Gardner Denver L Series Original User And Service Manual
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- Page 1 L-SERIES FRAME 6 BASE MOUNTED COMPRESSOR Original User and Service Manual MODELS: L160-290C 215, 270, 335, 400 HP LRS160-290C 160, 200, 250, 290 kW 13-25-640 Version 00 November 12, 2020 13-25-640 v00 Page 1...
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Page 2: Table Of Contents
TABLE OF CONTENTS FOREWORD ........................4 About these Operating Instructions....................4 Notes ............................. 4 Intended Use ..........................5 Foreseeable Misuse ........................6 Service ............................7 Rating Plate ........................... 7 SAFETY REQUIREMENTS ....................8 General Safety Instructions ......................8 Warnings about Special Types of Hazard ..................8 Protective and Safety D evices ...................... - Page 3 COMMISSIONING AND OPERATION ................38 First Commissioning ........................38 Check the Direction of Rotation of the Drive Motor ..............39 Normal operation ........................40 Display of the Compressor Controller ..................40 Routine Commissioning ......................41 Commissioning after extended downtime ................. 42 Commissioning after a fault ......................
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Page 4: Foreword
FOREWORD Gardner Denver screw compressors are the result of many years of research and development. This background and a high-quality standard ensure that the screw compressors we manufacture have long service lives with higher reliability and economic operation. Naturally, we also ensure that strict environmental protection requirements are met. -
Page 5: Intended Use
Guarantee Gardner Denver is not liable for the functional safety of the compressor if any actions are taken that are contrary to the intended use, or if used for any other purpose than those listed in the operating instructions. Gardner Denver refuses any guarantee or liability for cases of: ... -
Page 6: Foreseeable Misuse
Depending on the operating pressure, ambient humidity, and ambient temperature at which the compressor is operated, the permissible altitude of the installation site is limited. The permissible site altitude is determined by Gardner Denver for each individual case in consultation with the customer. Pressure equipment... -
Page 7: Service
Service In case of questions or problems with compressor, consult your Gardner Denver representative. Trained technicians provide fast, technically accurate assistance. For questions In case of questions or spare parts orders, please provide the model, identification, and year built, as indicated on the model rating plate. -
Page 8: Safety Requirements
Every person involved with the operation, maintenance, and repair of the compressor must read and follow the safety requirements. Gardner Denver accepts no responsibility for material damage or injuries that arise from non- observation of safety conditions or the failure to observe normal levels of care and attention, even where this is not expressly stated in these operating instructions. -
Page 9: Protective And Safety Devices
Noise The sound pressure level without the sound-proofing enclosure is approx. 95 dB(A). Remaining for long periods alongside the compressor without its sound-proofing enclosure can result in irreversible hearing impairment. Only operate the compressor without the sound- proofing enclosure during test runs. Wear personal hearing protection. -
Page 10: Residual Risks
Protective covers and enclosure panels The cooling air fans are covered with protective mesh. The coupling between the drive and the compressor is protected by a mesh guard. The housing of the compressor is designed so that any broken parts that may be thrown off are retained within the compressor. -
Page 11: Safety Symbols
Safety Symbols The safety symbols (hazard warning signs) can be used in the operating instructions and in the environment around the compressor. Safety Symbol Meaning Application / Behavior General hazard Warning of a general hazard. Follow the warning and proceed with the required caution (e.g., protective clothing) and care. - Page 12 Safety Symbol Meaning Application / Behavior Secure against being Secure against being switched back on again during electrical switched on again work Secure against being switched back on again when working on rotating parts Secure against being switched back on again during repair work Label for areas with elevated sound pressure level.
- Page 13 Safety Symbol Meaning Application / Behavior Warning of a crushing Warning of crush hazards on a piece of equipment (e.g., a hazard machine) or structural components (e.g., covers, enclosures, guards, fences) during transport. Working at the labeled workstations requires increased vigilance.
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Page 14: Transport And Installation
Transport and Installation Transport A suitable forklift with sufficiently long forks must be used to transport the compressor. Dependent on type, the compressor weighs up to 4,700 kg / 10,362 lbs. Insert the forks only at the lifting points provided. The compressor, even in its packed state, may not be transported by crane. -
Page 15: Special Work
Special Work Organizational The maintenance work and intervals are specified in the operating manual, including information about replacing parts/partial equipment. Maintenance and repair work may be performed only under supervision, or by a person qualified for this work. Secure an ample working area, if needed. Workshop equipment suitable for the work is absolutely required to perform maintenance and repair work. -
Page 16: Modifications And Changes To The Machine
Original parts are specially designed for the machine. We explicitly give notice that parts and special equipment not provided by Gardner Denver are also not approved by Gardner Denver. The installation and/or use of such products can therefore degrade active and/or passive safety. -
Page 17: Construction Of The Compressor
Construction of the Compressor Air Cooled Figure 3-1 Air Cooled Intake Filter 16. Oil Temperature Regulator 20. Base Frame Suction Regulator 21. Control Panel Electric Motor 22. Emergency Stop Button Screw Compressor 23. Switch Cabinet Oil Reservoir 25. Final Compression Pressure Sensor Fine Oil Separator 27. - Page 18 Air Cooled Figure 3-2 Air Cooled Oil Level Indicator 17. Cooling Fan Oil Cooler 18. Cooling Air Inlet Filter Pad Pressure Relief Valve 19. Compressed Air Outlet Minimum Pressure and Non 24. Cable Entry Return Valve Air Cooler 26. System Pressure Sensor 13-25-640 v00 Page 18...
- Page 19 Water Cooled Figure 3-3 Water Cooled Intake Filter 21. Control Panel Suction Regulator 22. Emergency Stop Button Electric Motor 23. Switch Cabinet Screw Compressor 24. Cable Entry Oil Filter 28. Fork Lift opening Cooling Air Inlet Filter Pad 13-25-640 v00 Page 19...
- Page 20 Water Cooled Figure 3-4 Water Cooled Oil Reservoir Cooling Fan Fine Oil Separator Compressed Air outlet Base Frame Oil Fill Final Compression Pressure Sensor Oil Drain System Pressure Sensor Oil Level Indicator 11. Oil Cooler Pressure Relief for Cooler Cooling Water Inlet 12.
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Page 21: System Schematic
System Schematic Figure 3-5: System schematic 13-25-640 v00 Page 21... - Page 22 System Schematic Intake Filter Solenoid Valve (Y1) Intake Regulator Pressure Relief Valve (Y4) 2.1. Actuator Oil Thermostat 2.2. Throttle Valve Oil Level Indicator Electric Motor Intake Filter Monitor (S7) *) Airend Compressor Fine Separator Monitor (S6) Final Compression Temperature Sensor Cooling Air Fan (Oil Cooler) Speed Regulated *) (R2) Cooling Water Temperature Monitor (S14)
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Page 23: Oil Circuit
Oil Circuit The oil flows from the pressure reservoir (-6-) into the oil thermostat (-21-). With oil temperatures <131°F, the oil flows via the by-pass of the oil cooler directly into the oil filter (-11-) and is then injected into the screw compressor (-4-). - Page 24 Stopping the system Solenoid valve (-19- (Y1)) is de-energized when the STOP button on the operating panel of the compressor controller touch screen is pressed. The upper control space of the actuator (-2.1-) is ventilated by the solenoid valve (-19- (Y1)), the pressure spring in the actuator causes the throttle valve (-2.2-) in the intake regulator to close.
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Page 25: Heat Recovery L160-L290
Heat Recovery L160-L290 WARNING Contamination with Legionella Health hazard with open-loop cooling systems. Continuous monitoring of water quality and germ count in the cooling circuit. Heat recovery function schematic Figure 3-6 1. Heat recovery 2. Temperature regulator with switch-off function 3. -
Page 26: Transport And Installation
When received, check for shipping damage. 1. Check the delivery for visible damage. 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 / 10,362 lbs (gross). - Page 27 NOTICE Property damage Do not lift up or lash the compressor system by its enclosure. Note fork length of forklift. Transporting the compressor Figure 4-1 Lifting points Figure 4-2 1. Wire pin 2. Hinge pin Before Transporting, the “R” Clips and doors must be removed as follows: Remove bolts from the transport pallet.
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Page 28: Storage
Damage to property due to exceeding the permissible temperature range Where there is a risk that the permissible temperature limits of +2°C to +65°C / +36°F to +149°F could be exceed or underrun, contact Gardner Denver. Corrosion protection All compressors are protected at the factory against corrosion for shipping and short-term storage prior to commissioning. - Page 29 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.
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Page 30: Preparing For Commissioning
Figure 4-4 1. Cooling Air Intake, Motor 2. Cooling Air Intake, Oil Cooler 3. Cooling Air Intake, Air Cooler 4. Air Intake for Airend 5. Cooling Air Intake, Starter Box 6. Cooling Air Exhaust PREPARING FOR COMMISSIONING Piping Remove all blank flanges, stoppers, caps, and desiccant bags before installing the piping. Distributor piping and pipe connections must be the correct size and designed for the operating temperatures and pressures. -
Page 31: Compressed Air Connection
Compressed Air Connection Figure 5-1 Compressed Air Connection 1. Compressed Air connection 2. Thread identification of compressed air connection 3. Cooling Water Outlet 4. Cooling Water Inlet WARNING Risk of injury A defective connection to the compressed-air system may jeopardize safe operation of the compressed-air system. -
Page 32: Cooling Water Connection
Check the connection flange The pressure connection comprises a DIN / ANSI B16.5 flange. The connection is identified by a stamp on the outside of the flange plate: DN80, PN16 / 3"-8 NPT Read the connection ID. Ensure that the connection and the flange match each other. Connect the compressor to the compressed air network. - Page 33 This data is based on fresh water and the cooling-water quality recommended by Gardner Denver. Please contact Gardner Denver if the cooling-water data diverges from this. The flow of cooling-water for the water cooler at commissioning can be adjusted by means of a manual control valve.
- Page 34 NOTICE The information set out below is intended for guidance and may differ under certain conditions of operation. The total composition and the operating temperature are always decisive. Warranty claims may not be derived from this. Circulating Constituent elements of Pass- through water water / characteristic values...
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Page 35: Electrical Connection
The power supply to the compressor must be suitable for industrial equipment and must meet all requirements of 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. - Page 36 Electrically connect the compressor Figure 5-3 Electrical connection Install a customer supply line cover. Run the supply lines through the openings in the electrical enclosure (A). Connect the supply lines; see Detail A and wiring diagram. Tighten the cable screws. Variable speed units are supplied with terminal blocks to land incoming power conductors.
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Page 37: Check The Setting Of The Fan Overload Protection Switch(Es)
The oil level must lie between the “maximum oil level” and “minimum oil level” marks on the oil reservoir. If required, top up oil. Use Gardner Denver oil only. Close the oil filler cap firmly. -
Page 38: Commissioning And Operation
This ensures that the capacitors are functional and prevents them from being damaged. If the compressor has been stored for longer than 2 years, consult Gardner Denver. Perform initial commissioning as follows: ... -
Page 39: Check The Direction Of Rotation Of The Drive Motor
Check the Direction of Rotation of the Drive Motor Figure 6-1 Drive motor direction of geared compressors Figure 6-2 Drive motor direction of direct drive compressors Figure 6-3 Air Cooled Units Figure 6-4 Water Cooled Units 1. Arrow “direction of rotation for compressor” (direction of rotation may deviate from this representative). Temperature start-up protection The screw compressor unit will not start up if the ambient temperature is lower than 34°F. -
Page 40: Normal Operation
Normal operation 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. Then proceed as described in “First Commissioning”... -
Page 41: Routine Commissioning
Condensate Drain The condensate drain on the aftercooler is actuated via sensor control. Switching off Press stop button < O > on the control panel, not the Emergency Stop button. After shutdown, the compressor has a run on time of 30-50 seconds (soft stop). NOTICE The unit may only be shut down using the emergency stop button in real emergencies. -
Page 42: Commissioning After Extended Downtime
Property damage due to incorrect/unsuitable measures for fault clearing. If the solutions listed here are not sufficient to clear the fault. Contact Gardner Denver. For fault and warning messages that are displayed on the display of the electronic controller, follow the instructions in the chapter "Fault/warning"... - Page 43 Fault: Unit will not start Potential root cause Remedy Missing operating or control voltage Check fuses, main disconnect switch, and supply lines. Fault not acknowledged Acknowledge a fault in the electronic controller. Wait for depressurization. Screw compressor does not Pressure vessel not depressurized. start up when the vessel pressure is greater than the preset value.
- Page 44 Fault: Unit switches off. Potential root cause Remedy Water inlet temperature too high (for water- Check cooling water feed. cooled compressors only) Ambient temperature too high Ventilate the compressor room. Electric motor defective Check the electric motor and posistor. Fan is defective Check fans, replace if needed.
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Page 45: Maintenance And Service
Compliance with the specified maintenance interval and the careful performance of maintenance and care tasks are therefore mandatory. Help is available from your responsible Gardner Denver representative, who can create an individualized maintenance plan. - Page 46 Protection measures for safe maintenance (Safety routine) For all maintenance work, if not expressly otherwise stated: 1. Lockout and Tagout. 2. Allow the compressor to come to a stop. 3. Wait for automatic pressure relief. 4. Close the shutoff valve (customer provided) in the supply line. 5.
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Page 47: Service
(and replaced even in case of minor damage). When assembling always use new seals. Service For any spare parts needed, the local Gardner Denver branch or representative retailer is available. The local Gardner Denver subsidiary or the responsible dealer is available for any spare parts requirements. - Page 48 WARNING Risk of burns/scalding Risk of burns/scalding due to escaping hot oil (oil mist) / hot compressed air. Wear suitable protective clothing. Slowly unscrew the knurled cap. Do not unscrew the knurled cap too far out of the housing. ...
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Page 49: Routine Maintenance
All maintenance, repairs, and service work performed on the compressor must be documented. Service and maintenance work should be performed by the local Gardner Denver representative. Cleanliness The compressor room and the environment of the compressor must always be kept clean. -
Page 50: Maintenance Schedule
Maintenance Schedule DANGER High Voltage Hazard of shock, burn or death Work on the electrical equipment may be performed only by specialized electrical technicians. Only units with Variable Frequency Drives, there is a risk of electric shocks due to charged capacitors! Isolate the compressor and wait 10 minutes before touching any electrical parts. - Page 51 Maintenance Schedule Replace Oil Filter element Oil Sample Replace Lubricant * Replace Air Filter element Replace Air/Oil Separator Replace Cabinet Air Filter Pad Replace Control Box Filter (if app.) Check Air/Oil Reservoir oil level Check operation of the machine, is it loading and unloading Check discharge pressure and temperature Check control panel for advisory text messages Check Pressure Relief Valve...
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Page 52: Maintenance Work
Maintenance Work 8.6.1 Filter Mats Figure 8-3 Filter mats 1. Motor Cooling Air Inlet 2. Oil Cooler and Aftercooler Cooling Air Inlet 3. Suction Air Compressor Inlet 4. Control System Inlet Filter Replacement times for the filter pad 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 pad. -
Page 53: Switch Cabinet Inlet Filter
8.6.2 Switch Cabinet Inlet Filter Figure 8-4 Louvered Grille Figure 8-5 Filter Element Replacement Change inlet filter 1. Open the mesh cover on the intake filter. 2. Remove dirty filter. 3. Insert new filter. 4. Close louvered grille. Replacement times for the inlet filter elements The operating modes and the quality of the suction air (e.g. -
Page 54: Oil Change
8.6.3 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 55: Changing The Oil Filter Cartridge
The changing intervals can be found in the maintenance schedule. Perform oil changes as follows: Turn off the screw compressor unit, secure it against accidental restarts and make sure that the demister vessel is depressurized. Slowly open the oil screw plug to relieve the screw compressor of any residual pressure in the system. - Page 56 Figure 8-7 Oil filter 1. Oil filter The changing intervals can be found in the maintenance schedule. Replace the oil filter cartridge as follows: Switch off the screw compressor unit, secure it against an accidental restart and ensure that it is depressurized.
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Page 57: Oil Fine Separator
8.6.5 Oil Fine 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 58 Changing the oil fine separator The changing intervals can be found in the maintenance schedule. If the fine oil separator is monitored (optional), then a differential pressure that is too high will be shown in the control panel of the compressor controller. When the corresponding warning lights up, it is time to change the fine oil separator.
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Page 59: Air Filter
Changing times for the fine oil separator 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 SO2 and solvent vapors) have a strong influence on the filter lifespan (air filter, oil filter, fine separator). -
Page 60: Pressure Relief Valve
Changing intervals for air filter cartridge The operating conditions (e.g., coolant temperatures), the operating modes and the quality of the intake air (e.g., content of dust, content of gaseous foreign substances such as SO2 and solvent vapors, etc.) have a strong influence on the service life of the filters (air filters, water filters, fine separators). Where such conditions exist the filter element may require changing more frequently. - Page 61 Figure 8-10 Pressure Relief Valve 1. Pressure Relief Valve 2. Pull Ring The pressure relief valve has no user serviceable or repairable components. Testing the pressure relief valve The valve can be tested: 1. On a separate compressed-air system. 2. When raising the system operating pressure to its normal level. 3.
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Page 62: Connecting Terminals In The Switch Cabinet
The exact oil change schedule according to the actual operating conditions should be set by performing oil tests. 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 1(800) 682-9868. - Page 63 Motor Lubrication Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The following chart show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions. The following procedure should be used in regreasing: 1.
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Page 64: Appendix
In order to prevent renewed commissioning of the compressor or misuse by unknown persons, the compressor must be rendered unusable. The compressor is made unusable by removing the electronic controller. Consult Gardner Denver. Consumables and Auxiliary Materials The compressor contains approximately 120 liters / 31.7 gal of oil. -
Page 65: Disassembly
Disassembly WARNING Damage to health Risk of damage to health from consumables and auxiliary materials Consumables and auxiliary materials can cause irreparable damage to health, induce allergies, or irritate mucous membranes. Follow the locally applicable operating instructions and hazardous material safety data sheets when handling consumables and auxiliary materials. -
Page 66: Disposal
Remove the oil filter 1. Remove all oil filters in the lubrication system. Dispose of the filters. Oil filter Oil fine separator Remove the air filter 1. Remove all filter elements and filter mats. Dispose of filter elements and filter mats. ... -
Page 67: Installation Plan
Installation Plan Figure 9.1 Air-Cooled Unit (all dimensions in inches) 13-25-640 v00 Page 67... - Page 68 Figure 9.2 Air-Cooled Unit (all dimensions in inches) 13-25-640 v00 Page 68...
- Page 69 Figure 9.3 Water-Cooled Unit (all dimensions in inches) 13-25-640 v00 Page 69...
- Page 70 Figure 9.4 Water-Cooled Unit (all dimensions in inches) 13-25-640 v00 Page 70...
- Page 71 NOTES: 13-25-640 v00 Page 71...
- Page 72 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2020 Gardner Denver, Inc. Printed in U.S.A.