Gardner Denver AirSmart VS135A, Operating And Service Manual

Page 1: ...13 18 607 Version 13 June 2 2015 VARIABLE SPEED SINGLE STAGE STATIONARY BASE MOUNTED COMPRESSOR AirSmart CONTROLLER VS135A VS170A 135 170kW 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ...it 3 A full line of factory tested AEON compressor lubricants specifically formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the necessary parts to simplify...

Page 3: ...mical 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...

Page 4: ...low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Li...

Page 5: ...r oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any...

Page 6: ...hangers Oil Air Axial Cooling Fans 54 Section 7 Air Filter 60 Section 8 Shaft Coupling 62 Section 9 Minimum Pressure Check Valve 67 Section 10 Inlet Control Valve 68 Section 11 Pressure Relief Valve 7...

Page 7: ...4 75 Minimum Pressure Check Valve Section 9 67 Moisture Separator Trap 14 Oil Filter 49 Oil Reservoir Drain 13 Oil System Addition Of Oil Between Changes 47 Compressor 45 Draining And Cleaning 48 Mois...

Page 8: ...tage VS135 Control 37 Figure 4 6 Wiring Diagram Water Cooled Single Stage VS170 Control 41 Figure 5 1 Oil Level Sight Glass 46 Figure 5 2 Load VS Sight Glass Oil Level Change 47 Figure 5 3 Thermostati...

Page 9: ...ain rotor lobe enters the gate rotor groove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volume redu...

Page 10: ...13 18 607 Page 9 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED External Details 300CGF804 B Ref Drawing Page 1 of 2...

Page 11: ...13 18 607 Page 10 Figure 1 3 PACKAGE ILLUSTRATION AIR COOLED Internal Details 300CGF804 B Ref Drawing Page 2 of 2...

Page 12: ...may also be moved into location by rolling on bars Lift compressor package by base only Do not use other places such as motors compressors or discharge manifold piping as lifting points The eyebolts...

Page 13: ...led Units Separate air and oil coolers are supplied as standard equipment on all air cooled packages The heat exchangers require sufficient cooling air flow to operate efficiently please refer to Sect...

Page 14: ...ner of the controller side of the base frame see Package Illustrations for further details If this is not sufficient to conveniently drain the oil other methods are 1 Elevate the compressor unit on a...

Page 15: ...able for relocation as its housing assembly is an integral part of the enclosure sheet metal components See LOCATION comments on this section of the manual for duct work recommendations to bring in ve...

Page 16: ...ire NOTES Model Input Package Amps NEC Package Copper Wire Copper Wire Voltage Estimated Amps at 30 C Sized at 40 C Sized at 40 C VS 135 460 215 36 265 36 350 or 2 sets of 3 0 300 or 2 sets of 2 0 Set...

Page 17: ...6 Other large loads on the same power feed as the compressor GD Model Volts VFD HP RATINGS Max KVA 3 Line Reactor GD Part Number VS135 400 480 150 1500 90500144 VS170 400 480 250 2500 90500144 Figure...

Page 18: ...9000SP lubricating coolant suitable for the first 8000 hours under normal operating conditions See Section 5 for more details on the compressor oil system N N NO O OT T TI I IC C CE E E Regular maint...

Page 19: ...Section 2 for installation instructions 6 Grounding Equipment must be properly grounded according to Gardner Denver Guidelines for proper wiring grounding and feed power conditioning Failure to proper...

Page 20: ...Operation with incorrect motor rotation can damage equipment and cause oil eruption from the compressor inlet When checking motor rotation induce minimum rotation less than one revolution if possible...

Page 21: ...isplay should read READY on line 3 Next press the Enter button to access the Adjustment Menu tree Since the Target Pressure setting is under the Operation Adjustment menu press Enter again to access t...

Page 22: ...ressure is the third item in the Operation Adjustment sub menu so press the Down button to navigate to the Unload Pressure setting The Unload Pressure will control at which pressure the compressor unl...

Page 23: ...AILY CHECK Refer to Section 14 Maintenance Schedule STOPPING THE UNIT Press STOP RESET button The oil reservoir will automatically blow down as the main motor is de energized If the unit is a water co...

Page 24: ...13 18 607 Page 23 Operation of the unit with improper pressure relief valve setting can result in severe personal injury or machine damage Ensure properly set valves are installed and maintained...

Page 25: ...ave been selected into the controller compressor operation may commence For your convenience a Quick Start excerpt from the controller manual is shown on Section 3 8 Press the red STOP RESET button to...

Page 26: ...RILLE FILTER 9 OPERATOR 10 CONTACT BLOCK 11 POWER SUPPLY 12 POWER DISTRIBUTION BLOCK 13 FUSE 14 FUSE HOLDER 15 FUSE 16 FUSE BLOCK 17 FUSE 18 RELAY 19 TERMINAL BLOCK 20 TERMINAL BLOCK 21 GROUND BLOCK 2...

Page 27: ...pet forcing it upward close and block off the compressor intake This prevents trapped air and oil within the compressor from exiting through the inlet filter See SECTION 10 for further details Minimum...

Page 28: ...up of compressed air in the sump Check Valve Auxiliary Purge Z This device supplies air to the compressor inlet during operation which requires the inlet valve to remain closed e g unloaded running A...

Page 29: ...13 18 607 Page 28 Figure 4 2 PIPING AND INSTRUMENTATION ILLUSTRATION 305CGF797 A Ref Drawing...

Page 30: ...13 18 607 Page 29 Figure 4 3 WIRING DIAGRAM AIR COOLED Single Stage VS135 Control 300CGF546 D Ref Drawing Page 1 of 4...

Page 31: ...13 18 607 Page 30 300CGF546 D Ref Drawing Page 2 of 4...

Page 32: ...13 18 607 Page 31 300CGF546 D Ref Drawing Page 3 of 4...

Page 33: ...13 18 607 Page 32 300CGF546 D Ref Drawing Page 4 of 4...

Page 34: ...13 18 607 Page 33 Figure 4 4 WIRING DIAGRAM AIR COOLED Single Stage VS170 Control 302CGF546 E Ref Drawing Page 1 of 4...

Page 35: ...13 18 607 Page 34 302CGF546 E Ref Drawing Page 2 of 4...

Page 36: ...13 18 607 Page 35 302CGF546 E Ref Drawing Page 3 of 4...

Page 37: ...13 18 607 Page 36 302CGF546 E Ref Drawing Page 4 of 4...

Page 38: ...13 18 607 Page 37 Figure 4 5 WIRING DIAGRAM WATER COOLED Single Stage VS135 Control 303CGF546 C Ref Drawing Page 1 of 4...

Page 39: ...13 18 607 Page 38 303CGF546 C Ref Drawing Page 2 of 4...

Page 40: ...13 18 607 Page 39 303CGF546 C Ref Drawing Page 3 of 4...

Page 41: ...13 18 607 Page 40 303CGF546 C Ref Drawing Page 4 of 4...

Page 42: ...13 18 607 Page 41 Figure 4 6 WIRING DIAGRAM WATER COOLED Single Stage VS170 Control 305CGF546 C Ref Drawing Page 1 of 4...

Page 43: ...13 18 607 Page 42 305CGF546 C Ref Drawing Page 2 of 4...

Page 44: ...13 18 607 Page 43 305CGF546 C Ref Drawing Page 3 of 4...

Page 45: ...13 18 607 Page 44 305CGF546 C Ref Drawing Page 4 of 4...

Page 46: ...njected oil absorbs heat from compression while progressing through the compression chamber and is then discharged back into the oil separation chamber as a mixture of liquids and aerosols oil and gas...

Page 47: ...icants at www gardnerdenverproducts com downloads aspx MOISTURE IN THE OIL SYSTEM The oil mixing valve provided with your compressor package has been designed to avoid water vapor condensation during...

Page 48: ...l oil charge inches Oil Sight Glass lowest acceptable level in 100 4 0 2 0 80 3 5 1 5 60 3 0 1 0 40 2 5 5 20 2 0 0 Figure 5 2 LOAD VS SIGHT GLASS OIL LEVEL CHANGE ADDITION OF OIL BETWEEN CHANGES Oil l...

Page 49: ...lways drain the complete system Draining when the oil is hot will help to prevent varnish deposits and carry away impurities To drain the system use the following method See Figure 1 3 page 10 1 Be su...

Page 50: ...compressor it is best avoided by following the recommended filter replacement intervals Improper oil filter maintenance will cause damage to equipment Replace filter element every 1000 hours of operat...

Page 51: ...in its modulating range between extremes of valve position a compressor discharge temperature deviation exceeding 10 F from the calculated value will trigger an alarm display to caution that a system...

Page 52: ...oil aerosol are trapped in the element media coalesced then gravity drained through a low point connection and associated tubing oil return line into a lower pressure region of the compressor Separati...

Page 53: ...differential of 15 psi will initiate a system shutdown Using an oil separator element at excessive pressure differential can cause damage to equipment Replace the separator when the Change Separator...

Page 54: ...e and strainer for fouling Replace if necessary 7 Lower elements into sump and press element down into respective holder Do not use excessive force as element damage may occur 8 Carefully place sump c...

Page 55: ...GERS The heat of compression absorbed by the oil injected into the compressors for cooling and lubrication is ultimately rejected in a convenient medium such as air for air cooled cores or water for w...

Page 56: ...Air Flow Requirements CFM KW Air Cooled Heat Exchangers Enclosure Ventilation Fans 135 9300 4712 170 14900 5240 Figure 6 1 AIR FLOW CHART All the required hardware mechanical and electrical connectio...

Page 57: ...rface 7 Wipe up and remove all traces of cleaning residue and cleaning materials 8 Reinstall all access panels and guards that were removed to access the fans 9 Follow the Lock Out Tag Out procedures...

Page 58: ...ppm Oil and Grease 5 ppm Sulfate 50 ppm Chloride 50 ppm Nitrate 2 ppm Corrosivity Langelier Index between 0 to1 It is strongly recommended that a reputable local firm be contracted to evaluate the qua...

Page 59: ...se and finally retighten the nut finger tight Tightening the packing nut too tight may cause erratic operation An occasional drop of oil on the valve stem at the packing nut will prolong packing life...

Page 60: ...he drain valve is fouled with dirt cleanse the collection bowl also 1 Be sure the unit is completely off and oil sump is depressurized 2 Disconnect tag and lockout power supply to the compressor packa...

Page 61: ...ficient compressor package operation depends on the unrestricted clean supply of fresh air delivered by the air filter In turn the longevity of the filter element depends on the cleanliness of the loc...

Page 62: ...er tube against which the element makes a seal Wipe dirt from outer surface if necessary Also visually inspect the matching o ring seal that is bonded to the element for defects and dirt then wipe cle...

Page 63: ...coupling The coupling assembly requires no lubrication Coupling Element Rotex size 75 Inspection and Replacement 1 Disconnect lockout and tagout power supply to the compressor package 2 Remove fasten...

Page 64: ...l 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 in proper alig...

Page 65: ...daptor housing Lift Pull away compressor and main motor adaptor from motor until coupling hubs separate and allow removal of spider Inspect coupling element for signs of wear and tear such as indentat...

Page 66: ...al tool part number 90500151 available contact GD for sourcing details Before removing an interference fitted hub note and record the position of the hub with respect to the end of the companion shaft...

Page 67: ...13 18 607 Page 66 Figure 8 3 COUPLING REMOVAL TOOL Figure 8 4 LOCATION AIREND COUPLING HUB INSTALLATION TOOL 300SQP810 A Ref Drawing...

Page 68: ...e Failure to release pressure or properly disconnect the power may result in personal injury or death NOTICE Working spring within valve body is under tension Failure to relieve spring tension gradual...

Page 69: ...tial resulting from the incoming air stream During stopped operation modes e g commanded from keypad or initiated by protective shutdown the 3 way solenoid valve feeds an air signal to the underside o...

Page 70: ...Item 13 securing valve body to compressor body and remove valve 6 Inspect poppet seal o ring Item 6 10 for wear and tear Replace if necessary 7 Remove lock ring Item 12 and pull out cover Item 4 8 Ins...

Page 71: ...RELIEF VALVE Pressure Relief Valve This device protects the pressure containing components of the compressor package against pressures exceeding 200 psig It is installed on the dry side of the oil su...

Page 72: ...ith improper relief valve setting can result in severe personal injury or machine damage Ensure properly set valves are installed and maintained Pressure Relief Valve Check During Operation The pressu...

Page 73: ...is completely off and oil reservoir is depressurized 2 Disconnect lockout and tagout power supply to the compressor package 3 To service intake side filter open access door on the right hand side of t...

Page 74: ...e sure that their spring loaded covers are operational 3 Locate the grease fittings provided at each end of the motor top end be aware the one or both may be relocated away from the motor for easier a...

Page 75: ...g pressures temperatures speeds load levels etc helps identify when abnormal operation occurs AirSmart Controller Messages and Alarms Acknowledge the presence of an abnormal condition and take action...

Page 76: ...mended cleaning procedures Pressure Relief Valve Check operation of device see Section 11 page 70 for test procedure Motor Lubrication Inspect motors for abnormal noise and vibration Grease lubricate...

Page 77: ...essage on control panel 4 Take appropriate action See Manual 13 17 600 5 Remote Contact is open 5 Replace switch or jumper 6 Variable Frequency Drive fault active 6 Investigate and correct cause of fa...

Page 78: ...e piping 2 Inspect and clean service piping 3 Restriction in control tubing 3 Inspect and clean control tubing Compressor starts too slowly 1 Acceleration time in VFD set too long 1 Contact your Gardn...

Page 79: ...r cooler 4 Clogged oil lines 4 Inspect and clear oil lines 5 Low oil level 5 Add oil to proper level High discharge air oil Temperature air cooled cores 1 Dirty or clogged cooler outer surfaces 1 Insp...

Page 80: ...rn line fittings 4 Inspect and tighten or replace 5 Ruptured oil separator element 5 Replace element 6 Loose assembly 6 Tighten all fittings and gaskets 7 Foam caused by use of incorrect oil 7 Use Gar...

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Page 82: ...For additional information contact your local representative or visit www contactgd com compressors 2015 Gardner Denver Inc Printed in U S A...