Gardner Denver AirSmart G2 Скачать руководство пользователя

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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

Содержание AirSmart G2

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 69: ...NOTES...

Страница 70: ...NOTES...

Страница 71: ...NOTES...

Страница 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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