Gardner Denver L Series Original User And Service Manual
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Summary of Contents for Gardner Denver L Series
- Page 1 L-SERIES FRAME 2+ BASE MOUNTED COMPRESSOR Original User and Service Manual MODELS: L23-29E 30, 35 & 40 HP LRS23-29E 23, 26 & 29 kW 13-25-641 Version 00 January 30, 2020...
- Page 2 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.
- Page 3 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 terminal strip of the frequency converter by measuring Check and, if required, re-tighten connection terminals. this between the For further details, see the operating instructions. +DC and -DC terminals (the exact position can be found Danger of electric shock from loaded condensers! in the supplied operating manual of the frequency Please always first disconnect the system from the converter), between the +DC terminal and the chassis as...
- Page 5 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 operator’s manual before proceeding with this Opening pressure relief valve = xx bar (value "xx" see task.
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Page 6: Preface
Fig. 1 Your Gardner Denver distributor Name: Address: Telephone: Fax: Contact: Spare Parts: Service: 13-25-641 v00 Page 5... -
Page 7: Compressor Information
Maintenance and Care manual. Proper maintenance and care are necessary to ensure Gardner Denver will not guarantee the safe operation of that the screw compressor fulfills the requirements the machine/equipment if it is not handled in a way which made of it. Therefore, it is essential that the prescribed... - Page 8 • failing to use genuine Gardner Denver replacement parts • alterations to the equipment. The warranty or liability terms of Gardner Denver’s Terms and Conditions are not expanded by the foregoing. independent alterations compressor equipment/station or installing components which have not been approved by the manufacturer (e.g., separator) will result in the...
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Page 9: Table Of Contents
Warning -Prohibition - Mandatory Label Information ..................... 2 Preface....................................5 Compressor Information .............................. 6 Intended Use ................................6 Maintenance and Care ..............................6 Notes .................................... 6 Table of contents ................................. 8 Safety regulations ................................10 General safety regulations ............................10 Particular dangers associated with compressed air .................... - Page 10 10 Service and maintenance ..............................35 10.1 Maintenance recommendations ..........................35 10.2 Maintenance Electric Motor ............................. 35 10.2.1 Motor Lubrication……………………………………………………………………………………………………… . 35 10.3 Maintenance and inspection schedule ........................35 10.3.1 Service Check List ............................36 10.4 Oil change ................................38 10.5 Change oil filter cartridge ............................
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Page 11: Safety Regulations
4.1 General safety regulations Danger Safety measure required Working with compressors involves Everyone working with the machine must have first read and understood the operating manual. Don’t leave this until you start work – it’s too late. dangers that are not immediately apparent. -
Page 12: Particular Dangers Associated With Compressed Air
4.2 Particular dangers associated with compressed air Danger Safety measure required Compressed air is very powerful. It Never play with compressed air. can be used, for example, to break open concrete but can also put lives at risk. Small parts propelled at high speed When using compressed air to clean equipment, work with extreme caution and by compressed air can penetrate the always wear suitable eye protection. - Page 13 Danger Safety measure required Compression results in high The system should be set up such that hazardous mixtures (flammable solvent temperatures. Risk of explosion vapors etc., but also dusts and other dangerous or toxic materials) cannot be from drawn-in materials. drawn in.
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Page 14: Particular Dangers Associated With Machines
4.3 Particular dangers associated with machines Danger Safety measure required Risk of electric shock. Electrical connections must meet local regulations. Power units must be connected to earth and protected from short-circuits by means of fuses. Insufficient power quality could Always check a correct power supply to the compressor before commissioning. The voltage supply has to fulfill the requirements of NFPA70-NEC f o r this type of have a strong effect on health &... -
Page 15: Dangers Present When Loading/Moving Machines
Dangers present when loading/moving machines Danger Safety measure required Loose parts may fall off when lifting. All loose parts must first be removed or secured; parts fitted so that they can turn like doors etc. must be secured and made immobile. Parts to be removed for transport purposes must be carefully refitted and fixed again before putting the machine/installation back into operation. -
Page 16: General Workplace Dangers
General workplace dangers Danger Safety measure required This manual only describes how to Please note and pass on general statutory and other binding regulations that work safely with the compressor itself. may supplement the operating manual for the prevention of accidents and the But other dangers will arise during protection of the environment. -
Page 17: Dangers During Maintenance And Repairs
Contact your Gardner Denver agent. removed. maintain compressor and have not been trained by Gardner Denver, you will put yourself and others at risk. Incorrectly installed spare parts may Spare parts must meet the technical requirements laid out by the manufacturer. - Page 18 Danger Safety measure required Never weld any pressure reservoir or modify it in any way. During the course of maintenance and repairs, parts can be damaged which If work which produces heat, flames, or sparks has to be carried out on a are important for safety.
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Page 19: Dangers Resulting From Conversion Work/Modifications On The Machine
Gardner Denver. Installing or using such products will adversely affect active and/or passive safety. The manufacturer accepts no liability whatsoever for damage resulting from the use of non-original parts or special accessories. -
Page 20: Design And Functioning
Design of the unit Fig. 2 Fig. 2 14. Air Cooler 27. Final Compression Pressure Sensor Intake Filter 15. Fine Oil Separator Extraction 28. Opening For Lifting Equipment Suction Regulator 16. Oil Temperature Regulator 29. Fan Guard Electric Motor 17. Cooling Fan 30. -
Page 21: System Schematic
System Schematic Fig. 3 Intake filter Valve oil drain 19 Discharge pressure sensor (B1) Suction regulator Pressure relief valve 20 Motor temperature (R1) 2.1 Centering actuator 10 Oil filter 21 Frequency converter (only for 2.2 Pressure valve L23RS-L29RS) 11 Oil cooler 2.3 Non-return valve 12 Throttle 2.4 Throttle valve... -
Page 22: Oil Circuit
Oil circuit System control Oil passes from the pressure reservoir (-6- Fig. 3) into the oil temperature regulator (-15- Fig. 3). At temperatures of <131°F the oil flows directly through the oil coolers bypass line to the oil filter (-10- Fig. 3) and is then injected into the screw compressor (-4- Fig. - Page 23 The piston chamber of the regulator is relieved by the The compressor sucks in a certain volume of air throttle valve (-2.4- Fig. 4) and the spring pushes the through the non-return valve (-2.3- Fig. 4) to keep the piston down.
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Page 24: Manner Of Operation Of The Suction Regulator
Automatic operation (open-close operation) If the system pressure reaches the preset maximum value, the speed of the electric motor (-3- Fig. 4) is regulated down to adjust the delivered quantity to match the actual compressed air consumption. If the minimum motor speed is reached and system pressure continues to rise, power is cut to the solenoid valve (-Y1- Fig. -
Page 25: Transport And Installation
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 may be damaged if lifted incorrectly. Always observe the safety notes in Section 4.5 of the user manual. -
Page 26: 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 mixtures (solvent vapors etc.) cannot be sucked in. -
Page 27: Preparations For Commissioning
If conditions are not favorable, we recommend the Cooling air volume/minimum cross installation of venting ducts. However, the velocity of the cooling air should not exceed 17ft/sec. We recommend a minimum duct cross-section of approx. 6 ft Fig. 9 Cool air intake Cool air exhaust (Fan rotation counter-clockwise) Switch cool air intake (L23RS-L29RS only) figures... -
Page 28: Compressed-Air Connection
7.2 Compressed air connection WARNING Fig. 12 1 Compressed-air connection The compressed air distribution system is connected to external threaded connector screw compressor (-1- Fig. 12) USA/CANADA Version: ANSI B 1.20.1 1-1/4" NPT This should be done with a flexible connection. (e.g., compressed air hose, compensator). -
Page 29: Electrical Connection (Usa/Canada Version Only)
To establish an electrical connection, proceed as Electrical connection follows: (USA/CANADA Version only) Route the supply cable (-1- Fig. 13) through the cable gland on the switch cabinet and tighten screws. DANGER Connect the supply line to the connecting terminals as Risk of severe damages and fire on the shown in the circuit diagram. -
Page 30: Checking The Oil Level
(-4- Fig. 14) marks on the oil gauge. CAUTION If required, top up oil. Use Gardner Denver oil only. Close the oil filler cap (-1- Fig. 14) firmly. 7.41 Noise Level Noise levels are measured according to ISO 2151 at full load at an 11-yard distance dB(A) (tolerance +/- 3 dB(A)). -
Page 31: Commissioning
First commissioning is carried out as follows: First commissioning Remove transport guards, if fitted. DANGER Check the oil level in the pressure reservoir (also see Section 7.4 Fig. 14) The rotation should be checked by visually looking at the coupling through the coupling Check settings of the fan motor protection switch (only L23RS-L29RS) (see Section 7.3.1) guard. - Page 32 Fig. 15 a 1 Drive motor direction of geared compressors Fig. 15 c Cooling air intake Cooling air outlet Arrow “direction of rotation for compressor“ (direction of rotation may deviate from this representation) NOTICE For switching the compressor off “normally”, use only the stop push-button (-3- Fig.
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Page 33: Putting A Decommissioned Compressor Back Into Operation
Routine commissioning Putting a decommissioned compressor back into operation WARNING Before commissioning the compressor all the electrical and electronic components and units should be checked for the ingress of water or condensation. If the electronic control system was removed during shut down, it must be re-installed. -
Page 34: Commissioning After Malfunction
8.5 Commissioning after malfunction Re-start after an automatic shutdown due to a malfunction as follows: Faults are shown as text in the compressor controller Alarms menu. Turn master switch off and secure it from being switched on again. Eliminate fault. ... -
Page 35: Storage Of Compressors
9.1 Decommissioning All compressors are protected against corrosion at the factory for transport and for brief storage before commissioning. If the compressors are to be stored for period exceeding six months, additional precautions must be taken. Compressors which are to be shut down for a lengthy period must also be protected from corrosion. -
Page 36: Service And Maintenance
WARNING 10.1 Maintenance recommendations 10.2 Maintenance Electric Motor 10.2.1 Motor Lubrication Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of bearings. following charts show recommended grease qualities and re-greasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions. -
Page 37: Service Check List
2. An oil sample will need to be taken and sent to the "Compressor Oil System Check". Gardner Denver oil lab. See section 5.1 (Fig.2 & 17) for oil sampling valve location. Refer to oil change 7. Inspect, replace if necessary the drive coupling spider procedure in section 10.4 for proper oil draining... - Page 38 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 Inspect, Clean if necessary Cooler / Fan ...
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Page 39: Oil Change
10.4 Oil change DANGER Air/oil under pressure will cause severe personal injury or death. Shut down the compressor, relieve the system pressure, disconnect, lockout and tagout the power supply to compressor package before removing valves, caps, plugs, fittings, bolts and filters. CAUTION ... -
Page 40: Change Oil Filter Cartridge
The oil level must lie between the “maximum oil level” and “minimum oil level” (-5- Fig. 18). 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 as SO and solvent vapors) have a strong influence on... -
Page 41: Changing The Fine Oil Separator
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 42: Change Of Air Intake Filter
Pivot the MPV back to its starting position and install it with the corresponding screws. Finally, install and tighten the last missing hex. screws in the reservoir cover. Pivot the reservoir cover back to the starting position. Tighten the cheese-head screws used to raise the reservoir cover (-5- Fig. -
Page 43: Pressure Relief Valve
Housing cover 10.8 Pressure relief valve Intake filter monitor (visual) DANGER Air intake filter When checking pressure relief valve there is As a standard, the air filter is provided with a visual in- an explosive release of pressure. take filter monitor (-2- Fig. 22), which indicates clogging of the air filter cartridge. -
Page 44: Connecting Terminals In The Switch Cabinet
DANGER A defective pressure relief valve may result in pressure that is too high, breaking open parts of the system and causing serious or fatal injury. Never operate a screw compressor system with a defective pressure relief valve or without pressure relief valve! 10.9 Connecting terminals in the switch cabinet DANGER... -
Page 45: Screw Connections
10.10 Screw connections 10.12 Clean / change filter with cool air intake and switch cabinet inlet The screw connections of the air, oil, and water circuits have to be checked and, if required, re-tightened DANGER according to the maintenance schedule. Only perform checks and carry out work on Check the hose and piping for unsealed areas. - Page 46 Fig. 25 Fig. 26 Perform filter mat change as follows: Open the louver grilles of the inlet filter (Fig. 25). Remove the filter pad. Insert the new filter pad into the louver grille. Ensure that the smooth side (-A- Fig. 26) of the filter pad faces the air inlet side.
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Page 47: Maintenance Notes And Lubricant Recommendations For Stationary Compressors
Please note that proper lubrication can significantly increase the lifespan of your compressor system. Material Safety Data Sheets (MSDS) are available for all Gardner Denver lubricants from your authorized accordance with valid accident... -
Page 48: Troubleshooting
11. Troubleshooting In the case of faults or warnings that are detected by the compressor controller, please refer to the chapter “Fault/warning table” in the operating instructions of the controller. Malfunction Possible cause Remedy Unit cannot be started No operating or control voltage Check fuses, main switch and supply line Malfunction not acknowledged Acknowledge fault message... - Page 49 Malfunction Possible cause Remedy Ambient temperature is too high Ventilate the compressor room Unit switches off 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 50: Annex
12.1 Layout plan Fig. 27 13-25-641 v00 Page 49... - Page 51 Fig. 28 13-25-641 v00 Page 50...
- Page 52 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2020 Gardner Denver, Inc. Printed in U.S.A.
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