Gardner Denver ELECTRA SAVER Operating & Service Manual
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Gardner Denver ELECTRA SAVER Operating & Service Manual

Base mounted compressor
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ELECTRA SAVER/SAVER II G2
BASE MOUNTED COMPRESSOR
SAV125-150G2A / ST125-200G2A
Operating & Service Manual
MODELS:
SAVG2-125
STG2-125
125 HP
SAVG2-150
STG2-150
150 HP
STG2-200
200 HP
13-21-616
Version 00
October 1, 2020

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Summary of Contents for Gardner Denver ELECTRA SAVER

  • Page 1  ELECTRA SAVER/SAVER II G2 BASE MOUNTED COMPRESSOR SAV125-150G2A / ST125-200G2A Operating & Service Manual MODELS: SAVG2-125 STG2-125 125 HP SAVG2-150 STG2-150 150 HP STG2-200 200 HP 13-21-616 Version 00 October 1, 2020...

  • Page 2: Maintain Compressor Reliability And Performance

    Whenever an airend requires replacement or repair, Gardner Denver offers an industry unique, factory remanufactured airend exchange program. From its modern factory, Gardner Denver is committed to supplying you with the highest quality, factory remanufactured airends that are guaranteed to save you time, aggravation and money When ordering parts, specify Compressor MODEL, Method of Cooling, POWER and SERIAL NUMBER (see nameplate on unit).

  • Page 3: Warning, Prohibition, Mandatory Label Information

    WARNING, PROHIBITION, MANDATORY LABEL INFORMATION Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment.
  • Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard, Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.

  • Page 5: Safety Precautions

    SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Maintain Compressor Reliability and Performance ..................1 Instructions for Ordering Repair Parts/Remanufactured Airends ..............1 Warning, Prohibition, Mandatory Label Information..................2 Safety Precautions ............................4 Index ................................6 List of Illustrations ............................7 Section 1, General Information........................8 Section 2, Installation ..........................

  • Page 7: Index

    INDEX Addition Of Oil Between Changes ........58 Oil Separator Air Filter Element Life ............72 Compressor (GD Eliminator) ........... 67 Air Filter Vacuum Switch ............. 37 Inspection ................ 68 Air Filter, Heavy Duty (Standard) ........71 Oil Carryover ..............67 Air Flow In The Compressor System ........

  • Page 8: List Of Illustrations

    Figure 4-2 – Schematic Tubing Diagram ........................34 Figure 4-3 – Minimum Discharge Pressure/Check Valve ..................35 Figure 4-4 – Turn Valve, Electra Saver Only ......................37 Figure 4-6 – Compressor Package P&ID ......................... 40 Figure 4-7 – Compressor Package Control Component States ................41 Figure 4-8 –...

  • Page 9: Section 1, General Information

    Figure 1-1 COMPRESSION CYCLE COMPRESSOR - The Gardner Denver Rotary Screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads.

  • Page 10: Figure 1-2 Starter Box

    LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through the oil cooler, thermostatic mixing valve, and oil filter and 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 the compression chamber to remove heat of compression, seal internal clearances and lubricate the rotors.

  • Page 11: Figure 1-4 - Compressor / Motor Side

    Figure 1-4 COMPRESSOR / MOTOR SIDE 125-150 HP 300EBG797-00 (Ref. Drawing) Figure 1-4a COMPRESSOR / MOTOR SIDE 200 HP 13-21-616 v00 Page 10...

  • Page 12: Figure 1-5 - Cooler / Reservoir Side

    300EBG797-00 (Ref. Drawing) Figure 1-5 COOLER / RESERVOIR SIDE Figure 1-6 AIR/OIL FLOW DIAGRAM 307EBD797-EA (Ref. Drawing) 13-21-616 v00 Page 11...

  • Page 13: Section 2, Installation

    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 Do not electric weld on the compressor or base; bearings can be damaged by passage of current.

  • Page 14: Figure 2-1 Typical Compressor Room

    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. A typical inlet-outlet air flow arrangement is shown in Figure 2-1. Figure 2-1 TYPICAL COMPRESSOR ROOM Air-Cooled Units - A combination oil/aftercooler is supplied as standard equipment on all air-cooled units.
  • Page 15 Allow four (4) feet (1.2 M) to the nearest obstruction above the unit. FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be made at a maximum 10...

  • Page 16: Figure 2-3 - Cold Weather Installation

    Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000 SP lubricant. Monitor the unit carefully during start-up and operation to be sure it is functioning normally.

  • Page 17: Figure 2-4 Inlet Line Lengths

    Refer to Engineering Data Sheet 13-9-411, available from an authorized Gardner Denver distributor, for the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit.

  • Page 18: Figure 2-5 - Heat Exchanger (Oil Cooler) Approximate Water Flow

    DISCHARGE SERVICE LINE - The discharge service line connection on both water-cooled and air-cooled units is made at the right hand corner of the unit, viewed from the opposite end from control panel side. When manifolding two or more rotary screw units on the same line, each unit is isolated by the check valve in the unit discharge line.

  • Page 19: Figure 2-6 Aftercooler Approximate Water Flow

    AFTERCOOLER Water Temperature to Approximate Heat Exchanger Maximum Water Water Pressure Drop Gallons/minute Flow @ 90F Water (Minimum) Gallons/minute * Temperature PSI Model 60 F 70 F 80 F 90 F 13.3 16.6 22.1 33.2 SAV125-150G2A 16.0 20.0 26.6 39.9 ST125-200G2A 21.8 27.3...

  • Page 20: Figure 2-7 Series Piping

    The heat exchanger system is designed to operate with water inlet temperatures from 60F to 90F (16C to 32C) and a water outlet temperature not to exceed 110F (43C). If water colder than 60F is used, high water outlet temperatures (over 110F, 43C) will be experienced along with shortened heat exchanger life caused by tube fouling and corrosion.
  • Page 21 PARALLEL PIPING (Figure 2-8, page 19) A separate water control valve is required to control the discharge air temperature. If a remote (externally mounted) water-cooled aftercooler is piped in parallel with the heat exchanger, provide a separate water control valve for the aftercooler and pipe separate inlet water lines to both the aftercooler and heat exchanger.
  • Page 22 MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The following charts show recommended grease qualities and re- greasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions.

  • Page 23: Section 3, Starting & Operating Procedures

    Compressor Oil - Check the oil level in the reservoir. Add oil only if the oil level gauge reads in the low oil level range. Do not mix different type oils. The unit is shipped filled with Gardner Denver AEON 9000 SP Lubricating Coolant which is suitable for the first 8000 hours under normal operating conditions.
  • Page 24 5. Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See Section 4 for general wiring diagrams and Section 2 for installation instructions. Grounding - Equipment must be properly grounded according to Section 250 of the National Electrical Code.
  • Page 25 The compressor starts and stops automatically. Automatic restarting can cause injury or death. Open, lockout and tagout main disconnect and any other circuits before servicing the unit. STARTING THE UNIT - Observe the following starting procedures. Unit Cold - If the unit is a water-cooled heat exchanger model, open any manual water inlet valves wide open.

  • Page 26: Figure 3-1: Login Button

    Quick Start Guide For your convenience, the following excerpt from the Controller Operating and Service Manual is presented to assist in programming the basic operating parameters. However, we strongly recommend you read the Controller Operating and Service manual before attempting operating the compressor package. The Governor controller will automatically boot to the Home Screen after applying power to the machine.
  • Page 27 This password should only be required under unusual circumstances and must be provided by Gardner Denver Technical Support. Note that the passwords can be changed from the default using the Adjustments button on the left of the screen once logged in.

  • Page 28: Figure 3-3: Configuration Menu

    Setting Up Before running the machine, there are several basic configuration settings that may need to be changed. Controller Configuration Basic controller configuration is located under the Settings -> Configuration menu as shown in Figure 3-3. Figure 3-3: Configuration Menu First, ensure that the units are set as desired by selecting the Locale link from the Configuration menu.

  • Page 29: Figure 3-5: Date And Time Configuration

    It is important to verify that the Date, Time, and Timezone are set properly for the site. The date and time are relied on for logs, timer control, trends, etc. Setting the timezone properly ensures that daylight savings time adjustments will be accounted for automatically.

  • Page 30: Figure 3-7: Control Settings

    Control Settings The settings under the Control Menu determine how the machine operates to match the process requirements of the customer. The default settings of the machine are acceptable for most installations. However, if the Pressure Band displayed on the gauge on the Home screen does not match the desired pressure range for the site, the Pressure Band must be adjusted.

  • Page 31: Figure 3-8: Primary Pressure Band Setting

    The p1 Pressure Band Setting screen is shown in Figure 3-8 below. The bar graph gives a visual indication of the pressure band settings. Press the numerical value boxes to make adjustments as needed. Note that the minimum and maximum values that will be allowed for each box will change dynamically based on the design pressure of the machine as well as the values of the other settings.

  • Page 32: Figure 3-9: Active Alarms Screen

    Clearing Alarms If there are any faults present on the machine, they must first be cleared to allow the machine to be started. If the machine has been powered on recently and Auto Restart is not enabled, a Power Loss fault will be present. If a fault is active on the machine, the Active Alarms screen can be accessed by pressing on the Alarm triangle on the Message Status Bar on the Home screen, or by navigating to Alarms ->...

  • Page 33: Figure 3-10 - Jogs Motor Screen

    Jogging the Motors If this is the first time that the machine has been started after being connected to power, the motors must be jogged to verify correct rotation. To do this, you must be logged in as a Technician. After logging in, navigate to Diagnostics ->...

  • Page 34: Section 4, Controls & Instrumentation

    CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION The Gardner Denver rotary screw compressor is pre-wired with all controls, motor and starter to match specific voltage and horsepower as ordered. It is necessary only to connect the compressor unit to the correct power supply and to the shop air line. A standard package unit consists of the modular compressor assembly, air/oil cooling and filtration system, control components, electric motor drive, associated starting module, sound attenuation metal enclosure and common support steel base.

  • Page 35: Figure 4-2 Schematic Tubing Diagram

    Operation 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. 301EBD797-00 (Ref. Drawing) FIGURE 4-2 SCHEMATIC TUBING DIAGRAM Blowdown Valve ( Figure 4-2 ) This valve normally is used for control functions, but also serves to relieve reservoir pressure following a shutdown.

  • Page 36: Figure 4-3 Minimum Discharge Pressure/Check Valve

    To service the valve, make sure all pressure is relieved, disconnect the unit from the power supply, lockout and tagout, then unscrew the valve cap from the body. The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor. 13-21-616 v00...
  • Page 37 Inlet Valve (Figure 1-4, page 10 and Figure 4-2 page 34) The Inlet valve restricts the inlet to control delivery and closes to unload the compressor. At shutdown, the inlet valve closes to prevent the back flow of air. The inlet valve position is controlled by air pressure in its piston cylinder, which is controlled by the Governor Controller through solenoid valves IVC and IVO.

  • Page 38: Figure 4-4 Turn Valve, Electra Saver Only

    Figure 4-4 Turn Valve, Electra Saver Only Turn Valve (Electra Saver only) (Figure 4-4) The turn valve is a helical valve which, when rotated, opens and closes a series of ports cast into the compressor cylinder. When these ports are open, they direct some of the air which would otherwise be compressed back to the inlet, reducing both capacity and power consumption.
  • Page 39 Air Filter - This switch is used to monitor air filter condition and alert the user if the filter requires service or replacement. Discharge Temperature Sensor - This sensor is located directly in the compressor discharge pipe. Its signal is used to monitor compressor temperature and shut down the compressor if a coolant problem is detected.
  • Page 40 Power Supply - This device changes the incoming AC supply voltage to 24 volts DC for use by all unit control devices. For 575 volt AC units only, a control transformer is provided to supply 120 volts AC input to the power supply.

  • Page 41: Figure 4-6 - Compressor Package P&Id

    FIGURE 4-6 COMPRESSOR PACKAGE P&ID 300EBF797-EB (Ref. Drawing) 13-21-616 v00 Page 40...

  • Page 42: Figure 4-7 Compressor Package Control Component States

    Package Control Component States Main Reservoir Inlet Blowdown Compressor Action Motor Pressure Valve Solenoid Solenoid Solenoid Solenoid Solenoid (BD) Test State Flow State State (PSIG) (IC) Test Port Port Closed Closed Closed Open Closed Start Up Closed Increasing Close, TV Closed Closed Closed...

  • Page 43: Figure 4-8 Electra Saver (Ii) Wiring Diagrams

    WIRING VOLTAGE STARTER DIAGRAM 311EBG546 575-3-60 380-3-50 313EBG546 380-3-60 313EBG546 460-3-60 380-3-50 314EBG546 380-3-60 380-3-50 329EBG546 380-3-60 330EBG546 460-3-60 331EBG546 575-3-60 FIGURE 4-8 ELECTRA SAVER (II) WIRING DIAGRAMS 13-21-616 v00 Page 42...
  • Page 44 313EBG546-06 FIGURE 4-9 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT (Ref. Drawing) Page 2 of 14 13-21-616 v00 Page 43...
  • Page 45 313EBG546-06 FIGURE 4-10 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT (Ref. Drawing) Page 3 of 14 13-21-616 v00 Page 44...
  • Page 46 313EBG546-06 (Ref. Drawing) FIGURE 4-11 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT Page 4 of 14 13-21-616 v00 Page 45...
  • Page 47 313EBG546-06 FIGURE 4-12 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT (Ref. Drawing) Page 5 of 14 13-21-616 v00 Page 46...

  • Page 48: Figure 4-9 - Wiring Diagram, Wye Delta, Air Cooled / Water Cooled

    313EBFG46-06 FIGURE 4-13 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT (Ref. Drawing) Page 6 of 14 313EBG546-06 (Ref. Drawing) Page 7 of 14 FIGURE 4-14 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT 13-21-616 v00 Page 47...
  • Page 49 313EBG546-06 (Ref. Drawing) Page 8 of 14 FIGURE 4-15 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT 13-21-616 v00 Page 48...
  • Page 50 313EBG546-06 (Ref. Drawing) Pages 9 of 14 FIGURE 4-16 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT 13-21-616 v00 Page 49...
  • Page 51 313EBG546-06 (Ref. Drawing) Pages 10 of 14 FIGURE 4-17 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT 313EBG546-06 (Ref. Drawing) Pages 11 of 14 FIGURE 4-18 WIRING DIAGRAM, WYE DELTA, AIR COOLED / WATER COOLED, 125-200 HP, 460 VOLT 13-21-616 v00 Page 50...

  • Page 52: Section 5 Lubrication Oil Cooler, Oil Filter & Separator

    AEON lubricants are available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000SP lubricating coolant which can be used for year-round operation. AEON 9000SP is a synthetic, extended life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based lubricant.
  • Page 53 Do not repeatedly restart the unit after high temperature stops operation. Find and correct the malfunction before resuming operation. All materials used in Gardner Denver compressor units are compatible with AEON 9000 SP Lubricating Coolant. Use caution when selecting downstream components such as air line lubricating bowls, gaskets and valve trim.

  • Page 54: Figure 5-1 Dew Point Chart F

    Figure 5-1 DEW POINT CHART F DEW POINT CHART C Figure 5-2 These charts are easily used by reading the ambient temperature 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.

  • Page 55: Figure 5-3 - Flow Diagram, Air/Oil System

    300EBF797-EB (Ref. Drawing) Figure 5-3 FLOW DIAGRAM, AIR/OIL SYSTEM 13-21-616 v00 Page 54...

  • Page 56: Figure 5-4 - Oil Flow Diagram, Remote Mounted Cooler

    301EBG797-00 Figure 5-4 OIL FLOW DIAGRAM, REMOTE MOUNTED COOLER (Ref. Drawing) 13-21-616 v00 Page 55...
  • Page 57 REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be disconnected after test and the vent fan motor connected in its place. The vent fan will be mounted in the enclosure.
  • Page 58 NOTICE When removing the cooling module from the package for remote operation, do not use the flexible coupling (when supplied) between the air/oil separator housing and the minimum pressure/check valve. The discharge piping from the air/oil separator housing should be piped into the minimum pressure/check valve, then into piping to the cooler, with a flexible connection between the minimum pressure/check valve and aftercooler to keep the weight of the piping off of the cooler.
  • Page 59 COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation,” Section 2. ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is in the red range on the gauge as read while the unit is on. To add oil, follow these steps: Be sure the unit is completely off and that no air pressure is in the oil reservoir.

  • Page 60: Figure 5-5 Oil Level Gauge

    Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis program with the AEON lubricants and we recommend a sample be sent in at 100 hours on a new unit.

  • Page 61: Figure 5-6 Oil Change Interval

    Discharge AEON 4000 AEON 9000SP Temperature Change Interval Change Interval 4000 hrs. 8000 hrs. Up to 180 F (82 C) 3000 hrs. 6000 hrs. 180 F to 190 F (82 C to 88 C) 2000 hrs. 4000 hrs. 190 F to 200 F (88 C to 93 C) 1000 hrs.
  • Page 62 DRAINING AND CLEANING OIL SYSTEM Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation.

  • Page 63: Figure 5-8 Approximate Oil System Capacities

    FILLING OIL RESERVOIR Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, lockout and tagout the power supply to the starter.
  • Page 64 COMPRESSOR OIL FILTER (Figure 5-3, Page 54) - This screw on oil filter is a vital part in maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is located in the oil filter head. The relief valve opens in the event the element becomes dirty enough to block the flow of oil.

  • Page 65: Figure 5-9 Thermostatic Mixing Valve Element

    COMPRESSOR OIL COOLER - RADIATOR TYPE (Figure 1-5, page 10) The oil cooler motor and fan is mounted on the oil cooler module; air is pushed through the oil cooler and away from the unit. Do not obstruct air flow to and from the oil cooler. Allow a minimum of three (3) feet clearance around the cooler. Keep both faces of cooler core clean for efficient cooling of compressor oil.

  • Page 66: Figure 5-10 Water Control Valve

    It is mandatory that any water-cooled unit be installed in a shelter heated to temperatures above freezing (32F, 0C). Oil cooler malfunction may be traced by checking pressure at oil inlet and outlet. At normal operating air service pressure (65 psig to 200 psig, 4.5 bar to 13.8 bar) with the unit warm, a pressure drop of 5 psi to 20 psi (0.35 bar to 1.38 bar) can be expected between the oil inlet and the oil outlet.

  • Page 67: Figure 5-11 Flow Diagram - Water Cooled System

    WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) (Figure 5-10, page 65) The water flow control valve is adjustable to compensate for varying water inlet temperatures and pressures and is to be mounted in the water outlet line after the oil cooler (Figure 5-11). Use the compressor discharge air temperature gauge on the instrument panel in setting the flow control valve.
  • Page 68 WATER SHUTOFF VALVE - WATER-COOLED HEAT EXCHANGER (Optional Equipment) (Figure 5-11, page 66) A magnetic solenoid-operated water shutoff valve rated at 150 psig (10.3 bar) water pressure should be mounted in the water outlet line after the oil cooler. The valve should be wired into the compressor control circuit so that the valve opens to allow water to flow any time the compressor is running.
  • Page 69 Oil carryover malfunctions of the oil separator are usually due to using elements too long, heavy dirt or varnish deposits caused by inadequate air filter service, use of improper oil or using oil too long for existing conditions. A ruptured or collapsed separator element is usually due to heavy dirt or varnish buildup in the filtering material.
  • Page 70 Removal of Oil Separator for Inspection or Replacement: Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters.
  • Page 71 Oil Cooler Oil Pressure Differential (Air-Cooled Radiator) - Check differential across oil system by measuring oil inlet pressure as described above. Oil Cooler Oil Pressure Differential (Water-Cooled Heat Exchanger) – 4 psid to 20 psid (.3 bar to 1.4 bar) (65 psig to 200 psig, 4.5 bar to 13.8 bar receiver pressure) - Check that oil inlet pressure is correct or measure the differential between drains on the oil cooler shell.

  • Page 72: Section 6, Air Filter

    IMPORTANT. An improperly maintained air filter can cause a loss of compressor air delivery. Filter Element - Inspect every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor.
  • Page 73 Do not oil this element. Do not wash as cleaning may damage the element. NOTICE Never operate the unit without the element. Never use elements that are damaged, ruptured or wet. Never use gaskets that won't seal. Keep spare elements and gaskets on hand to reduce downtime. Store elements in a protected area free from damage, dirt and moisture.

  • Page 74: Section 7, Coupling

    SECTION 7 COUPLING Figure 7-1 INSTALLATION OF COUPLING CUSHIONS Rotating machinery can cause personal injury or death. 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 with a single cushion.

  • Page 75: Figure 7-2 - Installation Of Coupling Cushions

    ASSEMBLY OF COUPLING ONTO THE AIREND AND MOTOR Figure 7-2 INSTALLATION OF COUPLING CUSHIONS Slide coupling halves over shaft extensions. Lock compressor half down with set screw. Assemble the motor to the compressor. Working through the coupling guard opening, slide motor half into compressor half. * After engaging each hub on the matching recesses of the coupling element, check that the gap between the hub flats (see dimension “E”...
  • Page 76 NOTICE Elements with non-uniform cross sections must be mounted with the rotation arrow on the 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 death. Do not operate unit with either the coupling guard removed.

  • Page 77: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE Service Check List Every 8 hours operation 1. Check air/oil reservoir oil level, add oil if required. See Section 5 for information. If oil consumption is high, refer to Section 9, Excessive Oil Consumption. DO NOT MIX LUBRICANTS. 2.
  • Page 78 Maintenance Schedule Check air/oil reservoir oil level Check operation of the machine, is it loading and unloading Check discharge pressure and temperature Check control panel for advisory text messages Inspect, Clean if necessary Cooler / Fan Replace oil filter element Replace Control Box Filter (if app.) Replace package enclosure filter pad (if app.) Replace air filter element...
  • Page 79 Maintenance Schedule Check air/oil reservoir oil level Check operation of the machine, is it loading and unloading Check discharge pressure and temperature Check control panel for advisory text messages Inspect, Clean if necessary Cooler / Fan Replace oil filter element Control Box Filter (if app.) Replace cool air inlet filter pad (if app.) Replace air filter element...

  • Page 80: Section 9, Troubleshooting

    SECTION 9 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate tripped. cause of overload. Pressure in reservoir. Inspect blowdown valve. Read error message on Take appropriate action.
  • Page 81 SYMPTOM POSSIBLE CAUSE REMEDY Compressor starts too Wye Delta switch time set Contact your distributor. slowly too long. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Compressor is low on Restricted air filter. Clean or replace filter.
  • Page 82 NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13-21-616 v00 Page 81...
  • Page 83 Electra Saver II and Electra Saver Series Gardner Denver (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, free of defects in material and workmanship.
  • Page 84  For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2020 Gardner Denver, Inc. Printed in U.S.A.

This manual is also suitable for:

Electra saver ii g2Savg2-125Stg2-125Savg2-150Stg2-150Stg2-200

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