Related Manuals for Gardner Denver L160 110A V2
Summary of Contents for Gardner Denver L160 110A V2
- Page 1 User manual Screw compressor L160 - L290 V2 L160RS- L290RS V2 America ZS1149274 / 03 - January 2017...
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Page 2: Table Of Contents
Table of Contents TABLE OF CONTENTS Commissioning and operation....34 Initial commissioning......34 Foreword..........4 Normal operation........ 36 About these operating instructions..4 Routine commissioning....... 37 Notes........... 4 Commissioning after extended Intended use........5 downtime..........37 Foreseeable misuse......6 Commissioning after a fault....37 Service.......... - Page 3 Table of Contents 9.6.3 L160 RS, 60Hz, air-cooled "A", water- cooled "W".......... 60 9.6.4 L200 RS, 60Hz, air-cooled "A", water- cooled "W".......... 62 9.6.5 L290 RS, 60Hz, air-cooled "A", water- cooled "W".......... 63 Installation plan........65 January 2017 America 3 /72...
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Page 4: Foreword
Foreword FOREWORD Performing regular visual inspections for damage Gardner Denver screw compressors are the Cleaning, maintenance, and repair of the product of years of research and development. compressor Together with high quality requirements, these conditions guarantee that the screw compressors... -
Page 5: Intended Use
Foreword Intended use Guarantee Gardner Denver is not liable for the functional The compressor uses the best available safety of the compressor if any actions are taken technology and meets applicable safety that are contrary to the intended use, or if used... -
Page 6: Foreseeable Misuse
Operation without protective and safety devices. Email: Operation with defective, deactivated, or manipulated protective and safety devices, or Chart 1-1: Local Gardner Denver representative safety values, or operation with other safety- related defects. Use by private users or users without technical training. -
Page 7: Rating Plate
Foreword Rating plate Fig. 1-1: Rating plate January 2017 America 7 /72... -
Page 8: Safety Requirements
Gardner Denver accepts no responsibility for conditions, such as with respect to work material damage or injuries that arise from non- organization, process flows, responsibilities, observation of safety conditions or the failure etc. -
Page 9: Protective And Safety Devices
Safety requirements The sound pressure level with sound-dampening 3 Unlock <Emergency-Stop> button. enclosure is about: (See "Technical data".) Turn the pushbutton anticlockwise. During normal operation the compressor may only 4 Start up the compressor. be operated with a closed acoustic hood. See section "Commissioning after a fault"... -
Page 10: Safety Symbol
Safety requirements These special warning notices serve to protect Description of the hazard (hazard source ): The against hazards and are close to the potential hazard source indicates the cause of the hazard. hazard in space and time: Protective measure (protection against hazard): The protection against the hazard On the system, near the source of hazard describes the measures for preventing the hazard. - Page 11 Safety requirements Safety symbol Meaning Application / behavior Electrical voltage Warning against dangerous electrical voltage. Work on the electrical equipment of the compressor may be done only by an electrician in accordance with electri- cal rules. System continues to run The compressor continues to run for 30 second after the stop button <O>...
- Page 12 Safety requirements Safety symbol Meaning Application / behavior Warning of automatic In normal operation the compressor can start automati- start cally at any time. Operational readiness of the compres- sor is indicated by the green LED on the control panel. Do not perform any work on the compressor when the green LED is lit.
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Page 13: Transport And Installation
Safety requirements Safety symbol Meaning Application / behavior Electrical voltage Warning against dangerous electrical voltage. Residual voltage on the Warning of stored energy in the form of capacitors. They capacitors carry deadly electrical voltage. Do not open the electrical switch cabinet (RS compres- sor or ARV ) for 10 minutes after disconnecting the com- pressor. -
Page 14: Special Work
Safety requirements Operate the compressor only if all protective and Maintenance and repair work may be performed safety devices, sound dampeners, ventilation and only under supervision, or by a person qualified for exhaust devices, and cooling water supply (for this work. water-cooled compressors only) are present and Secure an ample working area, if needed. -
Page 15: Modifications And Changes To The Machine
Modifications and changes to the machine Do not make any modifications, additions, or reconfigurations of the compressor without prior consultation with Gardner Denver. Unauthorized changes to the machine are not allowed for safety reasons. Original parts are specially conceived for the machine. -
Page 16: Design And Function
Design and function DESIGN AND FUNCTION Principle of compression The compressor stages consist of a main rotor General description and a secondary rotor with spiral teeth that mesh with each other. Compression chambers bounded The compressor is an oil-lubricated, compressing, by the flanks of the teeth and by the compressor single-stage screw compressor with one sound- housing are formed. -
Page 17: Construction Of The Compressor
Design and function Construction of the compressor Air-cooled Fig. 3-1: Overview Part 1 [20] Suction filter Base frame Intake regulator [21] Control system control panel Electric motor [22] EMERGENCY-Off button Screw compressor [23] Electrical enclosure [25] Fine precipitator Compression temperature sensor [10] Oil filter [27]... - Page 18 Design and function Fig. 3-2: Overview Part 2 (air-cooled) [14] Pressure vessel Air cooler Oil fill [17] Oil cooler cooling air fan Oil drain [18] Cooling air inlet filter pad Oil level indicator [19] Compressed air outlet [11] [24] Oil cooler Aftercooler cooling air fan [12] Safety valve...
- Page 19 Design and function Fig. 3-3: Overview Part 2 (water-cooled) Pressure vessel [14] Air cooler Oil fill [17] Cooling air fan Oil drain [18] Cooling air inlet filter fleece [19] Oil level indicator Compressed air outlet [11] Oil cooler [26] Line pressure sensor [12] Safety valve [30]...
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Page 20: System Schematic For Air-Cooled Compressor
Design and function System schematic for air-cooled compressor 2.2 2.1 6 S12* E5 E4 Fig. 3-4: Functional schematic Compressed air Control air Cooling water Chart 3-1: Lines Components Designation Designation Designation Intake air filter Throttle; orifice diameter Dirt trap (only LxxxW) 1.2 mm / 0.047 "... -
Page 21: Oil Circuit
Design and function Designation Designation Designation Suction regulator; resid- Pressure reducing valve 28 Cooling water solenoid ual pressure 1 - 1.5 bar / valve (Y) (only L xxxW) 15 - 22 psi Adjusting cylinder Pressure retention and Adjustable throttle valve check valve (only L xxxW) Opening pressure... -
Page 22: Air Circuit
Design and function • When switching the drive motor to Δ-operation, the solenoid valve (-19-(Y1)) switches, as it is During screw compressor off-load operation, being supplied with current. a sufficiently large drop in pressure, and thus the required oil injection volume, is achieved so •... -
Page 23: Lubricant System
Design and function • The cooling air fan (-25-) is speed-controlled based on the final compression temperature (only L xxx RS with fan speed control A – air- cooled units). • The cooling water solenoid valve (-xx-(Y6)) is opened and closed based on the final compression temperature (only L xxx W –... -
Page 24: Heat Recovery L160-L290
Design and function Function display on lubricator (*) When the lubricator issues this signal, the following message is output on the compressor control: [Warning: Mot.lubr. sys] (also refer to the operating instructions for the compressor control GD Pilot TS). If the lubricant pipe is blocked, the drive unit increases the pressure to 6bar / 87psi. - Page 25 Design and function Heat recovery function schematic Switching heat recovery on and off Connection from oil cooler Heat recovery Connection to compressor Temperature regulator with switch-off Connection from heat exchanger (WRG) function Heat recovery switched on Heat exchanger Heat recovery switched off Cooling water connection Turning the hex screw clockwise to the stop External connections...
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Page 26: Transport And Installation
Fig. 4-1: Lifting points 2 Use the packing list to check the delivery for completeness. 3 Immediately inform the freight forwarder, insurance, and Gardner Denver of any missing parts or damage. Weight Dependent on type, the compressor weighs up to 4,700 kg / 10362 lbs (gross). -
Page 27: Storage
+2 ...+65 °C / +36 ... L250 4625 kg / 4625 kg / +149 °F could be exceed or underrun, 10196 lbs 10196 lbs contact Gardner Denver. L290 110 4500 kg / 4500 kg / Corrosion protection (direct drive) 9921 lbs... - Page 28 Transport and installation Ventilation and exhaust DANGER Danger of asphyxiation Danger from asphyxiation due to insufficient ventilation and exhaust. The operator must provide sufficient ventilation and exhaust of the compressor room. In order to be able to dissipate the heat produced during operation, the compressor room must have sufficient volume and good ventilation.
- Page 29 Transport and installation Install compressor DANGER Risk of injury Danger from improper installation Consider the permissible load capacity of the foundation. Make sure the foundation is solid and flat. The compressor must be installed with full contact on a foundation with sufficient structural strength.
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Page 30: Preparing For Commissioning
Preparing for commissioning PREPARING FOR WARNING COMMISSIONING Risk of injury Piping If incorrectly connected, the connection Remove all blank flanges, stoppers, caps, and can come loose and the open desiccant bags before installing the piping. connection can cause severe personal Distributor piping and pipe connections must be injury. - Page 31 EN60204-1/IEC60204-1. If the installation conditions deviate from the conditions as described in EN 60204, consult Gardner Denver. Provide the electrical connection and protective measures according to VDE, BS, or local requirements. As a rule, additional regulations from the corresponding power company must also be complied with.
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Page 32: Cooling Water Connection
Preparing for commissioning Cooling water connection Check the settings of the control transformer DANGER Electric shock Dangerous electrical voltage Work on the electrical equipment may be performed by specialized electrical technicians only. With the speed-controlled types (RS) there is a risk of electric shocks due to charged capacitors! Isolate the compressor and wait 10 minutes before touching any... - Page 33 The values are based on freshwater quality without additives (e.g., antifreeze). If the cooling water quality deviates from this, please consult Gardner Denver. Adjust the volume of cooling water according to the description "Cooling water adjustment for water-cooled compressor systems".
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Page 34: Commissioning And Operation
If the compressor has been stored for longer than 2 years, consult Gardner Denver. Perform initial commissioning as follows 1 Check the oil level. 2 Check the settings of the fan motor protection switch. - Page 35 Commissioning and operation Check the direction of rotation of the fan motors (for RS compressors ) CAUTION Falling hazard The direction of rotation of the fan motors can be checked only "from above." Provide a safe means of climbing Fig. 6-1: Check the direction of rotation of the drive motor Protective cover (removed) 1 Switch off the main disconnect switch.
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Page 36: Normal Operation
Commissioning and operation 1 Place a suitable ladder next to the compressor Switching on and climb up. 1 Press start button < I > on the control panel. 2 Check the direction of rotation. – The compressor switches on. The rotational direction arrow is visible through –... -
Page 37: Routine Commissioning
2 Then proceed as described in the "Initial commissioning" section. Commissioning after extended downtime For commissioning after an extended idle period, consult Gardner Denver. Commissioning after a fault NOTICE Property damage Avoid switching on the compressor multiple times without clearing the fault, as this can lead to significant machine damage. -
Page 38: Clearing A Fault
The measures listed in these operating If the solutions listed here are not sufficient instructions for clearing faults may be performed to clear the fault. Contact Gardner Denver. only by specially trained personnel. Any other work beyond this must be performed by the... - Page 39 Clearing a fault Potential root cause Remedy Intake regulator does not close completely Make the intake regulator moveable, replace if needed. Check solenoid valves (Y1) and pressure reducing valve (14). Chart 7-2: Fault cleared by: Unit remains stopped during the run-up phase. Fault: Unit does not reach the set network pressure.
- Page 40 Clearing a fault Fault: Idle pressure too high Potential root cause Remedy Compressor does not give relief Check suction regulator, blow-off solenoid valve (Y4) and pressure-retaining and non-return valve, and replace if necessary. Intake regulator does not close completely Make the intake regulator moveable, replace if needed.
- Page 41 SET key. Lubricant cartridge empty, but no LC unit too small for the drive. Use the original LC unit MLS 120 “LC” message. of Gardner Denver. Chart 7-7: Troubleshooting and clearing faults on the lubricator January 2017 America 41 /72...
- Page 42 Message “LC” even though lubri- LC unit too big for the drive. Use the original LC unit MLS 120 cant cartridge is not completely of Gardner Denver. emptied. Display not working despite volt- Internal drive fault. Replace entire lubrication system age being supplied.
- Page 43 Clearing a fault NOTE Also note the fault messages on the display of the operator panel. The corresponding actions to clear the faults are described in the operating instructions for the electronic controls. January 2017 America 43 /72...
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Page 44: Maintenance And Service
Maintenance and service MAINTENANCE AND SERVICE Maintenance and service are decisive factors for the compressor to be able to meet the challenges of trouble-free operation and service life that it faces. Compliance with the specified maintenance interval and the careful performance of maintenance and care tasks are therefore mandatory. -
Page 45: Service
For any spare parts needed, the local Gardner ensured. Denver branch or representative retailer is available. Electrical components The local Gardner Denver subsidiary or the DANGER responsible dealer is available for any spare parts requirements. Electric shock It is important to provide the model name... -
Page 46: Routine Maintenance
1 Lockout and Tagout. Service and maintenance work should be 2 Open the enclosure, create access. performed by the local Gardner Denver 3 Press start button < I > representative. to allow the compressor to run under load. Cleanliness... -
Page 47: Maintenance Plan
The maintenance plan is suitable for most cases, but some detail changes may be needed under certain conditions. The maintenance plan should always be used as a guideline, but if a change is needed on the basis of experience, this should be discussed with Gardner Denver. Maintenance plan: Maintenance every 8 operating hours... - Page 48 Maintenance and service Maintenance plan: Maintenance every 4,000 hours, but at least once a year Components Measure Required qualification Completed Customer operating log Check and preserve operating User parameters. Electronic controls Check error statistics. User General Maintenance / cleaning Maintenance personnel Air filter Replace Maintenance personnel...
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Page 49: Maintenance Work
This will enable Gardner Denver to determine the specific service that your compressor needs. Maintenance work: The individual maintenance tasks that the service personnel can carry out, are detailed in the following chapter. -
Page 50: Oil Change
Maintenance and service 3 Insert new filter. 4 Close louvred grille. Replacement times for the inlet filter elements The operating modes and the quality of the suction air (e.g. dust content) have a significant impact on the service life of the filter elements. The filter elements should be inspected for dust accumulation at least weekly;... -
Page 51: Oil Filter
Maintenance and service With these compressors, the time for changing oil 11 Shut oil filler neck. is heavily dependent on the degree of soiling of 12 Close the enclosure. the circulating oil. It is vital you ensure that no oil- 13 Switch on the main disconnect switch. -
Page 52: Oil Fine Separator
Maintenance and service 4 Release the filter elements (for direction of 1 Switch OFF the main disconnect switch and rotation see illustration). secure it against switching on again. 5 Insert new filter elements. 2 Open the enclosure, create access. 6 Close the enclosure. 3 Open valve (1) for pressure relief. -
Page 53: Connection Terminals In The Switch Cabinet / Control Transformer Setting
Maintenance and service The compressor is equipped with two air filters. DANGER The air filter serves to filter the intake air. The condition of the air filter must be checked through Electric shock regular visual inspections. Dangerous electrical voltage The air filter elements must be changed, if the Work on the electrical equipment message [Service due] or [Air filter] is displayed may be performed by specialized... -
Page 54: Drive Motor / Lubricator
Maintenance and service Check the setting of the control transformer Replacing the grease cartridge as follows: • Switch on system as in chapter “Routine commissioning”. • In on-load operation check the control transformer’s output voltages. Several taps are provided for this purpose (see wiring diagram). If the output voltage is not correct, check the setting of the control transformer as follows: •... -
Page 55: Control System
[Emergency Stop Activated]. • AEON9000FG (optional) – The "Fault memory" register card blinks. • For further information, please contact your 2 Unlock the <E-stop> button. local CompAir Distributor or Gardner Denver- Turn the button counterclockwise. USA at 866-440-6241. January 2017 America... -
Page 56: Appendix
The compressor is made unusable by removing materials, consult a physician and the electronic controller. Consult Gardner Denver. indicate the material involved. Keep the safety data sheet for the Consumables and auxiliary causative material available. -
Page 57: Disposal
Appendix Remove the electrical connection Remove the drive motor lubricator grease cartridges DANGER 1 Open the enclosure, create access. Electric shock 2 Pull the plug from the lubrication system. Deadly electrical voltage 3 Unscrew the lubricator (grease cartridge with drive and cover) from the lubrication point. Work on the electrical equipment may be performed only by 4 Seal off the lubrication point. -
Page 58: Technical Data
Appendix Dissolved matter / key values Circulating water Flow-through water Sulfate < 0.0016 lb/gal < 0.0004 lb/gal Nitrate < 0.0008 lb/gal < 0.0008 lb/gal Organic materials (KMnO absorption) < 0.0002 lb/gal < 0.00008 lb/gal Free aggressive carbolic acid < 0.00017 lb/gal <... -
Page 59: L250-L290, 60Hz, Air-Cooled "A", Water-Cooled "W
Appendix L160-L200 L160 L200 60Hz, air-cooled "A" + water- cooled "W" Recommended cable cross section 2 x 3 x AWG4/0 / 2 x 3 x MCM350 (460V / 575V) 2 x 3 x AWG3/0 2 x 3 x MCM250 Recommended fuse size (time-delay) [A] 2 x 3 x 200 2 x 3 x 250 Cooling air volumetric flow rate... -
Page 60: L160 Rs, 60Hz, Air-Cooled "A", Water-Cooled "W
Appendix L250-L290 L250 L290 60Hz, air-cooled "A" + water- cooled "W" Electric motor IP55 (IE3) - IEC 60034-2-1 ECA Qualifying Nominal speed of drive motor [rpm] 3600 Nominal power of fan motor "A" [hp / kW] Air cooler = 3.0 / Air cooler = 3.0 / 2.2 / oil cooler = 2.2 / oil cooler =... - Page 61 Appendix L160 RS, L160 RS 60Hz, air-cooled "A" + water-cooled "W" Volume flow rate / Final pressure [bar] [cfm] 294.7 / 130 1026.4 / 130 Volume flow rate / Final pressure [bar] [cfm] 341.3 / 145 969.9 / 145 Volume flow rate / Final pressure [bar] [cfm] 490 / 190 836.8 / 190...
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Page 62: L200 Rs, 60Hz, Air-Cooled "A", Water-Cooled "W
Appendix 9.6.4 L200 RS, 60Hz, air-cooled "A", water-cooled "W" L200 RS, L200 RS 60Hz, air-cooled "A" + water-cooled "W" Maximum operating pressure [psig] Minimum operating pressure [psig] Ambient temperature [°F] 34 / 113 Min. speed Max. speed Volume flow rate / Final pressure [bar] [cfm] 228.7 / 110 1365.7 / 110... -
Page 63: L290 Rs, 60Hz, Air-Cooled "A", Water-Cooled "W
Appendix L200 RS, L200 RS 60Hz, air-cooled "A" + water-cooled "W" Weight [lbs] "A" = 10082 "W" = 9983 Dimensions L x W x H [in] 114.5 x 81.5 x 86.3 Chart 9-5: Technical data; L200 RSVS200, 60Hz, air-cooled "A", water-cooled "W" 9.6.5 L290 RS, 60Hz, air-cooled "A", water-cooled "W"... - Page 64 Appendix L290 RS, L290 RS 60Hz, air-cooled "A" + water-cooled "W" Cooling water inlet temperature "W" [°F] min. 41 / max. 95 Cooling water outlet temperature "W" [°F] x. 131 Cooling water pressure "W" [psig] max. 145 Cooling water connections "W"...
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Page 65: Installation Plan
Appendix Installation plan 10.8 11.5 19.1 16.7 15.6 81.5 33.8 23.8 39.5 114.4 28.5 40.2 12.7 56.3 10.2 18.1 31.1 31.1 34.6 Fig. 9-1: L160 - L290 RS air-cooled January 2017 America 65 /72... - Page 66 Appendix min. 29.5 min. 29.5 Fig. 9-2: L160 - L290 RS air-cooled Compressed air connection Motor cooling air inlet Compressor suction shaft Motor cooling air outlet Air and oil cooler cooling air inlet Frequency converter cooling air inlet (only speed-controlled system) [USA]Air and oil cooler cooling air outlet Switch cabinet cooling air inlet Cover for supply cable...
- Page 67 Appendix Fig. 9-3: L160 - L290 RS water-cooled January 2017 America 67 /72...
- Page 68 Appendix min. 29.5 min. 29.5 Fig. 9-4: L160 - L290 RS water-cooled Compressed air connection Motor cooling air inlet Compressor suction duct Motor cooling air outlet [C1] Cooling water inlet Switch cabinet cooling air inlet [C2] Cooling water outlet Switch cabinet cooling air outlet Cover for supply cable Condensate drain outlet 68 / 72...
- Page 69 Appendix January 2017 America 69 /72...
- Page 70 Appendix 70 / 72 America January 2017...
- Page 71 Appendix January 2017 America 71 /72...
- Page 72 Gardner Denver Compressor Division, 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Fax: (217) 224-7814...