Gardner Denver AirSmart Controller APEX5-15A Operating And Service Manual Download

Page: 1 / 72

13-25-600

Version: 02

November 3, 2015

APEX

SINGLE STAGE

BASE- MOUNTED and TANK MOUNTED

COMPRESSORS

AirSmart

Controller

MODELS-APEX5-15A

5, 7.5,10 and 15 HP

60HZ

OPERATING AND

SERVICE MANUAL

Summary of Contents for AirSmart Controller APEX5-15A

Page 1: ...13 25 600 Version 02 November 3 2015 APEX SINGLE STAGE BASE MOUNTED and TANK MOUNTED COMPRESSORS AirSmart Controller MODELS APEX5 15A 5 7 5 10 and 15 HP 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ...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 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: ...trations 8 Section 1 General Information 9 Section 2 Installation 12 Section 3 Starting Operating Procedures 19 Section 4 Controls Instrumentation 25 Section 5 Lubrication Oil Cooler Oil Filter Separa...

Page 7: ...Grounding 17 High Temperature Operation 46 Inlet Line 15 Inlet Screen And Tube 58 Installation Cold Weather 15 General 12 Section 2 12 Lifting Unit 12 Location 12 Lubricant Recommended 45 Lubricant C...

Page 8: ...4 Every 1000 Hours Operation 64 Every 125 Hours Operation 64 Every 4000 Hours Operation 64 Every 8 Hours Operation 64 Every Year 64 Motor Lubrication 64 Package Inlet Filter 64 Starting Operating Proc...

Page 9: ...olt Multi Volt 35 Figure 4 7 Wiring Diagram Full Volt Standard 37 Figure 4 8 Wiring Diagram Wye Delta Voltage Standard 39 Figure 4 9 Wiring Diagram Single Phase 230 Volt 41 Figure 4 10 Wiring Diagram...

Page 10: ...B 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...

Page 11: ...13 25 600 Page 10 Figure 1 2 COMPRESSOR ILLUSTRATION 303ELA797 B Ref Drawing Page 1 of 2...

Page 12: ...13 25 600 Page 11 Figure 1 3 COMPRESSOR ILLUSTRATION TANK MOUNTED 303ELA797 B Ref Drawing Page 2 of 2...

Page 13: ...r 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 snow and freezing...

Page 14: ...sor requires no special foundation but should be mounted on a smooth solid surface Whenever possible install the unit near level Temporary installation may be made at a maximum 5 angle lengthwise or 5...

Page 15: ...sure Service panels are provided for maintenance access Be sure to allow enough space around the unit for the panels to be removed Any of the enclosure panels may be removed by opening the latch and l...

Page 16: ...r unsheltered outside installations should be avoided where possible Installation next to a heated building where enough heat can be used to keep the compressor room above freezing will save many comp...

Page 17: ...by the check valve in the unit discharge line If a rotary screw unit is manifolded to another compressor be sure the other compressor has a check valve in the line between the machine and the manifold...

Page 18: ...following charts show recommended grease qualities and regreasing intervals for ball bearing motors For additional information refer to the motor manufacturer s instructions The following procedure sh...

Page 19: ...ING INTERVAL Type of Service Typical Rating Relubrication Interval Standard One or Two Shift Operation Up to 150 HP 112 KW 18 Months Above 150 HP 112 KW 12 Months Severe Continuous Operation Up to 150...

Page 20: ...ssary to achieve maximum service and extended drain intervals of AEON 4000 lubricant Use only genuine Gardner Denver filters designed and specified for this compressor Always stop the unit and release...

Page 21: ...ction of rotation must be checked every time the compressor is reconnected to the power supply 7 System Pressure The discharge pressure of the unit is set at the factory To change the discharge pressu...

Page 22: ...tomatic start stop sequence built in You do NOT need to close the air service valve Closing the air service valve on start up or prior to shutdown will cause rapid cycling and could cause a high press...

Page 23: ...nute The unit is equipped with a minimum 65 psig pressure check valve no special procedure to maintain the unit reservoir pressure is required DAILY CHECK Refer to Maintenance Schedule SECTION 8 page...

Page 24: ...n of the compressor the machine must be stopped and in the Ready mode Stop the compressor by pressing the Stop Reset button The front panel display should read READY on line 3 Next press the Enter but...

Page 25: ...at were made press the Enter button If the Stop Reset button is pressed the parameter changes will be lost the next time the compressor power is turned off Setting The Unload and Load Pressure After s...

Page 26: ...operating mode from the controller keypad Prior to starting the STOP RESET key must be pressed to place the controller into its READY state as indicated on the display Compressor operation may then b...

Page 27: ...13 25 600 Page 26 Figure 4 1 CONTROL SCHEMATIC 300ELA797 B Ref Drawing...

Page 28: ...and Service Manual 13 17 600 Figure 4 2 KEY PAD Pressure Relief Valve A pressure relief valve is installed in the final discharge line and set to approximately 120 125 of the unit s full load operatin...

Page 29: ...tream reservoir side of the valve When the system pressure rises the spring is overridden and the valve opens to full porting The valve does not require adjustment If the Valve fails to function check...

Page 30: ...isolating compressor package from air system 4 Identify by position each tube connected to the valve body and remove 5 Remove four bolts 7 securing valve body to compressor body and remove valve 6 In...

Page 31: ...Reservoir Pressure Transducer Figure 4 1 page 26 This transducer is connected to the coolant system Its signal is used to prevent loaded starts monitor oil pressure and to monitor the condition of the...

Page 32: ...or transformer supply voltage to 24 volts DC for use by all unit control devices Terminal Strip This provides connections for all 24 volt devices not contained within the enclosure Main Starter This...

Page 33: ...cal shock can cause injury or death Open lockout and tagout main disconnect and any other circuits before servicing unit Operation with incorrect motor rotation can damage equipment and cause oil erup...

Page 34: ...ace transformer primary fuses with two FNQ R 5 amp fuses 24CA2785 For a 230VAC supply voltage replace transformer primary fuses with two FNQ R 5 amp fuses 24CA2785 For a 460VAC supply voltage replace...

Page 35: ...f the motor Adjustment is performed by turning the adjustment dial located on the overload relay 10 Open compressor package enclosure to locate the electric motor terminal connection box Disconnect an...

Page 36: ...13 25 600 Page 35 Figure 4 6 WIRING DIAGRAM FULL VOLT MULTI VOLT 300ELA546 B Ref Drawing Page 1 of 2...

Page 37: ...13 25 600 Page 36 300ELA546 B Ref Drawing Page 2 of 2...

Page 38: ...13 25 600 Page 37 Figure 4 7 WIRING DIAGRAM FULL VOLT STANDARD 301ELA546 B Ref Drawing Page 1 of 2...

Page 39: ...13 25 600 Page 38 301ELA546 B Ref Drawing Page 2 of 2...

Page 40: ...13 25 600 Page 39 Figure 4 8 WIRING DIAGRAM WYE DELTA VOLTAGE STANDARD 304ELA546 B Ref Drawing Page 1 of 2...

Page 41: ...13 25 600 Page 40 304ELA546 B Ref Drawing Page 2 of 2...

Page 42: ...13 25 600 Page 41 Figure 4 9 WIRING DIAGRAM SINGLE PHASE 230 VOLT 305ELA546 B Ref Drawing Page 1 of 2...

Page 43: ...13 25 600 Page 42 305ELA546 B Ref Drawing Page 2 of 2...

Page 44: ...13 25 600 Page 43 Figure 4 10 WIRING DIAGRAM WYE DELTA VOLT MULTI VOLT 309ELA546 B Ref Drawing Page 1 of 2...

Page 45: ...13 25 600 Page 44 309ELA546 B Ref Drawing Page 2 of 2...

Page 46: ...tion cooling and sealing The air oil mixture is then discharged to the oil reservoir where a large part of the entrained oil drops out of the air stream the air then passes through the final oil separ...

Page 47: ...he recommended year round lubricant AEON 4000 LUBRICANT CHANGE PROCEDURE Upgrading to a longer life lubricant is essentially a very worthwhile practice Following are the primary steps to be completed...

Page 48: ...igh temperature during and after operation High temperature operation can cause damage to equipment or personal injury Do not repeatedly restart the unit after high temperature stops operation Find an...

Page 49: ...he power supply to the starter 3 Wipe away all dirt around the oil filler plug 4 Remove the oil filler plug and add oil as required to return the oil level to the bottom of the sight gauge 5 Install o...

Page 50: ...compressor lubrication and may cause excessive oil carryover in the lubricant or compressor failure Please note that the airend discharge temperature must be maintained a minimum of 10 F above the pr...

Page 51: ...re 100 Relative Humidity 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 20 30 40 50 60 70 80 90 100 110 120 Ambient Temp F Dew Point Temp F 100 psig 125 psig 150 psig 175 ps...

Page 52: ...rature Figure 5 5 page 52 shows how the change interval is affected by temperature When operating conditions are severe very dusty high humidity etc it will be necessary to change the oil more frequen...

Page 53: ...2 If the unit is elevated so that the oil reservoir drain can be used empty the oil reservoir through the drain valve to a suitable container or sump 3 If the drained oil and or the oil filter element...

Page 54: ...oil required to raise the oil level from ADD to FULL is shown in Figure 5 1 page 45 this section Repeated addition of oil between oil changes may indicate excessive oil carryover and should be invest...

Page 55: ...and check for leaks COMPRESSOR OIL COOLER The cooler fan is mounted on the compressor motor shaft air is exhausted through the oil cooler and away from the unit Do not obstruct air flow to and from t...

Page 56: ...e separator manifold to the compressor cylinder is not clogged or pinched off the check valve in the oil return is functioning properly and there is not water or an oil water emulsion in the oil Oil c...

Page 57: ...essor should be at operating temperature at the time of the checks One half hour of loaded operation is usually sufficient to reach level out operating temperatures Air and Oil Discharge Temperature 1...

Page 58: ...ery 50 to 150 operating hours depending on dust conditions NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units Genuine parts are available through your author...

Page 59: ...his would indicate a rupture or crack Inlet Tube Inspect the inlet screen and tube for dirt accumulation each time the filter is serviced Clean the tube when required by ramming a clean dry cloth thro...

Page 60: ...nd run jackbolt down so that airend lowers loosening the belts 6 Remove the belts 7 Replace the old belts with new ones For proper belt life use only genuine Gardner Denver belts 8 Check the sheave al...

Page 61: ...sheave 10 Grease the mounting screws and lightly tighten them 11 Clean the shaft and mount the sheave assembly Align the motor sheave to the airend sheave When mounting the sheave assembly the bushin...

Page 62: ...sheave assembly and insert one in the jackbolt hole Figure 7 2 Figure 7 1 REMOVING THE MOTOR SHEAVE 27 Tighten the screw until the drive bushing and sheave are loose They can be removed from the airen...

Page 63: ...ave assembly the bushing clamps to the shaft first the sheave can still be moved a little This can affect the alignment of the sheaves Figure 7 3 INSTALLING DRIVE SHEAVE ON COMPRESSOR OR MOTOR 31 Tigh...

Page 64: ...tion Force Pounds Newtons per belt Deflection in Inches mm 5 HP 4 kW 2 6 to 8 5 1 3 to 1 9 5 16 8 7 5 HP 5 kW 2 6 to 7 1 3 to 1 5 5 16 8 10 HP 7 kW 3 6 to 8 5 1 3 to 1 9 5 16 8 15 HP 11 kW 3 6 to 7 1...

Page 65: ...dirt accumulation on oil aftercooler core faces and the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solven...

Page 66: ...il Separator Check Reservoir Oil Level Check for Proper Load Unload Check Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Strainer Change Compressor Lubricant AEON 4000 Check Re...

Page 67: ...starter overload relay tripped 4 Reset and investigate cause of overload Compressor does not unload or load 1 Improperly adjusted control 1 Refer to Control Manual 13 17 600 and adjust control 2 Air...

Page 68: ...id valve is faulty 6 Replace 7 Leaks in the compressed air system 7 Check for leaks fix any leaks found 8 V Belts broken 8 Replace 9 V Belts slipping 9 Test belt tensioning 10 Pressure limits incorrec...

Page 69: ...ct oil 5 Use Gardner Denver AEON lubricating coolant 6 Inoperative minimum pressure valve 6 Replace seals in valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See High Discharg...

Page 70: ...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 71: ...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 72: ...For additional information contact your local representative or visit www contactgd com compressors 2015 Gardner Denver Inc Printed in U S A...

Search results

Summary of Contents for AirSmart Controller APEX5-15A

Reviews:

Related manuals for AirSmart Controller APEX5-15A

Brands by name

Popular brands

Gardner Denver AirSmart Controller APEX5-15A, Operating And Service Manual

Search results

Summary of Contents for AirSmart Controller APEX5-15A

Reviews:

Related manuals for AirSmart Controller APEX5-15A

Brands by name

Popular brands