Gardner Denver AirSmart VS20A Service manual

+
13-18-604
Version: 10
April 6, 2010
VARIABLE SPEED
SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AIRSMART™CONTROLLER
VS20A
20kW
60HZ
OPERATING AND
SERVICE MANUAL

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. An AirSmart™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 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 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.
For the location of your local authorized Gardner Denver Air Compressor distributor, refer to the yellow
pages of your phone directory, check the Gardner Denver Web Site at www.gardnerdenver.com or contact:
Gardner Denver
1800 Gardner Expressway
Quincy, IL 62305
Phone: [phone]
Fax: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS/REMANUFACTURED AIRENDS
Whenever an airend requires replacement or repair, Gardner Denver offers an industry unique, factory
remanufactured airend exchange program. From its modern Remanufacturing center in Indianapolis, IN., Gardner
Denver is committed to supplying you with the highest quality, factory remanufactured airends that are guaranteed to
save you time, aggravation and money
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 bearing 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.

13-18-604 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 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

13-18-604 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 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

13-18-604 Page 3
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.

13-18-604 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/Remanufactured Airends................................................................1
Warning – Prohibition – Mandatory Label Information..................................................................................1
Safety Precautions........................................................................................................................................3
Index..............................................................................................................................................................5
List Of Illustrations.........................................................................................................................................6
Section 1, General Information .....................................................................................................................7
Section 2, Installation..................................................................................................................................12
Section 3, Starting & Operating Procedures...............................................................................................18
Section 4, Controls & Instrumentation ........................................................................................................25
Section 5, Compressor Lubrication - Separation, Filtration And Controls..................................................42
Section 6 - Heat Exchangers (Oil, Air)........................................................................................................50
Section 7, Air Filter......................................................................................................................................54
Section 8, Shaft Coupling............................................................................................................................56
Section 9, Minimum Pressure/Check Valve................................................................................................60
Section 10, Inlet Control Valve....................................................................................................................62
Section 11, Pressure Relief Valve ..............................................................................................................64
Section 12, Ventilation Fans, Filters (Electrical Enclosure)........................................................................66
Section 13, Motor Lubrication .....................................................................................................................67
Section 14, Maintenance Schedule ............................................................................................................68
Section 15, Troubleshooting .......................................................................................................................70
This book covers the following models:
KW PSIG Air Cooled Parts List Controller Manual Dryer Comm. Module
20 100 THRU 175
VS20A
13-18-502 13-17-600 13-18-605 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.

13-18-604 Page 5
INDEX
Air Filter, Section 7...........................................54
Air Flow In The Compressor System.................7
Air-Cooled Units, Location ...............................13
Auxiliary Air Receiver.......................................15
Cold Weather Installation.................................14
Compression Principle.......................................7
Compressor Lubrication – Separation, Filtration
And Controls, Section 5................................42
Control Piping...................................................15
Controls & Instrumentation, Section 4 .............25
Discharge Service Line....................................15
Electrical Wiring ...............................................16
Enclosure .........................................................14
Foundation .......................................................14
General Information, Section 1 ..........................7
Grounding.........................................................17
Heat Exchangers (Oil, Air), Section 6 ..............50
Inlet Control Valve, Section 10.........................62
Inlet Line...........................................................15
Installation, Section 2.......................................12
Lifting Unit ........................................................12
Location
Air-Cooled Units ...........................................13
Location............................................................12
Lubrication
Cooling............................................................7
Sealing............................................................7
Maintenance Schedule, Section 14 .................68
Minimum Pressure/Check Valve, Section 9.....60
Moisture Separator/Trap..................................15
Oil Filter............................................................45
Oil Reservoir Drain...........................................14
Oil System
Addition Of Oil Between Changes................43
Compressor..................................................42
Draining And Cleaning.................................44
Moisture........................................................43
Oil Change Interval ......................................44
Oil Filter........................................................45
Oil Mixing Valve............................................46
Oil Separation Reservoir/Coalescing Element
..................................................................48
Oil Sight Glass..............................................43
Oil Specifications..........................................42
Recommended Lubricant.............................42
Refilling Oil...................................................45
Piping
Blow Down Valve .........................................15
Control..........................................................15
Pressure Relief Valve, Section 11...................64
Prestart-Up Instructions...................................18
Quick Start Guide.............................................20
Safety Precautions.............................................3
Service Check List...........................................68
Every 1000 Hours ........................................68
Every 8000 Hours ........................................68
Weekly..........................................................68
Yearly...........................................................69
Shaft Coupling, Section 8................................56
Starting & Operating Procedures, Section 3....18
Starting The Unit..............................................22
Stopping The Unit............................................23
Troubleshooting, Section 15............................70
Ventilation Filters (Electrical Enclosure),
Section 12........................................................66
Warning – Prohibition – Mandatory Label
Information .....................................................1

13-18-604 Page 6
LIST OF ILLUSTRATIONS
Figure 1-1 – Compression Cycle ..................................................................................................................7
Figure 1-2 – Package Illustration (Air-Cooled) – External Details ................................................................8
Figure 1-3 – Package Illustration (Air-Cooled) – Internal Details..................................................................9
Figure 1-4 – Outline-Unit/Pkg, Air-Cooled With Dryer – External Details...................................................10
Figure 1-5 – Outline-Unit/Pkg, Air-Cooled With Dryer – Internal Details....................................................11
Figure 2-1 – Typical Compressor Room.....................................................................................................13
Figure 2-2 – Package Maximum Current Consumption Summary.............................................................16
Figure 2-3 – Line Reactor Sizing Recommendations.................................................................................16
Figure 4-1 – Electrical Enclosure Hardware ...............................................................................................26
Figure 4-2 – Piping And Instrumentation Illustration...................................................................................29
Figure 4-3 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 460 Volt........................................30
Figure 4-4 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 460 Volt........................................31
Figure 4-5 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 460 Volt........................................32
Figure 4-6 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 460 Volt........................................33
Figure 4-7 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 200/230 Volt.................................34
Figure 4-8 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 200/230 Volt.................................35
Figure 4-9 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 200/230 Volt.................................36
Figure 4-10 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 200/230 Volt...............................37
Figure 4-11 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 575 Volt......................................38
Figure 4-12 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 575 Volt......................................39
Figure 4-13 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 575 Volt......................................40
Figure 4-14 – Wiring Diagram – (Air-Cooled) Single-Stage VS Control, 575 Volt......................................41
Figure 5-1 – Checking Oil Level..................................................................................................................45
Figure 5-2 – Changing Oil Filter..................................................................................................................45
Figure 5-3 – Thermostatic Mixing Valve Element.......................................................................................46
Figure 5-4 – Pressure Dew Point Of Compressed Air................................................................................47
Figure 5-5 – Changing Oil Coalescing Element..........................................................................................49
Figure 6-1 – Air Flow Chart.........................................................................................................................51
Figure 6-2 – Cooler Housing Side Covers..................................................................................................52
Figure 6-3 – Water Separator And Drain....................................................................................................52
Figure 7-1 – Air Filter (Standard)................................................................................................................54
Figure 8-1 – Coupling Components............................................................................................................56
Figure 8-2 – Coupling Element...................................................................................................................57
Figure 8-3 – Motor Removal Hardware.......................................................................................................57
Figure 8-4 – Coupling Removal Tool – VS40 Model Shown ......................................................................59
Figure 9-1 – Minimum Discharge Pressure/Check Valve...........................................................................61
Figure 10-1 – Inlet Control Valve ................................................................................................................62

13-18-604 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 near the drive shaft end. The discharge port
is located near the bottom at the opposite end of the compressor cylinder. Figure 1-1 is an inverted view
to show inlet and discharge ports. 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 flow of air that is continuous, smooth and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 4-2, page 29) - 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 a coalescing element 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 29) - 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.

13-18-604 Page 8
Figure 1-2 – PACKAGE ILLUSTRATION (AIR-COOLED) – External Details
300CGB804-
A
(Ref. Drawing)
Pa
g
e 1 of 2

13-18-604 Page 9
Figure 1-3 – PACKAGE ILLUSTRATION (AIR-COOLED) – Internal Details
300CGB804-
A
(Ref. Drawing)
Page 2 of 2

13-18-604 Page 10
Figure 1-4 – OUTLINE-UNIT/PKG, AIR-COOLED WITH DRYER – External Details
301CGB804-
A
(Ref. Drawing)
Page 1 of 2

13-18-604 Page 11
Figure 1-5 – OUTLINE-UNIT/PKG, AIR-COOLED WITH DRYER – Internal Details
301CGB804-
A
(Ref. Drawing)
Page 2 of 2

13-18-604 Page 12
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.
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
C
C
CA
A
AU
U
UT
T
TI
I
IO
O
ON
N
N
C
C
CA
A
AU
U
UT
T
TI
I
IO
O
ON
N
N

13-18-604 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, page 51 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 thru
Figure 1-4, pages 8 thru 12, 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.

13-18-604 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, page 51 of this manual for enclosure ventilation
requirements. Refer to Package Illustrations on Figure 1-2 thru Figure 1-4, pages 8 thru 10.
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 10” 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.
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.
C
C
CA
A
AU
U
UT
T
TI
I
IO
O
ON
N
N

13-18-604 Page 15
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. This device is not used on packages equipped
with integrated dryers!
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 the 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.

13-18-604 Page 16
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 2-3, for a
summary of maximum package current consumption values.
Package Size Voltage Maximum Current Draw
VS20 200 100 Amps
VS20 230 99 Amps
VS20 460 46 Amps
VS20 575 36 Amps
Figure 2-2 – PACKAGE MAXIMUM CURRENT CONSUMPTION SUMMARY
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
•Line has switched Power Factor correction capacitors.
•Existing line reactor not properly sized – see Figure 2-3.
•Other large loads on the same power feed as the compressor.
GD Model Volts VFD HP RATINGS Max KVA
VS20 200 30 400
VS20 230 50 400
VS20 460 25 300
VS20 575 30 300
Figure 2-3 – LINE REACTOR SIZING RECOMMENDATIONS

13-18-604 Page 17
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, page 68 of this manual for complete
motor lubrication specifications and details.

13-18-604 Page 18
SECTION 3
STARTING & OPERATING PROCEDURES
N
N
NO
O
OT
T
TI
I
IC
C
CE
E
E
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 site 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
N
NO
O
OT
T
TI
I
IC
C
CE
E
E
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
N
NO
O
OT
T
TI
I
IC
C
CE
E
E
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 1/4 gallon
of oil through the intake valve opening.