Related Manuals for Gardner Denver APEX15-25A
Summarization of Contents
General Information
COMPRESSION PRINCIPLE
Explains the fundamental process of air compression using meshing rotors.
AIR FLOW IN THE COMPRESSOR SYSTEM
Describes the path air takes from intake to discharge within the unit.
LUBRICATION, COOLING AND SEALING
Details the functions of the oil system for lubrication, heat management, and sealing.
Installation
GENERAL INSTALLATION PROCEDURES
Covers initial checks, lifting, and location requirements for unit placement.
AIR-COOLED UNIT DETAILS
Specifics for air-cooled units, including ventilation and clearance requirements.
FOUNDATION AND ENCLOSURE REQUIREMENTS
Discusses mounting surface needs and the compressor cabinet.
COLD WEATHER OPERATION CONSIDERATIONS
Guidance for installing and operating the compressor in low temperatures.
ELECTRICAL WIRING AND GROUNDING
Essential safety and connection procedures for electrical systems.
MOTOR LUBRICATION
Information regarding the lubrication of motor bearings.
Starting and Operating Procedures
PRESTART-UP INSTRUCTIONS
Critical steps to perform before the unit's initial operation.
PIPING AND FILTER CHECKS
Verifying the integrity of air intake and discharge lines and filters.
BELT SYSTEM AND ROTATION CHECKS
Ensuring proper belt tension, alignment, and motor rotation direction.
PRESSURE SETTINGS (LOAD/UNLOAD/TARGET)
Configuration of system pressure parameters for optimal operation.
OPERATING MODES AND ENCLOSURE CHECKS
Verifying controller modes and ensuring enclosure panels are secure.
STARTING AND STOPPING THE UNIT
Procedures for safely starting and shutting down the compressor.
QUICK START GUIDE OVERVIEW
A condensed guide for basic setup and programming of operating parameters.
SETTING OPERATING PRESSURES
Step-by-step instructions for adjusting pressure setpoints on the controller.
Controls and Instrumentation
GENERAL DESCRIPTION OF CONTROLS
An overview of the compressor's control system and main components.
ELECTRONIC CONTROLLER AND STARTER ASSEMBLY
Details on the main control hardware, including the controller and starter.
AIRSMART G2 CONTROLLER FEATURES
Functions, display, and keypad layout of the AirSmart G2 controller.
SAFETY AND CONTROL COMPONENTS
Information on emergency stop, control transformer, and fuse blocks.
POWER SUPPLY AND TERMINAL STRIP
Details on internal power distribution and interconnection points.
MOTOR STARTERS
Description of the starters for the main and cooling fan motors.
MULTI-VOLTAGE ELECTRICAL SYSTEM CONVERSION
Procedure for converting the electrical system to different voltage configurations.
Standard Warranty Information
STANDARD WARRANTY PERIOD AND COVERAGE
Details warranty duration for components like package, airend, and motors.
WARRANTY EXCLUSIONS
Lists conditions, such as misuse or improper maintenance, that void the warranty.
STANDARD WARRANTY DISCLAIMER
Legal disclaimers, limitations of liability, and warranty transferability.
Lubrication, Oil Cooler, Filter and Separator Systems
COMPRESSOR OIL SYSTEM OVERVIEW
Explains the oil flow path and its functions in cooling, lubrication, and sealing.
RECOMMENDED LUBRICANT AND SPECIFICATIONS
Details approved oils, their properties, and suitability for operating conditions.
OIL LEVEL INDICATOR (GAUGE) AND CAPACITY
Instructions on checking the oil level and the system's total oil capacity.
LUBRICANT CHANGE PROCEDURE
Step-by-step instructions for draining and refilling the compressor lubricant.
MOISTURE IN THE OIL SYSTEM
Discusses causes and detection methods for water contamination in the oil.
OIL CHANGE INTERVALS
Guidelines for recommended oil change frequencies based on operating temperature.
DRAINING AND REFILLING THE OIL SYSTEM
Procedure for servicing the oil system, including filter and separator replacement.
THERMOSTATIC MIXING VALVE (TMV) FUNCTION
Explains the operation and testing of the valve controlling oil temperature.
OIL SUMP (RESERVOIR) DETAILS
Description of the oil sump's role in air/oil separation and oil storage.
AIR / OIL SEPARATOR FUNCTION
Details on the final stage of oil separation and its performance factors.
Heat Exchangers (Oil/Air)
OIL/AIR HEAT EXCHANGER PROCESSES
How heat of compression is rejected through air-cooled cores.
VENTILATION CONFIGURATION
Details the airflow path for cooling the heat exchangers and components.
HEAT EXCHANGER MAINTENANCE
Procedure for cleaning the exterior fins of the air-cooled heat exchangers.
Air Filters
COMPRESSOR AIR FILTER FUNCTION
Role and importance of the single-stage, high-efficiency air filter.
PACKAGE PRE-FILTER MAINTENANCE
Instructions for cleaning the intake pre-filter media.
Belt Drive System
MOTOR JACKING ASSEMBLY
Mechanism used for adjusting belt tension and motor positioning.
V-BELT DRIVE COMPONENTS
Identification of the main parts of the belt drive system.
SHEAVE SET ALIGNMENT PROCEDURES
Guidance on aligning pulleys for optimal belt life and performance.
REPLACING COMPRESSOR BELTS
Step-by-step instructions for replacing worn or damaged drive belts.
REPLACING SHEAVES
Instructions for removing, installing, and aligning belt pulleys.
Servicing Miscellaneous Devices
INLET CONTROL VALVE ASSEMBLY
Description and function of the air intake control valve assembly.
Inlet Valve (Body) Inspection
Procedure for inspecting the inlet valve for wear and tear.
PRESSURE RELIEF VALVE
Function, testing, and maintenance of the safety pressure relief valve.
MINIMUM PRESSURE VALVE
Role and replacement procedure for the minimum pressure check valve.
THERMOSTATIC MIXING VALVE
Explanation of the TMV's operation, settings, and testing.
INPUT SHAFT SEAL ASSEMBLY
Information regarding maintenance and inspection of the input shaft seal.
Tank Mounted Compressor - Total System
SYSTEM DESCRIPTION AND COMPONENTS
Overview of the integrated compressor package with optional air dryer.
DRYER MODELS, INSTALLATION, AND OPERATION
Details for the optional refrigerated air dryer, including its models and operation.
Maintenance Schedule
SERVICE CHECK LIST
A general list of maintenance tasks and their recommended frequencies.
EVERY 8 HOURS OPERATION
Daily checks including oil level, unit loading, and pressure monitoring.
EVERY 125 HOURS OPERATION
Periodic cleaning of heat exchanger fins and cooling fan.
EVERY 1000 HOURS OPERATION
Procedure for changing the oil filter element.
EVERY 4000 HOURS OPERATION
Instructions for changing the compressor lubricant.
EVERY YEAR
Annual maintenance tasks, such as checking the pressure relief valve.
Troubleshooting Guide
COMPRESSOR FAILS TO START
Potential causes and remedies for startup failures.
COMPRESSOR STARTS BUT STOPS EARLY
Diagnosing and resolving issues causing short cycling.
COMPRESSOR DOES NOT UNLOAD/LOAD
Troubleshooting problems with pressure regulation and load/unload functions.
COMPRESSOR CYCLES EXCESSIVELY
Addressing frequent load/unload transitions and their potential causes.
COMPRESSOR STARTS TOO SLOWLY
Identifying causes for slow compressor startup.
COMPRESSOR DOES NOT REACH LOAD PRESSURE
Diagnosing issues preventing the compressor from achieving operating pressure.
HIGH DISCHARGE AIR TEMPERATURE
Identifying and resolving causes of compressor overheating.
EXCESSIVE OIL CONSUMPTION
Troubleshooting reasons for high oil usage by the compressor.
OIL CARRYOVER ISSUES
Addressing problems related to oil being carried over into the air lines.
EXCESSIVE WATER IN AIR DELIVERY LINE
Diagnosing and resolving moisture issues in the compressed air output.
TROUBLESHOOTING VOLTAGE PROBLEMS
Identifying and resolving issues related to electrical supply voltage.
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