Gardner Denver ELECTRA-SAVER G2 Operating And Service Manual

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Support Services
Instructions for Ordering Repair Parts/Remanufactured Airends
Warning - Prohibition - Mandatory Label Information
Safety Precautions
Table of Contents
Index
List of Illustrations
Section 1, General Information
Air Flow in the Compressor System
Compression Principle
Compressor
Figure 1-1 - Compression Cycle
Cooling, Sealing and Lubrication
Figure 1-2 - Starter Box
Figure 1-3 - Control Box
Figure 1-4 - Compressor / Motor Side
Figure 1-5 - Cooler / Reservoir Side
Figure 1-6 - Air/Oil Flow Diagram
Section 2, Installation
Lifting Unit
Location
Air-Cooled Units, Location
Air-Cooled Units
Figure 2-1 - Typical Compressor Room
Figure 2-2 - Air Flow Chart
Foundation
Water-Cooled Units
Drain
Cold Weather Operation
Cold Weather Operation, Installation for
Installation for Cold Weather Operation
Figure 2-3 - Cold Weather Installation
Auxiliary Air Receiver
Control Piping
Inlet Line
Moisture Separator/Trap
Figure 2-4 - Inlet Line Lengths
Blowdown Valve Piping
Figure 2 5 - Heat Exchanger (Oil Cooler) Approximate Water Flow
Water Piping
Figure 2-6 - Aftercooler Approximate Water Flow
Water Piping (Series)
Figure 2-7 - Series Piping
Figure 2-8 - Parallel Piping
Electrical Wiring
Grounding
Water Piping (Parallel)
Lubrication Motor
Section 3, Starting & Operating Procedures
Prestart-Up Instructions
Daily Check
Starting the Unit
Unit Cold
Unit Hot
Stopping the Unit
Quick Start Guide (Controller)
Section 4, Controls & Instrumentation
Controls & Instrumentation Airsmart G2 Controller Operation
General Description
Figure 4-1 - Controller Keypad
Figure 4- 2- Schematic Tubing Diagram
Blowdown Valve
Minimum Discharge Pressure Valve
Figure 4- 3- Minimum Discharge Pressure/Check Valve
Inlet Valve
Pressure Regulator
Shuttle Valve
Solenoid Valves IVC and IVO
Air Filter Vacuum Switch
Plant Delivery
Reservoir
Separator
Figure 4-4 -Turn Valve - Electra Saver Only
Emergency Stop Push-Button
Temperature Sensor Discharge
Separator
Fan Starter
Fuse Blocks
Main Starter
Power Supply
Terminal Strip
Figure 4- 5- Compressor Package P&ID
Figure 4- 6- Compressor Package Control Component States
Figure 4- 7- Electra Saver Wiring Diagrams
Figure 4- 8- Electra Saver II Wiring Diagrams
Figure 4- 9- Wiring Diagram - WYE DELTA (AIR-COOLED / WATER-COOLED)
Figure 4- 10- Wiring Diagram - WYE DELTA (AIR-COOLED / WATER-COOLED)
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator
Lubricant Recommended
Oil Specifications
Oil System Compressor
High Temperature Operation
Moisture in the Oil System
Figure 5-1 - Dew Point Chart F
Figure 5-2 - Dew Point Chart C
Figure 5-3 - Flow Diagram - Air/Oil System
Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted Cooler
Remote Mounted Elevated Cooler Assembly
Heat Exchanger (Oil) Piping
Addition of Oil between Changes
Cold Ambient Operation
Lubricant Change Procedure
Oil Change Interval
Oil Level Gauge
Figure 5-5 - Oil Level Gauge
Oil Sampling Valve
Figure 5-6 - Oil Change Interval
Figure 5-7 - Oil Sampling Valve Location
Draining and Cleaning
Filling
Figure 5-8 - Approximate Oil System Capacities
Oil Filter
Compressor Oil Cooler - Water-Cooled Heat Exchanger
Oil Cooler - Radiator Type
Thermal Control (Thermostatic Mixing) Valve
Figure 5-9 - Thermostatic Mixing Valve Element
Figure 5-10 - Water Control Valve
Water Flow Control Valve for Heat Exchanger
Oil Reservoir
Oil Separator Compressor (GD Eliminator)
Oil Carryover
Water Shutoff Valve - Water-Cooled Heat Exchanger
Figure 5-11 - Oil Separator
Inspection
Pressure Differential Gauging
Removal for Inspection or Replacement
Oil System Check
Air and Oil Discharge Temperature
Oil Inlet Pressure
Oil Inlet Temperature
Oil Cooler Oil Pressure Differential (Air-Cooled Radiator)
Oil Cooler Oil Pressure Differential (Water-Cooled Heat Exchanger)
Oil Cooler Temperature Differential (Air-Cooled Radiator)
Oil Cooler Temperature Differential (Water-Cooled Heat Exchanger)
Oil Cooler Water Pressure Differential (Water-Cooled Heat Exchanger)
Section 6, Air Filter
Air Filter, Heavy Duty (Standard)
Filter Element
Figure 6-1 - Heavy Duty Air Filter
Air Filter Element Life
Inlet Tube
Section 7, Coupling
Coupling
Figure 7-1 - Installation of Coupling Cushions
Figure 7-2 - Installation of Coupling Cushions
Section 8, Maintenance Schedule
Service Check List
Every 1000 Hours Operation
Every 125 Hours Operation
Every 8 Hours Operation
Every 2000 Hours Operation
Service Check List
Section 9, Troubleshooting

Quick Links

1 Section 8, Maintenance Schedule
2 Section 9, Troubleshooting
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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

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Gardner Denver ELECTRA-SAVER G2 Operating And Service Manual

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