Gardner Denver ELECTRA-SAVER Service manual

GARDNER DENVER@ 13-9/1 0-641
7th Edition
May, 1995
ELECTRA-SAVER@
ELECTRA-SAVER Il@
STATIONARY BASE-MOUNTED
COMPRESSOR
DOMESTIC MODELS
40- IOOHP
EBH, EBM, EBP &EAP
INTERNATIONAL MODELS
EBM B-60-100 HP(45-75K~
--
OPERATING AND
SERVICE MANUAL

MAINTAIN COMPRESSOR RELIABILlTY AND PERFORMANCE WITH
GENUINE GARDNER DENVER AND JOY COMPRESSOR
PARTS AND SUPPORT SERVICES
Gardner Denver and Joy Compressor genuine parts,
engineered to original tolerances, are designed for opti-
mum dependability -–- specifically for Gardner Denver
and Joy compressor systems. Design and material in-
novations are the result of years of experience with
hundreds of different compressor applications. Reli-
ability in materials and quality assurance are incorpo-
rated in our genuine replacement parts.
Your authorized Gardner Denver Compressor distribu-
tor offers all the backup you’ll need. Aworldwide net-
work of authorized distributors provides the finest prod-
uct support in the air compressor industry,Your local
authorized distributor maintains alarge inventory of
genuine parts and he is backed up for emergency parts
by direct access to the Gardner Denver Machinery Inc.
Master Distribution Center (MDC) in Memphis, Ten-
nessee.
Your authorized distributor can support your Gardner
Denver or Joy air compressor with these services:
1.
2.
3.
4.
Trained parts specialists to assist you in selecting
the correct replacement parts.
Factory warranted new and remanufactured
rotary screw air ends. Most popular model reman-
ufactured air ends are maintained instock at MDC
for purchase on an exchange basic with liberal
core credit available for the replacement unit.
Afull line offactory tested AEON compressor lu-
bricants specifically formulated for use in Gardner
Denver and Joy compressors.
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]
[phone]
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,
Gardner Denver iscommitted to supplying you with 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. Every remanufactured air end receives
anew overhaul kit: bearings, gears, seals, sleeves and
gaskets.
Extensive Testing
Gardner Denver performs testing that repair houses
just don’t do. Magnaflux and ultrasonic inspection spot
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 anew warranty ...18 months from purchase,
12 months from service.
Gardner Denver remanufactured air ends deliver 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]
13-9/1 0-641 Page

FOREWORD
Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To
be assured of receiving maximum service from this machine the owner must exercise care in itsoperation and main-
tenance. This book iswritten to give the operator and maintenance department essential information for day-to-day
operation, maintenance and adjustment. Careful adherence to these instructions will result in economical operation
and minimum downtime.
DANGER
Danger is used to indicate the presence of ahazard which will cause severe personal
injury, death, or substantial property damage if the warning is ignored.
AWARNING
Warning is used to indicate the presence of ahazard which can cause severe person-
al injury, death, or substantial property damage if the warning is ignored.
~CAUTION
Caution is used to indicate the presence of ahazard which will or can cause minor
personal injury or property damage if the warning is ignored.
NOTICE
Notice is used to notify people of installation, operation or maintenance information
which is important but not hazard-related.
13-9/10-641 Page ii

This book covers the following models:
DOMESTIC MODELS:
HP PSIG Air Cooled Water Cooled Parts List
40 100, 125 EBHQHA EBHSHA 13-9-555
EBHQHB EBHSHB 13-9-550
50 100, 125, 150 EBHQJA EBHSJA 13-9-555
EBHQJB EBHSJB 13-9-550
60 100, 125, 150 EBMQKA EBMSKA 13-9-557
EBMQKC EBMSKC 13-9-551
75 100,125,150 EBMQLA EBMSLA 13-9-557
EBMQLC EBMSLC 13-9-551
100 100,125,150 EBPQMA EBPSMA 13-9-556
EBPQMB EBPSMB 13-9-548
EAPQMC EAPSMC 13-10-507
INTERNATIONAL MODELS:
HP (KW) PSIG(BARS) Air Cooled Water Cooled Parts List
100,125,150 EBMQKB EBMSKB 13-9-557X
(45) (6.9, 8.6, 10.3)
100,125,150 EBMQLB EBMSLB 13-9-557X
(55) (6.9, 8.6, 10.3)
100 100,125,150 EBMQMB EBMSMB 13-9-557X
(75) (6.9, 8.6, 10.3)
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL,
Method of Cooling, HORSEPOWER and SERIAL
NUMBER (see nameplate on unit). The Serial Number
is also stamped on top of the cylinder flange to the right
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 (l); where more than one is
13-9/1 0-641
required per unit, quantity is indicated in parenthesis.
SPECIFY EXACTLY THE NUMBER OF PARTS RE-
QUIRED.
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 indi-
cated in parenthesis following the part name, i.e. (RH)
& (LH) .
Page iii

TABLE OF CONTENTS
REMANUFACTURED AIR ENDS..... ....................................,........................
FOREWARD ................................................. ....
,...
. .
. .
. .
.,
............. ......... ii
INSTRUCTIONS FOR ORDERING REPAIR PARTS .... ...
.,. Ill
...iv
.ix
. .
. .
. .
. .
.,
,.
. . . . . .
. .
. .
.,
...
,.
. .
. .
. .
,.
. .
. .
. .
,..
INDEX ....................
LIST OF ILLUSTRATIONS . .
. . . . .
.....
............
..........
. . . .
...
. .
. .
..... ...............,
SECTION 1, GENERAL INFORMATION ........... ............... ................................ I
SECTION 2,1 NSTALLATION ...................................... .........................8
SECT1ON 3, STARTlNG&OPERATlNG PROCEDURES ..........................................’....16
SECT1ON 4, CONTROLS &lNSTRUMENTAT10N ................................ ................18
, . . . . . . , ,’. . , . . , . . , 42
SECTION 5,LUBRICATION,
SECTION 6, AIR FILTER ,..
SECTION 7, COUPLING . ..
OIL FILTER&SEPARATOR
. .
....
..,. . ..,,.,, . . . . 54 ........
,.,.., .
. .
,
...
..................
..................
. .
......,
....... ., 56
. . . . 57
....58
. . . . 61
..,.,. . . . . .......
.......
.......
,.
. .
. . .
. .
. .
. .
SECTION 8, MAINTENANCE SCHEDULE ,..
SECTION9,TROUBLE SHOOTING ..........
.
....
. .
. .
. .
..... .
.,
. .
...
.,
.s.
. .
.,
...
.....
......
. . . .
SECTION1O,TROUBLE SHOOTING CONTROLS ......... ..... ................,..,
WARRANTY ............................................................................. Last Page
13-9/10-641 Pageiv

Actuator, Turn Valve .............., .......30
Addition of Oil Between Changes ........... 46
Advisories
Clearing ...........................20
Service and Maintenance ............... 20
AIR FILTER, SECTION 6........ ..........54
Air Filter Element Life ..,.,.... . . . . . . . . . ...54
Air Filter Vacuum Switch ..................31
Air Filter, Heavy Duty (Standard) ........... 54
Compression Principle ..................... 1
Air Flow in the Compressor System .......... 1
Air Receiver, Auxiliary......,,. ............ 10
Air-Cooled Units, Location .................. 8
Alarm Relay, ............................27
Auto Sentry-ES Control Display ............ 19
Auto Sentry-ES Controller
Alarm Relay ..........................27
Automatic Sequence Change ........... 26
Connection to External Controls ......... 26
Establishing Initial Sequence ............ 24
HowAuto Sentry-ES Controls Pressure while
Sequencing, ..................,.,.25
Installation ......,.. . ....24
Operation ............................24
Other Features ........................ 26
Programming and Setup ... ........ 21
Programming Steps ....................21
RemoteOn/Off.., ....................26
Serial Communications ................. 27
Auto Sentry-ES Operation.,,. ............. 18
Automatic Mode ....................... 19
Constant Run Mode ................... 18
Low Demand Mode .................... 18
Sequence Mode ....................... 19
Automatic Mode Operation ................ 19
Auxiliary Air Receiver ..................... 10
Blowdown Valve ............. ..........28
Change Procedure, Lubricant .............. 46
Check, Daily ............................. 17
Cleaning and Draining Oil System .......... 48
Clearing Advisories ....................... 20
Cold Ambient Operation ................... 46
Cold Weather Operation ................... 10
Cold Weather Operation, installation for . . . . . . 9
Compressor .............................. 1
Compressor (GDEliminator) Oil Separator ... 52
Compressor Capacity Control -Turn Valve
Units Only ...........................32
Compressor Oil Cooler....,.. .............49
Compressor Oil Filter .....................49
Compressor Oil System ................... 42
Compressor Oil System Check. ............ 53
Constant Run Mode Operation ............. 18
Control Devices, Other .................... 27
Control Piping ............................ 11
Control Transformer .........,............31
CONTROLS &lNSTRUMENTS, SECTION 4 18
Controls &instruments, General Description .18
Cooler, Compressor Oil ...................49
Cooling, Seaiing and Lubrication ............. 1
COUPLING, SECTION 7... . . . . . . . . . . 56
Coupling, ...................,...........56
Alignment ............................56
Individual Cushion Design .............. 56
Daily Check ............................. 17
Decals .................................6.7
Discharge Service Line .................... 12
Discharge Thermistor .,,,.... . . . . . . . . . . . . . 31
Drain, Oil Reservoir ........................ 9
Draining and Cleaning Oil System .......... 48
Electric Motor Grease Recommendations . . . . 15
Electric Motor Regreasinglnterval .......... 15
Electrical Wiring .......................... 14
Standard Units ........................ 14
Element Life, Air Filter .................... 54
Emergency Stop Push-Button ............. 31
13-9/10-641 Pagev

Emergency Stop Shutdown ................ 21
Enclosure ................................9
External Device Shutdown ................. 21
Fan Starter ..............................31
Filter, Compressor Oil .....................49
Filter Element ............................54
Filter, Heavy DutyAir (Standard) ........... 54
Foreword ..................................ii
Foundation ...............................9
Gauge, Oil Level ......................28.47
GENERAL INFORMATION, SECTION 1..... 1
Grease Recommendations, Electric Motor ... 15
Grounding ............................... 14
High Pressure Shutdown .................. 21
High Temperature Operation ............... 42
High Temperature Shutdown ............... 20
Inlet Line ................................ 11
inlet Screen and Tube .....................55
Inlet Valve ...............................29
INSTALLATION, SECTION2 ............... 8
installation, General ....................... 8
installation for Cold Weather Operation ....... 9
Lifting Unit ................................ 8
Line, Discharge Service ................... 12
Line, inlet ............................... 11
Location .................................. 8
Air-Cooled Units .......................8
Water-Cooled Units .................... 9
Low Demand Mode Operation.. ............ 18
Low Oil Pressure Shutdown ............... 21
Lubricant, Recommended ................. 42
Lubricant Change Procedure.. ............. 46
Lubrication, Motor ........................ 14
Lubrication, Cooling and Sealing. ............ 1
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR, SECTION 5............. 42
Main Starter .............................31
MAINTENANCE SCHEDULE,SECTION 8. . 57
Minimum Discharge Pressure Valve ......... 28
Moisture in the Oil System ................. 47
MoistureSeparator/Trap ................... 10
Motor Grease Recommendations ........... 15
Motor Lubrication ......................... 14
Motor Protective Devices .................. 20
Motor Regreasinglnterval ................. 15
Oil Change Interval ....................... 47
Oil Cooler, Compressor ...................49
Oil Filter, Compressor ..................... 49
Oil Level Gauge .......................28.47
Oil Reservoir ............................. 52
Oil Reservoir Drain ........................9
Oil Separator
Compressor (GD Eliminator) ............ 52
Inspection ............................52
Oil Carryover .........................52
Removal for inspection or Replacement . . 53
Oil Specifications .....................
Oil System
Compressor ......................
Draining and Cleaning ..............
Oil System Check ....................
Air and Oil Discharge Temperature ...
Compressor Oil lnletTemperature . . .
Oil Cooler Oil Pressure Differential . . .
Oil CoolerTemperature Differential ...
Oil Cooler Water Pressure Differential
Oil inlet Pressure, .................
Operation
Automatic Mode ...................
Cold Ambient.............,.. .....
Constant Run Mode ...............
High Temperature .................
Low Demand Mode....,,,,,. ......
. . . . 42
..,. 42
..,. 48
. . . . 53
. . . . 53
.s.. 53
. . . . 53
..,. 53
. . . . 53
. . . . 53
. . . . 19
. . . . 46
. . . . 18
.,.. 42
. . . . 18
13-9/10-641 Pagevi

Sequence Mode ....................... 19
Optional Switches ........................31
Piping, Control ........................... 11
Power Failure ............................21
Pressure Differential Gauging .............. 52
Pressure Regulator .......................29
Prestart-Up Instructions ................... 16
Air Filter .............................. 16
Coupling ............................. 16
Electrical ............................. 16
Enclosure ............................ 17
Grounding ............................ 16
Operating Mode ....................... 17
Piping ................................ 16
Rotation .............................. 16
System Pressure ...................... 17
Programming and Setup, AutoSentry-ES
Controller ............................21
Protective Shutdowns .....................20
Purge Valve .............................30
Recommended Lubricant .................. 42
Regressing interval, Electric Motor ......... 15
Regulator, Pressure ......................29
ReliefValve ..............................27
RemoteOn/Off .........................26
Repair Parts, Ordering instructions .......... iii
Reservoir, Oil ............................52
Reservoir Pressure Transducer ............ 31
Safety Precautions ......................4.5
Sealing, Lubrication and Cleaning ........... 1
Separator, Compressor (GD Eliminator) Oil . . 52
Separator Differential Pressure Shutdown . . . 21
Separator/Trap,Moisture .................. 10
Sequence Mode Operation ................ 19
Sequencing Compressors with
Auto Sentry-ES ......................24
Serial Communications ....................27
13-9/10-641
Service Advisories ........................ 20
SERVICE CHECK LIST, AIR FILTER ....... 57
Service Check List ........................57
Every 1000 Hours Operation ............ 57
Every 125 Hours Operation :............ 57
Every 6000 Hours Operation ............ 57
Every 8Hours Operation ............... 57
Every Year ...........................57
Motor Lubrication ......................57
Oil Separator .........................57
Shutdowns
Emergency Stop ......................21
External Device .......................21
High Pressure ......................... 21
High Temperature .....................20
Low Oil Pressure ......................21
Motor Protective Devices ............... 20
Other ................................ 21
Power Failure ......................... 21
Separator Differential Pressure .......... 21
Shuttle Valve ............................30
Solenoid Valves lVCandlVO .............. 29
Solenoid Valves TVCandTVO ............. 31
Specifications, Oil ........................42
Starter
Fan .................................. 31
Main .................................31
STARTING&OPERATING PROCEDURES,
SECTION . ......................... 16
Starting the Unit .......................... 17
Unit Cold ............................. 17
Unit Hot .............................. 17
Stopping the Unit ......................... 17
Strip, Terminal ...........................31
Switch
Air Filter Vacuum ...................... 31
Vibration .............................31
Switches, Optional ........................ 31
System Pressure Transducer .............. 31
System Thermistor .......................31
Page vii

INDEX
Terminal Strip ............................31
Thermistor
Discharge ............................31
System ..............................31
Transducer
Reservoir Pressure ....................31
System Pressure ......................31
Transformer, Control ..........,...........31
TROUBLE SHOOTING,SECTION 9........ 58
TROUBLESHOOTING CONTROLS,
SECTION 10 ......................... 61
Tube, inlet ...............................55
Turn Valve .............................1.30
Turn Valve Actuator .......................30
Valve
Blowdown ............................28
Inlet, ................................29
Minimum Discharge Pressure ........... 28
Purge ................................30
Relief ................................ 27
Shuttle ............................... 30
Solenoid lVC and lVO . . . . . . . . . . . ,..,... 29
Solenoid TVC and TVO ......... ...31
Turn .................................30
Vibration Switch .......................... 31
Warranty, ......................... Last Page
Water-Cooled Units, Location. .............. 9
Wiring, Electrical, ..............., ........14
13-9/10-641 Pageviii

LIST OF ILLUSTRATIONS
Figure #
Figure 1-1
Figure 1-2
Figure 1-3
Figure 1-4
Figure 1-5
Figure 1-6
Figure 2-1
Figure 2-2
Figure 2-3
Figure 2-4
Figure 2-5
Figure 2-6
Figure 2-7
Figure 2-8
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 4-5
Figure 4-6
Figure 4-7
Figure 4-8
Figure 4-9
Figure 4-10
Figure 4-11
Figure 4-12
Figure 4-13
Figure 4-14
Figure 4-15
Figure 4-16
Figure 5-1
Figure 5-2
Figure 5-3
Figure 5-4
Figure 5-5
Figure 5-6
Figure 5-7
Figure 5-8
Figure 5-9
Figure 5-10
Figure 6-1
Figure 7-1
Description Page
Compression Cycle ........................................................1
Starter Box ........................................................, ......2
Package -Controller&Starters .............................................2
Package -Drive Motor &Air Filter. ..........................................2
Package -Oil Filter, Oil Level Gauge, Mixing Valve, Minimum Pressure Valve
and Check Valve ..........................................................3
Package -Air/Oil Flow Diagram .,, ..........................................3
Typical Compressor Room ..................................................8
Air Flow Chart ................................................ .........9
Cold Weather installation .................................., ...............10
inlet Line Lengths ........................................., ...............11
Heat Exchanger (Oil Cooler) Approximate Water Flow ......................... 11
Aftercooler Approximate Water Flow .........................,, ,............12
Series Piping ........................... s.................................13
Parallel Piping ...................................’.........................13
Auto Sentry-ES Display ...................................................19
Schematic Tubing Diagram ................................................27
Blowdown Valve ..........................................................28
Minimum Discharge Pressure Valve .........................................28
Inlet Valve ..............................................................29
Shuttle Valve ..............................................,,, ............30
Turn Valve -Turn Valve Units Only ..........................................30
Control Schematic -Compressor Unloaded -Constant Speed Mode,
EBH&EBM Units Only ......................................, .............33
Control Schematic -Compressorat Full Load -Constant Speed Mode,
EBH&EBM Units Only .... ............................................34
Control Schematic -Compressor Unloaded -LowDemand Mode orAuto Mode
EBH&EBM Units Only ....................................................35
Control Schematic-Compressor at Full Load, Turn Valve Units Only ............ 36
Control Schematic -Compressor Fully Unload -Low Demand Mode Switch Off,
Turn Valve Units Only .....................................................37
Control Schematic -Compressor Fully Loaded -Low Demand Mode Sw”tch On,
Turn Valve Units Only ......................................., .............38
Wiring Diagram -207ECP546 .............................................39
Wiring Diagram -209ECP546 ... ............................... ,.......40
Wiring Diagram -202EAQ546 ...............................,............41
Flow Diagram ............................................................43
Oil Flow Diagram -Remote Overhead Mounted .............................,44
Cooler Drain Detail ........................................................45
Oil Level Gauge ............................................,, ,...........47
Oil Change Interval .......................................................47
Approximate Oil System Capacities .........................................48
Thermostatic Mixing Valve Element .........................................50
Water Control Valve.......,,, ............................,................51
Dew Point Temperaturevs. Ambient Temperature, (100% Relative Humidity) ..... 51
Oil Separator ................................................, ............52
Heavy Duty Air Filter (Standard), ..............................,............54
installation of Coupling Cushions ...........................................56
13-9/10-841 Pageix

SECTION 1
GENERAL INFORMATION
v
FIGURE 1-1 -COMPRESSION CYCLE
COMPRESSOR -The Gardner Denver Rotary Screw
compressor is asingle stage, positive displacement
rotary machine using meshing helical rotors to effect
compression. Both rotors are supported between high
capacity roller bearings located outside the compres-
sion chamber. Single width cylindrical roller bearings
are used at the inlet end of the rotors to carry part of the
radial loads. Tapered roller bearings at the discharge
end locate each rotor axially and carry all thrust loads
and the remainder of the radial loads.
COMPRESSION PRINCIPLE (FIGURE l-l) -Com-
pression is accomplished by the main and secondaty
rotors synchronously meshing in aone-piece cylinder.
The main rotor has four (4) helical lobes 90° apart. The
secondary rotor has six (6) matching helical grooves
60° apart to allow meshing with main rotor lobes.
The air inlet port is located on top ofthe compressor cyl-
inder near the drive shaft end. The discharge port is
near the bottom at the opposite end of the compressor
cylinder. Figure 1-1 is an invetted view to show inlet
and discharge ports. The compression cycle begins as
rotors unmesh at the inlet port and air is drawn into the
cavity between the main rotor lobes and secondary ro-
tor grooves (A). When the rotors pass the inlet port cut-
off, air istrapped inthe interlobe cavity and flows axially
with the meshing rotors (B). As meshing continues,
more of the main rotor lobe enters the secondary rotor
grove, normal volume is reduced and pressure in-
creases.
Oil is injected into the cylinder to remove the heat of
compression and seal internal clearances. Volume re-
duction and pressure increase continues untilthe air/oil
mixture trapped in the interlobe cavity by the rotors
passes the discharge port and is released to the oilres-
13-9/1 0-641
v
ervoir (C). Each rotor cavity follows the same “fill–com-
press-discharge” cycle in rapid succession to produce
adischarge air flow that is continuous, smooth and
shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM
(FIGURE 5-1, page 42) -Air enters the air filter and
passes through the inlet unloader valve to the com-
pressor. After compression, the air/oii mixture passes
into the oil reservoir where most of the entrained oil is
removed by velocity change and impingement and
drops back into the reservoir. The air and remaining oil
passes intothe separator and separator housing where
the oilisseparated and passes through tubing connect-
ing the separator housing and compressor. The air
passes through the minimum pressure valve, dis-
charge check valve and cooler, then to the plant air
lines.
LUBRICATION, COOLING AND SEALING -Oil is
forced by air pressure from the oil reservoir through the
oil cooler, thermostatic mixing valve, and oil filter and
discharges into the compressor main oil gallery. Apor-
tion of the oil is directed through internal passages to
the bearings, gears and shaft oil seal. The balance of
the oilisinjected directly intothe compression chamber
to remove heat of compression, seal internal clear-
ances and lubricate the rotors,
TURN VALVE (EAP UNITS ONLY) -The turn valve is
arotary helical valve located on the discharge side of
the cylinder toward the inlet end, The valve opens and
closes ports in the cylinder which communicates with
the inlet passage. This varies the compressor rotor vol-
ume to match the demand for air, thus reducing the
part-load power requirement.
Page 1

FIGURE 1-2- STARTER BOX
EKRENCY STOP
SUTTON
LED. CONTROLPANEL~~EMERGENCYSTOP
CONTROLTWSFORMER
oI
FIGURE 1-3- PACXAGE -CONTROLLER &STARTERS
cOwL’N’G”MDl
rA’RF’LTERrc
INLET VAVE ~
COMPKSSOR
7\\
SLJTTON
~FM MOTOR
STARTER
1/- ~lVE MOTOR
FIGURE 1-4- PACKAGE -DRIVE MOTOR &AIR FILTER
13-9/10-641 Page 2

rOIL FILTER
DI
MINIMUNOISCHARG[
PRESS~ CHECK
VALVE
\“’L::’:::L------L -------
o\
1I/
1
FIGURE 1-5- PACKAGE -OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE,
MINIMUM PRESSURE VALVE &CHECK VALVE
-NLETVAL’E
I
—OIL LEVEL GAUGE
FINAL
-
SCHAR
PRESS I
1VALVE ‘
4
MIXINQ
VALVE
FIGURE 1-6-PACKAGE -AIR/OIL FLOW DIAGRAM
13-9/1 0-641 Page 3

SAFETY PRECAUTIONS
Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances
cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for
safety hazards and be cautious.
Some general safety precautions are given below:
~DANGER
Failure to observe these notices could result in injury to or death of personnel.
.Keep fingers and clothinq awav from revolving fan, drive coupling, etc.
●Donotuse the air discharge from this unit for breathing -not suitable for hu-
man consumption.
●Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostat-
ic mixing valve or break any connections, etc., in the compressor air or oil sys-
tem until the unit is shut down and the air pressure has been relieved.
.Electrical shock can and may be fatal.
.Compressor unit must be carounded in accordance with the National Electrical
Code. Aground jumper equal to the size of the equipment ground conductor
must be used to connect the compressor motor base to the unit base.
.Fan motors must remain grounded to the main base through the starter
mounting panel in accordance with the National Electrical Code.
.Open main disconnect switch, tag and lockout before working on the control.
.Disconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit -this machine is automatically controlled and may
start at any time.
13-9/1 0-641 Page 4

WARNING
Failure to observe these notices could result in damage to equipment.
●
●
●
●
●
Stop the unit if any repairs or adjustments on or around the compressor are
required.
Disconnect the compressor unit from its power source, tag and lockout be-
fore working on the unit -this machine is automatically controlled and may
start at any time.
An Excess Flow Valve should be on all compressed air supply hoses ex-
ceeding 1/2 inch inside diameter. (OSHA Regulation, Section 1926.302)
Do not exceed the rated maximum Pressure values shown on the nameplate.
Do not operate unit if safety devices are not operating properly. Check peri-
odically. Never bypass safety devices.
13-9/10-641 Page 5

DISCHARGEAIR USEDFOR
BREATHINGWILL CAUSE
SEVERE INJURYORDEATH.
CONSULTFILTRATION
SPECIALIST FOR
ADDITIONALFILTRATION
ANDTREATMENT EQUIPNENT
TO MEET HEALTH AND
SAFETY REGULATIONS.
206EAQ077
DECALS
AIR AND OIL UNDER PRESSURE
WILL CAUSE SEVERE PERSONA
INJURY OR DEATH.
SHUTDOWNCOMPRESSORAND
RELIEVE SYSTEMOF ALL
PRESSUREBEFOREREMOVING
VALVES.CAPS,PLUGS,
FITTINGS, BOLTSANDFILTERS
-
212 EAQ077
HIGH VOLTAGE,
ROTATING MACHINERY.
AIR AND OIL
UNDER PRESSURE.
IMPROPER MODIFICATION
T
DO NOT MODIFY
OF EQUIPMENT WILL UNIT WITHOUT
CAUSE SEVERE PERSONAL WRITTENPERMISSION
INJURY OR DEATH. FROMMANUFACTURER.
t- 1
211 EAQ077
218EAQ077
ROTATING MACHINERY CAN
CAUSE INJURY OR DEATH.
KEEP ALL GUARDSAND
SAFETY DEVICES IN
PLACE.
UNIT CANAUTOMATICALLY
RESTART.
CANCAUSEPERSONALINJURY
ORDEATH.
KNOWMODEOF OPERATION
BEFOREWORKINGONOR
NEARTHE MACHINE. —
207 EAQ077
13-9/10-641 Page 6/’

DECALS
ELECTRICAL SHOCK FROM
IMPROPER GROUNDING CAN
CAUSE INJURY OR DEATH.
GROUND UNIT AND RELATED
EQUIPMENT ACCORDING TO
NATIONAL ELECTRIC CODE
AND LOCAL REGULATIONS.
216EAQ077
WARNING
AIR AND OIL UNDER
PRESSURE.
CAN CAUSE SEVERE
PERSONAL INJURY
OR DEATH.
INSPECT OIL RESERVOIR
FOR CRACKS AT LEAST
ANNUALLY. n-
217EAQ077
ELECTRICAL ARCING CAN
CAUSE AFIRE WHEN UNIT IS
MOUNTED ON ACOMBUSTIBLE
SURFACE RESULTING IN
PERSONAL INJURY OR
PROPERTY OAMAGE.
UNIT MUST BE MOUNTEOON
AFLOOR PLATE EXTENDING
ON ALL SIDES.
SEE INSTALLATION
DRAWINGFOR PROPER
DIMENSIONS.
221EAQ077
1I
ELECTRICAL SHOCK CAN
CAUSE INJURY OR DEATH.
DISCONNECT ALL CIRCUITS
BEFORE WORKINQON THIS
CONTROL.
SEE WIRING DIAGRAM.
222EAQ077
@
MACHINE OAMAGEOR INJURY
CAN OCCURDUE TO IMPROPER
LIFTING.
DO NOT LIFT MACHINE WITH
THE MOTOR EYEBOLT.
208EAQ077
13-9/10-641 Page7

SECTION 2
INSTALLATION
GENERAL -On receipt of the unit, check for any dam-
age that may have been incurred during transit. Report
any damage or missing parts as soon as possible.
~CAUTION
Do not electric weld on the compres-
sor or base; bearings can be damaged
by passage of current.
LIFTING UNIT -Proper lifting and/or transporting
methods must be used to prevent damage. LiftingslotS
are provided inthe base for towmotor use. The unit may
also be moved into location by rolling on bars. -
~CAUTION
Lift compressor unit by base only. Do
not use other places such as motor,
compressor or discharge manifold
piping as lifting points.
~DANGER
The eyebolts or lugs provided on the
motor are for lifting the motor only
and should not be used to lift any
additional weight. All eyebolts must
be securely tightened. When lifting
the motor the lifting angle must not
exceed 15 degrees. Failure to observe
this warning may result in damage to
equipment or personal injury.
~DANGER
Compressor, air/oil reservoir, separa-
tion chamber and all piping and tub-
ing may beat high temperature during
and after operation.
LOCATION -The compressor should be installed,
whenever possible, in aclean, well-lighted, well–venti-
Iated area with ample space all around for mainte-
nance. Select alocation that provides acool, clean, dry
source of air. In some cases it may be necessary to
install the air filter at some distance from the compres-
sor to obtain proper air supply.
Both the air-cooled and water-cooled units require
cooling air as well as air to the compressor inlet. Proper
ventilation MUST be provided; hot air must be ex-
hausted from the compressor operating area. Atypical
inlet–outlet air flow arrangement is shown in
FIGURE 2-1,
Air-Cooled Units -Acombination oil/aftercooler is
supplied as standard equipment on all air-cooled units.
The air-cooled unit with the standard enclosure re-
quires sufficient flow, FIGURE 2-2, page 9, for the
compressor oil/aftercooling system and for electric mo-
tor cooling. Air is drawn into the unit at the motor side
of the enclosure and is exhausted at the oil cooler side.
Do not block the air flow to and from the unit. Allow
three and one-half (3-1/2) feet (1.1M) to the nearest
obstruction on the starter end and control box end of
the unit. Allow three (3) feet (.9 M) to the nearest ob-
struction above and on other sides of unit. For continu-
ous efficiency, oil cooler cores must be periodically
cleaned with either vacuum or compressed air. If wet
cleaning is required, shield motor and spray on amild
soap solution and flush with clean water.
LO UVERFD EXHAUST FAN LOUVERED
WINDOW WINDOW
\
/
A75119
FIGURE 2-1 -TYPICAL COMPRESSOR ROOM
13-9/10-641 Page 8

Minimum Air Flow *For Compression
And Cooling -Cubic Feet/Minute
(Cubic Meters/Minute)
IHP (KW) IAir Cooled ]Water Cooled I
40& 50 HP 6,500 1,400
60-100 HP 12,500 1,700
(45-75 Kw) (354) (48)
*80° F(27° C) Inlet Air
FIGURE 2-2 -AIR FLOW CHART
~wARNING
For aluminum oil coolers, do not use
any cleaning solution that is not com-
patible with aluminum. Use of improp-
er solution may result in damage to
the cooler.
Water-Cooled Units -The water-cooled unit with the
standard enclosure requires sufficient air flow,
FIGURE 2-2, for electric motor cooling. Air is drawn
intothe unit at the top of the enclosure and isexhausted
at the motor side, Do not block airflow to and from unit.
Allow three and one-half (3-1/2) feet (1.1 M) to the
nearest obstruction on the starter end and control box
side of the unit. Allow three (3) feet (.9 M) to the nearest
obstruction above and on other sides of the unit.
FOUNDATION -The G-D Rotary Screw compressor
requires no special foundation, but should be mounted
on asmooth, solid surface. Whenever possible install
the unit near level. Temporary installation may be made
at amaximum 10° angle lengthwise or 10° sidewise.
Mounting bolts are not normally required. However,
installation conditions such as piping rigidity, angle of
tilt, or danger of shifting from outside vibration or mov-
ing vehicles may require the use of mounting bolts and
shims to provide uniform support for the base.
OIL RESERVOIR DRAIN -The oil drain is piped from
the bottom of the reservoir to the side of the frame. This
drain is approximately 4.50 inches(115 mm) above the
floor level, If this is not sufficient to conveniently drain
the oil some other methods of providing drain are:
1. Elevate the compressor unit on asuitable struc-
ture to obtain the desired drain height.
~CAUTION
If the compressor unit base is raised
above floor level, the space between
the floor and the base bottom must be
closed with solid material all around
to prevent recirculation of hot air from
the oil cooler end and over tempera-
ture operation.
2. Construct an oil sump or trough below the floor
level and pump or bail the drained oil.
3. Pump oil from the reservoir filler opening or drain
to acontainer.
ENCLOSURE -The compressor, electric motor, oil
cooler and aftercooler are mounted inside the enclo-
sure. Service doors are provided for maintenance ac-
cess. Be sure to allow enough space around the unit
for the doors to open completely. Any of the enclosure
doors may be removed by opening the door and lifting
it up slightly to disengage the hinges.
I~DANGER
Do not operate the compressor with
the fan and coupling guard removed.
Exposed fan and belts may cause
injury to personnel.
The motor inspection/air filter service panel is held by
two latches and lifts away from the enclosure, The air
outlet panel isattached by screws to the enclosure and
is not readily removable.
INSTALLATION FOR COLD WEATHER OPERA-
TION (FIGURE 2-3, page 10) -It is recommended
that the unit be installed inside ashelter that will be
heated to temperatures above freezing (32° F, O°C).
This will eliminate many of the problems associated
with operating units in cold climates where freezing
rain, drifting snow, freezing condensate and bitter cold
temperatures are encountered.
Refer to Engineering Data Sheet 13-9-411 for the ad-
vantages of using the heat recovered from rotary com-
pressors. This heat recovery could easily pay for an ad-
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:
13-9/10-841 Page 9

WLLMN WINT 2-ELEMENT
HLATER (OR EOUAL) AWAY FROM PREVAIL ING WIND
RH7~ WITH 121 RH7W
ELWEN1.S -2 REOD
6ZC4 WATTS EACH
8FT. (2.4M)
PLYWOOD ““F ENCEoo
@FT PLWOW FENCC
(2.4 M) 4,m\_COMPKSS~
~LLMffl wlANT 2+LEMEN1
tEATER (OR EcUAL)
RH400 WITH ~RH4~
ELEMENTS -ZSfOD
3200 wATTS EACH +“ 4
MOTOR
/“
LJ
‘\
3FT
4FT.
~’(1.2M)
FIGURE 2-3- COLD WEATHER INSTALLATION
ELEVATION VIEW
Cold Weather (Down To +IO” F, -12°C)
1.
2.
3.
4,
5,
6.
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.
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.
Provide at least some simple shelter such as a ply-
wood windbreak to protect against drifting snow.
Use only Gardner Denver@ AEON 9000 SP lu-
bricant.
Monitor the unit carefully during start-up and op-
eration to be sure it is functioning normally.
Specify NEMA 4enclosure for electrical devices.
Extreme Cold Weather Operation (Down To -40° F,
-40° c)
In addition to the above, the following should be pro-
vided:
1. It will be necessary to provide shutters or to block
off part of the cooler in some manner since the
cooler is greatly oversized for operation in these
low temperatures. Since shutters are not pro-
vided as a factory option, blocking off aportion of
the cooler with plywood should be satisfactory.
2. Auto operation should not be used in extreme en-
vironments.
3. Some means of providing heat during shutdown
should be provided. There are various methods
to accomplish this, but since openings are not pro-
vided for sump heaters, the use of radiant heaters
is recommended, The heaters should be sized to
provide at leasta+1O”F(-12°C) environment for
coolers, motor and sump. FIGURE 2-3, page 10,
shows how these might be located in atypical
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.
Refer to Engineering Data Sheet 13-9-411, available
from an authorized Gardner Denver distributor, for the
advantages of using the heat recovered from rotary
compressors. This heat recovery could easily pay for
an adequate shelter for the unit.
AUXILIARY AIR RECEIVER -An auxiliary air receiver
is not required ifthe piping system islarge and provides
sufficient storage capacity to prevent rapid cycling.
When used, an air receiver should be of adequate size,
provided with arelief valve of proper setting, apressure
gauge and ameans of draining condensate. Ameans
of draining condensate will need to be provided for.
MOISTURE SEPARATOR/TRAP -Since the unit is
equipped with abuilt–in aftercooler, acombination
moisture separator and trap is furnished with the unit.
13-9/10-641 Page 10