Gardner Denver VS45A, Operating And Service Manual

Page 1: ...DENVER 13 18 601 Version 02 October 11 2005 VS45 70A VARIABLE SPEED SINGLE STAGE STATIONARY BASE MOUNTED COMPRESSOR AIRSMART CONTROLLER DOMESTIC MODELS VS45 50 70A 45 50 70kW 60HZ OPERATING AND SERVIC...

Page 2: ...ory tested AEON compressor lubricants specifically formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the necessary parts to simplify servicing your compresso...

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: ...39 Section 6 Heat Exchangers Oil Air 47 Section 7 Air Filter 53 Section 8 Shaft Coupling 55 Section 9 Minimum Pressure Check Valve 58 Section 10 Inlet Control Valve 60 Section 11 Pressure Relief Valv...

Page 7: ...mum Pressure Check Valve Section 9 58 Moisture Separator Trap 16 Oil Filter 42 Oil Reservoir Drain 15 Oil System Addition Of Oil Between Changes 40 Compressor 39 Draining And Cleaning 41 Moisture 40 O...

Page 8: ...VS Control 33 Figure 4 6 Wiring Diagram Air Cooled Single Stage VS Control 34 Figure 4 7 Wiring Diagram Water Cooled Single Stage VS Control 35 Figure 4 8 Wiring Diagram Water Cooled Single Stage VS...

Page 9: ...volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volume reduction and pressure continues to increase until the...

Page 10: ...13 18 601 Page 9 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED External Details 302CGD804 B Ref Drawing Page 1 of 2...

Page 11: ...13 18 601 Page 10 Figure 1 3 PACKAGE ILLUSTRATION AIR COOLED Internal Details 302CGD804 B Ref Drawing Page 2 of 2...

Page 12: ...13 18 601 Page 11 Figure 1 4 PACKAGE ILLUSTRATION WATER COOLED External Details 303CGD804 A Ref Drawing Page 1 of 2...

Page 13: ...13 18 601 Page 12 Figure 1 5 PACKAGE ILLUSTRATION WATER COOLED Internal Details 303CGD804 A Ref Drawing Page 2 of 2...

Page 14: ...eyebolts or lugs provided on the motors are for lifting the motors only and should not be used to lift any additional weight All eyebolts must be securely tightened When lifting the motors the liftin...

Page 15: ...ow to operate efficiently please refer to Section 6 Fig 6 1 of this manual for detailed instructions on the operation and maintenance of air cooled heat exchangers including minimum heat exchanger coo...

Page 16: ...il filter is 9 above the floor level If this is not sufficient to conveniently drain the oil other methods are 1 Elevate the compressor unit on a suitable structure to obtain the desired drain height...

Page 17: ...VS compressor package is not suitable 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 w...

Page 18: ...lowed in order to protect the VFD electronics Failure to do so will void your warranty Electrical Wire Sizing A certified electrician familiar with National Electric Codes and applicable local codes s...

Page 19: ...nce with the National Electrical Code and or applicable local codes Failure to properly ground the compressor package could result in injury or death Install ground wiring in accordance with the Natio...

Page 20: ...is shipped it is filled with Gardner Denver AEON 9000SP lubricating coolant suitable for the first 8000 hours under normal operating conditions N N NO O OT T TI I IC C CE E E Regular maintenance and r...

Page 21: ...ired See Figure 4 3 thru Figure 4 10 for general wiring diagrams and Section 2 for installation instructions Make sure to check the wiring of the optional compressed air dryer as it is serviced by an...

Page 22: ...system pressure Quick Start Guide Operation of the AirSmart controller is easy Simply select a Target Pressure and then press the Run button to start the compressor no other settings are required The...

Page 23: ...rget Pressure value is displayed press the Enter button to save the new value Pressing the Stop Reset button will abort the change and restore the previous value In order to save the changes made to p...

Page 24: ...it nameplate 9 Operating Mode Refer to Controller Manual 13 17 600 for more detailed information on the control system 10 Enclosure Check for damaged panels or doors Check all screws and latches for t...

Page 25: ...DAILY 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 c...

Page 26: ...13 18 601 Page 25 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 27: ...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 28: ...7 CONTROL BOX ENCLOSURE 8 ELECTRICAL FILTER 9 OPERATOR 10 CONTACT BLOCK 11 POWER SUPPLY 12 FUSE HOLDER 13 TERMINAL LUG 14 FUSE HOLDER 15 FUSE 16 FUSE BLOCK 17 FUSE 18 RELAY 19 TERMINAL BLOCK 20 TERMIN...

Page 29: ...d by protective shutdown the 3 way solenoid valve feeds an air signal to the underside of the poppet forcing it upward close and block off the compressor intake This prevents trapped air and oil withi...

Page 30: ...emporarily stopped due to line pressure reaching unload pressure the blow down valve remains energized closed and the air oil reservoir remains pressurized When compressor operation is halted e g by u...

Page 31: ...13 18 601 Page 30 Figure 4 2 PIPING AND INSTRUMENTATION ILLUSTRATION 300CGD797 A Ref Drawing...

Page 32: ...13 18 601 Page 31 Figure 4 3 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGD810 E Ref Drawing Page 1 of 4...

Page 33: ...13 18 601 Page 32 Figure 4 4 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGD810 E Ref Drawing Page 2 of 4...

Page 34: ...13 18 601 Page 33 Figure 4 5 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGD810 E Ref Drawing Page 3 of 4...

Page 35: ...13 18 601 Page 34 L1 GND T2 T1 L3 L2 T3 GND F3 F2 F1 L2 L1 L3 Figure 4 6 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGD810 E Ref Drawing Page 4 of 4...

Page 36: ...13 18 601 Page 35 Figure 4 7 WIRING DIAGRAM WATER COOLED Single Stage VS Control 301CGD810 E Ref Drawing Page 1 of 4...

Page 37: ...13 18 601 Page 36 Figure 4 8 WIRING DIAGRAM WATER COOLED Single Stage VS Control 301CGD810 E Ref Drawing Page 2 of 4...

Page 38: ...13 18 601 Page 37 Figure 4 9 WIRING DIAGRAM WATER COOLED Single Stage VS Control 301CGD810 E Ref Drawing Page 3 of 4...

Page 39: ...13 18 601 Page 38 L1 GND T2 T1 L3 L2 T3 GND F2 F1 F3 L2 L1 L3 Figure 4 10 WIRING DIAGRAM WATER COOLED Single Stage VS Control 301CGD810 E Ref Drawing Page 4 of 4...

Page 40: ...il 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 air Cent...

Page 41: ...may indicate that the oil mixing valve is malfunctioning Contact your authorized Gardner Denver factory distributor for assistance OIL SIGHT GLASS This device indicates oil level within the air oil r...

Page 42: ...t in between 40 100 hours of operation DRAINING AND CLEANING OIL SYSTEM Always drain the complete system Draining when the oil is hot will help to prevent varnish deposits and carry away impurities To...

Page 43: ...and components and achieve normal oil level COMPRESSOR OIL FILTER The oil filter is a vital part in maintaining a trouble free compressor since it removes dirt and abrasives from the circulated oil It...

Page 44: ...vided valve isolating compressor package from air system 4 Unscrew the cartridge with adequate tool e g strap wrench and remove 5 Clean wipe and lubricate sealing surface on filter housing with grease...

Page 45: ...ated value will trigger an alarm display to caution that a system malfunction is taking place Note that the alarm is not triggered once the valve has reached either end of travel position as oil mixin...

Page 46: ...adequate oil in use High oil level in air oil reservoir Blockage of oil return line strainer or orifice Abnormally frequent or fast depressurization cycles leading to oil foaming Oil separator element...

Page 47: ...for damage Before installing new or old element apply heavy grease to sealing o ring Oil may be wiped off by the holder and the o ring could be damaged 6 Inspect oil scavenge orifice 3 and strainer 4...

Page 48: ...th Disconnect lockout and tagout package from the power supply OIL AIR HEAT EXCHANGERS The heat of compression absorbed by the oil injected into the compressors for cooling and lubrication is ultimate...

Page 49: ...ventilation and compressor intake Furthermore when package location makes it necessary to duct fresh cooling air in out these ducts must be sized with a maximum total pressure loss of 1 inch water gau...

Page 50: ...HANGERS Optional water cooled cores brazed plate type are available Both core are of a counter current and cross flow design The cooling water is fed to the cores in a series arrangement it passes thr...

Page 51: ...olved Solids TDS 500 ppm Iron 2 ppm Total Hardness 60 ppm Silica 25 ppm Oil and Grease 5 ppm Sulfate 50 ppm Chloride 50 ppm Nitrate 2 ppm Corrosivity Langelier Index between 0 to1 It is strongly recom...

Page 52: ...ions will make the valve inoperative Never attempt to change capillary length Excess capillary tube should be carefully coiled and placed so that damage will not occur with normal maintenance or traff...

Page 53: ...loss of compressed air by only allowing the discharge of liquid water during its opening phase An isolation ball valve 5 is provided between the separator bowl 3 and the drain valve body 1 This allows...

Page 54: ...on 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 local environment NOTICE Use only gen...

Page 55: ...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 clean if necessary...

Page 56: ...coupling The coupling assembly requires no lubrication Coupling Element Rotex size 48 Inspection and Replacement 1 Disconnect lockout and tagout power supply to the compressor package 2 Remove fasten...

Page 57: ...sure that keys are in proper alignment with key ways on hubs Figure 8 2 COUPLING ELEMENT 4 For hub to shaft interference fit hubs main drive motor removal is necessary Figure 8 3 MOTOR REMOVAL HARDWAR...

Page 58: ...e by axially displacing the input shaft Make sure that keys are in proper alignment with key ways on hubs Apply a thread locking compound to the hub setscrews M8 size and tighten to 88 5 lb in 10 N m...

Page 59: ...pressor package 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 t...

Page 60: ...13 18 601 Page 59 Figure 9 1 MINIMUM DISCHARGE PRESSURE CHECK VALVE...

Page 61: ...the underside of the poppet forcing it upward closed and block off the compressor intake The internal blow off valve is also forced closed by the incoming air signal Figure 10 1 INLET CONTROL VALVE I...

Page 62: ...l proceed to dismantle internal blow off valve Carefully lift and remove poppet Item 3 Remove lock ring Item 20 Pull cover Item 16 and seal Item 17 Inspect seals Items 18 19 for wear and tear Replace...

Page 63: ...exceeding 188 5 psig It is installed on the dry side of the oil sump Before inspecting the pressure relief valve release air pressure lockout and tagout the power supply to the compressor package Fai...

Page 64: ...alve has no user serviceable or repairable components However it should be tested for proper operation at least once every year To test the pressure relief valve Raise the system operating pressure to...

Page 65: ...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 oil filter side and remove latched access doo...

Page 66: ...wing procedure should be used in re greasing 1 Disconnect lockout and tagout power supply to the compressor package 2 Wipe lubrication fitting clean and add grease with a hand operated grease gun 3 Wi...

Page 67: ...nal Parameters Maintaining a periodic log of package critical parameters e g pressures temperatures speeds load levels etc helps identify when abnormal operation occurs AirSmart Controller Messages an...

Page 68: ...ecommended cleaning procedures Pressure Relief Valve Check operation of device see Section 11 for test procedure Motor Lubrication Inspect motors for abnormal noise and vibration Grease lubricate per...

Page 69: ...and press STOP RESET button to reset 4 Read error message 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 Driv...

Page 70: ...ction in control tubing 3 Inspect and clean control tubing Compressor starts too slowly 1 Acceleration time in VFD set too long 1 Contact your Gardner Denver distributor 2 Minimum Pressure Check Valve...

Page 71: ...clear 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...

Page 72: ...r 1 Overfilling oil separation vessel 1 Drain excess oil from system 2 Clogged oil return line orifice 2 Inspect and service 3 Clogged oil return line strainer 3 Inspect and service 4 Clogged broken o...

Page 73: ...ranted for 12 months from date of initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company...

Page 74: ...e Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all major cities For parts information contact Gardner Denver Master Distribution Center Memphis TN Telephone 800 245 4946 FAX...