMOVING
VALVES, CAPS. PLUGS,
FITTINGS. BOLTS ANO FILTERS.
212EAQ077
DO NOTMODIFY
UNITWITHOLIT
WRITTEN PERMISSION
FROMMANUFACTURER.
218EAQ077
UNIT CAN AUTOMATICALLY
RESTART.
CAN CAUSR PIRSONAL INJUR
OR OEATH.
KNOW MODS OF 0PERATION
BEFORE WORKING ON OR
NSAR THE MACHINE. -
207EAQ077
13-8-610 Section 1Page 7

DECALS
ELECTRICAL SHOCK FROM
IMPROPER GROUNDING CAN
CAUSE INJURY OR DEATH.
GROUND UNIT AND RELATED
EQUIPMINT ACCORDING TO
NATIONAL ELECTRIC COOE
AND LOCAL REGULATIONS.
—
216EAQ077
AIR AND OIL UNDER
PRESSURE.
CANCAUSESEVERE
PERSONALINJURY
ORDEATH.
INSPECTOIL RESERVOIR
FORCRACKSAT LEAST
ANNUALLY. -
217EAQ077
J
ELECTRICAL SHOCK CAN
CAUSE INJURY OR DEATH.
DISCONNECT ALL CIRCUITS
BEFORE WORKING ON THIS
CONTROL.
SEE WIRING DIAGRAM.
222EAQ077
ELECTRICAL ARCING CAN
CAUSE AFIRE WHEN UNIT IS
MOUNTEO ON AcOMBUSTIBLE
SURFACE RESULTING IN
PiRSONAl INJURY OR
PRoPERTY OAMAGE.
UNIT MUST BE MOUNTID ON
AFLOOR PLATE EXTENDING
ON ALL SIOES.
SEE INSTALLATION
DRAWING FoR PROPER
DIMENSIONS. -
221EAQ077
@
MACHINE DAMAGE OR INJURY
CAN OCCUR DUE TO IMPROPER
LIFTING.
00 NOT LIFT MACH INF. WITH
THE MO1OR LYEBOLT.
I—1
208EAQ077
13-8-610 Section 1Page 8

SECTION 2
INSTALLATION
GENERAL -On receipt of unit, check for any damage
that may have been incurred during transit. RepoRtany
damage or missing parts as soon as possible.
~CAUTION
Do not electric weld on the compressor
or base; bearings can be damaged by
passage of current.
LIFTING UNIT -Proper lifting and/or transporting
methods must be used to prevent damage.
~CAUTION
Lift compressor unit by base only. Do
not use other places such as enclosure,
motor, compressor oil discharge
manifold and piping as lifting points.
~DANGER I
The eyebolts or lugs provided on the
motor are for lifting the motor only and
should not be used to lift any additional
weight. All eyebolts must be securely
tightened. When lifting the motor the
lifting angle must not exceed 15
degrees. Failure to observe this warn-
ing may result in damage to equipment
or personal injury.
Lifting slots are provided in the base for towmotor use.
Unit may also be moved into location by rolling on bars.
LOCATION -The compressor should be installedwhere
it is protected from rain, snow and freezing tempera-
tures, in aclean, well-lighted, well-ventilated area with
ample space all around for maintenance. Select aloca-
tion that provides acool, clean, dry source ofair. In some
cases it may be necessary to installthe air filter at some
distance from the compressor to obtain proper air supp-
ly.
AIR-COOLED UNIT -Acombination oil/aftercooler is
supplied as standard equipment on all air-cooled units.
The air-cooled unit with the standard enclosure requires
sufficient flow, Figure 2-2, for the compressor oil/after-
cooling system and electric motor cooling. Air isdrawn
into the unit at the motor side of the enclosure and is
exhausted at the oil cooler side. Do not block the airflow
to and from the unit. Allow three (3) feet to the nearest
obstruction on the starter end and control box end ofthe
unit. Allow two (2) feet to the nearest obstruction above
and on other sides of unit. For continuous efficiency, oil
cooler cores must be periodically cleaned with either
vacuum or compressed air. If wet cleaning is required,
shield motor and spray on amild soap solution and flush
with clean water. - -
~WARNING
For aluminum oil coolers, do not use
any cleaning solution that is not com-
patible with aluminum. Use of improper
solution may result in damage to
cooler.
FOUNDATION -The Electra-Screw@ comPressor re-
quires no special foundation, but should be mounted on
asmooth, solid surface. Whenever possible install the
unit near level. Temporary installation may be made at a
maximum 10° angle lengthwise or 10° sidewise.
Mounting bolts are not normally required. However, in-
stallation conditions such as piping rigidity, angle of tilt,
LOUVERED ExHAUST FAN LO UVEREO
A75119
FIGURE2-1 -TYPICAL COMPRESSOR ROOM
IMinimum Air Flow* For Compressor
And CoolinG (Cubic Feet/Minute)
I I Air Cooled
IAll Models I6500 cfm
*80”F inlet air
FIGURE2-2
13-8-610 Section 2Page 1

MOTOR TrCOMPRESSOR
AWAY FROM PREVAILING WINDS
/’”-8FT. PLYWOOD FENCE’” 8FT. PLYWOOO “FENCE”
fWELL MAN RADIANT 2-ELEMENT
HEATER (OR EOUAL)
RH400 WITH (21 RH4502
ELEMENTS -2REQD.
5,200 WATTS EACH 7
4FT.
VP ‘._ //
/
—OIL RESERVOIR \’ ●/
\/
WELLMANRADIANT 2-ELEMENT
HEATER (oR EOUA)
RH7000 WI TH (2) RH7502
ELEMENTS -2REOD
6.200 WATTS EACH
FIGURE2-3- COLD WEATHER INSTALLATION
ELEVATION VIEW
or danger of shifting from outside vibration or moving
vehicles may require the use of mounting bolts and
shims to provide uniform support for the base. Belt
alignment and tension should be checked after installa-
tion. (For information on belt alignment and tension see
Section 7, page 1.)
OIL RESERVOIR DRAIN -The oildrain ispiped from the
botTomof the reservoir to the side ofthe frame. Thisdrain
is approximately 2inches above the floor level. If this is
not sufficient to conveniently drain the oil some other
methods of providing drain are:
1. Elevate the comPressor unit on asuitable structure
to obtain the deSired drain height,
~CAUTION
If the compressor unit base is raised
above floor level, the space between
the floor and the base bottom must be
closed with solid material all around to
prevent recirculation of hot air from the
oil cooler end and over temperature
operation.
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.
ENCLOSURE -The compressor, electric motor, oil
cooler and afTercooler are mounted insidethe enclosure.
Service doors are provided for maintenance access. Be
sure to allow enough space around the unitfor the doors
to open completely.
Any ofthe enclosure doors maybe removed by opening
the door and liftingitup slightiyto disengage the hinges.
I~DANGER
Do not operate compressor with fan
and belt guard removed. Exposed fan
and belts may cause injury to person-
nel.
The motor inspection/air filter service panel is held by
two latches and lifts away from the enclosure. The air
outlet panel is attached by screws to the enclosure and
is not readily removable.
INSTALLATION FOR COLD WEATHER OPERATION
-It is recommended that the unit be installed inside a
shelter that will be heated to temperatures above freez-
ing (32”F, O“C).This will eliminate many of the problems
associated with operating units in cold climates, such as
freezing in control lines and downstream of the cooler.
Refer to Engineering Data Sheet 13-9-411 for the ad-
vantages of using the heat recovered from rotary com-
pressors. This heat recovery could easily pay for an
adequate shelter for the unit.
When an outside installation must be made, the precau-
tions required will depend on how severe the environ-
ment. The following are general guidelines for outside
installations:
Cold Weather (Down To +10”F)
1. Be sure all drains, traps and control lines including
pressure transducer linesare heated to avoid freez-
ing of condensate. Heat tape with thermostat con-
trol is generally satisfactory for this purpose and
‘;
13-8-610 Section 2Page 2

can be obtained at various local plumbing or
hardware outlets at nominal cost.
2. Ifan air-cooled aftercooler isto be used, provisions
to bypass the aftercooler must be made. Since cold
air contains very little moisture, successful opera-
tion can be achieved without the aftercooler.
3. Provide at least some simple shelter such as a
plywood windbreak to protect against drifting
snow.
4. Use only Gardner-Denver@ AEON ‘M 9000 SP
lubricant.
5. Monitor unit carefully during start-up and operation
to be sure it isfunctioning normally.
6. Specify NEMA 4enclosure for electrical devices.
Extreme Cold Weather Operation (Down To -40”F)
In addition to the above, the following should be
provided:
1.
2.
3.
It will be necessary to provide shutters or to block
off part of the cooler in some manner since the
cooler isgreatly oversized for operation inthese low
temperatures. Since shutters are not provided as
afactory option, blocking offaportion of the cooler
with plywood should be satisfactory.
In extreme environments, run the unit in “Constant
Speed” only.
Some means of ProvidinG heat during shutdown
should be provided. TherE are various-methods to
accomplish this, but since openings are not
provided for sump heaters, the use of radiant
heaters is recommended. The heaters should be
sized to provide at least a+10°F environment for
coolers, motor and sump. Figure 3-2 shows how
these might be located in atypical installation 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 com-
plications in the operation and installation of the unit.
Refer to Engineering Data Sheet 13-9-411, available from
an authorized Gardner Denver distributor, for the ad-
vantages of using the heat recovered from rotary com-
pressors. This heat recovery could easily pay for an
adequate shelter for the unit.
AUXILIARY AIR RECEIVER -An auxiliary air receiver is
not required if the piping system is large and provides
sufficient storage capacity to prevent rapid cycling.
When used, an air receiver should be of adequate size,
provided with arelief valve of proper setting, apressure
gauge and ameans of draining condensate.
MOISTURE SEPARATOR/TRAP -Since unit is
equipped with abuilt-inaftercooler, acombination mois-
ture separator and trap isfurnished with the unit.
CONTROL PIPING -Control piping is not necessary
since the Electra-Screw@ unit isfactory wired and piped
for the control system specified.
INLET LINE -Where an inlet line is used between the air
filter and the compressor, it must be thoroughly cleaned
on the inside to prevent dirt or scale from entering the
compressor. If welded construction is used, the line
must be shot blasted and cleaned to remove welding
scale. In either case, the inlet line must be coated
internally by galvanizing or painting with amoisture and
oil-proof sealing lacquer. Up to ten (1O) feet in length,
the inlet line should be the full size of the inlet opening
on the compressor. If an extra-long line is necessary,
the pipe size should be increased according to Inlet Line
Chart below.
Accessibility for inlet air filter servicing must be con-
sidered when relocating the filters from the unit to a
remote location.
DISCHARGE SERVICE LINE -The discharge service
line connection is made at the upper right hand corner
of the cooler, viewed from the oil cooler side. Ahand
operated valve, (air service valve) must be installed be-
tween the unit and the customer’s air system. When
manifolding two or more Electra-Screw” units on the
same line, each unit is isolated by the check valve inthe
unit discharge line. If an Electra-Screw@ unit is
manifolded to another compressor, be sure the other
compressor has acheck valve in the line between the
machine and the manifold. If an Electra-Screw” and a
reciprocating compressor are manifolded together, an
air receiver Rust be located between the two units.
DANGER
Discharge air used for breathing will
cause severe injury or death.
Consult filtration specialists for addi-
tional filtration and treatment equip-
ment to meet health and safety
standards.
INLET LINE LENGTHS
Length of Inlet Line Diameter of Pipe Size
Oto 10 Feet .......................................................................................................... Same as Compressor Inlet Opening
10to 17 Feet ..........................................................................................................One Size Larger Than Inlet Opening
17t038 Feet ........................................................................................................Two Sizes Larger Than Inlet Opening
13-8-610 Section 2Page 3

BLOWDOWN VALVE PIPING -The blowdown valve is
fitted with amuffler for operation indoors. ifthe installa-
tion requires, the muffler may be removed and the blow-
down valve piped to the outside with apipe sizethe same
as the blowdown valve outlet connection.
ELECTRICAL WIRING -Standard Units -The Electra-
Screw@ compressor is factory wired for all starter to
motor and control connections for the voltage specified
on the order. It is necessary only to connect the unit
starter to the correct power supply. The standard unit is
supplied with an open drip-proof motor, aNEMA 12
starter and control enclosure. See “Location”paragraph
fordistanceto nearest obstruction on statterand control
box sides of the unit.
The overload heaters are to be selected according to
starter manufacturer’s tables, which are attached to the
inside of the control box, based on motor nameplate full
load amperage.
wARNING
Electrical shock can cause injury or
death. Open main disconnect switch,
tag and lockout before working on
starter/control box.
GROUNDING -Equipment must be grounded inaccor-
dance with Section 250 of the National Electrical Code.
WARNING
Failure to properly ground the com-
pressor package could result in con-
troller malfunction.
MOTOR LUBRICATION -Long time satisfactory oper-
ation of an electric motor depends in large measure on
proper lubrication of the bearings. The following charts
show recommended grease qualities and regressing
intervalsfor ball bearing motors. For additional informa-
tion refer to the motor manufacturer’s instructions.
The following procedure should be used in regressing:
1. Stop the unit.
2. Disconnect, tag and lockout the unit from the
power supply.
3. Remove the relief plug and free hole of hardened
grease.
4. Wipe lubrication fitting clean and add grease with
ahand-operated grease gun.
5. Leave the relief plug temporarily off. Reconnect
unit and run for about 20 minutes to expell the
excess grease.
6. Stop the unit. Replace the relief plug.
7. Restart the unit.
wARNiNG
Rotating machinery can cause injury or
death. Open main disconnect, tag and
lockout before working on electric
motor.
ELECTRIC MOTOR GREASE RECOMMENDATIONS
Worked Penetration .......................................................................................
Grease Viscosity, SSU At 100°F .....................................................................
Soap Type ......................................................................................................
N-H Bomb, Minimum Hours For20 PSI Drop at 21O”F.................................
Bleeding, Maximum Weight % In 500 Hours 212°F. .....................................
Rust inhibiting..................................................................................................
Standard
Service
265-296
400-550
Lithium
750
10
Yes
High
Temperature
220-240
475-525
Lithium
1000
3
Yes
13-8-610 Section 2Page 4

ELECTRIC MOTOR REGRESSING INTERVAL
Type of Service Typical Examples Rating Relubrication Interval
Standard One- or Two-Shift Operation 150 HP& Below 18 Months
Severe Continuous Operation 150 HP &Below 9Months
Very Severe Dirty Locations, High 150 HP& Below 4Months
Ambient Temperature
13-8-610 Section 2Page 5