Gardner Denver ELECTRA-SAVER II Operating And Service Manual
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Gardner Denver ELECTRA-SAVER II Operating And Service Manual

Gardner Denver ELECTRA-SAVER II Operating And Service Manual

Stationary base–mounted compressor
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GARDNER DENVER
STATIONARY BASE–MOUNTED
AUTO SENTRY –ES+ CONTROLS
AUTO SENTRY –ES CONTROLS
EBM – 45 – 75 KW (60 – 100 HP)
ELECTRA–SAVER
ELECTRA–SAVER II
COMPRESSOR
DOMESTIC MODELS
40 – 100 HP
EBH, EBM, EBP & EAP
INTERNATIONAL MODELS
OPERATING AND
SERVICE MANUAL
13–9/10–641
9th Edition
March, 1997

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  • Page 1 13–9/10–641 GARDNER DENVER 9th Edition March, 1997 ELECTRA–SAVER ELECTRA–SAVER 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)

  • Page 2: Remanufactured Air Ends

    They are ready to respond and assist you by pro- Denver air compressor with these services: viding fast, expert maintenance and repair services. For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact: Distribution Center: Factory: Gardner Denver Machinery Inc.

  • Page 3: Foreword

    FOREWORD 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 main- tenance. This book is written to give the operator and maintenance department essential information for day–to–day operation, maintenance and adjustment.

  • Page 4: Instructions For Ordering Repair Parts

    This book covers the following models: DOMESTIC MODELS: Controller PSIG Air Cooled Water Cooled Parts List Manual 100, 125 EBHQHC EBHSHC 13–9–555 13–9/10–647 EBHQHD EBHSHD 13–9–555 13–9/10–647 100, 125, 150 EBHQJC EBHSJC 13–9–555 13–9/10–647 EBHQJD EBHSJD 13–9–555 13–9/10–647 100, 125, 150 EBMQKE EBMSKE 13–9–557...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Remanufactured Air Ends ................Foreword .

  • Page 6: Index

    INDEX Actuator, Turn Valve ..... . . Individual Cushion Design ....Addition of Oil Between Changes .
  • Page 7 INDEX Oil Cooler Water Pressure Differential ..Location ........Oil Inlet Pressure .
  • Page 8 INDEX Thermistor Every 8 Hours Operation ....Discharge ......Every Year .
  • Page 9 LIST OF ILLUSTRATIONS Figure # Description Page Figure 1–1 Compression Cycle ..............Figure 1–2 Starter Box .

  • Page 10: Section 1, General Information

    SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSION CYCLE COMPRESSOR – The Gardner Denver Rotary Screw ervoir (C). Each rotor cavity follows the same “fill–com- compressor is a single stage, positive displacement press–discharge” cycle in rapid succession to produce rotary machine using meshing helical rotors to effect a discharge air flow that is continuous, smooth and compression.

  • Page 11: Figure 1-2 Starter Box

    217ECM797 (Ref. Drawing) FIGURE 1–2 – STARTER BOX FIGURE 1–3 – PACKAGE – CONTROLLER & STARTERS 217ECM797 (Ref. Drawing) FIGURE 1–4 – PACKAGE – DRIVE MOTOR & AIR FILTER 13–9/10–641 Page 2...

  • Page 12: Figure 1-5 Package - Oil Filter, Oil Level Gauge, Mixing Valve, Minimum Pressure Valve, Check Valve

    217ECM797 (Ref. Drawing) FIGURE 1–5 – PACKAGE – OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE, MINIMUM PRESSURE VALVE & CHECK VALVE 219ECM797–A (Ref. Drawing) FIGURE 1–6 – PACKAGE – AIR/OIL FLOW DIAGRAM 13–9/10–641 Page 3...
  • Page 13 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 14 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
  • Page 15 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–9/10–641 Page 6...
  • Page 16 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–9/10–641 Page 7...

  • Page 17: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- LOCATION – The compressor should be installed, age that may have been incurred during transit. Report whenever possible, in a clean, well–lighted, well–venti- any damage or missing parts as soon as possible. lated area with ample space all around for mainte- nance.

  • Page 18: Figure 2-2 Air Flow Chart

    Minimum Air Flow * For Compression And Cooling – Cubic Feet/Minute (Cubic Meters/Minute) If the compressor unit base is raised HP (KW) Air Cooled Water Cooled above floor level, the space between the floor and the base bottom must be 40 &...

  • Page 19: Figure 2-3 Cold Weather Installation

    Refer to Engineering Data Sheet 13–9–411, available Monitor the unit carefully during start–up and op- from an authorized Gardner Denver distributor, for the eration to be sure it is functioning normally. advantages of using the heat recovered from rotary compressors.

  • Page 20: Figure 2-4 Inlet Line Lengths

    Length of Inlet Line Diameter of Pipe Size 0 to 10 Feet (0 to 3 Meters) ........Same as Compressor Inlet Opening 10 to 17 Feet (3 to 5 Meters) .

  • Page 21: Figure 2-6 Aftercooler Approximate Water Flow

    AFTERCOOLER (DOMESTIC) Approx. Water Temperature to Heat Exchanger Water Pressure Gallons/minute Maximum Drop @ 90 F Water Flow Water Temp. Model 60 F. 70 F. 80 F. 90 F. GPM* 40 HP EBHSH_ 26.0 50 HP EBHSJ_ 26.0 Less than 1 PSI 60 HP EBMSK_ 26.0...

  • Page 22: Figure 2-7 Series Piping

    * (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY. FIGURE 2–7 – SERIES PIPING FIGURE 2–8 – PARALLEL PIPING blowdown valve piped to the outside with a pipe size the (43 C). If water cooler than 60 F is used, high water same as the blowdown valve outlet connection.
  • Page 23 justment instructions and maximum allowable lubricant temperature. Failure to properly ground the com- ELECTRICAL WIRING – Standard Units – The Elec- pressor package could result in con- tra–Saver compressor is factory wired for all starter troller malfunction. to motor and control connections for the voltage speci- fied on the order.
  • Page 24 ELECTRIC MOTOR GREASE RECOMMENDATIONS (–30 to 50 C) MANUFACTURER TRADE NAME CHEVRON SRI #2 SHELL DOLIUM R EXXON UNIREX #2 EXXON POLYREX ELECTRIC MOTOR REGREASING INTERVAL Relubrication Type of Service Typical Examples Rating Interval Up to 150 HP (112 KW) 18 Months Standard One–...

  • Page 25: Section 3, Starting & Operating Procedures

    Air Filter – Inspect the air filter to be sure it is clean red “ADD OIL” range. Do not mix different type and tightly assembled. Refer to Section 6, “Air Fil- oils. The unit is shipped filled with Gardner Denver ter,” page 45, for complete servicing instructions. AEON 9000 SP Lubricating Coolant which is Be sure the inlet line, if used, is tight and clean.
  • Page 26 System Pressure – Set the controls to the de- Check all screws and latches for tightness. Be sired load pressure. DO NOT EXCEED THE sure doors are closed and latched. MAXIMUM OPERATING PRESSURE ON THE STARTING THE UNIT – Observe the following starting COMPRESSOR NAMEPLATE.
  • Page 27 SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION – The Gardner Denver justed for the compressor package, but allows tuning rotary screw compressor is prewired with all controls, for specific applications. motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the Relief Valve –...

  • Page 28: Figure 4-1 Schematic Tubing Diagram

    211ECM797–B (Ref. Drawing) FIGURE 4–1 – SCHEMATIC TUBING DIAGRAM Blowdown Valve (FIGURE 4–2) – This valve normal- ly is used for control functions, but also serves to relieve reservoir pressure following a shutdown. The blow- down valve is a two–way solenoid valve which is piped into the oil reservoir outlet ahead of the minimum pres- sure valve.

  • Page 29: Figure 4-3 Minimum Discharge Pressure Valve

    The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver Machinery distributor. Inlet Valve (FIGURE 1–4, page 2, and FIGURE 4–4) FIGURE 4–3 – MINIMUM DISCHARGE PRESSURE / –...

  • Page 30: Figure 4-5 Shuttle Valve

    Pressure Regulator – The pressure regulator is used to supply a constant and low control pressure to pre- vent damage to the inlet valve from “slamming.” The regulator should be set for 25–30 psig. Shuttle Valve (FIGURE 4–5) – Also known as a double check valve, the shuttle valve is a device which will take two (2) supply signals and allow the one with the highest pressure to pass through.
  • Page 31 rack and rotate the valve. Located on the ends of the only – use the keypad [STOP/RESET] for normal con- cylinders are adjusting screws which limit the travel of trolled stopping. the actuator. When looking at the rear of the compres- sor, the adjusting screw on the right on the compressor adjusts the fully closed (full–load) position of the valve.
  • Page 32 side the cover of the enclosure. Wye–delta starters mum capacity. The inlet valve throttles to control com- employ three contactors which are controlled sequen- pressor delivery to match demands of 0% to 40% of the tially to provide low current starting. For wye–delta compressors maximum capacity.

  • Page 33: Figure 4-7 Control Schematic - Compressor Unloaded - Constant Speed Mode, Ebh & Ebm Units

    225ECM797–B (Ref. Drawing) FIGURE 4–7 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – CONSTANT SPEED MODE EBH & EBM UNITS ONLY...

  • Page 34: Figure 4-8 Control Schematic - Compressor At Full Load - Constant Speed Mode, Ebh & Ebm Units

    226ECM797–B (Ref. Drawing) FIGURE 4–8 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD – CONSTANT SPEED MODE EBH & EBM UNITS ONLY...

  • Page 35: Figure 4-9 Control Schematic - Compressor Unloaded - Low Demand Mode Or Auto Mode

    227ECM797–B (Ref. Drawing) FIGURE 4–9 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – LOW DEMAND MODE OR AUTO MODE EBH & EBM UNITS ONLY...

  • Page 36: Figure 4-10 Control Schematic - Compressor At Full Load, Eap Units Only

    214ECM797–B (Ref. Drawing) FIGURE 4–10 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD EAP UNITS ONLY...

  • Page 37: Figure 4-11 Control Schematic - Compressor Fully Unload - Low Demand Mode Switch Off, Eap Units

    215ECM797–B (Ref. Drawing) FIGURE 4–11 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF EAP UNITS ONLY...

  • Page 38: Figure 4-12 Control Schematic - Compressor Fully Loaded - Low Demand Mode Switch On, Eap Units

    216ECM797–B (Ref. Drawing) FIGURE 4–12 – CONTROL SCHEMATIC – COMPRESSOR FULLY LOADED – LOW DEMAND MODE SWITCH ON EAP UNITS ONLY...

  • Page 39: Figure 4-13 Wiring Diagram - 207Ecp546, Wye Delta - Ebh, Ebm & Ebp Units With Es Controls

    FIGURE 4–13 – WIRING DIAGRAM – 207ECP546 (WYE–DELTA – EBH, EBM & EBP UNITS WITH ES CONTROLS)

  • Page 40: Figure 4-14 Wiring Diagram - 209Ecp546, Full Voltage - Ebh, Ebm & Ebp Units With Es Controls

    FIGURE 4–14 – WIRING DIAGRAM – 209ECP546 (FULL VOLTAGE – EBH, EBM & EBP UNITS WITH ES CONTROLS)

  • Page 41: Figure 4-15 Wiring Diagram - 216Eap546, Wye Delta - Eap With Es+ Controls And Current Monitor

    FIGURE 4–15 – WIRING DIAGRAM – 216EAP546 (WYE–DELTA – EAP UNITS WITH ES+ CONTROLS AND CURRENT MONITOR)
  • Page 42 Air/oil under pressure will cause severe personal injury or death. Shut OIL SPECIFICATIONS (Domestic and International) – down compressor, relieve system of The factory fill compressor lubricant is Gardner Denver all pressure, disconnect, tag and AEON 9000 SP lubricating coolant which can be lockout power supply to the starter used for year–round operation.

  • Page 43: Figure 5-1 Flow Diagram - Air/Oil System - Turn Valve Units

    221ECM797–B (Ref. Drawing) FIGURE 5–1 – FLOW DIAGRAM – AIR/OIL SYSTEM – TURN VALVE UNITS...

  • Page 44: Figure 5-2 Oil Flow Diagram - Remote Overhead Mounted Cooler

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

  • Page 45: Figure 5-3 Cooler Drain Detail

    All materials used in Gardner Denver compressor units are compatible with AEON 9000 SP Lubricating Coolant. Use caution when selecting down- stream components such as air line lubricating bowls, gaskets and valve trim. AEON 9000 SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints.
  • Page 46 age, the thermal mixing valve (H) remains on the pack- ADDITION OF OIL BETWEEN CHANGES must be age. Control group part number 200ECM4002 will be made when the oil level is in the red range on the gauge mounted on package at the factory. This group controls as read while the unit is on.

  • Page 47: Figure 5-4 Oil Level Gauge

    pleted when upgrading or changing the type of lubri- cant. Thoroughly drain system: – Drain oil from air end and cooler while hot. – Break low point connections and drain oil from pipe runs. – Dump oil from the filter and reinstall used fil- ter.

  • Page 48: Figure 5-6 Approximate Oil System Capacities

    Gardner Denver offers a free oil analysis program with the AEON lubricants and we recommend a sam- If the drained oil and/or the oil filter element are ple be sent in at 100 hours on a new unit.
  • Page 49 Add oil, if necessary, to bring level to the center of the green range on the gauge. On unloaded operation and after shutdown some oil will Air/oil under pressure will cause drain back into the oil reservoir and the oil level gauge severe personal injury or death.

  • Page 50: Figure 5-7 Thermostatic Mixing Valve Element

    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 pres- sure at oil inlet and outlet. At normal operating air ser- vice pressure (65 to 150 psig, 4.5 to 10.3 Bars) with the unit warm, a pressure drop of 3 to 15 psi (.2 to 1 Bar) can be expected between the oil inlet and the oil outlet.

  • Page 51: Figure 5-8 Water Control Valve

    To decrease water flow (increase compressor dis- charge air temperature) turn the adjusting screw from left to right, increasing spring tension. To increase wa- ter flow (decrease compressor discharge air tempera- ture) turn the adjusting screw in the opposite direction. The groove at the lower edge of the adjusting screw is an index line for use with the index scale 0 to 8 in obtain- ing a desired setting.

  • Page 52: Figure 5-10 Oil Separator

    separator 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 carryover malfunctions of the oil separator are usu- ally due to using elements too long, heavy dirt or var- nish deposits caused by inadequate air filter service, use of improper oil or using oil too long for existing...
  • Page 53 Removal Of Oil Separator For Inspection Or Re- condition. Compressor should be at operating temper- placement: ature at the time of checks. One–half hour of loaded op- eration is usually sufficient to reach level–out operating temperatures. Air and Oil Discharge Temperature – 165 to 195 F (74 to 91 C) –...

  • Page 54: Figure 6-1 Heavy Duty Air Filter

    Never use elements that are damaged, ruptured or wet. Never use gaskets that won’t seal. Keep spare Use only genuine Gardner Denver air elements and gaskets on hand to re- filter elements on Gardner Denver duce downtime. Store elements in a compressor units.
  • Page 55 Pressure drop through a filter with a freshly tube when required by ramming a clean dry cloth cleaned element is below three (3) inches (76 through the tube. Wipe the inside of the filter body to mm) of water with the compressor running at full remove any dirt falling from the inlet tube before rein- load –...

  • Page 56: Figure 7-1 Installation Of Coupling Cushions

    SECTION 7 COUPLING (17 N–M) (37 N–M) (1.6 mm to 3.2 mm) FIGURE 7–1 – INSTALLATION OF COUPLING CUSHIONS Working through the coupling guard opening, cen- ter the coupling over the gap between the shafts, maintaining the gap as shown in FIGURE 7–1 be- tween the ends of the jaws on one coupling body Rotating machinery...
  • Page 57 SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. If the “CHANGE AIR FILTER” message is Check for dirt accumulation on oil/aftercooler core displayed, air filter requires servicing or changing. See faces and the cooling fan.
  • Page 58 SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
  • Page 59 3. Ruptured oil separator 3. Replace element. element. 4. Loose assembly. 4. Tighten all fittings and gaskets. 5. Foam caused by use of 5. Use Gardner Denver incorrect oil. AEON 9000 SP Lubricating Coolant. 6. Inoperative minimum 6. Clean out or replace valve.
  • Page 60 9. Check oil reservoir tempera– ture and if low, change thermal mixing valve element to higher temperature. Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13–9/10–641...
  • Page 61 Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.

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