Gardner Denver AirSmart VS25A Service manual

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13
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18
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603
Version: 20
May 23, 2014
VARIABLE SPEED,
SINGLE STAGE
STATIONARY BASE-MOUNTED
COMPRESSOR
AirSmartäCONTROLLER
MODELS
VS25A, VS30A, VS40A
25-30-40kW
60HZ
OPERATING AND
SERVICE MANUAL

13-18-603 Page 1
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 AirSmartänetwork 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, POWER and SERIAL NUMBER (see
nameplate on unit). The Airend Serial Number is 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.

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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
.

13-18-603 Page 3
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.............................................................................................................................21
Section 3, Starting & Operating Procedures...........................................................................................27
Section 4, Controls & Instrumentation....................................................................................................33
Section 5, Compressor Lubrication - Separation, Filtration And Controls................................................79
Section 6 - Heat Exchangers (Oil, Air), Axial Cooling Fans.....................................................................88
Section 7, Air Filter................................................................................................................................95
Section 8, Shaft Coupling......................................................................................................................97
Section 9, Minimum Pressure/Check Valve..........................................................................................102
Section 10, Inlet Control Valve.............................................................................................................104
Section 11, Pressure Relief Valve........................................................................................................106
Section 12, Ventilation Fans, Filters (Electrical Enclosure)...................................................................108
Section 13, Motor Lubrication..............................................................................................................109
Section 14, Maintenance Schedule......................................................................................................110
Section 15, Troubleshooting................................................................................................................112
This book covers the following models:
KW PSIG
Air Cooled and
Water Cooled Parts List
Controller
Manual Dryer
Comm.
Module
25, 30, 40 100 Thru 175 VS25A VS30A
VS40A 13-18-501 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.

13-18-603 Page 6
INDEX
Air Filter, Section 7.........................................96
Air Flow In The Compressor System................ 8
Air-Cooled Units, Location..............................22
Auxiliary Air Receiver......................................24
Cold Weather Installation................................23
Compression Principle..................................... 8
Compressor Lubrication –Separation, Filtration
And Controls, Section 5...............................80
Control Piping.................................................24
Controls & Instrumentation, Section 4.............34
Discharge Service Line...................................24
Electrical Wiring..............................................25
Enclosure.......................................................23
Foundation.....................................................23
General Information, Section 1 ........................ 8
Grounding ......................................................26
Heat Exchangers (Oil, Air), Section 6..............89
Inlet Control Valve, Section 10......................105
Inlet Line ........................................................24
Installation, Section 2......................................21
Lifting Unit......................................................21
Location
Air-Cooled Units..........................................22
Water-Cooled Units.....................................22
Location .........................................................21
Lubrication
Cooling........................................................ 8
Sealing ........................................................ 8
Maintenance Schedule, Section 14...............111
Minimum Pressure/Check Valve, Section 9...103
Moisture Separator/Trap.................................24
Oil Filter..........................................................83
Oil Reservoir Drain.........................................23
Oil System
Addition Of Oil Between Changes...............81
Compressor................................................80
Draining And Cleaning................................82
Moisture.....................................................81
Oil Change Interval.....................................82
Oil Filter......................................................83
Oil Mixing Valve..........................................84
Oil Separation Reservoir/Coalescing Element
...............................................................86
Oil Sight Glass............................................81
Oil Specifications........................................80
Recommended Lubricant............................80
Refilling Oil.................................................83
Piping
Blow Down Valve........................................24
Control .......................................................24
Water.........................................................24
Pressure Relief Valve, Section 11 ................107
Prestart-Up Instructions..................................27
Quick Start Guide...........................................29
Safety Precautions...........................................4
Service Check List .......................................111
Every 1000 Hours.....................................111
Every 8000 Hours.....................................111
Weekly.....................................................111
Yearly.......................................................112
Shaft Coupling, Section 8...............................98
Starting & Operating Procedures, Section 3 ...27
Starting The Unit............................................31
Stopping The Unit..........................................32
Troubleshooting, Section 15.........................113
Ventilation Filters (Electrical Enclosure),
Section 12................................................109
Warning –Prohibition –Mandatory Label
Information...................................................2
Water-Cooled Units, Location.........................22

13-18-603 Page 7
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 –Outline-Unit/Pkg, VS25-40 Air-Cooled With Dryer (External Details)...................................................11
Figure 1-5 –Outline-Unit/Pkg, VS25-40 Air-Cooled With Dryer (Internal Details)....................................................12
Figure 1-6 –Outline-Unit/Pkg, VS25-40 Water-Cooled Standard (External Details)................................................13
Figure 1-7 –Outline-Unit/Pkg, VS25-40 Water-Cooled Standard (Internal Details) .................................................14
Figure 1-8 –Outline-Unit/Pkg, VS25-40 Water-Cooled With Dryer (External Details)..............................................15
Figure 1-9 –Outline-Unit/Pkg, VS25-40 Water-Cooled With Dryer (Internal Details)...............................................16
Figure 1-10 –Outline-Unit/Pkg, VS30-40 Air-Cooled Alternate Volt With Dryer Option (External Details).................17
Figure 1-11 –Outline -Unit/Pkg, VS30-40 Air-Cooled Alternate Volt With Dryer Option (Internal Details).................18
Figure 1-12 –Outline-Unit/Pkg, VS30-40 Water-Cooled Alternate Volt With Dryer Option (External Details)............19
Figure 1-13 –Outline-Unit/Pkg, VS30-40 Water-Cooled Alternate Volt With Dryer Option (Internal Details).............20
Figure 2-1 –Typical Compressor Room.................................................................................................................22
Figure 2-2 –Package Maximum Current Consumption Summary...........................................................................25
Figure 2-3 –Line Reactor Sizing Recommendations..............................................................................................26
Figure 4-1 –Electrical Enclosure Hardware...........................................................................................................34
Figure 4-2 –Piping And Instrumentation Illustration................................................................................................38
Figure 4-3 –Wiring Diagram –(Air-Cooled) –(460 Volt) Single-Stage VS Control...................................................39
Figure 4-4 –Wiring Diagram –(Water-Cooled) –(460 Volt) Single-Stage VS Control..............................................43
Figure 4-5 –Wiring Diagram –(Air-Cooled) –(200 & 230 Volt) VS30......................................................................47
Figure 4-6 –Wiring Diagram –(Air-Cooled) –(575 Volt) VS30 ...............................................................................51
Figure 4-7 –Wiring Diagram –(Air-Cooled) –(200 & 230 Volt) VS40......................................................................55
Figure 4-8 –Wiring Diagram –(Air-Cooled) –(575 Volt) VS40 ...............................................................................59
Figure 4-9 –Wiring Diagram –(Water-Cooled) –(200 & 230 Volt) VS 30................................................................63
Figure 4-10 –Wiring Diagram –(Water-Cooled) –(575 Volt) VS30.........................................................................67
Figure 4-11 –Wiring Diagram –(Water-Cooled) –(200 & 230 Volt) VS40...............................................................71
Figure 4-12 –Wiring Diagram –(Water-Cooled) –(575 Volt) VS40.........................................................................75
Figure 5-1 –Checking Oil Level.............................................................................................................................82
Figure 5-2 –Changing Oil Filter.............................................................................................................................82
Figure 5-3 –Thermostatic Mixing Valve Element....................................................................................................84
Figure 5-4 –Pressure Dew Point Of Compressed Air.............................................................................................85
Figure 5-5 –Changing Oil Coalescing Element......................................................................................................86
Figure 6-1 –Air Flow Chart ...................................................................................................................................89
Figure 6-2 –Cooler Housing Side Covers..............................................................................................................90
Figure 6-3 –Water-Cooled Heat Exchanger Coolant Requirements........................................................................91
Figure 6-4 –Water Control Valve ..........................................................................................................................92
Figure 6-5 –Water Separator And Drain................................................................................................................93
Figure 6-6 –Water Separator And Drain Details ....................................................................................................93
Figure 7-1 –Air Filter (Standard)...........................................................................................................................95
Figure 8-1 –Coupling Components.......................................................................................................................97
Figure 8-2 –Coupling Element..............................................................................................................................98
Figure 8-3 –Motor Removal Hardware..................................................................................................................98
Figure 8-4 –Locating Airend Coupling Hub Installation Tool –VS40 Model Shown...............................................101
Figure 8-5 –Locating Motor Coupling Hub Installation Tool –VS40 Model Shown................................................101
Figure 9-1 –Minimum Discharge Pressure/Check Valve......................................................................................103
Figure 10-1 –Inlet Control Valve.........................................................................................................................104

13-18-603 Page 8
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 flow of air that is continuous, smooth and shock free.
AIR FLOW IN THE COMPRESSOR SYSTEM (Figure 4-2, page 38) - 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 38) - 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.

13-18-603 Page 9
Figure 1-2 –PACKAGE ILLUSTRATION (AIR-COOLED) –External Details
300CGC804
-
B
(Ref. Drawing)
Page 1 of 2

13-18-603 Page 10
Figure 1-3 –PACKAGE ILLUSTRATION (AIR-COOLED) –Internal Details
300CGC804
-
B
(Ref. Drawing)
Page 2 of 2

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Figure 1-4 –OUTLINE-UNIT/PKG, VS25-40 AIR-COOLED WITH DRYER (External Details)
301CGC804
-
A
(Ref. Drawing)
Page 1 of 2

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FIGURE 1-5 –OUTLINE-UNIT/PKG, VS25-40 AIR-COOLED WITH DRYER (Internal Details)
301CGC804
-
A
(Ref. Drawing)
Page 2 of 2

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Figure 1-6 –OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED STANDARD (External Details)
3
02CGC804
-
A
(Ref. Drawing)
Page 1 of 2

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Figure 1-7 –OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED STANDARD (Internal Details)
302CGC804
-
A
(Ref. Drawing)
Page 2 of 2

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Figure 1-8 –OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED WITH DRYER (External Details)
303CGC804
-
A
(Ref. Drawing)
Page 1 of 2

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Figure 1-9 –OUTLINE-UNIT/PKG, VS25-40 WATER-COOLED WITH DRYER (Internal Details)
303CGC804
-
A
(Ref. Drawing)
Page 2 of 2

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Figure 1-10 –OUTLINE-UNIT/PKG, VS30-40 AIR-COOLED ALTERNATE VOLT WITH DRYER OPTION (External Details)
304CGC804
-
A
(Ref. Drawing)
Page 1 of 2

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Figure 1-11 –OUTLINE -UNIT/PKG, VS30-40 AIR-COOLED ALTERNATE VOLT WITH DRYER OPTION (Internal Details)
304CGC804
-
A
(Ref. Drawing)
Page 2 of 2

13-18-603 Page 19
Figure 1-12 –OUTLINE-UNIT/PKG, VS30-40 WATER-COOLED ALTERNATE VOLT WITH DRYER OPTION (External Details)
305CGC804
-
A
(Ref. Drawing)
Page 1 of 2