Gardner Denver AirSmart VS20A User Manual Download

Page: 1 / 77

13-18-604

Version: 10

April 6, 2010

VARIABLE SPEED

SINGLE STAGE

STATIONARY BASE-MOUNTED

COMPRESSOR

AIRSMART

™

CONTROLLER

VS20A

20kW

60HZ

OPERATING AND

SERVICE MANUAL

Summary of Contents for AirSmart VS20A

Page 1: ...13 18 604 Version 10 April 6 2010 VARIABLE SPEED SINGLE STAGE STATIONARY BASE MOUNTED COMPRESSOR AIRSMART CONTROLLER VS20A 20kW 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ...are factory trained and skilled in compressor maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local au...

Page 3: ...mical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriate...

Page 4: ...low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Li...

Page 5: ...r oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any...

Page 6: ...trols 42 Section 6 Heat Exchangers Oil Air 50 Section 7 Air Filter 54 Section 8 Shaft Coupling 56 Section 9 Minimum Pressure Check Valve 60 Section 10 Inlet Control Valve 62 Section 11 Pressure Relief...

Page 7: ...4 68 Minimum Pressure Check Valve Section 9 60 Moisture Separator Trap 15 Oil Filter 45 Oil Reservoir Drain 14 Oil System Addition Of Oil Between Changes 43 Compressor 42 Draining And Cleaning 44 Mois...

Page 8: ...0 Volt 34 Figure 4 8 Wiring Diagram Air Cooled Single Stage VS Control 200 230 Volt 35 Figure 4 9 Wiring Diagram Air Cooled Single Stage VS Control 200 230 Volt 36 Figure 4 10 Wiring Diagram Air Coole...

Page 9: ...of the main rotor lobe enters the gate rotor groove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Vo...

Page 10: ...13 18 604 Page 8 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED External Details 300CGB804 A Ref Drawing Page 1 of 2...

Page 11: ...13 18 604 Page 9 Figure 1 3 PACKAGE ILLUSTRATION AIR COOLED Internal Details 300CGB804 A Ref Drawing Page 2 of 2...

Page 12: ...13 18 604 Page 10 Figure 1 4 OUTLINE UNIT PKG AIR COOLED WITH DRYER External Details 301CGB804 A Ref Drawing Page 1 of 2...

Page 13: ...13 18 604 Page 11 Figure 1 5 OUTLINE UNIT PKG AIR COOLED WITH DRYER Internal Details 301CGB804 A Ref Drawing Page 2 of 2...

Page 14: ...eyebolts or lugs provided on the motors are for lifting the motors only and should not be used to lift any additional weight All eyebolts must be securely tightened When lifting the motors the liftin...

Page 15: ...se from nearby machinery Air Cooled Units A combination oil air cooler is supplied as standard equipment on all air cooled packages The heat exchangers require sufficient cooling air flow to operate e...

Page 16: ...er is 10 above the floor level If this is not sufficient to conveniently drain the oil other methods are 1 Elevate the compressor unit on a suitable structure to obtain the desired drain height 2 Cons...

Page 17: ...s factory wired and piped for the control system specified INLET LINE The air filter assembly used in the VS compressor package is not suitable for relocation as its housing assembly is an integral pa...

Page 18: ...e electrical power wires serving the compressor package Refer to Figure 2 3 for a summary of maximum package current consumption values Package Size Voltage Maximum Current Draw VS20 200 100 Amps VS20...

Page 19: ...sor package could result in injury or death Install ground wiring in accordance with the National Electrical Code and any applicable local codes MOTOR LUBRICATION Long time satisfactory operation of a...

Page 20: ...shipped it is filled with Gardner Denver AEON 9000SP lubricating coolant suitable for the first 8000 hours under normal operating conditions N N NO O OT T TI I IC C CE E E Regular maintenance and rep...

Page 21: ...and Section 2 page 13 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 6 Grounding Equipment m...

Page 22: ...ler 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 ordere...

Page 23: ...rget 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 p...

Page 24: ...ir pressure above the maximum stamped on the unit nameplate 9 Operating Mode Refer to Controller Manual 13 17 600 for more detailed information on the control system 10 Enclosure Check for damaged pan...

Page 25: ...or all installation operation and maintenance instructions DAILY CHECK Refer to Section 14 page 69 Maintenance Schedule STOPPING THE UNIT Press STOP RESET button The oil reservoir will automatically b...

Page 26: ...13 18 604 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...

Page 27: ...ave been selected into the controller compressor operation may commence For your convenience a Quick Start excerpt from the controller manual is shown on Section 3 8 Press the red STOP RESET button to...

Page 28: ...13 18 604 Page 26 Figure 4 1 ELECTRICAL ENCLOSURE HARDWARE 301CGB810 C Ref Drawing...

Page 29: ...LY 12 POWER DISTRIBUTION BLOCK 13 TERMINAL LUG not shown 14 FUSE HOLDER 15 FUSE 16 FUSE BLOCK 17 FUSE 18 RELAY 19 TERMINAL BLOCK 20 TERMINAL BLOCK 21 GROUND BLOCK not shown 23 GROUND BLOCK 24 TERMINAL...

Page 30: ...nts the poppet internals to atmosphere allowing it to open normal state When the compressor is stopped a sump pressure signal is fed to the poppet internals forcing it closed and preventing trapped ai...

Page 31: ...aching unload pressure the blow down valve remains energized closed and the air oil reservoir remains pressurized When compressor operation is halted e g by use of the red STOP controller button by lo...

Page 32: ...13 18 604 Page 30 Figure 4 3 WIRING DIAGRAM AIR COOLED Single Stage VS Control 460 VOLT 300CGB546 F Ref Drawing Page 1 of 4...

Page 33: ...13 18 604 Page 31 Figure 4 4 WIRING DIAGRAM AIR COOLED Single Stage VS Control 460 VOLT 300CGB546 F Ref Drawing Page 2 of 4...

Page 34: ...13 18 604 Page 32 Figure 4 5 WIRING DIAGRAM AIR COOLED Single Stage VS Control 460 VOLT 300CGB546 F Ref Drawing Page 3 of 4...

Page 35: ...13 18 604 Page 33 Figure 4 6 WIRING DIAGRAM AIR COOLED Single Stage VS Control 460 VOLT 300CGB546 F Ref Drawing Page 4 of 4...

Page 36: ...13 18 604 Page 34 Figure 4 7 WIRING DIAGRAM AIR COOLED Single Stage VS Control 200 230 VOLT 301CGB546 C Ref Drawing Page 1 of 4...

Page 37: ...13 18 604 Page 35 Figure 4 8 WIRING DIAGRAM AIR COOLED Single Stage VS Control 200 230 VOLT 301CGB546 C Ref Drawing Page 2 of 4...

Page 38: ...13 18 604 Page 36 Figure 4 9 WIRING DIAGRAM AIR COOLED Single Stage VS Control 200 230 VOLT 301CGB546 C Ref Drawing Page 3 of 4...

Page 39: ...13 18 604 Page 37 Figure 4 10 WIRING DIAGRAM AIR COOLED Single Stage VS Control 200 230 VOLT 301CGB546 C Ref Drawing Page 4 of 4...

Page 40: ...13 18 604 Page 38 Figure 4 11 WIRING DIAGRAM AIR COOLED Single Stage VS Control 575 VOLT 302CGB546 C Ref Drawing Page 1 of 4...

Page 41: ...13 18 604 Page 39 Figure 4 12 WIRING DIAGRAM AIR COOLED Single Stage VS Control 575 VOLT 302CGB546 C Ref Drawing Page 2 of 4...

Page 42: ...13 18 604 Page 40 Figure 4 13 WIRING DIAGRAM AIR COOLED Single Stage VS Control 575 VOLT 302CGB546 C Ref Drawing Page 3 of 4...

Page 43: ...13 18 604 Page 41 Figure 4 14 WIRING DIAGRAM AIR COOLED Single Stage VS Control 575 VOLT 302CGB546 C Ref Drawing Page 4 of 4...

Page 44: ...bsorbs heat from compression while progressing through the compression chamber and is then discharged back into the oil separation chamber as a mixture of liquids and aerosols oil and gas air Centrifu...

Page 45: ...in the oil it may indicate that the oil mixing valve is malfunctioning Contact your authorized Gardner Denver factory distributor for assistance OIL SIGHT GLASS This device indicates oil level within...

Page 46: ...ould be sent in between 40 100 hours of operation DRAINING AND CLEANING OIL SYSTEM Always drain the complete system Draining when the oil is hot will help to prevent varnish deposits and carry away im...

Page 47: ...and oil filter a much larger volume of oil will be required The VS20 package requires nearly 2 gallons of AEON 9000SP Synthetic Lubricating Coolant to fill all the lines and components and achieve no...

Page 48: ...ge from air system 4 Unscrew counter clockwise the cartridge with adequate tool e g strap wrench and remove 5 Clean wipe and lubricate sealing surface on filter housing with grease 6 Lubricate o ring...

Page 49: ...will trigger an alarm display to caution that a system malfunction is taking place Note that the alarm is not triggered once the valve has reached either end of travel position as oil mixing no longer...

Page 50: ...charge of the package will be lower and will depend on the amount of moisture rejected by the aftercooler This high level of performance will be affected by the following typical offset conditions Con...

Page 51: ...lement for damage Before installing new or old element apply heavy grease to sealing o ring to avoid damage during installation 6 Inspect oil scavenge orifice 3 and strainer 4 for fouling Replace if n...

Page 52: ...ct lockout and tagout package from power supply Automatic restarting or electrical shock can cause injury or death Disconnect lockout and tagout package from the power supply OIL AIR HEAT EXCHANGERS T...

Page 53: ...quires the combined total of the heat exchanger plus the enclosure ventilation flow rates which include motor ventilation and compressor intake Furthermore when package location makes it necessary to...

Page 54: ...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 WATER SEPARATOR...

Page 55: ...rain valve body 1 This allows the safe and quick removal of the drain valve for servicing in case the drain valve malfunctions In case the drain valve is fouled with dirt cleanse the collection bowl a...

Page 56: ...package operation depends on the unrestricted clean supply of fresh air delivered by the air filter In turn the longevity of the filter element depends on the cleanliness of the local environment NOT...

Page 57: ...ner tube against which the element makes a seal Wipe dirt from outer surface if necessary Also visually inspect the matching o ring seal that is bonded to the element for defects and dirt then wipe cl...

Page 58: ...coupling The coupling assembly requires no lubrication Coupling Element Rotex size 28 Inspection and Replacement 1 Disconnect lockout and tagout power supply to the compressor package 2 Remove fasten...

Page 59: ...uld cause compressor damage by axially displacing the input shaft Make sure that keys are in proper alignment with key ways on hubs Figure 8 2 COUPLING ELEMENT 4 For hub to shaft interference fit hubs...

Page 60: ...pulling tool and or heat dilation The recommended steps are based on the assumption that the main motor has been pulled away from the compressor and that the motor adaptor housing is still attached t...

Page 61: ...m it indicates that a heavy interference fit between the hub and the shaft exists and heat dilation must be used to expand the hub and loosen its grip on the shaft surface Secure a suitable heating so...

Page 62: ...vailable 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 compress...

Page 63: ...en sump and bottom of MPV frame 5 Inspect clean and or replace o ring prior to re installation 9 Re install MPV unto sump with provided bolts 10 Adjust nut 13 so that there is a small 05 to 08 between...

Page 64: ...protective shutdowns the 3 way solenoid valve feeds sump air to the underside of the poppet forcing it upward closed and blocking off the compressor intake The internal blow off valve is also forced...

Page 65: ...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 3 Remove lock ring 16 Pull cover...

Page 66: ...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 Fai...

Page 67: ...lief valve has no user serviceable or repairable components However it should be tested for proper operation at least once every year To test the pressure relief valve Raise the system operating press...

Page 68: ...and oil reservoir is depressurized 2 Disconnect lockout and tagout power supply to the compressor package 3 To service intake side filter open access door oil filter side and remove access door locate...

Page 69: ...d make sure that their spring loaded covers are operational 3 Locate the grease fittings provided at each end of the motor top end be aware the one or both may be relocated away from the motor for eas...

Page 70: ...Operational Parameters Maintaining a periodic log of package critical parameters e g pressures temperatures speeds load levels etc helps identify when abnormal operation occurs AirSmart Controller Mes...

Page 71: ...ecommended cleaning procedures Pressure Relief Valve Check operation of device see Section 11 for test procedure Motor Lubrication Inspect motors for abnormal noise and vibration Grease lubricate per...

Page 72: ...and press STOP RESET button to reset 4 Read error message on control panel 4 Take appropriate action See Manual 13 17 600 5 Remote Contact is open 5 Replace switch or jumper 6 Variable Frequency Driv...

Page 73: ...control tubing Compressor starts too slowly 1 Acceleration time in VFD set too long 1 Contact your Gardner Denver distributor 2 Minimum Pressure Check Valve is leaking 2 Repair or replace Compressor i...

Page 74: ...alve coupling Check rotation of ball valve 2 Clogged oil filter 2 Inspect and replace filter 3 Clogged cooler interior 3 Inspect and clear cooler 4 Clogged oil lines 4 Inspect and clear oil lines 5 Lo...

Page 75: ...r 1 Overfilling oil separation vessel 1 Drain excess oil from system 2 Clogged oil return line orifice 2 Inspect and service 3 Clogged oil return line strainer 3 Inspect and service 4 Clogged broken o...

Page 76: ......

Page 77: ...sion 1800 Gardner Expressway Quincy Illinois 62305 Customer Service Department Telephone 800 682 9868 FAX 217 224 7814 Visit our Web Site www gardnerdenver com Sales and Service in all major cities Sp...

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