Gardner Denver AirSmart VS45-70C Operating And Service Manual
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Gardner Denver AirSmart VS45-70C Operating And Service Manual

Gardner Denver AirSmart VS45-70C Operating And Service Manual

Variable speed single stage stationary base-mounted compressor
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13-18-611
Version: 00
Dec 3, 2018
VARIABLE SPEED
SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AirSmart CONTROLLER
VS45-70C
45-50-70kW
60HZ
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver AirSmart VS45-70C

  • Page 1 13-18-611 Version: 00 Dec 3, 2018 VARIABLE SPEED SINGLE STAGE STATIONARY BASE-MOUNTED COMPRESSOR AirSmart CONTROLLER VS45-70C 45-50-70kW 60HZ OPERATING AND SERVICE MANUAL...

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

    3. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.

  • 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/Remanufactured Airends ..............1 Warning – Prohibition – Mandatory Label Information .................. 1 Safety Precautions ............................3 Index ................................

  • Page 7: Index

    INDEX Air Filter, Section 7 ........... 61 Addition Of Oil Between Changes ....47 Air Flow In The Compressor System ....7 Compressor ..........46 Air-Cooled Units, Location ....... 13 Draining And Cleaning ......... 48 Auxiliary Air Receiver ........15 Moisture ............

  • Page 8: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ........................7 Figure 1-2 – Package Illustration (Air-Cooled) – External Details ..............8 Figure 1-3 – Package Illustration (Water-Cooled) – External Details ............10 Figure 2-1 – Typical Compressor Room ..................... 13 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

    302CGD804-D (Ref. Drawing) Page 1 of 2 Figure 1-2 – PACKAGE ILLUSTRATION (AIR-COOLED) – External Details...
  • Page 11 302CGD804-D (Ref. Drawing) Page 2 of 2...

  • Page 12: Figure 1-3 - Package Illustration (Water-Cooled) - External Details

    303CGD804-C (Ref. Drawing) Page 1 of 2 Figure 1-3 – PACKAGE ILLUSTRATION (WATER-COOLED) – External Details...
  • Page 13 303CGD804-C (Ref. Drawing) Page 2 of 2...

  • Page 14: 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 15: 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 16 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 17 Note that 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 18: 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 19: 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 20: 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 21 Figure 4-6, for general wiring diagrams and Section 2, for installation instructions. Make sure to check the wiring of the optional compressed air dryer, as it is serviced by an independent electrical power feed. 5. Grounding - Equipment must be properly grounded according to Gardner Denver Guidelines for proper wiring, grounding and feed power conditioning.

  • Page 22: Figure 3-1 - Motor Fan Rotation Check

     Use Controller “JOG MODE” to bump heat exchanger cooling fan. Proper rotation shall be counterclockwise facing rear of fan drive motor.  Use Controller “JOG MODE” to bump main motor cooling fan. Proper rotation is achieved when cooling air is discharged over the main motor body or when fan rotation matches that indicated by the arrow decal affixed to the fan hub, as viewed via the serrated cutout on the fan shroud See Figure 3-1 for details.

  • Page 23: Operation Adjustment

    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 24 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 25 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 26                         Never paint, lubricate or alter a pressure relief valve. Do not plug vent or restrict discharge. Operation of the unit with improper pressure relief valve setting can result in severe personal injury or machine damage.

  • Page 27: 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 28: Figure 4-1 - Electrical Enclosure Hardware

    308CGD810-E (Ref. Drawing) ASSEMBLED CONTROL BOX WITH EMC FILTER............ASSEMBLED CONTROL BOX WITHOUT EMC FILTER ..........Ref. No. Name of Part AIRSMART CONTROL BOX ..................... GRP-DRIVE (VS45-US) ..................... CABLE ASSEMBLY ......................SPLITTER CABLE ......................SCREW TERMINAL PLUG ....................CONTROL BOX ENCLOSURE ..................ELECTRICAL FILTER......................
  • Page 29 Heat Exchanger Fan/Motor and Starter - The combination axial fan/motor (two units on VS50 and VS70, one unit on VS45) 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.
  • Page 30 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 31: Figure 4-2 - Piping And Instrumentation Illustration

    Figure 4-2 – PIPING AND INSTRUMENTATION ILLUSTRATION 300CGD797-B (Ref. Drawing)

  • Page 32: Figure 4-3 - Wiring Diagram - (Air-Cooled) 460V - Single-Stage Vs Control

    300CGD546-08 (Ref. Drawing Page 1 of 4 Figure 4-3 – WIRING DIAGRAM – (AIR-COOLED) 460V - Single-Stage VS Control...
  • Page 33 300CGD546-08 (Ref. Drawing) Page 2 of 4...
  • Page 34 300CGD546-08 (Ref. Drawing) Page 3 of 4...
  • Page 35 300CGD546-08 (Ref. Drawing) Page 4 of 4...

  • Page 36: Figure 4-4 - Wiring Diagram - (Water-Cooled) 460V - Single-Stage Vs Control

    301CGD546-G (Ref. Drawing) Page 1 of 4 Figure 4-4 – WIRING DIAGRAM – (WATER-COOLED) 460V - Single-Stage VS Control...
  • Page 37 301CGD546-G (Ref. Drawing) Page 2 of 4...
  • Page 38 301CGD546-G (Ref. Drawing) Page 3 of 4...
  • Page 39 301CGD546-G (Ref. Drawing) Page 4 of 4...

  • Page 40: Figure 4-5 - Wiring Diagram - (Air-Cooled) 575V - Single Stage Vs Control

    302CGD546-05 (Ref. Drawing) Page 1 of 4 Figure 4-5 – WIRING DIAGRAM – (AIR-COOLED) 575V – Single Stage VS Control...
  • Page 41 302CGD546-05 (Ref. Drawing) Page 2 of 4...
  • Page 42 302CGD546-05 (Ref. Drawing) Page 3 of 4...
  • Page 43 302CGD546-05 (Ref. Drawing) Page 4 of 4...

  • Page 44: Figure 4-6 - Wiring Diagram - (Water-Cooled) 575V - Single Stage Vs Control

    303CGD546-B (Ref. Drawing) Page 1 of 4 Figure 4-6 – WIRING DIAGRAM – (WATER-COOLED) 575V – Single Stage VS Control...
  • Page 45 303CGD546-B (Ref. Drawing) Page 2 of 4...
  • Page 46 303CGD546-B (Ref. Drawing) Page 3 of 4...
  • Page 47 303CGD546-B (Ref. Drawing) Page 4 of 4...

  • Page 48: 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 49 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 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 9000SP lubricant. The first sample from a new unit should be sent in between 40-100 hours of operation.

  • Page 51: 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 47, for full details. The only exception is that to fill all the empty lines and components (e.g., oil cooler, compressors, and oil filter) a much larger volume of oil will be required.

  • Page 52: Figure 5-3 - Thermostatic Mixing 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 53: 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 54 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 55: 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 body of MPV/sump cover (1).

  • Page 56: Section 6 - Heat Exchangers (Oil, Air)

    SECTION 6 HEAT EXCHANGERS (OIL, AIR) 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 57: Figure 6-1 - Air Flow Chart

    1600 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 58: Figure 6-2 - Cooler Housing Side Covers

    Remove all loose debris and water from cooler box after cleaning process is complete. 7. Re-attach cooler housing side covers with provided fasteners and re-install enclosure door panels. Figure 6-2 – COOLER HOUSING SIDE COVERS Automatic restarting or electrical shock can cause injury or death. Disconnect, lockout and tagout package from the power supply.

  • Page 59: 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 60: 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 61: Figure 6-5 - Water Separator And Drain

    OPTIONAL 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. The optional water separator assembly is shipped loose and must be field-installed by the end user. Note that this device is not used if the optional compressed air dryer is supplied, as the latter’s water separator is employed for this process.
  • Page 62 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 63: 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 64 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 65: 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 66: Figure 8-2 - Coupling Element

    Figure 8-2 – COUPLING ELEMENT 4. For hub-to-shaft interference fit hubs, main drive motor removal is necessary: 300CGD810-B (Ref. Drawing) Figure 8-3 – MOTOR REMOVAL HARDWARE  Remove coupling guard (19) by removing four bolts  Remove two bolts securing (cooling fan) support (27) to base frame (2) ...
  • Page 67 Coupling Hub Installation:  Have coupling installation tool part number CC1021460 available – contact Gardner Denver for sourcing details.  Mount coupling hub unto tool via provided magnets.

  • Page 68: Figure 8-4 - Coupling Removal Tool - Vs40 Model Shown

    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...

  • Page 69: Figure 8-5 - Location Airend Coupling Hub Installation Tool - Vs40 Model Shown

    Figure 8-5 – LOCATION AIREND COUPLING HUB INSTALLATION TOOL Figure 8-6 – LOCATING MOTOR COUPLING HUB INSTALLATION TOOL 13-18-611 Page 67...

  • Page 70: Section 9, Minimum Pressure/Check Valve

    Check internal components in the minimum pressure valve such as seals and seat (Item 2, 3, 4 and 18 in Figure 9-1, page 69) for signs of damage. 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 71: Figure 9-1 - Minimum Discharge Pressure/Check Valve

    5. Remove snap ring on MPV cover, remove cover and gently pry out MPV. 6. Gradually back off nut (7) while keeping bolt (5) from turning until spring pressure is released. Remove MPV internal parts. Inspect and/or replace parts. 7. Re-assemble in reverse order. Figure 9-1 –...

  • Page 72: 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 73: 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 74 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 75: 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 76: 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 77: 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 for air filter details.  Oil Separator Element - Replace when controller displays “CHANGE OIL SEPARATOR ELEMENT”. Refer to Section 5 for oil separator element details.
  • Page 78 Yearly Checks:  Heat Exchangers (air and water-cooled) – Check cooling performance of air and oil cores – see Section 6 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 for test procedure. ...

  • Page 79: 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 80 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 81 SYMPTOM POSSIBLE CAUSE REMEDY 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. High discharge Oil mixing valve stuck on bypass Check 24dcv power feed to servo.
  • Page 82 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 83 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 84 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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