Gardner Denver VS-11 Operating And Service Manual Download

Page: 1 / 68

13-18-606

Version: 09

March 1, 2011

VARIABLE SPEED

SINGLE STAGE

STATIONARY BASE-MOUNTED

COMPRESSOR

AirSmart

™

CONTROLLER

VS11A

11kW

60HZ

OPERATING AND

SERVICE MANUAL

Summary of Contents for VS-11

Page 1: ...13 18 606 Version 09 March 1 2011 VARIABLE SPEED SINGLE STAGE STATIONARY BASE MOUNTED COMPRESSOR AirSmart CONTROLLER VS11A 11kW 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ...lly formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor Authorized distributor service technicians ar...

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: ...6 Heat Exchangers Oil Air 43 Section 7 Air Filter 47 Section 8 Shaft Coupling 49 Section 9 Minimum Pressure Check Valve 52 Section 10 Inlet Control Valve 54 Section 11 Pressure Relief Valve 56 Sectio...

Page 7: ...4 60 Minimum Pressure Check Valve Section 9 52 Moisture Separator Trap 16 Oil Filter 38 Oil Reservoir Drain 15 Oil System Addition Of Oil Between Changes 37 Compressor 35 Draining And Cleaning 38 Mois...

Page 8: ...am Air Cooled Single Stage VS Control 32 Figure 4 5 Wiring Diagram Air Cooled Single Stage VS Control 33 Figure 4 6 Wiring Diagram Air Cooled Single Stage VS Control 34 Figure 5 1 Checking Oil Level 3...

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 9 Figure 1 2 PACKAGE OUTLINE AIR COOLED 300CGA804 A Ref Drawing Page 1 of 2...

Page 11: ...13 18 604 Page 10 Figure 1 3 PACKAGE OUTLINE AIR COOLED 300CGA804 A Ref Drawing Page 2 of 2...

Page 12: ...13 18 604 Page 11 Figure 1 4 PACKAGE OUTLINE AIR COOLED TANK MOUNTED 301CGA804 A Ref Drawing Page 1 of 2...

Page 13: ...13 18 604 Page 12 Figure 1 5 PACKAGE OUTLINE AIR COOLED TANK MOUNTED 301CGA804 A Ref Drawing Page 2 of 2...

Page 14: ...ible Do not electric weld on the compressor or base bearings can be damaged by passage of current LIFTING UNIT Proper lifting and or transporting methods must be used to prevent damage 1 Lift from lon...

Page 15: ...n a clean well lighted well ventilated area with ample space all around for maintenance Select a location that provides a cool clean dry source of air In some cases it may be necessary to install duct...

Page 16: ...n 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 m...

Page 17: ...of the compressor package during final installation This device is not used on packages equipped with integrated dryers CONTROL PIPING Control piping is not necessary since the Gardner Denver compress...

Page 18: ...MUM COPPER SUPPLY WIRE RECOMMENDATIONS Minimum 75 C wire Minimum 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...

Page 19: ...perly sized see Figure 2 4 Other large loads on the same power feed as the compressor GD Model Volts VFD HP RATINGS Max KVA VS11 400 480 15 250 Figure 2 4 LINE REACTOR SIZING RECOMMENDATIONS GROUNDING...

Page 20: ...ipped 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 replac...

Page 21: ...wired See Figure 4 3 thru Figure 4 6 pages 31 thru 34 for general wiring diagrams and Section 2 for installation instructions Make sure to check the wiring of the optional compressed air dryer as it i...

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: ...shut down the compressor Please refer to the dryer manual 13 18 605 for all installation operation and maintenance instructions DAILY CHECK Refer to Section 14 Maintenance Schedule STOPPING THE UNIT P...

Page 26: ...lief 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 Ensure properly set valves ar...

Page 27: ...sor operation may commence For your convenience a Quick Start excerpt from the controller manual is shown in Section 3 Press the red STOP RESET button to clear any conditions e g Loss of Power when el...

Page 28: ...13 18 606 Page 27 Figure 4 1 ELECTRICAL ENCLOSURE HARDWARE 302CGA810 D Ref Drawing...

Page 29: ...ILTER 9 OPERATOR 10 CONTACT BLOCK 11 POWER SUPPLY 12 POWER DISTRIBUTION BLOCK 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 30: ...pressure 60 psig within the air oil reservoir thus insuring lubrication cooling oil injection flow into the compressors It also prevents the back flow of compressed air from the customer s piping bac...

Page 31: ...13 18 606 Page 30 Figure 4 2 PIPING AND INSTRUMENTATION ILLUSTRATION 300CGB797 B Ref Drawing...

Page 32: ...13 18 606 Page 31 Figure 4 3 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGA546 D Ref Drawing Page 1 of 4...

Page 33: ...13 18 606 Page 32 Figure 4 4 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGA546 D Ref Drawing Page 2 of 4...

Page 34: ...13 18 606 Page 33 Figure 4 5 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGA546 D Ref Drawing Page 3 of 4...

Page 35: ...13 18 606 Page 34 Figure 4 6 WIRING DIAGRAM AIR COOLED Single Stage VS Control 300CGA546 D Ref Drawing Page 4 of 4...

Page 36: ...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 37: ...provided with your compressor package has been designed to avoid water vapor condensation during all modes of operation e g load level ambient temperature or relative humidity and discharge pressure S...

Page 38: ...3 Close when provided valve isolating compressor package from air system 4 Wipe away all dirt around the oil filler plug 5 Remove the oil filler plug 1 and add or drain by removing plug 3 if correctin...

Page 39: ...steps 1 2 3 4 6 and 7 to correct oil level 9 If the drained oil and or the oil filter element are contaminated with dirt flush the entire system reservoir oil cooler mixing valve and lines Inspect th...

Page 40: ...en provided valve isolating 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 fi...

Page 41: ...nt temperature or load the mixing valve sends more oil flow to the cooler to maintain adequate compressor discharge temperature See Figure 5 3 for pressure dew point trends at various combinations of...

Page 42: ...g element resides The fine droplets of oil aerosol are trapped in the element media coalesced then gravity drained through a low point connection and associated tubing oil return line into a lower pre...

Page 43: ...sits or breaks ruptures in its media Also inspect sealing o ring in element for damage Before installing new or old element apply heavy grease to sealing o ring to avoid damage during installation 6 I...

Page 44: ...R HEAT EXCHANGERS The heat of compression absorbed by the oil injected into the compressors for cooling and lubrication is ultimately rejected in a convenient medium such as air for air cooled cores o...

Page 45: ...auge to avoid impacting the heat exchanger cooling air system An external ventilation fan may be required to properly evacuate hot air from the compressor room Minimum Cooling Air Flow Requirements CF...

Page 46: ...Note that if this device is not used the optional compressed air dryer is supplied as the latter s water separator is employed for this process Figure 6 3 WATER SEPARATOR AND DRAIN The separator 4 re...

Page 47: ...depressurized 2 Disconnect lockout and tagout power supply to the compressor package 3 Close when provided valve isolating compressor package from air system 4 Unscrew drain valve 1 from isolation val...

Page 48: ...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 49: ...Visually inspect housing inner 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 d...

Page 50: ...ervicing the V Belts Figure 8 1 V BELT ASSEMBLY 1 Disconnect lockout and tagout power supply to the compressor package 2 Lift pivot compressor to loosen and remove belts 3 Inspect belts for signs of w...

Page 51: ...he holes shown in threads are cut in the sheave and tighten lightly 8 Cleanse shaft surface and slide sheave bushing assembly unto shaft Make sure position the motor sheave in alignment with its matin...

Page 52: ...l part number EFC03477088 through the three holes in the sheave Always replace both wear sleeve 3 and shaft seal 4 whenever servicing either part 5 Pull out shaft seal 4 with a suitable extractor Prot...

Page 53: ...e always stop the unit 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...

Page 54: ...ll MPV unto sump with provided bolts 10 Adjust nut 13 so that there is a small 05 to 08 between itself and the frame 5 surface 11 Check for leaks after unit is back in operation Figure 9 1 MINIMUM DIS...

Page 55: ...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 c...

Page 56: ...ry 7 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 13 Pull c...

Page 57: ...psig It is installed on the dry side of the oil sump Figure 11 1 PRESSURE RELIEF VALVE Before inspecting the pressure relief valve release air pressure lockout and tagout the power supply to the compr...

Page 58: ...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 59: ...completely off 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 to the control panel Refer to...

Page 60: ...in disconnect lockout and tagout power supply to compressor package before working on the electric motor Motor Lubrication Your WEG motor is supplied with sealed bearings which were greased at the fac...

Page 61: ...nal 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 Messages an...

Page 62: ...mmended cleaning procedures Pressure Relief Valve Check operation of device see Section 11 page 56 for test procedure Motor Lubrication Inspect motors for abnormal noise and vibration Grease lubricate...

Page 63: ...press STOP RESET button to reset 4 Read error message on control panel 4 Take appropriate action See Control Manual 13 17 600 5 Remote Contact is open 5 Replace switch or jumper 6 Variable Frequency...

Page 64: ...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 65: ...and replace filter 3 Clogged cooler interior 3 Inspect and clear cooler 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...

Page 66: ...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 67: ......

Page 68: ...7 224 7814 Visit our Web Site www gardnerdenver com For additional information contact your local representative or Gardner Denver Inc 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9...

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