Gardner Denver ELECTRA-SAVER II, Service Manual

Page 1: ...13 9 630 13 9 630 1 st Edition ELECTRA SAVERII STATIONARY BASE MOUNTED COMPRESSOR Models 125 HP ECQQN ECQSN 150 HP ECQQO ECQSO r 141GARDNER DENVER COMPRESSORS 1 COOPER INDUSTRIES I...

Page 2: ...CTRA SAVER SE ST PACKAGES ALL BARE AIR ENDS Any product which has in the Company s judgment been subject to negligience accident improper storage or improper installation or application Any product wh...

Page 3: ...ER notice could result in injury to or death of personnel WARNING _ Failure toobserve WARNING notice could result in damage to equipment CAU T ION CAUTION notices set forth general reminders of good s...

Page 4: ...ystem Automatic StarVTimed Stop With Low Demand Mode 4 6 Control System Constand Speed With Low Demand Mode 4 6 Control System Low Demand Mode 4 6 Control Thermostatic Mixing valve Thermal 5 4 Control...

Page 5: ...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 Operati...

Page 6: ...7 Valve Bleed Air 4 5 Valve Check Oil Reservoir 4 5 Valve Flow ControFCheck 4 7 Valve Inlet 4 5 Valve Minimum Discharge Pressure 4 5 Valve Piping Blowdown 2 5 Valve Safety 4 3 Valve Thermal Control T...

Page 7: ...rotor groove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volume reduction and pressure increase co...

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Page 9: ...VER BYPASS SAFETY DEVICES DANGER KEEP FINGERS AND CLOTHING AWAY FROM REVOLVING FAN DRIVE COUPLING ETC DO NOT USE THE AIR DISCHARGED FROM THIS UNIT FOR BREATHING NOT SUITABLE FOR HUMAN CONSUMPTION DO N...

Page 10: ...odule is to be installed at a location remote from the compressor unit be sure that adequate ventilation is provided Figure 2 2 Hot air must be exhausted from the oil cooler area Open Unit Open With C...

Page 11: ...e system to keep the pressure loss low All pipe and fittings used in a remote oil cooler system should be galvanized or treated internally to pre vent rust and all valves are to be of a nonferrous con...

Page 12: ...ons in the operation and installation of the unit AUXILIARY AIR RECEIVER The unit requires an auxiliary air receiver unless the piping system is large and provides sufficient storage capacity to preve...

Page 13: ...ture To Heat Exchanger Maximum Drop Pressure Size Water Maximum Flow PSIG 60 F 70 F 80 F 90 F Flow Psi 125 HP ALL 12 0 15 5 20 5 32 0 60 20 150 HP ALL 15 5 19 0 25 5 37 5 60 20 The Maximum Water Flow...

Page 14: ...r location The water source should be capable of supplying up to the maximum flow shown in Figure 5 2 at a minimum pres sure of 40 PSIG maximum allowable water pressure is 150 PSIG The water flow rate...

Page 15: ...electric motor depends in large measure on the bearings and timely lubrication The following charts show recommended grease qualities and regressing intervals for motor supplied with ball bearings For...

Page 16: ...ms and Section 2 for installation instructions 6 Rotation Check the motor rotation by momen tarily starting the motor Compressor drive shaft rota 13 9 630 Section tion is counterclockwise standing at...

Page 17: ...units the transformer in the control enclosure is connected to change the specified user s power supply voltage to 115 volt control voltage RESET The Reset Button must be pushed whenever power is inte...

Page 18: ...le since the use of a third overload derates each overload for a given enclosure due to the extra heat An overload from a 2 overload heater table would be undersize The overload heaters are in a commo...

Page 19: ...down Blowdown time is usually about 45 seconds WARNING Do not set the switch higher than 5 PSIG or render the switch inoperative severe damage to the motor can occur if started with pressure in the o...

Page 20: ...MANUAL OPERATOR TAB 1 N C TIMING CONTACT MOVEABLE INSTAN 1 TANEOUS CONTACT CARRIER DO NOTL uSE AS A MANUAL OPERATOR I TIME SETTING AOJUSTING XREW J A75852 FIGURE 3 4 LOW OIL PRESSURE TIME DELAY SWITCH...

Page 21: ...o prevent moisture buildup and carryover into the control lines INLET VALVE Figure 7 4 The inlet valve is a piston actuated device which controls the compressor inlet and operates on air pressure from...

Page 22: ...HE UNIT NAMEPLATE MINIMUM OPERA TING PRESSURE IS 65 PSIG LOW DEMAND MODE CONTROL SYSTEM The low demand mode control system is suitabie for use only on water cooled or air cooled units which have the o...

Page 23: ...without an auxiliary air receiver LOW STARTING TORQUE Unloaded Start CONTROL Optional Equipment When a reduced voltage closed transition starter is used problems may arise as the torque required by th...

Page 24: ...SURE AIR FROM SHUTTLE TH REE wAY FROM TEE AT INLET VALVE AT CONTROL N 0 VALVE 80x SIDE OF INLET VALVE SUBTRACTIVE PILOT I o 0 1 FIGURE 10 4 SCHEMATIC AND OUTLINE LOW STARTING TORQUE CONTROL FIGURE 11...

Page 25: ...SURE PREVENTS COMP STARTING AFTER A POWE SHUTDOWN AN D OR POWER INTERRUPTION NT L RESERVO R pRESSURE IS BELOW 5 psi __ _______ I FOGCDTAWIRE5QE L T L a SEE NO1 x 3 G D AFT cOOLcR T 0 1 C Q H BTEW 60 6...

Page 26: ...5 PSI d fl I IX 3 x75 w 1XYX13 5LG W D COMPRESSOR 3 FQwER SUPPLY LI _ vOLTS pHAsE L2 HERTZ L3 SEE NOTE A 5EE TEDV L2 IC5J lCR22 1 lb F P T RU5HUTTL ALUF TO DISCHARGE MA MfF OLD mm COMPRESSOR SEPbR lO...

Page 27: ...UNTIL RESERVOIR PRESSURE IS 8ELOW 5 PSI T o c _ _ ___ ORIF C OM A I flTTT l OF O OOE 4 140 TeANS FORMER _ J PWE PPLY m lp 4 ti VR 2 RPS 4 15 L 2 3Z 2 P O_W OW_P LY r z o 1 Vz c I ExHAuST 5ET IQ 8Er S...

Page 28: ...v E TO l scoyDi NoTE RE5E7 BUTTON MUST BE PRESSED AFTER A PO R TURN OFF POWER interrupt ON HD T S X CONTACT CLOSIO M BD 5tiu TD0wN OR L OP H T ti L _ J FIGURE 15 4 WIRING DIAGRAM WATER COOLED UNITS CO...

Page 29: ...ARTING AFTER A pOw ER 5HUTDOWN AND OR POwER INTERRUPTION UNTIL RESERVOIR PRESSURE IS 8ELoW 5 PSI cK cw Dow k II 1 1 m E NOTE Y OIL COOLE OR C0M01Nf1710N v TS AA I 7 I I LMANIFOLD I I L 8 LPS 10 T 2 AA...

Page 30: ...F RESET PB 6 24 CA 817 TERMINAL LIJ 2 MECE KNOb At ALLEN scscw AT 19 MIN UAGX3 4 N J H 24CA Z MOUE S C Al fiY o 0 1 u i 1 w 20 WXHAUSI A A D2026343 FIGURE 17 4 WIRING DIAGRAM WATER COOLED UNITS AUTOMA...

Page 31: ...rol transformer The contact relay or fan oil cooler starter interlock from the compres sor control panel to the remote mounted starter control circuit is rated 600 volts D1 Remote mounted magnetic com...

Page 32: ...e C Not furnished as standard item if ordered it is remote mounted and wired by customer The aftercooler when sized for an individual com presser starter coil is 120 volts and is wired and interlocked...

Page 33: ...mpressor Starter M U B D V Magnetic Unloader Blowdown Solenoid Valve 1 10 120 V 50 60 Hz Four Way 91 B34 The LOW DEMAND MODE switch should be in the OFF position when starting the unit to keep the com...

Page 34: ...ther or not these N O AUX contacts are required look at the typical wiring diagram shown in most starter manufacturers control handbook digest catalog etc If the typical wiring diagram shows two or mo...

Page 35: ...xture is discharged to the oil reservoir where most of the entrained oil is removed by impingement and velocity change The air and remaining oil then passes through the final oil separator The sep ara...

Page 36: ...four 4 hours of sus tained discharge temperatures Up to 210 F do not require a change from the recommended year round lubricant GD800 When installing GD8000 the original lubricant should be drained c...

Page 37: ...n the oil is hot will help to prevent varnish deposits and to carry away impurities To drain the system use one of the following methods If the unit is not elevated high enough to use the oil reservoi...

Page 38: ...cked or distorted by overtorquing and should be replaced COMPRESSOR OIL COOLER RADIATOR TYPE MODULE The air cooled oil cooler module is remote mounted The oil cooler requires pipe and electrical conne...

Page 39: ...OOLED HEAT EXCHANGER Figure 3 1 The heat exchanger oil cooler is a multiple pass type with water in the tubes and oil in the shell The oil temperature is controlled by the thermal control thermostatic...

Page 40: ...R Figure 9 5 located in the vertical section of the oil reservoir consists of two re newable cartridge type separator elements and provides the final removal of oil from the air stream Oil from inside...

Page 41: ...ly Connect the other end of the tube to the compressor oil return tee trim any excess from new tube to fit into tee do not bend tube to fit or raise tube any further from bottom of separator PRESSURE...

Page 42: ...d Ra diaton The oil temperature differential depends on the temperature of the air at the oil cooler fan and clean Iiness of the core faces As ambient temperatures and core restrictions increase the o...

Page 43: ...horoughly with clean water a hose maybe used if the water pressure does not exceed 40 PSIG Inspect the element for ruptures or cracks in the pleated media replace with new element if any are found Ins...

Page 44: ...flag reaches the top and locks in position as long as the inlet system vacuum is maintained If indicating the need for filter servicing the vacuum is broken because of a defective filter gasket After...

Page 45: ...1 7 between the ends of the jaws on one coupling body and the flange on the opposite coupling body Tighten set screws in each coupling body Insert individual cushions as shown in Figure 1 7 and slide...

Page 46: ...t valve pilots and on separate air receiver and moisture sep arator if used 4 If moisture is noted in the oii level gauge drain accumulated moisture and see Section 5 Moisture in the Oii System Every...

Page 47: ...low oil pressure shutdown switch Time delay on timing relay for low oil pressure shut down set too short a time MAXIMUM DELAY SETTING IS 15 SECONDS Timing relay setting screw not engaged a Faulty or...

Page 48: ...Litho in U S A 1M 1 O 83 GARDNER DENVER INDUSTRIAL MACHINERY DIVISION 1800 GARDNER EXPRESSWAY o QUINCY ILLINOIS 62301 0 217 222 5400 SALES AND SERVICE OFFICES IN ALL PRINCIPAL CITIES...