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Gardner Denver VS45A User Manual

Gardner Denver VS45A
74 pages
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GARDNER DENVER
®
13-18-601
Version: 02
October 11, 2005
VS45-70A
VARIABLE SPEED, SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AIRSMART CONTROLLER
DOMESTIC MODELS
VS45-50-70A
45-50-70kW
60HZ
OPERATING AND
SERVICE MANUAL

Table of Contents

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Gardner Denver VS45A Specifications

General IconGeneral
BrandGardner Denver
ModelVS45A
CategoryAir Compressor
LanguageEnglish

Summary

OPERATING AND SERVICE MANUAL

Genuine Parts and Support Services

Information on genuine Gardner Denver compressor parts and support services.

Ordering Repair Parts

Guidelines for specifying and ordering necessary repair parts for compressors.

Safety Precautions

Hazard Warning Labels

Explains DANGER, WARNING, CAUTION labels and associated hazards.

Prohibition and Mandatory Actions

Lists prohibited actions and required safety procedures for operation.

Section 1 General Information

Compression Cycle and Principle

Details the rotary screw compressor's compression cycle and operating principle.

Air Flow and Lubrication Systems

Describes air flow path, oil system, and cooling mechanisms within the compressor.

Section 2 Installation

General Installation and Handling

Covers unit receipt, inspection, lifting, and handling precautions.

Compressor Room Requirements

Specifies requirements for the installation environment, including ventilation.

Foundation and Enclosure

Details foundation requirements and enclosure access for maintenance.

Electrical Wiring and Grounding

Provides guidelines for electrical wiring, grounding, and line reactor installation.

Section 3 Starting & Operating Procedures

Pre-Start Up and Initial Checks

Outlines essential checks and procedures before operating a new compressor unit.

System Pressure and Controller Settings

Explains how to set system pressure and operate the AirSmart controller.

Unit Starting and Stopping

Details the correct procedures for starting and stopping the compressor unit.

Section 4 Controls & Instrumentation

AirSmart Controller Functionality

Describes the AirSmart controller's integration of functions, safety, and regulation.

Main VFD and Motor Operation

Explains the role of the Variable Frequency Drive (VFD) and motor in matching air supply to demand.

Section 5 Compressor Lubrication – Separation, Filtration and Controls

Compressor Oil System Overview

Details the function and components of the compressor's oil system.

Oil Maintenance and Change Intervals

Covers oil change intervals, draining, cleaning, and recommended lubricants.

Compressor Oil Filter Service

Describes the function and replacement procedure for the compressor oil filter.

Oil Separation and Coalescing Element

Explains the oil separation process and monitoring of the coalescing element.

Section 6 Heat Exchangers (Oil, Air)

Heat Exchanger Functionality

Explains how heat exchangers manage compression heat for optimal efficiency.

Air-Cooled Heat Exchanger Maintenance

Details the maintenance and cleaning requirements for air-cooled heat exchangers.

Water-Cooled Heat Exchanger Requirements

Outlines cooling water flow rates, quality standards, and valve requirements.

Section 7 Air Filter

Air Filter Function and Care

Describes the air filter's role in cleaning intake air and the importance of its cleanliness.

Filter Element Inspection and Replacement

Provides instructions for inspecting and replacing the air filter element.

Section 8 Shaft Coupling

Shaft Coupling Components and Function

Explains the function of shaft couplings and their components.

Coupling Element Inspection and Replacement

Details the procedure for inspecting and replacing the coupling element.

Section 9 Minimum Pressure/Check Valve

Minimum Pressure/Check Valve Function

Describes the valve's role in maintaining reservoir pressure and preventing backflow.

MPV Inspection Procedure

Provides a step-by-step guide for inspecting the Minimum Pressure/Check Valve.

Section 10 Inlet Control Valve

Inlet Control Valve Function

Explains the valve's function in controlling compressor intake air.

Inlet Control Valve Inspection

Outlines the procedure for inspecting the inlet control valve for wear.

Section 11 Pressure Relief Valve

Pressure Relief Valve Function

Describes the valve's purpose in protecting against over-pressurization.

Pressure Relief Valve Inspection

Details the procedure for testing the pressure relief valve's operation.

Section 12 Ventilation Filters (Electrical Enclosure)

Ventilation Filter Function

Explains the role of filters in maintaining electronics efficiency and preventing stoppages.

Filter Inspection and Cleaning

Provides instructions for inspecting and cleaning ventilation filter elements.

Section 13 Motor Lubrication

Motor Lubrication Procedure

Details the procedure for greasing electric motor bearings.

Motor Grease Specifications

Lists recommended grease types and part numbers for motor lubrication.

Motor Regreasing Intervals

Specifies lubrication intervals based on service type (Standard vs. Severe).

Section 14 Maintenance Schedule

Daily and Weekly Checks

Lists routine daily and weekly maintenance tasks for the compressor.

Periodic Maintenance Intervals

Outlines required maintenance tasks at 1000 and 8000-hour intervals.

Yearly Maintenance Tasks

Details annual checks for heat exchangers, relief valve, motor lubrication, and couplings.

Section 15 Troubleshooting

Compressor Failures to Start

Lists possible causes and remedies for compressor start-up failures.

Operational Issues and Solutions

Addresses issues like compressor not unloading, excessive cycling, and low pressure.

Temperature and Oil Related Issues

Provides solutions for high discharge temperatures and excessive oil consumption.

Warranty Information

General Warranty Provisions

Covers general terms, limitations, and exclusions of the product warranty.

Warranty Periods by Component

Specifies the warranty duration for different compressor components like airends and major parts.

Labor, Disclaimer, and Claims

Outlines labor coverage, warranty disclaimers, and procedures for making claims.

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