Gardner Denver AirSmart VS135A Service manual

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13
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607
Version: 13
June 2, 2015
VARIABLE SPEED
SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AirSmartäCONTROLLER
VS135A, VS170A
135-170kW
60HZ
OPERATING AND
SERVICE MANUAL

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MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER® COMPRESSOR PARTS AND SUPPORT SERVICES
Gardner Denver® Compressor genuine parts, manufactured to design tolerances, are developed for optimum
dependability –specifically for Gardner Denver compressor systems. 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. A worldwide network of
authorized distributors provides the finest product support in the air compressor industry.
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 factory, 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 compressor.
Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair. They
are ready to respond and assist you by providing fast, expert maintenance and repair services.
To Contact Gardner Denver or locate your local distributor:
Visit: www.contactgd.com/compressors
Or
Call: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Compressor MODEL, Method of Cooling, HORSEPOWER and SERIAL NUMBER (see
nameplate on unit). The Airend Serial Number is also stamped on top of the discharge bearing carrier casting.
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.

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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 economical 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

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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
result in a
minor or moderate injury.
Burn Hazard –Hot surface
PROHIBITION/MANDATORY ACTION REQUIREMENTS
Do not Operate Compressor with Guard Removed
Do Not Lift Equipment with Hook –No Lift Point
Handle Package at Forklift Points Only
Lockout Electrical Equipment in De-Energized
State
Loud Noise Hazard –Wear Ear Protection
Read the Operator’s Manual Before Proceeding
with Task

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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 established 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 from rotating fan, drive coupling, etc.
·Disconnect the compressor unit from its power source, lockout and tagout before working on the
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 connections, etc., in the compressor air or oil system until the unit is shut down and
the air pressure has been relieved.
·Electrical shock can and may be fatal.
·Perform all wiring in accordance with the National Electrical Code (NFPA-70) and any applicable
local electrical codes. Wiring and electrical service must be performed only by qualified
electricians.
·Open main disconnect switch, lockout and tagout before working on the control, wait 10 minutes
and check for voltage.
Failure to observe these notices could result in damage to equipment.
·Stop the unit if any repairs or adjustments on or around the compressor are required.
·Do not use the air discharge from this unit for breathing –not suitable for human consumption.
·An Excess Flow Valve should be on all compressed air supply hoses exceeding 1/2 inch
inside diameter (OSHA Regulation, Section 1926.302).
·Do not exceed the rated maximum pressure values shown on the nameplate.
·Do not operate unit if safety devices are not operating properly. Check periodically. Never
bypass safety devices.

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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
Safety Precautions ..................................................................................................................................4
Index.......................................................................................................................................................6
List Of Illustrations...................................................................................................................................7
Section 1, General Information ................................................................................................................8
Section 2, Installation.............................................................................................................................11
Section 3, Starting & Operating Procedures...........................................................................................17
Section 4, Controls & Instrumentation....................................................................................................24
Section 5, Compressor Lubrication - Separation, Filtration And Controls................................................45
Section 6 - Heat Exchangers (Oil, Air), Axial Cooling Fans.....................................................................54
Section 7, Air Filter................................................................................................................................60
Section 8, Shaft Coupling......................................................................................................................62
Section 9, Minimum Pressure/Check Valve............................................................................................67
Section 10, Inlet Control Valve...............................................................................................................68
Section 11, Pressure Relief Valve..........................................................................................................70
Section 12, Ventilation Fans, Filters (Electrical Enclosure).....................................................................72
Section 13, Motor Lubrication................................................................................................................73
Section 14, Maintenance Schedule........................................................................................................74
Section 15, Troubleshooting..................................................................................................................76
This book covers the following models:
KW PSIG
Air Cooled and
Water Cooled Parts List
Controller
Manual
Comm.
Module
135, 170 100 THRU 175 VS135-170A 13-18-504 13-17-600 13-17-604
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.

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INDEX
Air Filter, Section 7.........................................60
Air Flow In The Compressor System................ 8
Air-Cooled Units, Location..............................12
Auxiliary Air Receiver......................................14
Cold Weather Installation................................13
Compression Principle..................................... 8
Compressor Lubrication –Separation, Filtration
And Controls, Section 5...............................45
Control Piping.................................................14
Controls & Instrumentation, Section 4.............24
Discharge Service Line...................................14
Electrical Wiring..............................................15
Enclosure.......................................................13
Foundation.....................................................13
General Information, Section 1 ........................ 8
Grounding ......................................................16
Heat Exchangers (Oil, Air), Axial Cooling Fans
Section 6.....................................................54
Inlet Control Valve, Section 10........................69
Inlet Line ........................................................14
Installation, Section 2......................................11
Lifting Unit......................................................11
Location
Air-Cooled Units..........................................12
Water-Cooled Units.....................................12
Location .........................................................12
Lubrication
Cooling........................................................ 8
Sealing ........................................................ 8
Maintenance Schedule, Section 14.................75
Minimum Pressure/Check Valve, Section 9.....67
Moisture Separator/Trap.................................14
Oil Filter..........................................................49
Oil Reservoir Drain.........................................13
Oil System
Addition Of Oil Between Changes...............47
Compressor................................................45
Draining And Cleaning................................48
Moisture.....................................................46
Oil Change Interval.....................................48
Oil Filter......................................................49
Oil Mixing Valve..........................................49
Oil Separation Reservoir/Coalescing Element
...............................................................51
Oil Sight Glass............................................46
Oil Specifications........................................45
Recommended Lubricant............................45
Refilling Oil.................................................49
Piping
Blow Down Valve........................................14
Control .......................................................14
Water.........................................................14
Pressure Relief Valve, Section 11 ..................71
Prestart-Up Instructions..................................17
Quick Start Guide...........................................20
Safety Precautions...........................................4
Service Check List .........................................75
Every 1000 Hours.......................................75
Every 8000 Hours.......................................75
Weekly.......................................................75
Yearly.........................................................76
Shaft Coupling, Section 8...............................62
Starting & Operating Procedures, Section 3 ...17
Starting The Unit............................................22
Stopping The Unit..........................................22
Troubleshooting, Section 15...........................77
Ventilation Filters (Electrical Enclosure), Section
12...............................................................73
Warning –Prohibition –Mandatory Label
Information...................................................2
Water-Cooled Units, Location.........................12

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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 2-1 –Typical Compressor Room.................................................................................................12
Figure 2-2 –Package Maximum Current Consumption Summary...........................................................15
Figure 2-3 –Line Reactor Sizing Recommendations..............................................................................16
Figure 3-1 –Motor Fan Rotation Check .................................................................................................19
Figure 4-1 –Electrical Enclosure Hardware ...........................................................................................25
Figure 4-2 –Piping And Instrumentation Illustration ...............................................................................28
Figure 4-3 –Wiring Diagram –(Air-Cooled) Single-Stage VS135 Control..............................................29
Figure 4-4 –Wiring Diagram –(Air-Cooled) Single-Stage VS170 Control..............................................33
Figure 4-5 –Wiring Diagram –(Water-Cooled) Single-Stage VS135 Control.........................................37
Figure 4-6 –Wiring Diagram –(Water-Cooled) Single-Stage VS170 Control.........................................41
Figure 5-1 –Oil Level Sight Glass..........................................................................................................46
Figure 5-2 –Load VS Sight Glass Oil Level Change..............................................................................47
Figure 5-3 –Thermostatic Mixing Valve Element ...................................................................................50
Figure 5-4 –Pressure Dew Point Of Compressed Air.............................................................................51
Figure 5-5 –Changing Oil Coalescing Element......................................................................................52
Figure 6-1 –Air Flow Chart....................................................................................................................55
Figure 6 2 –Water-Cooled Heat Exchanger Coolant Requirements.......................................................56
Figure 6-3 –Water Control Valve...........................................................................................................57
Figure 6-4 –Water Separator And Drain................................................................................................58
Figure 6-5 –Detailed Water Separator And Drain..................................................................................59
Figure 7-1 –Air Filter (Standard)............................................................................................................60
Figure 8-1 –Coupling Components........................................................................................................62
Figure 8-2 –Coupling Element ..............................................................................................................63
Figure 8-3 –Coupling Removal Tool......................................................................................................66
Figure 8-4 –Location Airend Coupling Hub Installation Tool ..................................................................66
Figure 9-1 –Minimum Discharge Pressure/Check Valve........................................................................67
Figure 10-1 –Inlet Control Valve............................................................................................................68
Figure 11-1 –Pressure Relief Valve.......................................................................................................70

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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
arrangement of both roller and ball bearings is designed to withstand reverse 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 28) - 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 28) - 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.

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Figure 1-2 –PACKAGE ILLUSTRATION (AIR-COOLED) –External Details
300CGF804
-
B
(Ref. Drawing)
Page 1 of 2

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Figure 1-3 –PACKAGE ILLUSTRATION (AIR-COOLED) –Internal Details
300CGF804
-
B
(Ref. Drawing)
Page 2 of 2

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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.
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.

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LOCATION - The compressor package shall be installed in a clean, well-lighted, well-ventilated 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
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 - Separate air and oil coolers are 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 water-
cooled 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 water-
cooled heat exchangers, including minimum cooling water flow requirements.

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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 1-2 and Figure 1-3, pages 9 and 10, 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 is located on the lower, right hand corner of the controller-
side of the base-frame –see Package Illustrations for further details. 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.
Ducting may be required on air
-
cooled enclosed machines.
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.
Do not operate the compressors with the fan or coupling guard removed.
Exposed fan and couplings may cause personal injury.

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Unsheltered (outside) installations should be avoided whenever possible. 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.
CONTROL PIPING - Control piping is not necessary since the Gardner Denver compressor package is
factory wired and piped for the control system specified.
INLET LINE –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 air-
cooled 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.

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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 compressor package. Refer to Figure 2-2, for a
summary of maximum package current consumption values.
460-575 VOLT VS-135 and VS-170 MINIMUM COPPER SUPPLY WIRE RECOMMENDATIONS
Minimum 75ºC wire Minimum 90ºC wire NOTES
Model Input
Package
Amps
NEC
Package Copper Wire Copper Wire
Voltage
(Estimated)
Amps
at
30ºC
Sized at
40ºC
Sized at
40ºC
VS-135 460 215.36 265.36 350 or 2 sets of 3/0 300 or 2 sets of 2/0
Sets of wires are
sized with
derate for 2 parallel sets in a
single conduit.
VS 135 575 148.70 182.45 4/0 3/0
VS-170 460 305.36 377.86 2 sets of 300 500 or 2 sets of 4/0
Sets of wires are sized with
derate for 2 parallel sets in a
single conduit.
VS 170 575 214.70 264.95 350 or ( 3/0 (2) ) 300 or ( 2/0 (2) )
2/0 wire sized for 2 parallel sets
of conductors in 1 conduit at 40
degrees C ambient.
The NEC requires that wire sizes be determined by using the appropriate multiplier for the conductor temperature rating at
ambient temperatures other than 30º C and then selecting the wire that has sufficient ampacity, after correction, to meet the load
requirements shown in the"NEC Package Amps @ 30ºC" column above. Wire ampacity is to be corrected, not "Package Amps”.
Additional correction multipliers apply based on more than three conductors in one conduit. The appropriate installation and use
of 75ºC and 90ºC wire is the responsibility of the electrical professional(s) performing the installation and must be per NEC, local
and state regulations as allowed. All of the above recommended minimum wire sizes are based on all terminal connections being
rated at 75ºC minimum temperature rating and copper wire run lengths of 100 feet or less. Please note that all UL-508A listed
control panels are rated for 40ºC ambient conditions.
Figure 2-2 –PACKAGE MAXIMUM CURRENT CONSUMPTION SUMMARY

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Electrical Wire Routing –Routing of the electrical power wires into the electrical hardware enclosure 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 16.
·Line has switched Power Factor correction capacitors.
·Existing line reactor not properly sized –see Figure 2-3, page 16.
·Other large loads on the same power feed as the compressor.
GD Model Volts VFD HP RATINGS Max KVA
3% Line Reactor
GD Part Number
VS135 400/480 150 1500 90500144
VS170 400/480 250 2500 90500144
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.
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.

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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 sight gauge should be full
or nearly so. Add oil, with unit stopped and depressurized, only if the sight gauge does not show an
oil level during steady, warm operation. 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. See Section 5 for more details on the compressor oil system.
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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
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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 2 gallons of
oil through the intake valve opening.

13-18-607 Page 18
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 filters to be sure they are clean and the assembly is sealed tight. Refer to
Section 7, 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 and Figure 4-4, pages 29 and 33, for general wiring diagrams and Section 2, for
installation instructions.
6. Grounding - Equipment must be properly grounded according to Gardner Denver Guidelines for
proper wiring, grounding and feed power conditioning.
Failure to properly ground the compressor package could result in controller
malfunction.
N
N
NO
O
OT
T
TI
I
IC
C
CE
E
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
counterclockwise when facing the compressor shaft end.
·Use controller “JOG MODE”to bump heat exchanger cooling fan. Proper rotation shall be
clockwise when facing intake side of fan.
·Use controller “JOG MODE”to bump main motor cooling fan. Proper rotation is achieved when
cooling air is discharged over the main motor body or when fan rotation matches the indicated by
the arrow decal affixed to the fan hub, as viewed via the serrated cutout on the fan shroud. See
Figure 3-1 for details.

13-18-607 Page 19
·In case the main motor or any of the axial fan/motor combinations are replaced or disconnected
from the package wiring system, their rotation must be verified. If the incorrect rotation is noted
on any one electric motor, take the following steps to make the necessary correction:
·Disconnect, lockout and tagout power supply to the compressor package.
·Locate, within the electrical enclosure, the three (3) wires feeding power to the motor in
question.
·Loosen, reverse, and re-fasten the connections of any two (2) of the wires.
·Re-energize compressor package and recheck rotation.
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.
The compressor unit’s direction of rotation must be checked every time the
compressor is reconnected to the power supply.
The radial fan/motor combinations are integrated, and the incoming electrical
power connections do not affect their rotation. If reverse rotation is noted for
either radial fan, please notify Gardner Denver for corrective action.
Figure 3-1 –MOTOR FAN ROTATION CHECK
8. System Pressure –For your convenience, the following excerpt from the Controller Manual
13-17-600 is presented to assist in programming the target system pressure: