Gardner Denver APEX25-30A, Operating And Service Manual

Page 1: ...5 608 Version 01 March 21 2016 APEX SINGLE STAGE VARIABLE AND FIXED SPEED BASE MOUNTED and TANK MOUNTED COMPRESSORS AirSmart G2 Controller MODELS APEX25 30A APEXVS18 22A 60HZ OPERATING AND SERVICE MAN...

Page 2: ...nit 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 3: ...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 4: ...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 5: ...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 6: ...19 SECTION 4 Controls Instrumentation 24 SECTION 5 Lubrication Oil Cooler Oil Filter Separator 53 SECTION 6 HEAT EXCHANGERS OIL AIR 62 SECTION 7 Air Filters 65 SECTION 8 Belt Drive System 67 SECTION 9...

Page 7: ...E SCHEDULE SECTION 10 77 SECTION 12 80 Miscellaneous Control Devices 49 Moisture Separator Trap Standard 16 Motor Lubrication 18 MOTOR LUBRICATION SECTION 11 79 Oil Reservoir Drain 14 Piping Control 1...

Page 8: ...igure 4 7 Wiring Diagram FS 575 Volt 44 Figure 4 8 Piping And Instrumentation Illustration 52 Figure 5 1 Oil Level Sight Glass 53 Figure 5 2 Dew Point Chart F 57 Figure 5 3 Dew Point Chart C 57 Figure...

Page 9: ...rt is located on top of the compressor cylinder near the drive shaft end The discharge port is near the bottom at the opposite end of the compressor cylinder Figure 1 1 is an inverted view to show inl...

Page 10: ...n passes through the air oil separator The air then passes through the minimum pressure check valve the after cooler and the moisture separator and into the plant air lines LUBRICATION COOLING AND SEA...

Page 11: ...13 25 608 Page 10 Figure 1 2 COMPRESSOR ILLUSTRATION VARIABLE SPEED 304USC797 A Ref Drawing...

Page 12: ...13 25 608 Page 11 Figure 1 3 COMPRESSOR ILLUSTRATION FIXED SPEED 305USC797 A Ref Drawing...

Page 13: ...13 25 608 Page 12 Figure 1 4 COMPRESSOR ILLUSTRATION TOTAL SYSTEM 301USC804 A Ref Drawing Page 1 of 1...

Page 14: ...pressor air oil reservoir separator chamber and all piping and tubing may be at high temperature during and after operation LOCATION Figure 2 1 page 14 The compressor must be installed where it is pro...

Page 15: ...re 2 2 AIR 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...

Page 16: ...be 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...

Page 17: ...When used an air receiver should be of adequate size provided with a relief valve of proper setting a pressure gauge and a means of draining condensate STANDARD MOISTURE SEPARATOR TRAP The unit is pr...

Page 18: ...be selected based on motor nameplate full load amperage UL Type 1 IP54 VFD and controls enclosure and TEAO main motor on VS variants See Location paragraph on page 13 for distance to the nearest obst...

Page 19: ...ection capacitors Existing line reactor is not properly sized see Fig 2 5 Other large loads share the power feed to the compressor package GD Model Voltage VFD kW Rating Max kVA VS 18 22 575 18 22 Con...

Page 20: ...nt Use only 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 resu...

Page 21: ...or to reach full speed The compressor unit s direction of rotation must be checked every time the compressor package or its main motor is reconnected to the power supply N N NO O OT T TI I IC C CE E E...

Page 22: ...ce Manual Operation at excessive discharge air pressure can cause personal injury or damage to equipment Do not adjust the full discharge air pressure above the maximum stamped on the unit nameplate 1...

Page 23: ...e 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 tempera...

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: ...e controller keypad and display Controller functions include safety and shutdown compressor regulation operator control and advisory maintenance indicators The keypad and display provides a logical an...

Page 26: ...trifugal fan ventilates the interior of the electrical enclosure by drawing fresh air through a reusable foam filter assembly and discharging it into the confines of the sound attenuating package encl...

Page 27: ...13 25 608 Page 26 Figure 4 2 WIRING DIAGRAM VS 230 VOLT 306USC546 01 Ref Drawing Page 1 of 4...

Page 28: ...13 25 608 Page 27 Figure 4 3 WIRING DIAGRAM VS 230 VOLT 306USC546 01 Ref Drawing Page 2 of 4...

Page 29: ...13 25 608 Page 28 Figure 4 3 WIRING DIAGRAM VS 230 VOLT 306USC546 01 Ref Drawing Page 3 of 4...

Page 30: ...13 25 608 Page 29 Figure 4 3 WIRING DIAGRAM VS 230 VOLT 306USC546 01 Ref Drawing Page 4 of 4...

Page 31: ...13 25 608 Page 30 Figure 4 3 WIRING DIAGRAM VS 575 VOLT 307USC546 02 Ref Drawing Page 1 of 4...

Page 32: ...13 25 608 Page 31 Figure 4 4 WIRING DIAGRAM VS 575 VOLT 307USC546 02 Ref Drawing Page 2 of 4...

Page 33: ...13 25 608 Page 32 Figure 4 4 WIRING DIAGRAM VS 575 VOLT 307USC546 02 Ref Drawing Page 3 of 4...

Page 34: ...13 25 608 Page 33 Figure 4 4 WIRING DIAGRAM VS 575 VOLT 307USC546 02 Ref Drawing Page 4 of 4...

Page 35: ...13 25 608 Page 34 Figure 4 4 WIRING DIAGRAM VS 380 460 VOLT 311USC546 01 Ref Drawing Page 1 of 4...

Page 36: ...13 25 608 Page 35 Figure 4 5 WIRING DIAGRAM VS 380 460 VOLT 311USC546 01 Ref Drawing Page 2 of 4...

Page 37: ...13 25 608 Page 36 Figure 4 5 WIRING DIAGRAM VS 380 460 VOLT 311USC546 01 Ref Drawing Page 3 of 4...

Page 38: ...13 25 608 Page 37 Figure 4 5 WIRING DIAGRAM VS 380 460 VOLT 311USC546 01 Ref Drawing Page 4 of 4...

Page 39: ...13 25 608 Page 38 Figure 4 5 WIRING DIAGRAM FS 208 230 460 VOLT 308USC546 01 Ref Drawing Page 1 of 3...

Page 40: ...13 25 608 Page 39 Figure 4 6 WIRING DIAGRAM FS 208 230 460 VOLT 308USC546 01 Ref Drawing Page 2 of 3...

Page 41: ...13 25 608 Page 40 Figure 4 6 WIRING DIAGRAM FS 208 230 460 VOLT 308USC546 01 Ref Drawing Page 3 of 3...

Page 42: ...13 25 608 Page 41 Figure 4 6 WIRING DIAGRAM FS 380 415 460 VOLT 310USC546 01 Ref Drawing Page 1 of 3...

Page 43: ...13 25 608 Page 42 Figure 4 7 WIRING DIAGRAM FS 380 415 460 VOLT 310USC546 01 Ref Drawing Page 2 of 3...

Page 44: ...13 25 608 Page 43 Figure 4 7 WIRING DIAGRAM FS 380 415 460 VOLT 310USC546 01 Ref Drawing Page 3 of 3...

Page 45: ...13 25 608 Page 44 Figure 4 7 WIRING DIAGRAM FS 575 VOLT 309USC546 01 Ref Drawing Page 1 of 3...

Page 46: ...13 25 608 Page 45 Figure 4 8 WIRING DIAGRAM FS 575 VOLT 309USC546 01 Ref Drawing Page 2 of 3...

Page 47: ...13 25 608 Page 46 Figure 4 8 WIRING DIAGRAM FS 575 VOLT 309USC546 01 Ref Drawing Page 3 of 3...

Page 48: ...k of the compressed air and injection oil streams 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 sep...

Page 49: ...e an exceedingly high temperature is detected The following items are provided in the Total System Hardware option Receiver 21 Provides storage of compressed air and serves as a support for the compre...

Page 50: ...ed Check valves 30 3 These devices control the unidirectional flow of compressed air within the modulation system Two way solenoid valve Fill 30 4 This devices fills the inlet valve Actuator 2 1 with...

Page 51: ...13 25 608 Page 50 Figure 4 8 PIPING AND INSTRUMENTATION ILLUSTRATIONJ 301USC797 C Ref Drawing...

Page 52: ...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 lubricants are available throug...

Page 53: ...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 main...

Page 54: ...ain valve at its bottom Close drain valve Drain oil from the air end by removing the G1 1 2 plug at the bottom of the discharge housing Replace the plug Drain oil from the oil cooler by removing the G...

Page 55: ...r 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 cont...

Page 56: ...0 120 130 Ambient Temp oF Discharge PDP oF 100psig 125psig 150psig 175psig Figure 5 2 Dew Point Chart F Pressure Dew Point Trend 100 r h 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 1...

Page 57: ...9000SP Change Interval Up to 180 F 82 C 4000 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 Int...

Page 58: ...ure limits the valve gradually mixes hot separator oil with cooled heat exchanger oil to maintain a nearly constant injection temperature When the oil temperature exceeds the element s setting the val...

Page 59: ...op across the separator is equivalent to the difference between the two 2 pressure sensors in use The pressure differential value may be calculated by subtracting the sump dry side pressure value from...

Page 60: ...13 25 608 Page 59 7 Run the unit and check for leaks Figure 5 4 Air Oil Separation Housing Illustration 336LSE810 B Ref Drawing...

Page 61: ...hind the fresh air inlet grille delivers an air stream to meet the cooling demands of the air oil combination heat exchanger on its way out the package confines The fan is driven by a close coupled IP...

Page 62: ...nclosure door panel adjacent to the cooler assembly Unscrew and remove end grilled panel housing the non metallic pre filter mat 3 Unscrew the access panel attached to the side of the fan air plenum S...

Page 63: ...ed package relies on positive back pressure to cool the heat exchanger Make sure that the access panel next to the heat exchanger is closed during operation or the compressor discharge temperature wil...

Page 64: ...ng 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 wet Never use gaskets...

Page 65: ...NCE 1 Remove the intake air grill panel from the package by first removing the top located screws and washers 2 Remove the vfd filter by sliding out sideways through the provided slot 3 If fouling is...

Page 66: ...lockout and tag out main disconnect and any other circuits before servicing the unit Coupling Element and Hub Inspection 1 Rotating machinery can cause injury or death Open main disconnect lockout an...

Page 67: ...en to 10 N m torque Reinstall the coupling guard with provided fasteners Coupling Hub Removal To remove either coupling hub the compressor must be removed from the package first 1 Drain oil entrained...

Page 68: ...d be sufficient to pull hub from shaft See Figure 8 4 for details 2 Prior to hub removal note and record position of shaft end with respect to coupling hub inner surface Same offset shall be provide w...

Page 69: ...e 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 forcing it and the inlet...

Page 70: ...ve the poppet assembly and the poppet return spring 8 Unscrew the valve body from the compressor housing using the hex pattern provided on the valve body See for Figure 9 1 details 9 Inspect poppet se...

Page 71: ...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 72: ...s fittings bolts and filters 1 Be sure the unit is completely off and that no air pressure is in the oil reservoir and in the air cooled after cooler Close the service valve 2 Disconnect lockout and t...

Page 73: ...ing 4 Inspect the valve seat surfaces for damage or foreign matter Note its setting temperature it is stamped on the valve seat area and will read 55 C or 70 C 5 Immerse the valve body in a bath of co...

Page 74: ...ly to the starter 4 Remove the compressor from the package and remove its coupling hub refer to Coupling Hub Removal in Section 8 page 67 for instructions 5 Remove four 4 bolts securing the seal cover...

Page 75: ...13 25 608 Page 74 FIGURE9 1 Compressor Direct Drive variant Hardware Illustration 308USC810 C Ref Drawing...

Page 76: ...line drawing Refer to Fig 4 9 on Page 52 for the instrument and piping schematic and to Sec 4 for the description of the main components that comprise the Total System Refer to vendor supplied instruc...

Page 77: ...service valve 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...

Page 78: ...one at each motor bottom end and make sure that their spring loaded covers are operational 3 Locate the grease fittings provided at each motor top end Wipe each grease fitting clean and add grease wi...

Page 79: ...lowing compressed air 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 e...

Page 80: ...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 81: ...vfd 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 6 7 High oil...

Page 82: ...n 5 Inspect clean or replace drain valve 6 Leaks in the compressed air system 6 Check for leaks fix any leaks found 7 Pressure limits incorrectly set 7 Check correct pressure limits in the AirSmart Co...

Page 83: ...ature and if low change thermal mixing valve element to one with higher temperature setting Excessive water in air delivery line 1 Water separator drain basic unit or total system receiver and or drye...

Page 84: ...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 85: ...ESS MADE IN WRITING AND EXECUTED BY AN OFFICER OF THE COMPANY THIS WARRANTY SHALL NOT BE EFFECTIVE AS TO ANY CLAIM WHICH IS NOT PRESENTED WITHIN 30 DAYS AFTER THE DATE UPON WHICH THE PRODUCT IS CLAIME...

Page 86: ...For additional information contact your local representative or visit www contactgd com compressors 2016 Gardner Denver Inc Printed in U S A...