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

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

Single stage base- mounted and tank mounted compressors
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13-25-600
Version: 02
November 3, 2015
APEX
SINGLE STAGE
BASE- MOUNTED and TANK MOUNTED
COMPRESSORS
AirSmartä Controller
MODELS-APEX5-15A
5, 7.5,10 and 15 HP
60HZ
OPERATING AND
SERVICE MANUAL

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Summary of Contents for Gardner Denver AirSmart Controller APEX5-15A

  • Page 1 13-25-600 Version: 02 November 3, 2015 APEX SINGLE STAGE BASE- MOUNTED and TANK MOUNTED COMPRESSORS AirSmartä Controller MODELS-APEX5-15A 5, 7.5,10 and 15 HP 60HZ OPERATING AND SERVICE MANUAL...

  • Page 2: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services

    A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.

  • Page 3: 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 4 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.

  • Page 5: 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 6: 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, 3 Safety Precautions ..........................4 Index ..............................

  • Page 7: Index

    INDEX Addition Of Oil Between Changes ....48 Installation Air Cooled Unit ..........12 Cold Weather ..........15 Air Filter General ............12 Section 6.............57 Section 2 ............ 12 Air Filter Element Life ........58 Air Filter, Heavy Duty (Standard) ....57 Lifting Unit ............12 Air Flow In Compressor System .......
  • Page 8 Electrical .............19 Every 8 Hours Operation ......64 Enclosure ............20 Every Year ..........64 Grounding ...........19 Motor Lubrication ........64 Inlet Filter ............19 Package Inlet Filter ........64 Operating Mode ..........20 Starting & Operating Procedures Piping ............19 Section 3 ..........19, 64 Rotation ............20 Starting The Unit ..........

  • Page 9: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compressor Cycle ....................... 9 Figure 1-2 – Compressor Illustration ...................... 10 Figure 2-1 – Typical Compressor Room ....................13 Figure 2-2 – Air Flow Chart ........................13 Figure 2-3 – Cold Weather Installation ....................14 Figure 4-1 –...

  • 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 roller bearings located outside the compression chamber. Single width cylindrical 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

    303ELA797-B Figure 1-2 – COMPRESSOR ILLUSTRATION (Ref. Drawing) Page 1 of 2...
  • Page 12 Figure 1-3 – COMPRESSOR ILLUSTRATION-TANK MOUNTED 303ELA797-B (Ref. Drawing) Page 2 of 2...

  • Page 13: 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 14: Figure 2-1 - Typical Compressor Room

    For continuous efficiency, oil 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 15: Figure 2-3 - Cold Weather Installation

    If the compressor unit base is raised above floor level, the space between the floor and the base bottom must be closed with solid material all around to prevent recirculation of hot air from the oil cooler end and over temperature operation.
  • Page 16 Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000SP lubricant. Monitor unit carefully during start-up and operation to be sure it is functioning normally.
  • Page 17 INLET LINE LENGTHS Length of Inlet Line Diameter of Pipe Size 0 to 10 Feet ............Same as Compressor Inlet Opening 10 to 17 Feet ............One Size Larger Than Inlet Opening 17 to 38 Feet ............Two Sizes Larger Than Inlet Opening Figure 2 4 DISCHARGE SERVICE LINE - The discharge service line connection is made at the left hand corner of the package when viewed from the control box end.
  • Page 18 Electrical shock can cause injury or death. Open main disconnect switch, lockout and tagout before working on control box. GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical Code. Failure to properly ground the compressor package could result in injury or death.
  • Page 19 ELECTRIC MOTOR GREASE RECOMMENDATIONS (-30° TO 50°C) MANUFACTURER TRADE NAME CHEVRON SRI #2 SHELL DOLIUM R EXXON UNIREX #2 EXXON POLYREX ELECTRIC MOTOR REGREASING INTERVAL Type of Service Typical Rating Relubrication Interval Up to 150 HP (112 KW) 18 Months Standard One or Two Shift Operation Above 150 HP (112 KW)

  • Page 20: Section 3, Starting & Operating Procedures

    For instructions on checking the oil and the proper oil level, refer to “Oil level gauge”, SECTION 5, page 49. 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. Rotation - Check for correct motor rotation by jogging the motor. See “Unit Setup Adjust Menu” in Controller Operating and Service Manual. Compressor drive shaft rotation must be counterclockwise, standing facing the compressor sheave.
  • Page 22 The compressor starts and stops automatically. Automatic restarting can cause injury or death. Open, lockout and tagout main disconnect and any other circuits before servicing the unit. The enclosure doors must be closed and latched to keep the compressor package from overheating when the compressor is running. After an emergency stop, be sure that the pressure in the air/oil reservoir is less than 5 psig.
  • Page 23 Unit Hot (No warm-up period is required): Open the air service valve (customer furnished) between the main air system and the check valve on the package. Run for approximately one minute. The unit is equipped with a minimum (65 psig) pressure/check valve, no special procedure to maintain the unit reservoir pressure is required.
  • Page 24 Quick Start Guide Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run button to start the compressor, no other settings are required. The Target Pressure comes preset to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure setting is desired, the following steps can be used as a guide.
  • Page 25 To change the Target Pressure, press the Enter button to edit the value. OPERATION ADJUSTMENT TARGET PRESSURE 100 PSI (EDIT PARAMETER) A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the Plus and Minus buttons to change its value.

  • Page 26: Section 4, Controls & Instrumentation

    CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION The Gardner Denver rotary screw compressor is prewired 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 27: Figure 4-1 - Control Schematic

    Figure 4-1 – CONTROL SCHEMATIC 13-25-600 Page 26...

  • Page 28: Figure 4-2 - Key Pad

    CONTROL DEVICES Controller - This compressor unit features the "AirSmart" controller, which integrates all the control functions under microprocessor control. Its functions include safety and shutdown, compressor regulation, operator control, and advisory/maintenance indicators. The keypad and display provide the operator with a logical and easily operated control of the compressor and indication of its condition. The controller is factory adjusted for the compressor package, but allows tuning for specific applications.
  • Page 29 See the Parts List 13-25-500, for a listing of the kits available for rebuilding or replacing the valve. Repair kits are available from your local authorized Gardner Denver distributor. Inlet Valve This device is located at the intake flange of the compressor, and allows the compressor to remain pressurized and ready for quick response to air demand when the latter is not running.

  • Page 30: Figure 4-3 - Inlet Valve

    D301977-B (Ref. Drawing) Figure 4-3 – INLET VALVE 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.
  • Page 31 Magnetic Unloader Solenoid Valve (Figure 4-1, page 26) - This valve controls the position of the inlet valve in response to signals from the AirSmart Controller. During stopped operation, the unloader valve supplies compressed air under the poppet to close the inlet valve. During run operation, the unloader valve vents the underside of the poppet, allowing it to open.
  • Page 32 Control Transformer – For 575 volt AC units, a control transformer is provided to supply 230 volts AC input to the power supply. A secondary fuse is provided on the control transformer. Refer to adjacent labeling for replacement information. For 208-230/460 volt AC units, that can be converted using conversion kit 313EFC6005, a control transformer is provided to supply 115-120 volts AC input to the power supply.
  • Page 33 CHANGING MINIMUM PRESSURE/CHECK VALVE SEALS 1. Be sure the unit is completely off and that no air pressure is in the oil reservoir and in the air cooled aftercooler. Close the service valve. 2. Disconnect lockout and tagout the power supply to the starter. 3.

  • Page 34: Figure 4-4 - Example Of Factory 230Vac Label

    1. Open, lockout and tagout the main disconnect and any other circuits before doing any conversion work on the compressor package. 2. All fuses, decals and voltage markers are supplied in conversion kit 304ELA6005. 3. Open the compressor electrical control panel. Locate the control transformer (CT) as shown on the applicable wiring diagram (see wiring diagram attachments).

  • Page 35: Figure 4-5 - Example Label

    Figure 4-5 – EXAMPLE LABEL Note: Transformer secondary fuse and decal do not require replacement. Refer to the transformer wiring diagram, located on side of transformer and as illustrated in attachment 5 of this instruction, to ensure proper transformer primary wiring connections. 9.

  • Page 36: Figure 4-6 - Wiring Diagram - Full Volt (Multi-Volt)

    300ELA546-B (Ref. Drawing) Page 1 of 2 Figure 4-6 – WIRING DIAGRAM – FULL VOLT (MULTI-VOLT)
  • Page 37 300ELA546-B (Ref. Drawing) Page 2 of 2...

  • Page 38: Figure 4-7 - Wiring Diagram - Full Volt (Standard)

    301ELA546-B (Ref. Drawing) Page 1 of 2 Figure 4-7 – WIRING DIAGRAM – FULL VOLT (STANDARD)
  • Page 39 301ELA546-B (Ref. Drawing) Page 2 of 2...

  • Page 40: Figure 4-8 - Wiring Diagram - Wye-Delta Voltage (Standard)

    304ELA546-B (Ref. Drawing) Page 1 of 2 Figure 4-8 – WIRING DIAGRAM – WYE-DELTA VOLTAGE (STANDARD)
  • Page 41 304ELA546-B (Ref. Drawing) Page 2 of 2...

  • Page 42: Figure 4-9 - Wiring Diagram - Single Phase (230 Volt)

    305ELA546-B (Ref. Drawing) Page 1 of 2 Figure 4-9 – WIRING DIAGRAM – SINGLE PHASE (230 VOLT)
  • Page 43 305ELA546-B (Ref. Drawing) Page 2 of 2...

  • Page 44: Figure 4-10 - Wiring Diagram - Wye-Delta Volt (Multi-Volt)

    309ELA546-B (Ref. Drawing) Page 1 of 2 Figure 4-10 – WIRING DIAGRAM – WYE-DELTA VOLT (MULTI-VOLT)
  • Page 45 309ELA546-B (Ref. Drawing) Page 2 of 2...

  • Page 46: Section 5, Lubrication. Oil Cooler, Oil Filter & Separator

    The separated oil is returned to the compressor and the air passes to the final discharge line. RECOMMENDED LUBRICANT - Gardner Denver compressors are factory filled with Gardner Denver AEON lubricants.
  • Page 47 (93° C to 99° C) for a period of more than four (4) hours due to continuing high ambient air temperature, use Gardner Denver AEON 9000TH Lubricating Coolant which is a superior synthetic lubricant. Short periods of up to four (4) hours of sustained discharge temperatures up to 210° F (99° C) do not require a change from the recommended year-round lubricant AEON 4000.
  • Page 48 Do not repeatedly restart the unit after high temperature stops operation. Find and correct the malfunction before resuming operation. 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.
  • Page 49 COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation”, page 15 and Figure 2-3 page 14. 5 & 7.5 HP 10 & 15 HP Reservoir Capacity to “FULL” Level 1.00 U.S. Gallons (4.5 Liters) 1.00 U.S. Gallons (4.5 Liters) System Capacity: Reservoir Plus Oil Cooler and Piping 1.6 U.S.
  • Page 50 Excessive oil carry-over can damage equipment. Never fill oil reservoir above the “FULL” marker. OIL LEVEL GAUGE (Figure 1-3, page 9) indicates the amount of oil in the oil reservoir. Read oil level when unit is shut off and the foam has settled out. In operation the oil level will fluctuate as the compressor loads and unloads.

  • Page 51: Figure 5-2 - Dew Point Chart °F

    Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 100 psig 125 psig 150 psig 175 psig Ambient Temp. F FIGURE 5- 3 – DEW POINT CHART °F FIGURE 5- 4 – DEW POINT CHART °C 13-25-600 Page 50...

  • Page 52: 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 53 DRAINING AND CLEANING OIL SYSTEM 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. Always drain the complete system.
  • Page 54 Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. 1. Be sure the unit is completely off and that no air pressure is in the oil reservoir. 2. Disconnect, tag and lockout the power supply to the starter. 3.
  • Page 55 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. Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation.
  • Page 56 To check the element, heat in oil - it should be fully extended at 170° F (77° C). If the unit shuts down due to high air discharge temperature, the cause may be that the element is stuck open to the bypass, in which case bypass lines (Figure 5-1, page 45) will be hot to touch and lines out of mixing valve much cooler.
  • Page 57 NOTICE A sudden drop of zero pressure differential or sudden heavy oil carryover may indicate a ruptured element. Inspection - After removal of separator element, shine a light inside the element to reveal areas of heavy dirt or varnish deposits or breaks (ruptures) in element media. Oil Separator for Inspection or Replacement.

  • Page 58: Section 6, Air Filter

    IMPORTANT. An improperly maintained air filter can cause a loss of compressor air delivery. Air Filter Element - Clean every 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 authorized Gardner Denver distributor.
  • Page 59 Figure 1-2, Page 10. These filters should be inspected every 1,000 hours. If dirty they should be replaced. The filters should not be cleaned. 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 60: Section 7, Belt Drive

    Remove the belts. Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver belts. Check the sheave alignment. Replace the fan orifice (center the orifice around the fan), fan guard and enclosure panels.
  • Page 61 SHAFT. Fill the holes in the bushing/sheave with grease to protect them from dirt and debris. Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver belts. Check the sheave alignment. Remove the screws from the bushing/sheave assembly.

  • Page 62: Figure 7-1 - Removing The Motor Sheave

    REPLACING THE AIREND SHEAVE Disconnect, lockout and tagout the power supply to the starter 21. Remove the enclosure panel under the control box. 22. Remove the fan guard and fan orifice. 23. Remove side door panel. 24. Loosen bolts holding airend to support, then loosen nut on jackbolts so that airend lowers, loosening the belts.

  • Page 63: Figure 7-3 - Installing Drive Sheave On Compressor Or Motor

    Clean the shaft and mount the sheave assembly (Figure 7-3). Align the airend sheave to the motor sheave. When mounting the sheave 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 –...

  • Page 64: Figure 7-4 - Belt Tension - J Section Micro-V Belts

    Deflection Motor Force Pounds (Newtons) Deflection in H.P. (kW) No. of Belts (per belt) Inches (mm) 5 HP (4 kW) 6 to 8.5 (1.3 to 1.9) 5/16 (8) 7.5 HP (5 kW) 6 to 7 (1.3 to 1.5) 5/16 (8) 10 HP (7 kW) 6 to 8.5 (1.3 to 1.9) 5/16 (8)

  • Page 65: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter - Operating conditions determine frequency of service. See “Air Filter,” SECTION 6, page 57. Package Inlet Filters - Operating conditions determine frequency of service. See “Air Filter,” SECTION 6, page 57. Motor Lubrication - Refer to SECTION 2, page 17.
  • Page 66 MAINTENANCE SCHEDULE (See Detail Notes above) Maintenance Action As Indicated by Every Every Every Every Every Every AirSmart 1000 4000 Year Controller Hours Hours Hours Hours Hours · Check/Change Air Filter ............· Check/Change Package Inlet Filters ........· · Change Oil Separator ............

  • Page 67: Section 9, Troubleshooting

    SECTION 9 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate relay tripped . cause of overload. Pressure in reservoir. Inspect blowdown valve. Emergency stop Release button.
  • Page 68 SYMPTOM POSSIBLE CAUSE REMEDY Compressor starts too Wye Delta switch time set Contact your Gardner slowly too long. Denver distributor. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Compressor is low on Restricted air filter.
  • Page 69 Ruptured oil separator Replace element. element. Loose assembly. Tighten all fittings and gaskets. Foam caused by use of Use Gardner Denver incorrect oil. AEON lubricating coolant. Inoperative minimum Replace seals in valve. pressure valve. Operation at elevated Reduce temperature. See “High Discharge Air...
  • Page 70 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 71 HR Series STANDARD WARRANTY Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, free of defects in material and workmanship.
  • Page 72 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2015 Gardner Denver, Inc. Printed in U.S.A.

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