Gardner Denver AirSmart G2 User Manual Download

Page: 1 / 72

13-25-606

Version: 03

January 27, 2016

APEX

SINGLE STAGE

BASE- MOUNTED and TANK MOUNTED

COMPRESSORS

AirSmart

G2 Controller

MODELS-APEX15-25A

15, 20 and 25 HP

60HZ

OPERATING AND

SERVICE MANUAL

Summary of Contents for AirSmart G2

Page 1: ...13 25 606 Version 03 January 27 2016 APEX SINGLE STAGE BASE MOUNTED and TANK MOUNTED COMPRESSORS AirSmart G2 Controller MODELS APEX15 25A 15 20 and 25 HP 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: ...ction 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 Se...

Page 8: ...chedule Section 10 58 Section 11 60 Miscellaneous Control Devices 33 Moisture Separator Trap Standard 15 Motor Lubrication 17 Oil Reservoir Drain 13 Piping Control 15 Prestart Up Instructions 18 Air F...

Page 9: ...4 4 Wiring Diagram Wye Delta 200 230 460 Volt 27 Figure 4 5 Wiring Diagram Wye Delta 575 Volt 30 Figure 4 6 Piping and Instrumentation Illustration 35 Figure 5 1 Oil Level Sight Glass 36 Figure 5 2 De...

Page 10: ...s 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 compressio...

Page 11: ...13 25 606 Page 9 1 2 Figure 1 2 COMPRESSOR ILLUSTRATION EXTERNAL DETAILS 300UCC797 B Ref Drawing Page 1 of 2...

Page 12: ...13 25 606 Page 10 1 3 Figure 1 3 COMPRESSOR ILLUSTRATION INTERNAL DETAILS 300UCC797 B Ref Drawing Page 2 of 2...

Page 13: ...13 25 606 Page 11 1 4 Figure 1 4 COMPRESSOR ILLUSTRATION TOTAL SYSTEM 306UCC804 A Ref Drawing Page 1 of 1...

Page 14: ...l reservoir 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 ra...

Page 15: ...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 are no...

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: ...ficient storage capacity to prevent rapid cycling When used an air receiver should be of adequate size provided with a pressure relief valve of proper setting a pressure gauge and a means of draining...

Page 18: ...nits The stand alone compressor package is factory wired for all connections from the starter to the motor for the horsepower and voltage specified on the order The standard unit is supplied with tota...

Page 19: ...5 48 9 Figure 2 4 Electrical Wiring Sizing Data GROUNDING Equipment must be grounded in accordance with Section 250 of the National Electrical Code Failure to properly ground the compressor package co...

Page 20: ...of AEON 4000 lubricant 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 rele...

Page 21: ...from 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 mu...

Page 22: ...ischarge air pressure above the maximum stamped on the unit nameplate 12 Operating Mode See Operational Settings Operating Mode menu in Controller Operating and Service Manual 13 Enclosure Check for d...

Page 23: ...d 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 tem...

Page 24: ...ate 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 displa...

Page 25: ...eneral detail of the controller keypad and display Controller functions include safety and shutdown compressor regulation operator control and advisory maintenance indicators The keypad and display pr...

Page 26: ...OTICE Read the Operator s Manual before operating the compressor It is critical that the detailed instructions for the controller found in the controller manual are read and understood Once the approp...

Page 27: ...30VAC supply voltage reconnect to the transformer primary labeled H2 c For a 460VAC supply voltage reconnect to the transformer primary labeled H1 5 Replace the two 2 transformer primary fuses with ne...

Page 28: ...r electronic relay OL as shown on the applicable wiring diagram and adjust the relay according to the motor nameplate amperage times its service factor for the corresponding conversion kit voltage Adj...

Page 29: ...13 25 606 Page 27 4 5 Figure 4 4 WIRING DIAGRAM WYE DELTA 200 230 460 VOLT 300UCC546 C Ref Drawing Page 1 of 3...

Page 30: ...4 6 13 25 606 Page 28 300UCC546 C Ref Drawing Page 2 of 3...

Page 31: ...13 25 606 Page 29 4 7 300UCC546 C Ref Drawing Page 3 of 3...

Page 32: ...13 25 606 Page 30 4 8 Figure 4 5 WIRING DIAGRAM WYE DELTA 575 VOLT 303UCC546 D Ref Drawing Page 1 of 3...

Page 33: ...13 25 606 Page 31 4 9 303UCC546 D Ref Drawing Page 2 of 3...

Page 34: ...13 25 606 Page 32 4 10 303UCC546 D Ref Drawing Page 3 of 3...

Page 35: ...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 separation process within the oil sump Oil F...

Page 36: ...signal for use by the AirSmart G2 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...

Page 37: ...13 25 606 Page 35 4 13 Figure 4 6 PIPING AND INSTRUMENTATION ILLUSTRATION 301UCC797 D Ref Drawing Page 1 of 1...

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

Page 39: ...ng may 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 equipmen...

Page 40: ...om 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 th...

Page 41: ...humidity 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...

Page 42: ...190 200 210 220 230 240 250 260 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...

Page 43: ...program with the AEON lubricants and we recommend a sample be sent in at 100 hours on a new unit Discharge Temperature AEON 4000 Change Interval AEON 9000SP Change Interval Up to 180 F 82 C 4000 hrs...

Page 44: ...e 10 for its location The thermostatic element expands with heat When oil is below 122 F 50 C the oil flow from the cooler is blocked When oil coming for the sump is between 122 F 50 C and 131 F 55 C...

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: ...r inlet 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...

Page 47: ...unit 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 page 46 for details 3 Inspect core area If blocke...

Page 48: ...relies 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...

Page 49: ...nflammable 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 wet...

Page 50: ...e 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 R...

Page 51: ...voting bracket see Figure 1 3 Page 10 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 tra...

Page 52: ...oves 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...

Page 53: ...ssor 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 will need this information to re install each pair...

Page 54: ...s done 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...

Page 55: ...remove 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 fro...

Page 56: ...result in 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 inj...

Page 57: ...he 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 pr...

Page 58: ...he 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 reaches...

Page 59: ...13 25 606 Page 57 9 6 Figure 9 6 Compressor Module Hardware 308UCC810 C Ref Drawing Page 1 of 1...

Page 60: ...r 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 Section 4 page 23 for the description of the main...

Page 61: ...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 give the...

Page 62: ...ning is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow This cleaning op...

Page 63: ...t Filters 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 A...

Page 64: ...low 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 fault...

Page 65: ...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 Dirty or cl...

Page 66: ...er 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 separator drai...

Page 67: ...voltage 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 Th...

Page 68: ...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 69: ...NOTES...

Page 70: ...NOTES...

Page 71: ...NOTES...

Page 72: ...For additional information contact your local representative or visit www contactgd com compressors 2016 Gardner Denver Inc Printed in U S A...

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