Gardner Denver ELECTRA-SAVER EAU PD - 200 HP Service manual

GARDNER DENVER
ELECTRA–SAVER
STATIONARY SCREW
COMPRESSOR
With AUTO SENTRY–ES CONTROLLER
MODELS
EAU_PD – 200 HP
EAU_QD – 250 HP
EAU_RD – 300 HP
OPERATING AND
SERVICE MANUAL
13–10–612
1st Edition
August, 1994

13–10–612 Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVERRAND JOY COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner DenverRand Joy Compressor genuine parts,
engineeredtooriginaltolerances,aredesignedforopti-
mumdependability–––specificallyforGardnerDenver
and Joy compressor systems. Design and material in-
novations are the result of years of experience with
hundreds of different compressor applications. Reli-
ability in materials and quality assurance are incorpo-
rated in our genuine replacement parts.
YourauthorizedGardner DenverRCompressordistrib-
utor offers all the backup you’ll need. A worldwide net-
workofauthorizeddistributorsprovidesthefinestprod-
uct support in the air compressor industry.Your local
authorized distributor maintains a large inventory of
genuinepartsandheisbackedupforemergencyparts
by direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
DenverRor Joy air compressor with these services:
Call Gardner Denver today for a quote.
1. Trained parts specialists to assist you in selecting
the correct replacement parts.
2. Factory warranted new and remanufactured
rotaryscrewair ends.Most popularmodelreman-
ufacturedairendsaremaintainedinstockatMDC
for purchase on an exchange basic with liberal
core credit available for the replacement unit.
3. AfulllineoffactorytestedAEONtcompressorlu-
bricantsspecifically formulatedfor use inGardner
Denver and Joy compressors.
4. Repair and maintenance kits designed with the
necessary parts to simplify servicing your com-
pressor.
Authorized distributor service technicians are factory–
trained and skilled in compressor maintenance and re-
pair. They are ready to respond and assist you by pro-
viding fast, expert maintenance and repair services.
For the location of your local authorized Gardner Denver 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]
(800) 245–4946
Fax: [phone]
REMANUFACTURED AIR ENDS
Whenever an air end requires replacement or repair,
Gardner Denver offers an industry unique, factory re-
manufactured air end exchange program. From its
modern Remanufacturing Center in Indianapolis, IN,
GardnerDenver iscommittedtosupplyingyou withthe
highest quality, factory remanufactured air ends that
are guaranteed to save you time, aggrevation and
money.
Immediately Available
Repair downtime costs you money, which is why there
are over 200 remanufactured units in inventory at all
times, ready for immediate delivery.
Skilled Craftsmen
Our Remanufacturing assembly technicians average
over 20 years experience with air compression products.
Precision Remanufacturing
All potentially usable parts are thoroughly cleaned, in-
spected and analyzed. Only those parts that can be
brought back to original factory specifications are re-
manufactured. Everyremanufactured airend receives
anewoverhaulkit: bearings,gears,seals,sleevesand
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
justdon’t do. Magnafluxand ultrasonicinspectionspot
cracked or stressed castings, monochromatic light
analysis exposes oil leaks, and coordinate measure-
ment machine inspects to +/– .0001”, insuring that all
remanufactured air ends meet factory performance
specifications.
Warranty
Gardner Denver backs up every remanufactured air
end with a new warranty . . . 18 months from purchase,
12 months from service.
GardnerDenverremanufacturedairendsdeliver
quali-
ty without question . . . year in and year out.
Call Gardner Denver for information on the air end ex-
change program and the name of your authorized dis-
tributor. Phone Number: 800–245–4946 or
FAX: [phone]

13–10–612 Page ii
FOREWARD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To
beassuredofreceivingmaximumservicefromthismachinetheownermustexercisecareinitsoperationandmain-
tenance.Thisbookiswrittentogivetheoperatorandmaintenancedepartmentessentialinformationforday–to–day
operation,maintenanceandadjustment.Careful adherenceto theseinstructions willresultin economicaloperation
and minimum downtime.
Danger is used toindicate the presenceof a hazardwhich will causesevere personal
injury, death, or substantial property damage if the warning is ignored.
Warning isusedto indicatethepresence ofahazard whichcancause severeperson-
al injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
Notice is used tonotify people of installation, operationor maintenance information
which is important but not hazard–related.
This book covers the following models:
HP PSI Air Cooled Water Cooled Parts List
200 100, 125, 150 EAUQPD EAUSPD 13–10–509
250 100, 125, 150 EAUQQD EAUSQD 13–10–509
300 100, 125, 150 EAUQRD EAUSRD 13–10–509

13–10–612 Page iii
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–10–612 Page iv
Acoustic Enclosure 9. . . . . . . . . . . . . . . . . . . . . . . . .
Actuator, Turn Valve 23. . . . . . . . . . . . . . . . . . . . . . .
Addition of Oil Between Changes 36. . . . . . . . . . . .
Aftercooler 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Machine 10. . . . . . . . . . . . . . . . . . . . .
Water–Cooled Machine 11. . . . . . . . . . . . . . . . . .
Aftercooler – Heat Exchanger Water Piping 14. . .
Air Control Components 23. . . . . . . . . . . . . . . . . . . .
Air Filter Vacuum 25. . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 23. . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure/Check Valve 24.
Pressure Regulator 23. . . . . . . . . . . . . . . . . . . . . .
Purge Air Valve 23. . . . . . . . . . . . . . . . . . . . . . . . .
Reservoir Pressure Transducer 25. . . . . . . . . . .
Shuttle Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valves IVC and IVO 23. . . . . . . . . . . . .
Solenoid Valves TVC and TVO 23. . . . . . . . . . . .
System Pressure Transducer 25. . . . . . . . . . . . .
Turn Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve Actuator 23. . . . . . . . . . . . . . . . . . . . . .
Vibration Switch 25. . . . . . . . . . . . . . . . . . . . . . . . .
Air Ends, Remanufactured i. . . . . . . . . . . . . . . . . . . .
Air Filter 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Vacuum Switch 25. . . . . . . . . . . . . . . . . . .
Air Filter, Heavy Duty
200 HP Units 46. . . . . . . . . . . . . . . . . . . . . . . . . . .
250 and 300 HP Units 47. . . . . . . . . . . . . . . . . . . .
Air Filter, Heavy Duty – 200 HP
Dust Cup 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Element 46. . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Element Life 46. . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 47. . . . . . . . . . . . . . . . . . . .
Air Filter, Heavy Duty – 250 and 300 HP
Dust Cup 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Element 47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Element Life 48. . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 48. . . . . . . . . . . . . . . . . . . .
AIR FILTERS, SECTION 6 48. . . . . . . . . . . . . . . . .
Air Flow 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . .
Air Receiver, Auxiliary 10. . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Machine, Aftercooler 10. . . . . . . . . . . .
Air–Cooled Oil Cooler Module 9. . . . . . . . . . . . . . . .
Auto Sentry–ES 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Mode Operation 26. . . . . . . . . . . . . . .
Constant Run Mode Operation 26. . . . . . . . . . . .
Control Transformer 25. . . . . . . . . . . . . . . . . . . . .
Emergency Stop 25. . . . . . . . . . . . . . . . . . . . . . . .
Fan Starter 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Demand Mode Operation 26. . . . . . . . . . . .
Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming and Setup Instructions 27. . . . . . .
Terminal Strip 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Air Receiver 10. . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 22, 23. . . . . . . . . . . . . . . . . . . . . .
Change Procedure, Lubricant 34. . . . . . . . . . . . . . .
Check CN7 (8, 9) 22. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Draining Oil System 37. . . . . . . . . . .
Clearing Advisories 26. . . . . . . . . . . . . . . . . . . . . . . .
Cold Ambient Operation 36. . . . . . . . . . . . . . . . . . . .
Cold Weather Operation, Installation 11. . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Capacity Control 22. . . . . . . . . . . . . . .
Compressor Oil Cooler (Radiator Type) 39. . . . . .
Compressor Oil Cooler – Water Cooled
Heat Exchanger 40. . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Filter 38. . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Separator 42. . . . . . . . . . . . . . . . . .
Inspection 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal for Inspection 43. . . . . . . . . . . . . . . . . . .
Separator Differential Gauging 42. . . . . . . . . . . .
Compressor Oil System 34. . . . . . . . . . . . . . . . . . . .
Control Piping 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Display 26. . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Advisories 26. . . . . . . . . . . . . . . . . . . . . .
CONTROLS & INSTRUMENTS, EAU UNITS,
SECTION 4 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–10–612 Page v
Controls and Instruments,General 20. . . . . . . . . . .
Cooler, Comressor Oil (Radiator Type) 39. . . . . . .
Cooler Module Air–Cooled Oil 9. . . . . . . . . . . . . . .
Cooling, Sealing and Lubrication 1. . . . . . . . . . . . .
COUPLING, SECTION 7 49. . . . . . . . . . . . . . . . . . .
Coupling 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Individual Cushion Design 49. . . . . . . . . . . . . . . .
Daily Check 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 6–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 13. . . . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 9. . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning Oil System 37. . . . . . . . . . .
Dust Cup 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dust Cup, Heavy Duty Air Filter 46. . . . . . . . . . . . .
Electric Motor Grease Recommendations 15. . . .
Electric Motor Regreasing Interval 15. . . . . . . . . . .
Electrical Wiring 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Element, Filter 45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Heavy Duty Air Filter 46, 48. . . . . .
Element, Heavy Duty Air Filter 46, 47. . . . . . . . . .
Emergency Stop Shutdown 22. . . . . . . . . . . . . . . . .
Enclosure, Acoustic 9. . . . . . . . . . . . . . . . . . . . . . . .
Extreme Cold Weather Operation 12. . . . . . . . . . .
Filling Oil Reservoir 38. . . . . . . . . . . . . . . . . . . . . . . .
Filter
Air 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air – Heavy Duty – 200 HP Units 46. . . . . . . . . .
Air – Heavy Duty – 250 and 300 HP Units 47. .
Compressor Oil 37. . . . . . . . . . . . . . . . . . . . . . . . .
Filter Element 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Element Life 45. . . . . . . . . . . . . . . . . . . . . . . . .
Foreward ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foundation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Oil Level 37. . . . . . . . . . . . . . . . . . . . . . . . . .
Gauges and Displays 22. . . . . . . . . . . . . . . . . . . . . .
Oil Filter Indicator 22. . . . . . . . . . . . . . . . . . . . . . .
Oil Level 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . .
Grease Recommendations, Electric Motor 15. . . .
Grounding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger (Oil) Piping 39. . . . . . . . . . . . . . . .
High Pressure 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature Operation 34. . . . . . . . . . . . . . . .
High Temperature Probes 21. . . . . . . . . . . . . . . . . .
High Vibration Shutdown 22. . . . . . . . . . . . . . . . . . .
Indicator, Oil Filter 22. . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Line 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 47, 48. . . . . . . . . . . . . . . . .
Inlet Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection, Oil Separator 42. . . . . . . . . . . . . . . . . . .
INSTALLATION SECTION 2 8. . . . . . . . . . . . . . . . .
Installation
Cold Weather 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Extreme Cold Weather 12. . . . . . . . . . . . . . . . . . .
General 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation for Cold Weather Operation 11. . . . . .
Lifting Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 13. . . . . . . . . . . . . . . . . . . .
Line, Inlet 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and General Piping 9. . . . . . . . . . . . . . . . .
Low Oil Pressure Protection 9. . . . . . . . . . . . . . . . .
Low Oil Pressure Shutdown 22. . . . . . . . . . . . . . . .
Lubricant Change Procedure 34. . . . . . . . . . . . . . .
Lubricant, Recommended 34. . . . . . . . . . . . . . . . . .
Lubrication, Cooling and Sealing 1. . . . . . . . . . . . .
Lubrication, Motor 15. . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 34. . . . . . . . . . . . . .

INDEX
13–10–612 Page vi
MAINTENANCE SCHEDULE, SECTION 8 50. . .
Maintenance Schedule 50. . . . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure/Check Valve 24. . .
Moisture in Oil System 37. . . . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 15. . . . . . . . . . .
Motor Lubrication 15. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Protection Devices 20. . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 15. . . . . . . . . . . . . . . . . .
Oil Change Interval 37. . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler
Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location and General Piping 9. . . . . . . . . . . . . . .
Low Oil Pressure Protection 9. . . . . . . . . . . . . . .
Ventilation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Module, Air–Cooled 9. . . . . . . . . . . . . . .
Oil Cooler Oil Pressure Differential (Air–Cooled
Radiator) 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Oil Pressure Differential (Water–
Cooled Heat Exchanger) 44. . . . . . . . . . . . . . .
Oil Cooler Pressure Differential (Water–Cooled
Radiator) 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Temperature Differential (Air–Cooled
Radiator) 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Temperature Differential (Water–
Cooled Radiator) 44. . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Compressor – Water Cooled
Heat Exchanger 40. . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Indicator 22. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Gauge 22, 38. . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 9. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Specifications 34. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System Check 43. . . . . . . . . . . . . . . . . . . . . . . . .
Air and Oil Discharge Temperature 43. . . . . . . .
Oil Cooler Oil Pressure Differential (Air–Cooled
Radiator) 44. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Oil Pressure Differential (Water–
Cooled Heat Exchanger) 44. . . . . . . . . . . . . .
Oil Cooler Pressure Differential (Water–Cooled
Heat Exchanger) 44. . . . . . . . . . . . . . . . . . . . .
Oil Cooler Temperature Differential (Air–Cooled
Radiator) 44. . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Temperature Differential (Water–
Cooled Heat Exchanger) 44. . . . . . . . . . . . . .
Oil Inlet Pressure 44. . . . . . . . . . . . . . . . . . . . . . . .
Oil System, Draining and Cleaning 37. . . . . . . . . .
Operation
Automatic Mode 26. . . . . . . . . . . . . . . . . . . . . . . . .
Cold Ambient 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Constant Run Mode 26. . . . . . . . . . . . . . . . . . . . .
Extreme Cold Weather 12. . . . . . . . . . . . . . . . . . .
High Temperature 34. . . . . . . . . . . . . . . . . . . . . . .
Low Demand Mode 26. . . . . . . . . . . . . . . . . . . . . .
Piping
Aftercooler – Heat Exchanger Water 14. . . . . . .
Control 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger (Oil) 39. . . . . . . . . . . . . . . . . . . .
Oil Cooler – Location and General 9. . . . . . . . . .
Water 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Failure Shutdown 22. . . . . . . . . . . . . . . . . . .
Pressure, Oil Inlet 44. . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Regulator 23. . . . . . . . . . . . . . . . . . . . . . . .
Prestart–up Instructions 16. . . . . . . . . . . . . . . . . . . .
Air Filter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil 16. . . . . . . . . . . . . . . . . . . . . . . . .
Coupling 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moisture Separator Trap 16. . . . . . . . . . . . . . . . . .
Operating Mode 17. . . . . . . . . . . . . . . . . . . . . . . . .
Piping 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 17. . . . . . . . . . . . . . . . . . . . . . . .
Programming & Setup for Auto Sentry–ES 27. . . .
Protective Devices, Advisories & Shutdowns 20. .
Blowdown Valve 22. . . . . . . . . . . . . . . . . . . . . . . . .
Check CN7 (8, 9) 22. . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 22. . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–10–612 Page vii
High Pressure 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 21. . . . . . . . . . . . . . . . . . . . . . .
High Vibration 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure 22. . . . . . . . . . . . . . . . . . . . . . . .
Motor Protective Devices 20. . . . . . . . . . . . . . . . .
Power Failure 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief Valve 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separator Differential Pressure 21. . . . . . . . . . . .
Purge Air Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . .
Receiver, Auxiliary Air 10. . . . . . . . . . . . . . . . . . . . . .
Recommended Lubricant 34. . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 15. . . . . . . . . .
Regulator, Pressure 23. . . . . . . . . . . . . . . . . . . . . . .
Relief Valve 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of Oil Separator for Inspection 43. . . . . .
Reservoir Pressure Transducer 25. . . . . . . . . . . . .
Reservoir, Filling Oil 38. . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions 4–5. . . . . . . . . . . . . . . . . . . . . . .
Sealing, Lubrication and Cleaning 1. . . . . . . . . . . .
Separator Differential Gauging 42. . . . . . . . . . . . . .
Separator Differential Pressure 21. . . . . . . . . . . . . .
Separator, Compressor Oil 42. . . . . . . . . . . . . . . . .
Sequencing Compressors 17. . . . . . . . . . . . . . . . . .
Automatic Sequence Change 19. . . . . . . . . . . . .
Controlling Pressure while Sequencing 18. . . . .
Establishing Initial Sequence 18. . . . . . . . . . . . . .
Installation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Features 19. . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE CHECK LIST, AIR FILTER 50. . . . . . . .
Service Check List 50. . . . . . . . . . . . . . . . . . . . . . . .
Every 1000 Hours Operation 50. . . . . . . . . . . . . .
Every 125 Hours Operation 50. . . . . . . . . . . . . . .
Every 6000 Hours Operation 50. . . . . . . . . . . . . .
Every 8 Hours Operation 50. . . . . . . . . . . . . . . . .
Every Year 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 50. . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator 50. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Line, Discharge 13. . . . . . . . . . . . . . . . . . . .
Shuttle Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valves IVC and IVO 23. . . . . . . . . . . . . . .
Solenoid Valves TVC and TVO 23. . . . . . . . . . . . . .
Specifications, Oil 34. . . . . . . . . . . . . . . . . . . . . . . . .
Starter, Electrical Wiring 14. . . . . . . . . . . . . . . . . . . .
Starter/Control Panel 25. . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES
SECTION 3 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Switch
Air Filter Vacuum 25. . . . . . . . . . . . . . . . . . . . . . . .
Vibration 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure Transducer 25. . . . . . . . . . . . . . .
Table of Contents iii. . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal Control (Thermostatic Mixing) Valve 40.
Transducer
Reservoir Pressure 25. . . . . . . . . . . . . . . . . . . . . .
System Pressure 25. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING, SECTION 9 51. . . . . . . . .
Trouble Shooting, Auto Sentry ES Controller
Advisories 54. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve 1, 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve Actuator 23. . . . . . . . . . . . . . . . . . . . . . . .
Valve
Blowdown 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure/Check Valve 24.
Purge Air 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid IVC and IVO 23. . . . . . . . . . . . . . . . . . .
Solenoid TVC and TVO 23. . . . . . . . . . . . . . . . . .
Thermal control (Thermostatic Mixing) 40. . . . .
Turn 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX
13–10–612 Page viii
Water Flow Control for Heat Exchanger 41. . . .
Water Shutoff, Water–Cooled
Heat Exchanger 42. . . . . . . . . . . . . . . . . . . . .
Ventilation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation, Oil Cooler Module 9. . . . . . . . . . . . . . . .
Vibration Switch 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Flow Control Valve for
Heat Exchanger 41. . . . . . . . . . . . . . . . . . . . . . .
Water Piping, Water–Cooled
Heat Exchanger 13. . . . . . . . . . . . . . . . . . . . . . .
Water Piping, Aftercooler – Heat Exchanger 14. .
Water Shutoff Valve – Water–Cooled
Heat Exchanger 42. . . . . . . . . . . . . . . . . . . . . . .
Water–Cooled Machine, Aftercooler 11. . . . . . . . .
Wiring, Electrical 14. . . . . . . . . . . . . . . . . . . . . . . . . .

13–10–612 Page ix
LIST OF ILLUSTRATIONS
Figure 1–1 Compression Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 Package – Unit with Water Cooled Aftercooler 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–3 Package – Unit with Water Cooled Aftercooler 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–4 Starter Box 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–5 Package – Controller and Starters 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–1 Typical Compressor Room 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Minimum Air Flow for Compression and Cooling, (Cubic Feet/Minute) 8. . . . . . . . . . . .
Figure 2–3 Piping Schematic 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–4 Piping Diagram for Aftercooler and Heat Exchanger 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–5 Installation for Cold Weather Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–6 Inlet Line Lengths 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–7 Heat Exchanger (Oil Cooler) Approximate Water Flow 13. . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–8 Aftercooler Approximate Water Flow 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–1 Schematic Tubing Diagram 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Inlet Valve 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Blowdown Valve 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Shuttle Valve 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Turn Valve 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Minimum Discharge Pressure Valve (Older Models) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Minimum Discharge Pressure Valve (Current Models) 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–8 Control Schematic – Compressor at Full Load 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–9 Control Schematic – Compressor Fully Loaded – Low Demand Mode 31. . . . . . . . . . . .
Figure 4–10 Wiring Diagram 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–11 Auto Sentry–ES Controller Display 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Flow Diagram – Air/Oil System 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Oil System Capacities 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Oil Change Interval 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–4 Compressor Oil Filter 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–5 Oil Flow Diagram – Remote Overhead Mounted Oil Cooler 39. . . . . . . . . . . . . . . . . . . . . .
Figure 5–6 Thermal Control (Thermostatic Mixing) Valve 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–7 Water Control Valve 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–8 Dew Point Temperature vs. Ambient Temperature 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–9 Single–Element Oil Separator 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–10 Discharge Temperature Chart 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy–Duty Air Filter, 200 HP 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–2 Heavy–Duty Air Filter, 250 & 300 HP 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Installation of Coupling Cushions 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–10–612 Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSION CYCLE
COMPRESSOR – The Gardner DenverRElectra–
SaverRcompressor is a single–stage, positive dis-
placementrotarymachineusing meshinghelicalrotors
to effect compression. The input drive shaft and helical
drive gear are supported in the gear case by high ca-
pacity tapered roller bearings. The drive gear meshes
with a driven gear mounted on the main rotor shaft to
drive the rotors. Both rotors are supported between
largecapacityanti–frictionbearingslocatedoutsidethe
compression chamber. Single–width cylindrical roller
bearings are used at the inlet end of the rotors. Early
models used two (2) heavy–duty, single–row, angular
contact ball bearings at the discharge end to locate
each rotor axially and carry all thrust loads; later mod-
els use tapered roller bearings in this location.
COMPRESSION PRINCIPLE (FIGURE 1–1) – Com-
pression is accomplished by the main and secondary
rotors synchronously meshing in a one–piece cylinder.
Themain rotorhas four(4)helical lobes90_apart. The
secondary rotor has five (5) matching helical grooves
72_apart to allow meshing with main rotor lobes.
The air inlet port is located on top of the compressor
near the center. 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 dis-
charge 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 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 com-
pression and seal internal clearances. Volume reduc-
tion and pressure increase continues until the air/oil
mixture trapped in the interlobe cavity by the rotors
passesthedischargeportandisreleasedtotheoilres-
ervoir(C). Each rotor cavityfollows the same”fill–com-
press–discharge” cycle in rapid succession to produce
a discharge air flow that is continuous, smooth, and
shock–free.
AIR FLOW (FIGURE 1–2 and FIGURE 1–3, Page 2)
–Airenterstheairfilterandpassesthroughtheinletun-
loadervalve to thecompressor. Aftercompression, 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 separa-
tor; the separated oil is returned to the system through
tubing connecting the separator and compressor. The
air passes through the reservoir discharge manifold,
discharge check valve, minimum pressure valve and
the customer furnished unit shutoff globe valve to the
plant air lines.
LUBRICATION, COOLING, AND SEALING – Oil is
forcedbyair pressurefromtheoilreservoir throughthe
oil cooler, thermal control (thermostatic mixing) valve
and oil filter and discharges into the compressor main
oilgallery.Aportionoftheoilisdirectedthroughinternal
passagestothebearings,gears,andshaftoilseal.The
balance of the oil is injected directly into the compres-
sion chamber to remove the heat of compression, seal
internal clearances, and lubricate the rotors.
TURN VALVE – The turn valve is a rotary helical valve
locatedonthedischargesideofthecylindertowardthe
inletend.Thevalveopensandclosesportsinthecylin-
der which communicates with the inlet passage. This
varies the compressor rotor volume to match the de-
mand for air, thus reducing the part–load power re-
quirement.

13–10–612 Page 2
FIGURE 1–2 – PACKAGE – UNIT WITH WATER COOLED AFTERCOOLER
FIGURE 1–3 – PACKAGE – UNIT WITH WATER COOLED AFTERCOOLER

13–10–612 Page 3
FIGURE 1–4 – STARTER BOX
FIGURE 1–5 – PACKAGE – CONTROLLER AND STARTERS

13–10–612 Page 4
SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances
cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for
safety hazards and be cautious. Some general safety precautions are given below:
Failure to observe these notices could result in injury to or death of personnel.
DKeep fingers and clothing away from revolving fan, drive coupling, etc.
DDo not use the air discharge from this unit for breathing – not suitable for hu-
man consumption.
DDonot loosen orremove theoil fillerplug, drainplugs, covers,the thermostat-
icmixingvalve orbreakanyconnections,etc., inthecompressorairor oilsys-
tem until the unit is shut down and the air pressure has been relieved.
DElectrical shock can and may be fatal.
DCompressor unit mustbe grounded inaccordancewith the National Electrical
Code. A ground jumper equal to the size of the equipment ground conductor
must be used to connect the compressor motor base to the unit base.
DFan motors must remain grounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.
DOpen main disconnect switch, tag and lockout before working on the control.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.

13–10–612 Page 5
Failure to observe these notices could result in damage to equipment.
DStop the unit if any repairs or adjustments on or around the compressor are
required.
DDisconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit – this machine is automatically controlled and may
start at any time.
DAn Excess Flow Valve should be on all compressed air supply hoses ex-
ceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)
DDonot exceed the ratedmaximum pressure values shownon the nameplate.
DDo not operate unit if safety devices are not operating properly. Check peri-
odically. Never bypass safety devices.

13–10–612 Page 6
DECALS
206EAQ077 212EAQ077
218EAQ077
211EAQ077 207EAQ077

13–10–612 Page 7
DECALS
216EAQ077
217EAQ077
222EAQ077
221EAQ077 208EAQ077

13–10–612 Page 8
SECTION 2
INSTALLATION
GENERAL– On receipt of theunit, check for any dam-
agethatmayhavebeenincurredduringtransit. Report
any damage or missing parts as soon as possible.
Do not electric weld on the compres-
sor or base; bearings can be damaged
by passage of current.
LIFTING UNIT
Lift compressor unit by base only. Do
not use other places such as the mo-
tor, compressor or discharge man-
ifold piping as lifting points.
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 warning may result in damage to
equipment or personal injury.
LOCATION (FIGURE 2–1) – The compressor should
be installed in a clean, well–lighted, well–ventilated
areawith ample spaceall around formaintenance. Se-
lecta location 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
a proper air supply.
The compressor unit requires electric motor cooling air
aswellasairtothecompressorinlet.Properventilation
MUST be provided (FIGURE 2–2); hot air must be ex-
hausted from compressor operating area. A typical in-
let–outletairflowarrangementisshowinFIGURE2–1.
If the air–cooled oil cooler module is to be installed at
a location remote from the compressor unit, be sure
that adequate ventilation is provided, FIGURE 2–2.
Hot air must be exhausted from the oil cooler area.
Do not block the air flow to and from the unit. Allow
3–1/2 feet to the nearest obstruction on the control box
side of the unit and 3 feet on all other sides.
FIGURE 2–1 – TYPICAL COMPRESSOR ROOM
* 80oF Inlet Air
FIGURE 2–2 – MINIMUM AIR FLOW FOR COMPRESSION
AND COOLING (CUBIC FEET/MINUTE)
Open Unit
With Oil
Open Cooler Module
Compr. Oil Cooler Discharge In
Size Unit Module Same Room
200 HP 8,000 23,000 31,000
250 HP 9,900 24,800 33,900
300 HP 11,900 24,000 35,900
VENTILATION – The unit, whether air– or water–
cooled, requires sufficient air flow, FIGURE 2–2, for
electric motor cooling. Air is drawn into the back and
front of motor and is discharged out the sides. Do not
block air flow to and from the unit.
FOUNDATION – The Electra–Savercompressor re-
quiresno specialfoundationbutshouldbe mountedon
asmooth, solid surface ofsufficientstrengthtosupport
the weight of the unit. Whenever possible, install the

13–10–612 Page 9
unit near level. Temporary installation may be made at
a maximum of 10_angle lengthwise or 30_sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt,ordanger ofshiftingfromoutsidevibrations ormov-
ing vehicles may require the use of mounting bolts to
the foundation.
OIL RESERVOIR DRAIN (FIGURE 1–3, page 2) –
The oil reservoir drain valve is located near the center
of the oil reservoir just below the separator tower. The
drain valve is approximately five (5) inches from the
floor level. If this height is not sufficient toconveniently
drain the oil, some other methods of providing oil drain
are:
1. Elevate the compressor unit on the foundation to
obtain the desired drain height.
2. Construct an oil sump or trough below the floor
level and pump or bail the drained oil.
3. Pump oil from the reservoir filler opening or reser-
voir drain to a container.
ACOUSTICENCLOSURE – The Electra–Saver unit is
furnishedwithanacousticenclosureoverthecompres-
sor only, as standard equipment. The enclosure re-
ducesthenormaloperatingsoundoftheunitto90DBA
or below in free field conditions.
AIR–COOLED OIL COOLER MODULE – The air–
cooled oil cooler is a separate module and may be
mounted remote to the compressor unit.
Ventilation – The oil cooler requires adequate cooling
air flow. Proper ventilation MUST be provided, with hot
air exhausted away from the cooler; take care that hot
air is not recirculated from the exhaust to the inlet side
ofthecooler.Coolingairflowdirectionisfromthemotor
side through the grille side of the oil cooler. Do not ob-
struct the air flow to or from the cooler. Allow two (2)
feet clearance on all sides of the cooler module. See
FIGURE 2–2, page 8, for cooling air flow require-
ments.
LowOil Pressure Protection–The standardfactory–
installed low oil pressure shutdown is incorporated in
the functions of the Auto Sentry ”ES” Controller, and
willpreventstart–uporshuttheunitdownifoilpressure
is not established or maintained due to malfunction in
the oil cooler system.
Oil Cooler – Location and General Piping – The oil
coolermodulecanbemountedinanyofseveralremote
locations: close coupled but not joined to the compres-
sor unit; horizontal remote, located on the same level
as the compressor unit, but some distance away; or
overhead remote, located above level of the compres-
sor unit, as on a roof.
The low demand mode switch cannot
be used with remote overhead oil
coolers. These units require special
wiring diagram – check with the facto-
ry. Use of low demand switch with an
overhead cooler could result in dam-
age to the compressor.
All piping and wiring between the compressor unit and
the remote oil cooler is to be supplied by the user. The
design of the remote oil cooler module system
must be approved by the Factory before installa-
tion. The design information to be submitted for ap-
proval includes:
1. Locationof oil cooler module–inside or outdoors.
2. Range of operating ambient temperatures at the
oil cooler location.
3. Elevation of the oil cooler above the compressor
unit.
4. Pipe type and size(s) to be used to connect the oil
cooler and the compressor unit. Minimum pipe
size is 2” NPT.
5. Horizontal and vertical lengths of the pipe run. If
morethanonepipesizeisused,listlengthofeach
size and total length.
6. Number and size of elbows, tees, unions, reduc-
ers, and valves to be used in the pipe run.
7. A dimensional sketch of the proposed piping sys-
tem showing location of the compressor unit, oil
cooler, and pipe and fittings of 3 through 6 above.
All remote piping should be of adequate size to insure
the minimum pressure loss. Number 4 above lists the
pipesize at thecompressor unitoilinlet andoutlet con-
nectionsandistheminimumpipesizetobeused.Long
runs of pipe and the use of valves and fittings require
larger than the minimum pipe sizes in the system to
keep the pressure loss low. All pipe and fittings used in
a remote oil cooler system should be galvanized or
treated internally to prevent rust, and all valves are to
be of a nonferrous construction to prevent corrosion
and fouling.
The remote cooler should be placed so that the fan air
flow through the cooler (air flow is from motor side
throughcore ) andthe prevailingwindsare inthe same
direction. A baffle should be provided on the exhaust
sideofthecoolerforprotectionagainstoccasionalwind
shifts.

13–10–612 Page 10
FIGURE 2–3 – PIPING SCHEMATIC
When the oil cooler is mounted above the compressor
unit,acheckvalveis tobe mountedon thecompressor
unit in the line to the oil cooler; see FIGURE 5–5, page
39. A pneumatic pilot–operated normally–closed valve
is to be mounted at the oil filter inlet on the compressor
unit line from the oil cooler; see FIGURE 5–5, page 39.
The check valve permits oil flow to the oil cooler during
operation, but prevents return oil flow from the cooler
whenthe unit isshut down. Thepilot valve isheld open
by air pressure from the unit oil reservoir during opera-
tion and closes under spring load when the unit is shut
down to prevent return oil flow from the oil cooler.
An oil filler stand pipe and plug must be located in the
pipingon theoil cooler modulefor easeoffilling ofa re-
mote oil cooler, see FIGURE 5–4, page 38.
Oil Cooler – Installation – Inspect the unit upon arriv-
al. In case of damage, report immediately to the trans-
portationcompany.Beforeinstallation,checktherating
plate on the motor to verify that power input and motor
specification requirements match available electric
power at the point of installation.
1. Set the unit level on a firm, solid foundation. The
larger oil cooler models have lifting holes to facili-
tate unit hoisting.
2. Allow for linear expansion and contraction of pip-
ing in the direction away from the oil cooler. Use
flexibleconnectorsorsuitable expansionjointson
all oil cooler inlet and outlet piping. See
FIGURE 2–3 for typical schematics.
3. Select properly tensioned and aligned piping sup-
port clamps or hangers and position them to re-
lieve any piping stress at the oil cooler inlet and
outlet ports. Do not support from flexible connec-
tors.
4. Service – For continuous efficiency, oil cooler
cores must be periodically cleaned with either
vacuum or compressed air. If wet cleaning is re-
quired, shield motor and spray on a mild soap
solution and flush with clear water.
For aluminum oil coolers do not use
any cleaning solution that is not com-
patible with aluminum. Use of im-
proper solution may result in damage
to the cooler.
AUXILIARY AIR RECEIVER – The unit requires an
auxiliary air receiver unless the piping system is large
andprovidessufficientstoragecapacitytopreventrap-
idcycling.Whenused,anairreceivershouldbeofade-
quatesize,providedwithareliefvalveofpropersetting,
a pressure gauge, and a means of draining conden-
sate.
AFTERCOOLER (FIGURE 1–2 and FIGURE 1–3,
page2)–Anaftercoolerwillprovidecontrolofmoisture
entering the shop air lines while reducing the normal
low discharge temperature of about 180_F at 100
PSIG discharge pressure to near inlet air temperature,
or cooling water temperature.
Air–Cooled Machines – When an aftercooler is fur-
nished on an air–cooled machine, the aftercooler is
installed on the oil cooler module between the fan and
the oil cooler. The moisture separator is furnished by
GardnerDenver but mustbe mounted by thecustomer
between the aftercooler and the auxiliary air receiver
with a condensate drain provided at the bottom. All air
piping from the compressor discharge to aftercooler to
auxiliary air receiver is to be furnished and mounted by
the customer. The design of the aftercooler piping