This document is an Operating and Service Manual for Gardner Denver Variable Speed Single Stage Stationary Base-Mounted Compressors, specifically models VS80A and VS110A, with power ratings of 80-110kW and operating at 60Hz. The manual provides essential information for day-to-day operation, maintenance, and adjustment to ensure optimal performance and minimize downtime.
Function Description:
The Gardner Denver Variable Speed Single Stage Stationary Base-Mounted Compressor is a positive displacement rotary screw compressor designed to deliver continuous, smooth, and shock-free compressed air. It utilizes meshing helical rotors within a one-piece cylinder to achieve compression. Air is drawn into the cavity between the main rotor lobes and gate rotor grooves, trapped, and then compressed as the rotors mesh, reducing volume and increasing pressure. Oil is injected into the cylinder for heat removal, sealing internal clearances, and lubricating the rotors. The compressor package integrates various components including an AirSmart™ controller, main drive motor, Variable Frequency Drive (VFD), oil/air cooling system, and a sound-attenuating enclosure.
Important Technical Specifications:
- Models: VS80A, VS110A
- Power Ratings: 80-110kW
- Frequency: 60Hz
- Controller: AirSmart™ Controller (Manual 13-17-600)
- Lubricant: Factory-filled with Gardner Denver AEON™ 9000SP synthetic lubricating coolant. This is a polyalphaolefin (PAO) synthetic lubricant formulated for rotary screw compressor service.
- Oil Capacity: Approximately 16 gallons for VS80/110 package to fill all lines and components and achieve normal oil level.
- Air/Oil Separation: Designed to yield 2 ppm total oil carryover at the discharge of the air/oil reservoir.
- Minimum Pressure Valve: Maintains a minimum pressure of 80 psig (5.5 bar) within the air/oil reservoir.
- Pressure Relief Valve: Protects components from pressures exceeding 200 psig.
- Operating Temperature Range: 40°F to 113°F (at up to 1000 meter elevation).
- Electrical Power: Designed to operate with 3ph-60Hz-460Vac electrical power. Step-down transformers are included for 3ph-60Hz-575Vac electrical power.
- Enclosure: IP54 protected electrical enclosure for VFD and controller.
- Cooling Air Flow Requirements (Air Cooled):
- VS80: 14299 CFM (Heat Exchangers), 3895 CFM (Enclosure Ventilation Fans)
- VS110: 15183 CFM (Heat Exchangers), 3895 CFM (Enclosure Ventilation Fans)
- Cooling Water Flow Requirements (Water Cooled, Maximum Water Flow):
- VS80A: 48 gpm (at 60-90°F inlet water temp)
- VS110A: 48 gpm (at 60-90°F inlet water temp)
- Maximum Allowable Supply Water Pressure (Water Cooled): 150 psig (10.3 bar)
- Maximum Allowed Outlet Water Temperature (Water Cooled): 110°F (43°C)
- Cooling Water Quality Standards: Total Dissolved Solids <500 ppm, Iron <2 ppm, Total Hardness <60 ppm, Silica <25 ppm, Oil and Grease <5 ppm, Sulfate <50 ppm, Chloride <50 ppm, Nitrate <2 ppm, Langelier Index between 0 to 1.
- Line Reactor Sizing Recommendations: Specific GD Part Numbers are provided for 400/480V and 575V models based on VFD HP ratings and Max KVA.
Usage Features:
- AirSmart™ Controller: Integrates all control functions, including safety, shutdown, regulation, operator control, and advisory/maintenance indicators. The keypad and display provide logical and easy operation.
- Variable Speed Drive (VFD): Controls the compressor motor to match compressed air supply to demand in real-time, offering step-less modulation of compressor speed.
- Prestart-Up Instructions: Emphasizes checking oil level, ensuring clean air filters, checking coupling tightness, verifying piping, and proper electrical wiring and grounding.
- Motor Rotation Check: Utilizes the controller's "JOG MODE" to verify correct rotation of the compressor motor, heat exchanger cooling fan, and main motor cooling fan.
- Target Pressure Setting: Allows users to set the operating point of the compressor via the AirSmart™ controller.
- Unload and Load Pressure Settings: Configurable through the controller to define when the compressor unloads/stops and starts up again after unloading.
- Automatic Start/Stop: The unit can be started by pushing the green "START" button and stopped by pressing the red "STOP/RESET" button.
- Oil Mixing Valve (Electronic): Prevents water vapor condensation in the oil system by mixing cooled and hot oil to maintain an optimal compressor discharge temperature.
- Water Flow Regulating Valve (Optional): Adjusts cooling water flow in proportion to temperature to maintain optimal heat exchanger performance.
- Water Flow Shutoff Valve: Completely shuts off cooling water flow when compressors are not operating, preventing waste.
Maintenance Features:
- Service Check List: Provides a detailed schedule for maintenance tasks at various intervals (Every 8 hours, 125 hours, 1000 hours/3 months, 2000 hours/6 months, 3000 hours/9 months, 4000 hours/12 months, 8000 hours/24 months).
- Oil Filter Replacement: Recommended every 1000 hours or 3 months, or sooner depending on operating conditions.
- Air Filter Element Replacement: Recommended every 2000 hours or 6 months, or as indicated by the controller.
- Air/Oil Separator Replacement: Recommended every 4000 hours or 12 months, or as indicated by the controller.
- Oil Analysis Program: Gardner Denver offers a free oil analysis program for AEON™ 9000SP lubricant; first sample recommended between 40-100 hours of operation.
- Oil System Draining and Cleaning: Detailed procedure for draining the complete system, especially when oil is hot, to prevent varnish deposits and remove impurities.
- Motor Lubrication: Specifies KLUBER QUIET BQ 72-72 grease (GD Part No. 28H311, 28H312, 28H313) with a regreasing interval of 3000 hours for 80-110kW motors in continuous operation, humid, dirty, high ambient sites.
- Heat Exchanger Cleaning: Procedures for cleaning air-cooled heat exchanger cores using compressed air or water, avoiding caustic liquids.
- Ventilation Filter Maintenance: Regular inspection and cleaning (with soapy water) or replacement of electrical enclosure ventilation filters to ensure efficient electronics operation.
- Coupling Element Inspection and Replacement: Instructions for inspecting the curved jaw-type coupling element for wear and tear and replacement if necessary.
- Interference-fitted Coupling Hub Installation and Removal: Detailed steps for installing and removing coupling hubs using specialized tools and heat dilation, with warnings about potential shaft seal damage.
- Minimum Pressure/Check Valve Inspection: Procedure for inspecting internal parts and reassembling the valve.
- Pressure Relief Valve Check: Annual testing of the pressure relief valve by manually opening and allowing it to snap shut.
- Inlet Control Valve Inspection: Procedure for inspecting poppet seals and other internal components for wear and tear.
- Water Separator and Drain Maintenance: Instructions for cleaning the collection bowl and drain valve.
Safety Precautions:
The manual includes numerous DANGER, WARNING, and CAUTION notices to ensure user safety and prevent equipment damage. Key safety points include:
- Always disconnect, lockout, and tagout power supply and relieve air pressure before any service or inspection.
- Avoid electric welding on the compressor or base to prevent bearing damage.
- Do not operate the compressor with guards removed.
- Do not use discharge air for breathing without proper filtration.
- Do not adjust discharge air pressure above the maximum stamped on the nameplate.
- Use only genuine Gardner Denver parts and lubricants.
- Do not mix different types of lubricants.
- Do not operate the unit without the air filter element.
- Do not paint, lubricate, or alter the pressure relief valve.
- Ensure proper grounding of the compressor package.
- Exercise caution around hot surfaces and rotating machinery.
- Do not restart the unit repeatedly after high-temperature shutdown without correcting the malfunction.
- Ensure water-cooled units are installed in a heated shelter to prevent freezing.
Need help?
General
To Next Page