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13-17-605 Page 76

Yearly Checks

Heat Exchangers (air and water-cooled)

– Check cooling performance of air and oil cores – see

Section 6, page 50 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, page 69 for test procedure.

Motor Lubrication –

Inspect motors for abnormal noise and vibration. Grease-lubricate per

guidelines included in Section 13, page 72 of this manual.

Compressor/Motor shaft couplings –

Check coupling element for signs of wear and tear

– see

Section 8, page 57 for detailed instruction on coupling inspection procedures.

Содержание VST110

Страница 1: ...13 17 605 Version 10 May 27 2014 VARIABLE SPEED TWO STAGE STATIONARY BASE MOUNTED COMPRESSOR AirSmart CONTROLLER MODELS VST110 150 180A 110 150 180kW 60HZ OPERATING AND SERVICE MANUAL...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...s Oil Air Axial Cooling Fans 52 Section 7 Air Filter 57 Section 8 Shaft Coupling 59 Section 9 Minimum Pressure Check Valve 65 Section 10 Inlet Control Valve 67 Section 11 Pressure Relief Valve 71 Sect...

Страница 7: ...alve Section 9 65 Moisture Separator Trap 17 Motor Lubrication 74 Motor Lubrication 20 Motor Lubrication Section 13 74 Oil Filter 47 Oil Reservoir Drain 16 Oil System Addition Of Oil Between Changes 4...

Страница 8: ...37 Figure 4 8 Wiring Diagram Water Cooled Two Stage VS Control 38 Figure 4 9 Wiring Diagram Water Cooled Two Stage VS Control 39 Figure 4 10 Wiring Diagram Water Cooled Two Stage VS Control 40 Figure...

Страница 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...

Страница 10: ...nifold 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 bal...

Страница 11: ...13 17 605 Page 10 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED External Details 300VST804 B Ref Drawing Page 1 of 2...

Страница 12: ...13 17 605 Page 11 Figure 1 3 PACKAGE ILLUSTRATION AIR COOLED Internal Details 300VST804 B Ref Drawing Page 2 of 2...

Страница 13: ...13 17 605 Page 12 Figure 1 4 PACKAGE ILLUSTRATION WATER COOLED External Details 301VST804 B Ref Drawing Page 1 of 2...

Страница 14: ...13 17 605 Page 13 Figure 1 5 PACKAGE ILLUSTRATION WATER COOLED Internal Details 301VST804 B Ref Drawing Page 2 of 2...

Страница 15: ...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 eyebolts...

Страница 16: ...evel 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 Cooled Units A combination oil air cooler i...

Страница 17: ...nting bolts are not normally required However installation conditions such as piping rigidity angle of tilt or danger of shifting from outside vibration or moving vehicles may require the use of mount...

Страница 18: ...uilt in aftercooler a combination moisture separator and drain valve are furnished with the unit CONTROL PIPING Control piping is not necessary since the Gardner Denver compressor package is factory w...

Страница 19: ...alists for additional filtration and treatment equipment to meet health and safety standards BLOW DOWN VALVE PIPING The blow down valve is vented between the air filter and inlet valve thus avoiding t...

Страница 20: ...sets of 4 0AWG conductors in a single conduit VST 150 460 325 23 404 83 350 2 250 2 Two parallel sets of conductors in single conduit VST 180 460 365 23 454 83 400 2 300 2 Two parallel sets of conduct...

Страница 21: ...rge loads on the same power feed as the compressor GD Model Volts VFD HP RATINGS Max KVA VST110 400 480 2 100 HP 10 HP 1000 VST150 400 480 2 125 HP 10 HP 1000 VST180 400 480 2 125 HP 10 HP 1000 Figure...

Страница 22: ...der 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 high level at the s...

Страница 23: ...See Figure 4 4 thru Figure 4 11 pages 34 thru 41 for general wiring diagrams and Section 2 page 14 for installation instructions 6 Grounding Equipment must be properly grounded according to Gardner D...

Страница 24: ...s 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 gui...

Страница 25: ...yed 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 Rese...

Страница 26: ...meplate 9 Operating Mode Refer to Section 4 page 28 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 l...

Страница 27: ...electrical shock can cause injury 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 h...

Страница 28: ...13 17 605 Page 27 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...

Страница 29: ...600 are read and understood Once the appropriate parameters have been selected into the controller compressor operation may commence Press the red STOP RESET button to clear any conditions e g Loss of...

Страница 30: ...only 23 Starter 5 Cable 24 Fuse 6 Splitter 25 Overload Relay 7 Resistor 26 Terminal Block 8 Control Box 27 Terminal Block 9 Filter 28 Terminal Block 10 Fan Filter 29 Terminal Block 13 Control Transfo...

Страница 31: ...13 17 605 Page 30 Item Description 2 Key Pad 11 Emergency Stop Operator 12 Contact Block 35 Decal Figure 4 2 ELECTRICAL ENCLOSURE HARDWARE 300VST810 H Ref Drawing Page 2 of 2...

Страница 32: ...e intake flange of the compressor During compressor operation the underside of the poppet is vented to atmosphere via a 3 way solenoid valve allowing the poppet to fall open and feed fresh air to the...

Страница 33: ...ve Oil Drain W This device allows the drainage of oil entrapped within the compressors interstage pipe and oil separation vessel during oil change operation Check Valve Oil Flow Control X This devices...

Страница 34: ...13 17 605 Page 33 Figure 4 3 PIPING AND INSTRUMENTATION ILLUSTRATION 300VST797 B Ref Drawing...

Страница 35: ...13 17 605 Page 34 Figure 4 4 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300VST546 C Ref Drawing Page 1 of 4...

Страница 36: ...13 17 605 Page 35 Figure 4 5 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300VST546 C Ref Drawing Page 2 of 4...

Страница 37: ...13 17 605 Page 36 Figure 4 6 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300VST546 C Ref Drawing Page 3 of 4...

Страница 38: ...13 17 605 Page 37 Figure 4 7 WIRING DIAGRAM AIR COOLED Two Stage VS Control 300VST546 C Ref Drawing Page 4 of 4...

Страница 39: ...13 17 605 Page 38 Figure 4 8 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301VST546 C Ref Drawing Page 1 of 4...

Страница 40: ...13 17 605 Page 39 Figure 4 9 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301ETK546 C Ref Drawing Page 2 of 4...

Страница 41: ...13 17 605 Page 40 Figure 4 10 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301VST546 C Ref Drawing Page 3 of 4...

Страница 42: ...13 17 605 Page 41 Figure 4 11 WIRING DIAGRAM WATER COOLED Two Stage VS Control 301VST546 C Ref Drawing Page 4 of 4...

Страница 43: ...at 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 Centrifugal actio...

Страница 44: ...from your authorized Gardner Denver distributor or by calling 217 222 5400 MOISTURE IN THE OIL SYSTEM The oil injection system provided with your compressor package has been designed to avoid water v...

Страница 45: ...ill 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 to...

Страница 46: ...ed 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 itself...

Страница 47: ...oir drain line to drain oil a small hand electric or air operated pump should be used to drain reservoir through the oil filler opening or from the drain valve 4 If the unit is elevated so that the oi...

Страница 48: ...ller display See controller manual 13 17 600 advisory 320 for further details The pressure switch also includes a red auto resetting pop up visual indicator that confirms a triggered condition Note th...

Страница 49: ...ic element of this device expands with heat When the hot oil coming from the separator reservoir is below 140 F the valve bypasses oil flow around the oil cooler Within the range of nearly 8 F above 1...

Страница 50: ...not react the best course of action is to replace the complete valve Figure 5 4 PRESSURE DEW POINT OF COMPRESSED AIR LOW AIR DEMAND AND PACKAGE OPERATION During periods of very low air demand such as...

Страница 51: ...on 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 the package wil...

Страница 52: ...ary shine a 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...

Страница 53: ...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...

Страница 54: ...when package location makes it necessary to duct fresh cooling air in out these ducts must be sized with a maximum total pressure loss of 0 2 water gauge to avoid impacting the heat exchanger cooling...

Страница 55: ...surface grime from both sides of the blade surface 7 Wipe up and remove all traces of cleaning residue and cleaning materials 8 Reinstall all access panels and guards that were removed to access the...

Страница 56: ...rt and other fowling agents In order to protect package components that are in contact with the cooling water from attack by corrosive or fouling agents we recommend that the cooling water meet the fo...

Страница 57: ...lary length Excess capillary tube should be carefully coiled and placed so that damage will not occur with normal maintenance or traffic past the unit If a leak develops through the packing tighten th...

Страница 58: ...ient compressor package operation depends on the unrestricted clean supply of fresh air delivered by the air filters In turn the longevity of the filter element depends on the cleanliness of the local...

Страница 59: ...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...

Страница 60: ...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 shaft fit...

Страница 61: ...EMENT Apply a thread locking compound to the hub set screws M10 size and tighten to 150 5 lb in 17 N m of torque Reinstall coupling guard with provided fasteners 4 For hub to shaft interference fit hu...

Страница 62: ...s deformation extrusions etc Replace if necessary Re assemble main motor and cooling fan components in reverse order of disassembly After engaging each hub on the matching recesses of the coupling ele...

Страница 63: ...remove the coupling hub and tool kit assembly from the heat source and quickly bring it to the companion shaft Engage the coupling hub bore unto the companion shaft and slide until the latter contacts...

Страница 64: ...Make sure to use suitable heat protective gloves and clothes N N NO O OT T TI I IC C CE E E If heat was applied to the compressor coupling hub during its removal there is the possibility that the com...

Страница 65: ...13 17 605 Page 64 Figure 8 4 COUPLING INSTALLATION TOOL KIT Figure 8 5 COUPLING REMOVAL TOOL KIT...

Страница 66: ...ressure 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 persona...

Страница 67: ...13 17 605 Page 66 Figure 9 1 MINIMUM DISCHARGE PRESSURE CHECK VALVE...

Страница 68: ...pring loaded check feature is pushed open by a very small pressure differential resulting from the incoming air stream During stopped operation modes e g commanded from keypad or initiated by protecti...

Страница 69: ...body and remove 5 Remove four bolts Item 13 securing valve body to compressor body and remove valve 6 Inspect poppet seal O Ring Item 6 10 for wear and tear Replace if necessary 7 Remove lock ring It...

Страница 70: ...13 17 605 Page 69 Figure 10 2 INLET CONTROL VALVE ACTUATOR...

Страница 71: ...r 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 packa...

Страница 72: ...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 sep...

Страница 73: ...f 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 pressu...

Страница 74: ...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 ass...

Страница 75: ...ructions The following procedure should be used in re greasing 1 Disconnect lockout and tagout power supply to the compressor package 2 Wipe lubrication fitting clean and add grease with a hand operat...

Страница 76: ...critical parameters e g pressures temperatures speeds load levels etc helps identify when abnormal operation occurs AirSmart Controller Messages and Alarms Acknowledge the presence of an abnormal cond...

Страница 77: ...ed cleaning procedures Pressure Relief Valve Check operation of device see Section 11 page 69 for test procedure Motor Lubrication Inspect motors for abnormal noise and vibration Grease lubricate per...

Страница 78: ...ress 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 Confirm...

Страница 79: ...ice 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 Gar...

Страница 80: ...l 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 42 Compressor Lubrication for details High...

Страница 81: ...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 Tig...

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Страница 84: ...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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