Related Manuals for Gardner Denver L15
Summary of Contents for Gardner Denver L15
- Page 1 Original Operating and Service Manual Screw Air Compressor L15 - L22 L15 RS - L22 RS ● Id. no. ZS1138156 / 00 - April 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
War nin g -Pr o hibi ti on - M an dat or y Lab el I nf or m ati on 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
2. Preface Compressor Information Maintenance and Care Gardner Denver screw compressors are the result of Proper maintenance and care are necessary to ensure many years of research and development. This that the screw compressor fulfills the requirements background and a high-quality standard ensure that the made of it. - 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
Dangers resulting from conversion work/modifications on the machine.............. 17 5 Design and functioning ..............................18 Design of the unit ..............................18 5.1.1 Design of the unit - L15 - L22, L15 RS -L22 RS ..................18 Schematic diagram ..............................19 Oil circuit .................................. 20 Air circuit .................................. 20 System control................................. - Page 11 Fault messages............................35 9.10 Menu structure (only L15- L22) (values are examples) ..................36 9.11 Menu structure (only L15 RS - L22 RS) (values are examples) ................37 10 Service and maintenance ..............................38 10.1 Maintenance recommendations ..........................38 10.2 Maintenance electric motor ............................
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Page 12: Safety Regulations
4. Safety regulations Safet y r eg ula tio ns 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: Dangers Present When Loading/Moving Machines
4. Safety regulations 4.4 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. Safety regulations 4.6 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 wear over time. stipulated in the operating manual, including information about the replacement of parts / partial sections. -
Page 18: Dangers During Maintenance And Repairs
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: Dangers Resulting From Conversion Work/Modifications On The Machine
4. Safety regulations Danger Safety measure required Risk of fire with welding work Never weld or carry out other work which requires heat near the oil system. Pressure reservoir or components and pipes containing oil have to be drained completely and cleaned, for example by means of a steam jet, before beginning such work. -
Page 20: Design And Functioning
5. Design and functioning Desig n a n d f un cti oni ng Design of the unit 5.1.1 Design of the unit - L15 - L22, L15 RS -L22 RS a L15 - L22, L15 RS - L22 RS Fig. 2... -
Page 21: Schematic Diagram
6 Pressure reservoir 19 Filter mat cooling air inlet 7 Fine separator 20 Orifice 8 Oil filler cap 21 Check valve 9 Oil drain 22 Frequency converter 10 Oil-level indicator (only L15 RS-L22 RS) 11 Oil filter R1 Motor temperature... -
Page 22: Oil Circuit
(- 2 - Fig. 3) is closed, a vacuum pressure occurs in the intake connection. 5.5.1 System control L15-L22 Excess pressure of approx. 22 PSI is produced in the Standstill of the system pressure reservoir at the same time. -
Page 23: System Control L15 Rs-L22 Rs
5. Design and functioning Automatic operation (open-close operation) 5.5.2 System control L15 RS-L22 RS When the pressure reaches the upper switching • Standstill of the system point set on the network pressure sensor (-7- Fig. 4), When the system is at rest the suction regulator •... -
Page 24: Hood (Opening/Closing)
5. Design and functioning Speed control operation Hood (opening/closing) Speed is controlled using a software-implemented PI The compressor is provided with a detachable metal regulator that adapts the RPMs according to the need hood that allows easy access to all parts that are for compressed air. -
Page 25: Transport And Installation
Weights Transport The values listed below are approximate values, they refer to a screw compressor unit including oil fill: 335 kg 361 kg 367 kg L15 RS 365 kg L18 RS 381 kg L22 RS 386 kg Fig. 6 DANGER... -
Page 26: Installation
6. Transport and installation Proper ventilation has a considerable effect on the Installation service life and the performance of a compressor. A = 19.7“ B = 31.5“ Fig. 7 DANGER Always observe the safety notes in Section 3 of the user manual. Pay attention to the weight-bearing capacity of the ground. -
Page 27: Preparations For Commissioning
The cooling air volume required by these screw compressors is as follows: L15-L22 60-Hz: approx. 1942 cfm L15 RS-L22 RS 50/60 Hz: approx. 1659 cfm If conditions are not favorable, we recommend the installation of venting ducts. However, the velocity of the cooling air should not exceed 11 mph. -
Page 28: Compressed Air Connection
7. Preparations for commissioning For this you should use a flexible connection Compressed air connection (e.g. compressed air hose, compensator). Warning Connection: sleeve G 1" (1” NPT) A defective connection to the compressed NOTE air system may jeopardize safe operation of After-coolers, separators, collecting reservoirs the compressed air system. -
Page 29: Electrical Connection
Recommended supply cable diameters and fuses for multi-wire cables or three current-carrying conductors in raceway based on 86 °F ambient temperature Compressor type Supply Installed Fuse(s) Line cross section voltage nominal motor protection conductor rated power (slow-blow fuse) class J 140°F 167°F 194°F [HP] 60-Hz-compressors L15 RS L18 RS L22 RS... -
Page 30: Check The Control Transformer Setting
7. Preparations for commissioning 7.3.1 Check the control transformer Electric motor fasteners for secure setting transportation Fasteners used for securing the electric motor (-1- Fig. DANGER 12) during transportation must be removed prior to High Voltage – Hazard of Shock, Burn, or commissioning. -
Page 31: Oil Level Check
“maximum oil level” mark. (For oil filling also see Sections 10.4 and 10.15) Speed-controlled compressors dB(A) 50 Hz/ 60 Hz L15 RS L18 RS L22 RS Subject to technical revision. Fig. 13... -
Page 32: Commissioning
8. Commissioning Com m issio ni ng First commissioning is carried out as follows: First commissioning Remove transport guards (see Section 7.4, Fig. 12) DANGER Fill oil in the pressure vessel up to “maximum oil • level” mark. (This applies to compressor systems The rotational direction of the motor can which are delivered without having been filled with only be checked with the casing open. -
Page 33: Routine Commissioning
8. Commissioning For routine commissioning, proceed as follows: Check oil level in the pressure reservoir (see also • Section 7.5). Open shut-off valves between the screw • compressor, reservoir and pipe. Switch on the power supply master switch. • Once the power supply has been switched on, the •... -
Page 34: Control System
9. Control system Contr ol s yst em Status indicator (display / light General signals) This Section is used to quickly commission the unit. The control system is explained in detail in the separate The control system is fitted with a three-row display. GD PILOT operating instructions. -
Page 35: Displaying / Changing Values
[ FAULT MEMORY ] [ TIMER CONTROL ] 9.5.2 Setting network pressure [ LIMIT VALUES ] [OPTIONAL IN-/OUTPUTS] (only L15 - L22) Enter a sub-menu by pressing the Max. network pressure: Again here you can use the ... -
Page 36: Setting Line Pressure (Only L15 Rs - L22 Rs)
9. Control system 9.5.3 Setting line pressure (only L15 RS - You can now correct (increase or decrease) this value L22 RS) using . Then confirm the value set by pressing key. Speed is controlled with the aid of a PI controller implemented in the software and is matched to the demand for compressed air. -
Page 37: Switching Off The Unit
9. Control system Switching off the unit The unit is switched off by pressing the key on the GD PILOT. However the unit will only stop after a 30-second soft-stop. The soft-stop is preset to protect the compressor. NOTE The unit may only be shut down using the emergency off button in real emergencies. -
Page 38: Menu Structure (Only L15- L22) (Values Are Examples)
9. Control system 9.10 Menu structure (only L15- L22) (values are examples) + TOTAL RUNNING 12345h [MAINTENANCE SCHED.] LOADED HOURS 10987h + AIR FILTER IN 2000h OIL FILTER IN 2000h ... -
Page 39: Menu Structure (Only L15 Rs - L22 Rs) (Values Are Examples)
9. Control system 9.11 Menu structure (only L15 RS - L22 RS) (values are examples) + TOTAL RUNNING 12345h [MAINTENANCE SCHED.] LOADED HOURS 10987h + AIR FILTER IN 2000h ... -
Page 40: Service And Maintenance
Only perform checks and maintenance after To make this easier for you, the system comes with the observing the following: “Maintenance and Inspection Book for Gardner Denver Compressors”, in which you can enter maintenance • Press the STOP button on the control work in the specified intervals. -
Page 41: Service Check List
10. Service and maintenance Every 4000 hours operation or 12 months 10.3.1 Service Check List 1. Visually check for leakage on the shaft seal, replace Every 8 hours operation as required. See the parts lists for the kit part 1. Check air/oil reservoir oil level, add oil if required. number and for the tool kit part number. - Page 42 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 43: 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 44: Change Of Oil Filter Cartridge
10. Service and maintenance Wait at least 5 minutes for the oil to settle and for • the air to disperse Check oil level (see Section 7.5) • The oil level must be between the maximum level • (- 4 - Fig. 16) and minimum level (- 5 - Fig. 16) marked on the oil reservoir. -
Page 45: Change Of The Fine Separator Cartridge
10. Service and maintenance Where such conditions exist the filter element may require changing more frequently. 10.6 Change of the fine separator cartridge 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... -
Page 46: Change Of Air Intake Filter
10. Service and maintenance Change the oil fine separator as follows: Switch the screw compressor unit off and make sure • that it is depressurized and no voltage is supplied. Unscrew the fine separator cartridge (-1- Fig. 18) • using an appropriate tool Dispose of the fine separator cartridge according •... -
Page 47: Pressure Relief Valve
10. Service and maintenance 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 parts of the system and causing serious or is an explosive release of pressure. fatal injury. -
Page 48: Connecting Terminals In The Switch Cabinet/Control Transformer Setting
10. Service and maintenance 1 Cover cap NOTICE 2 Motion screw 3 Lock nut Making incorrect settings to the control 4 Holder transformer poses a risk to the trouble-free 5 V-belt set operating of the system. 6 Rotational axis Checking the setting of the control transformer is part of commissioning and part of regular The V-belt preload needed is specified by the weight of inspection/maintenance because the supply... -
Page 49: Screw Connections
1 Filter mat cooling air intake 2 Mounting bolt 3 Bottom access panel 4 Intake filter (only L15 RS - L22 RS) 5 Outlet filter (only L15 RS - L22 RS) a) Perform filter mat change as follows: * Remove mounting bolt (- 2 - Fig. 23). -
Page 50: Test Period For Pressure Reservoir And Electrical Installation
Intake filter and outlet filter of switch cabinet characteristics correspond to the expected operating (only L15 RS - L22 RS): conditions. * Open the louver grilles of the intake filter Avoid mixing different lubricating oils, i.e. when (-4- Fig. -
Page 51: Trouble-Shooting
11. Trouble-shooting Tr ou ble -s ho oti ng 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 Pressure reservoir not depressurized Wait until depressurized Electric motor defective Check connections, winding, etc. - Page 52 11. Trouble-shooting Malfunction Possible cause Remedy Unit switches off Ambient temperature too high Ventilate compressor room Electric motor defective Check electric motor and thermistor Fan defective Check/replace fan Cross section of the electric supply Measure power requirement, lines too small if necessary, replace lines Power requirement too high Oil fine separator clogged,...
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Page 53: Annex
12. Annex Ann ex 12.1 Technical data USA/Canada version L15-L22 60 Hz Technical data L15-L22 ; 60 Hz Maximum operating pressure psi g Minimum operating pressure psi g 73.0 Ambient temperature °F + 33.8 / + 113 Flow 91.5 85.5 65.1... -
Page 54: Technical Data Usa/Canada Version L15 Rs
12. Annex 12.2 Technical data USA/Canada version L15 RS Technical data 50Hz / 60Hz L15 RS Maximum operating pressure psi g Minimum operating pressure psi g Ambient temperature °F + 34 / + 113 Operating pressure psi g min. max. -
Page 55: Technical Data Usa/Canada Version L18 Rs
12. Annex 12.3 Technical data USA/Canada version L18 RS Technical data 50Hz / 60Hz L18 RS Maximum operating pressure psi g Minimum operating pressure psi g Ambient temperature °F + 34 / + 113 Operating pressure psi g min. max. min. -
Page 56: Technical Data Usa/Canada Version L22 Rs
12. Annex 12.4 Technical data USA/Canada version L22 RS Technical data 50Hz / 60Hz L22 RS Maximum operating pressure psi g Minimum operating pressure psi g Ambient temperature °F + 34 / + 113 Operating pressure psi g min. max. min. -
Page 57: Layout Plan L15 - L22, L15 Rs - L22 Rs
C = Cool air outlet D = Oil drain E = Cool air outlet of switch cabinet (only L15 RS -L22 RS) F = Cool air intake of switch cabinet (only L15 RS -L22 RS) H = Feed cable entry... - Page 60 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...