Gardner Denver VS200-250B Operating And Service Manual
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Gardner Denver VS200-250B Operating And Service Manual

Variable speed single stage stationary base-mounted compressor
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13-18-614
Version: 00
Nov 30, 2018
VARIABLE SPEED
SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AirSmart CONTROLLER
VS200-250B
200, 250kW
60HZ
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver VS200-250B

  • Page 1 13-18-614 Version: 00 Nov 30, 2018 VARIABLE SPEED SINGLE STAGE STATIONARY BASE-MOUNTED COMPRESSOR AirSmart CONTROLLER VS200-250B 200, 250kW 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 ........... 51 Oil System Air Flow In The Compressor System ....8 Addition Of Oil Between Changes ....39 Air-Cooled Units, Location ....... 12 Compressor ..........37 Auxiliary Air Receiver ........14 Draining And Cleaning ......... 40 Moisture ............

  • 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

    Figure 1-2 – PACKAGE ILLUSTRATION (AIR-COOLED) – External Details 300CGG804-01 (Ref. Drawing) Page 1 of 2...

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

    Figure 1-3 – PACKAGE ILLUSTRATION (AIR-COOLED) – Internal Details 300CGG804-01 (Ref. Drawing) Page 2 of 2...

  • 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 OPTIONAL MOISTURE SEPARATOR/TRAP – The unit can be provided with an optional stand-alone combination moisture separator and trap that is field-installed downstream of the aftercooler. 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 4-1 through Figure 4-10, pages 29 through 36 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 A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the Plus and Minus buttons to change its value. Use the Right and Left 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.
  • 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. 13-18-614 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

    313CGG810-A (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 FUSE HOLDER FUSE FUSE BLOCK FUSE RELAY TERMINAL BLOCK TERMINAL BLOCK GROUND BLOCK GROUND BLOCK...
  • Page 27 Heat Exchanger Fan/Motor and Starter - Three (3) 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 Ball Valve – Oil Drain (N) - This device allows the drainage of the oil charge held in the reservoir during oil change operation. 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);...

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

    Figure 4-2 – PIPING AND INSTRUMENTATION ILLUSTRATION 300CGG797-01 (Ref. Drawing)

  • Page 30: Figure 4-3 - Wiring Diagram - (Air-Cooled) Single-Stage Vs200 - Vs250 Control

    300CGG546-D (Ref. Drawing Page 1 of 4 Figure 4-3 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS200 – VS250 Control...

  • Page 31: Figure 4-4 - Wiring Diagram - (Air Cooled) Single Stage Vs200 - Vs250 Control

    300CGG546-D (Ref. Drawing) Page 2 of 4 Figure 4-4 – WIRING DIAGRAM - (AIR COOLED) Single Stage VS200 – VS250 Control...

  • Page 32: Figure 4-5 - Wiring Diagram - (Air Cooled) Single-Stage Vs200 - Vs250 Control

    300CGG546-D (Ref. Drawing) Page 3 of 4 Figure 4-5 – WIRING DIAGRAM – (AIR COOLED) Single-Stage VS200 – VS250 Control...

  • Page 33: Figure 4-6 - Wiring Diagram - (Air Cooled) Single-Stage Vs200 - Vs250 Control

    300CGG546-D (Ref. Drawing) Page 4 of 4 Figure 4-6 – WIRING DIAGRAM – (AIR COOLED) Single-Stage VS200 – VS250 Control...

  • Page 34: Figure 4-7 - Wiring Diagram - (Water Cooled) Single Stage Vs200 - Vs250 Control

    301CGG546-03 (Ref. Drawing) Page 1 of 4 Figure 4-7 – WIRING DIAGRAM – (WATER COOLED) Single Stage VS200 – VS250 Control...

  • Page 35: Figure 4-8 - Wiring Diagram - (Water-Cooled) Single-Stage Vs200 - Vs250 Control

    301CGG546-03 (Ref. Drawing) Page 2 of 4 Figure 4-8 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS200 – VS250 Control...

  • Page 36: Figure 4-9 - Wiring Diagram - (Water-Cooled) Single-Stage Vs200 - Vs250 Control

    301CGG546-03 (Ref. Drawing) Page 3 of 4 Figure 4-9 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS200 – VS250 Control...

  • Page 37: Figure 4-10 - Wiring Diagram - (Water-Cooled) Single-Stage Vs200 - Vs250 Control

    301CGG546-03 (Ref. Drawing) Page 4 of 4 Figure 4-10 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS200 – VS250 Control...

  • Page 38: 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 39: 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 40: 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 41 (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 42: Figure 5-3 - Thermostatic Valve Element

    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 43: Figure 5-4 - Pressure Dew Point Of Compressed Air

    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 44 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 45: Figure 5-5 - Changing Oil Coalescing Element

    Figure 5-5 – CHANGING OIL COALESCING ELEMENT Oil Coalescing Element Service – Use the following procedures to replace or inspect the element: Be sure the unit is completely off and that oil sump is depressurized. Disconnect, lockout and tagout power supply to the compressor package. Remove bolts holding the oil sump cover and lift the cover away.

  • Page 46: 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 47: Figure 6-1 - Air Flow Chart

    5270 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 48: Figure 6-2 - 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 49: Figure 6-3 - Water Control Valve

    It is strongly recommended that a reputable, local firm be contracted to evaluate the quality of water available and recommend corrective and/or preventive steps to meet our requirements. Automatic restarting or electrical shock can cause injury or death. Disconnect, lockout and tagout package from the power supply. AXIAL COOLING FANS 1.

  • Page 50: Figure 6-4 - Water Separator And Drain (Optional)

     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 51: 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 52: 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 53 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.                 ...

  • Page 54: 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 55: Figure 8-2 - Coupling Element

     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. ...
  • Page 56  Attached lifting eyelets on two (2) compressor and one (1) adaptor housing top-side locations.  Remove [lower] access panel on compressor-side of the enclosure, maneuver lifting arm (e.g., fork- lift blade) above compressor, and attached appropriate chains or straps between the lifting eyelets and the lifting arm.
  • Page 57 Contact Gardner Denver for further instructions. Coupling Hub Installation:  Have coupling installation tool part number CC1030337 available – contact Gardner Denver for sourcing details.  Assemble tool kit components onto coupling hub. The motor hub is attached to the tool head (2) via strong magnets imbedded in the head itself, and the hub/tool assembly can be handled via the provided arms (1) during hub hearting or installation.

  • Page 58: Figure 8-4 - Coupling Removal Tool (2-Jaws Type Shown)

    Figure 8-4 – COUPLING REMOVAL TOOL (2-JAWS TYPE SHOWN) CC1030337-B Ref. Drawing Figure 8-5 – COUPLING HUB INSTALLATION TOOL 13-18-614 Page 57...

  • Page 59: 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 60: 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 61 3. Close (when provided) valve isolating compressor package from air system. 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 62: 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 13-18-614 Page 61...
  • Page 63 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 64: 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 65: 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 66 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.
  • Page 67 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.
  • Page 68 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 app.) Replace package enclosure filter pad (if app.) Replace air filter element...

  • Page 69: Section 14, Maintenance Schedule

    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 app.) Replace cool air inlet filter pad (if app.) Replace air filter element...

  • Page 70: 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 71 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 72 SYMPTOM POSSIBLE CAUSE REMEDY Air demand exceeds supply Make sure air demand matches compressor specifications for flow and pressure. See “Oil Carryover” in this section. Excessive oil Oil separation malfunction consumption Oil leaks at fittings and gaskets Detect and correct oil leaks. Shaft seal leaking Inspect or replace shaft seal.
  • Page 73 Ruptured oil separator Replace element. element. Loose assembly Tighten all fittings and gaskets. Foam caused by use of Use Gardner Denver AEON incorrect oil lubrication only. Minimum pressure valve Repair or replace. Inspect, adjust or malfunction – discharge replace regulator.
  • Page 74 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.
  • Page 76 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2018 Gardner Denver, Inc. Printed in U.S.A.

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