Gardner Denver ELECTRA-SAVER G2 Operating And Service Manual Download

Page: 1 / 100

13-21-611

Version: 00

January 7, 2019

ELECTRA-SAVER G2 &

ELECTRA-SAVER II G2



STATIONARY BASE-MOUNTED

COMPRESSOR

AirSmart

™

G2 Controller

CONFIGURATOR

SAV75-100G2A - 75, 100 HP

ST75-100G2A - 75, 100 HP

OPERATING AND

SERVICE MANUAL

Summary of Contents for ELECTRA-SAVER G2

Page 1: ...Version 00 January 7 2019 ELECTRA SAVER G2 ELECTRA SAVER II G2 STATIONARY BASE MOUNTED COMPRESSOR AirSmart G2 Controller CONFIGURATOR SAV75 100G2A 75 100 HP ST75 100G2A 75 100 HP OPERATING AND SERVIC...

Page 2: ...necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair They are ready to respond and ass...

Page 3: ...mical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriate...

Page 4: ...low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Li...

Page 5: ...r oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any...

Page 6: ...trations 7 Section 1 General Information 8 Section 2 Installation 12 Section 3 Starting Operating Procedures 22 Section 4 Controls Instrumentation 33 Section 5 Lubrication Oil Cooler Oil Filter Separa...

Page 7: ...ng Valve 76 Oil Separator Compressor GD Eliminator 83 Inspection 84 Oil Carryover 83 Pressure Differential Gauging 84 Removal For Inspection Or Replacement 85 Oil Specifications 66 Oil System Compress...

Page 8: ...aver Only 37 Figure 4 5 Compressor Package P ID 41 Figure 4 6 Compressor Package Control Component States 42 Figure 4 7 Electra Saver Wiring Diagrams 43 Figure 4 8 Electra Saver II Wiring Diagrams 43...

Page 9: ...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 a...

Page 10: ...nd discharges into the compressor main oil gallery A portion 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...

Page 11: ...13 21 611 Page 10 1 3 Figure 1 4 COMPRESSOR MOTOR SIDE Figure 1 5 COOLER RESERVOIR SIDE 309EBD797 B Ref Drawing...

Page 12: ...13 21 611 Page 11 1 4 Figure 1 6 AIR OIL FLOW DIAGRAM 307EBD797 B Ref Drawing...

Page 13: ...as lifting points The eyebolts or lugs provided on the motors are for lifting the motors only and should not be used to lift any additional weight All eyebolts must be securely tightened When lifting...

Page 14: ...oling 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 1 M to...

Page 15: ...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 moving vehicles may requi...

Page 16: ...will depend on the severity of the environment The following are general guidelines for outside installations Cold Weather Down To 10 F 12 C 1 Be sure all drains traps and control lines including pre...

Page 17: ...provides sufficient storage capacity to prevent rapid cycling When used an air receiver should be of adequate size provided with a relief valve of proper setting a pressure gauge and a means of drain...

Page 18: ...ween the two units Discharge air used for breathing will cause severe injury or death Consult filtration specialists for additional filtration and treatment equipment to meet health and safety standar...

Page 19: ...OLER APPROXIMATE WATER FLOW WATER PIPING Water Cooled Heat Exchanger Models Only On machines equipped with water cooled heat exchangers the water inlet and outlet connections are located in the unit e...

Page 20: ...water warmer than 90 F 32 C is used higher compressor oil inlet temperatures and high water usage will result Most water systems will require control of impurities filtration softening or other treat...

Page 21: ...r package is factory wired for all connections from the starter to the motor for the horsepower and voltage specified on the order The standard unit is supplied with open drip proof motors and a UL Ty...

Page 22: ...harmful as insufficient grease The grease cavity should be about 1 2 full 5 Leave the relief plug temporarily off Reconnect the unit and run for about 20 minutes to expel the excess grease 6 Stop the...

Page 23: ...e and replacement at required intervals of the oil filter air filter and air oil separator is necessary to achieve maximum service and extended drain intervals of AEON 9000 SP synthetic lubricant Use...

Page 24: ...the compressor inlet When checking motor rotation induce minimum rotation less than one revolution if possible Never allow motor to reach full speed Check the compressor unit s direction of rotation e...

Page 25: ...by pressing RUN Since the unit is equipped with a minimum 65 psig 4 5 bar pressure discharge valve no special procedure to maintain unit reservoir pressure is required Unit Hot No warm up period is re...

Page 26: ...tomatically boot to the Home Screen after applying power to the machine Follow the steps below to log in to the controller verify the pressure setting and operating mode and start the compressor Loggi...

Page 27: ...3 5 Figure 3 2 Main Menu Figure 3 3 Select User Screen 3 Use the navigational buttons to choose the appropriate user level Maintenance Distributor or Factory Press the Enter button The Enter Passcode...

Page 28: ...avigate to and select ENTER when complete or simply press the Enter button to apply the code 5 The interface will automatically navigate to the Select User screen if the code is accepted If the code i...

Page 29: ...Operational Settings 4 Press the Enter button The Operational Settings menu will appear as illustrated by Figure 3 6 Figure 3 6 Operational Settings Menu 5 From the Operational Settings menu use the n...

Page 30: ...n currently highlighted When the target pressure has been entered navigate to and select ENTER when complete or simply press the Enter button to apply the target pressure If the value entered is withi...

Page 31: ...ic value as indicated by the white highlight CLR in Figure 3 9 The Select button is used to enter the number or function currently highlighted When the unload pressure has been entered navigate to and...

Page 32: ...dicated by the white highlight CLR in Figure 3 6 The Select button is used to enter the number or function currently highlighted When the load pressure has been entered navigate to and select ENTER wh...

Page 33: ...illustrated by Figure 3 11 Figure 3 11 Operating Mode Menu 4 Set the Operating Mode to Automatic by using the navigational buttons to choose the appropriate setting Press the Enter button to apply Aut...

Page 34: ...base ELECTRONIC CONTROLLER AND STARTER ASSEMBLY HARDWARE See to the Wiring Diagrams listed by voltage at the end of this section for more details on the location of the referred hardware AirSmart G2...

Page 35: ...ration of the unit with improper relief valve setting can result in severe personal injury or machine damage Ensure properly set valves are installed and maintained FIGURE 4 2 SCHEMATIC TUBING DIAGRAM...

Page 36: ...r even if the air service valve is fully open to atmospheric pressure This valve also functions as a check valve to prevent back flow of air from the process air line when the unit stops unloads or is...

Page 37: ...th both valves de energized the normally open IVC valve allows control pressure to the inlet piston to close the valve If IVC only is energized the inlet valve is held in its current position If both...

Page 38: ...ves TVC and TVO Electra Saver only These valves control the position of the turn valve in response to signals from the AirSmart controller With both valves de energized equal pressure is applied to bo...

Page 39: ...rature and shut down the compressor if high temperatures are detected Emergency Stop Push Button This is a maintained push button and removes power from the controller outputs regardless of controller...

Page 40: ...control and overload protection for the main drive motor Wiring diagrams for typical Wye Delta applications are illustrated on pages 44 thru 54 Overload protection is provided for each motor on voltag...

Page 41: ...4 10 THIS PAGE INTENTIONALLY LEFT BLANK 13 21 611 Page 40...

Page 42: ...4 10 FIGURE 4 6 COMPRESSOR PACKAGE P ID 13 21 611 Page 41 300EBF797 02 Ref Drawing...

Page 43: ...n Increasing Open TV Modulate Closed Off Closed On Open On Closed Off Closed On On A D D Open Decreasing Open IV Modulate Open On Closed On Closed Off Closed Off Closed On On A D D Open Increasing Clo...

Page 44: ...75 3 60 NO 100 323EBF546 75 230 3 60 460 3 60 380 3 60 380 3 50 NO 100 WIRING DIAGRAM HP VOLTAGE STARTER 302EBF546 75 460 3 60 YES 303EBF546 75 575 3 60 YES 100 304EBF546 75 380 3 60 380 3 50 YES 100...

Page 45: ...13 21 611 Page 44 4 11 FIGURE 4 9 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100 HP 460 VOLT 304EBF546 E Ref Drawing Page 1 of 9...

Page 46: ...13 21 611 Page 45 4 12 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 E Ref Drawing Page 2 of 9...

Page 47: ...13 21 611 Page 46 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 Ref Drawing Page 3 of 9...

Page 48: ...13 21 611 Page 47 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 E Ref Drawing Page 4 of 9...

Page 49: ...13 21 611 Page 48 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 E Ref Drawing Page 5 of 9...

Page 50: ...13 21 611 Page 49 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 E Ref Drawing Page 6 of 9...

Page 51: ...13 21 611 Page 50 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 E Ref Drawing Page 7 of 9...

Page 52: ...13 21 611 Page 51 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 E Ref Drawing Page 8 of 9...

Page 53: ...13 21 611 Page 52 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 100HP 460 VOLT 304EBF546 E Ref Drawing Page 9 of 9...

Page 54: ...13 21 611 Page 53 4 15 FIGURE 4 10 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 1 of 13...

Page 55: ...13 21 611 Page 54 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 2 of 13...

Page 56: ...13 21 611 Page 55 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 3 of 13...

Page 57: ...13 21 611 Page 56 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 4 of 13...

Page 58: ...13 21 611 Page 57 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 5 of 13...

Page 59: ...13 21 611 Page 58 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 6 of 13...

Page 60: ...13 21 611 Page 59 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 7 of 13...

Page 61: ...13 21 611 Page 60 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 8 of 13...

Page 62: ...13 21 611 Page 61 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 9 of 13...

Page 63: ...13 21 611 Page 62 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 10 of 13...

Page 64: ...13 21 611 Page 63 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 11 of 13...

Page 65: ...13 21 611 Page 64 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 12 of 13...

Page 66: ...13 21 611 Page 65 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 75 HP 460 VOLT 306EBF546 E Ref Drawing Page 13 of 13...

Page 67: ...NDED LUBRICANT Gardner Denver compressors are factory filled with AEON lubricants These lubricants are formulated to the highest quality standards and are factory authorized tested and approved for us...

Page 68: ...ironments with normal operating temperatures and pressures and low relative humidity the thermal mixing valve controls the oil temperature and prevents moisture accumulation in the oil Unusual cooling...

Page 69: ...re along the bottom axis of the chart and then reading the appropriate pressure curve to determine the corresponding dew point temperature on the left axis of the chart The compressor discharge temper...

Page 70: ...13 21 611 Page 69 5 4 Figure 5 3 FLOW DIAGRAM AIR OIL SYSTEM 300EBF797 02 Ref Drawing...

Page 71: ...5 5 13 21 611 Page 70 Figure 5 4 OIL FLOW DIAGRAM REMOTE MOUNTED COOLER 318EBD797 00 Ref Drawing...

Page 72: ...wrench when tightening the connection Use silicone sealant on all steel to aluminum threaded connections All piping should be firmly supported to avoid strain on the cooler manifold and connections F...

Page 73: ...ineering NOTICE When removing the cooling module from the package for remote operation the oil stop valve and the check valve that are shipped loose should be mounted as close to the compressor packag...

Page 74: ...13 21 611 Page 73 5 8 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 75: ...f the fill range is shown in Figure 5 5 page 75 Repeated addition of oil between oil changes may indicate excessive oil carry over and should be investigated Air oil under pressure will cause severe p...

Page 76: ...AUGE Figure 1 6 page 11 and Figure 5 5 indicates the amount of oil in the oil reservoir Read oil level only when unit is on In operation the oil level will fluctuate as the compressor loads and unload...

Page 77: ...Interval AEON 9000SP Change Interval Up to 180 F 82 C 4000 hrs 8000 hrs 180 F to 190 F 82 C to 88 C 3000 hrs 6000 hrs 190 F to 200 F 88 C to 93 C 2000 hrs 4000 hrs 200 F 93 C 1000 hrs 2000 hrs Figure...

Page 78: ...system use one of the following methods 1 If the unit is not elevated high enough to use the oil reservoir drain line to drain oil a small hand electric or air operated pump should be used to drain r...

Page 79: ...relieved 7 Add oil if necessary to bring level to the top of the fill range on the gauge On unloaded operation and after shutdown some oil will drain back into the oil reservoir and the oil level gau...

Page 80: ...wn on the filter tag or refer to the parts list for the part number Use the following procedure to replace the filter element Do not disturb the piping Air oil under pressure will cause severe persona...

Page 81: ...he cooler to mix with oil from the bypass After the unit is warmed up the mixing valve maintains oil injection temperature into the compressor at a minimum of 130 F 55 C or 160 F 71 C depending on the...

Page 82: ...an cause scale formation corrosion and plugging of any water cooled heat exchanger equipment Disregarding the possibility that one or more of these conditions exist may result in increased maintenance...

Page 83: ...t the lower edge of the adjusting screw is an index line for use with the index scale 0 to 8 in obtaining a desired setting These valves must be handled with care and proper tools and techniques must...

Page 84: ...auge actuation Figure 5 11 OIL SEPARATOR COMPRESSOR GD ELIMINATOR OIL SEPARATOR located in a separate housing consists of a renewable cartridge type separator element and provides the final removal of...

Page 85: ...e condition of the separator can be determined by pressure differential gauging or by inspection Pressure Differential Gauging The CHANGE SEPARATOR advisory will occur when the pressure differential a...

Page 86: ...to the housing Do not use excessive force as separator damage can occur 8 Place the spacer on the indent in the separator Swivel top back into position on top of the reservoir Install and tighten all...

Page 87: ...et temperature is approximately the same as air discharge temperature see the gauge on the instrument panel The outlet oil temperature may be checked by installing a tee at the oil filter outlet Oil C...

Page 88: ...dner Denver distributor To service 1 Remove the clamp and pull out the filter element 2 Visually inspect the element If cleaning is not necessary reinstall the filter element If the element requires c...

Page 89: ...indicates a rupture crack or pin hole in the pleated media Inspection should be done by placing a bright light inside the element 2 Pressure drop through a filter with a freshly cleaned element is be...

Page 90: ...th Turn the unit completely off open the main disconnect lockout and tagout before servicing the coupling COUPLING The motor and compressor are direct connected by a resilient type flexible coupling w...

Page 91: ...1 19 in 28 0 30 1 mm A smaller gap will produce abnormal wear of the element by friction and excessive thermal expansion the latter could cause compressor damage by axially displacing the input shaft...

Page 92: ...he coupling the same direction as the rotation arrow on the airend Incorrect rotation will greatly decrease the torque carrying capacity of the coupling Rotating machinery can cause personal injury or...

Page 93: ...age aluminum in a direction opposite that of the cooling air flow The cleaning operation will keep the exterior cooling surfaces clean and ensure effective heat dissipation Every 1000 hours operation...

Page 94: ...nt x x x x x x x x x x x Oil Sample x x x x x x x x x x Replace Air Oil Separator x x x x x x Inspect clean if necessary scavenge line replace check valve x x x x x Inspect service if necessary Inlet...

Page 95: ...x x x x x x x Oil Sample x x x x x x x x x x Replace Air Oil Separator x x x x x Inspect clean if necessary scavenge line replace check valve x x x x x Inspect service if necessary Inlet Valve x x x x...

Page 96: ...on 2 Blown fuse in starter control box 2 Replace fuse investigate if fuses continue to blow 3 Motor starter overload heaters trips 3 Reset and investigate cause of overload Compressor does not unload...

Page 97: ...leaks found 5 Aftercooler is frozen 5 Thaw out This machine cannot operate in temperatures below 32 F 0 C 6 Unload pressure adjusted too low 6 Adjust the unload pressure Excessive oil consumption 1 O...

Page 98: ...bricating coolants 6 Inoperative minimum pressure valve 6 Replace seals in valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See High Discharge Air Temperature this section 8 S...

Page 99: ...ESS MADE IN WRITING AND EXECUTED BY AN OFFICER 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 CLAIME...

Page 100: ...For additional information contact your local representative or visit www contactgd com compressors 2019 Gardner Denver Inc Printed in U S A...

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