Gardner Denver ELECTRA-SAVER Operating And Service Manual
Stationary base-mounted compressor
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ELECTRA-SAVER
ELECTRA-SAVER II
STATIONARY BASE-MOUNTED
AirSmart™ CONTROLLER
DOMESTIC and INTERNATIONAL MODELS
EAQ99W – 125, 150, and 200 HP, 60 HZ
EBQ99R – 125, 150, and 200 HP, 60 HZ
EAU99AB – 200 HP, 60 HZ
EBU99H – 200 HP, 60 HZ
EAQ99W – 100, 125, and 150 HP, 50 HZ
EBQ99R – 125 and 150 HP, (93, 112 KW) 50 HZ
EAU99AB – 200 HP, (150 KW) 50 HZ
EBU99H – 200 HP, (150 KW) 50 HZ
SERVICE MANUAL
COMPRESSOR
(75, 93, 112 KW)
OPERATING AND
13-21-608
Version: 00
September 7, 2018
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Summary of Contents for Gardner Denver ELECTRA-SAVER
- Page 1 13-21-608 Version: 00 September 7, 2018 ELECTRA-SAVER ELECTRA-SAVER II STATIONARY BASE-MOUNTED COMPRESSOR AirSmart™ CONTROLLER DOMESTIC and INTERNATIONAL MODELS EAQ99W – 125, 150, and 200 HP, 60 HZ EBQ99R – 125, 150, and 200 HP, 60 HZ EAU99AB – 200 HP, 60 HZ EBU99H –...
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Page 2: Maintain Compressor Reliability And Performance With
3. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors. -
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.
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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 With Genuine Gardner Denver Compressor Parts And Support Services ............1 Instructions For Ordering Repair Parts/Remanufactured Airends.............. 1 Warning – Prohibition – Mandatory Label Information ................2 Safety Precautions ..........................4 Index ............................... 6 List Of Illustrations ........................... -
Page 7: Index
Index Addition Of Oil Between Changes ....55 Inlet Screen And Tube ........67 Aftercooler Piping ...........53 Inlet Valve ............33 Air Filter Element Life ........67 Installation For Cold Weather Operation ..16 Air Filter Vacuum Switch .........35 Installation, Section 2 ........13 Air Filter, Heavy Duty (Standard) ....66 Air Filter, Section 6 .........66 Lifting Unit ............ - Page 8 Parallel Piping ..........22 Every Year ..........71 Piping Motor Lubrication ........71 Series ............21 Oil Separator ..........71 Power Supply ..........36 Service Check List Pressure Differential Gauging ......63 Air Filter ............71 Pressure Regulator .........34 Shuttle Valve ..........34 Prestart-Up Instructions ........24 Solenoid Valves Ivc And Ivo ......
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Page 9: List Of Illustrations
Figure 4-5 – Inlet Valve .......................... 33 Figure 4-6 – Shuttle Valve ........................34 Figure 4-7 – Turn Valve – Electra-Saver Only ..................35 Figure 4-8 – Control Schematic – Compressor Unloaded – Constant Speed Mode ........ 38 Figure 4-9 – Control Schematic – Compressor At Full Load – Constant Speed Mode ......39 Figure 4-10 –... -
Page 10: Section 1, General Information
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 11 TURN VALVE (ELECTRA-SAVER ONLY) - The turn valve is a rotary helical valve located on the discharge side of the cylinder toward the inlet end. The valve opens and closes ports in the cylinder which communicates with the inlet passage.
- Page 12 Figure 1-4 – COMPRESSOR / MOTOR SIDE 200EDM797-A (Ref. Drawing) Figure 1-5 – COOLER / RESERVOIR SIDE 13-21-608 Page 11...
- Page 13 202EDM797 (Ref. Drawing) Figure 1-6 – AIR/OIL FLOW DIAGRAM 13-21-608 Page 12...
- Page 14 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 15 LOCATION - The compressor should be installed, whenever possible, in a clean, well-lighted, 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 some distance from the compressor to obtain proper air supply.
- Page 16 (.9 m) to the nearest obstruction above and on other sides of 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 17 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 18 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 19 When connecting two or more GD rotary screw units on a common manifold, each unit is isolated by the check valve in the unit discharge line. If a Gardner Denver rotary screw unit is connected to another compressor on a common manifold be sure the other compressor has a check valve in the line between the machine and the manifold.
- Page 20 HEAT EXCHANGER (INTERNATIONAL) Water Temperature to Heat Exchanger (l/s) Approximate Water Maximum Pressure Drop @ 32° C Water Flow Water Temperature (l/s) * Model 16° C 21° C 27° C 32° C (bar) EAQ99W 0.51 0.64 0.85 1.28 2.52 EAQ99W, 0.68 0.85 1.14...
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