Related Manuals for Gardner Denver VS-11
Summary of Contents for Gardner Denver VS-11
- Page 1 13-18-606 Version: 09 March 1, 2011 VARIABLE SPEED SINGLE STAGE STATIONARY BASE-MOUNTED COMPRESSOR AirSmart™ CONTROLLER VS11A 11kW 60HZ OPERATING AND SERVICE MANUAL...
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Page 2: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services
Remanufacturing Center in Indianapolis, IN., for purchase on an exchange basis with liberal core credit available for the replacement unit. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors. -
Page 3: Warning - Prohibition - Mandatory Label Information
WARNING – PROHIBITION – MANDATORY LABEL INFORMATION Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. - Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.
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Page 5: Safety Precautions
SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel. -
Page 6: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services............................1 Instructions For Ordering Repair Parts ......................1 Warning – Prohibition – Mandatory Label Information.................. 2 Safety Precautions ............................4 Index................................6 List Of Illustrations............................7 Section 1, General Information ........................ -
Page 7: Index
INDEX Air Filter, Section 7...........47 Oil System Air Flow In The Compressor System ....8 Addition Of Oil Between Changes....37 Air-Cooled Units, Location .......15 Compressor..........35 Auxiliary Air Receiver ........16 Draining And Cleaning ......... 38 Moisture............36 Cold Weather Installation .........16 Oil Change Interval ........ -
Page 8: List Of Illustrations
LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ........................8 Figure 1-2 – Package Outline (Air-Cooled)....................9 Figure 1-3 – Package Outline (Air-Cooled)....................10 Figure 1-4 – Package Outline (Air-Cooled) - Tank Mounted ..............11 Figure 1- 5 – Package Outline (Air-Cooled) – Tank Mounted..............12 Figure 2-1 –... -
Page 9: Section 1, General Information
GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR – Your Gardner Denver Rotary Screw package is fitted with one (1) single stage, positive displacement rotary compressor using meshing helical rotors to effect compression. Each pair of rotors is supported between high capacity anti-friction bearings located outside the compression chamber. Single cylindrical roller bearings are used at each end of the rotors to carry the radial loads. -
Page 10: Figure 1-2 - Package Outline (Air-Cooled)
300CGA804-A (Ref. Drawing) Page 1 of 2 Figure 1-2 – PACKAGE OUTLINE (AIR-COOLED) -
Page 11: Figure 1-3 - Package Outline (Air-Cooled)
300CGA804-A (Ref. Drawing) Page 2 of 2 Figure 1-3 – PACKAGE OUTLINE (AIR-COOLED) -
Page 12: Figure 1-4 - Package Outline (Air-Cooled) - Tank Mounted
301CGA804-A (Ref. Drawing) Page 1 of 2 Figure 1-4 – PACKAGE OUTLINE (AIR-COOLED) - TANK MOUNTED... -
Page 13: Figure 1- 5 - Package Outline (Air-Cooled) - Tank Mounted
301CGA804-A (Ref. Drawing) Page 2 of 2 Figure 1- 5 – PACKAGE OUTLINE (AIR-COOLED) – TANK MOUNTED... -
Page 14: Section 2, Installation
SECTION 2 INSTALLATION GENERAL – When unit is received, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passage of current. -
Page 15: Figure 2-2 - Typical Compressor Room
40°F to 113°F (at up to 1000 meter elevation). Contact Gardner Denver for package operation at conditions exceeding the stipulated values. A typical ventilation arrangement is shown in Figure 2-2, page 14. - Page 16 FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface and as near level as possible. Temporary installation may be made at a maximum 10°...
- Page 17 Installer or end user must ensure that other compressors that are piped into a common pipe manifold with the Gardner Denver compressor package are each provided with an isolation check valve. It is recommended that an additional receiver be installed between the rotary screw and reciprocating compressors sharing a common pipeline.
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Page 18: Figure 2-3 - Package Maximum Current Consumption Summary
Electrical shock can cause injury or death. Open main disconnect switch, lockout and tagout before working on control box. Gardner Denver Guidelines for proper wiring, grounding and feed power conditioning - This compressor package is provided with a variable speed drive (VFD) to control compressor motor. The indicated Gardner Denver guidelines for proper wiring, grounding, and feed power conditioning must be followed in order to protect the VFD electronics. -
Page 19: Figure 2-4 - Line Reactor Sizing Recommendations
Electrical Wire Routing – Routing of the electrical power wires into the electrical hardware enclosure is best done through its roof area. Line Reactor – A line reactor provides conditioning of the electrical power supply to the compressor package by attenuating noise and fluctuations. -
Page 20: Section 3, Starting & Operating Procedures
Do not mix different type oils. When the unit is shipped, it is filled with Gardner Denver AEON™ 9000SP lubricating coolant, suitable for the first 8000 hours under normal operating conditions. - Page 21 Make sure to check the wiring of the optional compressed air dryer, as it is serviced by an independent electrical power feed. 6. Grounding - Equipment must be properly grounded according to Gardner Denver Guidelines for proper wiring, grounding and feed power conditioning.
- Page 22 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). Never allow motor to reach full speed. The compressor unit’s direction of rotation must be checked every time the compressor is reconnected to the power supply.
- Page 23 Next, press the Enter button to access the Adjustment Menu tree ADJUSTMENT MENU OPERATION ADJUSTMENT (SELECT SUB MENU) Since the Target Pressure setting is under the Operation Adjustment menu, press Enter again to access that sub-menu OPERATION ADJUSTMENT LANGUAGE-LANGUAGE ENGLISH (US) (SELECT PARAMETER) The Target Pressure is the second item in the Operation Adjustment sub-menu so press the Down button to navigate to the Target Pressure setting.
- Page 24 • Setting the Unload and Load Pressure After setting the Target Pressure, set the Unload and Load Pressures values in a similar fashion. The Unload pressure is the third item in the Operation Adjustment sub-menu so press the Down button to navigate to the Unload Pressure setting.
- Page 25 Unit Hot - Start-up instructions are the same as that of a cold start. Compressed Air Dryer (Optional) – The dryer module is supplied electrical power from a separate (off-package), disconnect provided by the end user – the disconnect must be engaged prior to dryer operation. Relay contacts, operated by the package AirSmart controller, engage and disengage the dryer from the external power source.
- Page 26 Never paint, lubricate or alter a pressure relief valve. Do not plug vent or restrict discharge. 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.
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Page 27: Section 4, Controls & Instrumentation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver rotary screw compressor package is pre-wired with all electrical components suitable for the voltage and horsepower at time of order. It is only necessary to connect the compressor unit to the correct power supply, to the shop air supply network and to the appropriate water supply, if using the water-cooled variant. -
Page 28: Figure 4-1 - Electrical Enclosure Hardware
302CGA810-D (Ref. Drawing) Figure 4-1 – ELECTRICAL ENCLOSURE HARDWARE... - Page 29 ASSEMBLED CONTROL BOX WITH EMC FILTER AIRSMART CONTROLLER DRIVE GROUP SCREW TERMINAL PLUG CONTROL BOX EXHAUST FILTER OPERATOR CONTACT BLOCK POWER SUPPLY POWER DISTRIBUTION BLOCK FUSE FUSE BLOCK FUSE RELAY TERMINAL BLOCK TERMINAL BLOCK GROUND BLOCK (not shown) GROUND BLOCK TERMINAL BLOCK DIN RAIL TRIM SEAL...
- Page 30 Heat Exchanger Fan/Motor and Starter - The combination axial fan/motor provides cooling air for the heat exchangers and electronics box. The starter provides control for the fan motor only, as the latter includes its own thermally-resettable, internal overload protection. This device is designed to operate with 3 ph-60 Hz-460 vac electrical power –...
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Page 31: Figure 4-2 - Piping And Instrumentation Illustration
300CGB797-B (Ref. Drawing) Figure 4-2 – PIPING AND INSTRUMENTATION ILLUSTRATION 13-18-606 Page 30... -
Page 32: Figure 4-3 - Wiring Diagram - (Air-Cooled) Single-Stage Vs Control
300CGA546-D Ref. Drawing) Page 1 of 4 Figure 4-3 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control... -
Page 33: Figure 4-4 - Wiring Diagram - (Air-Cooled) Single-Stage Vs Control
300CGA546-D (Ref. Drawing) Page 2 of 4 Figure 4-4 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control... -
Page 34: Figure 4-5 - Wiring Diagram - (Air-Cooled) Single-Stage Vs Control
300CGA546-D (Ref. Drawing) Page 3 of 4 Figure 4-5 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control... -
Page 35: Figure 4-6 - Wiring Diagram - (Air-Cooled) Single-Stage Vs Control
300CGA546-D (Ref. Drawing) Page 4 of 4 Figure 4-6 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control... -
Page 36: Section 5, Compressor Lubrication - Separation, Filtration And Controls
RECOMMENDED LUBRICANT – The Gardner Denver compressor is factory-filled with AEON 9000SP lubricant. This lubricant is formulated to the highest quality standards and is factory-authorized, tested and approved for use in our rotary screw compressors. AEON 9000SP lubricant is available through your authorized Gardner Denver compressor distributor. - Page 37 (Buna N) or acrylic paints. AEON 9000SP is compatible with most air system downstream components. Material Safety Data Sheets (MSDS) are available for all AEON lubricants from your authorized Gardner Denver distributor or by calling 217-222-5400. MOISTURE IN THE OIL SYSTEM - The oil mixing valve provided with your compressor package has been designed to avoid water vapor condensation during all modes of operation (e.g., load level, ambient temperature...
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Page 38: Figure 5-1 - Checking Oil Level
Figure 5-1 – CHECKING OIL LEVEL ADDITION OF OIL BETWEEN CHANGES – Oil losses (typically 2 ppm) from the oil separation system may require replenishment between scheduled changes. If (during operation only) the sight glass shows oil level below the “min” mark, add oil per following steps: (See Figure 5-1. Be sure the unit is completely off and oil sump is depressurized. - Page 39 (e.g., very dusty, high humidity, etc.), may require more frequent oil changes. Gardner Denver offers a free oil analysis program with our AEON 9000SP lubricant. The first sample from a new unit should be sent in between 40-100 hours of operation.
- Page 40 Improper oil filter maintenance will cause damage to equipment. Replace filter element every 1000 hours of operation. More frequent replacement could be required depending on operating conditions. A filter element left in service too long may damage equipment. The filter media is contained within an easily replaced, spin-on cartridge. Use the following procedure to replace the filter.
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Page 41: Figure 5-2 - Oil Mixing Valve (Thermostatic) Hardware
Figure 5-2 – OIL MIXING VALVE (THERMOSTATIC) HARDWARE The valve mixes cooled and hot oil, prior to delivery to the oil filter and oil injection line, to maintain a system discharge temperature of 203º F. At startup, the mixing valve is on full bypass mode. As system heat load increases with ambient temperature or load, the mixing valve sends more oil flow to the cooler to maintain adequate compressor discharge temperature. - Page 42 Low Air Demand and Package Operation – During periods of very low air demand, such as when the package is operated in short cycles, the oil system may not reach a high enough temperature to keep water vapor from condensing, in spite of the oil mixing valve bypassing all flow around the heat exchanger. Under these conditions, it is recommended that the package operation be prolonged after each unload condition is achieved –...
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Page 43: Figure 5-4 - Changing Oil Coalescing Element
A sudden drop to zero pressure differential or sudden heavy oil carryover may indicate a ruptured element. Figure 5-4 – CHANGING OIL COALESCING ELEMENT Oil Coalescing Element Service – Use the following procedures to replace or inspect the element: Be sure the unit is completely off and that oil sump is depressurized. Disconnect, lockout and tagout power supply to the compressor package. -
Page 44: Section 6 - Heat Exchangers (Oil, Air)
SECTION 6 HEAT EXCHANGERS (OIL, AIR) Compressor, air/oil reservoir, separator chamber and all piping and tubing may be at high temperature during and after operation. Do not attempt inspection or cleaning of air-cooled heat exchangers until cooling fan has stopped rotating. Disconnect, lockout and tagout package from power supply. -
Page 45: Figure 6-1 - Air Flow Chart
Figure 6-1 – AIR FLOW CHART All the required hardware, mechanical and electrical connections have been made at the Gardner Denver factory, thus the only regular maintenance required is to keep the exterior core fins free from dirt and other airborne debris per the following procedure: Air-cooled heat exchanger cores are fabricated from aluminum. -
Page 46: Figure 6-2 - Cleaning Cooler Core
(applied from inside) can also be employed to clean the heat exchanger cores – see Figure 6-2, for details. Remove all loose debris and water from cooler box after cleaning process is complete. 6. Re-attach cooler housing side covers with provided fasteners and re-install enclosure door panels. Figure 6-2 –... - Page 47 In case the drain valve is fouled with dirt, cleanse the collection bowl: 1. Be sure the unit is completely off and oil sump is depressurized. 2. Disconnect, lockout and tagout power supply to the compressor package. 3. Close (when provided) valve isolating compressor package from air system. 4.
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Page 48: Section 7, Air Filter
In turn, the longevity of the filter element depends on the cleanliness of the local environment. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. - Page 49 Never operate the unit without the air filter element. Never use elements that are damaged, ruptured or wet. Keep spare elements on hand to reduce downtime. Store elements in a protected area free from damage, dirt and moisture. Handle all parts with care. Filter Element Inspection and Replacement: 1.
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Page 50: Section 8, Shaft Coupling
SECTION 8 DRIVE V-BELTS DRIVE V-BELTS – Power supplied by the electric motor is transmitted to the compressor via shaft- mounted sheaves and V-belts. The electric motor is mounted on a fixed support, where as the compressor is mounted on a [two-point] pivoted support which automatically sets v-belt tension. Servicing the V-Belts: Figure 8-1 –... -
Page 51: Figure 8-2 - Motor Sheave And Bushing
SERVICING THE MOTOR SHEAVE ASSEMBLY: Figure 8-2 – MOTOR SHEAVE AND BUSHING 1. Disconnect, lockout and tagout power supply to the compressor package. 2. Lift/pivot compressor to loosen and remove belts. 3. Remove all screws from the bushing and insert one into the removal hole. 4. -
Page 52: Figure 8-4 - Compressor Sheave And Sleeve Servicing
Note that wear sleeve (3) comes off with the sheave. 4. Remove the wear sleeve (3) from the sheave by knocking it loose with Gardner Denver drift tool part number EFC03477088 through the three holes in the sheave. Always replace both wear sleeve (3) and shaft seal (4) whenever servicing either part. -
Page 53: Section 9, Minimum Pressure/Check Valve
The valve does not require maintenance or adjustment. If the valve fails to function, check the valve stem O-ring for sealing, valve orifices for restriction, or valve and valve seat for burrs and dirt. Repair kits are available from your local authorized Gardner Denver distributor. Before servicing the minimum pressure valve, always stop the unit, release air pressure, lockout and tagout the power supply to the compressor package. -
Page 54: Figure 9-1 - Minimum Discharge Pressure/Check Valve
9. Re-install MPV unto sump with provided bolts. 10. Adjust nut (13) so that there is a small (.05” to .08”) between itself and the frame (5) surface. 11. Check for leaks after unit is back in operation. Figure 9-1 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE 13-18-606 Page 53... -
Page 55: Section 10, Inlet Control Valve
SECTION 10 INLET CONTROL VALVE INLET CONTROL VALVE – This device is located at the intake flange of the compressor, and allows the compressor to remain pressurized and ready for quick response to air demand when the latter is not running. - Page 56 5. Remove four bolts (7) securing valve body to compressor body and remove valve. 6. Inspect poppet seal (o-ring) (5) for wear and tear. Replace, if necessary. 7. In case of noted malfunction (e.g., valve will not open/close properly with good air signal), proceed to dismantle internal blow-off valve.
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Page 57: Section 11, Pressure Relief Valve
SECTION 11 PRESSURE RELIEF VALVE Pressure Relief Valve - This device protects the pressure-containing components of the compressor package against pressures exceeding 188.5 psig. It is installed on the dry-side of the oil sump. Figure 11-1 – PRESSURE RELIEF VALVE Before inspecting the pressure relief valve, release air pressure, lockout and tagout the power supply to the compressor package. - Page 58 Operation 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 Check During Operation – The pressure relief valve has no user-serviceable or repairable components.
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Page 59: Section 12, Ventilation Fans, Filters (Electrical Enclosure)
SECTION 12 VENTILATION FILTERS (ELECTRICAL ENCLOSURE) Ventilation Filters - The electronics housed in the standard IP54 enclosure box are ventilated by a combination of an intake air filter and pressurized air provided by the heat exchanger cooling fans. Filter Inspection - In order to ensure the electronics operate at peak efficiency and free from troublesome temperature-related stoppages, it is imperative that the filter elements be kept clean: 1. -
Page 60: Section 13, Motor Lubrication
SECTION 13 MOTOR LUBRICATION Rotating machinery can cause injury or death. Open main disconnect, lockout and tagout power supply to compressor package before working on the electric motor. Motor Lubrication – Your WEG motor is supplied with sealed bearings which were greased at the factory. -
Page 61: Section 14, Maintenance Schedule
SECTION 14 MAINTENANCE SCHEDULE SERVICE CHECK LIST Daily Checks: • Air Filter (Compressor) - Replace when controller displays “CHANGE AIR FILTER” message. Refer to Section 7 for air filter details. • Oil Separator Element - Replace when controller displays “CHANGE OIL SEPARATOR ELEMENT”. Refer to Section 5 for oil separator element details. - Page 62 Yearly Checks: • Heat Exchangers (air cooled) – Check cooling performance of air and oil cores – see Section 6 of this manual for details on typical performance expectations as well as recommended cleaning procedures. • Pressure Relief Valve – Check operation of device – see Section 11, page 56 for test procedure. •...
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Page 63: Section 15, Troubleshooting
SECTION 15 TROUBLESHOOTING Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the compressor package before removing valves, caps, plugs, fittings, bolts and filters. SYMPTOM POSSIBLE CAUSE REMEDY... - Page 64 Restriction in service piping Inspect and clean service piping. Restriction in control tubing Inspect and clean control tubing. Acceleration time in VFD set too Contact your Gardner Denver distributor. Compressor starts too long slowly Minimum Pressure/Check Valve Repair or replace.
- Page 65 SYMPTOM POSSIBLE CAUSE REMEDY Excessive oil Oil separation malfunction See “Oil Carryover” in this section. consumption Oil leaks at fittings and gaskets Detect and correct oil leaks. Shaft seal leaking Inspect or replace shaft seal. High discharge Oil mixing valve stuck on bypass Check 24Vdc power feed to servo.
- Page 66 Ruptured oil separator Replace element. element. Loose assembly Tighten all fittings and gaskets. Foam caused by use of Use Gardner Denver AEON 9000SP incorrect oil oil only. Minimum pressure valve Repair or replace. Inspect, adjust or malfunction – discharge replace regulator.
- Page 68 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Telephone: (800) 682-9868 FAX: (217) 224-7814 FAX: (217) 224-7814 Specification subject to change without notice. Copyright © 2011 Gardner Denver, Inc. Litho in U.S.A Visit our Web Site: www.gardnerdenver.com Visit our Web Site: www.gardnerdenver.com...