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Summary of Contents for Gardner Denver L23
- Page 1 Original Operating and Service Manual Screw Compressor L23-L29 L23RS-L29RS ● Id. No. ZS1137206 / 01 - November 2015...
- Page 3 Gardner Denver parts will be used. Warranty The conditions of the Gardner Denver Warranty are set out in the company's standard Conditions of Sale available from the Distributor supplying the machine.
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Page 4: Warning -Prohibition - Mandatory Label Information
Warning -Proh ibition - Mand ator y L ab el Inform ation 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. - Page 5 1 Warning -Prohibition - Mandatory Label Information Check and, if required, re-tighten connection terminals. Danger of electric shock from loaded condensers! Please For further details, see the operating instructions. always first disconnect the system from the power supply and wait another 10 minutes before touching the electrical components.
- Page 6 1 Warning -Prohibition - Mandatory Label Information NOTICE Indicates a property damage message. PROHIBITION/MANDATORY ACTION REQUIREMENTS Asphyxiation Hazard – Never breathe in compressed air Never operate the unit with open doors or loose access from this system. panels. Read the operatorʼs manual before proceeding with this Opening pressure relief valve = xx bar (value "xx"...
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Page 7: Preface
2 Preface Pr eface Fig. 1 *) The values given on the nameplate are maximum values. Local Gardner Denver distributor Name: Address: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Telephone: Fax: Representative: Replacement parts: Service:... -
Page 8: Compressor Information
Therefore, it is essential that the prescribed manual. maintenance intervals are adhered to and that Gardner Denver will not guarantee the safe operation of maintenance and upkeep are done thoroughly, the machine/equipment if it is not handled in a way especially under difficult operating conditions. - Page 9 Gardner Denver replacement • parts alterations to the equipment. • The warrantee or liability terms of Gardner Denverʼs Terms and Conditions are not expanded by the foregoing. Any independent alterations to the compressor equipment/station or installing components which have not been approved by the manufacturer (e.g.,...
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Page 10: Table Of Contents
5.1 Assembling the System.............................. 19 5.2 System Schematic..............................20 5.3 Oil Circuit..................................21 5.4 Air Circuit..................................21 5.5 Regulation................................... 21 5.5.1 Regulator L23-L29 ............................21 5.5.2 Regulator L23RS-L29RS..........................22 6 Transportation and Installation............................24 6.1 Transportation................................24 6.2 Installation................................... 25 7 Preparation for Commissioning............................ - Page 11 Test period for pressure reservoir and electrical installation................51 11 Troubleshooting ................................52 12 Appendix .................................... 54 12.1 Technical Specifications............................. 54 12.1.1 US version L23-L29 60 Hz ..........................54 12.1.2 US Version L23RS............................55 12.1.3 US Version L26RS............................56 12.1.4 US Version L29RS............................57...
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Page 12: Safety Regulations
4 Safety Regulations Saf ety Regu lat ions General safety regulations Danger Safety measure required Working with compressors involves Everyone working with the machine must have first read and understood the dangers that are not immediately operating manual. Donʼt leave this until you start work – itʼs too late. apparent. -
Page 13: Particular Dangers Associated With Compressed Air
4 Safety Regulations 4.2 Particular dangers associated with compressed air Danger Safety measure required Compressed air is very powerful. It can Never play about with compressed air. be used for example to break open concrete but can also put lives at risk. Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution compressed air can penetrate the skin... - Page 14 4 Safety Regulations Danger Safety measure required Compression results in high The system should be set up such that hazardous mixtures (inflammable solvent vapors etc. but also dusts and other dangerous or toxic materials) temperatures. cannot be drawn in. The same applies to flying sparks. Never use the machine in environments where the possibility cannot be ruled out that inflammable or toxic vapors may be taken in.
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Page 15: Particular Dangers Associated With Machines
4 Safety Regulations 4.3 Particular dangers associated with machines Danger Safety measure required Risk of electric shock. Electrical connections must meet the local regulations. Power units must be connected to earth and protected from short-circuits by means of fuses. Insufficient power quality could have Always check a correct power supply to the compressor before commissioning. -
Page 16: Particular Dangers Associated With Water-Cooled Units
4 Safety Regulations 4.4 Particular dangers associated with water-cooled units Danger Safety measure required If open cooling towers are used in the The growth and spread of bacteria must be prevented by corresponding service cooling water circuit, it is possible for and water treatment methods. -
Page 17: General Workplace Dangers
4 Safety Regulations 4.6 General workplace dangers Danger Safety measure required This manual only describes how to work Please note and pass on general statutory and other binding regulations that safely with the compressor itself. But may supplement the operating manual for the prevention of accidents and the other dangers will arise during work. -
Page 18: Dangers Resulting From Neglecting To Perform Maintenance
Only persons with special knowledge and experience of hydraulics may work compressor and have not been trained on system elements, for example components under pressure. by Gardner Denver, you will put yourself and others at risk. Incorrectly configured spare parts may Spare parts must meet the technical requirements laid down by the jeopardize safety, e.g., tear when... - Page 19 4 Safety Regulations Danger Safety measure required Risk of electric shock. Work on the electrical systems of the machine / installation may only be carried out by a trained electrician in accordance with electrical regulations. The system must be secured from being switched on. Seal off the main switch and remove the key and/or attach a warning sign to the main switch.
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Page 20: Dangers Resulting From Conversion Work/Modifications On The Machine
4 Safety Regulations Danger Safety measure required Modifications to the machine impair After completing repair work, always check to see whether any tools, loose parts or cloths have been left in or on the machine, driving engine or driving safety. equipment. -
Page 21: Assembly And Operation
5 Assembly and Operation Assembly and Operation Assembling the System Fig. 2 1 Intake filter 12 Pressure relief valve 22 Emergency stop button 2 Suction regulator 13 Minimum pressure and non-return 23 Switch cabinet 3 Electric motor valves 24 Feed cable entry 4 Screw compressor 14 Air cooler 25 Final compression temperature... -
Page 22: System Schematic
5 Assembly and Operation System Schematic Fig. 3 1 Suction filter 8 Ball valve oil drain 20 Motor temperature (R1) 2 Suction regulator 9 Pressure relief valve 21 Frequency converter (only for 2.1 Centering actuator 10 Oil filter L23RS-L29RS) 2.2 Pressure valve 11 Oil cooler 22 Integr. -
Page 23: Oil Circuit
22 PSI (residual pressure) in the vessel. Fig. 4 5.5.1 Regulator L23-L29 Air Circuit System Idle Incoming air is passes through a suction filter (-1- Fig. 3) When the system is on idle the suction regulator •... -
Page 24: Regulator L23Rs-L29Rs
5 Assembly and Operation When switching to Δ operation of the electric motor • 5.5.2 Regulator L23RS-L29RS the solenoid valve (- Y1 - Fig. 4) is supplied with System Idle power which interrupts the connection between pressure reservoir and suction regulator. See 5.5.1 System Idle •... - Page 25 5 Assembly and Operation Regulated Speed Operation Speed control is achieved with the help of a software PI controller which adjusts the speed according to the need for compressed air. The controller attempts to hold the system pressure between the CUT-OUT POINT TARGET PRESSURE values set in the control system (see Section 9.5.3).
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Page 26: Transportation And Installation
6 Transportation and Installation Tran sport ation and Inst allation Transportation DANGER The compressor or parts of it may fall if mistakes are made when lifting, and this will put your life at risk. Safety devices my be damaged if lifted incorrectliy. •... -
Page 27: Installation
6 Transportation and Installation Installation DANGER Always observe the safety notes in Section 4 of the user manual. Pay attention to the weight-bearing capacity of the ground. DANGER Risk of explosion - The compressor intake should be set up such that hazardous A = 1 m/39.4”... -
Page 28: Preparation For Commissioning
The screw compressor is designed for ambient and cooling air temperatures of 33.8 °F to Fig. 9 L23 – L29 113 °F. For temperatures outside of this range, 1 Cool air intake please consult your expert advisor. 2 Cool air exhaust... -
Page 29: Compressed Air Connection
7 Preparation for Commissioning The following figures show recommended ventilation Compressed air connection arrangements: WARNING A defective connection to the compressed air system may jeopardize safe operation of the compressed air system. When connecting the compressor outlet to the customerʼs existing compressed air system, check that the necessary operating temperatures, operating pressures as well as the necessary connecting flange or... -
Page 30: Electrical Connection (Only Usa/Canada Version)
7 Preparation for Commissioning Feed the supply cable through the opening (-M50- Fig. 13) Electrical connection in the switch cabinet and screw tight. (only USA/CANADA version) Connect the supply cable to the connection terminal following the circuit diagram. DANGER Risk of strong damage and fire on the electric power components. -
Page 31: Check The Motor Protective Relay (Only For L23Rs-L29Rs)
7 Preparation for Commissioning Notes on the table: 7.3.2 Check the control transformer setting Ultimately the type of cable you use, its length and installation conditions (temperature, accumulation) are DANGER outside the scope of our knowledge. Therefore the above table only offers guidelines. High Voltage –... -
Page 32: Checking The Oil Level
7 Preparation for Commissioning Check the oil level as follows: Checking the Oil Level Shut off the compressor with the STOP button. • DANGER Wait at least 5 minutes until the oil has settled, i.e. • until the air has bubbled out. Air/oil under pressure will cause severe personal injury or death. -
Page 33: Commissioning
8 Commissioning Commissioning Carry out the first commissioning as follows: First commissioning If transport safety devices are present, remove • DANGER them. Fill the pressure reservoir with oil up to the • The rotational direction of the motor can “maximum oil level” mark (this applies to only be checked with the casing open. - Page 34 8 Commissioning Fig. 16 1 Drive motor direction of geared compressors Fig. 19 1 Cool air intake 2 Cool air exhaust 3 “Fan direction” arrow (the direction of rotation might be different than shown here) NOTICE In general, use the Stop button to shut off the compressor ...
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Page 35: Putting A Decommissioned Compressor Back Into Operation
After the machine has automatically shut If the compressor has been in storage for down due to a fault, re-commission as follows: longer than 2 years, please contact an authorized Gardner Denver Distributor prior to Turn off the main switch • start-up. -
Page 36: Control System
9 Control system Control system Status indicator (display / LEDs) General The controller is equipped with a three-row display. This chapter will help you to quickly commission the unit. The control system is explained in detail in the 1. Row: separate DELCOS Pro user manual. -
Page 37: Displaying / Changing Values
9 Control system Displaying / changing values Default settings 9.4.1 Selecting values WARNING You can display values, e.g., total hours, and set the When programming in standby, the control system, e.g., cut-in and cut-out times, in the machine may start up at any time. sub-menu. -
Page 38: Setting System Pressure (Only For L23Rs-L29Rs)
9 Control system 9.5.4 Setting time/date (timer) 9.5.3 Setting system pressure (only for L23RS-L29RS) The GD Pilot battery can bridge a loss of power lasting around two weeks. If power is lost for longer periods, Speed control is achieved with the help of a software the timer's time and date are lost and have to be re- controller which adjusts the speed according to the entered. -
Page 39: Emergency Off Button
9 Control system Emergency off button The emergency off button is located next to the GD Pilot. It is used to immediately shut down the unit. Only use the emergency off button to shut down the unit in emergencies. When shutting down normally, always ... -
Page 40: Menu Structure (Except For L23Rs-L29Rs) (Example Values)
9 Control system 9.10 Menu structure (except for L23RS-L29RS) (example values) + TOTAL RUNNING 12345 h [MAINTENANCE SCHED.] LOADED HOURS 10987 h + AIR FILTER IN ---- h OIL FILTER IN 9999 h ... -
Page 41: Menu Structure (Only For L23Rs-L29Rs) (Example Values)
9 Control system 9.11 Menu structure (only for L23RS-L29RS) (example values) + TOTAL RUNNING 12345 h [MAINTENANCE SCHED.] LOADED HOURS 10987 h + AIR FILTER IN 2000 h OIL FILTER IN 2000 h ... -
Page 42: Service And Maintenance
Only perform checks and maintenance after To make this easier for you, the system comes with the “Maintenance and Inspection Book for Gardner Denver observing the following: Compressors”, in which you can enter maintenance • Press the STOP button on the control work in the specified intervals. -
Page 43: Service Check List
10 Service and Maintenance 3. Replace Air/Oil Separator, operating conditions 10.3.1 Service Check List determine the frequency of service. The air/oil Every 8 hours operation separator will need to be changed as indicated by the GD Pilot, every 4000 hours or every year, 1. - Page 44 10 Service and Maintenance Maintenance Schedule - L Series Check air/oil reservoir oil level Check operation of the machine, is it loading and unloading properly Check discharge pressure and temperature Check control panel for advisory text messages ...
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Page 45: Oil Change
10 Service and Maintenance 10.4 Oil change DANGER Air/oil under pressure will cause severe personal injury or death. • Shut down the compressor, relieve the system of all pressure, disconnect, lockout and tagout the power supply to the compressor package before removing valves, caps, plugs, fittings, bolts and filters. -
Page 46: Change Oil Filter Cartridge
10 Service and Maintenance Check the oil level, (see Section 7.3.1) • The oil level must lie between the “maximum oil level” • and “minimum oil level” (- 5 - Fig. 21). If necessary, top up the oil. • Oil Change interval Operating conditions (e.g., coolant temperatures), the type of operation and the quality of the intake air (e.g., dust content, ratio of gaseous foreign substances such... -
Page 47: Changing The Fine Oil Separator
10 Service and Maintenance 10.6 Changing the fine oil separator DANGER Air/oil under pressure will cause severe personal injury or death. • Shut down the compressor, relieve the system of all pressure, disconnect, lockout and tagout the power supply to the compressor package before removing valves, caps, plugs, fittings, bolts and filters. -
Page 48: Change Air Filter
10 Service and Maintenance The changing intervals can be found in the Screw in and tighten crosswise all hex. screws except • maintenance schedule 10.3. for the two screws in the pivot area of the PMV. If the fine oil separator is monitored (optional), then a Pivot the PMV back to its starting position and install •... -
Page 49: Pressure Relief Valve
10 Service and Maintenance 1 Housing cover 2 Filter foam 3 Air filter The air filter cartridge should be changed at least as often as stated in Section 10.3. Check the air filter at least once a week and possibly daily for dust accumulation. -
Page 50: Connection Terminals In The Switch Cabinet/Control Transformer Settings
10 Service and Maintenance 10.9 Connection terminals in the switch cabinet/control transformer settings DANGER High voltage – Hazard of shock, burns, or death • Only qualified electricians may work on the control cabinet. • Only perform checks and carry out work on the screw compressor when the unit is out of operation, depressurized, and secured from being switched on again! -
Page 51: Screw Connections
10 Service and Maintenance 10.10 Screw connections 10.12 Clean/replace cool air intake and control box filter pads Check the air and oil system screw connections in accordance with the maintenance schedule and tighten DANGER if necessary. Only perform checks and carry out work on the screw compressor when the unit is out 10.11 General maintenance and cleaning of operation, depressurized, and secured... - Page 52 10 Service and Maintenance Fig. 31 Changing the control box filter (-4- Fig. 29) (only L23RS - L29RS) Fig. 29 • Open the louver grilles of the inlet filter (Fig. 30) 1 Inlet filter L23RS-L29RS • Remove the filter pad. •...
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Page 53: Maintenance Notes And Lubricant Recommendations For Stationary Compressors
Material Safety Data Sheets (MSDS) are available for all Gardner Denver lubricants from your authorized Gardner Denver distributor or by calling Gardner Denver-USA at (937) 498-2500. The following oil types should be used... -
Page 54: Troubleshooting
Pressure reservoir is not depressurized Wait for discharge Screw compressor will not start if the reservoir pressure is > 11.6 PSI for L23-L29 and > 29.0 PSI for L23RS- L29RS Electric motor is defective Check connections, winding, etc. Compressor is defective... - Page 55 11 Troubleshooting Fault Possible Cause Remedy Unit switches off Ambient temperature is too high Ventilate the compressor room Electric motor is defective Check the electric motor and PTC thermistor Faulty fan Check/exchange fan Faulty sensor, connection or cable Check the sensor, connection and cable Electrical cable gauge too small Measure the current draw and...
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Page 56: Appendix
12 Appendix Append ix 12.1 Technical Specifications 12.1.1 US version L23-L29 60 Hz Technical Specification L15-L22 ; 60 Hz Max. Positive operating pressure Min. positive operating pressure Ambient temperature °F 34 / 113 129.4 Flow volume 148.5 106.5 172.7 147.9 128.5... -
Page 57: Version L23Rs
12 Appendix 12.1.2 US Version L23RS Technical Specification 60Hz L23RS Max. positive operating pressure Min. positive operating pressure Ambient temperature °F 34 / 113 Operating pressure min. max. min. max. min. max. min. max. 39.1 145.5 37.9 36.3 123.5 47.7 102.1 Flow volume After-cooler exhaust temperature above ambient... -
Page 58: Version L26Rs
12 Appendix 12.1.3 US Version L26RS Technical Specification 50Hz / 60Hz L26RS Max. positive operating pressure Min. positive operating pressure Ambient temperature °F 34 / 113 Operating pressure min. max. min. max. min. max. min. max. Flow volume 39.1 168.9 37.9 157.4 36.4... -
Page 59: Version L29Rs
12 Appendix 12.1.4 US Version L29RS Technical Specification 50Hz / 60Hz L29RS Max. positive operating pressure Min. positive operating pressure Ambient temperature °F 34 / 113 Operating pressure min. max. min. max. min. max. min. max. Flow volume 39.0 190.9 37.8 175.8 36.3... -
Page 60: Installation Diagram
12 Appendix 12.2 Installation diagram Fig. 32 (All dimensions in inches) Compressed air connection External threaded connector 1¼ inch (USA NPT) Cool air intake Cool air exhaust Electrical connection Switch cabinet cool air intake (only L23RS-L29RS) - Page 61 12 Appendix Fig. 33 (All dimensions in inches)
- Page 62 12 Appendix Fig. 34 (All dimensions in inches)
- Page 64 Gardner Denver Compressor Division, 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Fax: (217) 224-7814 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Germany Tel. +49 (0)6761 832-0 Fax +49 (0)6761 832-409...
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