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13-18-603    Page 29 

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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).  Never allow motor to 
reach full speed. 

 
 

 
 
 
 

The compressor unit’s direction of rotation must be checked every time the 
compressor is reconnected to the power supply. 

 
 

8. 

System Pressure

 

– For your convenience, the following excerpt from the Controller Manual           

13-17-600 is presented to assist in programming the system pressure: 
 
 

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. 

 

·

 

Setting the Target Pressure 

 
The Target Pressure setting is used to set the operating point of the compressor.  To make any 
adjustments in the operation of the compressor, the machine must be stopped and in the Ready 

mode.  Stop the compressor by pressing the Stop/Reset 

 button.  The front panel display 

should read 

“READY” on line 3. 

 
 
 
 
 
 

C

C

C

A

A

A

U

U

U

T

TT

I

II

O

O

O

N

N

N

 

  

C

C

C

A

A

A

U

U

U

T

TT

I

II

O

O

O

N

N

N

 

  

0  PSI                           75°F 

10  HRS          AUTOMATIC 

READY 

NO  SERVICE  ADVISORY 

Summary of Contents for AirSmart VS25A

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

Page 2: ...unit 3 A full line of factory tested AEON compressor lubricants specifically formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the necessary parts to simplif...

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: ...Axial Cooling Fans 88 Section 7 Air Filter 95 Section 8 Shaft Coupling 97 Section 9 Minimum Pressure Check Valve 102 Section 10 Inlet Control Valve 104 Section 11 Pressure Relief Valve 106 Section 12...

Page 7: ...Pressure Check Valve Section 9 103 Moisture Separator Trap 24 Oil Filter 83 Oil Reservoir Drain 23 Oil System Addition Of Oil Between Changes 81 Compressor 80 Draining And Cleaning 82 Moisture 81 Oil...

Page 8: ...nstrumentation Illustration 38 Figure 4 3 Wiring Diagram Air Cooled 460 Volt Single Stage VS Control 39 Figure 4 4 Wiring Diagram Water Cooled 460 Volt Single Stage VS Control 43 Figure 4 5 Wiring Dia...

Page 9: ...olume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volume reduction and pressure continues to increase until the a...

Page 10: ...13 18 603 Page 9 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED External Details 300CGC804 B Ref Drawing Page 1 of 2...

Page 11: ...13 18 603 Page 10 Figure 1 3 PACKAGE ILLUSTRATION AIR COOLED Internal Details 300CGC804 B Ref Drawing Page 2 of 2...

Page 12: ...13 18 603 Page 11 Figure 1 4 OUTLINE UNIT PKG VS25 40 AIR COOLED WITH DRYER External Details 301CGC804 A Ref Drawing Page 1 of 2...

Page 13: ...13 18 603 Page 12 FIGURE 1 5 OUTLINE UNIT PKG VS25 40 AIR COOLED WITH DRYER Internal Details 301CGC804 A Ref Drawing Page 2 of 2...

Page 14: ...13 18 603 Page 13 Figure 1 6 OUTLINE UNIT PKG VS25 40 WATER COOLED STANDARD External Details 302CGC804 A Ref Drawing Page 1 of 2...

Page 15: ...13 18 603 Page 14 Figure 1 7 OUTLINE UNIT PKG VS25 40 WATER COOLED STANDARD Internal Details 302CGC804 A Ref Drawing Page 2 of 2...

Page 16: ...13 18 603 Page 15 Figure 1 8 OUTLINE UNIT PKG VS25 40 WATER COOLED WITH DRYER External Details 303CGC804 A Ref Drawing Page 1 of 2...

Page 17: ...13 18 603 Page 16 Figure 1 9 OUTLINE UNIT PKG VS25 40 WATER COOLED WITH DRYER Internal Details 303CGC804 A Ref Drawing Page 2 of 2...

Page 18: ...13 18 603 Page 17 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...

Page 19: ...13 18 603 Page 18 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...

Page 20: ...13 18 603 Page 19 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...

Page 21: ...13 18 603 Page 20 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...

Page 22: ...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 23: ...rate efficiently please refer to Section 6 Fig 6 1 page 89 of this manual for detailed instructions on the operation and maintenance of air cooled heat exchangers including minimum heat exchanger cool...

Page 24: ...filter is 6 9 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...

Page 25: ...compressor package is not suitable for relocation as its housing assembly is an integral part of the enclosure sheet metal components See LOCATION page 21 comments on this section of the manual for du...

Page 26: ...imum 90 C wire NOTES Model Input Package Amps NEC Package Copper Wire Copper Wire Voltage Estimated Amps at 30 C Sized at 40 C Sized at 40 C VS 25 460 54 22 65 97 4 4 VS 30 200 160 55 198 05 4 0 3 0 V...

Page 27: ...as the compressor GD Model Volts VFD HP RATINGS Max KVA VS25 460V 30 400 VS30 200V 50 450 VS30 230V 50 450 VS30 460V 40 450 VS30 575V 50 450 VS40 200V 60 750 VS40 230V 60 750 VS40 460V 60 750 VS40 57...

Page 28: ...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 29: ...ired See Figure 4 3 thru Figure 4 4 pages 40 thru 43 for general wiring diagrams and Section 2 page 21 for installation instructions Make sure to check the wiring of the optional compressed air dryer...

Page 30: ...system pressure 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...

Page 31: ...e 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...

Page 32: ...ully 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 Press the red STOP...

Page 33: ...y or death Disconnect lockout and tagout the unit from the power supply and any other circuits before servicing unit When the pressure relief valve opens a stream of high velocity air is released resu...

Page 34: ...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 35: ...13 18 603 Page 34 Figure 4 1 ELECTRICAL ENCLOSURE HARDWARE 310CGC810 D Ref Drawing...

Page 36: ...R SUPPLY 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 TE...

Page 37: ...block off the compressor intake This prevents trapped air and oil within the compressor from exiting through the inlet filter See SECTION 10 page 105 for further details Minimum Discharge Pressure Che...

Page 38: ...emporarily stopped due to line pressure reaching unload pressure the blow down valve remains energized closed and the air oil reservoir remains pressurized When compressor operation is halted e g by u...

Page 39: ...13 18 603 Page 38 Figure 4 2 PIPING AND INSTRUMENTATION ILLUSTRATION 300CGC797 A Ref Drawing...

Page 40: ...13 18 603 Page 39 Figure 4 3 WIRING DIAGRAM AIR COOLED 460 VOLT Single Stage VS Control 300CGC546 E Ref Drawing Page 1 of 4...

Page 41: ...13 18 603 Page 40 300CGC546 E Ref Drawing Page 2 of 4...

Page 42: ...13 18 603 Page 41 300CGC546 E Ref Drawing Page 3 of 4...

Page 43: ...13 18 603 Page 42 300CGC546 E Ref Drawing Page 4 of 4...

Page 44: ...13 18 603 Page 43 Figure 4 4 WIRING DIAGRAM WATER COOLED 460 VOLT Single Stage VS Control 301CGC546 E Ref Drawing Page 1 of 4...

Page 45: ...13 18 603 Page 44 301CGC546 E Ref Drawing Page 2 of 4...

Page 46: ...13 18 603 Page 45 301CGC546 E Ref Drawing Page 3 of 4...

Page 47: ...13 18 603 Page 46 301CGC546 E Ref Drawing Page 4 of 4...

Page 48: ...13 18 603 Page 47 Figure 4 5 WIRING DIAGRAM AIR COOLED 200 230 VOLT VS30 302CGC546 C Ref Drawing Page 1 of 4...

Page 49: ...13 18 603 Page 48 302CGC546 C Ref Drawing Page 2 of 4...

Page 50: ...13 18 603 Page 49 302CGC546 C Ref Drawing Page 3 of 4...

Page 51: ...13 18 603 Page 50 302CGC546 C Ref Drawing Page 4 of 4...

Page 52: ...13 18 603 Page 51 Figure 4 6 WIRING DIAGRAM AIR COOLED 575 VOLT VS30 303CGC546 C Ref Drawing Page 1 of 4...

Page 53: ...13 18 603 Page 52 303CGC546 C Ref Drawing Page 2 of 4...

Page 54: ...13 18 603 Page 53 303CGC546 C Ref Drawing Page 3 of 4...

Page 55: ...13 18 603 Page 54 303CGC546 C Ref Drawing Page 4 of 4...

Page 56: ...13 18 603 Page 55 Figure 4 7 WIRING DIAGRAM AIR COOLED 200 230 VOLT VS40 304CGC546 C Ref Drawing Page 1 of 4...

Page 57: ...13 18 603 Page 56 304CGC546 C Ref Drawing Page 2 of 4...

Page 58: ...13 18 603 Page 57 304CGC546 C Ref Drawing Page 3 of 4...

Page 59: ...13 18 603 Page 58 304CGC546 C Ref Drawing Page 4 of 4...

Page 60: ...13 18 603 Page 59 Figure 4 8 WIRING DIAGRAM AIR COOLED 575 VOLT VS40 305CGC546 C Ref Drawing Page 1 of 4...

Page 61: ...13 18 603 Page 60 305CGC546 C Ref Drawing Page 2 of 4...

Page 62: ...13 18 603 Page 61 305CGC546 C Ref Drawing Page 3 of 4...

Page 63: ...13 18 603 Page 62 305CGC546 C Ref Drawing Page 4 of 4...

Page 64: ...13 18 603 Page 63 Figure 4 9 WIRING DIAGRAM WATER COOLED 200 230 VOLT VS 30 306CGC546 C Ref Drawing Page 1 of 4...

Page 65: ...13 18 603 Page 64 306CGC546 C Ref Drawing Page 2 of 4...

Page 66: ...13 18 603 Page 65 306CGC546 C Ref Drawing Page 3 of 4...

Page 67: ...13 18 603 Page 66 306CGC546 C Ref Drawing Page 4 of 4...

Page 68: ...13 18 603 Page 67 Figure 4 10 WIRING DIAGRAM WATER COOLED 575 VOLT VS30 307CGC546 C Ref Drawing Page 1 of 4...

Page 69: ...13 18 603 Page 68 307CGC546 C Ref Drawing Page 2 of 4...

Page 70: ...13 18 603 Page 69 307CGC546 C Ref Drawing Page 3 of 4...

Page 71: ...13 18 603 Page 70 307CGC546 C Ref Drawing Page 4 of 4...

Page 72: ...13 18 603 Page 71 Figure 4 11 WIRING DIAGRAM WATER COOLED 200 230 VOLT VS40 308CGC546 C Ref Drawing Page 1 of 4...

Page 73: ...13 18 603 Page 72 308CGC546 C Ref Drawing Page 2 of 4...

Page 74: ...13 18 603 Page 73 308CGC546 C Ref Drawing Page 3 of 4...

Page 75: ...13 18 603 Page 74 308CGC546 C Ref Drawing Page 4 of 4...

Page 76: ...13 18 603 Page 75 Figure 4 12 WIRING DIAGRAM WATER COOLED 575 VOLT VS40 309CGC546 C Ref Drawing Page 1 of 4...

Page 77: ...13 18 603 Page 76 309CGC546 C Ref Drawing Page 2 of 4...

Page 78: ...13 18 603 Page 77 309CGC546 C Ref Drawing Page 3 of 4...

Page 79: ...13 18 603 Page 78 309CGC546 C Ref Drawing Page 4 of 4...

Page 80: ...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 81: ...g valve is malfunctioning Contact your authorized Gardner Denver factory distributor for assistance OIL SITE GLASS This device indicates oil level within the air oil reservoir Check oil level only wit...

Page 82: ...t 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 impurities To...

Page 83: ...s and components and achieve normal oil level 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...

Page 84: ...ating compressor package 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 grea...

Page 85: ...in its modulating range between extremes of valve position a compressor discharge temperature deviation exceeding 10 F from the calculated value will trigger an alarm display to caution that a system...

Page 86: ...oler compressor casings and piping Air oil final separation The aerosols and compressed air streams are led to the upper portion of the sump where the coalescing element resides The fine droplets of o...

Page 87: ...sure differential across the coalescing element A pressure differential of 8 psi will trigger a service advisory to change the element and a pressure differential of 15 psi will initiate a system shut...

Page 88: ...ew 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 necessary 7 Wipe the MPV sump cover se...

Page 89: ...Disconnect 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 EXC...

Page 90: ...the air cooled package requires the combined total of the heat exchanger plus the enclosure ventilation flow rates which include motor ventilation and compressor intake Furthermore when package locati...

Page 91: ...arge before beginning maintenance 2 Exercise caution around compressor parts after stopping the package for service Fans and coolers will be hot after stopping the compressor 3 Remove access panels an...

Page 92: ...the coolers may be fouled due to low water flow velocities resulting in poor cooler performance and shortened operational life All the required hardware mechanical and electrical connections have bee...

Page 93: ...ions will make the valve inoperative Never attempt to change capillary length Excess capillary tube should be carefully coiled and placed so that damage will not occur with normal maintenance or traff...

Page 94: ...IN Figure 6 6 WATER SEPARATOR AND DRAIN DETAILS 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 evacu...

Page 95: ...4 Unscrew drain valve 1 from isolation valve 5 5 Unscrew collection bowl 3 from separator housing 4 6 Inspect and clean collection bowl and sealing o ring 7 Reinstall in reverse order If the vent adap...

Page 96: ...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 97: ...inst 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 clean if neces...

Page 98: ...coupling The coupling assembly requires no lubrication Coupling Element Rotex size 38 Inspection and Replacement 1 Disconnect lockout and tagout power supply to the compressor package 2 Remove fasten...

Page 99: ...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 100: ...he motor adaptor housing is still attached to the compressor Coupling Hub Installation Have coupling installation tool part number CC1021459 available contact Gardner Denver for sourcing details Mount...

Page 101: ...s grip on the shaft surface Secure a suitable heating source and apply heat the hub body while slowly rotating the shaft by means of the removal tool handle Once the hub body has expanded enough the p...

Page 102: ...13 18 603 Page 101 Figure 8 4 LOCATING AIREND COUPLING HUB INSTALLATION TOOL VS40 MODEL SHOWN Figure 8 5 LOCATING MOTOR COUPLING HUB INSTALLATION TOOL VS40 MODEL SHOWN...

Page 103: ...ly disconnect the power may result in personal injury or death NOTICE Working spring within valve body is under tension Failure to relieve spring tension gradually may cause serious injury upon cap re...

Page 104: ...13 18 603 Page 103 Figure 9 1 MINIMUM DISCHARGE PRESSURE CHECK VALVE...

Page 105: ...to the underside of the poppet forcing it upward closed and block off the compressor intake The internal blow off valve is also forced closed by the incoming air signal Figure 10 1 INLET CONTROL VALVE...

Page 106: ...al 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 Inspect seals Items 18 19 for wear and tear Replace...

Page 107: ...s 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 Fa...

Page 108: ...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 109: ...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 latched access door lo...

Page 110: ...ake 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 easier...

Page 111: ...pressures temperatures speeds load levels etc helps identify when abnormal operation occurs AirSmart Controller Messages and Alarms Acknowledge the presence of an abnormal condition and take action t...

Page 112: ...ed cleaning procedures Pressure Relief Valve Check operation of device see Section 11 page 107 for test procedure Motor Lubrication Inspect motors for abnormal noise and vibration Grease lubricate per...

Page 113: ...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 114: ...ction in control tubing 3 Inspect and clean 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...

Page 115: ...ooler 4 Clogged oil lines 4 Inspect and clear oil lines 5 Low oil level 5 Add oil to proper level High discharge air oil Temperature air cooled cores 1 Dirty or clogged cooler outer surfaces 1 Inspect...

Page 116: ...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 117: ......

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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