Related Manuals for Gardner Denver VST225
Summary of Contents for Gardner Denver VST225
- Page 1 13-17-609 Version: 10 May 13, 2016 VARIABLE SPEED TWO-STAGE STATIONARY BASE-MOUNTED COMPRESSOR AirSmartä CONTROLLER MODELS VST225, 260A 225-260 kW 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
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. An AirSmart 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.
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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 ........................... -
Page 7: Index
INDEX Air Filter ............63 Compressor ..........46 Air Filter, Section 7 .........63 Draining And Cleaning ........ 50 Air Flow In The Compressor System ....8 Filling Oil Reservoir ........50 Air-Cooled Units, Location ......17 Low Air Demand And Package Operation ... 53 Auxiliary Air Receiver........20 Moisture ............. -
Page 8: List Of Illustrations
List Of Illustrations Figure 1-1 – Compression Cycle ......................8 Figure 1-2 – Package Illustration (Water Cooled) – External Details ............10 Figure 1-3 – Package Illustration (Water Cooled) – Internal Details ............11 Figure 1-4 – Package Illustration (Air Cooled) – External Details ............12 Figure 1-5 –... -
Page 9: Section 1, General Information
GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR – Your Gardner Denver Rotary Screw package is fitted with two (2) in-series single stage, positive displacement rotary compressors using meshing helical rotors to effect compression. Each pair of rotors is supported between high capacity anti-friction bearings located outside the compression chamber. - Page 10 LUBRICATION, COOLING AND SEALING (Figure 4-3, page 35) - Oil is forced by differential pressure from the oil reservoir through the oil cooler, thermostatic mixing valve/oil filter combination, distribution manifold, 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.
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Page 11: Figure 1-2 - Package Illustration (Water Cooled) - External Details
300ETW804-B (Ref. Drawing) Page 1 of 2 Figure 1-2 – PACKAGE ILLUSTRATION (WATER COOLED) – External Details... -
Page 12: Figure 1-3 - Package Illustration (Water Cooled) - Internal Details
300ETW804-B (Ref. Drawing) Page 2 of 2 Figure 1-3 – PACKAGE ILLUSTRATION (WATER COOLED) – Internal Details... -
Page 13: Figure 1-4 - Package Illustration (Air Cooled) - External Details
301ETW804-B (Ref. Drawing) Page 1 of 4 Figure 1-4 – PACKAGE ILLUSTRATION (AIR-COOLED) – External Details... -
Page 14: Figure 1-5 - Package Illustration (Air Cooled) - Internal Details
301ETW804-B (Ref. Drawing) Page 2 of 4 Figure 1-5 – PACKAGE ILLUSTRATION (AIR-COOLED) – Internal Details... -
Page 15: Figure 1-6 - Package Illustration (Air Cooled) - Remote Cooler Module Dimensions
301ETW804-B (Ref. Drawing) Page 3 of 4 Figure 1-6 – PACKAGE ILLUSTRATION (AIR-COOLED) – Remote Cooler Module Dimensions... -
Page 16: Figure 1-7 - Package Illustration (Air Cooled) - Remote Cooler Module Dimensions With Moisture
301ETW804-B (Ref. Drawing) Page 4 of 4 Figure 1-7 – PACKAGE ILLUSTRATION (AIR-COOLED) – Remote Cooler Module Dimensions with Moisture Separator Piping Instructions... -
Page 17: 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 18: Figure 2-1 - Typical Compressor Room
LOCATION - The compressor package shall be installed, whenever possible, in a clean, well-lighted, well-ventilated area with ample space all around for maintenance. Select a location that provides a cool, clean, dry source of air. In some cases it may be necessary to install duct work to reach a source of adequate cooling air, or to direct cooling air in and out of the compressor package to prevent re- circulation (e.g., not cooling the air entering the fresh air inlet). - Page 19 Do not block flow of air entering or exiting the enclosure - allow 3-1/2 feet (1.1 m) clearance to the nearest obstruction all around and on top. FOUNDATION - The Gardner Denver Rotary Screw compressor and the air-cooled module require no special foundation, but should be mounted on a smooth, solid surface and as near level as possible.
- Page 20 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) above the floor level. If this is not sufficient to conveniently drain the oil, other methods are: Elevate the compressor unit on a suitable structure to obtain the desired drain height.
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Page 21: Figure 2-2 - Inlet Line Length
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. - Page 22 (VFD’s) to control compressors and cooling fan motors. 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.
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Page 23: Figure 2-3 - Package Maximum Current Consumption Summary
Electrical Wire Sizing – A certified electrician familiar with National Electric Codes and applicable local codes shall size the electrical power wires serving the compressor package. Refer to Figure 2-3, for a summary of maximum package current consumption values. 460 VOLT VST225A and VST260A MINIMUM COPPER SUPPLY WIRE RECOMMENDATIONS 460 V VST-225 through VST 260 Minimum Copper Supply Wire Recommendations... -
Page 24: Figure 2-4 - Line Reactor Sizing Recommendations
Existing line reactor not properly sized – see Figure 2-4, page 23. · Other large loads on the same power feed as the compressor. GD Model Volts VFD HP RATINGS Max KVA VST225 400/480 2-150 HP 1000 VST260 400/480 2-200 HP... -
Page 25: Section 3, Starting & Operating Procedures
– typical level is middle of gauge under running conditions. Do not mix different type oils. When the unit is shipped, it is filled with Gardner Denver AEON™ 9000TH lubricating coolant, suitable for the first 8000 hours under normal operating conditions. - Page 26 Figure 4-4 thru Figure 4-8, pages 36 thru 40, for general wiring diagrams and Section 2, page 16 for installation instructions. Grounding - Equipment must be properly grounded according to Gardner Denver Guidelines for proper wiring, grounding and feed power conditioning.
- Page 27 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 28 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. OPERATION ADJUSTMENT TARGET PRESSURE 100 PSI (SELECT PARAMETER) To change the Target Pressure, press the Enter button to edit the value.
- Page 29 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. The Unload Pressure will control at which pressure the compressor unload and stops.
- Page 30 Unit Hot - Start-up instructions are the same as that of a cold start. DAILY CHECK - Refer to Section 14, page 81 “Maintenance Schedule”. STOPPING THE UNIT - Press “STOP-RESET” button. The oil reservoir will automatically blow down, as the motors are de-energized.
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Page 31: 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 32: Figure 4-1 - Electrical Enclosure Hardware
12 Contact Block Din Rail Kit 16 Power Supply Baffle 17 Fuse Decal 18 Power Distribution Block RJ45 Screw Terminal 19 Fuse Holder Note: VST225 EMC Filters are separate components VST260 EMC filters are integrated into VFD’s 13-17-609 Page 31... -
Page 33: Figure 4-2 - Electrical Enclosure Hardware
Figure 4-2 – ELECTRICAL ENCLOSURE HARDWARE 300ETW810-C (Ref. Drawing) Item Description Key Pad Emergency Stop Operator Contact Block Decal 13-17-609 Page 32... - Page 34 Fan VFD and Motors (Air-cooled module only) - The radial fan providing cooling air for the heat exchangers is driven by an inverter-duty (TEFC) electric motor, which in turn is energized by a pulse- width modulated, variable frequency drive (commonly referred to as VFD). This combination of components enables the controller to match the heat exchanger coolant needs in proportion with load level (e.g., flow capacity) of the compressor package, thus saving fan power.
- Page 35 Inlet Feed Valve (R) - This device supplies/vents the required pressure signal to actuate the inlet butterfly valve. When energized, the 3-way solenoid valve opens the inlet butterfly valve and when de- energized, it allows it to close. See Inlet Control (Butterfly) Valve, Section 10, page 74, for details. Oil Flow Control Valves (U) - These devices feed a regulated amount of oil into various areas of the 1st stage compressor and inter-stage manifold, in order to maintain optimal 1st and 2nd stage compressor discharge temperatures (between 195°F and 220°F).
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Page 36: Figure 4-3 - Piping And Instrumentation Illustration
300ETW797-A (Ref. Drawing) Figure 4-3 – PIPING AND INSTRUMENTATION ILLUSTRATION... -
Page 37: Figure 4-4 - Wiring Diagram - (Water Cooled) Two-Stage Vst Control
300ETW546-D Figure 4-4 – WIRING DIAGRAM – (WATER COOLED) Two-Stage VST Control (Ref. Drawing) Page 1 of 4... -
Page 38: Figure 4-5 - Wiring Diagram - (Water Cooled) Two-Stage Vst Control
300ETW546-D (Ref. Drawing) Page 2 of 4 Figure 4-5 – WIRING DIAGRAM – (WATER COOLED) Two-Stage VST Control... -
Page 39: Figure 4-6 - Wiring Diagram - (Water Cooled) Two-Stage Vst Control
300ETW546-D Figure 4-6 – WIRING DIAGRAM – (WATER COOLED) Two-Stage VST Control (Ref. Drawing) Page 3 of 4... -
Page 40: Figure 4-7 - Wiring Diagram - (Water Cooled) Two Stage Vst Control
300ETW546-D (Ref. Drawing) Figure 4-7 – WIRING DIAGRAM – (WATER COOLED) Two Stage VST Control Page 4 of 4... -
Page 41: Figure 4-8 - Wiring Diagram - (Air Cooled) Two-Stage Vst Control
Figure 4-8 – WIRING DIAGRAM – (AIR-COOLED) Two-Stage VST Control 301ETW546-B (Ref. Drawing) Page 1 of 2... -
Page 42: Figure 4-9 - Wiring Diagram - (Air Cooled) Two-Stage Vst Control
301ETW546-B (Ref. Drawing) Figure 4-9 – WIRING DIAGRAM – (AIR-COOLED) Two-Stage VST Control Page 2 of 2... -
Page 43: Figure 4-10 - Wiring Diagram - (Water Cooled) Two-Stage Vst 260 Control
302ETW546-C (Ref. Drawing) Figure 4-10 – WIRING DIAGRAM – (WATER COOLED) Two-Stage VST 260 Control Page 1 of 4... -
Page 44: Figure 4-11 - Wiring Diagram - (Water Cooled) Two-Stage Vst 260 Control
302ETW546-C (Ref. Drawing) Page 2 of 4 Figure 4-11 – WIRING DIAGRAM – (WATER COOLED) Two-Stage VST 260 Control... -
Page 45: Figure 4-12 - Wiring Diagram - (Water Cooled) Two-Stage Vst 260 Control
302ETW546-C (Ref. Drawing) Page 3 of 4 Figure 4-12 – WIRING DIAGRAM – (WATER COOLED) Two-Stage VST 260 Control... -
Page 46: Figure 4-13 - Wiring Diagram - (Water Cooled) Two-Stage Vst 260 Control
302ETW546-C (Ref. Drawing) Page 4 of 4 Figure 4-13 – WIRING DIAGRAM – (WATER COOLED) Two-Stage VST 260 Control... -
Page 47: Section 5, Compressor Lubrication - Separation, Filtration And Controls
AEON 9000TH lubricant is available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000TH lubricating coolant for all-year-round operation. This is a polyol ester (POE) synthetic lubricant specially formulated for high operating temperatures (210°F to 225°F), which can extend change intervals up to 4... - Page 48 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 9000TH Synthetic Lubricating Coolant. Use caution when selecting downstream components such as lubricating bowls, gaskets and valve trim.
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Page 49: Figure 5-1 - Oil Level Sight Glass
OIL SIGHT GLASS - This device indicates oil level within the air/oil reservoir – See Figure 5-1 for details. Figure 5-1 – OIL LEVEL SIGHT GLASS To ensure best performance from the oil separation system, adhere to the following guidelines: ·... - Page 50 (e.g., very dusty, high humidity, etc.), may require more frequent oil changes. Gardner Denver offers a free oil analysis program with our AEON 9000TH lubricant. The first sample from a new unit should be sent in between 40-100 hours of operation.
- Page 51 (e.g., oil cooler, compressors, and oil filter) a much larger volume of oil will be required. The VST225-260A package [water Cooled variant] requires 35 gal. of AEON 9000TH Synthetic Lubricating Coolant (oil) to fill all the lines and components. The provided sight glass has a working height of 4”, which represent a change of 7.7 gallons between its bottom edge (refill level) to its upper...
- Page 52 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 should be replaced every 1000 hours of operation and when the oil is changed. A bypass valve, mounted within the oil filter element, provides uninterrupted oil flow when the pressure drop exceeds 25psid –...
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Page 53: Figure 5-3 - Combination Oil Filter And Thermostatic Mixing Valve
OIL MIXING VALVE – This device, located at the inlet side of the oil cooler, mixes cooled and hot oil prior to delivery to the oil filter and oil injection manifold. It helps to maintain a minimum oil temperature of approximately 140°F at low load level or low ambient temperature conditions. -
Page 54: Figure 5-4 - Pressure Dew Point Of Compressed Air
OIL FLOW CONTROL VALVES - These devices feed a regulated amount of oil into various areas of the 1st stage compressor and inter-stage manifold. Each of three (3) normally open solenoid valves is paired with one or more in-line orifices to deliver distinct oil flows. When used in combination with a permanently open injection line, the system provides five (5) distinct oil flow regimes - a summary of the logical steps controlling the opening and closing of these valves is shown on the footnotes of Figure 4-3, page 35. -
Page 55: Figure 5-5 - Oil Coalescing Element (Single Element Shown)
OIL SEPARATION RESERVOIR / COALESCING ELEMENTS These devices serve multiple functions in the compressor package: · Air/oil centrifugal separation - The bulk of the liquid oil is separated, by centrifugal effects, away from the compressed air and aerosol streams, which is then gravity-collected at the bottom of the reservoir. - Page 56 Using oil separator elements at excessive pressure differential can cause damage to equipment. Replace the elements when the "Change Separator" advisory appears. A sudden drop to zero pressure differential or sudden heavy oil carryover may indicate a ruptured 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 pressure is depressurized.
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Page 57: Section 6, Heat Exchangers (Oil, Air), Axial Cooling Fans
SECTION 6 HEAT EXCHANGERS (OIL, AIR), AXIAL COOLING FANS 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 58: Figure 6-1 - Air Flow Chart
All the required [internal] 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 59: Figure 6-2 - Water Control Valve
Water Flow Model 60° F 70° F 80° F 90° F (gpm) * (psi) VST225-260A 57.7 77.6 118.5 250.0 250.0 25.2 * Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty. Figure 6-2 – WATER CONTROL VALVE – WATER COOLED HEAT EXCHANGER COOLANT... - Page 60 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 61 Adjustments – The regulator valve shall be adjusted so that it closes when the cooling water entering and exiting the package are at the same temperature – a condition that is present after the compressors have stopped and the heat exchangers have cooled down. This adjustment mode will prevent the circulation of cooling water when it is not needed.
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Page 62: Figure 6-3 - Water Separator And Drain
Figure 6-3 – WATER SEPARATOR AND DRAIN Figure 6- 4 – DETAILED WATER SEPARATOR AND DRAIN The separator (1) removes the liquid water from the compressed air stream by inertial effects and collected in its lower head. The collected water is evacuated by a float-type drain valve. The device prevents the loss of compressed air by only allowing the discharge of liquid water during its opening phase. - Page 63 In case the drain valve is fouled with dirt, cleanse the lower head also: 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 64: 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 65 Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water. Improper cleaning may damage the element. 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.
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Page 66: 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 67: Figure 8-2 - Coupling Element
Figure 8-2 – COUPLING ELEMENT · Apply a thread-locking compound to the hub set screws (M10 size) and tighten to 12.6 ft. lb. (17 N-m) of torque. Reinstall coupling guard with provided fasteners. For hub-to-shaft interference fit hubs, main drive motor removal is necessary. 13-17-609 Page 66... -
Page 68: Figure 8-3 - Motor Removal Hardware
302ETW810-B (Ref. Drawing) Figure 8-3 – MOTOR REMOVAL HARDWARE · Remove coupling guard by removing four bolts · Remove two bolt/nut/washer combos securing [main motor] rear support to baseframe. · Insert temporary support between adaptor casting and support frame (e.g., wood beam) to maintain compressor level when main motor is retrieved. - Page 69 · 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, page 66) is no less than 1.57/1.69 inches (40/43 mm). A smaller gap will produce abnormal wear of the element by friction and excessive thermal expansion –...
- Page 70 Make sure to use suitable heat protective gloves and clothes. If heat was applied to the [compressor] coupling hub during its removal, there is the possibility that the companion shaft seal has been damaged and it must be replaced. Contact Gardner Denver for further instructions. 13-17-609 Page 69...
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Page 71: Figure 8-4 - Coupling Installation Tool Kit
FIGURE 8-4 – COUPLING INSTALLATION TOOL KIT FIGURE 8-5 – COUPLING REMOVAL TOOL KIT 13-17-609 Page 70... -
Page 72: Section 9, Minimum Pressure/Check Valve
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 73: Figure 9-1 - Minimum Discharge Pressure/Check Valve
Figure 9-1 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE Item Name Of Part Qty. MINIMUM PRESSURE VALVE ASSEMBLY REPAIR KIT - Includes the following: BODY CHECK VALVE ASSEMBLY SPACER SPRING O-RING PISTON ASSEMBLY SPRING RETAINER SPRING 13-17-609 Page 72... -
Page 74: Section 10, Inlet Control Valve
SECTION 10 INLET CONTROL VALVE INLET CONTROL VALVE – This device is located at the intake flange of the 1st stage compressor. A spring-loaded pneumatic cylinder actuates the valve. During compressor operation (at least 5 Hz 1st stage compressor shaft speed), an air pressure signal (60 psig min) fed into the actuator overcomes the internal spring load and opens the valve. - Page 75 Inlet Control Valve (Body) Inspection - The valve does not require maintenance or lubrication. If air/oil leaks develop across the valve disc during pressurized conditions (e.g., machine stopped), valve seat and disc should be inspected for wear and tear signs: 1.
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Page 76: Figure 10-2 - Inlet Control Valve (Actuator)
Figure 10-2 – INLET CONTROL VALVE (ACTUATOR) 13-17-609 Page 75 10-3... - Page 77 Inlet Control Valve (Actuator) Inspection: The actuator does not require maintenance and is permanently lubricated at the factory with non-silicone grease. If air/oil leaks develop or abnormal (e.g., slow motion) performance is noted in spite of proper feed pressure then the complete actuator must be replaced: 1.
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Page 78: 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 accidentally exceeding 200 psig. It is installed on the dry-side of the oil separation reservoir. Figure 11-1 – PRESSURE RELIEF VALVE 13-17-609 Page 77 11-1... - Page 79 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.
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Page 80: Section 12, Ventilation Fans, Filters (Electrical Enclosure)
SECTION 12 VENTILATION FANS, FILTERS (ELECTRICAL ENCLOSURE) Ventilation Fans/Filters - The electronics housed in the standard IP54 enclosure box are ventilated by a combination of triple intake and discharge side air filters and a single roof-mounted axial fan. Refer to Figures 1-3 and 4-1, pages 11 and 31 in their corresponding Sections of this manual, for details. -
Page 81: 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 82: Section 14, Maintenance Schedule
SECTION 14 MAINTENANCE SCHEDULE SERVICE CHECK LIST Daily Checks: · Air Filters (Compressor) - Replace when controller displays “CHANGE AIR FILTER” message. Refer to Section 7, page 63 for air filter details. · Oil Separator Element - Replace when controller displays “CHANGE OIL SEPARATOR ELEMENT”. Refer to Section 5, page 46 for oil separator element details. -
Page 83: Section 15, Troubleshooting
Manual 13-17-600. Remote Contact is open Replace switch or jumper. Compressor lock-up Confirm compressor shaft is not free to turn, then call Gardner Denver for further instructions. See “High Discharge Air Temperature”, this section. Compressor See “High Discharge Air... - Page 84 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 is Repair or replace.
- Page 85 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 Thermostatic mixing valve stuck on Inspect or replace valve.
- Page 86 Ruptured oil separator element. Replace element. Loose assembly Tighten all fittings and gaskets. Foam caused by use of Use Gardner Denver AEON 9000TH incorrect oil oil only. Minimum pressure valve Repair or replace. malfunction – discharge pressure below 80 psig...
- Page 87 STANDARD WARRANTY Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, free of defects in material and workmanship.
- Page 88 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2016 Gardner Denver, Inc. Printed in U.S.A.