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Gardner Denver SAVG2-75, Installation, Operating & Service Manual

The Gardner Denver SAVG2-75 is a powerful and reliable industrial air compressor. Ensure smooth operation by referring to the comprehensive Installation, Operating & Service Manual. Download this essential manual for free from 88.208.23.73:8080, providing step-by-step instructions and maintenance guidelines to maximize the product's lifespan and efficiency.

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13-21-615 v01     Page 6 

 

INDEX 

 

Addition Of Oil Between Changes ...................................... 58 
Air Filter Element Life .......................................................... 72 
Air Filter Vacuum Switch ..................................................... 37 
Air Filter, Heavy Duty (Standard) ........................................ 71 
Air Flow In The Compressor System .................................... 8 
Air-Cooled Units, Location .................................................. 13 
Auxiliary Air Receiver .......................................................... 16 
Blowdown Valve .................................................................. 34 
Blowdown Valve Piping ....................................................... 17 
Cold Ambient Operation ...................................................... 58 
Cold Weather Operation ..................................................... 15 
Cold Weather Operation, Installation For ............................ 15 
Compression Principle .......................................................... 8 
Compressor .......................................................................... 8 
Compressor Oil Cooler, Water-Cooled Heat Exchanger .... 64 
Control Piping ..................................................................... 16 
Controls & Instrumentation 

Governor Controller Operation ....................................... 33 
General Description ........................................................ 33 

Cooling, Sealing And Lubrication .......................................... 9 
Coupling .............................................................................. 73 
Daily Check ......................................................................... 24 
Electrical Wiring .................................................................. 20 
Emergency Stop Push-Button ............................................. 38 
Fan Starter .......................................................................... 39 
Filter Element ...................................................................... 71 
Foundation .......................................................................... 14 
Fuse Blocks ........................................................................ 39 
Grounding ........................................................................... 20 
Heat Exchanger (Oil) Piping ............................................... 57 
High Temperature Operation .............................................. 52 
Inlet Line ............................................................................. 16 
Inlet Tube ............................................................................ 72 
Inlet Valve ........................................................................... 36 
Installation For Cold Weather Operation ............................. 15 
Lifting Unit ........................................................................... 12 
Location .............................................................................. 12 

Air-Cooled Units ............................................................. 13 
Water-Cooled Units ........................................................ 14 

Lubricant 

Recommended ............................................................... 51 

Lubricant Change Procedure .............................................. 58 
Lubrication 

Motor .............................................................................. 21 

Main Starter ........................................................................ 39 
Minimum Discharge Pressure Valve ................................... 35 
Moisture In The Oil System ................................................. 52 
Moisture Separator/Trap ..................................................... 16 
Oil Change Interval ............................................................. 59 
Oil Cooler, Radiator Type ................................................... 64 
Oil Filter ............................................................................... 63 
Oil Level Gauge .................................................................. 59 
Oil Reservoir ....................................................................... 67 
 

Drain ............................................................................... 14 

 

Filling .............................................................................. 62 

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 System 

Compressor .................................................................... 66 

 

Draining And Cleaning .................................................... 77 

Oil System Check ................................................................ 69 

Air And Oil Discharge Temperature ................................ 69 
Oil Cooler Oil Pressure Differential (Air-Cooled Radiator)

 .................................................................................... 70 

Oil Cooler Oil Pressure Differential (Water-Cooled Heat 

Exchanger) ................................................................. 70 

Oil Cooler Temperature Differential (Air-Cooled Radiator)

 .................................................................................... 70 

Oil Cooler Temperature Differential (Water-Cooled Heat 

Exchanger) ................................................................. 70 

Oil Cooler Water Pressure Differential (Water-Cooled 

Heat Exchanger) ......................................................... 70 

Oil Inlet Pressure ............................................................ 69 
Oil Inlet Temperature ...................................................... 69 

Piping 
 

Water Piping (Parallel) .................................................... 20 
Water Piping (Series) ...................................................... 19 

Power Supply ...................................................................... 39 
Pressure Regulator.............................................................. 36 
Pressure Transducer 
 

Plant Delivery .................................................................. 37 

 

Reservoir ......................................................................... 37 

 

Separator ........................................................................ 37 

Prestart-Up Instructions ....................................................... 22 
Quick Start Guide (Controller) ............................................. 25 
Remote Mounted Elevated Cooler Assembly ...................... 56 
Safety Precautions ................................................................ 4 
Service Check List ............................................................... 76 

Every 1000 Hours Operation .......................................... 76 
Every 125 Hours Operation ............................................ 76 
Every 8 Hours Operation ................................................ 76 
Every 2000 Hours Operation .......................................... 76 

Shuttle Valve ....................................................................... 36 
Solenoid Valves IVC And IVO ............................................. 36 
Starting The Unit .................................................................. 24 

Unit Cold ......................................................................... 24 
Unit Hot ........................................................................... 24 

Stopping The Unit ................................................................ 24 
Temperature Sensor 
 

Discharge ........................................................................ 38 

 

Separator ........................................................................ 38 

Terminal Strip ...................................................................... 39 
Thermal Control (Thermostatic Mixing) Valve ..................... 64 
Warning, Prohibition, Mandatory Label Information .............. 2 
Water Flow Control Valve For Heat Exchanger .................. 66 
Water Piping ........................................................................ 18 
Water Shutoff Valve, Water Cooled Heat Exchanger .......... 67 
 

Summary of Contents for SAVG2-75

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: ...the 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 assist you by providing fast expert maintenance and repairservices To Contact Gardner Denver or locate your local distributor Visit www contactgd com compressors Or Call 800 682 9868 INSTRUCTIONS FOR ...

Page 3: ...day 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 users of the following conditions Safety Labels are used within this manual and affixed to the appropriate areas of the compressor package to alert users of the following conditions Equipment starts ...

Page 4: ...derate 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 Electrical Equipment in De Energized State Do Not Lift Equipment with Hook No Lift Point Handle Package at Forklift Points Only Loud Noise Hazard Wear Ear Protection Read the Operator s Manual befor...

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 any repairs or adjustments on or around the compressor are required Do not use the air discharge from this unit for breathing not suitable for humanconsumption An Excess Flow Valve should be on all ...

Page 6: ...neral 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 Filter 71 Section 7 Coupling 73 Section 8 Maintenance Schedule 76 Section 9 Troubleshooting 79 This manual covers the following models HP PSIG Model Parts List Controller Manual 75 100 100 125 150 SAV75...

Page 7: ...2 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 System Compressor 66 Draining And Cleaning 77 Oil System Check 69 Air And Oil Discharge Temperature 69 Oil Cooler Oil Pressure Differential Air Cooled Radiator 70 Oil Cooler Oil Pressure Differential Wat...

Page 8: ...g 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 Figure 4 4 Turn Valve Electra Saver Only 37 Figure 4 6 Compressor Package P ID 40 Figure 4 7 Compressor Package Control Component States 41 Figure 4 8 Electra Saver II Wiring Diagrams 42 Figure 4 9 Wirin...

Page 9: ...ins 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 interlobe cavity and flows axially with the meshing rotors B As meshing continues more of the main rotor lobe enters the secondary rotor groove normal volume is reduced and pressure increases Oil is injec...

Page 10: ...d 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 the compression chamber to remove heat of compression seal internal clearances and lubricate the rotors Figure 1 2 STARTER BOX Figure 1 3 CONTROL BOX 319EBD797 00 Ref Drawing ...

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: ...ION 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 or transporting methods must be used to prevent damage Lifting slots are provided in the base for tow motor use The unit may also be moved into location by rolling on bars LOCATION The compressor sho...

Page 14: ...lectric 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 feet 1 1 M to the nearest obstruction on the starter end and control box end of the unit Allow three 3 feet 9 M to the nearest obstruction above and on other sides of unit For continuous efficiency ...

Page 15: ...nd 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 foundation but should be mounted on a smooth solid surface Whenever possible install the unit near level Temporary installation may be made at a maximum 10 angle lengthwise or 10 sidewise Mounting bolts are ...

Page 16: ...ed 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 pressure transducer lines are heated to avoid freezing of condensate Heat tape with thermostat control is generally satisfactory for this purpose and can be obtained at various local plumbing or hardwa...

Page 17: ...receiver 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 valve of proper setting a pressure gauge and a means of draining condensate OPTIONAL MOISTURE SEPARATOR TRAP The unit can be provided with an optional stand alone moisture separator and trap that is fiel...

Page 18: ...d 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 receiver must be located between the two units BLOWDOWN VALVE PIPING The blowdown valve is piped back into the airend between the inlet valve and air filter HEAT EXCHANGER Water Temperature to Heat Exc...

Page 19: ...Water 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 cooled heat exchangers the water inlet and outlet connections are located in the unit enclosure flange on the end of the unit opposite the control box The water source should be capable of supplying up to...

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 treatment See Section 5 Compressor Oil Cooler Water Cooled Heat Exchanger for more information on the water system 304EBD797 02 Ref Drawing Figure 2 7 SERIES PIPING SERIES PIPING Figure 2 7 Water flow must...

Page 21: ...40 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 adjustment instructions and maximum allowable lubricant temperature ELECTRICAL WIRING Standard Units The compressor package is factory wired for all connections from the starter to the motor for the horse...

Page 22: ...d 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 should be about 1 2 full 5 Leave the relief plug temporarily off Reconnect the unit and run for about 20 minutes to expel the excess grease 6 Stop the unit Replace the relief plug 7 Restart the unit ELEC...

Page 23: ...ay 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 the unit is operating at full load and normal pressure See Section 5 page 51 During unloaded operation and after shutdown the system will partially drain back into the oil reservoir and the oil leve...

Page 24: ...erly 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 Service Manual Compressor drive shaft rotation must be clockwise standing facing the compressor sheave on gear drive and counter clockwise on direct drive 50 HP 150 PSI ONLY 8 Plant Delivery Pressure T...

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 required If the unit is a water cooled heat exchanger model open any manual water inlet valves wide open Start the unit by pushing RUN DAILY CHECK Refer to Section 8 Maintenance Schedule page 76 STOPPI...

Page 26: ...the 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 level The current access level is indicated by the User button on the Status Bar in the bottom left of the screen as shown in Figure 3 1 below The text of the button indicates the current access leve...

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 changed This password should only be required under unusual circumstances and must be provided by Gardner Denver Technical Support Note that the passwords can be changed from the default using the A...

Page 28: ...the 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 Temperature and Flow Units can be set individually as shown in Figure 3 4 If the Language needs to be changed it may be changed by selecting the Language button below the units Figure 3 4 Locale Con...

Page 29: ...imezone 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 To set the timezone click on the Timezone box and use the selector dialog that appears to select the appropriate timezone for your region as shown in Figure 3 6 Figure 3 6 Timezone Selection ...

Page 30: ...ngs 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 must be adjusted To adjust the Pressure Band navigate to Settings Control as shown in Figure 3 7 Then press the Adjust button next to p1 Pressure Band Figure 3 7 Control Settings ...

Page 31: ...nd 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 pressure to 126 PSI in Figure 3 8 the Unload pressure and Target pressure would first need to be increased Figure 3 8 Primary Pressure Band Setting Once you are satisfied with the pressure band settings ...

Page 32: ...age 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 Alarm column is an outline as shown in Figure 3 9 the alarm is no longer active and may be reset If the alarm icon is solid the fault is still active and the condition must be resolved before it can be c...

Page 33: ...own 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 allow you time to get into a position to view the rotation before the motor is started Note that the controller will only allow one jog every 10 seconds and will disable the Start Jog button during t...

Page 34: ...See 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 Controller which integrates all the control functions under microprocessor control see Figure 4 1 for general detail of the controller keypad and display Controller functions include safety and shutdown com...

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 the coolant system to pressurize A control air check valve is provided to ensure that the inlet valve is closed during blowdown Operation of the unit with improper relief valve setting can result in...

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 does not require maintenance or adjustment If the valve fails to function check the valve stem O ring for sealing valve orifices for restriction or valve and valve seat for burrs and dirt The valve i...

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 valves are energized control pressure is relieved from the inlet piston to allow the valve to open Pressure Regulator The pressure regulator is used to supply a constant and low control pressure to prev...

Page 38: ...end 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 walls when moving the pistons Solenoid Valves TVC and TVO Electra Saver only These valves control the position of the turn valve in response to signals from the Governor Controller With both valves de en...

Page 39: ...ture 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 if high temperatures are detected Emergency Stop Push Button This is a maintained push button and removes power from the controller outputs regardless of controller status It is located on the upper...

Page 40: ...ontrol 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 and Wye Delta applications The overloads are adjustable and are factory set based on the motor nameplate amps and the instructions located inside the control box door Wye delta starters employ three ...

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

Page 42: ...V 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 On Closed On Closed Off Closed Off Closed On On A D D Open Increasing Close IV Modulate Closed Off Open Off Closed Off Closed Off Closed On On A D B Open Decreasing Blowndown Open On Open Off Closed O...

Page 43: ...nit 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 100 YES 328EBF546 75 380 3 60 380 3 50 YES 100 460 3 60 YES 329EBF546 75 230 3 60 YES 100 380 3 60 380 3 50 YES 337EBF546 75 575 3 60 NO 100 338EBF546 75 230 3 60 460 3 60 380 3 60 380 3 50 NO 100 ...

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: ...ischarged 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 separated oil is returned to the compressor and the air passes to the final discharge line RECOMMENDED LUBRICANT Gardner Denver compressors are factory filled with AEON lubricants These lubricants are f...

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 conditions to reduce moisture See Thermal Control Thermostatic Mixing Valve page 64 Water Shutoff Valve page 67 and Compressor Oil System Check page 69 for additional system considerations If moisture a...

Page 54: ...xis 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 maintained at a minimum of 10 F above this dew point temperature to prevent condensation accumulation in the lubricant reservoir These charts assume 100 relative humidity ...

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: ...contactor 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 connecting pipe fittings to the cooler support the threaded coupling with a pipe wrench when tightening the connection Use silicone sealant on all steel to aluminum threaded connections All piping sho...

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 recommended limits could result in high oil carryover and cause the machine to shut down on high discharge temperature When removing the cooling module from the package for remote operation the oil stop valve...

Page 59: ...ct 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 green range on the gauge 5 Install the oil filler plug restore power run and check for leaks DO NOT OVERFILL The quantity required to raise the oil level to the top of the fill range is shown in Figur...

Page 60: ...GAUGE 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 unloads Add oil only when the oil is at the bottom of the fill range on the gauge as read when the compressor is on Drain oil only when the oil level is above the top of the fill range on the gauge as read...

Page 61: ...Interval 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 6 OIL CHANGE INTERVAL Figure 5 7 OIL SAMPLING VALVE LOCATION ...

Page 62: ...e 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 reservoir through the oil filler opening or from the drain valve 2 If the unit is elevated so that the oil reservoir drain can be used empty the oil reservoir through the drain valve to a suitable con...

Page 63: ...drain 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 level DO NOT OVERFILL as oil carryover will result The quantity of oil required to raise the oil level from LOW to HIGH is shown in Figure 5 8 Repeated addition of oil between changes may indicate e...

Page 64: ...s 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 procedure to replace the filter element Do not disturb the piping 1 Stop the unit and be sure no air pressure is in the oil reservoir 2 Remove the spin on element 3 Clean the gasket face of the filter body...

Page 65: ...rvoir 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 valve maintains oil injection temperature into the compressor at a minimum of 130 F 55 C or 160 F 71 C depending on the air end This system provides proper compressor warm up and helps prevent moisture...

Page 66: ...an 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 and operation expense reduced equipment life and emergency shutdown It is strongly recommended that a reputable local water treatment concern be engaged to establish the corrosion scale forming and f...

Page 67: ...he 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 used when working on the valve Care must be used when handling the capillary tube a kink or break in the tubing or connections will make the valve inoperative Never attempt to change capillary length ...

Page 68: ...ol 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 provides the final removal of oil from the air stream Figure 5 11 Oil impinging on the outside of the separator element drains directly back into the oil reservoir by gravity Oil collected inside the...

Page 69: ...essive 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 quality of the oil used and the maintenance of the oil and air filters The condition of the separator can be determined by pressure differential gauging or by inspection Pressure Differential Gauging The C...

Page 70: ...nto 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 cap screws 9 Re install control lines 10 Run the unit and check for leaks COMPRESSOR OIL SYSTEM CHECK The following readings are based on ambient temperature of 80 F 27 C for air cooled oil cooler an...

Page 71: ...let 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 Cooler Temperature Differential Water Cooled Heat Exchanger The oil temperature differential depends on the inlet water temperature and the water flow rate permitted by the water flow control valve set...

Page 72: ...ting 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 the element requires cleaning follow steps 3 4 and 5 3 Wash the element by soaking about 15 minutes in warm water with a mild non sudsing detergent Rinse the element thoroughly with clean water a hos...

Page 73: ...d 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 the inside of the filter body to remove any dirt falling from the inlet tube before reinstalling the element Causes of short element life include severe dust conditions infrequent servicing improper cl...

Page 74: ...t 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 with a single cushion The coupling does not require lubrication If maintenance on mating parts is required reassemble coupling as follows ...

Page 75: ...o 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 smaller gap will produce abnormal wear of the element by friction and excessive thermal expansion the latter could cause compressor damage by axially displacing the input shaft Make sure that keys are ...

Page 76: ...pling 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 Do not operate unit with either the coupling guard removed All bolts and screws must be properly tightened NOTICE ...

Page 77: ...mage 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 or 3 months 1 Replace the control box filter if app as indicated by the Controller every 1000 hours or every 3 months whichever occurs first Every 2000 hours operation or 6 months 1 Replace air filte...

Page 78: ...x 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 Inspect service if necessary Inlet Valve x x x x x Visually check for leakage Shaft Seal x x x x x Inspect re grease if necessary Motor Bearings x x x x x Inspect Replace if necessary Drive Belts if app ...

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 if necessary Inlet Valve x x x x x Visually check for leakage Shaft Seal x x x x x Inspect re grease if necessary Motor Bearings x x x x x Inspect Replace if necessary Drive Belts if app x x x x x Rep...

Page 80: ...ion 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 or load 1 Improperly adjusted control 1 Refer to Controller Manual 13 17 621 and adjust control 2 Air leak in control lines 2 Determine source of leak and correct 3 Restricted control line 3 Clean co...

Page 81: ...y 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 Oil carryover through lines 1 See Oil Carryover in this section 2 Oil leaks at all fittings and 2 Tighten or replace fittings gaskets or gaskets 3 Shaft seal leaking 3 Replace shaft seal High discharg...

Page 82: ...ure 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 Discharge Air Temperature this section 8 Replace check valve 9 Water condensate in oil 9 Check oil reservoir temperature and if low change thermal mixing valve element to higher temperature NOTICE Gardner ...

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 labor rate schedule All costs of transportation of product parts and repaired or replacement parts claimed not to be as warranted to and from such service facilities shall be borne by the Purchaser ...

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

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