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13-17-618 Page 7

LIST OF ILLUSTRATIONS

– Compression Cycle .................................................................................................................. 8

Figure 1-2

– Package Illustration (Air-Cooled) – External Details .............................................................. 10

Figure 1-3

– Package Illustration (Air-Cooled) – Internal Details ................................................................ 11

Figure 1-4

– Package Illustration (Water-Cooled) – External Details ......................................................... 12

Figure 1-5

– Package Illustration (Water-Cooled) – Internal Details .......................................................... 13

Figure 2-1

– Typical Compressor Room ..................................................................................................... 15

Figure 2-2

– Inlet Line Lengths ................................................................................................................... 17

Figure 2-3

– Package Maximum Current Consumption Summary ............................................................. 19

Figure 2-4

– Line Reactor Sizing Recommendations ................................................................................. 20

Figure 4-1

– Electrical Enclosure Hardware ............................................................................................... 29

Figure 4-2

– Piping And Instrumentation Illustration ................................................................................... 32

Figure 4-3

– Wiring Diagram – (Air-Cooled) Two-Stage VS Control ......................................................... 33

Figure 4-4

– Wiring Diagram – (Air-Cooled) Two-Stage VS Control ......................................................... 34

Figure 4-5

– Wiring Diagram – (Air-Cooled) Two-Stage VS Control ......................................................... 35

Figure 4-6

– Wiring Diagram – (Air-Cooled) Two-Stage VS Control ......................................................... 36

Figure 4-7

– Wiring Diagram – (Water-Cooled) Two-Stage VS Control .................................................... 38

Figure 4-8

– Wiring Diagram – (Water-Cooled) Two-Stage VS Control ................................................... 39

Figure 4-9

– Wiring Diagram – (Water-Cooled) Two-Stage VS Control ................................................... 40

Figure 4-10

– Wiring Diagram – (Water-Cooled) Two-Stage VS Control .................................................. 41

Figure 5-1

– Thermostatic Mixing Valve Element ....................................................................................... 48

Figure 5-2

– Pressure Dew Point Of Compressed Air ................................................................................ 49

Figure 5-3

– Oil Coalescing Element .......................................................................................................... 50

Figure 6-1

– Air Flow Chart ......................................................................................................................... 53

Figure 6-2

– Cooler Housing Side Covers .................................................................................................. 54

Figure 6-3

– Water-Cooled Heat Exchanger Coolant Requirements ......................................................... 55

Figure 6-4

– Water Control Valve ............................................................................................................... 56

Figure 7-1

– Air Filter (Standard) ................................................................................................................ 57

Figure 8-1

– Coupling Components ............................................................................................................ 59

Figure 8-2

– Coupling Element ................................................................................................................... 60

Figure 8-3

– Motor Removal Hardware ....................................................................................................... 61

Figure 8-4

– Coupling Installation Tool Kit .................................................................................................. 64

Figure 8-5

– Coupling Removal Tool Kit ..................................................................................................... 64

Figure 9-1

– Minimum Discharge Pressure/Check Valve ........................................................................... 66

Figure 10-1

– Inlet Control Valve (Body) ..................................................................................................... 67

Figure 11-1

– Pressure Relief Valve ........................................................................................................... 69

Содержание VST55-90B

Страница 1: ...13 17 618 Version 00 Dec 7 2018 VARIABLE SPEED TWO STAGE STATIONARY BASE MOUNTED COMPRESSOR AirSmart CONTROLLER MODELS VST55 90B 55 75 90kW 60HZ OPERATING AND SERVICE MANUAL ...

Страница 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 simplify servicing your compressor Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair They are ready to respond and assist you by providing fast e...

Страница 3: ...omical 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 areas of the compressor package to alert users of the following conditions Indicates a hazard with a high level of risk which if not avoided WILL result in death or serious injury Equipment starts au...

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 Lift Equipment with Hook No Lift Point Handle Package at Forklift Points Only Lockout Electrical Equipment in De Energized State Loud Noise Hazard Wear Ear Protection Read the Operator s Manual Before ...

Страница 5: ...or 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 applicable local electrical codes Wiring and electrical service must be performed only by qualified electricians Open main disconnect switch lockout and tagout before working on the control wait 10 ...

Страница 6: ...on 6 Heat Exchangers 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 69 Section 12 Ventilation Fans Filters Electrical Enclosure 71 Section 13 Motor Lubrication 72 Section 14 Maintenance Schedule 73 Section 15 Troubleshooting 75 This book covers the followi...

Страница 7: ...heck Valve Section 9 63 Moisture Separator Trap Optional 17 Motor Lubrication 70 Motor Lubrication 20 Oil Filter 45 Oil Reservoir Drain 16 Oil System Addition Of Oil Between Changes 44 Compressor 41 Draining And Cleaning 44 Filling Oil Reservoir 45 Low Air Demand And Package Operation 46 Moisture 42 Oil Change Interval 44 Oil Filter 45 Oil Flow Control Valves 46 Oil Mixing Valve 46 Oil Separation ...

Страница 8: ...ontrol 35 Figure 4 6 Wiring Diagram Air Cooled Two Stage VS Control 36 Figure 4 7 Wiring Diagram Water Cooled Two Stage VS Control 38 Figure 4 8 Wiring Diagram Water Cooled Two Stage VS Control 39 Figure 4 9 Wiring Diagram Water Cooled Two Stage VS Control 40 Figure 4 10 Wiring Diagram Water Cooled Two Stage VS Control 41 Figure 5 1 Thermostatic Mixing Valve Element 48 Figure 5 2 Pressure Dew Poin...

Страница 9: ...mesh at 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 axially with the meshing rotors B As meshing continues more of the main rotor lobe enters the gate rotor groove normal volume is reduced and pressure increases Oil is injected into the cylinder to r...

Страница 10: ...old 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 balance of the oil is metered by solenoid valves and orifices and injected into the 1st stage compressor rotors and inter stage manifold to remove the heat of compression seal internal clearances and lubric...

Страница 11: ...13 17 618 Page 10 1 3 Figure 1 2 PACKAGE ILLUSTRATION AIR COOLED External Details 300ETK804 D Ref Drawing Page 1 of 2 ...

Страница 12: ...13 17 618 Page 11 1 4 Figure 1 3 PACKAGE ILLUSTRATION AIR COOLED Internal Details 300ETK804 D Ref Drawing Page 2 of 2 ...

Страница 13: ...13 17 618 Page 12 1 5 Figure 1 4 PACKAGE ILLUSTRATION WATER COOLED External Details 301ETK804 D Ref Drawing Page 1 of 2 ...

Страница 14: ...13 17 618 Page 13 1 6 Figure 1 5 PACKAGE ILLUSTRATION WATER COOLED Internal Details 301ETK804 D Ref Drawing Page 2 of 2 ...

Страница 15: ...or discharge manifold piping as lifting points The 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 lifting angle must not exceed 15 degrees Failure to observe this warning may result in damage to equipment or personal injury Compressor air oil reservoir s...

Страница 16: ...perate efficiently please refer to Section 6 Fig 6 1 page 53 of this manual for detailed instructions on the operation and maintenance of air cooled heat exchangers including minimum heat exchanger cooling and enclosure ventilation requirements Air for heat exchanger cooling is drawn in at the cooler end of the enclosure and is exhausted through a roof vent Air for motor cooling and for the compre...

Страница 17: ...lts and shims to provide uniform support for the base OIL RESERVOIR DRAIN The oil drain is piped from the bottom of the reservoir to the side of the base This drain is approximately 4 50 inches 115 mm 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 If the compres...

Страница 18: ...tional stand alone combination moisture separator and trap that is field installed downstream of the aftercooler CONTROL PIPING Control piping is not necessary since the Gardner Denver compressor package is factory wired and piped for the control system specified INLET LINE Where an inlet line is used between the air filter and the compressor it must be thoroughly cleaned on the inside to prevent ...

Страница 19: ...ecialists 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 the need of any external pipe work WATER PIPING Water Cooled Heat Exchanger Models Only On machines equipped with water cooled heat exchangers the water inlet and outlet connections are located in t...

Страница 20: ...pacity Minimum 75 C Copper Wire Sized 30 C Minimum 75 C Copper Wire Sized 40 C Minimum 75 C Copper Wire Sized 45 C Notes VST 55 162 2 0 3 0 3 0 VST 75 182 3 0 4 0 4 0 VST 90 220 4 0 250 300 or 2 0 2 1 Notes Wire sizes are per Table 310 15 B 16 in the National Electrical Code NEC 1 2 0 and 3 0 wires sized with derate for two parallel sets of conductors in a single conduit 2 Wires sized with derate ...

Страница 21: ...ther large loads on the same power feed as the compressor GD Model Volts VFD HP RATINGS Max KVA VST55 400 480 2 40 HP 7 5 HP 600 VST75 400 480 2 50 HP 7 5 HP 750 VST90 400 480 2 60 HP 7 5 HP 900 Figure 2 4 LINE REACTOR SIZING RECOMMENDATIONS GROUNDING Equipment must be properly grounded in accordance with the National Electrical Code and or applicable local codes Failure to properly ground the com...

Страница 22: ...t 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 high level at the sight glass DO NOT DRAIN OIL TO CORRECT as this condition will correct itself after resuming compressor operation NOTICE Regular maintenance and replacement at required intervals of the ...

Страница 23: ...ical Check the wiring diagrams furnished with the unit to be sure it is properly wired See Figure 4 3 thru Figure 4 11 pages 33 thru 41 for general wiring diagrams and Section 2 page 14 for installation instructions 6 Grounding Equipment must be properly grounded according to Gardner Denver Guidelines for proper wiring grounding and feed power conditioning Failure to properly ground the compressor...

Страница 24: ... desired load pressure DO NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE 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 to 100 PSI from the factory The Unload Pressure is preset to 110 PSI If a different pressur...

Страница 25: ...et 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 parameters press the Stop Reset button to go back to the heading of the current menu and then press the Stop Reset button again If parameter changes have been made the following screen will appear To per...

Страница 26: ... nameplate 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 latches for tightness Be sure doors are closed and latched STARTING THE UNIT Observe the following starting procedures Unit Cold If the unit is fitted with water cooled heat exchangers fully open wa...

Страница 27: ... or 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 high velocity air is released resulting in a high noise level and possible discharge of accumulated dirt or other debris Always wear eye and ear protection and stand clear of the discharge port when...

Страница 28: ...13 17 618 Page 27 3 7 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: ...pressor operation may commence Press the red STOP RESET button to clear any conditions e g Loss of Power when electrical system was energized and start the unit by pushing the green START button Since the unit is equipped with a minimum pressure 80 psig 5 5 bar valve no special procedure to maintain minimum reservoir pressure is required Main VFD and Motors Each compressor is driven by an inverter...

Страница 30: ...lay 8 Control Box 26 Terminal Block 9 Filter 27 Terminal Block 10 Fan Filter 28 Terminal Block 11 Emergency Stop Operator 29 Terminal Block 12 Contact Block 30 Terminal Block 13 Control Transformer 31 Terminal Block 14 Fuse 32 Terminal Block 15 Fuse 33 Baffle 16 Power Supply 34 EMC Filter Optional 17 Din Rail Kit 35 Screw Terminal Plug 18 Power Distribution Block 36 Wire 38 Variable Frequency Driv...

Страница 31: ...e 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 compressor inlet During stopped operation modes e g command from keypad or initiated by protective shutdown the 3 way solenoid valve feeds an air signal to the underside of the poppet forcing it upward close and block off...

Страница 32: ...tem startup Ball Valve Oil Drain W This device allows the drainage of oil entrapped within each compressor cylinder during oil change operation Check Valve Oil Flow Control X This devices prevent the reversal of oil flow from the higher pressure into lower pressure regions of the oil system Air Filter Vacuum Switch Y This device measures the vacuum pressure at the discharge side of the inlet air f...

Страница 33: ...13 17 618 Page 32 4 5 Figure 4 2 PIPING AND INSTRUMENTATION ILLUSTRATION 300ETK797 C Ref Drawing ...

Страница 34: ...13 17 618 Page 33 4 6 Figure 4 3 WIRING DIAGRAM AIR COOLED Two Stage VS Control 303ETK546 A Ref Drawing Page 1 of 5 ...

Страница 35: ...13 17 618 Page 34 4 7 Figure 4 4 WIRING DIAGRAM AIR COOLED Two Stage VS Control 303ETK546 A Ref Drawing Page 2 of 5 ...

Страница 36: ...13 17 618 Page 35 4 8 Figure 4 5 WIRING DIAGRAM AIR COOLED Two Stage VS Control 303ETK546 A Ref Drawing Page 3 of 5 ...

Страница 37: ...13 17 618 Page 36 4 9 Figure 4 6 WIRING DIAGRAM AIR COOLED Two Stage VS Control 303ETK546 A Ref Drawing Page 4 of 5 ...

Страница 38: ...13 17 618 Page 37 4 9 Figure 4 7 WIRING DIAGRAM AIR COOLED Two Stage VS Control 303ETK546 A Ref Drawing Page 5 of 5 ...

Страница 39: ...13 17 618 Page 38 4 10 Figure 4 8 WIRING DIAGRAM WATER COOLED Two Stage VS Control 304ETK546 A Ref Drawing Page 1 of 5 ...

Страница 40: ...13 17 618 Page 39 4 11 Figure 4 9 WIRING DIAGRAM WATER COOLED Two Stage VS Control 304ETK546 A Ref Drawing Page 2 of 5 ...

Страница 41: ...13 17 618 Page 40 4 12 Figure 4 10 WIRING DIAGRAM WATER COOLED Two Stage VS Control 304ETK546 A Ref Drawing Page 3 of 5 ...

Страница 42: ...13 17 618 Page 41 4 13 Figure 4 11 WIRING DIAGRAM WATER COOLED Two Stage VS Control 304ETK546 A Ref Drawing Page 4 of 5 ...

Страница 43: ...13 17 618 Page 42 4 13 Figure 4 12 WIRING DIAGRAM WATER COOLED Two Stage VS Controll 304ETK546 A Ref Drawing Page 5 of 5 ...

Страница 44: ...in 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 and is then discharged back into the oil separation chamber as a mixture of liquids and aerosols oil and gas air Centrifugal action within the air oil reservoir separates the bulk of the oil from the ...

Страница 45: ...H 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 217 222 5400 MOISTURE IN THE OIL SYSTEM The oil injection system provided with your compressor package has been designed to avoid water vapor condensation during all modes of operation e g load level ambient tem...

Страница 46: ...refill 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 its maximum oil capacity approximately 16 gallons may show a full sight glass this is normal and does not require oil drainage o The oil level in the sight glass will fluctuate as the compressor l...

Страница 47: ...l correct itself after resuming compressor operation Note that repeated addition of oil between oil changes may indicate excessive oil carry over and should be investigated Excessive oil carry over can damage equipment Never fill oil reservoir above top of the sight glass Use only CLEAN containers and funnels to avoid contamination of oil Provide for clean storage of oils Changing the oil will be ...

Страница 48: ... FILTER The oil filter is a vital part in maintaining a trouble free compressor since it removes dirt and abrasives from the circulated oil It should be replaced every 1000 hours of operation and when the oil is changed An internal flow bypass valve mounted inside the filter housing provides uninterrupted oil flow when the filter element is contaminated and its pressure loss exceeds 15 psid at typ...

Страница 49: ...s to maintain optimal 1st and 2nd stage compressor discharge temperatures between 195 F and 220 F The AirSmart controller governs the oil flow control valve operations refer to AirSmart Manual 13 17 600 for detailed information on programmed operations of these valves The energized state of each valve is visually confirmed by a light emitting diode LED housed within the transparent electrical plug...

Страница 50: ...oling filtering and re injection It also serves as a storage volume for the oil mass migrating from higher elevations e g oil cooler compressor casings and piping Air oil final separation The aerosols and compressed air streams are led to the upper portion of the reservoir where the coalescing element resides The fine droplets of oil aerosol are trapped in the element media coalesced then gravity ...

Страница 51: ...st depressurization cycles leading to oil foaming Oil separator element life cannot be predicted it will vary greatly depending on the conditions of operation the quality of the oil used and the maintenance of the oil and air filters The condition of the separator can be determined by pressure differential gauging or by inspection Oil Coalescing Element Monitoring The AirSmart controller keeps tra...

Страница 52: ...g for damage Before installing new or old element apply heavy grease to sealing o ring Oil may be wiped off by the chamfer and the o ring could be damaged 7 Wipe the cover seal o ring clean and inspect for damage Replace if necessary 8 Lower element into reservoir and center on the chamfer Press element down into reservoir Do not use excessive force as element damage may occur while centering it 9...

Страница 53: ...njury or death Disconnect lockout and tagout package from the power supply OIL AIR 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 or water for water cooled cores Proper operation of these heat exchangers is essential for the following processes The c...

Страница 54: ...er plus the enclosure ventilation flow rates which include motor ventilation and compressor intake Furthermore 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 1 8 inch water gauge to avoid impacting the heat exchanger cooling air system Minimum Cooling Air Flow Requirements CFM KW Air Cooled Heat Exchangers E...

Страница 55: ... Cover motors mixing valves fan motors and other electrical components to prevent damage from the cleaning process 5 Use a mild detergent or degreaser to soften and dissolve accumulated grime 6 Using a soft cloth or sponge remove the 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...

Страница 56: ...have been made at the Gardner Denver factory Regular maintenance is required to keep the interior core areas free from dirt 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 following quality standards Total Dissolved Solids TDS 500 ppm Iron 2 ppm Total H...

Страница 57: ...pillary 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 the packing gland nut firmly with a wrench to reseat the packing around the valve stem back off the nut until loose and finally retighten the nut finger tight Tightening the packing nut too tight may...

Страница 58: ... compressor 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 NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units Genuine parts are available through your authorized Gardner Denver distributor Do not oil this ele...

Страница 59: ...sing 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 defects and dirt then wipe clean if necessary 3 Visually inspect media If flaws e g tears of media damage to sealing o ring etc are evident or if the pressure loss has triggered the vacuum switch activation level is 30 inc...

Страница 60: ...r and compressor through a machined cast housing provides automatic alignment of shafts and coupling The coupling assembly requires no lubrication Coupling Element Rotex size 48 Inspection and Replacement 1 Disconnect 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...

Страница 61: ...element by friction and excessive thermal expansion the latter could 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 Apply a thread locking compound to the hub set screws M8 size and tighten to 88 5 lb in 10 N m of torque Reinstall coupling guard with provided fasteners 4 For hub to shaft in...

Страница 62: ...acks 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 element check that the gap between the hub flats see dimension E on Figure 8 2 is no less than 1 10 1 18 inches 28 30 mm A smaller gap will produce abnormal wear of the element by friction and excessi...

Страница 63: ...s 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 the stop item 1 on Figure 8 4 page 64 Once the coupling hub has cooled down sufficiently to grip the companion shaft remove the installation tool kit Coupling Hub Removal Have removal tool part num...

Страница 64: ...se severe burns Make sure to use suitable heat protective gloves and clothes NOTICE If heat was applied to the compressor coupling hub during its removal there is the possibility that the companion shaft seal has been damaged and it must be replaced Contact Gardner Denver for further instructions ...

Страница 65: ...13 17 618 Page 64 8 6 Figure 8 4 COUPLING INSTALLATION TOOL KIT Figure 8 5 COUPLING REMOVAL TOOL KIT 303SBK810 A Ref Drawing ...

Страница 66: ...m 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 personal injury or death Working spring within valve body is under tension Failure to relieve spring tension gradually may cause serious injury upon cap removal Minimum Pressure Check Valve Inspection 1 B...

Страница 67: ...13 17 618 Page 66 9 2 Figure 9 1 MINIMUM DISCHARGE PRESSURE CHECK VALVE ...

Страница 68: ...oil backflow 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 compressor inlet the spring 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 protect...

Страница 69: ... 2 Disconnect lockout and tagout power supply to the compressor package 3 Close when provided valve isolating compressor package from air system 4 Identify by position each tube connected to the valve 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: ...VE 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 separation reservoir Figure 11 1 PRESSURE RELIEF VALVE ...

Страница 71: ...n 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 pressure relief valve has no user serviceable or repairable components However it should be tested for proper operation at least once every year To test the relief valve raise the system operating pressu...

Страница 72: ...wer supply to the compressor package 3 Remove the access panel located below the electrical enclosure area by unlatching all four 4 provided latches The two 2 intake filter assemblies located on the floor of the electrical enclosure are now accessible 4 Remove the filter elements from each bracket by prying open the retaining grill area 5 Inspect the elements If dirty gently clean with soapy water...

Страница 73: ... Locate 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 end be aware the one or both may be relocated away from the motor for easier access Wipe each greased fitting clean and add grease with a hand operated gun until excess grease starts draining from ...

Страница 74: ...tc helps identify when abnormal operation occurs AirSmart Controller Messages and Alarms Acknowledge the presence of an abnormal condition and take action to correct it Weekly Checks Heat Exchangers air cooled Check for dirt accumulation on air cooled air oil heat exchanger finned surfaces Refer to Section 6 for detailed instructions to clean heat exchanger surfaces Axial cooling fans Check for gr...

Страница 75: ... manual for details on typical performance expectations as well as recommended cleaning procedures Pressure Relief Valve Check operation of device see Section 11 page 67 for test procedure 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 ...

Страница 76: ...and 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 Confirm compressor shaft is not free to turn then call Gardner Denver for further instructions See High Discharge Air Temperature this section Compressor starts but stops after a short time 1 High discha...

Страница 77: ...service 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 Gardner Denver distributor 2 Minimum Pressure Check Valve is leaking 2 Repair or replace Compressor is low on delivery and pressure 1 Improperly adjusted control 1 Refer to Manual 13 17 600 and adjus...

Страница 78: ...vel 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 41 Compressor Lubrication for details High discharge air oil Temperature air cooled cores 1 Dirty or clogged cooler outer surfaces 1 Inspect and clean cooler outer surfaces 2 Insufficient cooling air flow 2 Verify ductwork back pressure does...

Страница 79: ...il 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 Tighten all fittings and gaskets 7 Foam caused by use of incorrect oil 7 Use Gardner Denver AEON 9000TH oil only 8 Minimum pressure valve malfunction discharge pressure below 80 psig 8 Repair or repla...

Страница 80: ...LESS 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 CLAIMED NOT TO HAVE BEEN AS WARRANTED ANY ACTION FOR BREACH OF THIS WARRANTY MUST BE COMMENCED WITHIN ONE YEAR AFTER THE DATE UPON WHICH THE CAUSE OF ACTION OCCURRED ANY ADJUSTMENT MADE PURSUANT TO THIS WA...

Страница 81: ...NOTES ...

Страница 82: ...NOTES ...

Страница 83: ...NOTES ...

Страница 84: ...For additional information contact your local representative or visit www contactgd com compressors 2018 Gardner Denver Inc Printed in U S A ...

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