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GENERAL PROVISIONS AND LIMITATIONS

Gardner Denver Machinery Inc. (the “Company”) war-
rants 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.  No warranty is made with respect to:

1. Any product which has been repaired or altered

in such a way, in the Company’s judgment, as to
affect the product adversely.

2. Any product which has, in the Company’s judg-

ment been subject to negligence, accident, im-
proper storage, or improper installation or ap-
plication.

3. Any product which has not been operated or

maintained in accordance with the recommen-
dations of the Company.

4. Components or accessories manufactured, war-

ranted and serviced by others.

5. Any reconditioned or prior owned product.

Claims for items described in (4) above should be sub-
mitted directly to the manufacturer.

WARRANTY PERIOD

The Company’s obligation under this warranty is limited
to repairing or, at its option, replacing, during normal
business hours at an authorized service facility of the
Company, any part which in its judgment proved not to
be as warranted within the applicable Warranty Period
as follows.

COMPRESSOR AIR ENDS

Compressor air ends, consisting of all parts within and
including the compressor cylinder and gear housing,
are warranted for 24 months from date of initial use or
27 months from date of shipment to the first purchaser,
whichever occurs first.

Any disassembly or partial disassembly of the air end,
or failure to return the “unopened” air end per Company
instructions, will be cause for denial of warranty.

OTHER COMPONENTS

All other components are warranted for 12 months from
date of initial use or 15 months from date of shipment
to first purchaser, whichever occurs first.

LABOR TRANSPORTATION AND INSPECTION

The Company will provide labor, by Company repre-
sentative or authorized service personnel, for repair or

replacement of any product or part thereof which in the
Company’s judgment is proved not to be as warranted.
Labor shall be limited to the amount specified in the
Company’s labor rate schedule.

Labor costs in excess of the Company rate schedule
amounts or labor provided by unauthorized service per-
sonnel is not provided for by this warranty.

All costs of transportation of product, labor or parts
claimed not to be as warranted and, of repaired or re-
placement parts to or from such service facilities 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 facilities as designated by Company, trans-
portation prepaid by Purchaser, to establish a claim un-
der this warranty.

Replacement parts provided under the terms of the
warranty are warranted for the remainder of the War-
ranty Period of the product upon which installed to the
same extent as if such parts were original components.

DISCLAIMER

THE FOREGOING WARRANTY IS EXCLUSIVE AND
IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO
TITLE, THE COMPANY MAKES NO OTHER WAR-
RANTIES, EXPRESSED, IMPLIED OR STATUTORY,
INCLUDING ANY IMPLIED WARRANTY OF MER-
CHANTABILITY.

THE REMEDY PROVIDED UNDER THIS WARRAN-
TY SHALL BE THE SOLE, EXCLUSIVE AND ONLY
REMEDY AVAILABLE TO PURCHASER AND IN NO
CASE SHALL THE COMPANY BE SUBJECT TO ANY
OTHER OBLIGATIONS OR LIABILITIES. UNDER NO
CIRCUMSTANCES SHALL THE COMPANY BE LI-
ABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, EXPENSES,
LOSSES OR DELAYS HOWSOEVER CAUSED.

No statement, representation, agreement, or under-
standing, 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 an of-
ficer of the Company.

This warranty shall not be effective as to any claim
which is not presented within 30 days after the date
upon which the product is claimed not to have been as
warranted. Any action for breach of this warranty must
be commenced within one year after the date upon
which the cause of action occurred.

Any adjustment made pursuant to this warranty shall
not be construed as an admission by the Company that
any product was not as warranted.

WARRANTY

ROTARY SCREW COMPRESSORS

OIL INJECTED  

D

  OIL FREE

Summary of Contents for ELECTRA-SAVER ETY99A

Page 1: ...GARDNER DENVER ELECTRA SAVER TWO STAGE STATIONARY BASE MOUNTED COMPRESSOR AUTO SENTRY ES CONTROLS MODEL ETY99A 350 HP 500 HP OPERATING AND SERVICE MANUAL 13 13 600 1st Edition January 1998...

Page 2: ...er 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 Cen...

Page 3: ...severe personal injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severe person al injury death or substantial...

Page 4: ...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...

Page 5: ...ION 4 20 Controls Instruments General Description 20 Cooler Compressor Oil 36 Cooling Sealing and Lubrication 1 COUPLING SECTION 7 44 Coupling 44 Alignment 44 Individual Cushion Design 44 Daily Check...

Page 6: ...and Oil Discharge Temperature 41 Compressor Oil Inlet Temperature 41 Oil Cooler Oil Pressure Differential 41 Oil Cooler Temperature Differential 41 Oil Cooler Water Pressure Differential 41 Oil Inlet...

Page 7: ...ip 25 Thermal Control Thermostatic Mixing Valve 37 Thermistor Discharge 24 System 24 Transducer Reservoir Pressure 24 System Pressure 24 Transformer Control 25 TROUBLE SHOOTING SECTION 9 46 Tube Inlet...

Page 8: ...Ampacity Fuse and Breaker Sizes 15 Figure 4 1 Schematic Tubing Diagram 21 Figure 4 2 Blowdown Valve 22 Figure 4 3 Minimum Discharge Pressure Valve 22 Figure 4 4 Inlet Valve 23 Figure 4 5 Shuttle Valve...

Page 9: ...ve 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 duction and pressure increase continues u...

Page 10: ...er toward the inlet end The valve opens and closes ports in the cylin der which communicates with the inlet passage This varies the compressor rotor volume to match the de mand for air thus reducing t...

Page 11: ...13 13 600 Page 3 FIGURE 1 4 AIR COOLED UNIT LESS ENCLOSURE CONTROL BOX END 300ETY797 Ref Drawing FIGURE 1 5 AIR COOLED UNIT LESS ENCLOSURE OIL RESERVOIR END 300ETY797 Ref Drawing...

Page 12: ...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 D Electrical...

Page 13: ...and lockout be fore working on the unit this machine is automatically controlled and may start at any time D An Excess Flow Valve should be on all compressed air supply hoses ex ceeding 1 2 inch insid...

Page 14: ...13 13 600 Page 6 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 15: ...13 13 600 Page 7 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 16: ...ighted well ventilated area with ample space all around for maintenance Select a location that provides a cool clean dry source of air In some cases it may be necessary to install the air filter at so...

Page 17: ...conveniently drain the oil some other methods of providing oil drain are 1 Elevate the compressor unit on a suitable struc ture to obtain the desired drain height 2 Construct an oil sump or trough bel...

Page 18: ...remote located on the same level as the compressor unit but some distance away S Overhead remote located above level of the compressor unit as on a roof The machine cannot be run blown down with remo...

Page 19: ...ses under spring load when the unit is shut down to prevent return oil flow from the oil cooler A different control group will be assembled onto the package to control the oil stop valve and to preven...

Page 20: ...ler location 3 Pipe type and size s to be used to connect the af tercooler separator and compressor unit mini mum pipe size is 5 NPT 4 Lengths of the pipe run If more than one pipe size is used list l...

Page 21: ...he 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 recommend...

Page 22: ...If an Electra SaverR unit is manifolded to another com pressor be sure the other compressor has a check valve in the line between the machine and the manifold If an Electra SaverR and a reciprocating...

Page 23: ...m allowable water flow through the aftercooler is 70 gallons per minute on all 350 500 HP units Mini mum water pressure is 40 PSIG Maximum water pressure is 150 PSIG If another aftercooler is used con...

Page 24: ...nnection information Electrical shock can cause injury or death Open main disconnect switch tag and lockout before working on starter control box GROUNDING Equipment must be grounded in ac cordance wi...

Page 25: ...IUM R EXXON UNIREX 2 EXXON POLYREX Relubrication Type of Service Typical Examples Rating Interval Standard One or Two Shift Operation Above 150 HP 12 Months Severe Continuous Operation Above 150 HP 6...

Page 26: ...power may result in personal injury or death During unloaded operation and after shutdown the system will partially drain back into the oil res ervoir and the oil level may read higher than when oper...

Page 27: ...g starting procedures Unit Cold If the unit is a water cooled heat exchang er model open any manual water inlet valves wide open Start the unit by pushing either the CONSTANT RUN button or one of the...

Page 28: ...y time to stop the compressor under normal conditions Detailed instructions for the controller are found in the manual 13 9 10 647 Automatic restarting or electrical shock can cause injury or death Op...

Page 29: ...13 13 600 Page 21 FIGURE 4 1 SCHEMATIC TUBING DIAGRAM 302ETY797 A Ref Drawing...

Page 30: ...n the system pressure rises the spring is overridden and the valve opens to full porting The valve does not require maintenance or adjustment If the valve fails to function check the valve stem O ring...

Page 31: ...al discharge manifold to the compressor to counteract the oil knock that oc curs in oil flooded rotary screw compressors when they are completely unloaded with pressure in the oil reservoir This valve...

Page 32: ...use the keypad STOP RESET for normal controlled stopping Automatic restarting or electrical shock can cause injury or death Open tag and lockout main discon nect and any other circuits before servici...

Page 33: ...This provides connections for all 110 120 volt devices not contained within the enclo sure Fan Starter The starter is used to provide control and overload protection for the package fan Overload heate...

Page 34: ...13 13 600 Page 26 FIGURE 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD 304ETY797 A Ref Drawing...

Page 35: ...13 13 600 Page 27 FIGURE 4 9 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED CONSTANT SPEED MODE 305ETY797 A Ref Drawing...

Page 36: ...13 13 600 Page 28 FIGURE 4 10 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE 306ETY797 A Ref Drawing...

Page 37: ...13 13 600 Page 29 FIGURE 4 11 WIRING DIAGRAM 302ETY546 Ref Drawing...

Page 38: ...use in rotary screw compressors AEON lu bricants are available through your authorized Gardner Denver compressor distributor OIL SPECIFICATIONS The factory fill compressor lubricant is Gardner Denver...

Page 39: ...13 13 600 Page 31 FIGURE 5 1 FLOW DIAGRAM 303ETY797 A Ref Drawing...

Page 40: ...13 13 600 Page 32 307ETY797 A Ref Drawing OIL PIPING FOR REMOTE COOLER FIGURE 5 2 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED...

Page 41: ...vel from the red range to the center of the green range is shown in FIGURE 5 4 page 35 Repeated addition of oil between oil changes may indicate exces sive oil carry over and should be investigated Ai...

Page 42: ...se oil carryover If moisture is observed in the oil reservoir drain the moisture and correct the condition causing the accumulation See Compressor Oil System Check page 41 and Thermal Control Thermost...

Page 43: ...r plug 4 Remove the oil filler plug and add oil as required to return the oil level to the center of the green range on the gauge 5 Install the oil filler plug and operate the unit for about a minute...

Page 44: ...r from housing and remove 3 Screw new oil filter into housing 4 Run the unit and check for leaks BEARING OIL FILTER An oil filter of the spin on type is used This filter is a vital part in maintaining...

Page 45: ...rmal mixing valve as shown Modifications to the control lines will be made at the fac tory to control the oil stop valve Air to the oil stop valve must come from the dry side of the reservoir cover th...

Page 46: ...tain instances to inhibit corrosion and or remove dis solved solids to alter the water s tendency to form scale deposits or prevent the growth of microorgan isms The normal maintenance program for the...

Page 47: ...ional Equipment FIGURE 5 1 page 31 A magnetic solenoid oper ated water shutoff valve rated at 150 psig 10 3 Bars water pressure should be mounted in the water outlet line after the oil cooler The valv...

Page 48: ...re differential gauging or by in spection Pressure Differential Gauging The CHANGE SEPARATOR advisory will flash when the pressure differential across the oil separator reaches approxi mately 8 PSID 5...

Page 49: ...C Install a tee at the oil filter outlet and check with a thermometer Oil Inlet Pressure Check at the fitting in the line near the compressor oil inlet With air receiver pressure at 100 psi 6 9 Bar oi...

Page 50: ...arm water with a mild nonsudsing detergent Rinse the element thoroughly with clean water a hose may be used if the water pressure does not exceed 40 psig 2 8 Bars 4 Inspect the element for ruptures or...

Page 51: ...ect the inlet screen and tube for dirt accumulation each time the filter is serviced Clean the tube when required by ramming a clean dry cloth through the tube Wipe the inside of the filter body to re...

Page 52: ...sure the collar is installed on the shaft behind one coupling body 2 Assemble the motor to the compressor 3 Working through the coupling guard opening cen ter the coupling over the gap between the sh...

Page 53: ...core faces and the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of th...

Page 54: ...ps after a short time Air Temperature this section page 47 2 High discharge 2 Replace switch temperature switch malfunction 3 Blown fuse in starter 3 Replace fuse control box investigate if fuses cont...

Page 55: ...er or clean cooler interior cooler 5 Low compressor oil 5 Add oil to proper level Excessive Oil Consumption 1 Oil carryover through lines 1 See Oil Carryover below 2 Oil leaks at all fittings 2 Tighte...

Page 56: ...eration at elevated 7 Reduce temperature See discharge temperatures High Discharge Air Temperature page 47 this section 8 Scavenge line check 8 Replace check valve valve failure 9 Water condensate in...

Page 57: ...gment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedule amounts or labor provided...

Page 58: ...Specifications subject to change without notice Copyright 1998 Gardner Denver Machinery Inc...

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