Gardner Denver AirSmart VS135A Operating And Service Manual
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Gardner Denver AirSmart VS135A Operating And Service Manual

Gardner Denver AirSmart VS135A Operating And Service Manual

Variable speed single stage stationary base-mounted compressor
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13-18-607
Version: 13
June 2, 2015
VARIABLE SPEED
SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AirSmartä CONTROLLER
VS135A, VS170A
135-170kW
60HZ
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver AirSmart VS135A

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

  • Page 2: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services

    Reliability in materials and quality assurance is incorporated in our genuine replacement parts. Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. A worldwide network of authorized distributors provides the finest product support in the air compressor industry.

  • 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.

  • 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 ...........................

  • Page 7: Index

    INDEX Air Filter, Section 7 .........60 Oil System Air Flow In The Compressor System ....8 Addition Of Oil Between Changes ....47 Air-Cooled Units, Location ......12 Compressor ..........45 Auxiliary Air Receiver........14 Draining And Cleaning ........ 48 Moisture ............. 46 Cold Weather Installation ........13 Oil Change Interval ........

  • Page 8: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ......................8 Figure 1-2 – Package Illustration (Air-Cooled) – External Details .............. 9 Figure 1-3 – Package Illustration (Air-Cooled) – Internal Details ............. 10 Figure 2-1 – Typical Compressor Room ....................12 Figure 2-2 –...

  • 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 Illustration (Air-Cooled) - External Details

    300CGF804-B (Ref. Drawing) Page 1 of 2 Figure 1-2 – PACKAGE ILLUSTRATION (AIR-COOLED) – External Details...

  • Page 11: Figure 1-3 - Package Illustration (Air-Cooled) - Internal Details

    300CGF804-B (Ref. Drawing) Page 2 of 2 Figure 1-3 – PACKAGE ILLUSTRATION (AIR-COOLED) – Internal Details...

  • Page 12: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL - On receipt of the unit, 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 13: Figure 2-1 - Typical Compressor Room

    (e.g., hot cooling air entering the fresh air inlet). The package is designed to operate at ambient temperatures ranging from 40°F to 113°F (at up to 1000 meter elevation). Contact Gardner Denver for package operation at conditions exceeding the stipulated values.
  • Page 14 Do not block flow of air entering or exiting the enclosure - allow minimum of 3-1/2 feet (1.1 m) clearance to the nearest obstruction all around and on top. 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 15 (loose) with the unit. The device must be piped at the outlet of the compressor package during final installation. CONTROL PIPING - Control piping is not necessary since the Gardner Denver compressor package is factory wired and piped for the control system specified.

  • Page 16: Figure 2-2 - Package Maximum Current Consumption Summary

    (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. Failure to do so will void your warranty.

  • Page 17: Figure 2-3 - 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. It shall be required in your particular application if any of the following conditions exist: ·...

  • Page 18: 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. See Section 5 for more details on the compressor oil system.
  • Page 19 Figure 4-3 and Figure 4-4, pages 29 and 33, for general wiring diagrams and 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.

  • Page 20: Figure 3-1 - Motor Fan Rotation Check

    The radial fan/motor combinations are integrated, and the incoming electrical power connections do not affect their rotation. If reverse rotation is noted for either radial fan, please notify Gardner Denver for corrective action. Figure 3-1 – MOTOR FAN ROTATION CHECK 8.
  • Page 21 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 Target Pressure comes preset from the factory at pressure as ordered. The Unload Pressure is preset to 10 psi higher. If a different pressure setting is desired, the following steps can be used as a guide.
  • Page 22 buttons to move the cursor to other digits in the Target Pressure value. When the desired Target 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 parameters, press the Stop/Reset button to go back to the heading of the current menu and then press the Stop/Reset button again.
  • Page 23 STARTING THE UNIT - Observe the following starting procedures. Unit Cold - If the unit is fitted with water-cooled heat exchangers, fully open water inlet valve(s). If the unit is located in a cold environment (e.g., ambient temperature below 40°F, 5 °C), the required external heat source must be energized prior to start.
  • Page 24 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. 13-18-607 Page 23...

  • Page 25: 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 necessary only to connect the compressor unit to the correct power supply and to the shop air supply network - and to the appropriate water supply if using the water-cooled variant.

  • Page 26: Figure 4-1 - Electrical Enclosure Hardware

    313CGF810-D (Ref. Drawing) Ref. No. Name of Part AIRSMART CONTROL........... AIRSMART MODULE ............. DRIVE GROUP .............. SPLITTER CABLE............PLUG KIT ............... CONTROL BOX ............. BLACK GRILLE FILTER ..........OPERATOR ..............CONTACT BLOCK ............POWER SUPPLY ............POWER DISTRIBUTION BLOCK ........FUSE ................
  • Page 27 Heat Exchanger Fan/Motor and Starter - Two (2) radial fan/motor assemblies provide cooling air for the heat exchangers and electronics box. These integrated units enable the AirSmart controller to match the heat exchanger coolant needs in proportion to the package load level (specifically, the speed of the compressor provides the proportioning control signal), thus saving fan power at reduced load operation.
  • Page 28 Blow Down Valve (P) - This (two-way solenoid) device vents compressed air from the air/oil sump. During compressor operation (e.g., compressors are running or they have temporarily stopped due to line pressure reaching unload pressure); the blow down valve remains energized (closed) and the air/oil reservoir remains pressurized.

  • Page 29: Figure 4-2 - Piping And Instrumentation Illustration

    305CGF797-A (Ref. Drawing) Figure 4-2 – PIPING AND INSTRUMENTATION ILLUSTRATION...

  • Page 30: Figure 4-3 - Wiring Diagram - (Air-Cooled) Single-Stage Vs135 Control

    300CGF546-D (Ref. Drawing Page 1 of 4 Figure 4-3 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS135 Control...
  • Page 31 300CGF546-D (Ref. Drawing) Page 2 of 4...
  • Page 32 300CGF546-D (Ref. Drawing) Page 3 of 4...
  • Page 33 300CGF546-D (Ref. Drawing) Page 4 of 4...

  • Page 34: Figure 4-4 - Wiring Diagram - (Air-Cooled) Single-Stage Vs170 Control

    302CGF546-E (Ref. Drawing) Figure 4-4 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS170 Control Page 1 of 4...
  • Page 35 302CGF546-E (Ref. Drawing) Page 2 of 4...
  • Page 36 302CGF546-E (Ref. Drawing) Page 3 of 4...
  • Page 37 302CGF546-E (Ref. Drawing) Page 4 of 4...

  • Page 38: Figure 4-5 - Wiring Diagram - (Water-Cooled) Single-Stage Vs135 Control

    Figure 4-5 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS135 Control 303CGF546-C (Ref. Drawing Page 1 of 4...
  • Page 39 303CGF546-C (Ref. Drawing Page 2 of 4...
  • Page 40 303CGF546-C (Ref. Drawing Page 3 of 4...
  • Page 41 303CGF546-C (Ref. Drawing Page 4 of 4...

  • Page 42: Figure 4-6 - Wiring Diagram - (Water-Cooled) Single-Stage Vs170 Control

    305CGF546-C (Ref. Drawing Page 1 of 4 Figure 4-6 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS170 Control...
  • Page 43 305CGF546-C (Ref. Drawing Page 2 of 4...
  • Page 44 305CGF546-C (Ref. Drawing Page 3 of 4...
  • Page 45 305CGF546-C (Ref. Drawing Page 4 of 4...

  • Page 46: Section 5, Compressor Lubrication - Separation, Filtration And Controls

    AEON 9000SP lubricant is available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000SP lubricating coolant for all-year-round operation. This is a polyalphaolefin (PAO) synthetic lubricant specially formulated for rotary screw compressor service.

  • Page 47: Figure 5-1 - Oil Level Sight Glass

    Use of improper lubricants will cause damage to equipment. Do not mix different types of lubricants or use inferior lubricants. All materials used in Gardner Denver compressor units are compatible with AEON 9000SP Synthetic Lubricating Coolant. Use caution when selecting downstream components such as lubricating bowls, gaskets and valve trim.

  • Page 48: Figure 5-2 - Load Vs Sight Glass Oil Level Change

    To ensure best performance from the oil separation system, adhere to the following guidelines: · Before starting the unit, make sure that oil level is visible in the sight gauge. An oil level of at least ½ the sight gauge height will ensure there is enough oil to safely operate the compressor. ·...
  • Page 49 (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 50 REFILLING OIL SYSTEM - The steps to refill the drained oil system are the same as those already presented for the addition of oil between changes – see page 47, for full details. The only exception is that to fill all the empty lines and components (e.g., oil cooler, compressors, and oil filter) a much larger volume of oil will be required The VS135-170 package requires nearly 26 gallons of AEON 9000SP Synthetic Lubricating Coolant to fill all the lines and components and achieve normal oil level.

  • Page 51: Figure 5-3 - Thermostatic Mixing Valve Element

    Figure 5-3 – THERMOSTATIC MIXING VALVE ELEMENT Normal Package Operation - The AirSmart controller includes an algorithm that determines, in real time, and on the basis of the intake temperature and the programmed target discharge pressure, the minimum discharge temperature the compressor must attain in order to keep water vapor from condensing in the oil system.

  • Page 52: Figure 5-4 - Pressure Dew Point Of Compressed Air

    Pressure Dew Point Trend Ambient Temp - °F 100psig 125psig 150psig 175psig Figure 5-4 – PRESSURE DEW POINT OF COMPRESSED AIR OIL SEPARATION RESERVOIR / COALESCING ELEMENT - This device serves multiple functions in the compressor package: · Air/oil centrifugal separation - The bulk of the liquid oil is separated, by change of direction, impingement and additional centrifugal effects, away from the compressed air and aerosol streams, and is then gravity-collected at the bottom of the sump.

  • Page 53: Figure 5-5 - Changing Oil Coalescing Element

    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 maintenance of the oil and air filters. The condition of the separator can be determined by pressure differential gauging or by inspection. Oil Coalescing Element Monitoring - The AirSmart controller keeps track of the pressure differential across the coalescing element.
  • Page 54 Inspect and/or replace the elements if necessary - shine a light inside each element to reveal areas of heavy dirt, varnish deposits or breaks (ruptures) in its media. Also inspect (sealing) o-ring in elements 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.

  • Page 55: Section 6 - Heat Exchangers (Oil, Air), Axial Cooling Fans

    SECTION 6 HEAT EXCHANGERS (OIL, AIR), AXIAL COOLING FANS Compressor, air/oil sump 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 56: Figure 6-1 - Air Flow Chart

    5240 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 57: Figure 6 2 - Water-Cooled Heat Exchanger Coolant Requirements

    The ventilation system for the air-cooled package relies on positive back pressure to cool the heat exchanger. Make sure that the enclosure panels that surround the heat exchanger area are closed during compressor operation, or the compressor discharge temperature will reach shutdown levels quickly.

  • Page 58: Figure 6-3 - Water Control Valve

    All the required hardware, mechanical and electrical connections have been made at the Gardner Denver factory. Regular maintenance is required to keep the interior core areas free from dirt and other fowling agents.

  • Page 59: Figure 6-4 - Water Separator And Drain

    · To decrease water flow (e.g., increase exiting cooling water temperature) turn the adjusting screw from left to right, increasing spring tension. (The groove at the lower edge of the adjusting screw is an index line for use with the index scale 0 to 8 in obtaining a desired setting). ·...

  • Page 60: Figure 6-5 - Detailed Water Separator And Drain

    Figure 6-5 – DETAILED WATER SEPARATOR AND DRAIN The separator (4) removes the liquid water from the compressed air stream by inertial effects and collected in a lower bowl (3). The collected water is evacuated by a float-type drain valve (1). The device prevents the loss of compressed air by only allowing the discharge of liquid water during its opening phase.

  • Page 61: 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 62 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.

  • Page 63: Section 8, Shaft Coupling

    SECTION 8 SHAFT COUPLING Figure 8-1 – COUPLING COMPONENTS Rotating machinery can cause personal injury or death. Turn the unit completely off, open the main disconnect, lockout and tagout before servicing the coupling. SHAFT COUPLING – Main motors drive their companion compressors by means of curved jaw-type couplings.

  • Page 64: Figure 8-2 - Coupling Element

    · After engaging each hub on the matching recesses of the coupling element, check that the gap between the hub flats (see dimension “E” on Figure 8-2) is within 1.57/1.69 in (40/43 mm). A smaller gap will produce abnormal wear of the element by friction and excessive thermal expansion –...
  • Page 65 4. For hub-to-shaft interference fit hubs, main drive motor removal is necessary: · Remove coupling guard by removing fasteners · Remove coupling ventilation shroud by removing fasteners · Drain oil entrained in discharge manifold by placing appropriate collection pan underneath elbow segment and removing the 1/4”...
  • Page 66 Coupling Hub Installation: · Have coupling installation tool part number 300SQP074 available – contact Gardner Denver for sourcing details. · Assemble tool kit components onto coupling hub as shown on Fig 8-4. · Make sure that the keyway on the coupling hub and its companion shaft are properly de-burred, cleaned and that the key fits easily into either.

  • Page 67: Figure 8-3 - Coupling Removal Tool

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

  • Page 68: Section 9, Minimum Pressure/Check Valve

    SECTION 9 MINIMUM PRESSURE/CHECK VALVE MINIMUM PRESSURE/CHECK VALVE - This device maintains minimum pressure within the air/oil reservoir, thus insuring (cooling/lubricating) oil injection flow into the compressors. It also serves as a check valve to prevent back flow of compressed air flow from the customer’s piping or pipe network back into the compressor package when the compressor is not active.

  • Page 69: Section 10, Inlet Control Valve

    SECTION 10 INLET CONTROL VALVE INLET CONTROL VALVE – This device is located at the intake flange of the compressor. During compressor stoppage, planned or accidental (e.g., power failure), it blocks off the compressor intake and allows it to remain pressurized and ready for quick re-start. A spring-loaded check feature is provided as added insurance against air or oil backflow.
  • Page 70 4. Identify (by position) each tube connected to the valve body and remove. 5. Remove four bolts (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.

  • Page 71: 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 200 psig. It is installed on the dry-side of the oil sump. Figure 11-1 – PRESSURE RELIEF VALVE 13-18-607 Page 70...
  • Page 72 Before inspecting the pressure relief valve, 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 injury or death. Never paint, lubricate or alter a relief valve. Do not plug vent or restrict. Operation of the unit with improper relief valve setting can result in severe personal injury or machine damage.

  • Page 73: 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 74: 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 - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings.

  • Page 75: 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, page 59 for air filter details. · Oil Separator Element - Replace when controller displays “CHANGE OIL SEPARATOR ELEMENT”. Refer to Section 5, page 45 for oil separator element details.
  • Page 76 Yearly Checks: · Heat Exchangers (air and water-cooled) – Check cooling performance of air and oil cores – see Section 6, page 53 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 70 for test procedure. ·...

  • Page 77: 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 78 Restriction in service piping Inspect and clean service piping. Restriction in control tubing Inspect and clean control tubing. Compressor Acceleration time in VFD set too Contact your Gardner Denver starts too long distributor. slowly Minimum Pressure/Check Valve Repair or replace.
  • Page 79 SYMPTOM POSSIBLE CAUSE REMEDY Excessive oil See “Oil Carryover” in this section. Oil separation malfunction 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 24dcv power feed to servo.
  • Page 80 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 82 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2015 Gardner Denver, Inc. Printed in U.S.A.

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