Gardner Denver ELECTRA-SAVER EAY Service manual

GARDNER DENVER
ELECTRA–SAVER
STATIONARY BASE–MOUNTED
COMPRESSORS
AUTO SENTRY–ES+ CONTROLS
AUTO SENTRY–ES CONTROLS
MODEL
EAY
OPERATING AND
SERVICE MANUAL
13–10–613
3rd Edition
January, 1998

13–10–613 Page i
MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner Denver Compressor genuine parts, engine-
ered to original tolerances, are designed for optimum
dependability–––specificallyforGardnerDenvercom-
pressor systems. Design and material innovations are
theresultofyearsofexperiencewithhundredsofdiffer-
ent compressor applications. Reliability in materials
and quality assurance are incorporated in our genuine
replacement parts.
Your authorized Gardner Denver Compressor distribu-
tor 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
genuinepartsandheisbackedup foremergencyparts
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 air compressor with these services:
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 basis with liberal
core credit available for the replacement unit.
3. AfulllineoffactorytestedAEONtcompressorlu-
bricantsspecifically formulatedfor use inGardner
Denver 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 iscommitted tosupplying youwith the
highest quality, factory remanufactured air ends that
are guaranteed to save you time, aggravation 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]

13–10–613 Page ii
FOREWORD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To
beassuredofreceivingmaximumservicefromthismachinetheownermustexercisecareinitsoperationandmain-
tenance.Thisbookiswrittentogivetheoperatorandmaintenancedepartmentessentialinformationforday–to–day
operation,maintenance andadjustment.Careful adherenceto theseinstructions willresult ineconomical operation
and minimum downtime.
Danger is used toindicate the presenceof a hazard whichwill cause severepersonal
injury, death, or substantial property damage if the warning is ignored.
Warning isusedto indicatethe presenceofahazard whichcan causesevere person-
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:
Controller
HP PSIG Air Cooled Water Cooled Parts List Manual
350 100, 125, 150 EAYQSE EAYSSE 13–10–510 13–9/10–647
International EAYQSE EAYSSE 13–10–514X 13–9/10–647
400 100, 125, 150 EAYQTE EAYSTE 13–10–510 13–9/10–647
International EAYQTE EAYSTE 13–10–514X 13–9/10–647
500 100, 125, 150 EAYQVE EAYSVE 13–10–510 13–9/10–647
International EAYQVE EAYSVE 13–10–514X 13–9/10–647

13–10–613 Page iii
TABLE OF CONTENTS
Maintain Compressor Reliability and Performance With Genuine Gardner Denver Compressor Parts
and Support Services i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remanufactured Air Ends i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1, General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2, Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3, Starting & Operating Procedures 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4, Controls & Instrumentation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 6, Air Filter 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 7, Coupling 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8, Maintenance Schedule 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 9, Trouble Shooting 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER(see nameplateonunit). The SerialNumber
isalso stampedon topof thecylinder flangeto theright
of the inlet housing.
All orders for Parts should be placed with the nearest
authorized distributor.
Where NOT specified, quantity of parts required per
compressor or unit is one (1); where more than one is
required per unit, quantity is indicated in parenthesis.
SPECIFY EXACTLY THE NUMBER OF PARTS
REQUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left Hand side of a
compressor, stand at the motor end and look toward
the compressor. Right Hand and Left Hand are
indicated in parenthesis following the part name, i.e.
(RH) & (LH), when appropriate.

INDEX
13–10–613 Page iv
Actuator, Turn Valve 21. . . . . . . . . . . . . . . . . . . . . . .
Addition of Oil Between Changes 30. . . . . . . . . . . .
Aftercooler 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR FILTER, SECTION 6 39. . . . . . . . . . . . . . . . . . .
Air Filter 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Filter Element Life 39, 40. . . . . . . . . . . . . . . . . .
Air Filter Vacuum Switch 22. . . . . . . . . . . . . . . . . . .
Air Filter, Dust Cap 40. . . . . . . . . . . . . . . . . . . . . . . .
Air Filter, Heavy–Duty – 350 & 400 HP Units 39. .
Air Flow in the Compressor System 1. . . . . . . . . . .
Air Receiver, Auxiliary 11. . . . . . . . . . . . . . . . . . . . . .
Air–Cooled Oil Cooler Module 9. . . . . . . . . . . . . . . .
Auto Sentry Operation 18. . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Change Procedure, Lubricant 29. . . . . . . . . . . . . . .
Check, Daily 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Draining Oil System 31. . . . . . . . . . .
Cold Ambient Operation 30. . . . . . . . . . . . . . . . . . . .
Cold Weather Operation 12. . . . . . . . . . . . . . . . . . .
Cold Weather Operation, Installation for 12. . . . . .
Compression Principle 1. . . . . . . . . . . . . . . . . . . . . .
Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Capacity Control – Turn Valve
Units Only 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Cooler 33. . . . . . . . . . . . . . . . . . . . .
Compressor Oil Filter 32. . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Separator 36. . . . . . . . . . . . . . . . . .
Compressor Oil System 28. . . . . . . . . . . . . . . . . . . .
Compressor Oil System Check 38. . . . . . . . . . . . . .
Control Devices 18. . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Transformer 22. . . . . . . . . . . . . . . . . . . . . . .
Controller 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS & INSTRUMENTS, SECTION 4 18.
Controls & Instruments, General Description 18. .
Cooler, Compressor Oil 33. . . . . . . . . . . . . . . . . . . .
Cooling, Sealing and Lubrication 1. . . . . . . . . . . . .
COUPLING, SECTION 7 41. . . . . . . . . . . . . . . . . . .
Coupling 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Check 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals 6, 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Service Line 13. . . . . . . . . . . . . . . . . . . .
Discharge Thermistor 22. . . . . . . . . . . . . . . . . . . . . .
Drain, Oil Reservoir 9. . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning Oil System 31. . . . . . . . . . .
Dust Cap 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Motor Grease Recommendations 15. . . .
Electric Motor Regreasing Interval 15. . . . . . . . . . .
Electrical Wiring 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Element Life, Air Filter 39, 40. . . . . . . . . . . . . . . . .
Emergency Stop Push–Button 22. . . . . . . . . . . . . .
Enclosure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Starter 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Oil Reservoir 32. . . . . . . . . . . . . . . . . . . . . . . .
Filter, Compressor Oil 32. . . . . . . . . . . . . . . . . . . . . .
Filter Element 39, 40. . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Air (Standard) 39. . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foundation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge, Oil Level 19, 30. . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION, SECTION 1 1. . . . . .
Grease Recommendations, Electric Motor 15. . . .
Grounding 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature Operation 29. . . . . . . . . . . . . . . .
Inlet Line 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Screen and Tube 40. . . . . . . . . . . . . . . . . . . . .
Inlet Valve 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION, SECTION 2 8. . . . . . . . . . . . . . . .
Installation, General 8. . . . . . . . . . . . . . . . . . . . . . . .
Installation for Cold Weather Operation 12. . . . . .
Lifting Unit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line, Discharge Service 13. . . . . . . . . . . . . . . . . . . .

INDEX
13–10–613 Page v
Line, Inlet 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure Protection 9. . . . . . . . . . . . . . . . .
Lubricant, Recommended 28. . . . . . . . . . . . . . . . . .
Lubricant Change Procedure 29. . . . . . . . . . . . . . .
Lubrication, Cooling and Sealing 1. . . . . . . . . . . . .
Lubrication, Motor 15. . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5 28. . . . . . . . . . . . . .
Main Starter 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE, SECTION 8 42. . .
Minimum Discharge Pressure/Check Valve 19. . .
Moisture in the Oil System 30. . . . . . . . . . . . . . . . . .
Moisture Separator/Trap 12. . . . . . . . . . . . . . . . . . .
Motor Grease Recommendations 15. . . . . . . . . . .
Motor Lubrication 15. . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Regreasing Interval 15. . . . . . . . . . . . . . . . . .
Oil Change Interval 31. . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler, Compressor 33. . . . . . . . . . . . . . . . . . . .
Oil Cooler – Installation 11. . . . . . . . . . . . . . . . . . . .
Oil Cooler – Location and General Piping 9. . . . . .
Oil Filter, Compressor 32. . . . . . . . . . . . . . . . . . . . . .
Oil Level Gauge 19, 30. . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Reservoir Drain 9. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Separator
Compressor 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Carryover 36. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal for Inspection or Replacement 37. . .
Oil Specifications 28. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil System
Compressor 28. . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Cleaning 31. . . . . . . . . . . . . . . . . .
Oil System Check 38. . . . . . . . . . . . . . . . . . . . . . . . .
Air and Oil Discharge Temperature 38. . . . . . .
Oil Cooler Oil Pressure Differential 38. . . . . . . .
Oil Cooler Temperature Differential 38. . . . . . .
Oil Cooler Water Pressure Differential 38. . . . .
Oil Inlet Pressure 38. . . . . . . . . . . . . . . . . . . . . . .
Operation
Cold Ambient 30. . . . . . . . . . . . . . . . . . . . . . . . . .
High Temperature 29. . . . . . . . . . . . . . . . . . . . . .
Piping, Water 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Differential Gauging 37. . . . . . . . . . . . . . .
Pressure Regulator 21. . . . . . . . . . . . . . . . . . . . . . . .
Prestart–Up Instructions 16. . . . . . . . . . . . . . . . . . . .
Air Filter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil 16. . . . . . . . . . . . . . . . . . . . . . . .
Coupling 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode 17. . . . . . . . . . . . . . . . . . . . . . . .
Piping 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure 17. . . . . . . . . . . . . . . . . . . . . . .
Purge Valve 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Lubricant 28. . . . . . . . . . . . . . . . . . .
Regreasing Interval, Electric Motor 15. . . . . . . . . .
Regulator, Pressure 21. . . . . . . . . . . . . . . . . . . . . . .
Relief Valve 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Ordering Instructions iii. . . . . . . . . . .
Reservoir, Oil 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reservoir Pressure Transducer 22. . . . . . . . . . . . .
Safety Precautions 4, 5. . . . . . . . . . . . . . . . . . . . . . .
Sealing, Lubrication and Cleaning 1. . . . . . . . . . . .
Separator, Compressor Oil 36. . . . . . . . . . . . . . . . .
Separator/Trap, Moisture 12. . . . . . . . . . . . . . . . . . .
Service Check List 42. . . . . . . . . . . . . . . . . . . . . . . .
Air Filter 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 1000 Hours Operation 42. . . . . . . . . . . . .
Every 125 Hours Operation 42. . . . . . . . . . . . . .
Every 4000 Hours Operation 42. . . . . . . . . . . . .

INDEX
13–10–613 Page vi
Every 8 Hours Operation 42. . . . . . . . . . . . . . . .
Every Year 42. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Lubrication 42. . . . . . . . . . . . . . . . . . . . . . .
Oil Separator 42. . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle Valve 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valves IVC and IVO 21. . . . . . . . . . . . . . .
Solenoid Valves TVC and TVO 21. . . . . . . . . . . . . .
Specifications, Oil 28. . . . . . . . . . . . . . . . . . . . . . . . .
Starter
Fan 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING & OPERATING PROCEDURES,
SECTION 3 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Cold 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Hot 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Unit 17. . . . . . . . . . . . . . . . . . . . . . . . . .
Strip, Terminal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch
Air Filter Vacuum 22. . . . . . . . . . . . . . . . . . . . . . .
Vibration 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Pressure Transducer 22. . . . . . . . . . . . . . .
System Thermistor 22. . . . . . . . . . . . . . . . . . . . . . . .
Terminal Strip 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor
Discharge 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer
Reservoir Pressure 22. . . . . . . . . . . . . . . . . . . . .
System Pressure 22. . . . . . . . . . . . . . . . . . . . . . .
Transformer, Control 22. . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING, SECTION 9 43. . . . . . . . .
Tube, Inlet 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve 1, 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Valve Actuator – EAQ Units Only 21. . . . . . .
Valve
Blowdown 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum Discharge Pressure/Check Valve 19
Purge 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shuttle 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid IVC and IVO 21. . . . . . . . . . . . . . . . . . .
Solenoid TVC and TVO 21. . . . . . . . . . . . . . . . .
Turn 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration Switch 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Piping 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring, Electrical 14. . . . . . . . . . . . . . . . . . . . . . . . . .

13–10–613 Page vii
LIST OF ILLUSTRATIONS
Figure # Description Page
Figure 1–1 Compression Cycle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1–2 View of Water Cooled Unit with Aftercooler (less enclosure) – Motor Side 2. . . . . . . . . . . . . .
Figure 1–3 View of Water Cooled Unit with Aftercooler (less enclosure) – Motor End 2. . . . . . . . . . . . . .
Figure 1–4 View of Water Cooled Unit with Aftercooler (less enclosure) – Reservoir End 3. . . . . . . . . . .
Figure 1–5 View of Water Cooled Unit with Aftercooler (less enclosure) – Reservoir Side 3. . . . . . . . . .
Figure 2–1 Typical Compressor Room 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–2 Air Flow Chart 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–3 Piping Schematic 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–4 Piping Diagram for Aftercooler and Heat Exchanger 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2–5 Cold Weather Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–2 Blowdown Valve 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–3 Minimum Discharge Pressure Valve 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–4 Inlet Valve 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–5 Shuttle Valve 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–6 Turn Valve Control 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–7 Turn Valve Actuator 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–8 Control Schematic – Compressor at Full Load 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4–9 Control Schematic – Compressor Fully Unloaded – Constant Speed Mode 25. . . . . . . . . . . .
Figure 4–10 Control Schematic – Compressor Fully Unloaded – Low Demand Mode or Auto Mode 26. .
Figure 4–11 Wiring Diagram – 212EAP546 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–1 Flow Diagram – Air/Oil Systems 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–2 Oil System Capacities 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–3 Oil Change Interval 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–4 Compressor Oil Filter 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–5 Oil Flow Diagram – Remote Overhead Mounted Oil Cooler 33. . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–6 Thermostatic Mixing Valve Element 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–7 Water Control Valve 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–8 Dew Point Temperature VS. Ambient Temperature 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–9 Single Element Oil Separator 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5–10 Ambient Temperatures 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6–1 Heavy Duty Air Filter 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–1 Installation of Coupling Style “A” 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7–2 Installation of Coupling Style “B” 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13–10–613 Page 1
SECTION 1
GENERAL INFORMATION
FIGURE 1–1 – COMPRESSION CYCLE
COMPRESSOR – The Gardner Denver Electra–Sav-
erRcompressor is a single stage, positive displace-
mentrotarymachineusing meshinghelicalrotorsto ef-
fect 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 discharge
ports
.Thecompression cyclebeginsas rotorsunmesh
attheinlet port and air is drawn into the cavitybetween
the main rotor lobes and secondary rotor grooves (A).
When the rotors pass the inlet port cutoff, air is trapped
intheinterlobecavityandflowsaxiallywiththemeshing
rotors (B). As meshing continues, more of the main ro-
tor lobe enters the secondary rotor groove, normal vol-
ume is reduced and pressure increases.
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-
ductionandpressureincreasecontinuesuntiltheair/oil
mixture trapped in the interlobe cavity by the rotors
passesthedischargeportandisreleasedtotheoilres-
ervoir(C). Each rotor cavity followsthe 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 5–1, page 28) – Air enters the air
filterand passes through the inletunloader valve to the
compressor. After compression, the air/oil mixture
passes into the oil reservoir where most of the en-
trained oil is removed by velocity change and impinge-
ment and drops back into the reservoir. The air and re-
maining oil then passes through the oil separator; the
separated oil is returned to the system through tubing
connecting the separator and compressor. The air
passes through the reservoir discharge manifold, dis-
charge check valve, minimum pressure valve and the
customerfurnished unit shutoffglobe valve to the plant
air lines.
LUBRICATION, COOLING AND SEALING – Oil is
forcedbyair pressurefromthe oilreservoirthrough the
oil cooler, thermostatic mixing valve, and oil filter and
discharges into the compressor main oil gallery. A por-
tion of the oil is directed through internal passages to
the bearings, gears and shaft oil seal. The balance of
theoilisinjecteddirectlyintothecompressionchamber
to remove heat of compression, seal internal clear-
ances and lubricate the rotors.
TURN VALVE – The turn valve is a rotary helical valve
locatedonthedischargesideofthe cylindertowardthe
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.

13–10–613 Page 2
FIGURE 1–2 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – MOTOR SIDE
FIGURE 1–3 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) – MOTOR END

13–10–613 Page 3
FIGURE 1–4 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – RESERVOIR END
FIGURE 1–5 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) RESERVOIR SIDE

13–10–613 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 loosenor removetheoil fillerplug, drainplugs,covers, thethermostat-
icmixingvalve orbreakany connections,etc., in thecompressor airoroil sys-
tem until the unit is shut down and the air pressure has been relieved.
DElectrical shock can and may be fatal.
DCompressor unit must begrounded inaccordance withtheNational 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.

13–10–613 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 exceedthe ratedmaximum pressurevalues shownon thenameplate.
DDo not operate unit if safety devices are not operating properly. Check peri-
odically. Never bypass safety devices.

13–10–613 Page 6
DECALS
206EAQ077 212EAQ077
218EAQ077
211EAQ077 207EAQ077

13–10–613 Page 7
DECALS
216EAQ077
217EAQ077
222EAQ077
221EAQ077 208EAQ077

13–10–613 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 motor,
compressor or discharge manifold
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. Failureto observe
this warning may result in damage to
equipment or personal injury.
Compressor, air/oil reservoir, separa-
tion chamber and all piping and tub-
ingmaybe athightemperatureduring
and after operation.
LOCATION – The compressor should be installed in a
clean, well–lighted, well–ventilated area with ample
space all around for maintenance. Select a location
that provides a cool, clean, dry source of air. In some
casesitmaybenecessarytoinstalltheairfilteratsome
distance from the compressor to obtain proper air sup-
ply.
The compressor unit require electric motor cooling air
aswellasairtothecompressorinlet.Properventilation
MUST be provided (FIGURE 2–2); hot air must be ex-
hausted from the compressor operating area. A typical
inlet–outlet air flow arrangement is shown in
FIGURE 2–1.
FIGURE 2–1 – TYPICAL COMPRESSOR ROOM
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.
Open Unit With
Aftercooler Aftercooler & Oil
Open and Cooler Module
Compressor Oil Cooler Discharge in
Size Unit Module Same Room
350 HP 12,600 43,000 55,600
400 HP 14,400 43,000 57,400
500 HP 18,000 43,000 61,000
* 80_F Inlet Air
FIGURE 2–2 – AIR FLOW CHART

13–10–613 Page 9
FIGURE 2–3 – PIPING SCHEMATIC
PIPING SCHEMATIC OF COOLER
WITH SCREWED CONNECTIONS. PIPING SCHEMATIC OF COOLER
WITH FLANGED CONNECTIONS.
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 the motor and is discharged out the sides. Do
not block air flow to and from the unit.
FOUNDATION – The Electra–Saverrcompressor re-
quiresno specialfoundation butshould bemounted on
asmooth, solid surface of sufficientstrength to support
theweightoftheunit.Wheneverpossibleinstalltheunit
near level. Temporary installation may be made at a
maximum 10_angle lengthwise or 30_sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt,ordanger ofshiftingfrom outsidevibrationsor mov-
ing vehicles may require the use of mounting bolts to
the foundation.
OIL RESERVOIR DRAIN – (FIGURE 1–5, page 3)
The oil reservoir drain valve is located near the center
of the oil reservoir just below the separator tower. The
drainvalveis approximately5 inchesfromthe floorlev-
el.Ifthisheightisnotsufficienttoconvenientlydrainthe
oil, some other methods of providing oil drain are:
1. Elevate the compressor unit on a suitable struc-
ture 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 drain
to a container.
ACOUSTIC ENCLOSURE – The Electra–Saverrunit
is furnished with an acoustic enclosure over the com-
pressor only, as standard equipment. The enclosure
reduces the normal operating sound of the unit to 90
DBA 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
airflow. ProperventilationMUST beprovided, withhot
air exhausted away from the cooler; take care that hot
air is not recirculated form the exhaust to the inlet side
ofthecooler.Coolingairflowdirectionisfromthemotor
side through the grille side of the oil cooler. Do not ob-
structtheairflowtoorfromthecooler.Allowtwo(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–
installedlowoilpressureshutdownswitchinthecontrol
box will prevent start–up or shut the unit down if oil
pressure is not established or maintained due to mal-
function 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.

13–10–613 Page 10
FIGURE 2–4 – PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER
The machine cannot be run blown
down with remote overhead oil cool-
er. These units require special wiring
diagram – check with factory. Run-
ning the machine blown down with an
overhead cooler could result in dam-
age to 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 INSTALLATION. The design information to
be submitted for approval 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 2–1/2” 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, pipe, and fittings illustrating design in-
formationincluded in numbers3 through 6above.
All remote piping should be of adequate size to insure
a minimum pressure loss. Number 4 above lists the
minimum pipe size to be used. Long runs of pipe and
the use of valves and fittings require larger than the
minimumpipe sizesin thesystem to keepthe pressure
losslow.All pipeand fittings usedin a remote oilcooler
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 the motor side
through core) and the prevailing winds are in the same
direction. A baffle should be provided on the exhaust
sideofthecoolerforprotectionagainstoccasionalwind
shifts.
When the oil cooler is mounted above the compressor
unit,a checkvalveis tobe mountedon thecompressor
unit in the line to the oil cooler; see FIGURE 5–4, page
33. 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. The check valve permits oil
flow to the oil cooler during operation, but prevents re-
turn oil flow from the cooler when the unit is shut down.
Thepilotvalveisheldopenbyairpressurefromtheunit
oil reservoir during operation and closes under spring
loadwhentheunitisshutdowntopreventreturnoilflow
from the oil cooler.

13–10–613 Page 11
FIGURE 2–5 – COLD WEATHER INSTALLATION
An oil filler stand pipe and plug must be located in the
pipingon theoil cooler modulefor easeof filling ofa re-
mote oil cooler, see FIGURE 5–4, page 33.
Oil Cooler – Installation – Inspect unit upon arrival.
In case of damage, report immediately to transporta-
tioncompany. Before installation,check rating plate on
motorto verifythat powerinput andmotor specification
requirementsmatch available electricpower at pointof
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, page 9, 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.
AUXILIARY AIR RECEIVER – The unit requires an
auxiliary air receiver unless the piping system is large
andprovidessufficientstorage capacitytopreventrap-
idcycling.Whenused,anairreceivershouldbeofade-
quatesize,providedwithareliefvalveofpropersetting,
a pressure gauge, and a means of draining conden-
sate.
AFTERCOOLER (FIGURE 1–2 and FIGURE 1–5,
pages 2 and 3) – An aftercooler will provide control of
moisture entering the shop air lines while reducing the
normal low discharge temperature of about 180_F at
100PSIG dischargepressure tonear inletair tempera-
ture, 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 must bemounted by the customer
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
customer. The design of the aftercooler piping
must be approved by the factory before installa-
tion. Design information to be submitted for approval
includes:
1. Location of aftercooler module – inside or out-
doors.
2. Range of operating ambient temperatures at the
aftercooler location.
3. Pipetype andsize(s)to beused toconnect theaf-
tercooler, separator, and compressor unit – mini-
mum pipe size is 5” NPT.
4. Lengthsof thepiperun. Ifmore thanone pipesize
is used, list length of each size and total length.
5. Number and size of elbows, tees, unions, reduc-
ers, and valves to be used in the pipe run.
6. A dimensional sketch of the proposed piping sys-
tem showing location of the compressor unit, af-
tercooler,separatorandauxiliaryairreceiver,pipe
andfittingsillustratingdesigninformationincluded
in numbers 3 through 5 above.

13–10–613 Page 12
Water–Cooled Machines (FIGURE 2–4, page 10) –
On water–cooled machines with aftercooler, the mois-
tureseparatorandcondensatedrainareshippedloose
andmust be installed bycustomer.Customer mustfur-
nish and install all water piping required.
INSTALLATION FOR COLD WEATHER OPERA-
TION – It is recommended that the unit be installed in-
sideashelterthatwillbeheatedtotemperaturesabove
freezing (32_F, 0_ C). This will eliminate many of the
problems associated with operating units in cold cli-
mates where freezing rain, drifting snow, freezing con-
densateand bittercold temperaturesare encountered.
Refer to Engineering Data Sheet 13–9–411 for the ad-
vantages of using the heat recovered from rotary com-
pressors.Thisheatrecoverycouldeasilypayforanad-
equate shelter for the unit.
When an outside installation must be made, the pre-
cautions required will depend on the severity of the en-
vironment. The following are general guidelines for
outside installations:
Cold Weather (Down To +10_F)
1. Be sure all drains, traps, and control lines, includ-
ing pressure transducer lines are heated to avoid
freezing of condensate. Heat tape with thermo-
stat control is generally satisfactory for this pur-
pose and can be obtained at various local plumb-
ing or hardware outlets at nominal cost.
2. If an air–cooled aftercooler is to be used, provi-
sions to bypass the aftercooler must be made.
Since cold air contains very little moisture, suc-
cessful operation can be achieved without the af-
tercooler. Successful operation down to +15_F
can be accomplished by reversing fan flow, but
cooler bypass should still be provided should it be
required.
3. Provideatleastsomesimplesheltersuchasaply-
wood windbreak to protect against drifting snow.
4. Use only Gardner DenverRAEONt9000 SP lu-
bricant.
5. Monitor the unit carefully during start–up and op-
eration to be sure it is functioning normally.
6. Specify NEMA 4 enclosure for electrical devices.
Extreme Cold Weather Operation (Down To –40_F,
–40_C) – In addition to the above, the following should
be provided:
1. A temperature switch to control the fan should be
provided for better starting and quicker warm–up.
This switch can be provided from the factory and
willdelayfanstart–up untildischargetemperature
reaches approximately 150–160_F.
2. Itwillprobablybenecessarytoprovideshuttersor
to block off part of the cooler in some manner
since the cooler is greatly oversized for operation
inthese lowtemperatures. Shutters are nota fac-
tory option.
3. Auto operation should not be used in extreme en-
vironments.
4. Coolers should be located as close to the unit as
possible. Long lines to and from the cooler only
furthercomplicatethecirculationofoilflowoncold
starts. Heat tape and insulation may be required
on oil lines.
5. Some means of providing heat to the oil reservoir
and cooler during shutdown should be provided.
Therearevariousmethodstoaccomplishthis,but
sinceopeningsarenotprovidedforsumpheaters,
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 2–5,page11,showshowthesemightbe
located in a typical installation and sizes required.
Remember unsheltered (outside) installations should
be avoided where possible. Installation next to a
heated building where enough heat can be used to
keep the compressor room above freezing will save
many complications in the operation and installation of
the unit.
MOISTURE SEPARATOR/TRAP – Since the unit is
equipped with a built–in aftercooler, a combination
moisture separator and trap is furnished with the unit.
A means of draining condensate will need to be pro-
vided for.
INLET LINE – Where an inlet line is used between the
air filter and the compressor, it must be thoroughly
Length of Inlet Line Diameter of Pipe Size
0 to 10 Feet Same as Compressor Inlet Opening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 to 17 Feet One Size Larger Than Inlet Opening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 to 38 Feet Two Sizes Larger Than Inlet Opening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2–6 – INLET LINE LENGTHS