Related Manuals for Gardner Denver L30RS
Summary of Contents for Gardner Denver L30RS
- Page 1 Original User and Service Manual Screw Air Compressor L30 - L50 L30RS - L45RS ● Id. no. ZS1133367 / 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
1 Warning -Prohibition - Mandatory Label Information Warning -Prohibition - Mandatory 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 1 Warning -Prohibition - Mandatory Label Information Check and, if required, re-tighten connection terminals. Danger of electric shock from loaded condensers! Please always first disconnect the system from the power supply For further details, see the operating instructions. 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 pressure relief valve = xx bar (value task "xx"...
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Page 7: Preface
2 Preface Preface Fig. 1 Your Gardner Denver distributor Name: Address: ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Telephone: Fax: Contact: Spare Parts: Service:... -
Page 8: Compressor Information
Therefore, it is essential that the prescribed maintenance intervals are adhered to and that Gardner Denver will not guarantee the safe operation of maintenance and upkeep are done thoroughly, the machine/equipment if it is not handled in a way especially under difficult operating conditions. - Page 9 Gardner Denver replacement • parts alterations to the equipment. • The warrantee or liability terms of Gardner Denverʼs Terms and Conditions are not expanded by the foregoing. Any independent alterations to the compressor equipment/station or installing components which have not been approved by the manufacturer (e.g.,...
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Page 10: Table Of Contents
Cooling air volume/minimum cross .......................... 26 Compressed-air connection............................27 Electrical connection (USA/CANADA Version only)....................28 7.3.1 Check setting of the fan protection switch (only for L30RS-L45RS)............29 7.3.2 Checking the setting of the control-power transformer................. 29 Checking the Oil Level .............................. 30 Sound pressure level .............................. - Page 11 12 Annex ....................................50 12.1 Technical specifications............................50 12.1.1 North America version L30-L37........................50 12.1.2 North America Version L30RS ........................51 12.1.3 North America Version L37RS ........................52 12.1.4 North America version L45-L50........................53 12.1.5 North America version L45RS........................54 12.2...
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Page 12: Safety Regulations
4 Safety regulations Safety re gulations 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 temperatures. Risk of explosion from solvent vapors etc. but also dusts and other dangerous or toxic materials) drawn in materials. cannot be drawn 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 4.5 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 Safety regulations 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 wear over time. stipulated in the operating manual, including information about the replacement of parts / partial sections. -
Page 18: Dangers During Maintenance And Repairs
The system must be secured from being switched on. Seal off the main switch and remove the key and/or attach a warning sign to the main switch. L30RS-L45RS only: Danger of electric shock from loaded condensers! Always first disconnect the system from the power supply and wait another 10 minutes before touching the electrical components. - Page 19 4 Safety regulations Danger Safety measure required During the course of maintenance and Never weld any pressure reservoir or change it in any way. 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 20: Dangers Resulting From Conversion Work/Modifications On The Machine
4 Safety regulations 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 21: Design And Functioning
5 Design and functioning Design a nd functioning Design of the unit Fig. 2 1 Intake filter 13 Minimum pressure and non-return 24 Feed cable entry 2 Suction regulator valve 25 Final compression temperature 3 Electric motor 14 Air cooler sensor 4 Screw compressor 15 Fine oil separator extraction... -
Page 22: System Schematic
Final compression temperature 16 Compressed air after-cooler 29 Motor temperature (R1) sensor (R2) 18 Final compression pressure 32 RS frequency converter Pressure reservoir sensor (B2) (only L30RS-L45RS) Fine separator 19 Control valve (Y1) Oil draining 20 Control and blow-off valve (Y4) -
Page 23: Oil Circuit
5 Design and functioning Oil circuit System control The oil flows from the pressure reservoir (- 6 -) into the (See also operating instructions for the compressor oil thermostat (- 22 -). With oil temperatures < 131 °F control GD Pilot TS) 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 5. Design and functioning Stopping the system To de-energize the solenoid valves (- 19 - (Y1) and • - 20 - (Y4) ) press the OFF push-button on the keypad of the compressor control GD Pilot TS. The pressure control valve (- 2.2 -) in the suction •...
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Page 25: Manner Of Operation Of The Suction Regulator
5 Design and functioning 5.5.1 Manner of operation of the suction regulator Load running mode When switching over to delta connection the two upper control chamber of the actuator. The suction solenoid valves (7 (Y1) and 9 (Y4)) are supplied with regulator valve opens, the lower control chamber is bled power. -
Page 26: Transport And Installation
Shifting the system after it is lowered is not Hinge pin permitted. Weights The values listed below are approximate values, they refer to a screw compressor unit including oil fill: 2061 lbs L30RS 2039 lbs 2157 lbs L37RS 2099 lbs 2206 lbs 2356 lbs... -
Page 27: Installation
6 Transport and installation The screw compressor unit has to be leveled. The Installation system may not be run while on the transport pallet. DANGER A minimum distance from walls, other machines, etc. should be maintained so that there is sufficient Always observe the safety notes in Section clearance for maintenance and repair work (Fig. -
Page 28: Preparations For Commissioning
AIR CHANNEL INTAKE Fig. 10 1 Cool air intake 2 Cool air exhaust 3 Switch cabinet cool-air intake (L30RS-L45RS only) The cooling air volume required by these screw compressors is as follows: 2296 cfm INTAKE L30RS 2296 cfm... -
Page 29: Compressed-Air Connection
7 Preparations for commissioning 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 customerʼs 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 30: Electrical Connection (Usa/Canada Version Only)
NFPA 79 is inadmissible. • The electrical connection should be made by a qualified electrician. DANGER Only for L30RS-L45RS: There is a risk of electric shock from charged capacitors! • Disconnect the system from the mains and wait 10 minutes before touching Fig. -
Page 31: Check Setting Of The Fan Protection Switch (Only For L30Rs-L45Rs)
7.3.1 Check setting of the fan protection switch (only for L30RS-L45RS) NOTICE Check the setting of the motor protection switch in Incorrectly setting the control transformer poses... -
Page 32: Checking The Oil Level
(- 4 - Fig. 15) marks on the oil container. • Shut down the compressor, relieve the If required, top up oil. Use Gardner Denver oil only. • system of all pressure, disconnect, Close the oil filler cap (-1- Fig. 15) firmly. -
Page 33: Commissioning
Check settings of the fan motor protection switch • Rotating parts may lead to injuries, (only L30RS-L45RS) (see Section 7.3.1) e.g., cutting of finger or hand. Check the setting of the control-power transformer •... - Page 34 8. Commissioning Fig. 16 1 Drive motor direction of geared compressors Fig. 16 c 1 Cooling air intake 2 Cooling air outlet 3 Arrow “direction of rotation for compressor“ (direction of rotation may deviate from this representation) Fig. 16 b NOTICE 1 Drive motor direction with direct drive For switching the compressor off “normally”,...
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Page 35: Putting A Decommissioned Compressor Back Into Operation
The screw compressor unit will not start up if the final compression pressure is more than 11.6 PSI for L30-L50 or 29 PSI for L30RS-L45RS. Temperature start-up protection The screw compressor unit will not start up if the ambi- ent temperature is lower than 33.8 °F. -
Page 36: Commissioning After Malfunction
8. Commissioning 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 •... -
Page 37: Storage Of Compressors
9 Storage of compressors Stora ge of com press ors 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. -
Page 38: Service And Maintenance
If there is some uncertainty, powered. set the oil change interval by performing oil analysis. • Only for L30RS-L45RS: There is a risk of In the case of a very dirty atmosphere, the cleaning electric shock from charged capacitors! intervals have to be shortened as required. -
Page 39: 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 40 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 41: 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 42: Change Oil Filter Cartridge
10. Service and maintenance The oil level must lie between the “maximum oil level” • (- 4 - Fig. 18) 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... -
Page 43: Changing The Fine Oil Separator
10 Service and maintenance 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 44: Change Of Air Intake Filter
10. Service and maintenance 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. Screw the cheese-head screws (- 8 - Fig. 20) •... -
Page 45: Pressure Relief Valve
10 Service and maintenance 10.8 Pressure relief valve DANGER When checking pressure relief valve there is an explosive release of pressure. Failure to perform this operation in a safe manner or without safety equipment may result in personal injury or death. •... -
Page 46: Connecting Terminals In The Switch Cabinet/Control Transformer Setting
DANGER L30RS-L45RS: wait 10 minutes before touching • electrical components. The power capacitors need Only for L30RS-L45RS: There is a risk of this time to discharge. electric shock from charged capacitors! Change the control transformer setting. Fig. 14 •... -
Page 47: Screw Connections
10 Service and maintenance 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 48 (-A- Fig. 28) of the filter pad 2 Mounting bolts faces the air inlet side. 3 Sound-proofing element 4 Inlet filter (only L30RS-L45RS) Place the louver grille back onto the filter housing. • Changing times for the filter mat The operating modes and the quality of the suctioned air (e.g., dust content) has a strong influence on the...
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Page 49: 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 50: Trouble-Shooting
Pressure reservoir not depressurized Wait until depressurized Screw compressor does not start up, when reservoir pressure is > 11.6 PSI (L30-L50) or > 29.0 PSI (L30RS-L45RS) Electric motor defective Check connections, winding, etc. Compressor defective Turn the compressor manually; if required, replace Ambient temperature less than 33.8 °F... - Page 51 11 Trouble-shooting 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 52: Annex
12. Annex Annex 12.1 Technical specifications 12.1.1 North America version L30-L37 Technical Data 60Hz North America Nominal pressure psi g Maximum working pressure psi g Minimum working pressure psi g Ambient temperature - min / max °F 34...113 FAD at nominal pressure 203.7 187.5 154.3... -
Page 53: North America Version L30Rs
12 Annex 12.1.2 North America Version L30RS Technical Data 60Hz North America L30RS Maximum working pressure psi g 145.0 Minimum working pressure psi g 75.0 Ambient temperature min. / max. °F 34...113 at min. speed at max. speed 110 psi g... -
Page 54: North America Version L37Rs
12. Annex 12.1.3 North America Version L37RS Technical Data 60Hz North America L37RS Maximum working pressure psi g 190.0 Minimum working pressure psi g 75.0 Ambient temperature min. / max. °F 34...113 at min. speed at max. speed 110 psi g 51.9 241.7 130 psi g... -
Page 55: North America Version L45-L50
12 Annex 12.1.4 North America version L45-L50 Technical Data 60Hz North America Nominal pressure psi g Maximum working pressure psi g Minimum working pressure psi g Ambient temperature - min / max °F 34...113 FAD at nominal pressure 278.7 160.8 214.5 304.7 279.7... -
Page 56: North America Version L45Rs
12. Annex 12.1.5 North America version L45RS Technical Data 60Hz North America L45RS Maximum working pressure psi g 190.0 Minimum working pressure psi g 75.0 Ambient temperature min. / max. °F 34...113 at min. speed at max. speed 110 psi g 51.9 280.2 130 psi g... -
Page 57: Layout Plan
12 Annex 12.2 Layout plan L30-L50 (all dimensions in mm) Fig. 29 A Compressed air connection Canada USA version: male screwed thread NPT 1 1/2 - 11 ½ B Condensate connection (only for option of integrated water-separator) outer-∅ 10 for polyamide pipe PA11/12 C Water inlet (cold) (only for option of integrated heat recovery) D Water outlet (hot) (only for option of integrated heat recovery) E Cool air intake... - Page 58 C Water inlet (cold) (only for option of integrated heat recovery) D Water outlet (hot) (only for option of integrated heat recovery) E Cool air intake Cool air outlet Cool air intake, switch cabinet (L30RS-L45RS only) Feed cable entry K Center of gravity...
- Page 59 12 Annex (all dimensions in mm) Fig. 31...
- 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...