Gardner Denver L110 10A V4, Translation Of The Original Operating Instructions

Page 1: ...Translation of the original operating instructions Screw compressor L90 L132 V4 L90e L132e V4 L90RS L132RS V4...

Page 2: ...ection 31 6 Commissioning and operating 33 6 1 Initial commissioning 33 6 2 Normal operation 35 6 3 Routine commissioning 36 6 4 Commissioning after a long shutdown 36 6 5 Commissioning after a fault...

Page 3: ...ooled W 63 9 6 3 L132 L132e 50 Hz air cooled A water cooled W 65 9 6 4 L132 60Hz air cooled A water cooled W 66 9 6 5 L90 RS 50Hz 60Hz air cooled A water cooled W 67 9 6 6 L110 RS 50Hz 60Hz air cooled...

Page 4: ...10A V4 L132e 10W V4 These operating instructions are written for operat ing and maintenance personnel The basis of these operating instructions are the master operating instructions ZS1195529 00 which...

Page 5: ...es caused by non OEM com ponents Use of spare or wear parts or operating fluids that do not originate from or are not currently recommended by or have not been previously recommended by Gardner Denver...

Page 6: ...lx during normal operation The illumination for inspection and repair work must be 500 lx Ambient temperature for operation see Technical data Pressure equipment For pressure equipment systems a pres...

Page 7: ...entification number and year of manufacture on the name plate Specifi cation of this data will ensure that you receive the correct information and or spare parts Your Gardner Denver agency Please ente...

Page 8: ...o the responsible post person Faults especially those that could impair safety must be immediately rectified Other wise the compressor must not be operated All danger signs on and in the surroundings...

Page 9: ...e compressor in ex plosive atmospheres is forbidden 2 3 Protection and safety equipment The compressor is equipped with the protection and safety equipment described below All protective and safety eq...

Page 10: ...ce The danger se quence names the type of hazard Description of the danger danger source The danger source names the cause of the hazard Protective measure danger prevention Dan ger prevention describ...

Page 11: ...e compressor System runs on After pressing of the stop button O the compressor runs on for 30 seconds Do not open the compressor enclosure before the com pressor is stationary Observe the instruction...

Page 12: ...mpressor become very hot during opera tion up to 235 C 455 F Risk of injury due to hot sur faces Before starting any maintenance and repair work the compressor must be sufficiently cooled Warning of s...

Page 13: ...age free state Only a qualified electrician following electrotechnical reg ulations may carry out work on the electrical equipment of the compressor Der following section applies only for the frequenc...

Page 14: ...e free from faults The cooling water supply is guaranteed wa ter cooled compressors only Rules for working with compressed air Forbid all working practices that could pose a risk to safety Never play...

Page 15: ...oad capacity Never work or remain under suspended loads Spare parts Use only original spare parts Spare parts must correspond to the technical re quirements specified by the manufacturer This is only...

Page 16: ...otor and an auxiliary rotor with intermeshing spiral toothing Compression chambers are delimited by the flanks of the toothing and the compressor casing The ro tation of the rotors continuously reduce...

Page 17: ...vessel 21 Control system control panel 6 Fine separator 22 EMERGENCY Off button 7 Oil fill 23 Switch cabinet 8 Oil drain 24 Supply cable cable inlet 9 Oil level indicator 25 Final compression tempera...

Page 18: ...15 Fine separator suction 31 Heat recovery connection optional 16 Oil temperature regulator 32 Moisture sensor...

Page 19: ...inal compression temperature sensor 7 Oil fill 26 Line pressure sensor 8 Oil drain 27 Final compression pressure sensor 9 Oil level indicator 28 Opening for lifting tool 10 Oil filter 29 Fan guard 11...

Page 20: ...temperature monitor only Lxx W 19 Compressed air outlet 38 Moisture sensor 3 3 System scheme air cooled compressor 28 S7 27 1 17 E9 I 2 2 3 2 2 2 1 21 19 33 25 Y4 24 Y1 23 22 R1 4 3 5 R2 20 E5 E4 35 3...

Page 21: ...ching point 2 2 bar 32 psi 5 Final compression tem perature sensor R2 18 Oil filter 31 Dirt trap only xxxW 6 Pressure vessel 19 Cooling air fan 32 Cooling water solenoid valve Y6 only L xxxW 7 Fine se...

Page 22: ...or is closed 2 An overpressure of approx 1 5 bar off load pres sure is simultaneously generated in the pressure vessel 3 5 Air circuit The air drawn in reaches the screw compressor 4 via the suction f...

Page 23: ...e pressure sensor 13 B1 does not drop to the set lower switch ing point within the set run on time e g 120 seconds the drive motor 3 and the cooling air fan 19 are shut down and the unit is de pressur...

Page 24: ...ating instructions for the compressor control DELCOS XL If the lubricant pipe is blocked the drive unit in creases the pressure to 6 bar 87psi When max pressure is reached the lubricator starts a spec...

Page 25: ...r connection Switching heat recovery on off 1 2 3 A B 1 Connection from oil cooler 2 Connection to compressor 3 Connection from heat exchanger A Heat recovery switched on B Heat recovery switched off...

Page 26: ...Risk of fatal injury due to toppling or falling parts A suitable forklift with forks of ade quate length must be used to trans port the compressor Only insert the forks at the intended lifting points...

Page 27: ...laced on a sufficiently load bearing substrate The bearing surface must be level to within 3 mm 0 12 The installation location compressor room must be dimensioned such that a clearance of 1 m 39 on si...

Page 28: ...ll the compressors present in the compressor room The following figure shows the recommended ven tilation requirements Fig 4 3 Compressor room ventilation Positioning the compressor DANGER Risk of inj...

Page 29: ...ssed air connection 1 Compressed air connection 2 Electrical connection WARNING Risk of injury If an incorrect connection is made the connector could come loose and the free connection result in sever...

Page 30: ...e g lighting heating or similar that cannot be switched off from the main switch these excluded circuits must be labelled according to EN 60204 and routed separately Moreover warning signs must be att...

Page 31: ...r en dangers trouble free operation Checking of the setting of the control trans former forms part of commissioning and pe riodic inspection maintenance as the mains voltage conditions may vary 5 4 Co...

Page 32: ...ature T p Cooling water outlet pressure Cooling water inlet pressure p The values relate to fresh water quality without ad ditives e g antifreeze If the cooling water quality deviates from this please...

Page 33: ...missioning as follows 1 Check the oil level 2 Check the settings of the fan motor overload switch 3 Check the setting of the control transformer 4 Check all the terminals of the electronic control uni...

Page 34: ...O otherwise damage to the compressor may occur even if it only operates very briefly 8 Switch the main switch OFF 9 Correct the rotational direction Change the compressor rotating field 10 Replace the...

Page 35: ...4 Control panel 1 Touchscreen display 2 Start button I 3 Stop button O 4 red LED flashing slowly warning or maintenance flashing rapidly Fault 5 yellow LED flashing slowly Maintenance necessary 6 gree...

Page 36: ...after a fault in the chapter Commissioning and operation 6 3 Routine commissioning Routine commissioning is for example commis sioning after maintenance 1 Open the shut off valves between the compres...

Page 37: ...Pressure vessel not depressurised Wait for depressurisation Screw compressor does not start up when the pressure in the vessel is greater than the preset value See factory setting Start approval DELCO...

Page 38: ...gulator replace if necessary Check solenoid valves Y1 and pressure reducing valve 12 and replace if necessary Chart 7 3 Troubleshooting upon System does not reach the set line pressure Fault System sw...

Page 39: ...Replace the safety valve Line pressure sensor defective Replace the line pressure sensor Final compression pressure sensor defective Replace final compression pressure sensor Electronic control unit...

Page 40: ...e drive is fully visible Lubrication system is in pressure cut off OL Counter pressure to lubrica tion point 6 bar Flush lubrication point man ually or special dispensing PURGE I Pressure check if nec...

Page 41: ...not working despite volt age being supplied Internal drive fault Replace entire lubrication system Lo message on the display Lo Weak backup battery of the drive Change the CR2450 3V backup battery Ma...

Page 42: ...NOTE Observe the fault messages on the operating panel display The corresponding measures for fault clearance are described in the operating instructions of the elec tronic control unit...

Page 43: ...al equipment exercise ex treme care Before starting the maintenance work switch the compressor to a voltage free state and secure to pre vent switching back on WARNING Risk of risk of injury due to ho...

Page 44: ...measured at the mains ter minal strip of the frequency converter The precise position of the terminals DC and DC can be taken from the supplied frequency converter oper ating instructions 1 Measure th...

Page 45: ...functional check must be documented 1 Switch the main switch OFF 2 Open the enclosure create access 3 Press start button I Allow the compressor to run under load NOTICE Hearing damage Increased sound...

Page 46: ...fluids Carefully clear up any operating fluids that escape Observe the information in the hazardous sub stance data sheets Oil carbon deposits in the oil lubrication sys tem High oil temperatures redu...

Page 47: ...rs but no less than annually Component Measure Necessary qualification Executed Customer operations log Check and adhere to operat ing parameters Operator Electronic control unit Check fault statistic...

Page 48: ...work should be carried out regularly as recommended in the following maintenance plan In the majority of cases the maintenance plan is appropriate however under certain circumstances it is possible t...

Page 49: ...Maintenance personnel Frequency converter cooling air inlet filter RS Replace Maintenance personnel FLUIDFORCE SCREW WAR RANTY LUBRICANT com pressor oil Replace Maintenance personnel Moisture sensor r...

Page 50: ...concerning the maintenance points for the electronic control unit can be found in the elec tronic control unit operating instructions 8 7 Service plan assure Other service cycles are required for the...

Page 51: ...impact on the service life of the filter pad The filter pad should be inspected for dust accu mulation at least weekly daily if possible In these usage scenarios shorter replacement in tervals are po...

Page 52: ...x oil level marking 6 Oil outlet hose WARNING Risk of scalding Risk of scalding by hot oil Only change the oil when the com pressor is stationary and depres surised Caution when draining hot oil Oil m...

Page 53: ...e access 4 Open oil filler neck carefully Allow any resid ual pressure to be released 5 Provide an oil collecting vessel 6 Place oil drain hose over the collecting vessel 7 Open oil drain valve 8 Drai...

Page 54: ...n valve 1 for pressure relief 4 Detach pressure pipe 2 5 Detach suction pipe 3 6 Remove vessel cover screws 7 Raise vessel cover using the lifting device 4 8 Turn vessel cover by 180 9 Lift oil fine s...

Page 55: ...create access 3 Release pressing frame 4 Change the filter element 5 Attach pressing frame hexagon screw tighten ing torque 8 Nm 71 ft lbs 6 Shut enclosure 8 8 7 Moisture sensor protective cap 1 2 Fi...

Page 56: ...etting of the control transformer en dangers trouble free operation Checking of the setting of the control trans former forms part of commissioning and pe riodic inspection maintenance as the mains vo...

Page 57: ...intermesh 9 Apply drive union nut without tool max torque 2 3 Nm 18 27 ft lbs You must ensure that the triangular marks on the drive housing are fully visible If these marks are not fully visible rel...

Page 58: ...lease adhere to them 8 8 12 Maintenance instructions and lu bricant recommendations for fixed compressors Lubricant recommendation Please note that proper lubrication significantly in creases the serv...

Page 59: ...WAR RANTY LUBRICANT Lubricating grease MOBIL POLYREX EM 9 3 Removal WARNING Harmful to health Risk of damage to health due to operat ing fluids and additives Lubricants and additives may cause ir repa...

Page 60: ...ilter mats Air filter cartridge Filter mat Switch cabinet cooling air inlet filter only RS compressors Control air filter 9 4 Disposal General The compressor must be dismantled and stripped down by sp...

Page 61: ...No guarantee claims can be made based on the data Dissolved matter specific values Circulating water Through flow water pH value at 25 C 77 F 6 9 6 9 Carbonate hardness CaCO3 100 mg l 5 6 dH 50 mg l...

Page 62: ...nd pressure level ISO 2151 A dB A W dB A 73 74 75 75 Rated speed of drive motor kW 90 110 Total current consumption during load operation 400V A A W A 194 190 234 229 Total current consumption during...

Page 63: ...cooled W Data measurement and specification as per ISO1217 fourth edition Appendix C E and under the following con ditions Air suction pressure 1 bar a 14 5 psia Air suction temperature 20 C 68 F air...

Page 64: ...W l min 90 T 17K p 0 8 bar 125 T 14K p 1 4 bar Cooling water inlet temperature W C min 5 max 35 Cooling water outlet temperature W C max 55 Cooling water pressure W bar max 10 Cooling water connectio...

Page 65: ...W A 282 271 Electric motor IP55 IE3 IEC 60034 2 1 ECA Qualifying Electric motor version e IP55 IE4 IEC 60034 2 1 ECA Qualifying Rated speed of drive motor rpm 3000 Rated speed of fan motor A kW W kW 5...

Page 66: ...e reserve the right to alter technical data without prior notice 9 6 4 L132 60Hz air cooled A water cooled W L132 60Hz air cooled A water cooled W L132 Maximum operating pressure bar 7 5 10 13 Minimum...

Page 67: ...W Data measurement and specification as per ISO1217 fourth edition Appendix C E and under the following con ditions Air suction pressure 1 bar a 14 5 psia Air suction temperature 20 C 68 F air humidit...

Page 68: ...x 200 Cooling air volume flow A m3 min 223 50Hz 197 60Hz Cooling air volume flow W m3 min 100 Cooling air outlet temperature above ambient temperature A C 27 Residual pressure at ambient temperature...

Page 69: ...ISO 2151 A dB A W dB A 72 76 50Hz 72 77 60Hz 72 76 50Hz 72 77 60Hz Rated speed of drive motor kW 110 Total current consumption during load operation 380V 400V 460V A A W A 235 217 194 225 214 186 Elec...

Page 70: ...A At CompAir our philosophy is to continually improve our products We therefore reserve the right to alter technical data without prior notice 9 6 7 L132 RS 50Hz 60Hz air cooled A water cooled W L132...

Page 71: ...45 C 60Hz Cooling water volume T 12K W l min 170 p 2 1 bar Cooling water inlet temperature W C min 5 max 35 Cooling water outlet temperature W C max 55 Cooling water pressure W bar max 10 Cooling wate...

Page 72: ...plan 1225 17 77 660 210 680 210 660 2039 239 666 60 825 155 326 210 162 210 90 4 1321 241 965 1609 150 90 132kW Fixed Speed X 104 1119 1327 63 1374 2290 82 150 766 664 500 X 90 132kW Fixed Speed 55 3x...

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Page 74: ...oling air inlet E Electrical connection C Water inlet heat recovery F Cooling water inlet water cooled system CA Cooling air outlet air cooled system G Cooling water outlet water cooled system CW Cool...

Page 75: ...The machine does not fall under the Pressure Equipment Directive 2014 68 EU due to the criteria for exclusion as per Article 1 Para 2 c 2 f i and 2 j ii 3 In the event of the machine undergoing modifi...

Page 76: ...Gardner Denver Deutschland GmbH Argenthaler Str 11 55469 Simmern Germany Tel 49 0 6761 832 0 Homepage www compair com e Mail sales compair com...