Gardner Denver ELECTRA-SAVER II Operating And Service Manual Download Page 9

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13–9/10–641 Page viii

LIST OF ILLUSTRATIONS

Figure #

Description Page

Figure 1–1

Compression Cycle

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Figure 1–2

Starter Box

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Figure 1–3

Package – Controller & Starters

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Figure 1–4

Package – Drive Motor & Air Filter

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Figure 1–5

Package – Oil Filter, Oil Level Gauge, Mixing Valve, Minimum Pressure Valve, Check Valve

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Figure 1–6

Package – Air/Oil Flow Diagram

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Figure 2–1

Typical Compressor Room

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Figure 2–2

Air Flow Chart

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Figure 2–3

Cold Weather Installation

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Figure 2–4

Inlet Line Lengths

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Figure 2–5

Heat Exchanger (Oil Cooler) Approximate Water Flow

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Figure 2–6

Aftercooler Approximate Water Flow

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Figure 2–7

Series Piping

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Figure 2–8

Parallel Piping

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Figure 4–1

Schematic Tubing Diagram

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Figure 4–2

Blowdown Valve

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Figure 4–3

Minimum Discharge Pressure Valve

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Figure 4–4

Inlet Valve

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Figure 4–5

Shuttle Valve

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Figure 4–6

Turn Valve – Electra–Saver Only

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Figure 4–7

Control Schematic – Compressor Unloaded – Constant Speed Mode, EBH & EBM Units

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Figure 4–8

Control Schematic – Compressor at Full Load – Constant Speed Mode, EBH & EBM Units

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Figure 4–9

Control Schematic – Compressor Unloaded – Low Demand Mode or Auto Mode,
EBH & EBM Units

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Figure 4–10

Control Schematic – Compressor at Full Load, EAP Units Only

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Figure 4–11

Control Schematic – Compressor Fully Unload – Low Demand Mode Switch Off, EAP Units

Figure 4–12

Control Schematic – Compressor Fully Loaded – Low Demand Mode Switch On, EAP Units

Figure 4–13

Wiring Diagram – 207ECP546, Wye Delta – EBH, EBM & EBP Units with ES Controls

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Figure 4–14

Wiring Diagram – 209ECP546, Full Voltage – EBH, EBM & EBP Units with ES Controls

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Figure 4–15

Wiring Diagram – 216EAP546, Wye Delta – EAP with ES+ Controls and Current Monitor

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Figure 5–1

Flow Diagram – Air/Oil System – Turn Valve Units

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Figure 5–2

Oil Flow Diagram – Remote Overhead Mounted Cooler

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Figure 5–3

Cooler Drain Detail

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Figure 5–4

Oil Level Gauge

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Figure 5–5

Oil Change Interval

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Figure 5–6

Approximate Oil System Capacities

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Figure 5–7

Thermostatic Mixing Valve Element

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Figure 5–8

Water Control Valve

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Figure 5–9

Dew Point Temperature vs. Ambient Temperature, (100% Relative Humidity)

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Figure 5–10

Oil Separator

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Figure 6–1

Heavy Duty Air Filter

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Figure 7–1

Installation of Coupling Cushions

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Summary of Contents for ELECTRA-SAVER II

Page 1: ...VER II STATIONARY BASE MOUNTED COMPRESSOR AUTO SENTRY ES CONTROLS AUTO SENTRY ES CONTROLS DOMESTIC MODELS 40 100 HP EBH EBM EBP EAP INTERNATIONAL MODELS EBM 45 75 KW 60 100 HP OPERATING AND SERVICE MA...

Page 2: ...enver 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...

Page 3: ...will result in economical operation and minimum downtime Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warnin...

Page 4: ...7X 13 9 10 647 75 100 125 150 EBMQLD EBMSLE 13 9 557X 13 9 10 647 55 6 9 8 6 10 3 EBMQLG EBMSLG 13 9 557X 13 9 10 647 100 100 125 150 EBMQMD EBMSME 13 9 557X 13 9 10 647 75 6 9 8 6 10 3 EBMQMG EBMSMG...

Page 5: ...lustrations ix Section 1 General Information 1 Section 2 Installation 8 Section 3 Starting Operating Procedures 16 Section 4 Controls Instrumentation 18 Section 5 Lubrication Oil Cooler Oil Filter Sep...

Page 6: ...ansformer 22 Controller 18 CONTROLS INSTRUMENTS SECTION 4 18 Controls Instruments General Description 18 Cooler Compressor Oil 40 Cooling Sealing and Lubrication 1 COUPLING SECTION 7 47 Coupling 47 Al...

Page 7: ...ir and Oil Discharge Temperature 44 Compressor Oil Inlet Temperature 44 Oil Cooler Oil Pressure Differential 44 Oil Cooler Temperature Differential 44 Oil Cooler Water Pressure Differential 44 Oil Inl...

Page 8: ...Air Filter Vacuum 22 Vibration 22 Switches Optional 23 System Pressure Transducer 22 System Thermistor 22 Terminal Strip 22 Thermistor Discharge 22 System 22 Transducer Reservoir Pressure 22 System P...

Page 9: ...Load Constant Speed Mode EBH EBM Units 25 Figure 4 9 Control Schematic Compressor Unloaded Low Demand Mode or Auto Mode EBH EBM Units 26 Figure 4 10 Control Schematic Compressor at Full Load EAP Units...

Page 10: ...of compression and seal internal clearances Volume re duction and pressure increase continues until the air oil mixture trapped in the interlobe cavity by the rotors passes the discharge port and is...

Page 11: ...13 9 10 641 Page 2 FIGURE 1 2 STARTER BOX FIGURE 1 3 PACKAGE CONTROLLER STARTERS 217ECM797 Ref Drawing FIGURE 1 4 PACKAGE DRIVE MOTOR AIR FILTER 217ECM797 Ref Drawing...

Page 12: ...13 9 10 641 Page 3 FIGURE 1 5 PACKAGE OIL FILTER OIL LEVEL GAUGE MIXING VALVE MINIMUM PRESSURE VALVE CHECK VALVE 217ECM797 Ref Drawing FIGURE 1 6 PACKAGE AIR OIL FLOW DIAGRAM 219ECM797 A Ref Drawing...

Page 13: ...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 Electrica...

Page 14: ...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 insi...

Page 15: ...13 9 10 641 Page 6 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 16: ...13 9 10 641 Page 7 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 17: ...ea with ample space all around for mainte nance 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 some distance from the com...

Page 18: ...mpressor unit on a suitable struc ture to obtain the desired drain height If the compressor unit base is raised above floor level the space between the floor and the base bottom must be closed with so...

Page 19: ...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...

Page 20: ...th the inlet line should be the full size of the inlet opening on the compressor If an extra long line is necessary the pipe size should be increased according to Inlet Line Length Chart FIGURE 2 4 HE...

Page 21: ...table Accessibility for inlet air filter servicing must be consid ered when relocating the filters from the unit to a remote location DISCHARGE SERVICE LINE The discharge service line connection on b...

Page 22: ...r cooler than 60_ F is used high water outlet temperatures over 110_ F 43_ C will be experi enced along with shortened heat exchanger life caused by tube fouling and corrosion If water warmer than 90_...

Page 23: ...ctrical 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 with Table 250 95 of the N...

Page 24: ...EASING INTERVAL Relubrication Type of Service Typical Examples Rating Interval Up to 150 HP 112 KW 18 Months Standard One or Two Shift Operation Above 150 HP 112 KW 12 Months Up to 150 HP 112 KW 9 Mon...

Page 25: ...er Failure to re lease pressure or properly discon nect the power may result in personal injury or death During unloaded operation and after shutdown the system will partially drain back into the oil...

Page 26: ...ting 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 AUTO b...

Page 27: ...ut main discon nect and any other circuits before servicing the unit CONTROL DEVICES Controller This compressor unit features the AUTO SENTRY controller which integrates all the control functions unde...

Page 28: ...rol air check valve is provided to ensure that the inlet valve is closed during blowdown Oil Level Gauge FIGURE 1 6 Section 1 page 3 This gauge is located on the oil reservoir and indicates the oil le...

Page 29: ...pressure to open the valve in creases Conversely backing it out decreases the minimum pressure required to open the valve To service the valve unscrew the valve cap from the body The internal parts w...

Page 30: ...r the reservoir or plant air system as required during differ ent operating conditions Purge Air Valve The purge valve is a normally closed two way air actuated valve that admits purge air from the fi...

Page 31: ...nd is used to monitor temperature and shut down the compressor if high temperatures are de tected Emergency Stop Push Button This is a main tained push button and removes power from the con troller ou...

Page 32: ...ION COMPRESSOR CAPACITY CONTROL TURN VALVE UNITS ONLY The capacity of the compressor is controlled by the ac tion of the Turn Valve and the Compressor Inlet Valve The turn valve controls compressor de...

Page 33: ...13 9 10 641 Page 24 FIGURE 4 7 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE EBH EBM UNITS ONLY 225ECM797 B Ref Drawing...

Page 34: ...13 9 10 641 Page 25 FIGURE 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE EBH EBM UNITS ONLY 226ECM797 B Ref Drawing...

Page 35: ...13 9 10 641 Page 26 FIGURE 4 9 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE OR AUTO MODE EBH EBM UNITS ONLY 227ECM797 B Ref Drawing...

Page 36: ...13 9 10 641 Page 27 FIGURE 4 10 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD EAP UNITS ONLY 214ECM797 B Ref Drawing...

Page 37: ...13 9 10 641 Page 28 FIGURE 4 11 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF EAP UNITS ONLY 215ECM797 B Ref Drawing...

Page 38: ...13 9 10 641 Page 29 FIGURE 4 12 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE SWITCH ON EAP UNITS ONLY 216ECM797 B Ref Drawing...

Page 39: ...13 9 10 641 Page 30 FIGURE 4 13 WIRING DIAGRAM 207ECP546 WYE DELTA EBH EBM EBP UNITS WITH ES CONTROLS...

Page 40: ...13 9 10 641 Page 31 FIGURE 4 14 WIRING DIAGRAM 209ECP546 FULL VOLTAGE EBH EBM EBP UNITS WITH ES CONTROLS...

Page 41: ...13 9 10 641 Page 32 FIGURE 4 15 WIRING DIAGRAM 216EAP546 WYE DELTA EAP UNITS WITH ES CONTROLS AND CURRENT MONITOR...

Page 42: ...ternational The factory fill compressor lubricant is Gardner Denver AEONt 9000 SP lubricating coolant which can be used for year round operation AEONt 9000 SP is a synthetic extended life lubricant wh...

Page 43: ...13 9 10 641 Page 34 FIGURE 5 1 FLOW DIAGRAM AIR OIL SYSTEM TURN VALVE UNITS 221ECM797 B Ref Drawing...

Page 44: ...13 9 10 641 Page 35 201EAP797 Ref Drawing FIGURE 5 2 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED COOLER 218ECM797 A Ref Drawing...

Page 45: ...g should be firm ly supported to avoid strain on the cooler manifold and connections Flexible connections should be installed in all interconnecting piping adjacent to the cooler to avoid transmitting...

Page 46: ...ve and the oil stop valve to atmosphere This will shut the oil stop valve and prevent excessive oil from running into the reservoir Failure to install these parts could result in high oil car ryover a...

Page 47: ...oil level will fluctuate as the compressor loads and unloads Add oil only when the oil is at the bottom of the red range on the gauge as read when the compres sor is on Drain oil only when the oil lev...

Page 48: ...ervoir drain can be used empty the oil reservoir through the drain valve to a suitable container or sump 3 If the drained oil and or the oil filter element are contaminated with dirt flush the entire...

Page 49: ...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 personal injury o...

Page 50: ...ressure drop from that nor mally held may indicate tube leakage or fouling and should be investigated In many instances the cooling water supply for the heat exchanger will contain impurities in solut...

Page 51: ...n handling the capillary tube a kink or break in the tubing or connections will make the valve inoperative Never attempt to change capillary length Excess capillary tube should be carefully coiled and...

Page 52: ...parator housing to the compressor cylinder is not clogged or pinched off the check valve in the oil return line is functioning properly and there is not water or an oil water emulsion in the oil Oil c...

Page 53: ...heck with a thermometer at the discharge housing Compressor Oil Inlet Temperature 150_ to 160_ F 66_ to 71_ C Install a tee at the oil filter outlet and check with a thermometer Oil Inlet Pressure Che...

Page 54: ...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 cra...

Page 55: ...pect 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 r...

Page 56: ...e 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 s...

Page 57: ...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 the coo...

Page 58: ...ops after a short time Air Temperature this section page 50 2 High discharge 2 Replace switch temperature switch malfunction 3 Blown fuse in starter 3 Replace fuse control box investigate if fuses con...

Page 59: ...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 Tighten or replace fittings and gaskets or gask...

Page 60: ...0 this section 8 Scavenge line check 8 Replace check valve valve failure 9 Water condensate in oil 9 Check oil reservoir tempera ture and if low change thermal mixing valve element to higher temperatu...

Page 61: ...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 62: ......

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