Related Manuals for Gardner Denver L55
Summary of Contents for Gardner Denver L55
- Page 1 Original User and Service Manual Screw Air Compressor L55 - L75 L55RS - L75RS 13-21-605 VERSION: 00...
- 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 -Prohibition - Mandator y Label Information 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 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. The power condensers require this time in order to discharge! Check the DC bus voltage at the system terminal strip of the frequency converter by measuring this between the...
- Page 6 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 sticker on compressor) Handle package at forklift points only...
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Page 7: Preface
Preface Fig. 1 Your Gardner Denver distributor Name: Address: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Telephone: Fax: Contact: Spare Parts: Service: August 20, 2018... -
Page 8: Compressor Information
Service 2.1 Compressor Information If you encounter a fault or require spare parts, please Gardner Denver screw compressors are the result of contact your Gardner Denver representative. Trained many years of research and development. This expert staff will quickly and properly make repairs with background and a high-quality standard ensure that the genuine Gardner Denver replacement parts. - Page 9 You should only use the compressor after first fully learning its operation and in accordance with this manual. Gardner Denver will not guarantee the safe operation of the machine/equipment if it is not handled in a way which corresponds to accepted use or if it is used for other applications which are not named in the manual.
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Page 10: Table Of Contents
System Schematic ..........................21 Oil circuit .............................. 22 Air circuit .............................. 22 System control ............................. 22 5.5.1 System control L55-80 ........................22 5.5.2 System control L55RS-L75RS ...................... 23 6 Transport and installation ..........................26 Transport ............................. 26 Installation ............................27 7 Preparations for commissioning ........................ - Page 11 12 Annex ................................56 12.1 Technical specifications ........................56 12.1.1 USA/CANADA version L55-L80 A - air cooled ................56 12.1.2 USA/CANADA-Version L55 RS A - air cooled ................57 12.1.3 USA/CANADA version L75RS A - air cooled ................58 12.2 Layout plan ............................
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Page 12: Safety Regulations
Safety regulations 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 13: Particular Dangers Associated With Compressed Air
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 and always wear suitable eye protection. - Page 14 Danger Safety measure required Compression results in high The system should be set up such that hazardous mixtures (inflammable temperatures. Risk of explosion from solvent vapors etc. but also dusts and other dangerous or toxic materials) drawn in materials. 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
4.3 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: Dangers Present When Loading/Moving Machines
4.5 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 17: Dangers Resulting From Neglecting To Perform Maintenance
4.7 Dangers resulting from neglecting to perform maintenance Danger Safety measure required Components of importance to safety Observe the setting, maintenance, and inspection work and intervals stipulated in the operating manual, including information about the wear over time. replacement of parts / partial sections. This work may only be carried out by specialists. -
Page 18: Dangers During Maintenance And Repairs
Contact your Gardner Denver agent. removed. If you maintain the compressor and have not been trained 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: Dangers Resulting From Conversion Work/Modifications On The Machine
4.9 Dangers resulting from conversion work/modifications on the machine Danger Safety measure required Genuine parts are designed especially No alterations, additions, or modifications to the machine may be carried out for the machine. Modifications may without the approval of the manufacturer. Unauthorized modifications to the interfere with safety equipment or give machine are prohibited for reasons of safety. -
Page 20: Design And Functioning
Design and functioning Design of the unit 5.1.1 Design of air-cooled units August 20, 2018... - Page 21 Fig. 2 1 Intake filter 14 Air cooler 27 Final compression pressure 2 Suction regulator 15 Fine oil separator extraction sensor 3 Electric motor 16 Oil temperature regulator 28 Opening for lifting equipment 4 Screw compressor 17 Cooling fan 29 Fan guard 5 Pressure reservoir 18 Cool air inlet filter mat 30 Filter mat, cool air inlet, switch...
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Page 22: Design Of Water-Cooled Units
1 Intake filter 16 Oil temperature regulator 30 Filter mat, cool air inlet, switch 2 Suction regulator 17 Cooling fan cabinet (only L55 RS - L75RS) 3 Electric motor 18 Cool air inlet filter mat 31 Condensate connection (integrated 4 Screw compressor... -
Page 23: System Schematic
System Schematic Switching point: Switching point: 50 mbar/0.725 PSI 50 mbar0.725 PSI Opening pressure: 4.5 bar Idling pressure approx. 1.5 bar/21.8 PSI Pressure regulator output pressure: 2 bar/29 PSI Orifice diameter: 1.1 mm/0.043“ Start of opening: 55°C, 70°C Orifice diameter: 13 mm/0.52“... -
Page 24: Oil Circuit
Oil circuit 5.5.1 System control L55-80 The oil flows from the pressure reservoir (- 6 -) into the Standstill of the system oil thermostat (- 16 -). With oil temperatures < 131 °F · the oil flows via the by-pass of the oil cooler directly into... -
Page 25: System Control L55Rs-L75Rs
5.5.2 System control L55RS-L75RS Automatic operation (open-close operation) · Standstill of the system When the pressure reaches the upper switching point set on the system pressure sensor (- 28 - · If the plant is shut down, the suction controller (- 2 -) (B1)), solenoid valves (- 19 - (Y1) and - 20 - (Y4)) is closed by a pressure spring at the adjusting are de-energized. - Page 26 Controlled operation (speed control) · When the pressure at the system pressure sensor (- 28 - (B1)) does not fall to the set lower switching The speed is controlled with the help of a PI controller point within the set motor run-on time (e.g. 120 implemented in the control software, which regulates seconds), the drive motor (- 3 -) and the cooling fan the motor speed in dependence upon the demand for...
- Page 27 Fig. 5 August 20, 2018...
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Page 28: Transport And Installation
Transport and installation Transport 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. · Always observe the safety notes in Section 4.5 of the user manual. -
Page 29: Installation
6.2 Installation Proper ventilation has a considerable effect on the service life and the performance of a compressor. DANGER Once the compressor has been installed, the R-clips Always observe the safety notes in Section (- 1 - Fig. 8) can be removed from the hinge pins 4 of the user manual. -
Page 30: Preparations For Commissioning
(over 16.4 ft, more than one bend, filter cartridges, screens, etc.), please contact your technical adviser. Gardner Denver screw compressors are rated for ambient temperatures and cooling temperatures of 35.6 °F to 104 °F. In the case of temperatures other than the above limiting values, please consult your technical adviser. -
Page 31: Compressed-Air Connection
Compressed-air connection 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 customer’s existing compressed-air system, check that the necessary operating temperatures, operating pressures as well as the necessary connecting flange or connecting thread are appropriate and in perfect working order. -
Page 32: Water Connection For Water-Cooled Units
This data is based on fresh water and the cooling-water · Cooling water must not be discharged quality recommended by Gardner Denver (see indiscriminately into public waste-water Section 7.3.1). Please contact Gardner Denver if the and drain systems. Uncontrolled cooling-water data diverges from this. overflow of oil-separator basins into... -
Page 33: Limit Values Of The Constituent Elements In Water
7.3.1 Limit values of the constituent Electrical connection elements in water (USA/CANADA Version only) NOTICE DANGER The information set out below is intended for Risk of strong damages and fire on the guidance and may differ under certain electric power components. conditions of operation. - Page 34 To establish an electrical connection, proceed as follows: Route the supply cable (-1 - Fig. 12) through the cable gland on the switch cabinet and tighten screws. Connect the supply line to the connecting terminals as shown in the circuit diagram. Fig.
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Page 35: Check Setting Of The Fan Protection Switch (Only For L55Rs-L75Rs)
The control-power transformer is factory-preset to the Notes on the table: rated voltage. However, practice has shown that the Ultimately the type of cable you use, its length and actual supply voltage often differs from this value. installation conditions (temperature, accumulation) are outside the scope of our knowledge. -
Page 36: Sound Pressure Level
(- 3 - Fig. 14) and “minimum oil level” (- 4 - Fig. 14) marks on the oil container. · If required, top up oil. Use Gardner Denver oil only. · Close the oil filler cap (-1- Fig. 14) firmly. -
Page 37: Commissioning
GD Pilot TSoperating manual). NOTICE · Only L55-L80: Temporarily remove the panel in order When the compressor system is connected to a to check the direction of rotation. See (-1- Fig. 15) for power source for the first time, always check... - Page 38 Fig. 15 1 Drive motor direction of geared compressors Fig. 15 c – Water-cooled units 1 Cooling air intake 2 Cooling air outlet 3 Arrow “direction of rotation for compressor“ (direction of rotation may deviate from this representation) NOTICE Fig. 15 a For switching the compressor off “normally”, 1 Drive motor direction with direct drive use only the stop push-button (- 3 - Fig.
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Page 39: Putting A Decommissioned Compressor Back Into Operation
If the compressor has been in storage for longer than 2 years, please contact an · Check the oil level in the pressure reservoir authorized Gardner Denver Distributor prior to (also see Section 7.5) start-up. · Open shut-off valves between the screw compressor, reservoir and pipe. -
Page 40: Commissioning After Malfunction
8.5 Commissioning after malfunction NOTICE Do not switch the screw compressor on repeatedly without having rectified the malfunction, since this may cause considerable damage to the machine. Re-start after an automatic shutdown due to a malfunction as follows: · Faults are shown as text in the compressor control GD Pilot "fault memory"... -
Page 41: Storage Of Compressors
Storage of compressors 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 42: Service And Maintenance
(112kW) You can also have this maintenance work Severe Continuous Up to 9 Months performed by our trained technicians. Please ask your Gardner Denver distributor for a Operation 150 HP (112kW) maintenance contract. Above 6 Months 10.2 Maintenance Electric Motor... -
Page 43: Maintenance And Inspection Schedule
10.3 Maintenance and inspection Intervals are valid for normal industrial environments and operating conditions. If there is some uncertainty, schedule set the oil change interval by performing oil analysis. DANGER In the case of a very dirty atmosphere, the cleaning intervals have to be shortened as required. - Page 44 Every 4000 hours operation or 12 months 1. Visually check for leakage on the shaft seal, replace as required. See the parts lists for the kit part number and for the tool kit part number. The tool kit is required to change the oil seal. If the oil seal is a lip seal, the wear sleeve must always be replaced.
- Page 45 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 £...
- Page 46 £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £ £...
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Page 47: 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 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 Oil Filter Cartridge
· The oil level must lie between the “maximum oil level” (- 4 - Fig. 17) and “minimum oil level” (- 5 - Fig. 17). · If necessary, top up the oil. Changing times for lubricants 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... -
Page 49: 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 50: Change Of Air Intake Filter
· Pivot the reservoir cover 180°. · Remove the used fine oil separator (- 1 - Fig. 20). · Clean all seals and if necessary remove and clean the O-ring. · Install a new fine oil separator. · Pivot the reservoir cover back to the starting position. -
Page 51: Pressure Relief Valve
10.8 Pressure relief valve DANGER A defective pressure relief valve may result DANGER in pressure that is too high, breaking open When checking pressure relief valve there is parts of the system and causing serious or an explosive release of pressure. fatal injury. - Page 52 Fig. 23 Check the control transformer setting as follows: · Switch the unit on as described in Chapter 8.4. · Check the control transformer output voltages while operating under load. Several tapping points are provided for this purpose (see circuit diagram). ·...
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Page 53: Screw Connections
10.10 Screw connections The screw connections of the air, oil, and water circuits have to be checked and, if required, re-tightened according to the maintenance schedule. Check the hose and piping for unsealed areas. 10.11 General maintenance and cleaning WARNING Danger when cleaning system parts with compressed air: Small parts propelled at high speed by compressed air can penetrate... -
Page 54: Clean Dirt Interceptor (Only For Water-Cooled Units)
10.13 Clean dirt interceptor (only for water-cooled units) DANGER 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! Fig. 25 Fig. 27 1 Dirt interceptor 2 Cooling water solenoid valve 3 Manual regulating valve Lock water inflow and water outflow on the compressor. -
Page 55: Inspection Intervals For Pressure Reservoir And Electrical Installations
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 56: Trouble-Shooting
Deactivate remote control/timer Mains pressure exceeds the lower Wait until the mains pressure has fallen below the lower switching point switching point (L55-80) or the prescribed pressure (L55RS-L75RS) Suction regulator only closes part way, Make the suction regulator viable, Unit stops during the... - Page 57 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 58: Annex
Annex 12.1 Technical specifications 12.1.1 USA/CANADA version L55-L80 A - air cooled Technical data 60 Hz Nominal pressure psi g Maximum operating pressure psi g Minimum operating pressure psi g Ambient temperature -min / max °F 34...113 FAD at nominal pressure 380.80... -
Page 59: Usa/Canada-Version L55 Rs A - Air Cooled
12.1.2 USA/CANADA-Version L55 RS A - air cooled Technical data 60Hz L55 RS Maximum operating pressure psi g 145.0 Minimum operating pressure psi g 75.0 Ambient temperature min. / max. °F 34...113 at min. speed at max. speed 110 psi g 85.5... -
Page 60: Usa/Canada Version L75Rs A - Air Cooled
12.1.3 USA/CANADA version L75RS A - air cooled Technical data 60Hz L75RS Maximum operating pressure psi g 190.0 Minimum operating pressure psi g 75.0 Ambient temperature min. / max. °F 34...113 at min. speed at max. speed 110 psi g 79.4 475.5 130 psi g... -
Page 61: Layout Plan
12.2 Layout plan air-cooled variant water-cooled variant (all dimensions in mm) Fig. 28 1 Feed cable entry 10 water outlet (hot) (only for water-cooled variant) 2 Cool air outlet inside thread EN 10226-1 Rp 1" 3 Compressed air connection with male screwed thread + Adaptor 1"... - Page 62 (all dimensions in mm) Fig. 29 August 20, 2018...
- 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 Deutschland Tel. ++49 (0)6761 832-0 Fax ++49 (0)6761 832-409...