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