Gardner Denver VST55A, Operating And Service Manual

Page 1: ...13 17 601 Version 18 May 11 2016 VARIABLE SPEED TWO STAGE STATIONARY BASE MOUNTED COMPRESSOR AirSmart CONTROLLER MODELS VST55A VST75A VST90A 55 75 90kW 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ...nit 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: ...eat Exchangers Oil Air Axial Cooling Fans 50 Section 7 Air Filter 55 Section 8 Shaft Coupling 57 Section 9 Minimum Pressure Check Valve 63 Section 10 Inlet Control Valve 65 Section 11 Pressure Relief...

Page 7: ...e Check Valve Section 9 63 Moisture Separator Trap 17 Motor Lubrication 70 Motor Lubrication 20 Oil Filter 45 Oil Reservoir Drain 16 Oil System Addition Of Oil Between Changes 44 Compressor 41 Drainin...

Page 8: ...ntrol 35 Figure 4 6 Wiring Diagram Air Cooled Two Stage VS Control 36 Figure 4 7 Wiring Diagram Water Cooled Two Stage VS Control 37 Figure 4 8 Wiring Diagram Water Cooled Two Stage VS Control 38 Figu...

Page 9: ...unmesh at the inlet port and air is drawn into the cavity between the main rotor lobes and gate rotor grooves A When the rotors pass the inlet port cutoff air is trapped in the interlobe cavity and f...

Page 10: ...ld and enters the compressors and inter stage manifold A portion of the oil is directed to internal passages on both 1st and 2nd stage airends to lubricate the bearings and shaft oil seals The balance...

Page 11: ...13 17 601 Page 10 1 3 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED External Details 300ETK804 C Ref Drawing Page 1 of 2...

Page 12: ...13 17 601 Page 11 1 4 Figure 1 3 PACKAGE ILLUSTRATION AIR COOLED Internal Details 300ETK804 C Ref Drawing Page 2 of 2...

Page 13: ...13 17 601 Page 12 1 5 Figure 1 4 PACKAGE ILLUSTRATION WATER COOLED External Details 301ETK804 C Ref Drawing Page 1 of 2...

Page 14: ...13 17 601 Page 13 1 6 Figure 1 5 PACKAGE ILLUSTRATION WATER COOLED Internal Details 301ETK804 C Ref Drawing Page 2 of 2...

Page 15: ...r discharge manifold piping as lifting points The 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 secu...

Page 16: ...erate efficiently please refer to Section 6 Fig 6 1 page 51 of this manual for detailed instructions on the operation and maintenance of air cooled heat exchangers including minimum heat exchanger coo...

Page 17: ...ts and shims to provide uniform support for the base OIL RESERVOIR DRAIN The oil drain is piped from the bottom of the reservoir to the side of the base This drain is approximately 4 50 inches 115 mm...

Page 18: ...a built in aftercooler a combination moisture separator and drain valve are furnished with the unit CONTROL PIPING Control piping is not necessary since the Gardner Denver compressor package is factor...

Page 19: ...cialists for additional filtration and treatment equipment to meet health and safety standards BLOW DOWN VALVE PIPING The blow down valve is vented between the air filter and inlet valve thus avoiding...

Page 20: ...acity Minimum 75 C Copper Wire Sized 30 C Minimum 75 C Copper Wire Sized 40 C Minimum 75 C Copper Wire Sized 45 C Notes VST 55 162 2 0 3 0 3 0 VST 75 182 3 0 4 0 4 0 VST 90 220 4 0 250 300 or 2 0 2 1...

Page 21: ...her large loads on the same power feed as the compressor GD Model Volts VFD HP RATINGS Max KVA VST55 400 480 2 40 HP 7 5 HP 600 VST75 400 480 2 50 HP 7 5 HP 750 VST90 400 480 2 60 HP 7 5 HP 900 Figure...

Page 22: ...8000 hours under normal operating conditions Note that after compressor operation is stopped the oil charge may partially drain back into the oil separation reservoir and register an abnormally high...

Page 23: ...cal Check the wiring diagrams furnished with the unit to be sure it is properly wired See Figure 4 3 thru Figure 4 10 pages 33 thru 40 for general wiring diagrams and Section 2 page 14 for installatio...

Page 24: ...desired load pressure DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE Quick Start Guide Operation of the AirSmart controller is easy Simply select a Target Pressure and then p...

Page 25: ...t 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 para...

Page 26: ...nameplate 9 Operating Mode Refer to Section 4 page 28 and Controller Manual 13 17 600 for detailed information on the control system 10 Enclosure Check for damaged panels or doors Check all screws and...

Page 27: ...or electrical shock can cause injury or death Disconnect lockout and tagout the unit from the power supply and any other circuits before servicing unit When the pressure relief valve opens a stream of...

Page 28: ...13 17 601 Page 27 3 7 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 29: ...ressor operation may commence Press the red STOP RESET button to clear any conditions e g Loss of Power when electrical system was energized and start the unit by pushing the green START button Since...

Page 30: ...ay 8 Control Box 26 Terminal Block 9 Filter 27 Terminal Block 10 Fan Filter 28 Terminal Block 11 Emergency Stop Operator 29 Terminal Block 12 Contact Block 30 Terminal Block 13 Control Transformer 31...

Page 31: ...compressor During compressor operation the underside of the poppet is vented to atmosphere via a 3 way solenoid valve allowing the poppet to fall open and feed fresh air to the compressor inlet Durin...

Page 32: ...em startup Ball Valve Oil Drain W This device allows the drainage of oil entrapped within each compressor cylinder during oil change operation Check Valve Oil Flow Control X This devices prevent the r...

Page 33: ...13 17 601 Page 32 4 5 Figure 4 2 PIPING AND INSTRUMENTATION ILLUSTRATION 300ETK797 A Ref Drawing...

Page 34: ...13 17 601 Page 33 4 6 Figure 4 3 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300ETK546 G Ref Drawing Page 1 of 4...

Page 35: ...13 17 601 Page 34 4 7 Figure 4 4 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300ETK546 G Ref Drawing Page 2 of 4...

Page 36: ...13 17 601 Page 35 4 8 Figure 4 5 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300ETK546 E Ref Drawing Page 2 of 4 300ETK546 F Ref Drawing Page 3 of 4...

Page 37: ...13 17 601 Page 36 4 9 Figure 4 6 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300ETK546 G Ref Drawing Page 4 of 4...

Page 38: ...13 17 601 Page 37 4 10 Figure 4 7 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301ETK546 G Ref Drawing Page 1 of 4...

Page 39: ...13 17 601 Page 38 4 11 Figure 4 8 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301ETK546 G Ref Drawing Page 2 of 4...

Page 40: ...13 17 601 Page 39 4 12 Figure 4 9 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301ETK546 G Ref Drawing Page 3 of 4...

Page 41: ...13 17 601 Page 40 4 13 Figure 4 10 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301ETK546 G Ref Drawing Page 4 of 4...

Page 42: ...n the 1st stage compressor and inter stage pipe manifold through various solenoid valves and orifices The injected oil absorbs heat from compression while progressing through the compression chamber a...

Page 43: ...is compatible with most air system downstream components Safety Data Sheets SDS are available for all AEON 9000TH lubricants from your authorized Gardner Denver distributor or by calling 217 222 5400...

Page 44: ...efill intervals less frequent Note that each inch of oil level represents 2 0 gal of oil o Drain oil only when the level is above the HIGH mark on sight glass Be aware that a stopped unit when filled...

Page 45: ...correct itself after resuming compressor operation Note that repeated addition of oil between oil changes may indicate excessive oil carry over and should be investigated Excessive oil carry over can...

Page 46: ...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 should be replaced every 1000 hours of operation and when...

Page 47: ...to maintain optimal 1st and 2nd stage compressor discharge temperatures between 195 F and 220 F The AirSmart controller governs the oil flow control valve operations refer to AirSmart Manual 13 17 60...

Page 48: ...ling filtering and re injection It also serves as a storage volume for the oil mass migrating from higher elevations e g oil cooler compressor casings and piping Air oil final separation The aerosols...

Page 49: ...t depressurization cycles leading to oil foaming Oil separator element life cannot be predicted it will vary greatly depending on the conditions of operation the quality of the oil used and the mainte...

Page 50: ...for damage Before installing new or old element apply heavy grease to sealing o ring Oil may be wiped off by the chamfer and the o ring could be damaged 7 Wipe the cover seal o ring clean and inspect...

Page 51: ...jury or death 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...

Page 52: ...r plus the enclosure ventilation flow rates which include motor ventilation and compressor intake Furthermore when package location makes it necessary to duct fresh cooling air in out these ducts must...

Page 53: ...Cover motors mixing valves fan motors and other electrical components to prevent damage from the cleaning process 5 Use a mild detergent or degreaser to soften and dissolve accumulated grime 6 Using a...

Page 54: ...ave been made at the Gardner Denver factory Regular maintenance is required to keep the interior core areas free from dirt and other fowling agents In order to protect package components that are in c...

Page 55: ...illary length Excess capillary tube should be carefully coiled and placed so that damage will not occur with normal maintenance or traffic past the unit If a leak develops through the packing tighten...

Page 56: ...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 local envir...

Page 57: ...ing inner 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 w...

Page 58: ...and compressor through a machined cast housing provides automatic alignment of shafts and coupling The coupling assembly requires no lubrication Coupling Element Rotex size 48 Inspection and Replacem...

Page 59: ...lement 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 alignment with key ways on hubs Figu...

Page 60: ...cks deformation extrusions etc Replace if necessary Re assemble main motor and cooling fan components in reverse order of disassembly After engaging each hub on the matching recesses of the coupling e...

Page 61: ...remove the coupling hub and tool kit assembly from the heat source and quickly bring it to the companion shaft Engage the coupling hub bore unto the companion shaft and slide until the latter contact...

Page 62: ...e severe burns Make sure to use suitable heat protective gloves and clothes NOTICE If heat was applied to the compressor coupling hub during its removal there is the possibility that the companion sha...

Page 63: ...13 17 601 Page 62 8 6 Figure 8 4 COUPLING INSTALLATION TOOL KIT Figure 8 5 COUPLING REMOVAL TOOL KIT 303SBK810 A Ref Drawing...

Page 64: ...ssure valve always stop the unit release air pressure lockout and tagout the power supply to the compressor package Failure to release pressure or properly disconnect the power may result in personal...

Page 65: ...13 17 601 Page 64 9 2 Figure 9 1 MINIMUM DISCHARGE PRESSURE CHECK VALVE...

Page 66: ...il backflow During compressor operation the underside of the poppet is vented to atmosphere via a 3 way solenoid valve allowing the poppet to fall open and feed fresh air to the compressor inlet the s...

Page 67: ...2 Disconnect lockout and tagout power supply to the compressor package 3 Close when provided valve isolating compressor package from air system 4 Identify by position each tube connected to the valve...

Page 68: ...E Pressure Relief Valve This device protects the pressure containing components of the compressor package against pressures accidentally exceeding 200 psig It is installed on the dry side of the oil s...

Page 69: ...of the unit with improper relief valve setting can result in severe personal injury or machine damage Ensure properly set valves are installed and maintained Pressure Relief Valve Inspection The pres...

Page 70: ...er supply to the compressor package 3 Remove the access panel located below the electrical enclosure area by unlatching all four 4 provided latches The two 2 intake filter assemblies located on the fl...

Page 71: ...Locate the automatic grease relief fittings one at each motor bottom end and make sure that their spring loaded covers are operational 3 Locate the grease fittings provided at each end of the motor to...

Page 72: ...c helps identify when abnormal operation occurs AirSmart Controller Messages and Alarms Acknowledge the presence of an abnormal condition and take action to correct it Weekly Checks Heat Exchangers ai...

Page 73: ...manual for details on typical performance expectations as well as recommended cleaning procedures Pressure Relief Valve Check operation of device see Section 11 page 67 for test procedure Compressor M...

Page 74: ...nd press STOP RESET button to reset 5 Read error message on control panel 5 Take appropriate action See Manual 13 17 600 6 Remote Contact is open 6 Replace switch or jumper 7 Compressor lock up 7 Conf...

Page 75: ...ervice 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...

Page 76: ...el 5 Add oil to proper level 6 Low oil injection pressure but normal discharge pressure 6 Oil flow control solenoid valve malfunction Refer to Section 5 page 41 Compressor Lubrication for details High...

Page 77: ...l return line strainer 3 Inspect and service 4 Clogged broken or loose oil return line fittings 4 Inspect and tighten or replace 5 Ruptured oil separator element 5 Replace element 6 Loose assembly 6 T...

Page 78: ...ESS MADE IN WRITING AND EXECUTED BY AN OFFICER OF THE COMPANY THIS WARRANTY SHALL NOT BE EFFECTIVE AS TO ANY CLAIM WHICH IS NOT PRESENTED WITHIN 30 DAYS AFTER THE DATE UPON WHICH THE PRODUCT IS CLAIME...

Page 79: ......

Page 80: ...For additional information contact your local representative or visit www contactgd com compressors 2016 Gardner Denver Inc Printed in U S A...