Related Manuals for Gardner Denver L30-45E
Summary of Contents for Gardner Denver L30-45E
- Page 1 L-SERIES FRAME 3 BASE MOUNTED COMPRESSOR Original User and Service Manual MODELS L30-45E 40, 50, 60 HP LRS30-45E 30, 37, 45 kW 13-25-637 Version 02 January 20, 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 Check and, if required, re-tighten connection terminals. Check the DC bus voltage at the system terminal strip of For further details, see the operating instructions. the frequency converter by measuring this between the Danger of electric shock from loaded +DC and -DC terminals (the exact position can be found condensers! Please always first in the supplied operating manual of the frequency disconnect the system from the power...
- 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 sticker on compressor) Handle package at forklift points only...
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Page 6: Preface
Fig. 1 Your Gardner Denver distributor Name: Address: Telephone: Fax: Contact: Spare Parts: Service: 13-25-637 v02 Page 5... -
Page 7: Compressor Information
Therefore, it is essential that the prescribed Gardner Denver will not guarantee the safe operation of maintenance intervals are adhered to and that the machine/equipment if it is not handled in a way... - Page 8 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. Any independent alterations to the 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 can Never play 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 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 from vapors etc., but also dusts and other dangerous or toxic materials) cannot be 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 have Always check a correct power supply to the compressor before commissioning. -
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 work Please note and pass on general statutory and other binding regulations that safely with the compressor itself. But may supplement the operating manual for the prevention of accidents and the other dangers will arise during work. -
Page 17: 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 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 Pressure relief valve 21 Blow-off valve Suction regulator 10 Oil filter monitor (S5) * 22 Oil temperature regulator 2.1 Actuator 11 Oil filter 23 Oil level indicator 2.2 Throttle valve 12 Oil cooler 24 Intake filter monitor (S7)* 2.3 Non-return valve 13 Throttle 25 Fine separator monitor (S6)*... -
Page 22: Oil Circuit
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 the controller) oil flows via the by-pass of the oil cooler directly into the oil filter (-11-) and is then injected into the screw Standstill of the system compressor (-4-). - Page 23 Stopping the system WARNING WARNING Solenoid valve (-19- (Y1)) is de-energized when Do not stop the Unit using the Emergency Stop Button unless the STOP button on the operating panel of the there is a danger to the product or of personnel injury. compressor controller is pressed.
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Page 24: Manner Of Operation Of The Suction Regulator
5.5.1 Manner of operation of the suction regulator Load running mode When switching over to delta connection the upper control chamber of the actuator. The suction regulator two solenoid valves (7 (Y1) and 9 (Y4)) are valve opens, the lower control chamber is bled through the supplied with power. -
Page 25: 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 may be damaged if lifted incorrectly. Always observe the safety notes in Section 4.5 of the user manual. ... -
Page 26: 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 27: Preparations For Commissioning
Cooling air volume/minimum cross Fig. 9 Cool air intake Cool air exhaust (Fan rotation counter-clockwise) Control cabinet cool air intake (L30RS-L45RS only) The figures below show the recommended ventilation sections arrangement: The cooling air volume required by these screw compressors is as follows: 2296 cfm L30RS 2296 cfm... -
Page 28: Compressed-Air Connection
Compressed-air connection WARNING Fig. 11 Fig. 12 Compressed-air connection Thread identification of compressed-air connection The compressed-air line system is connected at the compressed air supply of the screw compressor (-1- Fig. 11). For this you should use 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
(-3- Fig. 14) and “minimum oil level” (-4- Fig. 14) marks on the oil gauge. If required, top up oil. Use Gardner Denver oil only. Close the oil filler cap (-1- Fig. 14) firmly. Also see Section 10.13 “Service and Maintenance.”... -
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 rotational direction of the motor can only be checked with the casing open. ... - Page 32 Fig. 15a 1 Drive motor direction of geared compressors Fig. 15c Cooling air intake Cooling air outlet Arrow “direction of rotation for compressor“ (direction of rotation may deviate from this representation) Fig. 15b 1 Drive motor direction with direct drive Temperature start-up protection The screw compressor unit will not start up if the ambient temperature is lower than 34°F.
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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
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
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
10.1 Maintenance recommendations WARNING 10.2 Maintenance Electric Motor 10.2.1 Motor Lubrication The motors used with this compressor package have sealed bearings which have been greased at the factory and require no re-greasing during their operational life. These motors do not have injection or drain ports for re-greasing. -
Page 37: Service Check List
Valve" and "Compressor Oil System Check". 2. An oil sample will need to be taken and sent to the Gardner Denver oil lab. See section 5.1 (Fig. 2 & 7. Inspect, replace if necessary the drive coupling 17) for oil sampling valve location. Refer to oil spider (coupling element). - 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 of all pressure, disconnect, lockout and tagout the power supply to the compressor package before removing valves, caps, plugs, fittings, bolts and filters. -
Page 40: Change Oil Filter Cartridge
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 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
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. 21) counter-clockwise until the reservoir cover is lying loosely on the pressure reservoir flange Fine oil separator ... -
Page 43: Pressure Relief Valve
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. Use the appropriate safety equipment, hearing and eye protection, and use safety precautions when performing this PRV check on an operating machine. -
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
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. The following oil types should be used a) AEON 9000SP... -
Page 48: Trouble-Shooting
11. Trouble-shooting 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 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 50: Annex
12.1 Layout plan Fig. 27 (all dimensions in mm) Compressed air connection • Canada/USA version: male pipe thread NPT 1 ½ - 11 ½ Cool air intake Cool air outlet Feed cable entry Center of gravity Control cabinet cool air intake (L30RS-L45RS only) 13-25-637 v02 Page 49... - Page 51 Fig. 28 (all dimensions in mm) * Lifting Slots 13-25-637 v02 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.