Gardner Denver APEXVS7-11A Operating And Service Manual
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Gardner Denver APEXVS7-11A Operating And Service Manual

Gardner Denver APEXVS7-11A Operating And Service Manual

Single stage base- mounted and tank mounted compressors
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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

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  • 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: 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 Safety Precautions ............................4 Index ................................6 List Of Illustrations ............................

  • Page 7: Index

    INDEX Addition Of Oil Between Changes ....47 General ............12 Air Cooled Unit ..........12 Section 2 ............12 Air Filter Section 6 ............56 Lifting Unit ............12 Air Filter Cleaning ..........57 Location ............12 Air Filter Element Life ........57 Lubricant Air Filter, Heavy Duty (Standard) .....
  • Page 8 Rotation ............20 Package Inlet Filter........63 System Pressure .......... 20 Starting & Operating Procedures Section 3 ..........19, 63 Quick Start Guide ..........23 Starting The Unit ..........21 Unit Cold ............21 Safety Precautions ..........4 Unit Hot ............22 Sealing, Lubrication And Cleaning .....

  • 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 - Control Assembly With Variable Frequency Drives ..............

  • 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 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 (VFD) to control compressor motor. The indicated Gardner Denver guidelines for proper wiring, grounding, and feed power conditioning must be followed in order to protect the VFD electronics. Failure to do so will void your warranty.
  • Page 19 Electrical Wire Routing – Routing of the electrical power wires into the electrical hardware enclosure is best done through its roof area. Line Reactor – A line reactor provides conditioning of the electrical power supply to the compressor package by attenuating noise and fluctuations. It shall be required in your particular application if any of the following conditions exist: •...

  • 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 48. 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

    SECTION 4, CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION GENERAL DESCRIPTION - The Gardner Denver rotary screw compressor package is pre-wired with all electrical components suitable for the voltage and horsepower at time of order. It is only necessary to connect the compressor unit to the correct power supply, to the shop air supply network. A standard...
  • Page 27 The drive and motor are designed to operate with 3ph, 60Hz, 200/230 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, lockout and tagout main disconnect and any other circuits before servicing unit.

  • Page 28: Figure 4-1 - Control Assembly With Variable Frequency Drives

    309ELA810-C (Ref. Drawing) Figure 4-1 - CONTROL ASSEMBLY WITH VARIABLE FREQUENCY DRIVES Ref. Name of Part AirSmart CONTROLLER ....... GASKET ..........OPERATOR ........... CONTACT BLOCK ........ NAME PLATE,EMERGENCY STOP ..DOOR LATCH ........DOOR LATCH, SLOTTED ..... VFD ............ADAPTOR ..........DIN RAIL ..........

  • Page 29: Figure 4-2 - Control Assembly With Variable Frequency Drives 10 & 15 Hp (575 Volt)

    310ELA810-B (Ref. Drawing) Figure 4-2 - CONTROL ASSEMBLY WITH VARIABLE FREQUENCY DRIVES 10 & 15 HP (575 VOLT) Ref.No. Name of Part AirSmart CONTROLLER ....... GASKET ..........OPERATOR ........... CONTACT BLOCK ........ NAME PLATE,EMERGENCY STOP ..DOOR LATCH ........DOOR LATCH, SLOTTED ..... VFD ............

  • Page 30: Figure 4-3 - Control Schematic

    300ELA797-A (Ref. Drawing) Figure 4-3 – CONTROL SCHEMATIC...

  • Page 31: Figure 4-4 - 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 32 See the Parts List 13-25-503, 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 33: Figure 4-5 - Inlet Valve

    D301977-B (Ref. Drawing) Figure 4-5 – 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 34 Magnetic Unloader Solenoid Valve (Figure 4-3, page 29) - 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 35 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. Fuse Blocks – Two class CC fuse blocks provide line side protection for the power supply and control transformer.
  • Page 36 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 37: Figure 4-6 - Wiring Diagram - Variable Speed (200V, 230V & 460V)

    302ELA546-B (Ref. Drawing) Page 1 of 4 Figure 4-6 – WIRING DIAGRAM – VARIABLE SPEED (200V, 230V & 460V)
  • Page 38 302ELA546-B (Ref. Drawing) Page 2 of 4...
  • Page 39 302ELA546-B (Ref. Drawing) Page 3 of 4...
  • Page 40 302ELA546-B (Ref. Drawing) Page 4 of 4...

  • Page 41: Figure 4-7 - Wiring Diagram - Variable Speed (575V)

    306ELA546-A (Ref. Drawing) Page 1 of 4 Figure 4-7 – WIRING DIAGRAM – VARIABLE SPEED (575V)
  • Page 42 306ELA546-A (Ref. Drawing) Page 2 of 4...
  • Page 43 306ELA546-A (Ref. Drawing) Page 3 of 4...
  • Page 44 306ELA546-A (Ref. Drawing) Page 4 of 4...

  • Page 45: 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 46 (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 47 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 48: Figure 5-2 - Approximate Oil System Capacities

    COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation”, page 15 and , page Figure 2-3 page 13. 10 & 15 HP Reservoir Capacity to “FULL” Level 1.00 U.S. Gallons (9.5 Liters) System Capacity: Reservoir Plus Oil Cooler and Piping 1.5 U.S.
  • Page 49 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 50: Figure 5-3 - 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 13-25-603 Page 49...

  • Page 51: Figure 5-5 - 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 52 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 53 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 54 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 55 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 44) will be hot to touch and lines out of mixing valve much cooler.
  • Page 56 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. 1.

  • Page 57: Section 6, Air Filter

    IMPORTANT. An improperly maintained air filter can cause a loss of compressor air delivery. 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 58 1. Remove Filters from base. 2. Clean Filters with running water. 3. Let dry. 4. Replace Filters  Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. 13-25-603 Page 57...

  • Page 59: Section 7, Belt Drive

    SECTION 7 BELT DRIVE Proper drive belt tension and alignment are provided at the factory, however, good practice dictates checking the drive alignment and tension after shipment and before initial start-up. Sheaves should align straight across the front with a straight edge. See Figure 7-4 page 62 for proper belt tension.
  • Page 60 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 61: Figure 7-1 - Removing The Motor Sheave

    REPLACING THE AIREND SHEAVE Disconnect, tagout and lockout 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 62: 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 63: 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 64: 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 56. Package Inlet Filters - Operating conditions determine frequency of service. See “Air Filter”, SECTION 6, page 56. Motor Lubrication - Refer to, page19.
  • Page 65 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 66: Section 9, Troubleshooting

    SECTION 9 TROUBLESHOOTING 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 SYMPTOM POSSIBLE CAUSE REMEDY Compressor...
  • Page 67 Restriction in service piping Inspect and clean service piping. Restriction in control tubing Inspect and clean control tubing. Compressor Acceleration time in VFD set too Contact your Gardner Denver distributor. starts too long slowly Minimum Pressure/Check Valve Repair or replace.
  • Page 68 SYMPTOM POSSIBLE CAUSE REMEDY Condensate drain Replace. solenoid valve is faulty. Leaks in the compressed Check for leaks, fix any air system. leaks found. V-Belts broken. Replace. V-Belts slipping. Test belt tensioning. Pressure limits incorrectly Check/correct pressure set. limits in the AirSmart Controller.
  • 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 4000 or AEON 9000SP oil only. Minimum pressure valve Repair or replace. Inspect, malfunction – discharge...
  • 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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