Gardner Denver ELECTRA-SCREW 60 HP Manuale utente

139-607

8th Edition

ELECTra- SCREW

STATIONARY

BASE MOUNTED

COMPRESSOR

●60Hp– Models ECK_.K (ESK)

●75 HP –Models ECK_L (ESL)

100 HP –Models ECK_M(ESM)

13-9-607

GARDNER-DENVER

COOPER

INDUSTRIES INDUSTRIAL MACHINERY DIVISION

ELECTRA-SCREW@

Gardner-Denver compressors (the “Company”) warrants its

products only as follows:

GENERAL PROVISIONS AND LIMITATIONS

The Company warrants to each original retail purchaser

(“Purchaser”) of its new products from the Company or its

authorized distributor that such products are, at the time of

delivery to the Purchaser, made with good material and work-

manship, provided that no warranty is made with respect to:

Any product which has been repaired or altered in

such away, in the Company’s judgment, as to affect

the product adversely.

Any product which has, in the Company’s judgment,

been subject to negligence, accident, improper storage,

or improper installation or application.

Any product which has not been operated or main-

tained in accordance with normal practice and with

the recommendations of the Company.

Components or accessories manufactured, warranted

and serviced by others, except as separately rated.

Any reconditioned or prior owned product.

Claims fur items described in (4) above should be submitted

directly to the manufacturer.

The Company’s obligation under this warranty is limited to

furnishing repaired part or, at its option, replacement part,

during normal business hoursat an authorized service facility

of the Company, for any part which in its judgment proved

not to be as warranted within the applicable Warranty Period.

During the first 90 days from initial use, not to exceed 120

days from date of shipment to fust Purchaser, labor forinstal-

lation of such apart will be provided without charge to the

user during normal working hours at an authorized service

facitity of the Company. All costs of transportation of parts

claimed not to be as warranted and ofrepaired or replacement

parts and service personnel from such service facility shall be

borne by the Purchaser. The Company may require the return

of any part claimed not to be as warranted to one of its facil-

ities as designated by Company, transportation prepaid by

Purchaser, to establish aclaim under this warranty.

Replacement parts provided under the terms of this warranty

are warranted for the remainder of the Warranty Period of

the product upon which installed to the same extent as if

such parts were original components thereof.

GARDNER-DENVER

AND ELECTRA-SAVER@ COMPRESSORS

WARRANTY

WARRANTY PERIOD

Basic compressor air ends, consisting of all parts within and

including the compressor cylinder and gear housing, are war-

ranted for 24 months from date of initial use or 27 months

from date of shipment to the frost Purchaser, whichever

occurs frost.

Electric motors and oil coolers are warranted for 12 months

from &te of initial use or 15 months from date of shipment

to first Purchaser. whichever occurs first.

All other components are warranted for 6months from date

of initial use or 9months from date of shipment to first

Purchaser, whichever occurs first.

DISCLAIMER

THE COMPANY MAKES NO OTHER WARRANTY OF

ANY KIND WHATSOEVER EXPRESSED OR IMPLIED

AND ALL WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR APARTICULAR PURPOSE ARE HERE-

BY DISCLAIMED BY THE COMPANY. THE COMPANY

SHALL IN NO CASE BE SUBJECT TO ANY OTHER

OBLIGATIONS OR LIABILITIES WHATSOEVER WITH

RESPECT TO PRODUCTS OR SERVICES MANUFAC-

TURED OR FURNISHED BY IT OR ANY ACTS OR

OMISSIONS RELATING THERETO. THE REMEDY PRO-

vided UNDER THIS WARRANTY SHALL BE THE

SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE

TO PURCHASER. UNDER NO CIRCUMSTANCES SHALL

THE COMPANY BE LIABLE FOR ANY SPECIAL, IN-

DIRECT, INCIDENTAL OR CONSEQUENTIAL dam-

AGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER

CAUSED.

NO statement, representation, agreement, or understanding,

oral or written, made by any agent, distributor, representative,

or employee of the Company which is not contained in this

Warranty will be binding upon the Company unless made

in writing and executed by

This warranty shall not be

is not presented within 30

the product is claimed not

action for breach of this

within one year after the

action occurred.

an officer of the Company.

effective as to any claim which

days after the date upon which

to have been as warranted. Any

warranty must be commenced

date upon which the cause of

Any adjustment made pursuant to this warranty shall not

be construed as an admission by the Company that any

product was not as warranted.

FOREWORD

GARDNER- denver ELECTRA-SCREw compressors are the result of advanced engineering and skilled manufacturing To be

assured of receiving maximum service from this machinery the owner must exercise care in its operation and maintenance This book

is written to give the operator and the 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

THIS BOOK COVERS THE FOLLOWING MODELS

?AIR COOLED WATER COOLED

60 HP ECKQ_D (ESKAE) 100 Psl ECKSK_D (ESKAF) 100 Psl

ECKQK_F (ESKBE) 125 PSI ECKSK_F (ESKBF) 125 PSI

ECKQL_D (ESLAE) 100 Psl ECKSL_D (ESLAF) 100 Psl

75 HP ECKQL_F (ESLBE) 125 PSI ECKSl_F (ESLBF) 125 PSI

ECKQi_H (ESLCE) 150 Psl ECKSL_H (ESLCF) 150 Psl

ECKQM_D (ESMAE) 100 Psl ECKSM_D (ESMAF) 100 Psl

100 HP ECKQM_F (ESMBE) 125 PSI ECKSM_F (ESMBF) 125 PSI

ECKQM_H (ESMCE) 150 Psl ECKSh4H (ESMCF) 150 Psl

INDEX

NOTE Numbers preceding dash are Section Numbers —numbers following dash are Page Numbers

Accessories Auxiliary ............................... .. 2-3

Acoustic Enclosure ............................... 2-2, 3-1

Addition of Oil Between Changes ..................... 5-2

Adjustment Operating Air Pressure

(Auto Start-Stop Control) ........................... 4-10

Adjustment Operating Air Pressure

(Constant Speed Control ........................... 4-9

Adjustment Operating Air Pressure

(Dual Control) ...................................... 4-11

Adjustment Operating Air Pressure

(Duomatic Control) ................................. 4-12

Aftercooler ............................................. 2-3

Aftercooler —Heat Exchanger Water Piping 2-5

Air-Cooled Unit —Location ........................... 2-1

Air Filter ..................................... 3-1, 6-1,8-1

Air Filter (Heavy Dutyj ................................. 6-1

AI RFILTERS(SECTION6) .......................... 6-1

Air Flow . . . . . . . 1-1

Air& Oil Discharge Temperature. . . . . . . . . . . . . . . . . . . . . 5-8

Air-Oil Systems Flow Diagram ......................... 5-1

Air Pressure Adjustment Operating

(Auto Start-Stop Control) . . 4-1o

Air Pressure Adjustment Operating

(Constant Speed Control) ........................ .. 4-9

Air Pressure Adjustment Operating

(Dual Control) . . 4-11

Air Pressure Adjustment Operating

(Duomatic Control) . . . 4-12

Air Pressure Gauge ................................... 4-8

Air Receiver, Auxiliary .2-3

Air Temperature Shutdowq High ...................... 4-1

Air valve Bleed ....................................... 4-9

Alignment Coupling ........ ..................... 3-1, 7-1

Alignment of Compressor& Motor ................... 10-9

Assembly instructions ................................ 10-4

Automatic Blowdown System... ....................... 5-7

Automatic Blowdown Valve ................... ........ 4-1

Automatic Start-Stop Control System . . 4-9

Automatic Start-Stop (Duomatic) ..................... 4-11

Automatic Start-Stop Timed (Duomatic) .4-11

Auxiliary Accessories .................................. 2-3

Auxiliary Air Receiver .................................. 2-3

Bleed Air Valve .............................. .. ...... 4-9

Blowdown system, Automatic ..... ............ ...... 5-7

Blowdown valve, Automatic ........................... 4-1

Blowdown Valve Piping ................................ 2-5

Breaker, Circuit ................. 4-1

Capacities Oil .................................... 5-2

Check List Service .............. . 8-1

Check Valve (Oil Reservoir) ........................... 4-8

Circuit Breaker ........................................ 4-1

Cleaning and Draining Oil System .5-2

Clearance Chart– Unit Cold ........................ 10-6

Clearances Running .......................... . 10-10

Cold Ambient Operation ............................... 5-2

Cold Weather Operation Installation for .2-2

Compression Principle ................................. 1-1

Compressor ............................................ 1-1

Compressor &Motor Alignment.. .................... 10-9

Compressor Lubricants ................ ..... .. ...... 5-1

Compressor Oil ................................. ...... 3-1

Compressor Oil Cooler –Radiator Type 5-3

Compressor Oil Cooler —

Water-Cooled Heat Exchanger .... ................. 5-4

Compressor Oil Filter ................ ................. 5-3

Compressor Oil Inlet Temperature .................... 5-8

Compressor Oil Separator ....... 5-5

Compressor Oil System ............................... 5-1

Compressor Oil System Check.. .............. ....... 5-8

COMPRESSOR OVERHAUL (SECTION 10) .10-1

13-9-607 Page i

Compressor, Sectional View 10-3

Constant Speed Control System . . . . . . . . . . . . . . . . . . . . 4-8

Constant Speed (Duomatic) . . . . . . . . . . . . . . . . . . . . . . . 4-11

Control Piping ............. .... ................. 2-5

CONTROLS &INSTRUMENTS (SECTION 4) 4-1

Control System Automatic Start-Stop . . . . . . . . . . . . 4-9

Control System, Constant Speed... ............4-8

Control System Dual . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Control System Duomatic . . . . . . . . . . . . . . . . . . 4-11

Control Valve Oil Flow

(Duomatic Control Unit Only) . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Control Valve Thermal (Thermostatic Mixing) 5-3

Control Valve, Water Flow . . . . . . . . 5-5

Control Voltage ................... 4-1

COUPLING (SECTION 7) . . . . . . . . . . . 7-1

Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagrams Wiring 4-2 thru 4-7

Differential Group Pressure ........................... 5-8

Differential\ Oil Cooler Oil Pressure

(Air-Cooled Radiatorj 5-8

Differential Oil Cooler Oil Pressure

(Water-Cooled Heat Exchanger 5-8

Differential\ Oil Cooler Temperature

(Air-Cooled Radiator 5-8

Differential!, Oil Cooler Temperature

(Water-Cooled Heat Exchanger 5-8

Differential Oil Cooler Water Pressure

(Water-Cooled Heat Exchanger) 5-8

Dimensions 10-10

Disassembly Instructions, ....... 10-1

Discharge Temperature Air &Oil 5-8

Discharge Pressure Valve Minimum 4-8

Discharge Service Line ................... ...... ..... 2-5

Drain Oil Reservoir ....................... ............ 2-2

Draining and Cleaning Oil System .5-2

Dual Control System .............. 4-10

Du,omatic Control System ..,..... 4-11

Dust Cup(Heavy-Duty Air filter) . . . . . . . . . . . . . . . . . . 6-1

Electrical ........................ 3-1

Electrical Wiring . . 4-9thru 4-12

Electrical Wiring Diagrams .4-2 thru 4-7

Electrical Wiring (Standard Units) 2-5

Element life, Filter (Heavy Duty). ..................... 6-2

Enclosure Acoustic ............................... 2-2, 3-1

Filling Oil Reservoir ... 5-3

Filter, Air ............................ 3-1, 6-1,8-1

Filter, Compressor Oil . . 5-3

Filter Element (Heavy Dutyj ........................... 6-1

Filter Element Life (Heavy Duty) . . . . . . . . . . . . . . . . . . . . . . 6-2

Filter, Heavy Duty Air ................... 6-1

FILTERS, AI R(SECTION6) . . . . . . . . . . . . . . . . . . . . . . . 6-1

Fits . .............. 1o-1o

Flow Control Valve Oil

(Duomatic Control Unit Only) ........................ 5-7

Flow Diagram —Air-Oil Systems. . . . . . . . . . . . . . . . . . . . . 5-1

Foundation . . 2-2

Gauge, Air Pressure .............. 4-8

Gauge, Oil Level ......................... ....... .... 5-2

Gauge, Oil Temperature ........... . . 4-8

Gauges& Instruments ................................. 4-8

General (Controls) .......................... .......... 4-1

GENERAL INFORMATION (SECTION 1) ... 1-1

General installation . . . . . . . . . . . . . . . . . . . 2-1

Grease Recommendations ........ 2-6

Grounding .................................... 2-6

Heat Exchanger, Water-Cooled Compressor

Oil Cooler ........... .. ................... . .. 5-4

Heat Exchanger Water Flow Control Valve 5-5

Heat Exchanger Water Shutoff Valve 5-5

Heavy Duty Air Filter ............. 6-1

High Air Temperature Shutdown 4-1

High Temperature Operation ............. . .......... 5-2

Hourmeter ........,..,.. 4-8

INFORMATION, GENERAL (SECTION 1) 1-1

Inlet Line, ...................... .... ..... ......... . 2-5

inlet Pressure Oil ................ 5-8

Inlet Screen &Tube (Heavy Duty Air Filter) 6-2

Inlet Temperature, Compressor Oil . . . . . . . . . . . . . . . . . . 5-8

Inlet Valve (Constant Speed Control 4-9

inlet Valve (Duomatic Control 4-12

Installation for Cold Weather Operation . . . . . . . . . . . . . 2-2

INSTALLATION (SECTION2) 2-1

INSTRUMENTS &CONTROLS

(sEcTloN 4) ........................................ 4-1

Instruments &Gauges ............ 4-8

Lifting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Light test, Operating ............. 3-1

Location (installation) ............. 2-1

Lubricantq Compressor 5-1

Lubricants, Synthetic ........... .... ..... .... ..... 5-1

Lubrications, Cooling &Sealing 1-1

Lubrication Motor..,.. 2-6, 8-1

LUBRICATION, OIL COOLER, OIL FILTER &

SEPARATOR (SECTION5) .5-1

Maintenance of Air Filters ....... 6-1, 6-2

MAINTENANCE SCHEDULE (SECTION 8) 8-1

Minimum Discharge Pressure Valve 4-8

Mixing Valve, Thermostatic (Thermal Control) 5-3

Mode, Operating ................... ............... ... 3-1

Moisture Separator Trap .. ....................... ... 3-1

Motor &Compressor Alignment . . . 10-9

Motor Lubrication ......................... ....... 2-6, 8-1

Motor Protection Devices 4-1

Oil& Air Discharge Temperature. .5-8

OiF-Air Systems Flow Diagram ......................... 5-1

Oil Capacities .................................... . 5-2

Oil Change Interval .................................... 5-2

oil, Compressor .................................... 3-1

Oil Cooler, Compressor –Radiator Type 5-3

Oil Cooler, Water-Cooled Heat Exchanger 5-4

Oil Cooler Oil Pressure Differential

(Air-Cooled Radiatorj ................................ 5-8

Oil Cooler Oil Pressure Differential

(Water-Cooled Heat Exchanger . . 5-8

Oil Cooler Temperature Differential

(Air-Cooled radiator ................................ 5-8

Oil Cooler Temperature Differential

(Water-Cooled Heat Exchanger) 5-8

Oil Cooler Water Pressure Differential

(Water-Cooled Heat Exchanger) . . 5-8

Oil Filter, Compressor . . . . . 5-3

Oil Flow Control Valve

(Duomatic Control Unit Only) ........................ 5-7

Oil Inlet Pressure ...................................... 5-8

Oil Inlet Temperature Compressor .................... 5-8

13-9-607 Page ii

Oil Level Gauge ..................... .... .... ....... 5-2

Oil Pressure Differential\ Oil Cooler

(Air-Cooled radiator . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Oil Pressure Differential\ Oil Cooler

(Water-Cooled Heat Exchanged 5-8

Oil Reservoir .................................... . .. 5-5

Oil Reservoir Check Valve 4-8

Oil Reservoir Drain ............... 2-2

Oil Reservoir, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Oil Separator, Compressor 5-5, 8-1

Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Oil System Check, Compressor 5-8

Oil System, Compressor . . . . . . . . . . 5-1

Oil system Draining &Cleaning 5-2

Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . 4-8

on-off Switch ....... .............. 4-1

Operating Air Pressure Adjustment

(Auto Start- Stop Control) ................ 4-10

Operating Air Pressure Adjustment

(Constant Speed Control) 4-9

Operating Air Pressure Adjustment

(Dual Control) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Operating Air Pressure Adjustment

(Duomatic Control) 4-12

Operating Light Test 3-1

Operating Mode . . . . . . . . . . . . . . . . . . 3-1

OPERATING PROCEDURES& STARTING

(sEcTloN 3) ........................................ 3-1

Operation High Temperature............,,., 5-2

OVERHAUL COMPRESSOR (SECTION 10) 10-1

Pilot Subtractive ................ 4-8

Piping ............................. 3-1

Piping Aftercooler —Heat Exchanger Water 2-5

Piping Blowdown Valve .... .......... .. ............ 2-5

Piping Water (Water-Cooled Heat Exchanger 2-5

Pressure Adjustment Operating Air

(Auto Start-Stop Control) ........................... 4-10

Pressure Adjustment Operating Air

(Constant Speed Control) ............ ............. 4-9

Pressure Adjustment Operating Air

(Dual Control) .4-11

Pressure Adjustment Operating Air

(Duomatic Control) 4-12

Pressure Differential Group 5-8

Pressure Differential\ Oil Cooler Oil

(Air-Cooled Radiator) . . 5-8

Pressure Differential\ Oil Cooler Oil

(Water-Cooled Heat Exchanger . . . . . . . . . . . . . . . . . . . . 5-8

Pressure Differential\ Oil Cooler Water

(Water-Cooled Heat Exchanger .5-8

Pressure Gauge Air . . . . . . . . . . . . . . . . 4-8

Pressure Oillnlet ..................... ............... 5-8

Pressure Switch Reservoir .......................... 4-12

Pressure System ................. 3-1

Pressure Valve Minimum Discharge 4-8

Radiator-Type Compressor Oil Cooler 5-3

Rebulding Data for Gear-Driven Compressors 10-10

Receiver, Auxiliary Air ........ ....... ............ ... 2-3

Regressing interval .................................... 2-6

Remote Starter . . . . . . . . . . . . . . . . . . . . 2-5

Reservoir Check Valve, 0il ............................ 4-8

Reservoir Drain Oil ................ 2-2

Reservoir, Oil .......................................... 5-5

Reservoir Pressure Switch ....... ............... ... 4-12

Rotation .................................. . 3-1

Running Clearances ................................ 10-10

Safety Devices ..... ...... .... ............. .... 4-1

Safety Valve ............. ..... ................ 4-8

Sectional View of Compressor . . . . . . . . . . . . . . . . . . 10-3

Separator, Compressor Oil 5-5, 8-1

Service Checklist .... ... .. ....... .. .... . ...... 8-1

Shutdown High Air Temperature ...................... 4-1

Shutoff Valve, Water —Heat Exchanger 5-5

Specifications, Oil ...... .. ...... ... .. ...... .. 5-1

Starter, Remote ................. 2-5

STARTING &OPERATING PROCEDURES

(sEcTloN 3) ........................................ 3-1

Starting Unit ...................... 3-1

Stopping Unit .................... 3-2

Subtractive Pilot ................ 4-8

Switch, On-Off ...................... 4-1

Switch, Reservoir Pressure . . . . . 4-12

Synthetic Lubricants ............. 5-1

System Pressure 3-1

Temperature Air& Oil Discharge 5-8

Temperature Compressor Oil Inlet ................... 5-8

Temperature Differential\ Oil Cooler

(Air-Cooled Radiator 5-8

Temperature Differential\ Oil Cooler

(Water-Cooled Heat Exchanger) 5-8

Temperature Gauge, Oil .,.,..... 4-8

Temperature Operation, High.5-2

Temperature Shutdown, High Air......,..,..,.. 4-1

Thermal Control (Thermostatic Mixing) Valve 5-3

Timed Automatic Start-Stop (Duomatic Control) 4-11

Torque Recommendations ..... . ................... 10-4

TROUBLE SHOOTING (SECTION 9) 9-1

Valve Automatic Blowdown 4-1

Valve, Bleed Air ............... ................. .. 4-9

Valve Check (Oil Reservoir) .4-8

Valve Inlet (Constant Speed Control) ..... ........... 4-9

Valve lnlet (Duomatic Control) .......... 4-12

Valve Minimum Discharge Pressure 4-8

Valve Oil Flow Control (Duomatic

Control Unit Onlyj ..... ... .. ..... .... ..... ..... 5-7

Valve Piping Blowdown .2-5

Valve Safety ........................... ............... 4-8

Valve Thermal Control (Thermostatic Mixing) 5-3

Valve, Water Flow Control ...... 5-5

Valve Water Shutoff —Heat Exchanger .5-5

Voltage Control .4-1

Water-Cooled Heat Exchanger Compressor

Oil Cooler ....................................... 5-4

Water-Cooled Unit —Location ........................ 2-1

Water Flow Control Valve for Heat

Exchanger ...................... . 5-5

Water Flow Rates ............. ....... ............ 2-5

Water Piping Aftercooler —Heat

Exchanger ........................ 2-5

Water Piping (Water-Cooled Heat Exchanger

Models Only) ..................... ................. 2-5

Water Pressure Differential\ Oil Cooler

(Water-Cooled Heat Exchanger) 5-8

Water Shutoff Valve —Water-Cooled Heat

Exchanger ......................... .......... 5-5

Wiring Diagrams ................ .. ......... 4-2 thru 4-7

Wiring Electrical ........................... 4-9, thru 4-12

Wiring Electrical —Standard Units 2-5

13-9-607 Page iii

SECTION 1

GENERAL INFORMATION

FIGURE 1-1. –COMPRESSION CYCLE

COMPRESSOR —The Gardner-Denver Model “ES" or

“ECK" Electra- Screw compressor is asingle stage positive

displacement rotary machine using meshing helical rotors

to effect compression The input drive shaft and helical

drive gear are supported in the gear case by high capacity

ball bearings the drive gear meshes with adriven gear

mounted on the main rotor shaft to drive the rotors Both

rotors are supported between large capacity antifriction

bearings located outside the compression chamber. Single

width cylindrical roller bearings are used at the inlet end of

the rotors Two heavy-duty single row angular contact ball

bearings at the discharge end locate each rotor axially and

carry all thrust loads

COMPRESSION PRINCIPLE (Figure l-l) —Compression

is accomplished by the main and secondary rotors

synchronously meshing in aone-piece cylinder. The main

rotor has four helical lobes 90° apart The secondary rotor

has six matching helical grooves 60° apart to allow meshing

with main rotor lobes

The air inlet port is located on top of the compressor 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 inverted 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 rotor grooves (A). When the rotors pass

the inlet port cutoff, air is trapped in the interlobe cavity and

flows axially with the meshing rotors (B). As meshing

continues more of the main rotor lobe enters the secondary

rotor groove normal volume is reduced and pressure

increases Oil is injected into the cylinder to remove the

heat of compression and seal internal clearances Volume

reduction and pressure increase continues until the air/oil

mixture trapped in the interlobe cavity by the rotors passes

the discharge port and is released to the oil reservoir (C).

Each rotor cavity follows the same “fill-compress-discharge”

cycle in rapid succession to produce adischarge air flow that

is continuous smooth and shock-free

AIR FLOW (Figure 1-5) —Air enters the air filter and

passes through the inlet unloader valve to the compressor.

After compression the air/oil mixture passes into the oil

reservoir where most of the entrained oil is removed by

velocity change and impingement and drops back into the

reservoir. The air and remaining oil then passes through the

oil separator the separated oil is returned to the system

through tubing connecting the separator and compressor.

The air passes through the reservoir discharge manifold

minimum pressure valve discharge check valve and the unit

shutoff globe valve to the plant air lines

DANGER

!Do not use the air dischargedfrom this unit for breathing

not suitable for human consumption

LUBRICATION, COOLING AND SEALING —Oil is forced

by air pressure from the oil reservoir through the oil cooler,

thermostatic mixing valve (mixing valve is not used with

the water-cooled oil cooler, and oil filter and discharges

into the compressor main oil gallery. Aportion of the oil

is directed through internal passages to the bearings gears

and shaft oil seal The balance of the oil is injected directly

into the compression chamber to remove heat of compres

sion seal internal clearances and lubricate the rotors

13-9-607 Section 1Page 1

13-9-607 Section 1Page 2

SECTION 2

INSTALLATION

GENERAL —On receipt of the unit check for any damage

that may have been incurred during transit Report any

damage or missing parts as soon as possible

~WARNING

DO NOT electric weld on the compressor or base,

bearings can be damaged by passage of current

LIFTING UNIT —Early models were furnished with

lifting bails, later models are not so equipped Proper lifting

and/or transporting methods must be used to prevent

damage

CAUTION

Where lifting bail is not supplied liftcompressor unit

by base only. Do not use other places such as enclosure

motor, compressor oil discharge manifold and piping as

lifting points

DANGER

The eyebolts or lugs provided on the motor are forlifting

the motor only and should not be used to lift any addi-

tional weight All eyebpolts must be securely tightened

When lifting the motor the lifting angle on the eyebolts

must not exceed 15 degrees. failure to observe this

warning may result in damage or personal injury.

Physical size and weight of unit Figure 1-2, may allow use

of tow motors Unit may also be moved into location by

rolling on bars Acoustic enclosure if supplied may easily

be removed if deemed necessary for weight or size reduction

‘.OUVERED

,,, !., mn,,, EXHAUST FAN LOUVERE-

,.,,.,--,.

AIR OUT M

Dimensions

Approx

Model HP Weight H’ HL* Lw w

ESK ECL_K 60 3800 60 56 76 70 54 48

ESL ECK_L 75 4000 60 56 76 70 54 46

ESM ECK_M 100 4600 60 56 76 70 54 48

FIGURE 1-2.

13-9-607 Section 2

A75119

FIGURE 2-2. –TYPICAL COMPRESSOR ROOM

LOCATION— The compressor should be installed where

ever possible in aclean well-lighted well ventilated area with

ample space all around for maintenance 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 compressor 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 exhausted from the

compressor operating area Atypical inlet-outlet air flow

arrangement is shown in Figure 2-2.

Air Cooled Unit —The air-cooled unit with the standard

acoustic enclosure requires sufficient air flow, Figure 3-2,

for the compressor oil cooling system and for electric motor

coolin”g Air is drawn into the unit around the base of

the enclosure and is exhausted vertically. Do not block

the air flow to and from the unit Allow two (2) feet

to the nearest obstruction on all sides and above the

unit When the air-cooled unit is used without an

enclosure all of the above ventilating and cooling air

requirements also apply.

IMinimum Air Flow For Compression

And Cooling (Cubic Feet/Minute) I

Model

ESK ECK_K

ESL ECK_L

ESM, ECK_M

Air Cooled Water Cooled

8400 cfm I2400 cfm I

8000 cfm I2400 cfm

*80° F. Inlet Air

FIGURE 3-2.

WaterCooled Unit —The water-cooled unit with the

standard acoustic enclosure requires sufficient air

flow, Figure 3-2, for electric motor (Main drive and

Page 1

enclosure vent fan) cooling Air is drawn into the unit

around the base of the enclosure and is exhausted vertically.

Do not block air flow to and from the unit Allow two (2)

feet to the nearest obstruction on all sides and above the

unit Lubricate the vent fan motor every 8000 hours of

operation with two (2) drops of SAE 20 oil When the water-

cooled unit is used without an acoustic enclosure all of the

above ventilation and cooling air requirements also apply.

FOUNDATION —The Electra-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 30° sidewise.

Mounting bolts are not normally required However, in-

stallation conditions such as piping rigidity, angle of tilt or

danger of shifting from outside vibration or moving vehicles

may require the use of mounting bolts to the foundation

Coupling alignment must be checked after installation

OIL RESERVOIR DRAIN —The oil reservoir drain valve

is located behind the reservoir foot at the instrument panel

end of the unit On all models the drain valve is approximately

six(6) inches from the floor level If this height is not sufficient

to conveniently drain the oil some other methods of pro

vialing oil drain are:

1. Elevate the compressor unit on raising blocks to ob

tain 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

acontainer.

ACOUSTIC ENCLOSURE —The Electra- Screw unit is

furnished with an acoustic enclosure as standard equipment

The enclosure reduces the normal operating sound of the

unit to alevel below 80 DBA in free field conditions

In order to maintain the sound reduction ability of the

cabinet only the final discharge air line penetrates the em

closure At the time of installation other openings for

electrical conduit oil drain piping and water piping are to

be cut into the enclosure at convenient positions for con-

nection to external wiring and piping All openings should

be no larger than necessary for conduit or pipe diameter

the conduit or pipe should not touch the enclosure When

all conduit pipes are in place the open space between them

and the enclosure panel should be sealed with arubber

grommet or elastic caulk

S’ervice doors are provided for access to the instrument

panel and controls the oil and air filters and the starter

enclosure Be sure to allow enough room above the unit for

panel and separator removal

The air for the compressor and for enclosure is drawn in

around the base and is exhausted from the top of the

enclosure Do not block this air flow or allow the floor area

near the enclosure to accumulate dirt

~WARNING

DO not operate unit with access doors removed Doors

must be in place and closed to direct cooling air over

motor and coolers

DANGER

Do not open service doors while compressor is operating

Open doors will expose rotating fan and coupling

INSTALLATION FOR COLD WEATHER OPERATION –

It is recommended that whenever possible the unit be in-

stalled inside ashelter that will be heated to temperatures

above freezing (32° F., 0° C.). This will eliminate many of

the problems associated with operating the units outside

in cold climates where freezing rain, drifting snow, freezing

condensate and bitter cold temperatures are encountered

When an outside installation must be made the precautions

required will depend on how severe the environment will

get The following are general guidelines for outside in-

stallations

Cold Weather (Down To +10° F.)

1. Be sure all control lines drains and traps are heated

“- ‘“

I~. ‘F’’::k:!:”(::”:::x:-’’’”’”’

&RH400 WITH (2) RH4502

1— I()l? ELEMENTS —2REQ’D.

3,2oO WATTS EACH .

8FT. PLYWOOD “FENCE”

\4FT.

VI IIh WE LLMAN RADIANT 2-ELEMENT

HEATER (OR EQUAL)

*’E;:’’’;’” r~h: }

~- [111

AWAV FROM PREVAILING WIND

TOP VIEW 8FT. PLVWOOD “FENCE” ELEVATION VIEW

FIGURE 4-2.

13-9-607 Section 2Page 2

SUPPLY LINES MUST DRAIN &WAY

FROM RECEIVER. PROVIDE DRAINS

As 5H0w N AND AT LOWER END.

wATER MuST BE PIPED

ABOVE TOP OF

AFT ERcoOLER TO

INSURE COMPLETE ‘- ““

IMMERSION OF TUBES

AIR

DISC HARGF -

5ERv1CE VALVF

COMPRESSOR

.OIL RESERVOIR

./ .. ..

WATER FLOW

CONTROL ____

REGULATOR

WHEN ORWRED

BYPASS VALVE

FOR INITIAL

FILLING

ADJuSTABLE

MINIMUM

BYPASS VALVE

WATER TO HEAT

EXChANGER OIL

COO1. EQ OR JRAIN

MAGNETIC

WATER SHUT

OFF VALVE

WHEN O,ROERED

MOISTURE ___

SE PA RATC6 ‘-

FLOAT TRAP

WHEN ORDERED

“\

[

!4$

To DRAIN-— --

\’ —,

FIGURE 5-2. –AUXILIARY

to avoid freezing of condensate Heat tape with thermo-

stat control is generally satisfactory for this purpose

and can be obtained at various local plumbing or hard

ware outlets at nominal cost

If an air-cooled aftercooler is to be used provisions to

bypass the aftercooler should be made Since cold air

contains very little moisture successful operation can

be achieved without the aftercooler.

Provide at least some simple shelter such as a plywood

windbreak to protect against drifting snow.

Use only Gardner-denver GD800 lubricant

Monitor unit carefully during start-up and operation to

be sure it is functioning normally.

Specify NEMA 4enclosure for electrical devices

Extreme Cold Weather Operation (Down To i40° F.)

In addition to the above the following should be provided

1. It will probably 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 provided as a

factory option blocking off aportion of the cooler with

plywood should be satisfactory.

3. Lo Demand operation should be used in extreme en-

vironments

SAFETY VALVE I

,/“ –---A

‘T

~~ II

.—

AIR RECEIVER

,GAUGE

OUTLET

3/ 411

“~

DROP

LEGS

\,RAIN/

VALVES

THIS TYPE CONNECTION

PREVENTS CONDENSATE

FROM BEING CARRIED

OVER WITH AIR

D75120

ACCESSORIES

4. Some means of providing heat to the oil reservoir and

cooler during shutdown should be provided There are

various methods to accomplish this but since openings

are not provided for sump heaters the use of radiant

heaters is recommended

The heaters should be sized to provide at leasta+10° F.

environment for the coolers motor and sump Figure

4-2 shows how these might be located in atypical in-

stallation and sizes required

Remember unsheltered (outside) installations should be

avoided where possible Installation next to aheated 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 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 —Constant speed control

units do not normally use an auxiliary air receiver. Auto-

matic start-stop dual and duomatic control units require an

auxiliary air receiver unless the piping system is large and

provides sufficient storage capacity to prevent rapid cycling

When used an air receiver should be of adequate size pro

vialed with arelief valve of proper setting apressure gauge

and ameans of draining condensate Figure 4-2 shows a

typical air receiver and auxiliary accessories

AFTERCOOLER (Figure 5-2) —An aftercooler will provide

13-9-607 Section 2Page 3

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