Gardner Denver APEX15-18A, Operating And Service Manual

Page 1: ...07 13 25 607 Version 00 July 30 2014 APEX SINGLE STAGE BASE MOUNTED and TANK MOUNTED COMPRESSORS AirSmart G2 Controller MODELS APEX15 18A 15 and 18 kW 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ......

Page 3: ...it 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...

Page 4: ...mical 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...

Page 5: ...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 Li...

Page 6: ...or 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...

Page 7: ...Section 3 Starting Operating Procedures 18 Section 4 Controls Instrumentation 23 Section 5 Lubrication Oil Cooler Oil Filter Separator 36 Section 6 Heat Exchangers Oil Air 44 Section 7 Air Filters 47...

Page 8: ...e Schedule Section 10 59 Section 11 61 Miscellaneous Control Devices 33 Moisture Separator Trap Standard 15 Motor Lubrication 17 Oil Reservoir Drain 13 Piping Control 15 Prestart Up Instructions 18 Ai...

Page 9: ...iring Diagram Wye Delta 575 Volt 31 Figure 4 5 Wiring Diagram Wye Delta 575 Volt 32 Figure 4 6 Piping And Instrumentation Illustration 35 Figure 5 1 Oil Level Sight Glass 36 Figure 5 2 Dew Point Chart...

Page 10: ...As meshing continues more of the main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression a...

Page 11: ...13 25 607 Page 9 Figure 1 2 COMPRESSOR ILLUSTRATION EXTERNAL DETAILS 300UCC804 C Ref Drawing Page 1 of 1...

Page 12: ...13 25 607 Page 10 Figure 1 3 COMPRESSOR ILLUSTRATION INTERNAL DETAILS 300UCC797 B Ref Drawing Page 2 of 2...

Page 13: ...13 25 607 Page 11 Figure 1 4 COMPRESSOR ILLUSTRATION TOTAL SYSTEM 307UCC804 B Ref Drawing Page 1 of 1...

Page 14: ...ervoir separator chamber and all piping and tubing may be at high temperature during and after operation LOCATION Figure 2 1 page 13 The compressor must be installed where it is protected from rain sn...

Page 15: ...R FLOW CHART FOUNDATION The rotary screw compressor requires no special foundation but should be mounted on a smooth solid surface Whenever possible install the unit near level Mounting bolts are not...

Page 16: ...e removed Any of the enclosure panels may be removed by opening the latch and lifting it up slightly Do not operate the compressor with the fan and belt guard removed Exposed fan and belts may cause i...

Page 17: ...and alone combination moisture separator and trap that is field installed downstream of the aftercooler CONTROL PIPING Control piping is not necessary since the rotary screw unit is factory wired and...

Page 18: ...e NFPA 70 and any applicable local electrical codes Wiring must be performed only by qualified electricians Electrical shock can cause injury or death Open main disconnect switch lockout and tag out b...

Page 19: ...D kW Rating Max KVA VS15 VS18 575 15 18 Consult factory 460 15 18 Consult factory 380 15 18 Consult factory 230 15 18 Consult factory Figure 2 5 Line Reactor Sizing GROUNDING Equipment must be grounde...

Page 20: ...genuine Gardner Denver filters designed and specified for this compressor Always stop the unit and release air pressure before removing oil filler plug Failure to release pressure may result in perso...

Page 21: ...om 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...

Page 22: ...perational Settings Operating Mode menu in Controller Operating and Service Manual 13 Enclosure Check for damaged panels or doors Check all screws and latches for tightness Be sure doors are closed an...

Page 23: ...the check valve on the package 3 Turn on power to the compressor package To start press STOP key to clear shutdown conditions then press RUN key 4 Run for approximately several minutes until the tempe...

Page 24: ...e with button to Set Points sub menu and press 8 button to enter selection 4 Navigate with button to Target Pressure sub menu and press 8 button to enter selection see Fig 3 2 for value entry display...

Page 25: ...essor control see Figure 4 1 for general detail of the controller keypad and display Controller functions include safety and shutdown compressor regulation operator control and advisory maintenance in...

Page 26: ...the air stream supplied by the heat exchanger cooling fan Reusable air filters protect the air stream from contaminants A temperature sensor monitors the average temperature within the common enclosur...

Page 27: ...13 25 607 Page 25 Figure 4 2 WIRING DIAGRAM VS 200 460 VOLT 306UCC546 A Ref Drawing Page 1 of 4...

Page 28: ...13 25 607 Page 26 Figure 4 3 WIRING DIAGRAM VS 200 460 VOLT 306UCC546 A Ref Drawing Page 2 of 4...

Page 29: ...13 25 607 Page 27 Figure 4 4 WIRING DIAGRAM VS 200 460 VOLT 306UCC546 A Ref Drawing Page 3 of 4...

Page 30: ...13 25 607 Page 28 Figure 4 5 WIRING DIAGRAM VS 200 460 VOLT 306UCC546 A Ref Drawing Page 4 of 4...

Page 31: ...13 25 607 Page 29 Figure 4 6 WIRING DIAGRAM VS 575 VOLT 307UCC546 A Ref Drawing Page 1 of 4...

Page 32: ...13 25 607 Page 30 Figure 4 7 WIRING DIAGRAM VS 575 VOLT 307UCC546 A Ref Drawing Page 2 of 4...

Page 33: ...13 25 607 Page 31 Figure 4 8 WIRING DIAGRAM VS 575 VOLT 307UCC546 A Ref Drawing Page 3 of 4...

Page 34: ...13 25 607 Page 32 Figure 4 9 WIRING DIAGRAM VS 575 VOLT 307UCC546 A Ref Drawing Page 4 of 4...

Page 35: ...ams and serves as a sump for the latter Air oil separator 7 Intercepts and coalesces the aerosol oil stream in the compressed air exiting the inertial separation process within the oil sump Oil Filler...

Page 36: ...al signal for use by the AirSmart controller for monitoring and control Its signal is used to monitor compressor temperature and also trigger a shutdown event in case an exceedingly high temperature i...

Page 37: ...13 25 607 Page 35 Figure 4 10 PIPING AND INSTRUMENTATION ILLUSTRATION 301UCC797 F Ref Drawing...

Page 38: ...one of several Gardner Denver AEO lubricants These lubricants are formulated to the highest quality standards and are factory authorized tested and approved for use in rotary screw compressors AEON l...

Page 39: ...ay be at high temperature during and after operation Use of improper lubricants will cause damage to equipment Do not mix different types of lubricants or use inferior lubricants Improper equipment ma...

Page 40: ...from air end and cooler by removing single drain plug at the bottom of the oil core tank see Figure 1 3 page 10 for details Reinstall the drain plug Remove and drain oil from the oil filter Reinstall...

Page 41: ...y or in the event of thermal mixing valve malfunction the oil charge residing in the sump may not reach a high enough temperature to keep water vapor from condensing as liquid water a condition that c...

Page 42: ...90 200 210 220 230 240 250 260 30 40 50 60 70 80 90 100 110 120 130 Ambient Temp oF Discharge PDP oF 100psig 125psig 150psig 175psig Pressure Dew Point Trend 100 r h 30 35 40 45 50 55 60 65 70 75 80 8...

Page 43: ...0 hrs 8000 hrs 180 to 190 F 82 C to 88 C 3000 hrs 6000 hrs 190 to 200 F 88 C to 93 C 2000 hrs 4000 hrs 200 F 93 C 1000 hrs 2000 hrs Figure 5 4 Oil Change Interval DRAINING AND REFILLING THE OIL SYSTEM...

Page 44: ...s hot and cooled oil and delivers a tempered mixture to the oil filter and finally the compressor injection port see Fig 1 2 Page 11 for its location Its thermostatic element expands with heat When oi...

Page 45: ...essure value from the compressor discharge pressure value A pressure differential of 8psi will trigger a service advisory to change the element A pressure differential of 15psi will trigger a system s...

Page 46: ...nlet grille delivers an air stream to a cool the exterior of the main electric motor and b meet the cooling demands of the air oil combination heat exchanger on its way out the package confines The fa...

Page 47: ...t is completely off and that oil reservoir is depressurized 2 Open and or remove enclosure door panels opposite the cooler assembly See Figure 6 2 see page 46 for details 3 Inspect core area If blocke...

Page 48: ...lies on positive back pressure to cool the heat exchanger Make sure that the enclosure panels that surround the heat exchanger area are closed during compressor operation or the compressor discharge t...

Page 49: ...n inflammable cleaning fluids Do not use solvents other than water Improper cleaning may damage the element Never operate the unit without the element Never use elements that are damaged ruptured or w...

Page 50: ...the pre filter media See Figure 7 2 for component details Note do not remove the fan grill 2 Cleanse the pre filter media with compressed air or with water to remove debris trapped in its fibers 3 Rep...

Page 51: ...els open 2 Loosen the two 2 slotted screws holding the cover in place Slide the cover upwards to uncover the air filter edge 3 Grab the outer edge of the air filter assembly and remove by pulling outw...

Page 52: ...pivoting bracket see Fig 1 2 Page 11 for details Figure 8 1 Motor Jacking Assembly Figure 8 2 V Belt Drive Components UNPACKING THE V BELT SYSTEM To protect the belts from shock and strain during tran...

Page 53: ...s of the motor sheave Make sure that each belt is engaged in its respective groove of each sheave 5 Turn the jacking screw counter clockwise to lower motor and transfer its weight unto the belt set Ma...

Page 54: ...belts 2 Remove the belts 3 Carefully sketch or photograph the orientation of each sheave bushing pair as they sit on their respective shaft You ll need this information to re install each pair 4 Loose...

Page 55: ...by venting to atmosphere the gas trapped underside of the piston via check valve 19 and orifice 18 During the unloaded state a two way solenoid valve feeds pressurized air underneath the piston 2 1 f...

Page 56: ...emove the filter element 6 Remove four bolts securing inlet flange to the compressor body and remove the flange 7 Remove the poppet assembly and the poppet return spring 8 Unscrew the valve body from...

Page 57: ...n personal injury or death Never paint lubricate or alter a relief valve Do not plug vent or restrict Operation of the unit with improper relief valve setting can result in severe personal injury or m...

Page 58: ...the compressor housing Cleanse or replace use 0 75 hex wrench to unscrew Note that fitting an o ring on the hex wrench body helps hold the seat in position during installation 5 Assemble the minimum p...

Page 59: ...n the valve seat area and will read 55 C or 70 C 5 Immerse the valve body in a bath of compressor oil heat the oil slowly and observe if the seat starts extending about 5 C below its setting and reach...

Page 60: ...13 25 607 Page 58 Figure 9 6 Compressor Module Hardware 308UCC810 C Ref Drawing Page 1 of 1...

Page 61: ...air dryer as shown on Figure 10 1 Refer to Figure 1 4 for dimensioned outline drawing Refer to Figure 4 6 for the instrument and piping schematic and to Sec 4 for the description of the main componen...

Page 62: ...lve and a separate swing type check valve must be installed between the unit and the customer s air system If a fast operating valve such as a ball valve is used it must be closed slowly to give the i...

Page 63: ...ir carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow This cleaning operation will keep the exterior cooling surfaces clean and ensure effective heat dissi...

Page 64: ...lters Change Oil Separator Check Reservoir Oil Level Check for Proper Load Unload Check Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Orifice Change Compressor Lubricant AEON...

Page 65: ...w 4 Motor starter overload relay tripped 4 Reset and investigate cause of overload 5 Fast pressure buildup due to open inlet valve 5 Inspect inlet valve and unloader valve operation Replace if faulty...

Page 66: ...orrectly set 9 Check correct pressure limits in the AirSmart Controller 10 Aftercooler is frozen 10 Thaw out This machine cannot operate in temperatures below 32 F 0 C High discharge air temperature 1...

Page 67: ...8 Water condensate in oil 8 Check oil reservoir temperature and if low change thermal mixing valve element to one with higher temperature setting Excessive water in air delivery line 1 Water separato...

Page 68: ...tage Operation with lower voltages will reduce motor life and load capacity As voltages get further below the design range other symptoms may show up Low voltages may lead to high motor currents The o...

Page 69: ......

Page 70: ...For additional information contact your local representative or visit www contactgd com compressors 2014 Gardner Denver Inc Printed in U S A...