Gardner Denver APEXVS7-11A Operating And Service Manual Download Page 1

Page: 1 / 71

13-25-603

Version: 01

June 11, 2013

APEX

VARIABLE SPEED

SINGLE STAGE

BASE- MOUNTED and TANK MOUNTED

COMPRESSORS

AirSmart



Controller

MODELS-APEXVS7-11A

7 and 11 Kw

60HZ

OPERATING AND

SERVICE MANUAL

Summary of Contents for APEXVS7-11A

Page 1: ...13 25 603 Version 01 June 11 2013 APEX VARIABLE SPEED SINGLE STAGE BASE MOUNTED and TANK MOUNTED COMPRESSORS AirSmart Controller MODELS APEXVS7 11A 7 and 11 Kw 60HZ OPERATING AND SERVICE MANUAL...

Page 2: ...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 simplif...

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: ...ations 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 Separato...

Page 7: ...emperature Operation 45 Inlet Line 15 Inlet Screen And Tube 57 Installation Cold Weather 15 General 12 Section 2 12 Lifting Unit 12 Location 12 Lubricant Recommended 44 Lubricant Change Procedure 45 L...

Page 8: ...on 63 Every 125 Hours Operation 63 Every 4000 Hours Operation 63 Every 8 Hours Operation 63 Every Year 63 Motor Lubrication 63 Package Inlet Filter 63 Starting Operating Procedures Section 3 19 63 Sta...

Page 9: ...matic 29 Figure 4 4 Key Pad 30 Figure 4 5 Inlet Valve 32 Figure 4 6 Wiring Diagram Variable Speed 200V 230V 460V 36 Figure 4 7 Wiring Diagram Variable Speed 575V 40 Figure 5 1 Flow Diagram Air Oil Sys...

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 25 603 Page 10 Figure 1 2 COMPRESSOR ILLUSTRATION 303ELA797 B Ref Drawing Page 1 of 2...

Page 12: ...13 25 603 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: ...er 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 com...

Page 17: ...The controller has an automatic 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...

Page 18: ...COPPER SUPPLY WIRE RECOMMENDATIONS Minimum 75 C wire Minimum 90 C wire NOTES Model Input Package Amps NEC Package Copper Wire Copper Wire Voltage Estimated Amps at 30 C Sized at 40 C Sized at 40 C AP...

Page 19: ...S11 400 480 15 250 Figure 2 5 LINE REACTOR SIZING RECOMMENDATIONS GROUNDING Equipment must be properly grounded in accordance with the National Electrical Code and or applicable local codes Failure to...

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: ...on Relay contacts operated by the package AirSmart controller engage and disengage the dryer from the external power source The dryer is turned on when the START button is pressed which also starts th...

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: ...er compressor operation may commence For your convenience a Quick Start excerpt from the controller manual is shown in Section 3 Press the red STOP RESET button to clear any conditions e g Loss of Pow...

Page 27: ...00 230 or 460 or 575 vac electrical power which must be installed in accordance with local site Electrical Code requirements Automatic restarting or electrical shock can cause injury or death Open loc...

Page 28: ...T 3 OPERATOR 4 CONTACT BLOCK 5 NAME PLATE EMERGENCY STOP 6 DOOR LATCH 7 DOOR LATCH SLOTTED 8 VFD 9 ADAPTOR 10 DIN RAIL 11 TERMINAL BLOCK END STOP 12 TERMINAL BLOCK 13 GROUND BLOCK 14 GROUND BLOCK 15 P...

Page 29: ...R 2 GASKET 3 OPERATOR 4 CONTACT BLOCK 5 NAME PLATE EMERGENCY STOP 6 DOOR LATCH 7 DOOR LATCH SLOTTED 8 VFD 9 ADAPTOR 10 DIN RAIL 11 TERMINAL BLOCK END STOP 12 TERMINAL BLOCK 13 GROUND BLOCK 14 GROUND B...

Page 30: ...13 25 603 Page 29 Figure 4 3 CONTROL SCHEMATIC 300ELA797 A Ref Drawing...

Page 31: ...and Service Manual 13 17 600 Figure 4 4 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 32: ...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 33: ...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 34: ...Reservoir Pressure Transducer Figure 4 3 page 29 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 35: ...nd control transformer Power Supply This device changes the incoming AC supply voltage or transformer supply voltage to 24 volts DC for use by all unit control devices Terminal Strip This provides con...

Page 36: ...e the valve 6 Assemble the minimum pressure check valve assembly into the housing 7 Run the unit and check for leaks CONVERSION INSTRUCTIONS Automatic restarting or electrical shock can cause injury o...

Page 37: ...13 25 603 Page 36 Figure 4 6 WIRING DIAGRAM VARIABLE SPEED 200V 230V 460V 302ELA546 B Ref Drawing Page 1 of 4...

Page 38: ...13 25 603 Page 37 302ELA546 B Ref Drawing Page 2 of 4...

Page 39: ...13 25 603 Page 38 302ELA546 B Ref Drawing Page 3 of 4...

Page 40: ...13 25 603 Page 39 302ELA546 B Ref Drawing Page 4 of 4...

Page 41: ...13 25 603 Page 40 Figure 4 7 WIRING DIAGRAM VARIABLE SPEED 575V 306ELA546 A Ref Drawing Page 1 of 4...

Page 42: ...13 25 603 Page 41 306ELA546 A Ref Drawing Page 2 of 4...

Page 43: ...13 25 603 Page 42 306ELA546 A Ref Drawing Page 3 of 4...

Page 44: ...13 25 603 Page 43 306ELA546 A Ref Drawing Page 4 of 4...

Page 45: ...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 46: ...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 47: ...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 and co...

Page 48: ...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 oil filler plug run and check for leaks DO N...

Page 49: ...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 50: ...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 51: ...rature Figure 5 5 page 50 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 52: ...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 53: ...oil required to raise the oil level from ADD to FULL is shown in Figure 5 2 page 47 this section Repeated addition of oil between oil changes may indicate excessive oil carryover and should be invest...

Page 54: ...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 55: ...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 56: ...ating 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 170 F to 200 F 77 C to 9...

Page 57: ...y 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 authoriz...

Page 58: ...l load this 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 cl...

Page 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...Smart Controller Messages and Alarms Acknowledge the presence of an abnormal condition and take action to correct it Every 125 Hours Operation 1 Check for dirt accumulation on oil aftercooler core fac...

Page 65: ...ange Compressor Lubricant AEON 4000 Check Relief Valve Check Condition of Hoses Check Operation of Condensate Removal Solenoid Valve Change Inlet Valve Seals AirSmart Operational Parameters 1 AirSmara...

Page 66: ...STOP RESET button to reset 4 Read error message on control panel 4 Take appropriate action See Control Manual 13 17 600 5 Remote Contact is open 5 Replace switch or jumper 6 Variable Frequency Drive...

Page 67: ...control tubing Compressor starts too slowly 1 Acceleration time in VFD set too long 1 Contact your Gardner Denver distributor 2 Minimum Pressure Check Valve is leaking 2 Repair or replace Compressor i...

Page 68: ...ng valve stuck on bypass mode 4 Repair or Replace Valve 5 Clogged Cooler lines 5 Inspect and clear cooler 6 Low oil level 6 Add oil to proper level 7 Clogged oil lines 7 Inspect and clear oil lines 8...

Page 69: ...broken or loose oil return line fittings 3 Inspect and tighten or replace 4 Ruptured oil separator element 4 Replace element 5 Loose assembly 5 Tighten all fittings and gaskets 6 Foam caused by use of...

Page 70: ......

Page 71: ...For additional information contact your local representative or visit www contactgd com compressors 2013 Gardner Denver Inc Printed in U S A...

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