Name: Gardner Denver ELECTRA-SAVER G2
Brand: Gardner Denver
Rating: 5 (1 reviews)

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13-21-611

Version: 00

January 7, 2019

ELECTRA-SAVER G2 &

ELECTRA-SAVER II G2



STATIONARY BASE-MOUNTED

COMPRESSOR

AirSmart

™

G2 Controller

CONFIGURATOR

SAV75-100G2A - 75, 100 HP

ST75-100G2A - 75, 100 HP

OPERATING AND

SERVICE MANUAL

Support Services2
Instructions for Ordering Repair Parts/Remanufactured Airends2
Warning - Prohibition - Mandatory Label Information3
Safety Precautions5
Table of Contents6
Index7
List of Illustrations8
Section 1, General Information9
Air Flow in the Compressor System9
Compression Principle9
Compressor9
Figure 1-1 - Compression Cycle9
Cooling, Sealing and Lubrication10
Figure 1-2 - Starter Box10
Figure 1-3 - Control Box10
Figure 1-4 - Compressor / Motor Side11
Figure 1-5 - Cooler / Reservoir Side11
Figure 1-6 - Air/Oil Flow Diagram12
Section 2, Installation13
Lifting Unit13
Location13
Air-Cooled Units, Location14
Air-Cooled Units14
Figure 2-1 - Typical Compressor Room14
Figure 2-2 - Air Flow Chart14
Foundation15
Water-Cooled Units15
Drain15
Cold Weather Operation16
Cold Weather Operation, Installation for16
Installation for Cold Weather Operation16
Figure 2-3 - Cold Weather Installation16
Auxiliary Air Receiver17
Control Piping17
Inlet Line17
Moisture Separator/Trap17
Figure 2-4 - Inlet Line Lengths17
Blowdown Valve Piping18
Figure 2 5 - Heat Exchanger (Oil Cooler) Approximate Water Flow18
Water Piping19
Figure 2-6 - Aftercooler Approximate Water Flow19
Water Piping (Series)20
Figure 2-7 - Series Piping20
Figure 2-8 - Parallel Piping20
Electrical Wiring21
Grounding21
Water Piping (Parallel)21
Lubrication Motor22
Section 3, Starting & Operating Procedures23
Prestart-Up Instructions23
Daily Check25
Starting the Unit25
Unit Cold25
Unit Hot25
Stopping the Unit25
Quick Start Guide (Controller)26
Section 4, Controls & Instrumentation34
Controls & Instrumentation Airsmart G2 Controller Operation34
General Description34
Figure 4-1 - Controller Keypad34
Figure 4- 2- Schematic Tubing Diagram35
Blowdown Valve36
Minimum Discharge Pressure Valve36
Figure 4- 3- Minimum Discharge Pressure/Check Valve36
Inlet Valve37
Pressure Regulator37
Shuttle Valve37
Solenoid Valves IVC and IVO37
Air Filter Vacuum Switch38
Plant Delivery38
Reservoir38
Separator38
Figure 4-4 -Turn Valve - Electra Saver Only38
Emergency Stop Push-Button39
Temperature Sensor Discharge39
Separator39
Fan Starter40
Fuse Blocks40
Main Starter40
Power Supply40
Terminal Strip40
Figure 4- 5- Compressor Package P&ID42
Figure 4- 6- Compressor Package Control Component States43
Figure 4- 7- Electra Saver Wiring Diagrams44
Figure 4- 8- Electra Saver II Wiring Diagrams44
Figure 4- 9- Wiring Diagram - WYE DELTA (AIR-COOLED / WATER-COOLED)45
Figure 4- 10- Wiring Diagram - WYE DELTA (AIR-COOLED / WATER-COOLED)54
Section 5, Lubrication, Oil Cooler, Oil Filter & Separator67
Lubricant Recommended67
Oil Specifications67
Oil System Compressor67
High Temperature Operation68
Moisture in the Oil System68
Figure 5-1 - Dew Point Chart F69
Figure 5-2 - Dew Point Chart C69
Figure 5-3 - Flow Diagram - Air/Oil System70
Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted Cooler71
Remote Mounted Elevated Cooler Assembly72
Heat Exchanger (Oil) Piping73
Addition of Oil between Changes75
Cold Ambient Operation75
Lubricant Change Procedure75
Oil Change Interval76
Oil Level Gauge76
Figure 5-5 - Oil Level Gauge76
Oil Sampling Valve77
Figure 5-6 - Oil Change Interval77
Figure 5-7 - Oil Sampling Valve Location77
Draining and Cleaning78
Filling79
Figure 5-8 - Approximate Oil System Capacities79
Oil Filter80
Compressor Oil Cooler - Water-Cooled Heat Exchanger81
Oil Cooler - Radiator Type81
Thermal Control (Thermostatic Mixing) Valve81
Figure 5-9 - Thermostatic Mixing Valve Element81
Figure 5-10 - Water Control Valve82
Water Flow Control Valve for Heat Exchanger83
Oil Reservoir84
Oil Separator Compressor (GD Eliminator)84
Oil Carryover84
Water Shutoff Valve - Water-Cooled Heat Exchanger84
Figure 5-11 - Oil Separator84
Inspection85
Pressure Differential Gauging85
Removal for Inspection or Replacement86
Oil System Check86
Air and Oil Discharge Temperature86
Oil Inlet Pressure86
Oil Inlet Temperature86
Oil Cooler Oil Pressure Differential (Air-Cooled Radiator)87
Oil Cooler Oil Pressure Differential (Water-Cooled Heat Exchanger)87
Oil Cooler Temperature Differential (Air-Cooled Radiator)87
Oil Cooler Temperature Differential (Water-Cooled Heat Exchanger)87
Oil Cooler Water Pressure Differential (Water-Cooled Heat Exchanger)87
Section 6, Air Filter88
Air Filter, Heavy Duty (Standard)88
Filter Element88
Figure 6-1 - Heavy Duty Air Filter88
Air Filter Element Life89
Inlet Tube89
Section 7, Coupling90
Coupling90
Figure 7-1 - Installation of Coupling Cushions90
Figure 7-2 - Installation of Coupling Cushions91
Section 8, Maintenance Schedule93
Service Check List93
Every 1000 Hours Operation93
Every 125 Hours Operation93
Every 8 Hours Operation93
Every 2000 Hours Operation93
Service Check List94
Section 9, Troubleshooting96

Brand	Gardner Denver
Model	ELECTRA-SAVER G2
Category	Air Compressor
Language	English

Gardner Denver ELECTRA-SAVER G2 User Manual

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