Gardner Denver AirSmart VS25A Operating And Service Manual
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Gardner Denver AirSmart VS25A Operating And Service Manual

Gardner Denver AirSmart VS25A Operating And Service Manual

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13-18-603
Version: 20
May 23, 2014
VARIABLE SPEED,
SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AirSmartä CONTROLLER
MODELS
VS25A, VS30A, VS40A
25-30-40kW
60HZ
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver AirSmart VS25A

  • Page 1 13-18-603 Version: 20 May 23, 2014 VARIABLE SPEED, SINGLE STAGE STATIONARY BASE-MOUNTED COMPRESSOR AirSmartä CONTROLLER MODELS VS25A, VS30A, VS40A 25-30-40kW 60HZ OPERATING AND SERVICE MANUAL...

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

    A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors. Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor.

  • 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 .........96 Oil System Air Flow In The Compressor System ....8 Addition Of Oil Between Changes ....81 Air-Cooled Units, Location ......22 Compressor ..........80 Auxiliary Air Receiver........24 Draining And Cleaning ........ 82 Moisture ............. 81 Cold Weather Installation ........23 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 1-4 – Outline-Unit/Pkg, VS25-40 Air-Cooled With Dryer (External Details) ........... 11 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 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.

  • Page 10: Figure 1-2 - Package Illustration (Air-Cooled) - External Details

    300CGC804-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

    300CGC804-B (Ref. Drawing) Page 2 of 2 Figure 1-3 – PACKAGE ILLUSTRATION (AIR-COOLED) – Internal Details...

  • Page 12: Figure 1-4 - Outline-Unit/Pkg, Vs25-40 Air-Cooled With Dryer (External Details)

    301CGC804-A (Ref. Drawing) Page 1 of 2 Figure 1-4 – OUTLINE-UNIT/PKG, VS25-40 AIR-COOLED WITH DRYER (External Details)

  • Page 13: Figure 1-5 - Outline-Unit/Pkg, Vs25-40 Air-Cooled With Dryer (Internal Details)

    301CGC804-A (Ref. Drawing) Page 2 of 2 FIGURE 1-5 – OUTLINE-UNIT/PKG, VS25-40 AIR-COOLED WITH DRYER (Internal Details)

  • Page 14: Figure 1-6 - Outline-Unit/Pkg, Vs25-40 Water-Cooled Standard (External Details)

    302CGC804-A (Ref. Drawing) Page 1 of 2 Figure 1-6 – OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED STANDARD (External Details)

  • Page 15: Figure 1-7 - Outline-Unit/Pkg, Vs25-40 Water-Cooled Standard (Internal Details)

    302CGC804-A (Ref. Drawing) Page 2 of 2 Figure 1-7 – OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED STANDARD (Internal Details)

  • Page 16: Figure 1-8 - Outline-Unit/Pkg, Vs25-40 Water-Cooled With Dryer (External Details)

    303CGC804-A (Ref. Drawing) Page 1 of 2 Figure 1-8 – OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED WITH DRYER (External Details)

  • Page 17: Figure 1-9 - Outline-Unit/Pkg, Vs25-40 Water-Cooled With Dryer (Internal Details)

    303CGC804-A (Ref. Drawing) Page 2 of 2 Figure 1-9 – OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED WITH DRYER (Internal Details)

  • Page 18: Figure 1-10 - Outline-Unit/Pkg, Vs30-40 Air-Cooled Alternate Volt With Dryer Option (External Details)

    304CGC804-A (Ref. Drawing) Page 1 of 2 Figure 1-10 – OUTLINE-UNIT/PKG, VS30-40 AIR-COOLED ALTERNATE VOLT WITH DRYER OPTION (External Details)

  • Page 19: Figure 1-11 - Outline -Unit/Pkg, Vs30-40 Air-Cooled Alternate Volt With Dryer Option (Internal Details)

    304CGC804-A (Ref. Drawing) Page 2 of 2 Figure 1-11 – OUTLINE -UNIT/PKG, VS30-40 AIR-COOLED ALTERNATE VOLT WITH DRYER OPTION (Internal Details)

  • Page 20: Figure 1-12 - Outline-Unit/Pkg, Vs30-40 Water-Cooled Alternate Volt With Dryer Option (External Details)

    305CGC804-A (Ref. Drawing) Page 1 of 2 Figure 1-12 – OUTLINE-UNIT/PKG, VS30-40 WATER-COOLED ALTERNATE VOLT WITH DRYER OPTION (External Details)

  • Page 21: Figure 1-13 - Outline-Unit/Pkg, Vs30-40 Water-Cooled Alternate Volt With Dryer Option (Internal Details)

    305CGC804-A (Ref. Drawing) Page 2 of 2 Figure 1-13 – OUTLINE-UNIT/PKG, VS30-40 WATER-COOLED ALTERNATE VOLT WITH DRYER OPTION (Internal Details)

  • Page 22: 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 23: 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 24 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 25 This device is not used on packages equipped with integrated dryers! CONTROL PIPING - Control piping is not necessary since the Gardner Denver compressor package is factory wired and piped for the control system specified.

  • Page 26: 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 27: 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 28: 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 29 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 30 · Start/Stop controller to bump main motor cooling fan. Proper rotation is achieved when cooling air is discharged over the main motor body. 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).
  • Page 31 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...
  • Page 32 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. OPERATION ADJUSTMENT UNLOAD PRESSURE 110 PSI (SELECT PARAMETER) The Load pressure is the fourth item in the Operation Adjustment sub-menu so press the Down...
  • Page 33 Please refer to the dryer manual 13-18-602 for all installation, operation and maintenance instructions. DAILY CHECK - Refer to Section 14, page 111 “Maintenance Schedule”. STOPPING THE UNIT - Press “STOP-RESET” button. The oil reservoir will automatically blow down, as the main motor is de-energized.

  • Page 34: 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 35: Figure 4-1 - Electrical Enclosure Hardware

    310CGC810-D (Ref. Drawing) Figure 4-1 – ELECTRICAL ENCLOSURE HARDWARE...
  • Page 36 ASSEMBLED CONTROL BOX WITH EMC FILTER ASSEMBLED CONTROL BOX WITHOUT EMC FILTER AIRSMART CONTROLLER DRIVE GROUP SPLITTER CABLE SCREW TERMINAL PLUG CONTROL BOX BLACK FILTER GRILL OPERATOR CONTACT BLOCK POWER SUPPLY POWER DISTRIBUTION BLOCK TERMINAL LUG (not shown) FUSE HOLDER FUSE FUSE BLOCK FUSE...
  • Page 37 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 –...
  • Page 38 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 39: Figure 4-2 - Piping And Instrumentation Illustration

    300CGC797-A (Ref. Drawing) Figure 4-2 – PIPING AND INSTRUMENTATION ILLUSTRATION...

  • Page 40: Figure 4-3 - Wiring Diagram - (Air-Cooled) - (460 Volt) Single-Stage Vs Control

    300CGC546-E Ref. Drawing) Page 1 of 4 Figure 4-3 – WIRING DIAGRAM – (AIR-COOLED) – (460 VOLT) Single-Stage VS Control...
  • Page 41 300CGC546-E (Ref. Drawing) Page 2 of 4...
  • Page 42 300CGC546-E (Ref. Drawing) Page 3 of 4...
  • Page 43 300CGC546-E (Ref. Drawing) Page 4 of 4...

  • Page 44: Figure 4-4 - Wiring Diagram - (Water-Cooled) - (460 Volt) Single-Stage Vs Control

    301CGC546-E (Ref. Drawing) Page 1 of 4 Figure 4-4 – WIRING DIAGRAM – (WATER-COOLED) – (460 VOLT) Single-Stage VS Control...
  • Page 45 301CGC546-E (Ref. Drawing) Page 2 of 4...
  • Page 46 301CGC546-E (Ref. Drawing) Page 3 of 4...
  • Page 47 301CGC546-E (Ref. Drawing) Page 4 of 4...

  • Page 48: Figure 4-5 - Wiring Diagram - (Air-Cooled) - (200 & 230 Volt) Vs30

    302CGC546-C (Ref. Drawing) Page 1 of 4 Figure 4-5 – WIRING DIAGRAM – (AIR-COOLED) – (200 & 230 VOLT) VS30...
  • Page 49 302CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 50 302CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 51 302CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 52: Figure 4-6 - Wiring Diagram - (Air-Cooled) - (575 Volt) Vs30

    303CGC546-C (Ref. Drawing) Page 1 of 4 Figure 4-6 – WIRING DIAGRAM – (AIR-COOLED) – (575 VOLT) VS30...
  • Page 53 303CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 54 303CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 55 303CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 56: Figure 4-7 - Wiring Diagram - (Air-Cooled) - (200 & 230 Volt) Vs40

    304CGC546-C (Ref. Drawing) Page 1 of 4 Figure 4-7 – WIRING DIAGRAM – (AIR-COOLED) – (200 & 230 VOLT) VS40...
  • Page 57 304CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 58 304CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 59 304CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 60: Figure 4-8 - Wiring Diagram - (Air-Cooled) - (575 Volt) Vs40

    Figure 4-8 – WIRING DIAGRAM – (AIR-COOLED) – (575 VOLT) VS40 305CGC546-C (Ref. Drawing) Page 1 of 4...
  • Page 61 305CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 62 305CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 63 305CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 64: Figure 4-9 - Wiring Diagram - (Water-Cooled) - (200 & 230 Volt) Vs 30

    Figure 4-9 – WIRING DIAGRAM – (WATER-COOLED) – (200 & 230 VOLT) VS 30 306CGC546-C (Ref. Drawing) Page 1 of 4...
  • Page 65 306CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 66 306CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 67 306CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 68: Figure 4-10 - Wiring Diagram - (Water-Cooled) - (575 Volt) Vs30

    Figure 4-10 – WIRING DIAGRAM – (WATER-COOLED) – (575 VOLT) VS30 307CGC546-C (Ref. Drawing) Page 1 of 4...
  • Page 69 307CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 70 307CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 71 307CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 72: Figure 4-11 - Wiring Diagram - (Water-Cooled) - (200 & 230 Volt) Vs40

    Figure 4-11 – WIRING DIAGRAM – (WATER-COOLED) – (200 & 230 VOLT) VS40 308CGC546-C (Ref. Drawing) Page 1 of 4...
  • Page 73 308CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 74 308CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 75 308CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 76: Figure 4-12 - Wiring Diagram - (Water-Cooled) - (575 Volt) Vs40

    Figure 4-12 – WIRING DIAGRAM – (WATER-COOLED) – (575 VOLT) VS40 309CGC546-C (Ref. Drawing) Page 1 of 4...
  • Page 77 309CGC546-C (Ref. Drawing) Page 2 of 4...
  • Page 78 309CGC546-C (Ref. Drawing) Page 3 of 4...
  • Page 79 309CGC546-C (Ref. Drawing) Page 4 of 4...

  • Page 80: 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 81 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 82 (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 83: Figure 5-1 - Checking Oil Level

    Figure 5-1 – CHECKING OIL LEVEL Figure 5-2 – CHANGING OIL FILTER 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 80, 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.
  • Page 84 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.

  • Page 85: 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 86: Figure 5-4 - Pressure Dew Point Of Compressed Air

    Pressure Dew Point Trend Am bient Tem p - °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 87: 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 88 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. Remove four cap screws (7) and body of MPV/sump cover (1). Lift the elements (2) from sump.

  • Page 89: 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 90: Figure 6-1 - Air Flow Chart

    1767 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 91: Figure 6-2 - Cooler Housing Side Covers

    4. Locate cooler housing side covers (See Figure 6-2) and remove by unscrewing fasteners. 5. Inspect core area. If blocked with debris, use a moderate (e.g., 100psi) source of compressed air and/or water while directing nozzle (pointed through core to inside) to dislodge debris and clean. Vacuum (applied from inside) can also be employed to clean the heat exchanger cores.

  • Page 92: Figure 6-3 - Water-Cooled Heat Exchanger Coolant Requirements

    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 93: Figure 6-4 - Water Control Valve

    Figure 6-4 – WATER CONTROL VALVE 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.

  • Page 94: Figure 6-5 - Water Separator And Drain

    WATER SEPARATOR AND DRAIN – These devices separate and drain the water (condensed by the air cooler) mixed with the compressed air delivered by the compressor package. Note that this device is not used the optional compressed air dryer is supplied, as the latter’s water separator is employed for this process.
  • Page 95 In case the drain valve is fouled with dirt, cleanse the collection bowl 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.

  • Page 96: 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 97 NOTICE 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 98: 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 99: 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 0.94/1.02 in (24/25.8 mm). A smaller gap will produce abnormal wear of the element by friction and excessive thermal expansion –...
  • Page 100 Coupling Hub Installation: · Have coupling installation tool part number CC1021459 available – contact Gardner Denver for sourcing details. · Mount coupling hub unto tool via provided magnets.
  • Page 101 If heat was applied to the [compressor] coupling hub during its removal, there is the possibility that the compressor shaft seal was damaged and it must be replaced. Contact Gardner Denver for further instructions. FIGURE 8-4 – COUPLING REMOVAL TOOL – VS40 model shown...

  • Page 102: Figure 8-4 - Locating Airend Coupling Hub Installation Tool - Vs40 Model Shown

    Figure 8-4 – LOCATING AIREND COUPLING HUB INSTALLATION TOOL – VS40 MODEL SHOWN Figure 8-5 – LOCATING MOTOR COUPLING HUB INSTALLATION TOOL – VS40 MODEL SHOWN 13-18-603 Page 101...

  • Page 103: 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 104: Figure 9-1 - Minimum Discharge Pressure/Check Valve

    Figure 9-1 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE 13-18-603 Page 103...

  • Page 105: 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 106 6. In case of noted malfunction (e.g., valve will not open/close properly with good air signal), proceed to dismantle internal blow-off valve. · Carefully lift and remove poppet (Item 3). · Remove lock ring (Item 20). · Pull cover (Item 16) and seal (Item 17). ·...

  • Page 107: 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. Before inspecting the pressure relief valve, release air pressure, lockout and tagout the power supply to the compressor package.
  • Page 108 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.

  • Page 109: 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 110: 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 111: 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 96 for air filter details. · Oil Separator Element - Replace when controller displays “CHANGE OIL SEPARATOR ELEMENT”. Refer to Section 5, page 80 for oil separator element details.
  • Page 112 Yearly Checks: · Heat Exchangers (air and water-cooled) – Check cooling performance of air and oil cores – see Section 6, page 89 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 107 for test procedure. ·...

  • Page 113: 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 114 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 distributor. starts too long slowly Minimum Pressure/Check Valve Repair or replace.
  • Page 115 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 24Vdc power feed to servo.
  • Page 116 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 118 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2014 Gardner Denver, Inc. Printed in U.S.A.

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