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Gardner Denver ELECTRA-SAVER User Manual

Gardner Denver ELECTRA-SAVER
105 pages
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13-21-601
Version: 02
March 15, 2011
ELECTRA-SAVER
ELECTRA-SAVER II
STATIONARY BASE-MOUNTED
COMPRESSOR
With
AirSmart
Controller
EAH99D - 50 HP
EBH99H - 40, 50 HP
EAM99D, EBM99M - 60, 75 HP
EAP99K, EBP99K - 100 HP
INTERNATIONAL MODELS
EBM99N 60, 75, 100 HP (45, 56, 75 KW)
OPERATING AND
SERVICE MANUAL

Table of Contents

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Gardner Denver ELECTRA-SAVER Specifications

General IconGeneral
BrandGardner Denver
ModelELECTRA-SAVER
CategoryAir Compressor
LanguageEnglish

Summary

COMPRESSOR PARTS AND SUPPORT SERVICES

INSTRUCTIONS FOR ORDERING REPAIR PARTS/REMANUFACTURED AIRENDS

Guidance on how to order replacement parts and remanufactured airends for compressors.

WARNING AND SAFETY PRECAUTIONS

MANDATORY LABEL INFORMATION

Details prohibitions, mandatory actions, and safety label meanings for operational awareness.

GENERAL SAFETY GUIDELINES

Essential safety guidelines and precautions for operating and maintaining the compressor unit.

SECTION 1 GENERAL INFORMATION

COMPRESSOR FUNDAMENTALS

Description of the compressor, its working principle, and system airflow.

LUBRICATION, COOLING, AND SEALING

Details on the oil system for lubrication, cooling, and sealing the compressor.

SECTION 2 INSTALLATION

GENERAL INSTALLATION REQUIREMENTS

Covers lifting, location, foundation, enclosure, and general setup for installation.

ENVIRONMENTAL CONSIDERATIONS

Guidelines for installation in cold weather and extreme cold weather conditions.

PIPING AND CONNECTIONS

Details on service lines, heat exchangers, aftercoolers, and piping configurations.

SECTION 3 STARTING & OPERATING PROCEDURES

PRESTART-UP AND INITIAL CHECKS

Essential steps before operating the unit, including oil checks and filter replacement.

UNIT STARTING AND STOPPING

Procedures for safely starting and stopping the compressor unit.

Quick Start Guide

SETTING OPERATING PARAMETERS

Instructions for adjusting target pressure, unload, and load pressures on the controller.

SECTION 4 CONTROLS & INSTRUMENTATION

AIRSMART CONTROLLER OPERATION

How to operate the compressor using the AirSmart controller and its features.

KEY CONTROL COMPONENTS

Details on essential control devices like relief valves, blowdown valves, and starters.

WIRING DIAGRAMS

WYE DELTA (AIR–COOLED / WATER–COOLED) - 200, 230, 460 VOLT

Electrical wiring diagram for Wye Delta configurations at 200, 230, 460V.

WYE DELTA (AIR–COOLED / WATER–COOLED) - 575 VOLT

Electrical wiring diagram for Wye Delta configurations at 575V.

FULL VOLT (AIR–COOLED / WATER–COOLED) – 200 & 230 VOLT

Electrical wiring diagram for Full Volt configurations at 200 & 230V.

FULL VOLT (AIR–COOLED / WATER–COOLED) – 460 VOLT

Electrical wiring diagram for Full Volt configurations at 460V.

FULL VOLT (AIR–COOLED / WATER–COOLED) – 575 VOLT

Electrical wiring diagram for Full Volt configurations at 575V.

LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 460 VOLT

Electrical wiring diagram for Less Starter configurations at 200, 230, 460V.

LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT

Electrical wiring diagram for Less Starter configurations at 575V.

WYE DELTA (AIR–COOLED / WATER–COOLED) – 200/230 VOLT

Electrical wiring diagram for Wye Delta configurations at 200/230V.

WYE DELTA (AIR–COOLED / WATER–COOLED) – 380/460 VOLT

Electrical wiring diagram for Wye Delta configurations at 380/460V.

WYE DELTA (AIR–COOLED / WATER–COOLED) – 575 VOLT

Electrical wiring diagram for Wye Delta configurations at 575V.

FULL VOLT (AIR–COOLED / WATER–COOLED) – 200 & 230 VOLT

Electrical wiring diagram for Full Volt configurations at 200 & 230V.

FULL VOLT (AIR–COOLED / WATER–COOLED) – 380/460 VOLT

Electrical wiring diagram for Full Volt configurations at 380/460V.

FULL VOLT (AIR–COOLED / WATER–COOLED) – 575 VOLT

Electrical wiring diagram for Full Volt configurations at 575V.

LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 380, 460 VOLT

Electrical wiring diagram for Less Starter configurations at 200, 230, 380, 460V.

LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT

Electrical wiring diagram for Less Starter configurations at 575V.

SECTION 5 LUBRICATION OIL COOLER, OIL FILTER & SEPARATOR

COMPRESSOR LUBRICATION SYSTEM OVERVIEW

Explanation of the compressor's oil system, lubricants, and specifications.

OIL MAINTENANCE PROCEDURES

Steps for lubricant change, oil level checks, and system draining and cleaning.

KEY OIL SYSTEM COMPONENTS

Details on the oil filter, oil cooler, and oil separator components.

SECTION 6 AIR FILTER

AIR FILTER MAINTENANCE AND SERVICE

Guidelines for servicing the heavy-duty air filter and its element life.

SECTION 7 COUPLING

COUPLING ASSEMBLY AND REPLACEMENT

Procedures for assembling and replacing the flexible coupling between the motor and airend.

SECTION 8 MAINTENANCE SCHEDULE

SERVICE CHECK LIST BY INTERVAL

Scheduled maintenance tasks categorized by operating hours and time intervals.

SECTION 9 TROUBLESHOOTING

COMMON COMPRESSOR ISSUES

Troubleshooting guide for common problems like starting, stopping, pressure, and temperature issues.

OIL AND DELIVERY PROBLEMS

Addressing issues related to oil consumption, delivery, pressure, and discharge temperature.

OIL CARRYOVER ISSUES

Diagnosing and resolving problems associated with oil carryover in the system.

WARRANTY INFORMATION

GENERAL PROVISIONS AND DISCLAIMER

Outlines the warranty terms, limitations, and disclaimers for the compressor unit.

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