Gardner Denver VST225 Installation, Operating And Service Manual Download

Page: 1 / 88

13-17-609

Version: 10

May 13, 2016

VARIABLE SPEED

TWO-STAGE

STATIONARY BASE-MOUNTED

COMPRESSOR

AirSmart

CONTROLLER

MODELS

VST225, 260A

225-260 kW

60HZ

OPERATING AND

SERVICE MANUAL

Summary of Contents for VST225

Page 1: ...13 17 609 Version 10 May 13 2016 VARIABLE SPEED TWO STAGE STATIONARY BASE MOUNTED COMPRESSOR AirSmart CONTROLLER MODELS VST225 260A 225 260 kW 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ...nit 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 simplify...

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: ...rs Oil Air Axial Cooling Fans 56 Section 7 Air Filter 63 Section 8 Shaft Coupling 65 Section 9 Minimum Pressure Check Valve 71 Section 10 Inlet Control Valve 73 Section 11 Pressure Relief Valve 77 Sec...

Page 7: ...arator Trap 20 Motor Lubrication 80 Motor Lubrication 23 Oil Filter 51 Oil Reservoir Drain 18 Oil System Addition Of Oil Between Changes 49 Compressor 46 Draining And Cleaning 50 Filling Oil Reservoir...

Page 8: ...Diagram Water Cooled Two Stage VST Control 39 Figure 4 8 Wiring Diagram Air Cooled Two Stage VST Control 40 Figure 4 9 Wiring Diagram Air Cooled Two Stage VST Control 41 Figure 4 10 Wiring Diagram Wat...

Page 9: ...the inlet port and air is drawn into the cavity between the main rotor lobes and gate rotor grooves A When the rotors pass the inlet port cutoff air is trapped in the interlobe cavity and flows axial...

Page 10: ...manifold and enters the compressors and inter stage manifold A portion of the oil is directed to internal passages on both 1st and 2nd stage airends to lubricate the bearings and shaft oil seals The b...

Page 11: ...13 17 609 Page 10 1 3 Figure 1 2 PACKAGE ILLUSTRATION WATER COOLED External Details 300ETW804 B Ref Drawing Page 1 of 2...

Page 12: ...13 17 609 Page 11 1 4 Figure 1 3 PACKAGE ILLUSTRATION WATER COOLED Internal Details 300ETW804 B Ref Drawing Page 2 of 2...

Page 13: ...13 17 609 Page 12 1 5 Figure 1 4 PACKAGE ILLUSTRATION AIR COOLED External Details 301ETW804 B Ref Drawing Page 1 of 4...

Page 14: ...13 17 609 Page 13 1 6 Figure 1 5 PACKAGE ILLUSTRATION AIR COOLED Internal Details 301ETW804 B Ref Drawing Page 2 of 4...

Page 15: ...13 17 609 Page 14 1 7 Figure 1 6 PACKAGE ILLUSTRATION AIR COOLED Remote Cooler Module Dimensions 301ETW804 B Ref Drawing Page 3 of 4...

Page 16: ...13 17 609 Page 15 1 8 Figure 1 7 PACKAGE ILLUSTRATION AIR COOLED Remote Cooler Module Dimensions with Moisture Separator Piping Instructions 301ETW804 B Ref Drawing Page 4 of 4...

Page 17: ...it may also be moved into location by rolling on bars Lift compressor package by base only Do not use other places such as motors compressors or discharge manifold piping as lifting points The eyebolt...

Page 18: ...ackage location be aware that its noise level may increase above its advertised free field condition by reflections from nearby objects e g walls machinery etc or by noise from nearby machinery Air Co...

Page 19: ...cooling is drawn in at the cooler end of the module and is exhausted through a top side opening Air for motor cooling electronics cooling and for the compressor intake is drawn in at the controller en...

Page 20: ...r drain to a container ENCLOSURE The compressors electric motors and control devices are mounted inside the compressor package enclosure Service doors are provided for maintenance access Be sure to al...

Page 21: ...o remove welding scale In either case the inlet line must be coated internally by galvanizing or painting with a moisture and oil proof sealing lacquer Up to ten 10 feet 3 meters in length the inlet l...

Page 22: ...o Section 6 page 50 of this manual for detailed instructions on the installation operation and maintenance of the water Cooled heat exchangers ELECTRICAL WIRING The compressor package is internally fa...

Page 23: ...e Sized 45 C Notes VST 225 488 250 2 300 2 350 2 3 VST 260 561 300 2 400 2 500 2 3 Notes Wire sizes are per Table 310 15 B 16 in the National Electrical Code NEC 3 Wires sized for 2 parallel sets of c...

Page 24: ...ther large loads on the same power feed as the compressor GD Model Volts VFD HP RATINGS Max KVA VST225 400 480 2 150 HP 1000 VST260 400 480 2 200 HP 2200 Air cooled module 400 480 1 20 HP 300 Figure 2...

Page 25: ...irst 8000 hours under normal operating conditions Note that after compressor operation is stopped the oil charge may partially drain back into the oil separation reservoir and register an abnormally h...

Page 26: ...is properly wired See Figure 4 4 thru Figure 4 8 pages 36 thru 40 for general wiring diagrams and Section 2 page 16 for installation instructions 6 Grounding Equipment must be properly grounded accor...

Page 27: ...ngs are required The Target Pressure comes preset to 100 PSI from the factory The Unload Pressure is preset to 110 PSI If a different pressure setting is desired the following steps can be used as a g...

Page 28: ...layed 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 parameters press the Stop Re...

Page 29: ...nameplate 9 Operating Mode Refer to Section 4 page 30 and Controller Manual 13 17 600 for detailed information on the control system 10 Enclosure Check for damaged panels or doors Check all screws and...

Page 30: ...the power supply and any other circuits before servicing unit When the pressure relief valve opens a stream of high velocity air is released resulting in a high noise level and possible discharge of...

Page 31: ...he detailed instructions for the controller found in the controller manual 13 17 600 are read and understood Once the appropriate parameters have been selected into the controller compressor operation...

Page 32: ...t stage 22 Fuse 4 Variable Frequency Drive 2nd stage 23 Relay 5 Cable 24 Fuse 6 Splitter 26 Terminal Block 7 Resistor 27 Terminal Block 8 Control Box 28 Ground Block 9 Filter ventilation 29 Ground Blo...

Page 33: ...13 17 609 Page 32 4 3 Figure 4 2 ELECTRICAL ENCLOSURE HARDWARE Item Description 2 Key Pad 11 Emergency Stop Operator 12 Contact Block 35 Decal 300ETW810 C Ref Drawing...

Page 34: ...cated at the intake flange of the 1st stage compressor A spring loaded pneumatic cylinder actuates the valve During compressor operation at least 5 Hz 1st stage compressor shaft speed an air pressure...

Page 35: ...he compressors interstage pipe and oil separation vessel during oil change operation Check Valve Oil Flow Control X This devices prevent the reversal of oil flow from the higher pressure into lower pr...

Page 36: ...13 17 609 Page 35 4 6 Figure 4 3 PIPING AND INSTRUMENTATION ILLUSTRATION 300ETW797 A Ref Drawing...

Page 37: ...13 17 609 Page 36 4 7 Figure 4 4 WIRING DIAGRAM WATER COOLED Two Stage VST Control 300ETW546 D Ref Drawing Page 1 of 4...

Page 38: ...13 17 609 Page 37 4 8 Figure 4 5 WIRING DIAGRAM WATER COOLED Two Stage VST Control 300ETW546 D Ref Drawing Page 2 of 4...

Page 39: ...13 17 609 Page 38 4 9 Figure 4 6 WIRING DIAGRAM WATER COOLED Two Stage VST Control 300ETW546 D Ref Drawing Page 3 of 4...

Page 40: ...13 17 609 Page 39 4 10 Figure 4 7 WIRING DIAGRAM WATER COOLED Two Stage VST Control 300ETW546 D Ref Drawing Page 4 of 4...

Page 41: ...13 17 609 Page 40 4 11 Figure 4 8 WIRING DIAGRAM AIR COOLED Two Stage VST Control 301ETW546 B Ref Drawing Page 1 of 2...

Page 42: ...13 17 609 Page 41 4 12 Figure 4 9 WIRING DIAGRAM AIR COOLED Two Stage VST Control 301ETW546 B Ref Drawing Page 2 of 2...

Page 43: ...13 17 609 Page 42 4 13 Figure 4 10 WIRING DIAGRAM WATER COOLED Two Stage VST 260 Control 302ETW546 C Ref Drawing Page 1 of 4...

Page 44: ...13 17 609 Page 43 4 14 Figure 4 11 WIRING DIAGRAM WATER COOLED Two Stage VST 260 Control 302ETW546 C Ref Drawing Page 2 of 4...

Page 45: ...13 17 609 Page 44 4 15 Figure 4 12 WIRING DIAGRAM WATER COOLED Two Stage VST 260 Control 302ETW546 C Ref Drawing Page 3 of 4...

Page 46: ...13 17 609 Page 45 4 16 Figure 4 13 WIRING DIAGRAM WATER COOLED Two Stage VST 260 Control 302ETW546 C Ref Drawing Page 4 of 4...

Page 47: ...n the 1st stage compressor and inter stage pipe manifold through various solenoid valves and orifices The injected oil absorbs heat from compression while progressing through the compression chamber a...

Page 48: ...is compatible with most air system downstream components Safety Data Sheets SDS are available for all AEON 9000TH lubricants from your authorized Gardner Denver distributor or by calling 800 682 9868...

Page 49: ...efill intervals less frequent Note that each inch of oil level represents 2 0 gal of oil o Drain oil only when the level is above the HIGH mark on sight glass Be aware that a stopped unit when filled...

Page 50: ...pped the oil charge may partially drain back into the oil separation reservoir and register an abnormally high level at the sight glass DO NOT DRAIN OIL TO CORRECT as this condition will correct itsel...

Page 51: ...he drained oil and or the oil filter element are contaminated with dirt flush the entire system reservoir oil cooler mixing valve and lines Inspect the oil separator element for dirt accumulation repl...

Page 52: ...on is evident 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 con...

Page 53: ...on housing with the oil filter see Figure 5 1 for details Figure 5 3 COMBINATION OIL FILTER AND THERMOSTATIC MIXING VALVE The thermostatic element of this device expands with heat When the hot oil com...

Page 54: ...nction with the matching sequence of outputs listed in the AirSmart Manual 13 17 600 will help verify the proper operation of each valve In case a solenoid valve malfunction is detected e g correct co...

Page 55: ...hown Separation performance The package oil separation system has been designed to yield 2ppm total oil carryover at the discharge of the air oil reservoir the oil content level at the discharge of th...

Page 56: ...light inside each element to reveal areas of heavy dirt varnish deposits or breaks ruptures in its media 6 Inspect the sealing o ring for damage Before installing new or old element apply heavy grease...

Page 57: ...ng 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 E...

Page 58: ...compressor inlet motors and electronics the air cooled module list the ventilation for the heat exchangers When location makes it necessary to duct fresh cooling air in out into both the compressor p...

Page 59: ...to re energize the package 10 Jog fans to verify there is no interference with the guard or cowling ring before the package is placed back in service All axial cooling fans should be inspected and cle...

Page 60: ...e cooling water from attack by corrosive or fouling agents we recommend that the cooling water meet the following quality standards Total Dissolved Solids TDS 500 ppm Iron 2 ppm Total Hardness 60 ppm...

Page 61: ...tic operation An occasional drop of oil on the valve stem at the packing nut will prolong packing life If the valve malfunctions check for a bend or binding in the capillary tube paint or corrosion on...

Page 62: ...cted in its lower head The collected water is evacuated by a float type drain valve The device prevents the loss of compressed air by only allowing the discharge of liquid water during its opening pha...

Page 63: ...or package from air system 4 Unscrew drain valve from isolation valve 5 Inspect and clean lower head 6 Reinstall in reverse order If the vent adaptor has been removed from the lower head note its loca...

Page 64: ...gh efficiency synthetic media element is housed in a non corrosive housing Efficient compressor package operation depends on the unrestricted clean supply of fresh air delivered by the air filters In...

Page 65: ...cover and remove filter elements 2 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...

Page 66: ...nnect lockout and tagout power supply to the compressor package 2 Remove fasteners securing coupling guard to access opening on compressor motor housing and remove guard 3 Depending on the bore to sha...

Page 67: ...ELEMENT Apply a thread locking compound to the hub set screws M10 size and tighten to 12 6 ft lb 17 N m of torque Reinstall coupling guard with provided fasteners 4 For hub to shaft interference fit h...

Page 68: ...g wood beam to maintain compressor level when main motor is retrieved Remove four bolts securing main motor to adaptor Slide Pull main motor away from adaptor until coupling hubs separate and allow re...

Page 69: ...mble tool kit components unto coupling hub as shown on Figure 8 4 page 70 Make sure that the keyway on the coupling hub and its companion shaft are properly de burred and clean and that the key fits e...

Page 70: ...rotating the companion shaft assembly by means of the removal tool handle Once the coupling hub metal has expanded enough the present tension of the removal tool will pull the coupling hub away from...

Page 71: ...13 17 609 Page 70 8 6 FIGURE 8 4 COUPLING INSTALLATION TOOL KIT FIGURE 8 5 COUPLING REMOVAL TOOL KIT...

Page 72: ...pressure valve 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 perso...

Page 73: ...SCHARGE PRESSURE CHECK VALVE Item Name Of Part Qty MINIMUM PRESSURE VALVE ASSEMBLY REPAIR KIT Includes the following 1 BODY 1 2 CHECK VALVE ASSEMBLY 1 3 SPACER 1 4 SPRING 1 5 O RING 1 6 PISTON ASSEMBL...

Page 74: ...re signal 60 psig min fed into the actuator overcomes the internal spring load and opens the valve During stopped operation modes e g commanded from keypad or initiated by protective shutdown the air...

Page 75: ...Drain oil trapped within 1st stage compressor via supplied drain valve 5 Remove valve and actuator from 1st stage compressor inlet flange by loosening all four 4 bolts removing top two 2 bolts and sp...

Page 76: ...13 17 609 Page 75 10 3 Figure 10 2 INLET CONTROL VALVE ACTUATOR...

Page 77: ...oper feed pressure then the complete actuator must be replaced 1 Be sure the unit is completely off and oil reservoir is depressurized 2 Disconnect lockout and tagout power supply to the compressor pa...

Page 78: ...E Pressure Relief Valve This device protects the pressure containing components of the compressor package against pressures accidentally exceeding 200 psig It is installed on the dry side of the oil s...

Page 79: ...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 Inspection The pres...

Page 80: ...ect lockout and tagout power supply to the compressor package 3 Remove the access panel located below the electrical enclosure area by unlatching all four 4 provided latches The three 3 intake filter...

Page 81: ...ocate the automatic grease relief fittings one at each motor bottom end and make sure that their spring loaded covers are operational 3 Locate the grease fittings provided at each end of the motor top...

Page 82: ...d air oil heat exchanger finned surfaces Refer to Section 6 page 56 for detailed instructions to clean heat exchanger surfaces Axial cooling fans Check for grime and dirt build up on fan blade surface...

Page 83: ...nd press STOP RESET button to reset 5 Read error message on control panel 5 Take appropriate action See Manual 13 17 600 6 Remote Contact is open 6 Replace switch or jumper 7 Compressor lock up 7 Conf...

Page 84: ...ervice piping 2 Inspect and clean service piping 3 Restriction in control tubing 3 Inspect and clean control tubing Compressor starts too slowly 1 Acceleration time in VFD set too long 1 Contact your...

Page 85: ...el 5 Add oil to proper level 6 Low oil injection pressure but normal discharge pressure 6 Oil flow control solenoid valve malfunction Refer to Section 5 page 46 Compressor Lubrication for details High...

Page 86: ...l return line strainer 3 Inspect and service 4 Clogged broken or loose oil return line fittings 4 Inspect and tighten or replace 5 Ruptured oil separator element 5 Replace element 6 Loose assembly 6 T...

Page 87: ...ESS MADE IN WRITING AND EXECUTED BY AN OFFICER OF THE COMPANY THIS WARRANTY SHALL NOT BE EFFECTIVE AS TO ANY CLAIM WHICH IS NOT PRESENTED WITHIN 30 DAYS AFTER THE DATE UPON WHICH THE PRODUCT IS CLAIME...

Page 88: ...For additional information contact your local representative or visit www contactgd com compressors 2016 Gardner Denver Inc Printed in U S A...

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