Related Manuals for Gardner Denver STG2-200
Summarization of Contents
Electra Saver/Saver II G2 Compressor Manual
Operating and Service Manual Overview
Introduces the manual's purpose and scope for the Electra Saver series.
Covered Compressor Models
Lists the specific models (SAVG2-125, STG2-125, etc.) detailed in this manual.
Safety and Warning Information
Genuine Parts and Support Services
Details benefits of using genuine Gardner Denver parts and authorized support.
Warning, Prohibition, Mandatory Label Information
Explains warning symbols (Danger, Warning, Caution) and mandatory actions.
Safety Precautions and Hazard Symbols
Outlines general safety precautions and common hazard symbols used in the manual.
General Information
Compression Principle
Explains how the Gardner Denver rotary screw compressor achieves compression.
Air Flow in the Compressor System
Describes the path of air through the compressor system components.
Lubrication, Cooling and Sealing
Details the system for oil circulation, cooling, and sealing internal clearances.
Installation Procedures
General Installation Notes
Provides initial checks for damage and general installation guidelines.
Lifting Unit Procedures
Outlines safe methods and precautions for lifting and transporting the compressor unit.
Location Requirements
Specifies ideal conditions and space needed for compressor installation.
Air-Cooled Units Installation
Details airflow and clearance requirements for air-cooled compressor units.
Water-Cooled Units Installation
Specifies airflow and clearance requirements for water-cooled units.
Foundation Requirements
Describes mounting surface and foundation considerations for the compressor.
Oil Reservoir Drain System
Explains the configuration of the oil reservoir drain valve and hose.
Installation for Cold Weather Operation
Provides guidelines for operating and installing the unit in cold climates.
Extreme Cold Weather Operation
Details additional precautions for operating in very low temperatures.
Auxiliary Air Receiver
Discusses the use and specifications of an auxiliary air receiver.
Inlet Line Lengths
Specifies pipe sizing based on inlet line length for optimal air supply.
Discharge Service Line Configuration
Details connections and recommendations for the discharge service line.
Blowdown Valve Piping
Explains the piping configuration for the blowdown valve.
Water Piping for Water-Cooled Models
Covers water inlet/outlet connections and piping for water-cooled heat exchangers.
Series Piping Diagram
Illustrates the water flow path in a series piping configuration.
Parallel Piping Diagram
Illustrates the water flow path in a parallel piping configuration.
Electrical Wiring Standards
Covers wiring requirements and adherence to electrical codes for standard units.
Grounding Requirements
Details the importance and method of proper equipment grounding.
Starting & Operating Procedures
Prestart-Up Instructions
Steps to check and service a new unit before initial operation.
Oil Filter Replacement Interval
Specifies the recommended interval for replacing the oil filter element.
Unit Starting Procedures
Guides on how to start the compressor unit when cold or hot.
Daily Check Procedures
Lists essential checks to perform daily for proper operation.
Unit Stopping Procedures
Explains the correct method for shutting down the compressor unit.
Quick Start Guide and Controller Setup
Logging In and Access Levels
Details how to log into the controller and the different access level permissions.
Locale Configuration Settings
Guides on setting pressure, temperature, and flow units for the controller.
Date and Time Configuration
Instructions for setting the unit's date, time, and timezone accurately.
Control Settings Adjustment
Explains how to adjust operating parameters like pressure bands and modes.
Clearing Alarms
Procedure for clearing active faults and alarms from the controller.
Jogging the Motors
Steps to jog motors for verifying correct rotation before operation.
Operating the Compressor
Provides an overview of how to operate the compressor after setup.
Controls & Instrumentation
General Description of Controls
Overview of the compressor package's control system and components.
Electronic Controller and Starter Hardware
Information on the main controller and starter assembly hardware.
Governor Controller Overview
Details the functions and operation of the Governor Controller.
Blowdown Valve Function
Explains the role of the blowdown valve in system control and shutdown.
Minimum Discharge Pressure/Check Valve
Describes the function of the minimum pressure and check valve assembly.
Inlet Valve Operation
Details the operation and control of the compressor inlet valve.
Solenoid Valves IVC and IVO
Explains the function of solenoid valves controlling the inlet valve.
Pressure Regulator Settings
Specifies the correct setting for the pressure regulator.
Shuttle Valve Function
Describes the shuttle valve's role in providing control air pressure.
Turn Valve (Electra Saver Only)
Details the operation of the turn valve for capacity control.
Turn Valve Actuator (Electra Saver Only)
Explains the mechanism positioning the turn valve.
Solenoid Valves TVC and TVO (Electra Saver Only)
Details solenoid valves controlling the turn valve position.
Pressure Transducer Functions
Describes the purpose of various pressure transducers in the system.
Air Filter Monitoring
Explains the air filter condition monitoring switch.
Temperature Sensors
Details the function of discharge and separator temperature sensors.
Emergency Stop Push-Button
Explains the function and use of the emergency stop button.
Power Supply and Fuse Blocks
Covers the unit's power supply and fuse protection.
Fan and Main Starters
Details the starters for the fan and main drive motor.
Compressor Capacity Control
Explains how the turn valve and inlet valve control compressor capacity.
Lubrication, Oil Cooler, Filter & Separator
Compressor Oil System Overview
Describes how the oil system cools, lubricates, and seals the compressor.
Recommended Lubricant
Specifies the factory-recommended AEON lubricants for Gardner Denver compressors.
Oil Specifications
Provides details on AEON 9000SP lubricating coolant and its benefits.
High Temperature Operation Considerations
Discusses effects of high temperatures on lubricant life and recommendations.
Moisture in the Oil System
Explains causes of moisture accumulation and its impact on compressor performance.
Remote Mounted Cooler Assembly Procedure
Instructions for installing and configuring remote mounted cooler assemblies.
Heat Exchanger (Oil) Piping
Guidelines for piping remote elevated cooler applications.
Cold Ambient Operation
Advice for operating the unit in cold ambient conditions.
Addition of Oil Between Changes
Procedure for checking and adding oil when the level is low.
Lubricant Change Procedure
Step-by-step guide for changing the compressor lubricant.
Oil Level Gauge Reading
How to correctly read the oil level gauge during operation and shutdown.
Oil Change Interval Guidelines
Recommended intervals for oil changes based on discharge temperature.
Draining and Cleaning Oil System
Procedure for safely draining and cleaning the compressor's oil system.
Filling Oil Reservoir
Instructions for adding oil to the reservoir, including fill capacity.
Compressor Oil Filter Maintenance
Details the importance and procedure for replacing the oil filter element.
Compressor Oil Cooler - Radiator Type
Information on the air-cooled oil cooler module and its maintenance.
Thermal Control (Thermostatic Mixing) Valve
Explains the function of the thermal mixing valve in oil temperature control.
Compressor Oil Cooler - Water-Cooled Heat Exchanger
Details the water-cooled oil cooler and its temperature control.
Water Flow Control Valve for Heat Exchanger
Instructions for adjusting the water flow control valve for optimal cooling.
Water Shutoff Valve - Water-Cooled Heat Exchanger
Describes the solenoid-operated water shutoff valve for water-cooled models.
Oil Reservoir and Oil Separator Functions
Explains the combined functions of the oil reservoir and primary oil separation.
Compressor (GD Eliminator) Oil Separator
Details the cartridge-type separator and its role in oil removal.
Oil Separator Maintenance and Gauging
Covers separator maintenance, pressure differential monitoring, and replacement.
Removal of Oil Separator for Inspection or Replacement
Step-by-step guide for removing and reinstalling the oil separator element.
Compressor Oil System Check
Procedures for checking key oil system parameters like temperature and pressure.
Oil Cooler Pressure Differential Checks
Explains how to check pressure differentials across air and water-cooled oil coolers.
Oil Cooler Temperature Differential Checks
Details how to check temperature differentials for oil coolers.
Air Filter Service
Heavy-Duty Air Filter Description
Overview of the standard heavy-duty dry type air filter used on the units.
Filter Element Inspection
Guidance on inspecting and servicing the air filter element.
Filter Element Life Factors
Discusses factors affecting the lifespan of the air filter element.
Inlet Tube Maintenance
Procedures for inspecting and cleaning the air filter inlet tube.
Coupling Maintenance
Coupling Installation Procedure
Steps for installing the coupling cushions and related components.
Coupling Description
Details the type of flexible coupling used and its lubrication requirements.
Assembly of Coupling onto Airend and Motor
Instructions for assembling the coupling halves onto the motor and airend shafts.
Coupling Alignment
Information on the permanent alignment of the coupling via flanges.
Maintenance Schedule
Service Check List
Routine checks to be performed at specified intervals (e.g., 8 hours).
Service Change List
Recommended intervals for changing components like filters, oil, and separators.
Troubleshooting Guide
Compressor Fails to Start
Possible causes and remedies for the compressor not starting.
Compressor Starts and Stops Briefly
Troubleshooting steps for units that stop shortly after starting.
Compressor Fails to Load/Unload
Solutions for issues with compressor loading or unloading functionality.
Compressor Cycles Excessively
Addresses causes and fixes for frequent load/unload cycling.
Compressor Starts Too Slowly
Diagnoses for slow compressor startup, including Wye Delta timing.
Low Delivery and Pressure Issues
Troubleshooting for problems related to reduced air delivery or pressure.
Excessive Oil Consumption
Identifies causes and solutions for high oil consumption in the compressor.
High Discharge Air Temperature
Troubleshooting steps for elevated discharge air temperatures.
Oil Carryover Causes
Explains common reasons for oil carryover and how to resolve them.
Standard Warranty Information
Standard Warranty Period Coverage
Details the warranty duration for different compressor components.
Warranty Exclusions and Limitations
Outlines conditions under which warranty coverage may be denied or limited.
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