Gardner Denver VS45A, VS50A, VS70A Operating And Service Manual

GARDNER DENVER®

VS45-70A

VARIABLE SPEED, SINGLE STAGE

STATIONARY BASE-MOUNTED

COMPRESSOR

AIRSMART™ CONTROLLER

13-18-601

Version: 02

October 11, 2005

DOMESTIC MODELS

VS45-50-70A

45-50-70kW

60HZ

OPERATING AND

SERVICE MANUAL

Gardner Denver

MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH

GENUINE GARDNER DENVER

®

Compressor genuine parts, manufactured to design tolerances, are developed for optimum

®

COMPRESSOR PARTS AND SUPPORT SERVICES

dependability – specifically for Gardner Denver compressor s ystems. Design and material innovations are the result
of years of experience with hundreds of different compressor applications. Reliability in materials and quality
assurance is incorporated in our genuine replacement parts.

Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. An AirSmart

™

network of
authorized distributors provides the finest product support in the air compressor industry. Your loca l authorized
distributor maintains a large inventory of genuine parts and he is backed up for emergency parts by direct access to
the Master Distribution Center (MDC) in Memphis, Tennessee.

Your authorized distributor can support your Gardner Denver air compressor with these services:

1. Trained parts specialists to assist you in selecting the correct replacement parts.

2. Factory warranted new and remanufactured rotary screw airends. Most popular model remanufactured
airends are maintained in stock at the Remanufacturing Center in Indianapolis, IN., for purchase on an
exchange basis with liberal core credit available for the replacement 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 c ompressor.

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, expert maintenance and repair services.

For the location of your local authorized Gardner Denver Air Compressor distributor, refer to the yellow
pages of your phone directory or contact:

Distribution Center:

Gardner Denver
Master Distribution Center
5585 East Shelby Drive

Gardner Denver

Factory:

1800 Gardner Expressway
Quincy, IL 62301

Memphis, TN 38141
Phone: [phone]

Phone: [phone]

[phone]
Fax: [phone] Fax: [phone]

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Compressor MODEL, Method of Cooling, POWER and SERIAL NUMBER (see
nameplate on unit). The airend Serial Numbers are also stamped on top of the discharge bear ing carrier castings.

All orders for Parts should be placed with the nearest authorized distributor.
Where NOT specified, quantity of parts required per compressor or unit is one (1); where more than one is required

per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right-Hand and Left-Hand side of a compressor, stand at the motor end and look toward the

compressor. Right-Hand and Left- Hand are indicated in parenthesis following the part name, i.e. (RH) and (LH),
when appropriate.

13-18-601 Page 1

WARNING – PROHIBITION – MANDATORY LABEL INFORMATION

Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled
manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise
care in its operation and maintenance. This book is written to give the operator and maintenance
department essential information for day-to-day operation, maintenance and adjustment. Careful
adherence to these instructions will result in economic al 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 automatically

Cutting of Finger or Hand Hazard – Rotating

impeller blade

Cutting of Finger or Hand Hazard – Rotating fan

blade

Health Hazard – Explosive Release of Pressure

High Voltage – Hazard of Shock, Burn, or Death

Present until Electrical Power is Removed

Entanglement of Fingers or Hand/Rotating Shaft

13-18-601 Page 2

Indicates a hazard with a medium level of risk which, if not avoided, COULD
result in death or serious injury.

Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air

Indicates a hazard with a low level of risk which, if not avoided, MAY
minor or moderate injury.

Burn Hazard – Hot surface

PROHIBITION/MANDATORY ACTION REQUIREMENTS

result in a

Do not Operate Compressor with Guard Removed

Do Not Lift Equipment with Hook – No Lift Point

Handle Package at Forklift Points Only

13-18-601 Page 3

Lockout Electrical Equipment in De-Energized

State

Loud Noise Hazard – Wear Ear Protection

Read the Operator’s Manual Before Proceeding

with Task

SAFETY PRECAUTIONS

Safety is everybody’s business and is based on your use of good common sense. All situations or
circumstances cannot always be predicted and covered by establi s hed rules. Therefore, use your past
experience, watch out for safety hazards and be cautious. Some general safety precautions are given
below:

Failure to observe these notices could result in injury to or death of personnel.

• Keep fingers and clothing away

• Disconnect the compressor unit

unit – this machine is automatically controlled and may start at any time.

• Do not loosen or remove the oil filler plug, drain plugs, covers, the thermostatic mixing valve or
break any connection s, etc., in the compressor air or oil system until the unit is shut down and
the air pressure has been relieved.

• Electrical shock

• Perform all wiring

local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.

• Open main disconnect switch
and check for voltage.

can and may be fatal.

in accordance with the National Electrical Code (NFPA-70) and any applicable

from rotating fan, drive coupling, etc.

from its power source, lockout and tagout before working on the

, lockout and tagout before working on the control, wait 10 minutes

Failure to observe these notices could result in damage to equipment.

• Stop the unit

• Do not use the air discharge

• An Excess Flow Valve

inside diameter (OSHA Regulation, Section 1926.30 2).

• Do not exceed the rated maximum pressure values shown on the nameplate.

• Do not operate unit

bypass safety d evices.

if any repairs or adjustments on or around the compressor ar e req uired.

from this unit for breathing – not suitable for human consumption.

should be on all compressed air supply hoses exceeding 1/2 inch

if safety devices are not operating properly. Check periodically. Never

13-18-601 Page 4

TABLE OF CONTENTS

Maintain Compressor Reliability And Performance With Genuine

Gardner Denver Compressor Parts And Support Services.....................................................................1

Instructions For Ordering Repair Parts.........................................................................................................1

Warning – Prohibition – Mandatory Label Information..............................................................................2, 3

Safety Precautions........................................................................................................................................4

Index..............................................................................................................................................................6

List Of Illustrations.........................................................................................................................................7

Section 1, General Information .....................................................................................................................8

Section 2, Installation..................................................................................................................................13

Section 3, Starting & Operating Procedures...............................................................................................19

Section 4, Controls & Instrumentation ........................................................................................................26

Section 5, Compressor Lubrication - Separation, Filtration And Controls..................................................39

Section 6 - Heat Exchangers (Oil, Air)........................................................................................................47

Section 7, Air Filter......................................................................................................................................53

Section 8, Shaft Coupling............................................................................................................................55

Section 9, Minimum Pressure/Check Valve................................................................................................58

Section 10, Inlet Control Valve....................................................................................................................60

Section 11, Pressure Relief Valve ..............................................................................................................62

Section 12, Ventilation Fans, Filters (Electrical Enclosure)........................................................................64

Section 13, Motor Lubrication .....................................................................................................................65

Section 14, Maintenance Schedule ............................................................................................................66

Section 15, Troubleshooting.......................................................................................................................68

This book covers the following models:

KW PSIG

45, 50, 70 100 THRU 175 VS45-70A 13-18-500 13-17-600

Air Cooled and

Water Cooled

Parts List

Controller

Manual

NOTICE

Gardner Denver factory remanufactured replacement compressor
airend units are available from your authorized distributor, on an
exchange basis, for all rotary screw compressor units.

13-18-601 Page 5

Air Filter, Section 7...........................................53

Air Flow In The Compressor System.................8

Air-Cooled Units, Location ...............................14

Auxiliary Air Receiver.......................................16

Cold Weather Installation.................................15

Compression Principle.......................................8

Compressor Lubrication – Separation, Filtration

And Controls, Section 5................................39

Control Piping...................................................16

Controls & Instrumentation, Section 4 .............26

Discharge Service Line....................................16

Electrical Wiring ...............................................17

Enclosure .........................................................15

Foundation .......................................................15

General Information, Section 1 ..........................8

Grounding.........................................................18

Heat Exchangers (Oil, Air), Section 6 ..............47

Inlet Control Valve, Section 10.........................60

Inlet Line...........................................................16

Installation, Section 2.......................................13

Lifting Unit ........................................................13

Location

Air-Cooled Units ...........................................14

Water-Cooled Units......................................14

Location............................................................13

Lubrication

Cooling............................................................8

Sealing............................................................8

Maintenance Schedule, Section 14 .................66

Minimum Pressure/Check Valve, Section 9.....58

Moisture Separator/Trap..................................16

Oil Filter............................................................42

Oil Reservoir Drain...........................................15

INDEX

Oil System

Addition Of Oil Between Changes................40

Compressor..................................................39

Draining And Cleaning.................................41

Moisture........................................................40

Oil Change Interval ......................................41

Oil Filter........................................................42

Oil Mixing Valve............................................43

Oil Separation Reservoir/Coalescing Element

..................................................................44

Oil Sight Glass..............................................40

Oil Specifications..........................................39

Recommended Lubricant.............................39

Refilling Oil...................................................42

Piping

Blow Down Valve .........................................16

Control..........................................................16

Water............................................................16

Pressure Relief Valve, Section 11...................62

Prestart-Up Instructions...................................19

Quick Start Guide.............................................21

Safety Precautions.............................................4

Service Check List...........................................66

Every 1000 Hours ........................................66

Every 8000 Hours ........................................66

Weekly..........................................................66

Yearly...........................................................67

Shaft Coupling, Section 8................................55

Starting & Operating Procedures, Section 3....19

Starting The Unit..............................................23

Stopping The Unit............................................24

Troubleshooting, Section 15............................68

Ventilation Filters (Electrical Enclosure), Section

12 .................................................................64

Warning – Prohibition – Mandatory Label

Information .....................................................2

Water-Cooled Units, Location..........................14

13-18-601 Page 6

LIST OF ILLUSTRATIONS

Figure 1-1 – Compression Cycle ..................................................................................................................8

Figure 1-2 – Package Illustration (Air-Cooled) – External Details................................................................9

Figure 1-3 – Package Illustration (Air-Cooled) – Internal Details................................................................10

Figure 1-4 – Package Illustration (Water-Cooled) – External Details.........................................................11

Figure 1-5 – Package Illustration (Water-Cooled) – Internal Details ..........................................................12

Figure 2-1 – Typical Compressor Room.....................................................................................................14

Figure 2-2 – Package Maximum Current Consumption Summary.............................................................17

Figure 2-3 – Line Reactor Sizing Recommendations.................................................................................18

Figure 4-1 – Electrical Enclosure Hardware ...............................................................................................27

Figure 4-2 – Piping And Instrumentation Illustration...................................................................................30

Figure 4-3 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control.....................................................31

Figure 4-4 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control.....................................................32

Figure 4-5 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control.....................................................33

Figure 4-6 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control.....................................................34

Figure 4-7 – Wiring Diagram – (Water-Cooled) Single-Stage VS Control................................................35

Figure 4-8 – Wiring Diagram – (Water-Cooled) Single-Stage VS Control................................................36

Figure 4-9 – Wiring Diagram – (Water-Cooled) Single-Stage VS Control................................................37

Figure 4-10 – Wiring Diagram – (Water-Cooled) Single-Stage VS Control..............................................38

Figure 5-1 – Checking Oil Level..................................................................................................................42

Figure 5-2 – Changing Oil Filter..................................................................................................................42

Figure 5-3 – Thermostatic Mixing Valve Element.......................................................................................43

Figure 5-4 – Pressure Dew Point Of Compressed Air................................................................................44

Figure 5-5 – Changing Oil Coalescing Element..........................................................................................46

Figure 6-1 – Air Flow Chart........................................................................................................................48

Figure 6-2 – Cooler Housing Side Covers.................................................................................................49

Figure 6 3 – Water-Cooled Heat Exchanger Coolant Requirements.........................................................49

Figure 6-4 – Water Control Valve...............................................................................................................51

Figure 7-1 – Air Filter (Standard)................................................................................................................53

Figure 8-1 – Coupling Components............................................................................................................55

Figure 8-2 – Coupling Element...................................................................................................................56

Figure 8-3 – Motor Removal Hardware.......................................................................................................56

Figure 9-1 – Minimum Discharge Pressure/Check Valve...........................................................................59

Figure 10-1 – Inlet Control Valve................................................................................................................60

13-18-601 Page 7

SECTION 1
GENERAL INFORMATION

Figure 1-1 – COMPRESSION CYCLE

COMPRESSOR – Your Gardner Denver Rotary Screw package is fitted with one (1) single stage, positive

displacement rotary compressor using meshing helical rotors to effect compression. Each pair of rotors is
supported between high capacity anti-friction bearings located outside the compression chamber. Single
cylindrical roller bearings are used at each end of the rotors to carry the radial loads. An additional
angular contact ball bearing is located at the discharge end of each rotor to carry axial thrust loads. The
main rotor sits next to its gate companion, in a side-by-side configuration.

COMPRESSION PRINCIPLE (Figure 1-1) - Compression is accomplished by the main and gate rotors
synchronously meshing in a one-piece cylinder. The main rotor has four (4) helical lobes, 90° apart,
which mesh with five (5) helical grooves, 72° apart, on its matching gate rotor.

The air inlet port is located on top of the compressor cylinder, and the discharge port is located below the
compressor cylinder. The compression cycle begins as the rotors unmesh 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 remove the heat of compression and seal internal clearances. Volume
reduction and pressure continues to increase until the air/oil mixture trapped in the interlobe cavity by the
rotors passes the discharge port (C). Each rotor cavity follows the same “fill-compress-discharge” cycle in
rapid succession to produce a discharge air flow that is continuous, smooth and shock free.

AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 4-2, page 30) - Air enters the air filter and passes
through the inlet control [poppet] valve to the compressor inlet flange. After compression, the air/oil
mixture enters the oil reservoir where most of the entrained oil is removed by change of direction and
impingent. It is further removed by centrifugal action and drained down into the reservoir. The air and
remaining aerosols pass into twin coalescing elements where the oil is captured and drained through a
drain line back into a lower pressure region of the compressor. The nearly oil-free air passes through the
minimum pressure valve, aftercooler, moisture separator, and finally to the distribution network.

LUBRICATION, COOLING AND SEALING (Figure 4-2, page 30) - Oil is forced by differential pressure
from the oil reservoir through the oil cooler, servo-driven oil mixing valve, oil filter, and enters the
compressor. A portion of the oil is directed to internal passages within the compressor to lubricate the
bearings and shaft oil seals. The balance of the oil is injected into the compressor rotors to remove the
heat of compression, seal internal clearances and lubricate the rotors.

13-18-601 Page 8

g

13-18-601 Page 9

302CGD804-B
(Ref. Drawing)

e 1 of 2

Pa

Figure 1-2 – PACKAGE ILLUSTRATION (AIR-COOLED) – External Details

13-18-601 Page 10

Figure 1-3 – PACKAGE ILLUSTRATION (AIR-COOLED) – Internal Details

302CGD804-B
(Ref. Drawing)
Page 2 of 2

13-18-601 Page 11

303CGD804-A
(Ref. Drawing)
Page 1 of 2

Figure 1-4 – PACKAGE ILLUSTRATION (WATER-COOLED) – External Details

13-18-601 Page 12

303CGD804-A
(Ref. Drawing)
Page 2 of 2

Figure 1-5 – PACKAGE ILLUSTRATION (WATER-COOLED) – Internal Details

SECTION 2
INSTALLATION

GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit.

Report any damage or missing parts as soon as possible.

Do not electric weld on the compressor or base; bearings can be damaged by
passage of current.

LIFTING UNIT - Proper lifting and/or transporting methods must be used to prevent damage. Lifting slots

are provided in the base for tow motor use. The unit may also be moved into location by rolling on bars.

C

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Lift compressor package by base only. Do not use other places such as
motors, compressors 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, separator chamber and all piping and tubing may
be at high temperature during and after operation.

LOCATION - The compressor package shall be installed in a clean, well-lighted, well-ventilate d area with

ample space all around for maintenance. Select a location that provides a cool, clean, dry source of air.
In some cases it may be necessary to install duct works to reach a source of adequate cooling air or to

13-18-601 Page 13

direct cooling air in and out of the compressor package, to prevent recirculation (e.g., hot cooling air
entering the fresh air inlet). The package is designed to operate at ambient temperatures ranging from
40°F to 113°F (at up to 1000 meter elevation). Contact Gardner Denver for package operation at
conditions exceeding the stipulated values.

A typical ventilation arrangement is shown in Figure 2-1.

Figure 2-1 – TYPICAL COMPRESSOR ROOM

When selecting the compressor package location, be aware that its noise level 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 is supplied as standard equipment on all air-cooled
packages. The heat exchangers require sufficient cooling air flow to operate efficiently – please refer to
Section 6, Fig 6-1 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.

Cooling air for the heat exchangers, main motors, and electronics box is drawn in at the intake grill end of
the enclosure and is exhausted through a roof vent. Refer to Package Illustrations on Figure 1-2 and
Figure 1-3, pages 9 and 10, for hardware details.

Do not block flow of air entering or exiting the enclosure - allow a minimum of 3-1/2 feet (1.1 m) clearance
to the nearest obstruction all around and on top.

Water-Cooled Units – Separate brazed plate-type coolers for air and oil services are supplied on water­cooled packages. The heat exchangers require sufficient cooling water flow to operate efficiently – please
refer to Section 6 of this manual for detailed instructions on the operation and maintenance of water­cooled heat exchangers, including minimum cooling water flow requirements.

13-18-601 Page 14

Air for motor cooling and for the compressor intake is drawn in at the intake grill end of the enclosure and
exhausted via a smaller roof vent – refer to Section 6 of this manual for enclosure ventilation
requirements. Refer to Package Illustrations on Figure 1-4 and Figure 1-5, page s 11 and 12, for
hardware details.

Do not block flow of air entering or exiting the enclosure - allow minimum of 3-1/2 feet (1.1 m) clearance
to the nearest obstruction all around and on top.

FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but
should be mounted on a smooth, solid surface and as near level as possible. Temporary installation may
be made at a maximum 10° angle lengthwise or 10° sidewise.

Mounting 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 mounting bolts
and shims to provide uniform support for the base.

OIL RESERVOIR DRAIN – Sump drain port, located near the oil filter, is 9” 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.

2. Construct an oil sump or trough below the floor level and pump or bail the drained oil.

3. Pump oil from the reservoir filler opening or drain to a container.

ENCLOSURE - The compressors, electric motors and oil/air cooler assembly are mounted inside the
enclosure. Service doors are provided for maintenance access. Be sure to allow enough space around
the unit for the doors to open completely.

To remove the enclosure doors, open the door and lift it up slightly to disengage the hinges.

C

A

U

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O

C

C

A

A

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Ducting may be required on air-cooled enclosed machines.

Do not operate the compressors with the fan or coupling guard removed.
Exposed fan and couplings may cause personal injury.

INSTALLATION FOR COLD WEATHER OPERATION It is recommended that the unit be installed

inside a shelter that will be heated to temperatures above freezing (40° F, 5° C). This will eliminate many
of the problems associated with operating units in cold climates where freezing rain, drifting snow,
freezing condensate and bitter cold temperatures are encountered.

13-18-601 Page 15

Unsheltered (outside) installations should be avoided whenever possi ble. Installation next to a heated
building where enough heat can be used to keep the compressor room above freezing will save many
complications in the operation and installation of the unit.

Refer to Engineering Data Sheet 13-9-411, available from an authorized Gardner Denver distributor, for
the advantages of using the heat recovered from rotary compressors. This heat recovery could easily
pay for an adequate shelter for the unit.

AUXILIARY AIR RECEIVER - An auxiliary air receiver is not required if the piping system is large and
provides sufficient storage capacity to prevent rapid cycling. An adequate receiver capacity for the VS
units is ½ gallon for each cfm delivered by the compressor package.

MOISTURE SEPARATOR/TRAP - Since the unit is equipped with a built-in aftercooler, a combination
moisture separator and drain valve are furnished (loose) with the unit. The device must be piped at the
outlet of the compressor package during final installation. This device is not used on packages equipped
with integrated dryers!

CONTROL PIPING - Control piping is not necessary since the Gardner Denve r compressor package is
factory wired and piped for the control system specified.

INLET LINE – The air filter assembly used in the VS compressor package is not suitable for relocation, as
its housing assembly is an integral part of the enclosure sheet metal components. See LOCATION
comments on this section of the manual for duct work recommendations to bring in ventilation air.

DISCHARGE SERVICE LINE - The discharge service line connection on both water-cooled and air­cooled units is located at the upper right-hand area of the intake grill side of the enclosure. Gardner
Denver compressor packages are inherently isolated from the service line by their own minimum
pressure/check valves. Installer or end user must ensure that other compressors that are piped into a
common pipe manifold with the Gardner Denver compressor package are each provided with an isolation
check valve. It is recommended that an additional receiver be installed between the rotary screw and
reciprocating compressors sharing a common pipeline. Do not install another check valve in the unit’s
discharge line as operational upsets will occur.

Discharge air used for breathing will cause severe injury or death.

Consult filtration specialists 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 next to air discharge
connection.

13-18-601 Page 16

CAUTION

It is mandatory that any water-cooled unit be installed in a shelter heated to
temperatures above freezing (40°F., 5°C).

Please refer to Section 6 of this manual for detailed instructions on the installation, operation and
maintenance of the water-cooled heat exchangers.

ELECTRICAL WIRING - The compressor package is (internally) factory wired for use with the voltage
specified on the order - it is only necessary to connect power supply and ground wires to the provided
wire terminal blocks.

Electrical shock can cause injury or death. Open main disconnect switch,
lockout and tagout before working on control box.

Gardner Denver Guidelines for proper wiring, grounding and feed power conditioning - This

compressor package is provided with a variable speed drive (VFD) to control compressor motor. The
indicated Gardner Denver guidelines for proper wiring, grounding, and feed power conditioning must be
followed in order to protect the VFD electronics. Failure to do so will void your warranty.

Electrical Wire Sizing – A certified electrician familiar with National Electric Codes and applicable local
codes shall size the electrical power wires serving the compre ssor package. Refer to Figure 2-3, for a
summary of maximum package current consumption values.

Package Size Maximum Current Draw

VS45 100 Amps
VS50 117 Amps
VS70 160 Amps

Figure 2-2 – PACKAGE MAXIMUM CURRENT CONSUMPTION SUMMARY

Electrical Wire Routing – Routing of the electrical power wires into the electrical hardware e nclosure is

best done through its roof area.

Line Reactor – A line reactor provides conditioning of the electrical power supply to the compressor
package by attenuating noise and fluctuations. It shall be required in your particular application if any of
the following conditions exist:

• Transformer KVA is greater than recommended – see Figure 2-3, page 18.

• Line has switched Power Factor correction capacitors.

• Existing line reactor not properly sized – see Figure 2-3, page 18.

• Other large loads on the same power feed as the compressor.

13-18-601 Page 17

GD Model

VS45 400/480 60 900 90500140
VS50 400/480 75 1000 90500141
VS70 400/480 100 1000 90500142

Figure 2-3 – LINE REACTOR SIZING RECOMMENDATIONS

GROUNDING – Equipment must be properly grounded in accordance with the National Electrical Code

and/or applicable local codes.

Volts

VFD HP RATINGS

Max KVA

3% Line Reactor

GD Part Number

Failure to properly ground the compressor package could result in injury or
death. Install ground wiring in accordance with the National Electrical Code
and any applicable local codes.

MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large

measure on proper lubrication of the bearings. Refer to Section 13 of this manual for complete motor
lubrication specifications and details.

13-18-601 Page 18

SECTION 3
STARTING & OPERATING PROCEDURES

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Read the Operator’s Manual before operating the compressor.

PRESTART-UP INSTRUCTIONS - A new unit as received from the factory has been tested and then

prepared for shipping only. DO NOT attempt to operate the unit until checked and serviced as follows:

1. Compressor Oil - Check the oil level in the sump – with unit stopped, the oil level should reach the
top of the measuring rod visible through the sight glass. Add oil, with unit stopped and depressurized,
when the oil level reaches the bottom of the mark on the measuring rod. Do not mix different type
oils. When the unit is shipped, it is filled with Gardner Denver AEON™ 9000SP lubricating coolant,
suitable for the first 8000 hours under normal operating conditions.

N

O

N

O

N

O

Regular maintenance and replacement at required intervals of the oil filter, air
filter and air/oil separator is necessary to achieve maximum service and
extended drain intervals of AEON 9000SP synthetic lubricating coolant. Use
only genuine Gardner Denver filters designed and specified for this
compressor.

N

O

N

O

N

O

Whenever the oil is drained from the compressor (e.g., due to oil change or
compressor replacement), a minimum amount must be replenished to lubricate
and seal rotors during the start-up phase. Temporarily remove the flexible hose
between the air filter assembly and the intake poppet valve and add 1 gallon of
oil through the intake valve opening.

13-18-601 Page 19

Before removing the oil filler plug, always stop the unit and 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.

2. Air Filter - Inspect the air filter to be sure it is clean and the assembly is sealed tight. Refer to
Section 7, “Air Filter”, for complete servicing instructions. Be sure the inlet line is clean and sealed
tight.

3. Couplings - Check setscrews for tightness. See Section 8.

4. Piping - Refer to Section 2, “Installation,” and make sure piping meets all recommendations.

5. Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See
Figure 4-3 thru Figure 4-10, for general wiring diagrams and Section 2, for installation instructions.
Make sure to check the wiring of the optional compressed air dryer, as it is serviced by an
independent electrical power feed.

6. Grounding - Equipment must be properly grounded according to Gardner Denve r Guidelines for
proper wiring, grounding and feed power conditioning.

C

A

U

C

A

U

C

A

U

Failure to properly ground the compressor package could result in controller
malfunction.

N

O

T

N

O

T

N

O

T

T

T

T

I

I

O

N

I

O

N

I

O

N

C

E

I

C

E

I

C

E

Read the Operator’s Manual before operating the compressor.

7. Rotation - Check for correct rotation of all electric motors:

• Use controller “JOG MODE” to bump compressor motor. Proper rotation shall be clockwise

when facing the compressor shaft end.

• Start/Stop controller to bump heat exchanger cooling fan. Proper rotation shall be

counterclockwise facing rear of fan drive motor.

13-18-601 Page 20

• Start/Stop controller to bump main motor cooling fan. Proper rotation is achieved when cooling

air is discharged over the main motor body.

C

A

U

C

A

U

C

A

U

Operation with incorrect motor rotation can damage equipment and cause oil
eruption from the compressor inlet. When checking motor rotation, induce
minimum rotation (less than one revolution if possible). Never allow motor to
reach full speed.

C

A

U

C

A

U

C

A

U

The compressor unit’s direction of rotation must be checked every time the
compressor is reconnected to the power supply.

8. System Pressure – For your convenience, the following excerpt from the Controller Manual
13-17-600 is presented to assist in programming the system pressure:

Quick Start Guide

Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run

T

T

T

T

T

T

I

I

I

O

O

O

I

I

I

O

O

O

N

N

N

N

N

N

button to start the compressor, no other settings are required. The Target Pressure comes
preset from the factory at pressure as ordered. The Unload Pressure is preset to 10 psi higher. If a
different pressure setting is desired, the following steps can be used as a guide.

• Setting the Target Pressure

The Target Pressure setting is used to set the operating point of the compressor. To make any
adjustments in the operation of the compressor, the machine must be stopped and in the Ready

mode. Stop the compressor by pressing the Stop/Reset
should read “READY” on line 3.

0 PSI 75°F

10 HRS AUTOMATIC

NO SERVICE ADVISORY

READY

button. The front panel display

13-18-601 Page 21

Next, press the Enter

ADJUSTMENT MENU

OPERATION ADJUSTMENT

(SELECT SUB MENU)

Since the Target Pressure setting is under the Operation Adjustment menu, press Enter
again to access that sub-menu

OPERATION ADJUSTMENT

LANGUAGE-LANGUAGE

ENGLISH (US)

(SELECT PARAMETER)

The Target Pressure is the second item in the Operation Adjustment sub-menu so press the
Down

button to navigate to the Target Pressure setting.

OPERATION ADJUSTMENT

TARGET PRESSURE

(SELECT PARAMETER)

100 PSI

To change the Target Pressure, press the Enter

OPERATION ADJUSTMENT

TARGET PRESSURE

(EDIT PARAMETER)

100 PSI

A flashing cursor will appear covering the least significant digit in the Target Pressure value, use
the Plus

and Minus buttons to change its value. Use the Right and Left

buttons to move the cursor to other digits in the Target Pressure value. When the desired Target
Pressure value is displayed, press the Enter

button to access the Adjustment Menu tree

button to edit the value.

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.

STORE MODIFIED

PARAMETERS?

STOP = NO

ENTER = YES

To permanently save the changes that were made, press the Enter

button. If the
Stop/Reset button is pressed, the parameter changes will be lost the next time the compressor
power is turned off.

13-18-601 Page 22

• Setting the Unload and Load Pressure

After setting the Target Pressure, set the Unload and Load Pressures values in a similar fashion.
The Unload pressure is the third item in the Operation Adjustment sub-menu so press the Down

button to navigate to the Unload Pressure setting. The Unload Pressure will control at

which pressure the compressor unload and stops.

The Load pressure is the fourth item in the Operation Adjustment sub-menu so press the Down
pressure the compressor will startup again after unloading.

OPERATION ADJUSTMENT

UNLOAD PRESSURE

110 PSI

(SELECT PARAMETER)

button to navigate to the Load Pressure setting. The Load Pressure will control at which

OPERATION ADJUSTMENT

LOAD PRESSURE

100 PSI

(SELECT PARAMETER)

Operation at excessive discharge air pressure can cause personal injury or
damage to equipment. Do not adjust the full discharge air pressure above the
maximum stamped on the unit nameplate.

9. Operating Mode - Refer to Controller Manual 13-17-600 for more 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 water inlet valve(s). If the

unit is located in a cold environment (e.g., ambient temperature below 40°F, 5 °C), the required external
heat source must be energized prior to start. 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 relief valve (80 psig, 5.5 bar), no
special procedure to maintain minimum reservoir pressure is required.

13-18-601 Page 23

Unit Hot - Start-up instructions are the same as that of a cold start.

Compressed Air Dryer (Optional) – The dryer module is fed electrical power from a separate (off­package), disconnect provided by the end user – it must be engaged prior to dryer operation. Relay
contacts, operated by the package AirSmart controller, engage and disengage the dryer from the external
power source. The dryer is turned on when the “START” button is pressed, which also starts the
compressor system. The dryer remains powered until the “STOP” button is pressed and rema ins in
operation during low air demand periods that temporarily shut down the compressor. Please refer to the
dryer manual 13-18-602 for all installation, operation and maintenance instructions.

DAILY CHECK - Refer to Section 14, “Maintenance Schedule”.
STOPPING THE UNIT - Press “STOP-RESET” button. The oil reservoir will automatically blow down, as

the main motor is de-energized. If the unit is a water-cooled heat exchanger type, close any manual
water inlet valves after unit has stopped. Be sure external heat is turned on if below 40°F (5°C),

Automatic restarting 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 testing the pressure relief valve to prevent injury.

A

A

A

U

U

U

T

T

T

I

O

N

I

O

N

I

O

N

C

C

C

Never paint, lubricate or alter a pressure relief valve. Do not plug vent or
restrict discharge.

13-18-601 Page 24

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.

13-18-601 Page 25

SECTION 4
CONTROLS & INSTRUMENTATION

GENERAL DESCRIPTION - The Gardner Denver rotary screw compressor package is pre-wired with all

electrical components suitable for the voltage and horsepower at time of order. It is necessary only to
connect the compressor unit to the correct power supply and to the shop air supply network - and to the
appropriate water supply if using the water-cooled variant. A standard single stage compressor pa ckage
consists of unitized module that houses a single rotary screw compressor, oil sump, separation, filtering,
and internal injection delivery system, a main drive motor, a VFD, an oil/air cooling system, IP54 electrical
enclosure to house VFD on common controller and a sound-attenuating enclosure. The various control
devices employed are described as follows:

Controller - The compressor package features the AirSmart controller, which integrates all the control
functions under microprocessor control. Controller functions include safety and shutdown, compressor
regulation, operator control and advisory/maintenance indicators. The keypad and display provides a
logical and easily operated control of the compressor and indication of its condition. The controller is
factory adjusted for the compressor package, but allows tuning for specific applications.

NOTICE

Read the Operator’s Manual before operating the compressor. It is critical that
the detailed instructions for the controller, found in the controller manual
13-17-600, are read and understood. Once the appropriate parameters have
been selected into the controller, compressor operation may commence. For
your convenience, a “Quick Start” excerpt from the controller manual is shown
on Section 3.8

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 rese rvoir pressure
is required.

Main VFD and Motor – The compressor is driven by an inverter-duty electric motor, which in turn is
energized by a pulse-width modulated, variable frequency drive (commonly referred to as VFD). This
combination of components enables the compressor package to match the supply of compressed air
(e.g., flow capacity) to meet the customer’s demand in real time and in a step-less fashion. The
operational logic which govern the drive and motor-combination is supplied by the AirSmart controller and
it is based on the following basic rules:

• The speed of the compressor is modulated (e.g., increased or decreased) until th e desired system
discharge pressure is achieved.

The drive shares a common IP54 protected enclosure with the AirSmart controller and assorted electri cal
hardware. Ventilation for the electronics is supplied forced air delivered by the heat exchanger cooling
fans and filtered by inlet and outlet filters. The motor is built with a TEFC protected frame and coupled to
the compressor via a NEMA-D flange. The drive includes adequate current overload p rotection for its
companion motor.

The drive and motor are designed to operate with 3ph-60Hz-460vac electrical power, which must be
installed in accordance with local (site) Electrical Code requirements.

13-18-601 Page 26

308CGD810-C
(Ref. Drawing)

ASSEMBLED CONTROL BOX WITH EMC FILTER............

ASSEMBLED CONTROL BOX WITHOUT EMC FILTER....

1 AIRSMART CONTROL BOX...............................................

2 GRP-DRIVE (VS45-US)......................................................

3 CABLE ASSEMBLY ............................................................

4 SPLITTER CABLE...............................................................

5 SCREW TERMINAL PLUG.................................................

7 CONTROL BOX ENCLOSURE...........................................

8 ELECTRICAL FILTER.........................................................

9 OPERATOR........................................................................

10 CONTACT BLOCK..............................................................

11 POWER SUPPLY................................................................

12 FUSE HOLDER...................................................................

13 TERMINAL LUG..................................................................

14 FUSE HOLDER...................................................................

15 FUSE...................................................................................

16 FUSE BLOCK......................................................................

17 FUSE...................................................................................

18 RELAY ................................................................................

19 TERMINAL BLOCK.............................................................

20 TERMINAL BLOCK.............................................................

21 GROUND BLOCK ...............................................................

22 GROUND BLOCK ...............................................................

23 GROUND BLOCK ...............................................................

24 TERMINAL BLOCK.............................................................

25 DIN RAIL.............................................................................

27 EMC FILTER.......................................................................

28 CONTROL BOX DECAL (not shown).................................

Figure 4-1 – ELECTRICAL ENCLOSURE HARDWARE

13-18-601 Page 27

Heat Exchanger Fan/Motor and Starter - The combination axial fan/motor (two units on VS50 and

VS70, one unit on VS45) provides cooling air for the heat exchangers and electronics box. The starter
provides control and overload protection for each fan motor. Overload heaters should be selected an d
adjusted based on the motor nameplate amps and the instructions located inside the cover of the
electrical box. These devices are designed to operate with 3 ph-60 Hz-460 vac electrical power – the
necessary electrical wiring has been provided.

Main Motor Ventilation Fan/Motor and Starter – The combination axial fan/motor cools the main motor
by blowing fresh air over its body. The starter provides control and overload protection for fan motor.
Overload heaters should be selected and adjusted based on the motor nam eplate amps and the
instructions located inside the cover of the electrical box. These devices are designed to operate with 3
ph-60 Hz-460 vac electrical power – the necessary electrical wiring has been provided.

Control Transformer - This device reduces the incoming power voltage to 110-120 volts for use by
various control components (e.g., 24 vdc power supply, electrical enclosure cooling fans, etc.). Two
primary fuses and one secondary fuse are provided for overload protection.

Power Supply (24vdc) - This device supplies electrical power to the AirSmart controller and various
solenoid valves.

For Letter References A thru U below, see Figure 4-2, page 30.
Inlet (Poppet) Valve (B) – This device is located at the 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 compressor inlet. During stopped operation
modes (e.g., commanded 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 the compressor
intake. This prevents trapped air and oil within the compressor from exiting through the inlet filter. See
SECTION 10 for further details.

Minimum Discharge Pressure/Check Valve (G) – This device maintains a minimum pressure [80psig]
within the air/oil reservoir, thus insuring (lubrication/cooling) oil injection flow into the compressors. It also
prevents the back flow of compressed air from the customer’s piping back into the compressor package
when the compressor is not running. See SECTION 9 for further details.

The spring-loaded [and pneumatically assisted] piston does not allow the discharge of compressed air
from the air/oil reservoir until the compressor builds up reservoir pressure beyond 80 psig. Beyond this
pressure level, the valve remains fully open.

Oil Mixing Valve (L) – This device prevents the compressor from operating at a pressure and
temperature combination that condenses water vapor in the oil system. The servo-driven, 3-way, ball
valve mixes cooled and hot oil, prior to delivery to the oil filter and oil injection line, as commanded by an
algorithm residing in the package controller. See SECTION 5 for further details.

Pressure Relief Valve (O) – This device protects the pressure containing components of the compressor
package against high pressure exceeding 188.5 psig. See SECTION 11 for further details.

Pressure Regulator (S) – This device supplies the pneumatic signal to actuate the minimum pressure
valve [G]. The regulator is adjusted to achieve an opening pressure at the MPV of 80psig.

Inlet Feed Valve (C) - This (three-way solenoid) device supplies/vents the required pneumatic signal to
actuate the inlet poppet valve. When energized, it opens [vents] the inlet poppet valve and when de­energized, it closes [pressurizes] it.

Ball Valve – Oil Drain (N) - This device allows the drainage of the oil charge held in the reservoir during
oil change operation.

13-18-601 Page 28

Blow Down Valve (P) - This (two-way solenoid) device vents compressed air from the air/oil sump.

During compressor operation (e.g., compressors are running or they have temporarily stopped due to line
pressure reaching unload pressure); the blow down valve remains energized (closed ) and the air/oil
reservoir remains pressurized. When compresso r operation i s halted (e.g., by use of the red “STOP”
controller button, by loss of electrical energy, or by a shutdown condition), the valve is de-energized
(normally open state) and the air/oil reservoir is blown down.

13-18-601 Page 29

A

13-18-601 Page 30

300CGD797­(Ref. Drawing)

Figure 4-2 – PIPING AND INSTRUMENTATION ILLUSTRATION

13-18-601 Page 31

300CGD810-E
(Ref. Drawing)
Page 1 of 4

Figure 4-3 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control

13-18-601 Page 32

300CGD810-E
(Ref. Drawing)
Page 2 of 4

Figure 4-4 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control

13-18-601 Page 33

300CGD810-E
(Ref. Drawing)
Page 3 of 4

Figure 4-5 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control

13-18-601 Page 34

L1GND

L2 T3

L3

300CGD810-E
(Ref. Drawing)
Page 4 of 4

L2L1 L3

F2F1

F3

T2T1

GND

Figure 4-6 – WIRING DIAGRAM – (AIR-COOLED) Single-Stage VS Control

13-18-601 Page 35

301CGD810-E
(Ref. Drawing)
Page 1 of 4

Figure 4-7 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS Control

13-18-601 Page 36

301CGD810-E
(Ref. Drawing)
Page 2 of 4

Figure 4-8 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS Control

13-18-601 Page 37

301CGD810-E
(Ref. Drawing)
Page 3 of 4

Figure 4-9 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS Control

13-18-601 Page 38

L1GND

L2 T3

L3

L2L1 L3

F2F1

F3

T2T1

GND

301CGD810-E
(Ref. Drawing)
Page 4 of 4

Figure 4-10 – WIRING DIAGRAM – (WATER-COOLED) Single-Stage VS Control

SECTION 5
COMPRESSOR LUBRICATION – SEPARATION, FILTRATION AND
CONTROLS

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the compressor package before removing valves, caps, plugs,
fittings, bolts and filters.

CAUTION

High temperature operation can cause damage to equipment or personal injury.
Do not restart the unit repeatedly after high temperature shutdown. Find and
correct the malfunction before resuming operation.

COMPRESSOR OIL SYSTEM – Lubricating oil is employed to absorb the heat of compression, lubricate

moving parts and seal internal clearances between the rotor and air cylinder. Pressure differential
between the air/oil reservoir and various injection points is used to flow oil through the package.

Oil exits the air/oil sump and is then routed to the heat exchanger and the thermal mixing valve, where
cold (oil cooler branch) and hot (bypass branch) are mixed to a temperature that will avoid water vapor
condensation within the oil system. Tempered oil is sent to the oil filter for cleaning, then onto injection.
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 air, where it is collected
and readied for the next cooling cycle. The compressed air and aerosols continue through a coalescing
filter, where all but 4 ppm of oil is removed from the compressed air and discharged to the aftercooler.

RECOMMENDED LUBRICANT – The Gardner Denver compressor is factory-filled with AEON 9000SP
lubricant. This lubricant is formulated to the highest quality standards and is factory-authorized, tested
and approved for use in our rotary screw compressors. AEON 9000SP lubricant is available throug h your
authorized Gardner Denver compressor distributor.

OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000SP
lubricating coolant for all-year-round operation. This is a polyolester (POE) synt hetic lubricant specially
formulated rotary screw compressor service.

It is highly recommended that the lubricating oil be analyzed frequently in order to identify its quality and
remaining operational life. A sampling valve, located on the tubing between the oil filter and the injection
manifold, is provided for this purpose.

13-18-601 Page 39

A

A

A

A

A

A

U

U

U

U

U

U

T

T

T

T

T

T

I

I

I

I

I

I

O

O

O

O

O

O

N

N

N

N

N

N

C

C

C

Use of improper lubricants will cause damage to equipment. Do not mix
different types of lubricants or use inferior lubricants.

C

C

C

All materials used in Gardner Denver compressor units are compatible with
AEON 9000SP Synthetic Lubricating Coolant. Use caution when selecting
downstream components such as lubricating bowls, gaskets and valve trim.

AEON 9000SP Synthetic Lubricating Coolant is not compatible with Nitrile
(Buna N) or acrylic paints. AEON 9000SP is compatible with most air system
downstream components.

Material Safety Data Sheets (MSDS) are available for all AEON lubricants from your authorized Gardner
Denver distributor or by calling 217-222-5400.

MOISTURE IN THE OIL SYSTEM - The oil mixing valve provided with your compressor package has
been designed to avoid water vapor condensation during all modes of operation (e.g., load level, ambient
temperature or relative humidity and discharge pressure). See “Oil Mixing Valve” notes within this section
for further details on this device.

This feature does not eliminate the need to analyze the lubricating oil frequently. If an analysis reveals
the presence of water in the oil, it may indicate that the oil mixing valve is malfunctioning. Contact your
authorized Gardner Denver factory distributor for assistance.

OIL SIGHT GLASS - This device indicates oil level within the air/oil reservoir. Check oil level only with
the compressor stopped. Normal oil level is the middle of the measuring rod. Add oil only when oil level
has reached the bottom of measuring rod. Drain oil only when the oil level is beyond the top of the
measuring rod.

ADDITION OF OIL BETWEEN CHANGES – Oil losses (typically 4 ppm) from the oil separation system
may require replenishment between scheduled changes. If (during operation only) the sight glass shows
no oil or less than 25% of full height, add oil per following steps: (See Figure 5-1, page 42).

1. Be sure the unit is completely off and oil sump is depressurized.

2. Disconnect, lockout and tagout the power supply to the compressor package.

3. Close (when provided) valve isolating compressor package from air system.

4. Wipe away all dirt around the oil filler plug.

5. Remove the oil filler plug (1) and add (or drain by opening valve (3) if correcting high level) sufficient
oil to adjust its level to nearly the top of the measuring rod.

6. Install the oil filler plug, open isolation valve (when provided), restore power, then run unit to check
for leaks.

13-18-601 Page 40

Note that repeated addition of oil between oil changes may indicate excessive oil carry-over and should
be investigated.

A

A

A

A

A

A

U

U

U

U

U

U

T

T

T

T

T

T

I

O

N

I

O

N

I

O

N

I

O

N

I

O

N

I

O

N

C

C

C

Excessive oil carry-over can damage equipment. Never fill oil reservoir above
top of the measuring rod

C

C

C

Use only CLEAN containers and funnels to avoid contamination of oil. Provide
for clean storage of oils. Changing the oil will be of little benefit if done in a
careless manner

OIL CHANGE INTERVAL – The AEON 9000SP Synthetic Lubricating Coolant shall be changed every

8000 hours of operation or as prescribed by the results of an oil analysis, whichever comes first. Note
that severe operating conditions (e.g., very dusty, high humidity, etc.), may require more frequent oil
changes.

Gardner Denver offers a free oil analysis program with our AEON 9000SP lubricant. The first sample
from a new unit should be sent in between 40-100 hours of operation.

DRAINING AND CLEANING OIL SYSTEM - Always drain the complete system. Draining when the oil is
hot will help to prevent varnish deposits and carry away impurities. To drain the system, use the following
method: (See Figure 5-1, page 42.

1. Be sure the unit is completely off and oil sump is depressurized.

2. Disconnect, lockout and tagout the power supply to the compressor package.

3. Close (if provided by user) valve isolating compressor package from air system.

4. Remove fill plug (1) and drain valve (3) to evacuate oil.

5. Close drain valve (3), add oil up to top of measuring rod, and replace fill plug.

6. If the drained oil and/or the oil filter element are contaminated with dirt, flush the entire system ,
reservoir, oil cooler, mixing valve and lines. Inspect the oil separator element for dirt accumulation;
replace if necessary. If a varnish deposit exists, contact the factory for recommendations for
removal of the deposit and prevention of varnish.

13-18-601 Page 41

Figure 5-1 – CHECKING OIL LEVEL

Figure 5-2 – CHANGING OIL FILTER

REFILLING OIL SYSTEM - The steps to refill the drained oil system are the same as those already

presented for the addition of oil between changes – see page 40, for full details. The only exception is
that to fill all the empty lines and components (e.g., oil cooler, compressors, and oil filter) a much larger
volume of oil will be required.

The VS45-70 package requires nearly 6 gallons of AEON 9000SP Synthetic Lubricating Coolant to fill all
the lines and components and achieve normal oil level.

COMPRESSOR OIL 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,
sooner if necessary due to dirty environmnent and when the oil is changed.

A flow bypass valve, mounted inside the filter cartridge, provides uninterrupted oil flow when the filter
element is contaminated and its backpressure exceeds 29-36 psid (at typical operating conditions of
140°F and 100 psi). However, since this condition introduces unfiltered, potentially contaminated oil into
the compressor, it is best avoided by following the recommended filter replacement intervals.

13-18-601 Page 42

C

C

C

A

A

A

U

U

U

T

T

T

I

O

N

I

O

N

I

O

N

Improper oil filter maintenance will cause damage to equipment. Replace filter
element every 1000 hours of operation. More frequent replacement could be
required depending on operating conditions. A filter element left in service too
long may damage equipment.

The filter media is contained within an easily replaced, spin-on cartridge. Use the following procedure to
replace the filter. Do not disturb the piping:

1. Be sure the unit is completely off and that the oil sump is depressurized.

2. Disconnect, lockout and tagout the power supply to the compressor package.

3. Close (when provided) valve isolating compressor package from air system.

4. Unscrew the cartridge with adequate tool (e.g., strap wrench) and remove.

5. Clean (wipe) and lubricate sealing surface on filter housing with grease.

6. Lubricate o-ring seal on new element with grease.

7. Screw-new element onto filter head firmly – approximately 3/4 turns after cartridge and head make

contact.

8. Open isolation valve (when provided), restore power, then run unit to check for leaks.

OIL MIXING VALVE (Electronic) – This device mixes cold (from oil cooler) and hot (bypassed) oil in
order to achieve a compressor discharge temperature above the saturation level of the water vapor
contained in the compressed air – thus avoiding water collection in the oil system.

Figure 5-3 – THERMOSTATIC MIXING VALVE ELEMENT

13-18-601 Page 43

The AirSmart controller includes an algorithm that determines, in real time, and on the basis of the intake
temperature and the programmed target discharge pressure, the minimum discharge temperature the
compressor must attain in order to keep water vapor from condensing in the oil system. Signals from the
controller command the 3-way ball valve servo to rotate and mix hot and cold oil streams until the desired
compressor discharge temperature is achieved. Refer to Figure 5-4 for the dew point trends of the
compressed air at four typical pressure levels.

At startup, the mixing valve is on full bypass mode. As system heat load increases with ambient
temperature or load, the mixing valve sends more oil flow to the cooler to maintain adequate compressor
discharge temperature.

While the mixing valve is in its modulating range (between extremes of valve position), a compressor
discharge temperature deviation exceeding +/- 10°F from the calculated value will trigger an alarm display
to caution that a system malfunction is taking place. Note that the alarm is not triggered once the valve
has reached either end-of-travel position, as oil mixing no longer controls the compressor discharge
temperature.

Pressure Dew Point Trend

260
250
240
230
220
210
200
190
180
170
160
150
140

Discharge PDP -°F

130
120
110
100

90
80

30 40 50 60 70 80 90 100 110 120 130

Ambient Temp - °F

100psig 125psig 150psig 175psig

Figure 5-4 – PRESSURE DEW POINT OF COMPRESSED AIR

OIL SEPARATION RESERVOIR / COALESCING ELEMENT - This device serves multiple functions in

the compressor package:

• Air/oil centrifugal separation - The bulk of the liquid oil is separated, by change of direction,

impingement and additional centrifugal effects, away from the compressed air and aerosol streams,
and is then gravity-collected at the bottom of the sump.

• Oil degassing and holding - The sump has sufficient holding capacity to degas the oil mass before

it is drained off on its way to cooling, 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).

13-18-601 Page 44

• Air/oil final separation - The aerosols and compressed air streams are led to the upper portion of

the sump, where the coalescing element resides. The fine droplets of oil (aeros ol) are trapped in the
element media, coalesced, then gravity-drained, through a low-point connection and associated
tubing (oil return line) into a lower pressure region of the compressor.

Separation performance - The package oil separation system has been designed to yield 4 ppm total oil
carryover at the discharge of the air/oil reservoir – the oil content level at the discharge of the package will
be lower and will depend on the amount of moisture rejected by the aftercooler.

This high level of performance will be affected by the following typical offset conditions:

• Contaminated (e.g., dirt, varnish, moisture) or damaged (e.g., ruptured) coalescing element.

• Contaminated (e.g., dirt, varnish, moisture) or inadequate oil in use.

• High oil level in air/oil reservoir.

• Blockage of oil return line strainer or orifice.

• Abnormally frequent or fast 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 track of the pressure d i fferential
across the coalescing element. A pressure differential of 8 psi will trigger a service advisory to change
the element and a pressure differential of 15 psi will initiate a system shutdown.

Using an oil separator element at excessive pressure differential can cause
damage to equipment. Replace the separator when the "Change Separator"
advisory appears.

A sudden drop to zero pressure differential or sudden heavy oil carryover may
indicate a ruptured element.

C

C

C

N

N

N

A

A

A

O

O

O

U

U

U

T

T

T

T

T

I

I

T

I

C

C

C

I

O

N

I

O

N

I

O

N

E

E

E

13-18-601 Page 45

Figure 5-5 – CHANGING OIL COALESCING ELEMENT

Oil Coalescing Element Service – Use the following procedures to replace or inspect the element:

1. Be sure the unit is completely off and that oil sump is depressurized.

2. Disconnect, lockout and tagout power supply to the compressor package.

3. Remove body of MPV/sump cover (1).

4. Lift the elements (2) from sump.

5. Inspect and/or replace the elements if necessary - shine a light inside each element to reveal areas
of heavy dirt, varnish deposits or breaks (ruptures) in its media. Also inspect (sealing) o-ring in
elements for damage. Before installing new or old element, apply (heavy) grease to sealing o-ring.
Oil may be wiped off by the holder and the o-ring could be damaged.

6. Inspect oil scavenge orifice (3) and strainer (4) for fouling. Replace if necessary.

7. Wipe the MPV/sump cover seal o-ring (5) clean and inspect for damage. Replace if necessary.

8. Lower elements into sump and press element down i nto respective holder. Do not use excessive
force as element damage may occur.

9. Carefully place MPV/sump cover and o-ring seal on sump flange. Check that cent ering pins (on
MPV/sump cover) have engaged each element cavity and that MPV/sump cover lays flat agains
sump flange. Install and tighten all cap screws.

10. After compressor is started and pressurized, inspect MPV/sump cover joint for leaks.

13-18-601 Page 46

SECTION 6
HEAT EXCHANGERS (OIL, AIR)

Compressor, air/oil reservoir, separator chamber and all piping and tubing may
be at high temperature during and after operation.

Do not attempt inspection or cleaning of air-cooled heat exchangers until
cooling fan has stopped rotating. 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 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 compressors require a stable, cool (140°F typical at 80°F ambient air) supply of injection oil in

order to operate at optimal efficiency. Under these conditions, the oil core allows 23gpm oil flow with

7.7psid pressure loss.

13-18-601 Page 47

• The lubricating and cooling oil must be kept at a normal operating temperature below 225°F in order

to preserve its longevity.

• The compressed air supply must be delivered into the distribution system at a temperature not

exceeding 15°F above the ambient level in order to protect other devices (e.g., filters, dryers, tools,
etc) against damage. At 100 psi of discharge pressure, the air core allows the flow of 427 cfm with

1.1 psid pressure loss.

AIR-COOLED HEAT EXCHANGERS – Air-cooled cores (radiator-type) are provided as standard feature.
Axial fans (one on VS45, two on VS50 and VS70), located below the heat exchangers, pump the required
amount of cooling air and expel it through an opening on the enclosure roof. Each fan is driven by a
close-coupled, IP54-protected, electric motor. A common full-voltage starter energizes the fan motors.

Refer to Figure 6-1 for estimates of ventilation requirements. Please note that the air-cooled package
requires the combined total of the heat exchanger 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 inch
water gauge to avoid impacting the heat exchanger cooling air system. An external ventilation fan may
be required to properly evacuate hot air from the compressor room.

Minimum Cooling Air Flow Requirements

CFM

KW

45 5200 1600
50 8223 1600
70 8223 1600

Figure 6-1 – AIR FLOW CHART

All the required hardware, mechanical and electrical connections have been made at the Gardner Denver
factory, thus the only regular maintenance required is to keep the exterior core fins free from dirt and
other airborne debris per the following procedure:

Air-Cooled

Heat

Exchangers

A

A

A

U

U

U

T

T

T

I

C

C

C

I

I

O

O

O

N

Enclosure

Ventilation

N

N

Fan

Air-cooled heat exchanger cores are fabricated from aluminum. Do not use
caustic liquids to cleanse core or permanent damage will take place.

1. Be sure the unit is completely off and that oil reservoir is depressurized.

2. Disconnect, lockout and tagout power supply to the compressor package.

3. Open and/or remove enclosure door panels adjacent to cooler assembly.

4. Locate cooler housing side covers (See Figure 6-2) and remove by unscrewing fasteners.

13-18-601 Page 48

5. Inspect core area. If blocked with debris, use a moderate (e.g., 100psi) source of compressed air

and/or water while directing nozzle (pointed through core to inside) to dislodge debris and clean.
Vacuum (applied from inside) can also be employed to clean the heat exchanger cores.

6. Remove all loose debris and water from cooler box after cleaning process is complete.

7. Re-attach cooler housing side covers with provided fasteners and re-install enclosure door panels.

Figure 6-2 – COOLER HOUSING SIDE COVERS

WATER-COOLED HEAT EXCHANGERS – Optional water-cooled cores (brazed-plate type) are

available. Both core are of a counter-current and cross-flow design. The cooling water is fed to the cores
in a series arrangement – it passes through the air core first and proceeds through the oil core before
exiting the package. Please refer to Figure 6-3 for estimates of requirements.

AIR & OIL COOLER (Series Water Piping)

Water flow requirements at

various inlet water temperatures

(gpm)

KW Model

60° F 70° F 80° F 90° F

Maximum

Water Flow

(gpm) *

Approximate (total) water

pressure drop @ 90° F

water flow

(psi)

All VS45-70A 8.5 12.8 25.6 40 40 20

* Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.

Figure 6 3 – WATER-COOLED HEAT EXCHANGER COOLANT REQUIREM ENTS

13-18-601 Page 49

The water supply shall be capable of delivering the flow/temperature combinations shown in Figure 6 3,
page 49, at a minimum pressure of 40 psig (2.8 bar) - the water flow rates shown are approximate and a
guide to sizing of piping, cooling tower and other water system equipment.

The maximum allowable supply water pressure is 150 psig (10.3 bar) and the maximum allowed
[package] outlet water temperature is 110°F (43°C). If a water supply with a temperature lower than 60°F
(16°C) is used, heat transfer areas of the coolers may be fouled due to low water flow velocities, resulting
in poor cooler performance and shortened operational life.

All the required hardware, mechanical and electrical connections 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 Hardness .......................................... <60 ppm

Silica .......................................................... <25 ppm

Oil and Grease........................................... <5 ppm

Sulfate........................................................ <50 ppm

Chloride...................................................... <50 ppm

Nitrate ........................................................ <2 ppm

Corrosivity.................................................. Langelier Index between 0 to1

It is strongly recommended that a reputable, local firm be contracted to evaluate the quality of water
available and recommend corrective and/or preventive steps to meet our requirements.

Hex head zinc anodes are used in the return bonnet (opposite end to the water pipe connections) of h eat
exchangers to provide internal water system corrosion protection. These anodes should be inspected
periodically and replaced when the zinc has been reduced to about 1/2 inch (1 3 mm) in length.

WATER FLOW REGULATING VALVE (Optional Hardware). This device is used to adjust the flow of
cooling water in proportion to its temperature. It’s a normally closed (two-way) valve which opens once
the thermostatic bulb senses a predetermined water temperature level and then continues to modulate
water flow to maintain water temperature – within a 2° F to 5° F span. The package piping provides a
permanent bypass line (1/4” tube) around the flow regulating valve to ensure a small amount of water
flows around the sensing bulb when the valve is in the closed position – it does not provide a complete
shutoff of water flow.

13-18-601 Page 50

Figure 6-4 – WATER CONTROL VALVE

Adjustments – The regulator valve shall be adjusted so that it closes when the cooling water entering

and exiting the package are at the same temperature – a condition that is present after the compressors
have stopped and the heat exchangers have cooled down. Note that the bypass line allows a small
amount of water flow when the valve closes. Adjustment to the regulator valve can be made as follows:

• To decrease water flow (e.g., increase exiting cooling water temperature) turn the adjusting screw
from left to right, increasing spring tension. (The groove at the lower edge of the adjusting screw is
an index line for use with the index scale 0 to 8 in obtaining a desired setting).

• To increase water flow (e.g., decrease exiting cooling water temperature) turn the adjusting screw
from right to left, decreasing spring tension. (The groove at the lower edge of the adjusting screw is
an index line for use with the index scale 0 to 8 in obtaining a desired setting).

Care must be used when handling the capillary tube; a kink or break in the tubing or connections will
make the valve inoperative. Never attempt to change capillary 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 cause erratic operation. An occasional drop of oil on the valve
stem at the packing nut will prolong packing life.

If the valve malfunctions, check for a bend or binding in the capillary tube, paint or corrosion on valve
stem, foreign material in valve, erosion or thermal system (capillary) failure.

WATER FLOW SHUTOFF VALVE (Optional Hardware) - This device completely shuts off the flow of
cooling water when the compressors are not operating. Its normally closed state prevents the waste of
cooling water even in the case of power failure. It is a common companion to the water flow regulating
valve.

The water flow regulating valve and the water shutoff valve are factory-installed options. If the presence
of foreign material or scale formation in the cooling water is likely, the use of a strainer in the inlet water
line is recommended.

13-18-601 Page 51

WATER SEPARATOR AND DRAIN – These devices separate and drain the water (condense d by the air

cooler) mixed with the compressed air delivered by the compressor package. Note that this device is not
used the optional compressed air dryer is supplied, as the latter’s water separator is employed for this
process.

Figure 6-5 – WATER SEPARATOR AND DRAIN

The separator (4) removes the liquid water from the compressed air stream by in ertial effects and
collected in a lower bowl (3). The collected water is evacuated by a float-type drain valve (1). The device
prevents the loss of compressed air by only allowing the discharge of liquid water during its opening
phase. An isolation ball valve (5) is provided between the separator bowl (3) a nd the drain valve body
(1). This allows the safe and quick removal of the drain valve for servicing, in case the drain valve
malfunctions.

In case the drain valve is fouled with dirt, cleanse the collection bowl also:

1. Be sure the unit is completely off and oil sump is depressurized.

2. Disconnect, lockout and tagout power supply to the compressor package.

3. Close (when provided) valve isolating compressor package from air system.

4. Unscrew drain valve (1) from isolation valve (5).

5. Unscrew collection bowl (3) from separator housing (4).

6. Inspect and cleans collection bowl and sealing o-ring.

7. Reinstall in reverse order.

13-18-601 Page 52

SECTION 7
AIR FILTER

Figure 7-1 – AIR FILTER (STANDARD)

AIR FILTER - This device cleans the air stream entering the compressor inlet and is furnished as

standard equipment with the compressor package. Its single high efficiency, synthetic media element is
housed in a metal housing integrated in the enclosure structure.

Efficient 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.

C

C

N

A

A

A

O

O

O

U

U

U

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T

T

T

I

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N

T

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N

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N

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C

E

I

C

E

I

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E

Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use
solvents other than water. Improper cleaning may damage the element.

C

N

N

13-18-601 Page 53

Never operate the unit without the air filter element. Never use elements that
are damaged, ruptured or wet. Keep spare elements on hand to reduce
downtime. Store elements in a protected area free from damage, dirt and
moisture. Handle all parts with care.

Filter Element Inspection and Replacement:

1. Remove air cleaner cover (1) and remove filter element.

2. Visually inspect housing 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 inches water gauge)
provided with the package instrumentation, replace the element. Cleansing the element with air or
water is not recommended, as media damage is very probable.

4. Replace element and cover and fasten cover to filter housing.

13-18-601 Page 54

SECTION 8
SHAFT COUPLING

Figure 8-1 – COUPLING COMPONENTS

Rotating machinery can cause personal injury or death. Turn the unit
completely off, open the main disconnect, lockout and tagout before servicing
the coupling.

SHAFT COUPLING – Main motors drive their companion compressors by mea ns of curved jaw-type

couplings. Each coupling hub is fixed to the shaft with a setscrew and key combinations. The power is
transmitted through a meshing, single, dry, vibrations damping element – see Figure 8-1, for details of
the main components.

The close-coupled arrangement of motor and compressor, through a machined cast housi ng, 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 housin g and
remove guard.

3. Depending on the bore-to-shaft fits (e.g., clearance or interference) on either of the coupling hubs,
proceeds as directed. For hub-to-shaft clearance fit hubs:

• Loosen setscrews fastening hubs to shafts and slide hubs away from each other to allow
removal of coupling element. Note that if the hubs do not slide on the shafts after this step, they
should be considered interference fitted, thus proceed directly to Step 4, for further removal
instructions.

• Inspect coupling element for signs of wear and tear such as indentations, cracks, deformation,
extrusions, etc. Replace, if necessary.

13-18-601 Page 55

• 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 1.1 in (28mm). A
smaller gap will produce abnormal wear of the 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

4. For hub-to-shaft interference fit hubs, main drive motor removal is necessary:

300CGD810-A
(Ref. Drawing)

Figure 8-3 – MOTOR REMOVAL HARDWARE

• Remove coupling guard (19) by removing four bolts

• Remove two bolts securing [cooling fan] support (27) to baseframe (2)

• Remove four bolts securing [main motor] rear support to baseframe (2)

• Remove upper two bolts securing main motor (24) to adaptor (16) and replace with longer

versions provided with package – there should be 3-in gap between bolt head and adaptor.

13-18-601 Page 56

• Slide/Pull main motor (24) away from adaptor (16) until coupling hubs separate and allow
removal of spider.

• Inspect coupling element for signs of wear and tear such as indentations, cracks, deformation,
extrusions, etc. Replace, if necessary.

• Re-assemble main motor and cooling fan components in reverse.

• 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 1.1 in (28mm). A
smaller gap will produce abnormal wear of the 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.

• Apply a thread-locking compound to the hub setscrews (M8 size) and tighten to 88.5 lb-in (10 N­ m) of torque. Reinstall coupling guard with provided fasteners.

N

O

T

I

C

E

N

N

O

O

T

T

I

C

E

I

C

E

Coupling hubs are designed to fit on compressor and motor shafts
with a transitional interference. If a coupling hub is interference
fitted over the companion shaft, it must be removed (and installed)
by using heat (200°F above ambient temperature) to dilate and
create a temporary clearance.

Before removing any interference fitted hub, note and record the
position of the hub with relation to the end of the companion shaft.
The hub must be re-installed at same relative position, in order to
provide the proper clearance for the coupling.

13-18-601 Page 57

SECTION 9
MINIMUM PRESSURE/CHECK VALVE

MINIMUM PRESSURE/CHECK VALVE - This device maintains minimum pressure within the air/oil

reservoir, thus insuring [cooling/lubricating] oil injection flow into the compressors. It also serves as a
check valve to prevent back flow of compressed air flow from the customer’s piping or pipe network back
into the compressor package when the compressor is not active. The valve does not require
maintenance or adjustment. If the valve fails to function, check the valve stem O-ring for sealing, valve
orifices for restriction, or valve and valve seat for burrs and dirt. Repair kits are available from your local
authorized Gardner Denver distributor.

Before servicing the minimum 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.

NOTICE

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 (MPV) Inspection:

1. Be sure the unit is completely off and that the oil sump is depressurized – including pipe works
between MVP and [external] isolation valve.

2. Disconnect, lockout and tagout power supply to the compressor package.

3. Remove tubing and fittings from top (center) of MPV.

4. Install (removal) bolt (5), located on side of MPV housing, on top, center hole of MPV and tighten nut
(7) securely. Note that this bolt keeps internal MPV parts from flying apart under spring pressure
during removal.

5. Remove snap ring on MPV cover, remove cover and gently pry out MPV.

6. Gradually back off nut (7) while keeo\ping bolt (5) from turning until spring pressure is released.
Remove MPV internal parts. Inspect and/or replace parts.

7. Re-assemble in reverse order.

13-18-601 Page 58

Figure 9-1 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE

13-18-601 Page 59

SECTION 10
INLET CONTROL VALVE

INLET CONTROL VALVE – This device is located at the intake flange of the compressor, and allows the

compressor to remain pressurized and ready for quick response to air demand when the latter is not
running.

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. An internal self­actuated blow-off valve assist in the fast venting of the air signal trapped below the poppet During
stopped operation modes (e.g., commanded 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 [closed] and block off
the compressor intake. The internal blow-off valve is also forced closed by the incoming air signal.

Figure 10-1 – INLET CONTROL VALVE

Inlet Control Valve (Body) Inspection - The valve does not require maintenance or lubrication. If air/oil

leaks develop across the valve disc during pressurized conditions (e.g., machine stopped), valve seals
should be inspected for wear and tear signs:

8. Be sure the unit is completely off and oil sump is depressurized.

9. Disconnect, lockout and tagout power supply to the compressor package.

10. Close (when provided) valve isolating compressor package from air system.

11. Identify (by position) each tube connected to the valve body and remove.

12. Remove four bolts (Item 13) securing valve body to compressor body and remove valve.

13. Inspect poppet seal [o-ring] (Item 5) for wear and tear. Replace, if necessary.

13-18-601 Page 60

14. In case of noted malfunction (e.g., valve will not open/close properly with good air signal), proceed to
dismantle internal blow-off valve.

• Carefully lift and remove poppet (Item 3).

• Remove lock ring (Item 20).

• Pull cover (Item 16) and seal (Item 17).

• Inspect seals (Items 18 & 19) for wear and tear. Replace if necessary.

• Re-assemble blow-off valve in reverse order.

15. Reassemble inlet control valve in reverse order.

13-18-601 Page 61

SECTION 11
PRESSURE RELIEF VALVE

Pressure Relief Valve - This device protects the pressure-containing componen ts of the compressor

package against pressures exceeding 188.5 psig. It is installed on the dry-side of the oil sump.

Before inspecting the pressure relief valve, 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.

Never paint, lubricate or alter a relief valve. Do not plug vent or restrict.

13-18-601 Page 62

Operation 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
pressure relief valve:

• Raise the system operating pressure to its normal level

• Turn the top cap on valve 1-2 turns counter-clockwise to open valve and let it vent for a few seconds.

• Close the valve by firmly turning top cap clockwise. Make sure that cap is firmly tightened to avoid

damage by vibrations.

13-18-601 Page 63

SECTION 12
VENTILATION FILTERS (ELECTRICAL ENCLOSURE)

Ventilation Filters - The electronics housed in the standard IP54 enclosure box are ventilated by a
combination of an intake air filter and pressurized air provided by the heat exchanger cooling fans.

Filter Inspection - In order to ensure the electronics operate at peak efficiency and free from

troublesome temperature-related stoppages, it is imperative that the filter elements be kept clean:

1. Be sure the unit is completely off and oil reservoir is depressurized.

2. Disconnect, lockout and tagout power supply to the compressor package.

3. To service intake-side filter, open access door (oil filter side) and remove [latched] access door
located on cooler housing cover – Refer to Fig 6-2 for details.

4. To service discharge-side filter, open access door (dryer side) and reach be hind electrical box .

5. Remove filter elements from each bracket by prying open the retaining grill area.

6. Inspect the elements. If dirty, gently clean with soapy water and allow to dry completely before re­installation. If damage is evident, replace.

7. Replace elements into frame and replace snap grills.

8. Replace access panel in reverse order.

9. Close access doors.

13-18-601 Page 64

SECTION 13
MOTOR LUBRICATION

Rotating machinery can cause injury or death. Open main disconnect, lockout
and tagout power supply to compressor package before working on the electric
motor.

Motor Lubrication - Long time satisfactory operation of an electric motor depends in large measure on

proper lubrication of the bearings. The following charts show recommended grease qualitie s and re­greasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s
instructions. 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-operated grease gun.

3. Wipe off only excess grease expelled by the automatic grease relief fitting supplied.

4. Restart the unit.

Main motors and aftercooler fan motor have automatic grease relief fittings.

Main Motor Grease Specifications:

MANUFACTURER TRADE NAME GD Part No.

KLUBER KLUBER QUIET BHQ 72-102

ELECTRIC MOTOR REGREASING INTERVAL

Type of
Service

Standard Continuous Operation
Severe

Humid, dirty, high ambient
sites

Typical

Rating

45-70 kW 8000 hrs
45-70 kW

13-18-601 Page 65

28H312 (1Kg can)
28H311 (400 Gram Cartridge)
28H313 (25 Kg pail)

Lubrication Interval

4000 hrs

SECTION 14
MAINTENANCE SCHEDULE

SERVICE CHECK LIST

Daily Checks:

• Air Filter (Compressor) - Replace when controller displays “CHANGE AIR FILTER” message. Refer
to Section 7 for air filter details.

• Oil Separator Element - Replace when controller displays “CHANGE OIL SEPARATOR ELEMENT”.
Refer to Section 5 for oil separator element details.

• Air/Oil Reservoir Oil Level - Check the reservoir oil level during compressor operation only - add oil
if required. Refer to Section 5 for full details. DO NOT MIX LUBRICANTS.

• Start/Modulation/Stop Operation – Verify that compressors maintain steady compressed air
pressure.

• AirSmart Operational Parameters – Maintaining a periodic log of package 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 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.

• Air Filter (Electrical Box) – Check filter elements for dirt accumulation. Refer to Section 12 for
detailed instruction to clean filter elements.

Every 1000 Hours or as often as operating conditions require it:

• Oil Filter - Replace.

• Oil - Sample and analyze.

Every 8000 Hours (or as Prescribed by Oil Analysis Results):

1. Compressor Lubricant – Replace.

13-18-601 Page 66

Yearly Checks:

• Heat Exchangers (air and water-cooled) – Check cooling performance of air and oil cores – see
Section 6 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 for test procedure.

• Motor Lubrication – Inspect motors for abnormal noise and vibration. Grease-lubri cate pe r

guidelines included in Section 13 of this manual.

• Compressor/Motor shaft couplings – Check coupling element for signs of wear and tear – see
Section 8 for detailed instruction on coupling inspection procedures.

13-18-601 Page 67

SECTION 15
TROUBLESHOOTING

Air/oil under pressure will cause severe personal injury or death. Shut down
compressor, relieve system of all pressure, disconnect, lockout and tagout
power supply to the compressor package before removing valves, caps, plugs,
fittings, bolts and filters.

SYMPTOM POSSIBLE CAUSE REMEDY

Compressor
fails to start

2. Blown fuses in control box 2. Check voltage and fuses. Replace

3. Shutdown event sensed by

4. Read error message on control

5. Remote Contact is open 5. Replace switch or jumper.

6. Variable Frequency Drive fault

7. System pressure exceeds set

Compressor
starts but
stops after a
short time

2.

3. Blown fuse in control box 3. Replace fuse (investigate if fuses

4. Variable Frequency Drive

1. Main disconnect open 1. Check and reset.

fuses.

3. Investigate cause of fault and press

controller not re-set

“STOP/RESET” button to reset.

4. Take appropriate action. See Manual

panel

13-17-600.

6. Investigate and correct cause of fault

active

and press “STOP/RESET” button to
reset.

7. Wait until system pressure falls below

pressure

set pressure.

1. High discharge temperature 1. See “High Discharge Air
Temperature,” this section.

Low oil injection pressure

overload sensor tripped

2. Check oil filter dP.

continue to blow).

4.

Reset and investigate cause of
overload.

13-18-601 Page 68

SYMPTOM POSSIBLE CAUSE REMEDY

Compressor
does not

1. Improperly adjusted controller 1. Refer to Manual 13-17-600 and adjust

control.

unload (or
load)

2. Feed pressure regulator not
adjusted

2. Inspect, adjust and replace pressure
regulator.

3. Feed 3-way solenoid valve

3. Repair, clean or replace valve.

malfunction

4. Inlet valve stuck 4. Inspect and replace valve.

5. Blow down valve malfunction 5. Repair, clean or replace valve.

Compressor

1. Insufficient receiver capacity 1. Increase receiver size

cycles from
load to unload
excessively

2.

3. Restriction in control tubing 3. Inspect and clean control tubing.

Compressor
starts too
slowly

Restriction in service piping

1. Acceleration time in VFD set too
long

2. Minimum Pressure/Check Valve

2. Inspect and clean service piping.

1. Contact your Gardner Denver
distributor.

2. Repair or replace.

is leaking

Compressor is
low on delivery

1, Improperly adjusted control 1. Refer to Manual 13-17-600 and adjust

control.

and pressure

2. Restricted air filter 2. Clean or replace filter element.

3. Inlet valve not fully open 3. Inspect, adjust or replace feed solenoid
valve and/or pressure regulator.

4. Minimum pressure valve stuck

4. Inspect, service or replace valve.

closed

5. Blowdown valve leaking 5. Inspect or replace solenoid valve.
Ensure local ambient temperature has
not exceeded 113°F. limit.

6. Air demand exceeds supply 6. Make sure air demand matches
compressor specifications for flow and
pressure.

13-18-601 Page 69

SYMPTOM POSSIBLE CAUSE REMEDY

Excessive oil

1. Oil separation malfunction 1. See “Oil Carryover” in this section.

consumption

High discharge
air, oil
Temperature
(air, water

2. Oil leaks at fittings and gasket s 2. Detect and correct oil leaks.

3. Shaft seal leaking 3.

1. Oil mixing valve stuck on bypass
mode

Inspect or replace shaft seal.

1. Check 24dcv power feed to servo.
Check ModBus connection to servo.
Check servo-to-valve coupling.
Check rotation of ball valve.

cooled cores)

High discharge
air, oil

2. Clogged oil filter 2. Inspect and replace filter.

3. Clogged cooler (interior) 3. Inspect and clear cooler.

4. Clogged oil li nes 4. Inspect and clear oil lines.

5. Low oil level 5. Add oil to proper level.

1. Dirty or clogg ed cooler outer
surfaces.

1. Inspect and clean cooler outer
surfaces.

Temperature
(air cooled
cores)

2. Insufficient cooling air flow 2. Verify (ductwork) back pressure does
not exceed .1” water gauge.

High discharge
air, oil

1. Optional wate r temp regulating or

shut-off valve malfunction

1. Refer to Section 6 “Heat Exchangers”
for details.

Temperature
(water cooled
cores)

2.

Insufficient cooling water flow

2

See Section 6 for details on adequate
cooling water flow rates.

VFD Shutdown
on Overheat

1.

Ambient temperature exceeds

C

45°

2.

VFD air filters dirty

1.

Check location ventilation and
improve if necessary.

2.

Inspect, clean or replace elements.

13-18-601 Page 70

SYMPTOM POSSIBLE CAUSE REMEDY

Excessive oil at
intake filter area

1. Intake valve seals leaking. 1. Check location ventilation and
improve if necessary. Inspect, repair
or replace valve.

2. Slow intake valve poppet

action

2. Inspect poppet and guide surfaces.
Replace if necessary.

3. Feed 3-way solenoid valve

3. Repair, clean or replace valve.

malfunction

Oil carryover

1. Overfilling oil separation

1. Drain excess oil from system.

vessel

2. Clogged oil return line orifice 2. Inspect and service.

3. Clogged oil return line strainer 3. Inspect and service.

4. Clogged, broken, or loose oil

4. Inspect and tighten or replace.

return line fittings

5. Ruptured oil separator

5. Replace element.

element.

6. Loose assembly 6. Tighten all fittings and gaskets.

7. Foam caused by use of
incorrect oil

7. Use Gardner Denver AEON 9000SP
oil only.

8. Minimum pressure valve
malfunction – discharge
pressure below 80 psig

8.

Repair or replace. Inspect, adjust or
replace regulator.

13-18-601 Page 71

GENERAL PROVISIONS AND LIMITATIONS

Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized
distributor that such products are, at the time of delivery to the Purchaser, free of defects in material and workmanship. No warranty is made with
respect to:

1. Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.

2. Any product which has, in the Company’s judgment been subject to negligence, accident, improper storage, or improper installation or
application.

3. Any product which has not been operated or maintained in accordance with the recommendations of the Company.

4. Any reconditioned or prior owned product.

Claims for items described in (4) above should be submitted directly to the manufacturer.
WARRANTY PERIOD

The Company’s obligation under this warranty is limited to repairing or, at its option, replacing, during normal business hours at an authorized service
facility of the Company, any part, which in its judgment proved not to be as warranted within the applicable Warranty Period as follows. Regular
lubricant sampling and use of genuine GD OEM parts is strongly recommended.

AIRENDS
Airends, consisting of all parts within and including the cylinder and gear housing, are warranted for 24 months from date of initial use or 27 months
from date of shipment to the purchaser, whichever occurs first. Shaft seals are a routine maintenance item and carry a 12 month warranty.

Any disassembly or partial disassembly of the airend, or failure to return the “unopened” airend per Company instructions, will be cause for denial of
warranty.

MAJOR PACKAGE COMPONENTS
The AirSmart
motor(s) are warranted for 24 months from date of initial use or 27 months from date of shipment to the first purchaser, whichever occurs first, as
provided in, and subject to the terms of the original component manufacturer’s warranty. The oil cooler and aftercooler are warranted for 36 months
from date of initial use or 39 months from date of shipment to the first purchaser, whichever occurs first, as provided in, and subject to the terms of the
original, component manufacturer’s warranty.

OTHER COMPONENTS
All other components not specified above are warranted for 12 months from date of initial use or 15 months from date of shipment to first purchaser,
whichever occurs first.

LABOR TRANSPORTATION AND INSPECTION
The Company will provide labor, by Company representative or authorized service personnel, for repair or replacement of any product or part thereof
which in the Company’s judgment is proved not to be as warranted. Labor shall be limited to the amount specified in the Company’s labor rate
schedule.

Labor costs in excess of the Company rate schedule amounts or labor provided by unauthorized service personnel is not provided for by this warranty.
All costs of transportation of product, labor or parts claimed not to be as warranted and, of repaired or replacement parts to or from such service

facilities shall be borne by the Purchaser. The Company may require the return of any part claimed not to be as warranted to one of its facilities as
designated by Company, transportation prepaid by Purchaser, to establish a claim under this warranty.

Replacement parts provided under the terms of the warranty are warranted for the remainder of the Warranty Period of the product upon which
installed to the same extent as if such parts were original components.

DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE COMPANY MAKES NO
OTHER WARRANTIES AND HEREBY EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, INCLUDING WITHOUT LIMITATION, EXPRESSED,
IMPLIED OR STATUTORY WARRANTIES, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
USE.

THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE TO PURCHASER
AND IN NO CASE SHALL THE COMPANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR LI ABILITIES. UNDER NO CIRCUMSTANCES
SHALL THE COMPANY BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES OR
DELAYS HOWSOEVER CAUSED.

NO STATEMENT, REPRESENTATION, AGREEMENT, OR UNDERSTANDING, ORAL OR WRITTEN, MADE BY ANY AGENT, DISTRIBUTOR,
REPRESENTATIVE, OR EMPLOYEE OF THE COMPANY WHICH IS NOT CONTAINED IN THIS WARRANTY WILL BE BINDING UPON THE
COMPANY UNLESS 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 WARRANTY SHALL NOT BE CONSTRUED AS AN ADMISSION BY THE COMPANY THAT
ANY PRODUCT WAS NOT AS WARRANTED.

™

controller, variable frequency drive, drive motor(s), reservoir, mixing valve, drive coupling, coupling insert, cooling fan(s) and cooling fan

BP-32 4/05

LUBRICATED ROTARY SCREW COMPRESSORS

COPYRIGHT

©

2005 Gardner Denver, Inc.

WARRANTY

VS AND VST SERIES

Specifications subject to change without notice.
Copyright © 2005 Gardner Denver, Inc. Litho in U.S.A.

http://www.gardnerdenver.com [e-mail]

For additional information contact your local representative or

Gardner Denver Compressor Division,
1800 Gardner Expressway, Quincy, Illinois 62301
Customer Service Department Telephone:
[phone] FAX: [phone]

Sales and Service in all major cities.

For parts information, contact Gardner Denver,
Master Distribution Center, Memphis, TN
Telephone: [phone] FAX: [phone]