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Gardner Denver APEXVS18-22A User Manual

Gardner Denver APEXVS18-22A
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13
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25
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608
Version: 01
March 21, 2016
APEX
SINGLE STAGE
VARIABLE AND FIXED SPEED
BASE- MOUNTED and TANK MOUNTED
COMPRESSORS
AirSmartä G2 Controller
MODELS
APEX25-30A, APEXVS18-22A
60HZ
OPERATING AND
SERVICE MANUAL

Table of Contents

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Gardner Denver APEXVS18-22A Specifications

General IconGeneral
Pressure maximum10 bar
Maximum Pressure10 bar
Voltage400 V
Frequency50 Hz
Free Air Delivery3.7 m³/min
TypeScrew
Drive TypeDirect Drive

Summary

WARNING – PROHIBITION – MANDATORY LABEL INFORMATION

DANGER Hazard Description

Indicates a hazard with a high risk of death or serious injury if not avoided.

Safety Warnings and Precautions

PROHIBITION/MANDATORY ACTION REQUIREMENTS

Lists actions that are prohibited or mandatory for safe operation.

SAFETY PRECAUTIONS

DANGER Safety Notices

Notices indicating potential injury or death of personnel if not observed.

SECTION 2 INSTALLATION

LOCATION Requirements

Requirements for installing the compressor in a suitable environment.

DANGER Fan and Belt Guard Warning

WARNING Enclosure Door Closure

Installation Considerations and Warnings

Cold Weather Installation

Recommendations for installing the unit in cold climates.

Automatic Start/Stop Sequence Warning

Warning about the controller's automatic start/stop sequence.

ELECTRICAL WIRING and Safety

DANGER Electrical Shock Hazard

Warning about electrical shock hazards and lockout/tagout procedures.

Grounding and Motor Lubrication

GROUNDING Requirements

Requirements for grounding the compressor package according to electrical codes.

DANGER Improper Grounding

Warning about potential injury or death due to improper grounding.

SECTION 3 STARTING & OPERATING PROCEDURES

PRESTART-UP INSTRUCTIONS

Steps to check and service the unit before initial operation.

Operating Safety and Component Checks

DANGER Oil Pressure Hazard

Warning about releasing pressure before removing oil filler plug.

Operational Checks and Warnings

Rotation Check Procedure

Procedure for checking correct motor rotation direction.

CAUTION Incorrect Rotation Warning

Warning against damage from incorrect motor rotation.

SECTION 4 CONTROLS & INSTRUMENTATION

AirSmart® G2 Controller Overview

Description of the ASG2 controller's functions and interface.

Control System Components

Emergency Stop Pushbutton Function

Location and function of the emergency stop pushbutton.

SECTION 5 LUBRICATION OIL COOLER, OIL FILTER & SEPARATOR

DANGER Air/Oil Pressure Hazard

CAUTION High Temperature Warning

Lubricant Compatibility Cautions

Lubricant Compatibility and Change Procedure

LUBRICANT CHANGE PROCEDURE

Step-by-step procedure for draining and refilling the oil system.

Oil Level Adjustment and Moisture Issues

CAUTION Overfilling Oil Reservoir

Warning against overfilling the oil reservoir.

MOISTURE IN THE OIL SYSTEM

Explains moisture condensation in oil and how to prevent it.

Oil Change and System Drain/Refill Procedures

OIL CHANGE INTERVAL

Recommended oil change intervals based on discharge temperature.

DRAIN AND REFILLING THE OIL SYSTEM

Procedure for draining and refilling the complete oil system.

Filter and Separator Maintenance

CAUTION Separator Pressure Differential

Warning about using oil separator elements at excessive pressure differential.

OIL FILTER, AIR/OIL SEPARATOR ELEMENT or OIL SCAVENGE RETURN ORIFICE INSPECTION PROCEDURE

Procedure for inspecting and cleaning filter elements and orifices.

SECTION 6 HEAT EXCHANGERS (OIL/AIR)

Heat Exchanger Maintenance

Heat Exchanger Cleaning Safety

DANGER Cooling Fan Safety

Warning not to inspect or clean heat exchangers until cooling fan stops.

SECTION 7 AIR FILTERS

Air Filter Element Handling and Maintenance

FILTER ELEMENT INSPECTION AND/OR REPLACEMENT

Procedure for inspecting and replacing the air filter element.

SECTION 8 DRIVE SHAFT COUPLING

Coupling Safety and Inspection

DANGER Automatic Restart Warning

Warning about automatic restarting causing injury or death.

Interference Fit Coupling Hub Installation and Removal

SECTION 9 SERVICING OF MISCELLANEOUS DEVICES

Inlet Valve Safety and Inspection

DANGER Air/Oil Pressure Hazard

Hazard of air/oil pressure causing injury or death.

PRESSURE RELIEF VALVE Function

DANGER Pressure Relief Valve Safety

Pressure Relief Valve Precautions and Testing

DANGER Improper Relief Valve Setting

Warning about improper relief valve setting causing injury or damage.

MINIMUM PRESSURE VALVE Function

DANGER Minimum Pressure Valve Safety

THERMOSTATIC MIXING VALVE Function

INPUT SHAFT SEAL ASSEMBLY Maintenance

Shaft Seal Replacement Procedure

SECTION 10 TANK MOUNTED COMPRESSOR - TOTAL SYSTEM

Total System Installation Requirements

Dryer Starting and Stopping Procedures

SECTION 11 MOTOR LUBRICATION

DANGER Rotating Machinery Hazard

Warning about rotating machinery causing injury or death.

Motor Lubrication Importance

Importance of lubrication for electric motor bearing longevity.

SECTION 12 MAINTENANCE SCHEDULE

SERVICE CHECK LIST

A comprehensive checklist for various maintenance tasks and intervals.

Maintenance Intervals: 1000 and 4000 Hours

Annual Maintenance Tasks

Maintenance Schedule Summary

SECTION 13 TROUBLESHOOTING

Compressor Fails to Start

Possible causes and remedies for compressor failure to start.

Compressor Starts but Stops After Short Time

Causes and remedies for the compressor stopping shortly after starting.

Troubleshooting Compressor Operation

Compressor Does Not Unload (or Load)

Causes and remedies for improper compressor unloading or loading.

Troubleshooting Compressor Performance Issues

Compressor Does Not Reach Load Pressure

Causes and remedies for the compressor failing to reach load pressure.

Troubleshooting Temperature and Oil Consumption

High Discharge Air Temperature

Causes and remedies for high discharge air temperature.

Excessive Oil Consumption

Causes and remedies for excessive oil consumption.

Troubleshooting Oil and Water Issues

Oil Carryover

Causes and remedies for oil carryover in the system.

Excessive Water in Air Delivery Line

Causes and remedies for excessive water in the air delivery line.

TROUBLESHOOTING VOLTAGE PROBLEMS

Standard Warranty Information

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