Applicable Systems
Electra Saver
Symptoms
Motor bearing vibration velocity exceeds 4.5 mm/s RMS. The Electra Saver smart controller logs a Major alarm based on the integrated vibration sensor on the motor drive-end.
Possible Causes
- Motor bearing grease depleted or contaminated after extended service interval
- Bearing inner race or rolling elements showing early fatigue spalling
- Motor misalignment or soft foot causing dynamic forces on the bearings
- Belt over-tension increasing radial load on the drive-end bearing
Troubleshooting Steps
- Step 1: Verify the vibration reading with a handheld analyzer at the same measurement point
If the portable analyzer also reads >4.5 mm/s, schedule bearing replacement within 500 hours - Step 2: For motors with grease fittings, pump the specified quantity of polyurea NLGI 2 grease
Wipe off purged old grease. Do not over-grease - excess causes churning and higher vibration - Step 3: Check motor soft foot by loosening each foot bolt one at a time and measuring the gap with a feeler gauge
Shim any gap >0.05 mm. Re-torque foot bolts to specification in a star pattern - Step 4: Check belt tension with a tension gauge - deflection should be 12 mm per 300 mm of span
Adjust motor slide rails and verify pulley alignment with a straightedge or laser tool
How to Reset
Reset: After bearing replacement, alignment correction, or greasing, press Reset. The alarm clears when vibration drops below 3.5 mm/s RMS for a continuous 10-minute run.
Common Replacement Parts
- GD-1020: Motor bearing kit, 6314/6312 (Drive-end and non-drive-end, C3 clearance)
- GD-1021: Belt tension gauge (Sonic type, for V-belts and multi-rib belts)
- GD-1022: Motor alignment shim set (Stainless steel, 0.05-2.0 mm, assorted)
Frequently Asked Questions
- Q: How often should motor bearings be greased?
Every 4000 hours for regreasable bearings. Sealed bearings require motor replacement when vibration rises above 7.1 mm/s.
- Q: What is soft foot?
A condition where one motor foot does not sit flat on the base, causing frame distortion and bearing misalignment when bolts are tightened. Always check with feeler gauges.
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Source: Gardner Denver Electra Saver II Operation and Maintenance Manual, GD-ESA-II-OM
Category: Compressor
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