Gardner Denver SAVG2-100, Installation, Operating & Service Manual

Page 1: ...ELECTRA SAVER SAVER II G2 BASE MOUNTED COMPRESSOR SAV75 100G2B ST75 100G2B Operating Service Manual MODELS SAVG2 75 STG2 75 75 HP SAVG2 100 STG2 100 100 HP 13 21 615 Version 01 December 30 2020...

Page 2: ...he necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair They are ready to respond and a...

Page 3: ...ay to day operation maintenance and adjustment Careful adherence to these instructions will result in economical operation and minimum downtime Boxed text formats are used within this manual to alert...

Page 4: ...erate injury Asphyxiation Hazard Poisonous Fumes or Toxic Gases in Compressed Air Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Lockout...

Page 5: ...Open main disconnect switch lockout and tagout before working on the control wait 10 minutes and check for voltage Failure to observe these notices could result in damage to equipment Stop the unit if...

Page 6: ...eral Information 8 Section 2 Installation 12 Section 3 Starting Operating Procedures 22 Section 4 Controls Instrumentation 34 Section 5 Lubrication Oil Cooler Oil Filter Separator 51 Section 6 Air Fil...

Page 7: ...Oil Sampling Valve 60 Oil Separator Compressor GD Eliminator 67 Inspection 68 Oil Carryover 67 Pressure Differential Gauging 68 Removal For Inspection Or Replacement 69 Oil Specifications 51 Oil Syst...

Page 8: ...30 Figure 3 9 Active Alarms Screen 31 Figure 3 10 Jogs Motor Screen 32 Figure 4 1 Controller Keypad 33 Figure 4 2 Schematic Tubing Diagram 34 Figure 4 3 Minimum Discharge Pressure Check Valve 35 Figu...

Page 9: ...ns as rotors unmesh at the inlet port and air is drawn into the cavity between the main rotor lobes and secondary rotor grooves A When the rotors pass the inlet port cutoff air is trapped in the inter...

Page 10: ...discharges into the compressor main oil gallery A portion of the oil is directed through internal passages to the bearings gears and shaft oil seal The balance of the oil is injected directly into th...

Page 11: ...13 21 615 v01 Page 10 Figure 1 4 COMPRESSOR MOTOR SIDE Figure 1 5 COOLER RESERVOIR SIDE 319EBD797 00 Ref Drawing...

Page 12: ...13 21 615 v01 Page 11 307EBD797 EA Ref Drawing Figure 1 6 AIR OIL FLOW DIAGRAM...

Page 13: ...ON 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 LIFTING UNIT Proper lifting and...

Page 14: ...ectric motor cooling Air is drawn into the unit at the motor side of the enclosure and is exhausted at the oil cooler side Do not block the air flow to and from the unit Allow three and one half 3 1 2...

Page 15: ...d control box side of the unit Allow three 3 feet 9 m to the nearest obstruction above and on other sides of the unit FOUNDATION The Gardner Denver Rotary Screw compressor requires no special foundati...

Page 16: ...d will depend on the severity of the environment The following are general guidelines for outside installations Cold Weather Down To 10 F 12 C 1 Be sure all drains traps and control lines including pr...

Page 17: ...eceiver is not required if the piping system is large and provides sufficient storage capacity to prevent rapid cycling When used an air receiver should be of adequate size provided with a relief valv...

Page 18: ...to another compressor be sure the other compressor has a check valve in the line between the machine and the manifold If a rotary screw and a reciprocating compressor are manifolded together anair re...

Page 19: ...ater Flow will cause severe erosion and will void unit warranty Figure 2 6 AFTERCOOLER APPROXIMATE WATER FLOW WATER PIPING Water Cooled Heat Exchanger Models Only On machines equipped with water coole...

Page 20: ...water warmer than 90 F 32 C is used higher compressor oil inlet temperatures and high water usage will result Most water systems will require control of impurities filtration softening or other treatm...

Page 21: ...0 F to 150 F 60 C to 66 C range regardless of inlet water flow or temperature as long as a minimum flow for a given temperature is met Figure 2 5 page 17 and Figure 2 6 page 18 See Section 5 for adjus...

Page 22: ...add grease with a hand operated grease gun Only enough grease should be added to replace the grease used by the bearing Too much grease can be as harmful as insufficient grease The grease cavity shou...

Page 23: ...y show the oil level in EXCESS OIL range After start up the oil will fall into the operating range as system components are filled If necessary add oil to bring the level to the top of full range when...

Page 24: ...rly grounded according to Section 250 of the National Electrical Code 7 Rotation Check for correct motor rotation by jogging the motor See Machine Configuration Menu in the Controller Operating and Se...

Page 25: ...by pressing RUN Since the unit is equipped with a minimum 65 psig 4 5 bar pressure discharge valve no special procedure to maintain unit reservoir pressure is required Unit Hot No warm up period is re...

Page 26: ...he controller verify the pressure setting and operating mode and start the compressor Logging In Before making any changes to the settings on the controller you must log in with an appropriate access...

Page 27: ...towards distributors and service technicians Factory Contact Gardner Denver Full access to all settings and features The password rotates automatically throughout the life of the machine It may not be...

Page 28: ...he Settings Configuration menu as shown in Figure 3 3 Figure 3 3 Configuration Menu First ensure that the units are set as desired by selecting the Locale link from the Configuration menu The Pressure...

Page 29: ...mezone properly ensures that daylight savings time adjustments will be accounted for automatically The Date and Time Configuration screen is shown in Figure 3 5 Figure 3 5 Date and Time Configuration...

Page 30: ...gs of the machine are acceptable for most installations However if the Pressure Band displayed on the gauge on the Home screen does not match the desired pressure range for the site the Pressure Band...

Page 31: ...d maximum values that will be allowed for each box will change dynamically based on the design pressure of the machine as well as the values of the other settings For example to increase the Load pres...

Page 32: ...ge Status Bar on the Home screen or by navigating to Alarms Active Alarms through the Menu The Active Alarms screen is shown in Figure 3 9 Figure 3 9 Active Alarms Screen If the alarm icon in the Alar...

Page 33: ...wn as shown You will need to jog both individually to verify correct rotation The Jog Delay field allows you to delay the start of the jog from the time that you press the Start Jog button This is to...

Page 34: ...ee to the Wiring Diagrams listed by voltage at the end of this section for more details on the location of the referredhardware Governor Controller The compressor package features the Governor Control...

Page 35: ...oil reservoir outlet ahead of the minimum pressure valve When the solenoid is de energized the valve opens and the coolant system is blown down When the solenoid is energized the valve closes to allow...

Page 36: ...approximately 65 psig in the oil reservoir When the air pressure on the upstream reservoir side of the valve rises above 65 psig the spring is overridden and the valve opens to full porting The valve...

Page 37: ...both valves de energized the normally open IVC valve allows control pressure to the inlet piston to close the valve If IVC only is energized the inlet valve is held in its current position If both val...

Page 38: ...nd of the actuator left side of the compressor and using a rod to push the pistons to the full load position The rod must be clean and free of burrs and scale Take care not to scrape the cylinder wall...

Page 39: ...ure and shut down the compressor if a coolant problem is detected Separator Temperature Sensor This sensor is located near the separator and is used to monitor temperature and shut down the compressor...

Page 40: ...ntrol and overload protection for the main drive motor Wiring diagrams for typical Wye Delta applications are illustrated on pages 43 thru 50 Overload protection is provided for each motor on voltage...

Page 41: ...13 21 615 v01 Page 40 FIGURE 4 6 COMPRESSOR PACKAGE P ID 300EBF797 EB Ref Drawing...

Page 42: ...Modulate Closed Off Closed On Closed Off Open On Closed On On A D D Open Increasing Open TV Modulate Closed Off Closed On Open On Closed Off Closed On On A D D Open Decreasing Open IV Modulate Open O...

Page 43: ...it before doing any service or diagnostics on the electrical system FIGURE 4 8 ELECTRA SAVER II WIRING DIAGRAMS WIRING DIAGRAM HP VOLTAGE STARTER 326EBF546 75 460 3 60 YES 327EBF546 75 575 3 60 YES 10...

Page 44: ...13 21 615 v01 Page 43 328EBF546 02 Ref Drawing Page 2 of 12 FIGURE 4 9 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 45: ...13 21 615 v01 Page 44 328EBF546 02 Ref Drawing Page 3 of 12 FIGURE 4 10 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 46: ...13 21 615 v01 Page 45 328EBF546 02 Ref Drawing Page 4 of 12 FIGURE 4 11 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 47: ...13 21 615 v01 Page 46 328EBF546 02 Ref Drawing Page 5 of 12 FIGURE 4 12 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 48: ...13 21 615 v01 Page 47 328EBF546 02 Ref Drawing Page 6 of 12 FIGURE 4 13 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 49: ...13 21 615 v01 Page 48 328EBF546 02 Ref Drawing Page 7 of 12 FIGURE 4 14 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 50: ...13 21 615 v01 Page 49 328EBF546 02 Ref Drawing Page 8 of 12 FIGURE 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 51: ...13 21 615 v01 Page 50 328EBF546 02 Ref Drawing Pages 9 10 11 of 12 FIGURE 4 16 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 100 HP 460 VOLT...

Page 52: ...scharged to the oil reservoir where a large part of the entrained oil drops out of the air stream the air then passes through the final oil separator where most of the remaining oil is removed The sep...

Page 53: ...for detecting moisture is a disciplined lubricant sampling analysis program every 2 000 hours of operation If moisture is observed in the oil reservoir drain the moisture and correct the operating con...

Page 54: ...is of the chart and then reading the appropriate pressure curve to determine the corresponding dew point temperature on the left axis of the chart The compressor discharge temperature must be maintain...

Page 55: ...13 21 615 v01 Page 54 300EBF797 EB Ref Drawing Figure 5 3 FLOW DIAGRAM AIR OIL SYSTEM...

Page 56: ...13 21 615 v01 Page 55 318EBD797 00 Ref Drawing Figure 5 4 OIL FLOW DIAGRAM REMOTE MOUNTED COOLER...

Page 57: ...ontactor starter will be shipped loose and remote mounted with the cooler by others upon start up at the job site The control box will be wired for remote elevated coolers at the factory NOTICE When c...

Page 58: ...This will shut the oil stop valve and prevent excessive oil from running into the reservoir Failure to install these parts or installations with pipe lengths and or vertical runs outside the recommend...

Page 59: ...t lockout and tagout the power supply to the starter 3 Wipe away all dirt around the oil filler plug 4 Remove the oil filler plug and add oil as required to return the oil level to the center of the g...

Page 60: ...AUGE Figure 1 6 page 11 and Figure 5 5 indicates the amount of oil in the oil reservoir Read oil level only when unit is on In operation the oil level will fluctuate as the compressor loads and unload...

Page 61: ...nterval AEON 9000SP Change Interval Up to 180 F 82 C 4000 hrs 8000 hrs 180 F to 190 F 82 C to 88 C 3000 hrs 6000 hrs 190 F to 200 F 88 C to 93 C 2000 hrs 4000 hrs 200 F 93 C 1000 hrs 2000 hrs Figure 5...

Page 62: ...system use one of the following methods 1 If the unit is not elevated high enough to use the oil reservoir drain line to drain oil a small hand electric or air operated pump should be used to drain r...

Page 63: ...rain back into the oil reservoir and the oil level gauge will read HIGH DO NOT DRAIN OIL TO CORRECT On the next start oil will again fill the system and the gauge will indicate operating at the proper...

Page 64: ...in the event the element becomes dirty enough to block the flow of oil Use only the replacement element shown on the filter tag or refer to the parts list for the part number Use the following proced...

Page 65: ...voir to compressor during warm up As oil warms element gradually closes to the bypass allowing more of the oil from the cooler to mix with oil from the bypass After the unit is warmed up the mixing va...

Page 66: ...n cause scale formation corrosion and plugging of any water cooled heat exchanger equipment Disregarding the possibility that one or more of these conditions exist may result in increased maintenance...

Page 67: ...e lower edge of the adjusting screw is an index line for use with the index scale 0 to 8 in obtaining a desired setting These valves must be handled with care and proper tools and techniques must be u...

Page 68: ...l and gauge actuation 303EBD797 Ref Drawing Figure 5 11 OIL SEPARATOR COMPRESSOR GD ELIMINATOR OIL SEPARATOR located in a separate housing consists of a renewable cartridge type separator element and...

Page 69: ...ssive tilt angle of the unit will also hamper separation and cause oil carryover Oil separator element life cannot be predicted it will vary greatly depending on the conditions of operation the qualit...

Page 70: ...to the housing Do not use excessive force as separator damage can occur 8 Place the spacer on the indent in the separator Swivel top back into position on top of the reservoir Install and tighten all...

Page 71: ...et temperature is approximately the same as air discharge temperature see the gauge on the instrument panel The outlet oil temperature may be checked by installing a tee at the oil filteroutlet Oil Co...

Page 72: ...ing hours depending on dust conditions NOTICE To service 1 Remove the clamp and pull out the filter element 2 Visually inspect the element If cleaning is not necessary reinstall the filter element If...

Page 73: ...indicate a rupture or crack Inlet Tube Inspect the inlet tube for dirt accumulation each time the filter is serviced Clean the tube when required by ramming a clean dry cloth through the tube Wipe th...

Page 74: ...and tagout before servicing the coupling SECTION 7 COUPLING Figure 7 1 INSTALLATION OF COUPLING CUSHIONS COUPLING The motor and compressor are direct connected by a resilient type flexible coupling w...

Page 75: ...compressor half After engaging each hub on the matching recesses of the coupling element check that the gap between the hub flats see dimension E on Figure 8 2 is within 1 10 1 19 in 28 0 30 1mm A sm...

Page 76: ...ling the same direction as the rotation arrow on the airend Incorrect rotation will greatly decrease the torque carrying capacity of the coupling Rotating machinery can cause personal injury or death...

Page 77: ...age aluminum in a direction opposite that of the cooling air flow The cleaning operation will keep the exterior cooling surfaces clean and ensure effective heat dissipation Every 1000 hours operation...

Page 78: ...x x x x x x Replace air filter element x x x x x x x x x x x Oil Sample x x x x x x x x x x Replace Air Oil Separator x x x x x x Inspect clean if necessary scavenge line replace check x x x x x Insp...

Page 79: ...x x Replace air filter element x x x x x x x x x x Oil Sample x x x x x x x x x x Replace Air Oil Separator x x x x x Inspect clean if necessary scavenge line replace check x x x x x Inspect service i...

Page 80: ...on 2 Blown fuse in starter 2 Replace fuse investigate control box if fuses continue to blow 3 Motor starter overload 3 Reset and investigate heaters trips cause of overload Compressor does not unload...

Page 81: ...leaks found 5 Aftercooler is frozen 5 Thaw out This machine cannot operate in temperatures below 32 F 0 C 6 Unload pressure adjusted 6 Adjust the unload too low pressure Excessive oil consumption 1 O...

Page 82: ...re valve 7 Operation at elevated discharge temperatures 8 Scavenge line check valve failure 5 Use Gardner Denver AEON lubricating coolants 6 Replace seals in valve 7 Reduce temperature See High Discha...

Page 83: ...service personnel for repair or replacement of any product or part which in the Company s sole judgment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s...

Page 84: ...For additional information contact your local representative or visit www contactgd com compressors 2020 Gardner Denver Inc Printed in U S A...