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Summary of Contents for Gardner Denver AirSmart G2
- Page 1 13-25-606 Version: 03 January 27, 2016 APEX SINGLE STAGE BASE- MOUNTED and TANK MOUNTED COMPRESSORS AirSmartä G2 Controller MODELS-APEX15-25A 15, 20 and 25 HP 60HZ OPERATING AND SERVICE MANUAL...
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Page 3: Support Services
A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors. -
Page 4: Warning - Prohibition - Mandatory Label Information
WARNING – PROHIBITION – MANDATORY LABEL INFORMATION Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. - Page 5 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.
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Page 6: Safety Precautions
SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices will result in injury to or death of personnel. -
Page 7: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ............................. 1 Instructions For Ordering Repair Parts ..................... 1 Warning – Prohibition – Mandatory Label Information ................2 Safety Precautions ..........................4 Index ............................... 6 Section 1, General Information ........................ -
Page 8: Index
Compression Principle ........8 Electrical ............ 18 Compressor ............. 8 Enclosure ........... 20 Controls & Instrumentation Grounding ..........18 AirSmart G2 Quick Start Guide....22 Inlet Filter ........... 18 General Description ........23 Operating Mode .......... 20 Section 4.............23 Piping ............18 Cooling, Sealing And Lubrication ..... - Page 9 LIST OF ILLUSTRATIONS Figure 1-1 - Compressor Cycle ........................ 8 Figure 1-1 - Compressor Cycle ........................ 8 Figure 1-2 – Compressor Illustration - External Details ................9 Figure 1-3 – Compressor Illustration - Internal Details ................10 Figure 1-4 – Compressor Illustration – Total System ................11 Figure 2-1 –...
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Page 10: Section 1, General Information
SECTION 1 GENERAL INFORMATION Figure 1-1 - COMPRESSOR CYCLE COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity anti- friction bearings located outside the compression chamber. Roller bearings are used at the inlet end of the rotors to carry part of the radial loads. -
Page 11: Figure 1-2 - Compressor Illustration - External Details
300UCC797-B Figure 1-2 – COMPRESSOR ILLUSTRATION - EXTERNAL DETAILS (Ref. Drawing) Page 1 of 2... -
Page 12: Figure 1-3 - Compressor Illustration - Internal Details
Figure 1-3 – COMPRESSOR ILLUSTRATION - INTERNAL DETAILS 300UCC797-B (Ref. Drawing) Page 2 of 2... -
Page 13: Figure 1-4 - Compressor Illustration - Total System
306UCC804-A (Ref. Drawing) Page 1 of 1 Figure 1-4 – COMPRESSOR ILLUSTRATION – TOTAL SYSTEM... -
Page 14: Section 2, Installation
SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passing of current. -
Page 15: Figure 2-1 - Typical Compressor Room
For continuous efficiency, the cooler cores must be periodically cleaned with either vacuum or compressed air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with clean water. NOTICE Coolers are aluminum; do not use any cleaning solution that is not compatible with aluminum. -
Page 16: Figure 2-3 - Cold Weather Installation
ENCLOSURE - The compressor, electric motor, oil cooler and aftercooler are mounted inside the enclosure. 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 lifting it up slightly. - Page 17 When the unit must be installed in an outdoors installation and/or exposed to ambient temperatures below freezing (32 F, 0 C), contact Gardner Denver for recommendations. ° ° When using a Total System with a compressed air dryer option, refer to Section 10, page 58 for details.
- Page 18 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 could cause a high pressure shutdown.
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Page 19: Figure 2-4 - Electrical Wiring Sizing Data
Electrical Wire Sizing - A certified electrician familiar with National Electric Codes and applicable local codes shall size the electrical power wires serving the compressor package. Refer to Fig 2-4 for a summary of maximum package current draw values. Package Power Voltage Max Current Draw - amps 25 / 20 / 15... -
Page 20: Section 3, Starting & Operating Procedures
For instructions on checking the oil and the proper oil level, refer to “Oil level gauge”, see Section 5, page 36 Do not mix different type oils. Standard Unit is shipped filled with Gardner Denver AEON 4000 lubricant which is suitable for the first 4000 hours under normal operating conditions. Other AEON lubricants are available. - Page 21 Failure to properly ground the compressor package could result in controller malfunction. V-Belt System - Refer to Section 8 page 49 for detailed instruction to unpack and check the alignment of the belt system. The motor jacking hardware must be re-configured, the disposable spacer removed, and belts engaged and the belt sheaves alignment checked prior to compressor operation.
- Page 22 11. Target Pressure - This is the package discharge pressure that the controller would maintain if inlet modulation, by any means (e.g., variable speed or inlet throttling), was available. Inlet modulation is not available with this fixed speed compressor package, thus the target pressure value does not initiate any action.
- Page 23 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 could cause a high pressure shutdown.
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Page 24: Figure 3- 1 - Controller Layout And Main Screen
Quick Start Guide For your convenience, the following excerpt from the Controller Operating and Service Manual is presented to assist in programming the basic operating parameters. However, we strongly recommend you read the Controller Operating and Service manual before attempting operating the compressor package. -
Page 25: Section 4, Controls & Instrumentation
CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION The Gardner Denver rotary screw compressor is pre-wired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop air line. - Page 26 Power Supply – This single-phase device supplies all 24 VDC needs within the control enclosure from the available AC supply line. Terminal Strip - This device provides an interconnection between the AirSmart G2 controller and the low voltage hardware such as sensors and switches within the enclosure.
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Page 27: Figure 4-2 - Example Label
The compressor unit’s direction of rotation must be checked every time the compressor is reconnected to the power supply. 1. Open, lockout and tagout the main disconnect and any other circuits before doing any conversion work on the compressor package. 2. -
Page 28: Figure 4-3 - Control Transformer Label
9. Replace the cooling fan assembly with new one provided in the conversion kit: Unscrew and remove the cooling fan panel door. Locate the cooling fan assembly electrical connections box, remove its cover, and disconnect the electrical power cable. Unscrew and remove, in order, the pre-filter cover, the prefilter, the fan grill, and the cooling fan assembly. -
Page 29: Figure 4-4 - Wiring Diagram - Wye-Delta (200-230/460 Volt)
300UCC546-C (Ref. Drawing) Page 1 of 3 Figure 4-4 – WIRING DIAGRAM – WYE-DELTA (200-230/460 VOLT) - Page 30 300UCC546-C (Ref. Drawing) Page 2 of 3...
- Page 31 300UCC546-C (Ref. Drawing) Page 3 of 3...
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Page 32: Figure 4-5 - Wiring Diagram - Wye-Delta (575 Volt)
303UCC546-D (Ref. Drawing) Page 1 of 3 Figure 4-5 – WIRING DIAGRAM – WYE-DELTA (575 VOLT) - Page 33 303UCC546-D (Ref. Drawing) Page 2 of 3...
- Page 34 303UCC546-D (Ref. Drawing) Page 3 of 3...
- Page 35 Electric Motor (3) – Drives the compressor (4) via a belt drive assembly (5). It is energized by the wye-delta- type starter, which in turn is controlled by the AirSmart G2 controller. Oil Sump (6) – This pressure vessel is an integral part of the compressor module. It separates by inertial effects the bulk of the compressed air and injection oil streams and serves as a sump for the latter.
- Page 36 Pressure Sensor - Sump Wet Side (B2) - This device is connected to the oil sump. It converts the pressure in the oil sump into an electrical signal for use by the AirSmart G2 controller for monitoring and control. Its signal, when compared to that of sensor (B1), indicates the pressure loss across the air/oil separator element and it can also trigger a shutdown event in case an exceedingly high pressure is detected.
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Page 37: Figure 4-6 - Piping And Instrumentation Illustration
301UCC797-D (Ref. Drawing) Page 1 of 1 Figure 4-6 – PIPING AND INSTRUMENTATION ILLUSTRATION... -
Page 38: Section 5, Lubrication. Oil Cooler, Oil Filter & Separator
AEON lubricants are available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The standard factory fill compressor lubricant is Gardner Denver AEON 4000, a superior semi-synthetic blend of petroleum stock and various protective additives, suitable for year-round operation. - Page 39 Before draining, adding, or changing the lubricant oil in the compressor, be aware of the following hazards associated with these tasks: Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters.
- Page 40 All materials used in Gardner Denver compressor units are compatible with AEON 9000SP Lubricant. Use caution when selecting downstream components such as air line lubricating bowls, gaskets and valve trim. AEON 9000SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints.
- Page 41 ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is below the minimum level of the sight glass as read while the unit is completely off and blown down, and the foam has settled out. Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, lockout and tagout the power supply to the starter.
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Page 42: Figure 5-2 - Dew Point Chart °F
Pressure Dew Point Trend (100% r.h.) 100psig 125psig 150psig 175psig Am bient Tem p - oF Figure 5-2 – Dew Point Chart °F Pressure Dew Point Trend (100% r.h.) 6.9bar 8.6bar 10.3bar 12.1bar 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 Ambient Temp - oC... -
Page 43: Figure 5-4 - Oil Change Interval
Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis program with the AEON lubricants, and we recommend a sample be sent in at 100 hours on a new unit. - Page 44 Optional Element. If the compressor is used in an predominantly cold (<32ºF, 0ºC) and/or humid environment, proper oil viscosity and avoidance of water vapor condensation in the oil system may be achieved by using a higher setting (158ºF, 70ºC) thermostatic element. Consult Gardner Denver for details.
- Page 45 AIR / OIL SEPARATOR - This device provides the final (2%) of the air/oil separation - typically 2ppm oil content at the final discharge of the compressor package. It is housed in a removable spin-on cartridge. Its high level of performance may be affected by the following conditions: ·...
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Page 46: Section 6, Heat Exchangers (Oil/Air)
HEAT EXCHANGER MAINTENANCE - All the required hardware, mechanical and electrical connections have been made at the Gardner Denver factory, thus the only regular maintenance required is to keep the exterior core fins free from dirt and other airborne debris per the following procedure:... - Page 47 Compressor, air/oil sump and all piping and tubing may be at high temperature during and after operation. Do not attempt inspection or cleaning of air-cooled heat exchangers until cooling fan has stopped rotating. Disconnect lockout and tagout package from power supply. Air-cooled heat exchanger cores are fabricated from aluminum.
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Page 48: Figure 6-2 - Cooler Access
The ventilation system for the air-cooled package 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 temperature will reach shutdown levels quickly. -
Page 49: Section 7, Air Filters
In turn, the longevity of the filter element depends on the cleanliness of the local environment. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. -
Page 50: Figure 7-1 - Compressor Air Filter
PACKAGE PRE-FILTER MAINTENANCE 1. Remove all four (4) wing-nuts securing the pre-filter cover to the grill assembly and remove 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. -
Page 51: Section 8, Belt Drive System
SECTION 8 BELT DRIVE SYSTEM The motor power is transmitted to the compressor with a system comprised of heavy-duty v-belts, sheaves, and bushings. Belt tension is provided by the motor weight with the help of a free-pivoting bracket -see Figure 1-3, Page 10, for details. Figure 8-1 –... -
Page 52: Figure 8-3 - Measuring Angular Misalignment
The motor jacking hardware must be re-configured, the disposable spacer removed, and belts engaged and the belt sheaves alignment checked prior to compressor operation. Failure to do so will prevent compressor operation and/or component damage. 1. Unlatch and remove the door panel opposite to the main cooling fan panel to gain access to the v-belt system –... - Page 53 (after loosening the jam nut) and raising the motor body until the v-belts can be dismounted from the motor sheave. Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver belts. Check the sheave alignment.
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Page 54: Section 9, Servicing Of Miscellaneous Devices
SECTION 9 SERVICING OF MISCELLANEOUS DEVICES This section will cover basic maintenance of various control devices used with the compressor module. Refer to Figure 9-1, Page 52, for pictorials of referenced hardware. INLET CONTROL VALVE ASSEMBLY Inlet-Valve Assembly (2) - This device is located within and below the intake flange of the compressor - see Figure 9-1 for internal details and Figure 4-6, page 35 for schematic details. -
Page 55: Figure 9-2 - Inlet Valve Body Hex
Inlet Valve (Body) Inspection - The valve does not require maintenance or lubrication. If air/oil leaks develop across the valve disc during pressurized conditions (e.g., machine stopped), valve seals should be inspected for wear and tear signs: 1. Be sure the unit is completely off and oil sump is depressurized. 2. -
Page 56: Figure 9-3 - Pressure Relief Valve
PRESSURE RELIEF VALVE Pressure Relief Valve - This device protects the pressure-containing components of the compressor package against pressures exceeding 218 psig. It is installed on the wet-side of the oil sump. Figure 9-3 - Pressure Relief Valve Before inspecting the pressure relief valve, release air pressure. Disconnect, lockout and tagout the power supply to the compressor package. -
Page 57: Figure 9-4 - Minimum Pressure Valve And Seat
Start the compressor and monitor the wet (B1) and dry (B2) sump pressure sensors by navigating the AirSmart G2 controller display until displaying their pressure outputs. c. Open the site vent valve to limit the dry sump pressure to about 40psig (2.8bar) d. -
Page 58: Figure 9-5 - Thermal Mixing Valve
Input Shaft Seal Maintenance – This device has no user-serviceable or repairable components. If oil leaks past its seal and unto the external portion of the shaft, contact Gardner Denver to have it inspected and/or repaired by a trained service technician. -
Page 59: Figure 9-6 - Compressor Module Hardware
308UCC810-C (Ref. Drawing) Page 1 of 1 Figure 9-6 – Compressor Module Hardware... -
Page 60: Section 10, Tank Mounted Compressor - Total System
SECTION 10 TANK MOUNTED COMPRESSOR - TOTAL SYSTEM DESCRIPTION - The basic compressor can be furnished mounted on an optional compressed air received (120 and 240 gallon sizes) and paired to an optional RNC [refrigerated non-cycling] compressed air dryer, as shown on Figure 10-1. ·... - Page 61 · Installation - Package must installed in a location with an ambient temperature range of 40ºF to 110ºF (3ºC to 43ºC). Consult Gardner Denver for operation outside this range. · Discharge service pipe - The discharge service line connection is provided at the outlet of the bypass valve assembly.
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Page 62: Section 11, Maintenance Schedule
SECTION 11 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter and Pre-Filter - Operating conditions determine frequency of service. See “Air Filter,” Section 7, page 47. Motor Lubrication - Refer to Section 2, page 12 Every 8 Hours Operation Check the reservoir oil level - add oil if required. See Section 5, page 36. Observe if the unit loads and unloads properly. - Page 63 MAINTENANCE SCHEDULE (See Detail Notes above) Maintenance Action As Indicated by Every Every Every Every Every Every AirSmart G2 1000 4000 Year Controller Hours Hours Hours Hours Hours · Check/Change Air Filter ..........· Check/Change Package Inlet Filters ......·...
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Page 64: Section 12, Troubleshooting
SECTION 12 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start No electrical power. Check main disconnect, fuses and supply line. Motor starter overload Reset and investigate relay tripped . cause of overload. Pressure in reservoir. Inspect unload valve. Wrong lead connections Change leads. - Page 65 Compressor does not Restricted air filter. Clean or replace filter. reach load pressure Partially open inlet valve. Inspect, clean or replace inlet valve. Minimum pressure valve Replace valve. stuck closed. Oil separator clogged. Replace. Condensate drain Inspect and replace. solenoid valve is faulty. Leaks in the compressed Check for leaks, fix any air system.
- Page 66 Inspect and cleanse. Ruptured oil separator Replace element. element. Loose assembly. Tighten all fittings and gaskets. Foaming caused by use of Use Gardner Denver incorrect oil. AEON lubricating coolant. Inoperative minimum Inspect and/or replace. pressure valve. Operation at elevated Reduce temperature. See “High Discharge Air...
- Page 67 Look for poor connections or undersized wiring. NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units.
- Page 68 Regular maintenance in accordance with the service manual is required. Use of genuine Gardner Denver OEM parts and lubricants are highly recommended. If a component failure is deemed a result of using non- genuine Gardner Denver parts and lubricants, warranty will not be allowed.
- 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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