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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .