Related Manuals for Gardner Denver L4-5C
Summary of Contents for Gardner Denver L4-5C
- Page 1 L-SERIES FRAME 0 SINGLE STAGE BASE-MOUNTED & TANK-MOUNTED COMPRESSOR Original User & Service Manual MODELS: L4-5C 5 & 7.5 HP 4 & 5 kW 13-25-629 Version 03 March 19, 2021...
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Page 2: Support Services
Compressor genuine parts, manufactured to design tolerances, are developed for optimum dependability, specifically for Gardner Denver compressor systems. Design and material innovations are the result of years of experience with hundreds of different compressor applications. Reliability in materials and quality assurance is incorporated in our genuine replacement parts. -
Page 3: 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. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. - Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.
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Page 5: Safety Precautions
SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices will result in injury to or death of personnel. -
Page 6: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ............................2 Instructions For Ordering Repair Parts ....................... 2 Warning – Prohibition – Mandatory Label Information ................3 Safety Precautions ............................5 Section 1, General Information ........................7 Section 2, Installation .......................... -
Page 7: Section 1, General Information
SECTION 1 GENERAL INFORMATION Figure 1-1 COMPRESSOR CYCLE COMPRESSOR - The rotary screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity anti- friction bearings located outside the compression chamber. Roller bearings are used at the inlet end of the rotors to carry part of the radial loads. - Page 8 302ECA797-A (Ref. Drawing) Page 1 of 2 Figure 1-2 COMPRESSOR ILLUSTRATION, EXTERNAL DETAILS 13-25-629 v03 Page 8...
- Page 9 302ECA797-A (Ref. Drawing) Page 2 of 2 Figure 1-3 COMPRESSOR ILLUSTRATION, INTERNAL DETAILS 13-25-629 v03 Page 9...
- Page 10 307ECA804-A (Ref. Drawing) Page 1 of 2 Figure 1-4 COMPRESSOR ILLUSTRATION, TOTAL SYSTEM (L4-5 Base Model with 120 gallon receiver and XGNC dryer shown) 13-25-629 v03 Page 10...
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Page 11: Section 2, Installation
SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passing of current. - Page 12 For continuous efficiency, the cooler cores must be periodically cleaned with either vacuum or compressed air. If wet cleaning is required, shield motor and spray on a mild soap solution and flush with clean water. NOTICE Coolers are aluminum; do not use any cleaning solution that is not compatible with aluminum.
- Page 13 ENCLOSURE - The compressor, electric motor, oil cooler and after cooler are mounted inside the enclosure. Service panels are provided for maintenance access. Be sure to allow enough space around the unit for the panels to be removed. Any of the enclosure panels may be removed by opening the latch and lifting it up slightly.
- Page 14 When the unit must be installed in an outdoors installation and/or exposed to ambient temperatures below freezing (32°F, 0°C), contact Gardner Denver for recommendations. When using a Total System with a compressed air dryer option, refer to Section 10 for details.
- Page 15 Discharge air used for breathing will cause severe injury or death. Consult filtration specialists for additional filtration and treatment equipment to meet health and safety standards. ELECTRICAL WIRING - Standard Units – The stand alone compressor package is factory wired for all connections from the starter to the motor, for the horsepower and voltage specified on the order.
- Page 16 GROUNDING - Equipment must be grounded in accordance with Section 250 of the National Electrical Code. Failure to properly ground the compressor package could result in injury or death. Install ground wiring in accordance with the National Electrical Code and any applicable local codes. MOTOR LUBRICATION - The Hebei type H112-2 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.
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Page 17: Section 3, Starting & Operating Procedures
For instructions on checking the oil and the proper oil level, refer to “Oil level gauge”, Section 5. Do not mix different type oils. Standard Unit is shipped filled with Gardner Denver AEON 4000 lubricant which is suitable for the first 4000 hours under normal operating conditions. Other AEON lubricants are available. - Page 18 Failure to properly ground the compressor package could result in controller malfunction. V-Belt System - Refer to Section 8 for detailed instruction to unpack and check the alignment of the belt system. The motor jacking hardware must be re-configured, the main motor carrier bracket removed, belts engaged, and the belt sheaves alignment checked prior to compressor operation.
- Page 19 10. For your convenience, the following excerpt from the Controller manual is presented to assist in programming the basic operating parameters. However, we strongly recommend you read the Controller manual before attempting operating the compressor package. Figure 3-1 GD Pilot Controller Layout and Main Screen ...
- Page 20 Operation at excessive discharge air pressure can cause personal injury or damage to equipment. Do not adjust the operating discharge air pressure above the maximum stamped on the unit nameplate. 11. Enclosure - Check for damaged panels or doors. Check all screws and latches for tightness. Be sure doors are closed and latched.
- Page 21 STARTING THE UNIT - Observe the following starting procedures: Unit Cold or Hot: 1. When using a Total System with a compressed air dryer option, refer to Section 10 for operating details. 2. Open the air service valve (customer furnished) between the main air system and the check valve on the package.
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Page 22: Section 4, Controls & Instrumentation
CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION The Gardner Denver rotary screw compressor is pre-wired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop airline. - Page 23 Terminal Strip - This device provides an interconnection between the GD Pilot controller and the low voltage hardware such as sensors and switches within the enclosure. Main Starter For 3 Phase variant models, a full-voltage starter provides control and overload protection for the main drive motor.
- Page 24 306ECA546-B (Ref. Drawing) Page 1 of 3 FIGURE 4-2 WIRING DIAGRAM, 208-230/460V, 60 Hz 13-25-629 v03 Page 24...
- Page 25 306ECA546-B (Ref. Drawing) Page 2 of 3 FIGURE 4-3 WIRING DIAGRAM, 208-230/460V, 60 Hz 13-25-629 v03 Page 25...
- Page 26 306ECA546-B (Ref. Drawing) Page 3 of 3 FIGURE 4-4 WIRING DIAGRAM, 208-230/460V, 60 Hz 13-25-629 v03 Page 26...
- Page 27 303ECA546-B (Ref. Drawing) Page 1 of 3 FIGURE 4-5 WIRING DIAGRAM, 380V, 60 Hz 13-25-629 v03 Page 27...
- Page 28 303ECA546-B (Ref. Drawing) Page 2 of 3 FIGURE 4-6 WIRING DIAGRAM, 380V, 60 Hz 13-25-629 v03 Page 28...
- Page 29 303ECA546-B (Ref. Drawing) Page 3 of 3 FIGURE 4-7 WIRING DIAGRAM, 380V, 60 Hz 13-25-629 v03 Page 29...
- Page 30 305ECA546-A (Ref. Drawing) Page 1 of 3 FIGURE 4-8 WIRING DIAGRAM, 575V 13-25-629 v03 Page 30...
- Page 31 305ECA546-A FIGURE 4-9 WIRING DIAGRAM, 575V (Ref. Drawing) Page 2 of 3 13-25-629 v03 Page 31...
- Page 32 305ECA546-A (Ref. Drawing) Page 3 of 3 FIGURE 4-10 WIRING DIAGRAM, 575V 13-25-629 v03 Page 32...
- Page 33 307ECA546-D Figure 4-11 WIRING DIAGRAM, 230V, 1 Phase (Ref. Drawing) Page 1 of 4 13-25-629 v03 Page 33...
- Page 34 307ECA546-D Figure 4-12 WIRING DIAGRAM, 230V, 1 Phase (Ref. Drawing) Page 2 of 4 13-25-629 v03 Page 34...
- Page 35 307ECA546-D (Ref. Drawing) Page 3 of 4 Figure 4-13 WIRING DIAGRAM, 230V, 1 Phase 13-25-629 v03 Page 35...
- Page 36 Figure 4-14 WIRING DIAGRAM, 230V, 1 Phase 307ECA546-D (Ref. Drawing) Page 4 of 4 13-25-629 v03 Page 36...
- Page 37 MISCELLANEOUS CONTROL DEVICES - Refer to Figure 4-15 for the schematic diagram of the control system. Intake [Air] Filter (1) - Captures solid impurities in the air stream entering compressor inlet. It also attenuates noise emitted by the compressor inlet. Inlet-Valve Assembly (2) - This device controls the intake of atmospheric air entering the compressor during the Load/Unload phases of operation.
- Page 38 Solenoid Valve (Y1) - This 2-way valve controls the position of the inlet valve in response to signals from the GD Pilot Controller. Pressure Sensor, Sump Dry Side (B1) - This device is connected after the minimum pressure valve. It converts the pressure in the plant air system into an electrical signal for use by the GD Pilot controller for monitoring and control load/unload operation.
- Page 39 301ECA797-01 (Ref. Drawing) Page 1 of 1 Figure 4-15 PIPING AND INSTRUMENTATION ILLUSTRATION 13-25-629 v03 Page 39...
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Page 40: Section 5, Lubrication. Oil Cooler, Oil Filter & Separator
AEON lubricants are available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The standard factory fill compressor lubricant is Gardner Denver AEON 4000, a superior semi-synthetic blend of petroleum stock and various protective additives, suitable for year-round operation. - Page 41 Before draining, adding, or changing the lubricant oil in the compressor, be aware of the following hazards associated with these tasks: Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters.
- Page 42 All materials used in Gardner Denver compressor units are compatible with AEON 9000SP Lubricant. Use caution when selecting downstream components such as air line lubricating bowls, gaskets and valve trim. AEON 9000SP Synthetic Lubricant is not compatible with low nitrile Buna N or acrylic paints.
- Page 43 Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis program with the AEON lubricants, and we recommend a sample be sent in at 100 hours on a new unit.
- Page 44 DRAINING AND REFILLING THE OIL SYSTEM - Always drain the complete system. Draining when the oil is hot will help to prevent varnish deposits and carry away impurities see Figure 1-3, for hardware details. 1. Be sure the unit is completely off and that no air pressure is in the oil reservoir. 2.
- Page 45 Optional Element. If the compressor is used in a predominantly cold (<32ºF, 0ºC) and/or humid environment, proper oil viscosity and avoidance of water vapor condensation in the oil system may be achieved by using a higher setting (208ºF, 98ºC) thermostatic element. Consult Gardner Denver for details.
- Page 46 AIR / OIL SEPARATOR - This device provides the final (2%) of the air/oil separation, typically 2ppm oil content at the final discharge of the compressor package. It is housed in a removable spin-on cartridge. Its high level of performance may be affected by the following conditions: ...
- Page 47 Pressure Dew Point Trend (100% r.h.) 100psig 125psig 150psig 175psig Am bient Tem p - oF Figure 5-3 Dew Point Chart F Pressure Dew Point Trend (100% r.h.) 6.9bar 8.6bar 10.3bar 12.1bar 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 Ambient Temp - oC Figure 5-4 Dew Point Chart C...
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Page 48: Section 6, Heat Exchangers (Oil/Air)
HEAT EXCHANGER MAINTENANCE - All the required hardware, mechanical and electrical connections have been made at the Gardner Denver factory, thus the only regular maintenance required is to keep the exterior core fins free from dirt and other airborne debris per the following procedure:... - Page 49 Compressor, air/oil sump and all piping and tubing may be at high temperature during and after operation. Do not attempt inspection or cleaning of air-cooled heat exchangers until cooling fan has stopped rotating. Disconnect lockout and tag out package from power supply.
- Page 50 The ventilation system for the air-cooled package relies on positive back pressure to cool the heat exchanger. Make sure that the enclosure panels that surround the heat exchanger area are closed during compressor operation, or the compressor discharge temperature will reach shutdown levels quickly. FIGURE 6-2 Cooler Access 13-25-629 v03 Page 50...
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Page 51: Section 7, Air Filters
In turn, the longevity of the filter element depends on the cleanliness of the local environment. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. - Page 52 PACKAGE PRE-FILTER MAINTENANCE 1. Remove the central screw and washer securing the pre-filter to the grill assembly and remove the pre-filter media (17). See Figure 7-2 for component details. Note: do not remove the fan grill. 2. Cleanse the pre-filter media with compressed air or with water to remove debris trapped in its fibers.
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Page 53: Section 8, Belt Drive System
SECTION 8 BELT DRIVE SYSTEM The motor power is transmitted to the compressor with a system comprised of heavy-duty v-belts, sheaves, and bushings. Belt tension is provided by the motor weight with the help of a free-pivoting bracket, see Figure 8-1 for details. Figure 8-1 Motor Jacking Assembly Figure 8-2 V-Belt Drive Components 13-25-629 v03... - Page 54 UNPACKING THE V-BELT SYSTEM To protect the belts from shock and strain during transportation, the free-swinging side of the motor frame is locked in place by means of a carrier bracket assembly. Proceed to prepare the belt system for operation as follows, refer to Figures 8-1 & 8-2 for component description: 1.
- Page 55 (after loosening the jam nut) and raising the motor body until the v-belts can be dismounted from the motor sheave. Replace the old belts with new ones. For proper belt life, use only genuine Gardner Denver belts. Check the sheave alignment.
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Page 56: Section 9, Servicing Of Miscellaneous Devices
SECTION 9 SERVICING OF MISCELLANEOUS DEVICES This section will cover basic maintenance of various control devices used with the compressor package. Refer to Fig 9-1 for pictorial with general locations of these devices. INLET CONTROL VALVE ASSEMBLY Inlet-Valve Assembly (2) - This device is located within and below the intake flange of the compressor, see Figure 9-1 for internal details and Figure 4-15 for schematic details. - Page 57 Inlet Valve (Body) Inspection - The valve does not require maintenance or lubrication. If air/oil leaks develop across the valve disc during pressurized conditions (e.g., machine stopped), valve seals should be inspected for wear and tear signs: 1. Be sure the unit is completely off and oil sump is depressurized. 2.
- Page 58 PRESSURE RELIEF VALVE Pressure Relief Valve - This device protects the pressure-containing components of the compressor package against pressures exceeding 218 psig. It is installed on the wet-side of the oil sump. Figure 9-2 Pressure Relief Valve Before inspecting the pressure relief valve, release air pressure, lockout and tagout the power supply to the compressor package.
- Page 59 MINIMUM PRESSURE VALVE Minimum Pressure Valve (MPV) Inspection – This device has no user-serviceable or repairable components. If it fails to maintain adequate minimum pressure (60 psig) or fails to check the backflow of system compressed air after compressor stoppage, replace it as follows: Figure 9-3 Minimum Pressure Valve and Seat Air/oil pressure will cause severe personal injury or death.
- Page 60 Input Shaft Seal Maintenance – This device has no user-serviceable or repairable components. If oil leaks past its seal and unto the external portion of the shaft, contact Gardner Denver to have it inspected and/or repaired by a trained mechanic.
- Page 61 Figure 9-5 Compressor Module Hardware 13-25-629 v03 Page 61...
- Page 62 4. Remove dust and debris from fan with a vacuum cleaner or replace if not operational. Contact Gardner Denver for a replacement cooling fan assembly. 5. Shake off debris and gently wash foam filter medial under tap water and dry off completely.
- Page 63 VFD Cooling Fan Removal and Replacement 1. Make sure that steps 1 and 2 of “Cooling System Inspection” have been completed. 2. Depress the right and left sides of the fan cover tabs and pull upward. Remove the fan cover from the top of the drive per Figure 9.7, one (1) fan assembly shown, but the same procedure applies to two (2) fan assembly.
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Page 64: Section 10, Tank Mounted Compressor - Total System
Installation - Package must installed in a location with an ambient temperature range of 40ºF to 110ºF (3ºC to 43ºC). Consult Gardner Denver for operation outside this range. Discharge service pipe - The discharge service line connection is provided at the outlet of the bypass valve assembly. -
Page 65: Section 11, Maintenance Schedule
SECTION 11 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter and Pre-Filter - Operating conditions determine frequency of service. See “Air Filter,” Section 7. Motor Lubrication, Refer to Section 2. Every 8 Hours Operation Check the reservoir oil level, add oil if required. See Section 5.. Observe if the unit loads and unloads properly. - Page 66 MAINTENANCE SCHEDULE (See Detail Notes above) As Indicated Every Every Every Every Every Every Maintenance Action 2000 4000 Year Controller Hours Hours Hours Hours Hours Check/Change Air Filter ...
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Page 67: Section 12, Troubleshooting
SECTION 12 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start No electrical power. Check main disconnect, fuses and supply line. Motor starter overload Reset and investigate cause of relay tripped. overload. Pressure in reservoir. Inspect unload valve. Wrong lead connections Change leads. - Page 68 SYMPTOM POSSIBLE CAUSE REMEDY Minimum pressure valve Replace valve. stuck closed. Oil separator clogged. Replace. Condensate drain Inspect and replace. solenoid valve is faulty. Leaks in the compressed Check for leaks, fix any leaks air system. found. V-Belts broken. Replace complete set. V-Belts slipping.
- Page 69 Inspect and cleanse. Ruptured oil separator Replace element. element. Loose assembly. Tighten all fittings and gaskets. Foaming caused by use of Use Gardner Denver incorrect oil. AEON lubricating coolant. Inoperative minimum Inspect and/or replace. pressure valve. Operation at elevated Reduce temperature. See “High Discharge Air...
- Page 70 Look for poor connections or undersized wiring. NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units.
- Page 71 STANDARD WARRANTY Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, free of defects in material and workmanship.
- Page 72 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2021 Gardner Denver, Inc. Printed in U.S.A.