This document is an operating and service manual for a Gardner Denver Variable Speed Single Stage Stationary Base-Mounted Compressor, specifically models VS200-250B, with power ratings of 200 and 250 kW, operating at 60 Hz. The compressor is equipped with an AirSmart™ Controller.
Function Description
The Gardner Denver Rotary Screw compressor is a positive displacement rotary compressor designed for industrial applications. It uses meshing helical rotors to compress air. Oil is injected into the compression chamber to remove heat, lubricate moving parts, and seal internal clearances. The compressed air/oil mixture then enters an oil reservoir where oil is separated from the air. The nearly oil-free air is then directed to a distribution network. The variable speed drive (VFD) allows the compressor to match its air supply (flow capacity) to the customer's demand in real-time, providing step-less modulation of speed.
Important Technical Specifications
- Compressor Type: Variable Speed, Single Stage, Stationary Base-Mounted, Rotary Screw.
- Models Covered: VS200-250B.
- Power Ratings: 200 kW, 250 kW.
- Frequency: 60 Hz.
- Pressure Range: 100 THRU 175 PSIG.
- Controller: AirSmart™ Controller.
- Oil Separation Performance: Designed to yield 2 ppm total oil carryover at the discharge of the air/oil reservoir.
- Ambient Operating Temperatures: 40°F to 113°F (at up to 1000 meter elevation).
- Minimum Discharge Pressure/Check Valve: Maintains a minimum pressure of 80 psig (5.5 bar) within the air/oil reservoir.
- Pressure Relief Valve Setting: Protects against pressures exceeding 200 psig.
- Electrical Power: Designed to operate with 3ph-60Hz-460vac electrical power.
- Enclosure: IP54 protected electrical enclosure.
- Cooling Air Flow Requirements (Air-Cooled):
- 200 kW: 24266 CFM (Heat Exchangers), 5270 CFM (Enclosure Ventilation Fans).
- 250 kW: 25770 CFM (Heat Exchangers), 5270 CFM (Enclosure Ventilation Fans).
- Water Flow Requirements (Water-Cooled, Maximum Water Flow): 150 gpm for both 200 kW (VS200A) and 250 kW (VS250A) models.
- Maximum Allowable Supply Water Pressure (Water-Cooled): 150 psig (10.3 bar).
- Maximum Allowed Package Outlet Water Temperature (Water-Cooled): 110°F (43°C).
- Lubricant: Factory-filled with Gardner Denver AEON™ 9000SP synthetic lubricating coolant (polyalphaolefin - PAO).
Usage Features
- AirSmart Controller: Integrates all control functions under microprocessor control, including safety, shutdown, compressor regulation, operator control, and advisory/maintenance indicators. The keypad and display provide logical and easy operation.
- Variable Speed Drive (VFD): Allows the compressor to match air supply to demand in real-time, offering step-less fashion operation.
- Oil Mixing Valve: Prevents water vapor condensation in the oil system by mixing cooled and hot oil to maintain discharge temperature above the saturation level of water vapor.
- Inlet (Poppet) Valve: Blocks off the compressor intake during stoppage to maintain pressurization for quick re-start and prevents air/oil backflow.
- Blow Down Valve: Vents compressed air from the air/oil sump when compressor operation is halted.
- Shaft Seal Drain Valve: Collects and drains oil bypassing the compressor shaft seal.
- Air Filter Vacuum Switch: Monitors vacuum pressure at the inlet air filter and triggers a service notification when necessary.
- Safety Features: Includes pressure relief valve, minimum pressure/check valve, and various electrical safety interlocks.
- Installation: Designed for installation in a clean, well-lighted, well-ventilated area. Air-cooled units require ample clearance for air flow, while water-cooled units require sufficient cooling water flow.
- Cold Weather Operation: Recommended to install in a heated shelter (above 40°F, 5°C) for cold climates. Water-cooled units must be installed in a heated shelter.
Maintenance Features
- Genuine Parts: Emphasizes the use of genuine Gardner Denver compressor parts, lubricants (AEON™ 9000SP), and filters for optimal dependability and extended service intervals.
- Service Manual: Provides detailed instructions for operation and maintenance.
- Maintenance Schedule: Includes a comprehensive service checklist with intervals for:
- Every 8 Hours: Check air/oil reservoir oil level, machine operation (loading/unloading), discharge pressure/temperature, and control panel for advisories.
- Every 125 Hours: Check and clean cooler/fan faces.
- Every 1000 Hours / 3 Months: Replace oil filter element, clean/replace control box filter.
- Every 2000 Hours / 6 Months: Replace air filter element, take oil sample, replace package enclosure filter pad.
- Every 4000 Hours / 12 Months: Replace air/oil separator, inspect scavenge line, inspect inlet valve, check shaft seal for leakage, inspect/re-grease motor bearings, inspect/replace drive belts, replace lubricant (under adverse conditions), check pressure relief valve.
- Every 8000 Hours / 24 Months: Inspect/replace solenoid valves/vacuum switch, blow-down valve, thermistor probes, pressure transducer, minimum pressure/check valve, thermal mixing valve, drive coupling spider, hoses, and turn valve.
- Oil Analysis: Recommends frequent oil analysis to identify quality and remaining operational life, with a sampling valve provided.
- Filter Element Replacement: Instructions for replacing oil filter and air filter elements.
- Heat Exchanger Cleaning: Procedures for cleaning air-cooled heat exchanger cores, with a caution against using caustic liquids on aluminum cores.
- Coupling Maintenance: Instructions for inspection, removal, and installation of coupling elements and hubs.
- Troubleshooting Guide: Provides symptoms, possible causes, and remedies for common operational issues (e.g., compressor fails to start, excessive oil consumption, high discharge temperature, VFD shutdown, oil carryover, low discharge temperature).
- Warranty: Standard warranty covers various components for specified periods, emphasizing regular maintenance and use of genuine parts to avoid voiding the warranty.
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