Maintenance Schedule - Gardner Denver ELECTRA-SAVER II Service Manual

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-1
Low Demand Mode Control System . . . . . . . . . . . . . . . ...4-6
Low Demand Mode Pressure Switch. . . . . . . . . . . . . . . ...4-3
Low Demand Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . ...4-2
Low Demand Mode Unloader Solenoid . . . . . . . . . . . . ...4-3
Low Oil Pressure Protection Air-Cooled Oil
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-2
Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . ...4-3
Low Oil Pressure Time Delay Switch . . . . . . . . . . . . . . ...4-4
Low Starting Torque (Unloaded Start) Control . . . . . ...4-7
Lubricant Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-2
Lubricants Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-2
Lubrication, Cooling and Sealing . . . . . . . . . . . . . . . . . . . . .. I-l
Lubrication, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-5.8-l
LUBRICATION, OIL COOLER, OIL FILTER &
SEPARATOR (SECTION 5) . . . . . . . . . . . . . . . . . . . . ...5-1
MAINTENANCE SCHEDULE (SECTION 8) . . . . . . . ...8-1
Minimum Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-1
Minimum Discharge Pressure Valve. . . . . . . . . . . . . . . . ...4-5
Minimum Operating Pressure . . . . . . . . . . . . . . . . . . . . . . ...4-6
Mode Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-l
Moisture lnThe Oil System . . . . . . . . . . . . . . . . . . . . . . . . ...5-3
Moisture Separator Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Motor Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-5.8-1
Motor Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-2
Oil Addition Between Changes . . . . . . . . . . . . . . . . . . . . ...5-2
Oil and Air Discharge Temperature . . . . . . . . . . . . . . . . ...5-7
Oil-Air Systems Flow Diagram. . . . . . . . . . . . . . . . . . . . . . ...5-1
Oil Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-3
Oil Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3.l
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-2
Oil Cooler, Compressor – Water-Cooled Heat
Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-5
Oil Cooler Module (Air-Cooled) . . . . . . . . . . . . . . . . . . . . . ...2-2
OIL COOLER, OIL FILTER, SEPARATOR &
LUBRICATION (SECTION 5)....... . . . . . . . . . . . ...5-1
Oil cooler Oil Pressure Differential (Water-Cooled
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Oil Cooler Pressure Differential (Air-Cooled
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Oil Cooler (Radiator Type) Module, Compressor . . . . . . 5-4
Oil Cooler Temperature Differential . . . . . . . . . . . . . . . . ...5-8
Oil Cooler Water Pressure Differential (Water-Cooled
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Oil Filter, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-3
Oil Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-4
OIL FILTER, SEPARATOR, OIL COOLER &
LUBRICATION (SECTION 5).... . . . . . . . . . . . . . . ...5-1
Oil Flow Diagram – Remote Overhead Mounted Oil
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-2
Oil lnlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-3
Oil Pressure Differential Oil Cooler . . . . . . . . . . . . . . . . . . . 5-8
Oil Pressure Protection Low (Air-Cooled Oil
Cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-2
Oil Pressure Shutdowm Low . . . . . . . . . . . . . . . . . . . . . . . ...4.3
Oil Pressure Time Delay Switch Low.. . . . . . . . . . . . . ...4-4
Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-6
Oil Reservoir Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . ...4-5
Oil Reservoir Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-1
Oil Reservoir, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-3
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-1
Oil Separator, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . ...5-6
Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-1
Oil System Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-3
Oil System Check Compressor. . . . . . . . . . . . . . . . . . . . ...5-7
Oil System Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-1
Oil System Draining and Cleaning . . . . . . . . . . . . . . . . . ...5-3
OmOff Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-2
Operating Air Pressure Adjustment . . . . . . . . . . . . . . . . ...4-6
Operating Light Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Operating Pressure Minimum . . . . . . . . . . . . . . . . . . . . . . ...4-6
OPERATING PROCEDURES & STARTING
(sEcTloN 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-l
Operation, High Temperature . . . . . . . . . . . . . . . . . . . . . . ...5-2
Overhau\ Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-1
Pilot inlet Valve Subtractive . . . . . . . . . . . . . . . . . . . . . . . ...4-5
Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-1
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Piping Blowdown Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-5
Piping Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-5
Piping Diagram for Aftercooler & Heat Exchanger . . . . 2-4
Piping Water (Water-Cooled Heat Exchanger Models
OnlY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pressure Adjustment Operating Air . . . . . . . . . . . . . . . . . . . 4-6
Pressure Adjustments Compressor Capacity and . . . . . 4-5
Pressure Differential Gauge . . . . . . . . . . . . . . . . . . . ...4-4. 5-7
Pressure Differential Oil Cooler (Air-Cooled
Radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Pressure Differential Oil Cooler Oil (Water-Cooled
Heat ExchangeO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Pressure Differential Oil Cooler Water (Water-Cooled
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Pressure Gauge, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-4
Pressure, Minimum Operating . . . . . . . . . . . . . . . . . . . . . . ...4-6
Pressure, Oillnlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-8
Pressure Protection Low Oil (Air-Cooled Oil
Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-2
Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-3
Pressure Shutdown Low Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Pressure Switch Low Demand Mode. . . . . . . . . . . . . . ...4-3
Pressure, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Pressure Time Delay Switch Low Oil . . . . . . . . . . . . . . . ..4-4
Pressure Valve Minimum Discharge . . . . . . . . . . . . . . . . . . 4-5
Regressing interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-6
Regulator, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-3
Reservoir Check Valve Oil . . . . . . . . . . . . . . . . . . . . . . . . . ...4-5
Reservoir Drain Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-1
Reservoir, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-6
Reservoir Pressure Switch . . . . . . . . . . . . . . . . . . . . ...4-3.4-7
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-1
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1-3
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-3
Separator, Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . ...5-6
Separator, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-1
SEPARATOR, OIL COOLER, OIL FILTER &
LUBRICATION (SECTION 5).... . . . . . . . . . . . . . . ...5-1
Service Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8-1
Service indicator, Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . ...6-1
Service Line Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2-5
Shutdown Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . ...4-3
Shutoff Valve Water – Water-Cooled Heat
Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-6
Solenoid Low Demand Mode Unloader . . . . . . . . . . . . . . . 4-3
Starter, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2.5
STARTING & OPERATING PROCEDURES
(sEcTloN 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-l
Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Stopping the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-1
Subtractive Pilot inlet Valve . . . . . . . . . . . . . . . . . . . . . . . ...4-5
Switch High Discharge Temperature . . . . . . . . . . . . . . ...4-2
Switch Low Demand Mode . . . . . . . . . . . . . . . . . . . . . . . . ...4-2
13-9-630
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