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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.
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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.
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.
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 ...........................
INDEX Air Filter, Section 7 .........62 Oil Reservoir Drain ......... 15 Air Flow In The Compressor System ....8 Oil System Air Cooled Units, Location ......14 Addition Of Oil Between Changes ....49 Auxiliary Air Receiver........16 Compressor ..........47 Draining And Cleaning ........ 50 Cold Weather Installation ........15 Moisture .............
GENERAL INFORMATION Figure 1-1 – COMPRESSOR 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.
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.
(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.
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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°...
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- the devices 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.
(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.
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: ·...
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.
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Figure 4-3 and Figure 4-4, pages 31 and35, 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. Failure to properly ground the compressor package could result in controller malfunction.
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.
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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.
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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.
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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.
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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. 13-18-609 Page 25...
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.
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 ..................
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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.
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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.
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.
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.
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. ·...
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(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.
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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, sooner if necessary due to dirty environment and when the oil is changed. (See Figure 1-3, page 10) and Figure 1-5, page 12) for the location of the oil filter within the package.
Figure 5- 3 – THERMOSTATIC OIL MIXING VALVE 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.
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.
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.
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Lift the element from the sump. Inspect and/or replace the elements if necessary - shine a light inside the element to reveal areas of heavy dirt, varnish deposits or breaks (ruptures) in its media. Also inspect (sealing) o-ring in element for damage.
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.
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.
Maximum water flow Water Flow Model 60° F 70° F 80° F 90° F (gpm) * (psi) VS80A 23.2 26.6 31.4 38.8 VS110A 30.3 34.8 41.0 48.0 * Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.
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.
· To increase water flow (e.g., decrease exiting cooling water temperature) turn the adjusting screw from right to left, decreasing 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). Care must be used when handling the capillary tube;...
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.
NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water.
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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.
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.
· A smaller gap will produce abnormal wear of the element by friction and excessive thermal expansion – the latter could cause compressor damage by axially displacing the input shaft. Make sure that keys are in proper alignment with key-ways on hubs. ·...
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Coupling Hub Installation: · Have coupling installation tool part number CC1026209 available – contact Gardner Denver for sourcing details. · Assemble tool kit components onto coupling hub as shown on Figure 8-4.
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.
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.
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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 seals should be inspected for wear and tear signs: 1. Be sure the unit is completely off and oil sump is depressurized. Disconnect, lockout and tagout power supply to the compressor package.
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 separator. Figure 11- 1 – PRESSURE RELIEF VALVE 13-18-609 Page 72 11-1...
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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.
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.
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.
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SECTION 14 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter) – Operating conditions determine frequency of service. See “Air Filter”, Section 7. Package Inlet Filters – Operating conditions determine frequency of service. See “Air Filter”, Section 7. Motor Lubrication – See “Installation”, Section 2. Every 8 Hours Operation Check air/oil reservoir oil level, add oil if required.
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SERVICE CHECK LIST : Every 4000 Hours Operation or 12 Months Replace Air/Oil Separator, operating conditions determine the frequency of service. The air/oil separator will need to be changed as indicated by the Controller, every 4000 hours or every year, whichever occurs first.
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Maintenance Schedule Check air/oil reservoir oil level Check operation of the machine, is it loading and unloading properly Check discharge pressure and temperature Check control panel for advisory text messages Inspect, Clean if necessary Cooler / Fan Replace oil filter element Replace Control Box Filter (if applicable) Replace package enclosure filter pad (if applicable) Replace air filter element...
Maintenance Schedule Check air/oil reservoir oil level Check operation of the machine, is it loading and unloading properly Check discharge pressure and temperature Check control panel for advisory text messages Inspect, Clean if necessary Cooler / Fan Replace oil filter element Control Box Filter (if applicable) Replace cool air inlet filter pad (if applicable) Replace air filter element...
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...
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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 slowly long distributor. Minimum Pressure/Check Valve Repair or replace.
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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.
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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.
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HR Series 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.
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