Gardner Denver L160 110A V2, User Manual

Page 1: ...User manual Screw compressor L160 L290 V2 L160RS L290RS V2 America ZS1149274 03 January 2017...

Page 2: ...connection 30 5 4 Cooling water connection 32 6 Commissioning and operation 34 6 1 Initial commissioning 34 6 2 Normal operation 36 6 3 Routine commissioning 37 6 4 Commissioning after extended downti...

Page 3: ...Contents January 2017 America 3 72 9 6 3 L160 RS 60Hz air cooled A water cooled W 60 9 6 4 L200 RS 60Hz air cooled A water cooled W 62 9 6 5 L290 RS 60Hz air cooled A water cooled W 63 9 7 Installatio...

Page 4: ...its qualified and experienced personnel is responsible for all repair work that exceeds typical maintenance and requires specialized technical knowledge All pressure values in these operating instruct...

Page 5: ...t these operating instructions in any case 1 3 Intended use The compressor uses the best available technology and meets applicable safety requirements at the time of sale in the context of correct usa...

Page 6: ...otective and safety devices Operation with defective deactivated or manipulated protective and safety devices or safety values or operation with other safety related defects Use by private users or us...

Page 7: ...Foreword 1 January 2017 America 7 72 1 6 Rating plate Fig 1 1 Rating plate...

Page 8: ...d warning signs on and near the compressor must be checked regularly for completeness and legibility Missing hazard warning signs must be replaced immediately The time frames from tests and inspection...

Page 9: ...r is placed in a safe condition 2 Rectify the fault that was the cause of the emergency stop See the Troubleshooting chapter 3 Unlock Emergency Stop button Turn the pushbutton anticlockwise 4 Start up...

Page 10: ...situation that if not prevented can result in death or extreme irreversible injury CAUTION Indicates a potential dangerous situation that if not prevented can result in slight or minor reversible inj...

Page 11: ...rking on rotating parts Secure against being switched back on again during repair work Use hearing protection Label for areas with elevated sound pressure level Enter the area only with suitable heari...

Page 12: ...vers enclosures guards fences during transport Working at the labeled workstations requires increased vigilance Do not go beneath the load Do not go beneath a suspended load The driver is not allowed...

Page 13: ...monitoring of the cooling water by mainte nance personnel Caution hot liquid Warning of hot oil or hot coolant Allow the compressor to cool before opening the fluid cir cuit lines Chart 2 1 Safety sym...

Page 14: ...work Organizational The maintenance work and intervals are specified in the operating manual including information about replacing parts partial equipment Maintenance and repair work may be performed...

Page 15: ...repair work Also check all the other bolt connections Before releasing the compressor for operation after maintenance and repair work ensure that the operating pressures temperatures and time setting...

Page 16: ...The compressor stages consist of a main rotor and a secondary rotor with spiral teeth that mesh with each other Compression chambers bounded by the flanks of the teeth and by the compressor housing a...

Page 17: ...t 1 1 Suction filter 20 Base frame 2 Intake regulator 21 Control system control panel 3 Electric motor 22 EMERGENCY Off button 4 Screw compressor 23 Electrical enclosure 6 Fine precipitator 25 Compres...

Page 18: ...oled 5 Pressure vessel 14 Air cooler 7 Oil fill 17 Oil cooler cooling air fan 8 Oil drain 18 Cooling air inlet filter pad 9 Oil level indicator 19 Compressed air outlet 11 Oil cooler 24 Aftercooler co...

Page 19: ...ter cooled 5 Pressure vessel 14 Air cooler 7 Oil fill 17 Cooling air fan 8 Oil drain 18 Cooling air inlet filter fleece 9 Oil level indicator 19 Compressed air outlet 11 Oil cooler 26 Line pressure se...

Page 20: ...5 B1 16 15 24 S6 9 8 7 6 S12 22 29 4 13 33 5 R2 12 21 11 10 S5 34 R1 3 32 E5 E4 31 28 Y6 27 Fig 3 4 Functional schematic Compressed air Oil Control air Cooling water Chart 3 1 Lines Components No Desi...

Page 21: ...cator 9 Safety valve 23 Suction filter monitoring S7 optional Switching point 50mbar 20 in H2O 10 Oil filter monitoring S5 optional Switching point 2 2 bar 32 psi 24 Fine separator monitor ing S6 opti...

Page 22: ...ressor due to the drop in pressure between the pressure vessel and the injection point in the screw compressor When switching the drive motor to operation the solenoid valve 19 Y1 switches as it is be...

Page 23: ...eset lower switching point within the set motor run on time the solenoid valve 19 Y1 is supplied with current again and the blow off valve 20 Y4 is shut The unit goes back to on load operation 3 7 Lub...

Page 24: ...efer to the operating instructions for the compressor control GD Pilot TS If the lubricant pipe is blocked the drive unit increases the pressure to 6bar 87psi If the max pressure is reached the lubric...

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

Page 26: ...to life from tipping or falling parts A suitable forklift with sufficiently long forks must be used to transport the compressor Use forks only at the labeled lifting points The compressor even in its...

Page 27: ...rty Damage to property due to exceeding the permissible temperature range Where there is a risk that the permissible temperature limits of 2 65 C 36 149 F could be exceed or underrun contact Gardner D...

Page 28: ...h as possible Cover ventilation openings with screens in order to prevent dirt from entering the compressor room The design of ventilation system is based primarily on the required amount of cooling a...

Page 29: ...d and flat The compressor must be installed with full contact on a foundation with sufficient structural strength The compressor must not be operated on the transport pallet No flammable or explosive...

Page 30: ...nnection 2 Condensate connection 3 Electrical connection WARNING Risk of injury If incorrectly connected the connection can come loose and the open connection can cause severe personal injury When con...

Page 31: ...ighting heating or the like that are not disconnected by the main disconnect switch then these excepted electrical circuits must be labeled and run separately per EN 60204 Warning labels must also be...

Page 32: ...nsformer settings can cause problems in operation Checking the control transformer settings is part of commissioning and periodic inspection and maintenance because grid voltage conditions can change...

Page 33: ...ement at maximum power and T 10K T Cooling water outlet temperature Cooling water inlet temperature T p Cooling water outlet pressure Cooling water inlet pressure p The values are based on freshwater...

Page 34: ...r Denver Perform initial commissioning as follows 1 Check the oil level 2 Check the settings of the fan motor protection switch 3 Check the settings of the control transformer 4 Check all connection t...

Page 35: ...to the compressor may occur even if it only operates very briefly 8 Switch off the main disconnect switch 9 Correct the direction of rotation Change the rotating field on the compressor 10 Mount the p...

Page 36: ...button I on the control panel The compressor switches on The compressor runs automatically automatic mode See the sequence description in the Sequence section of the chapter Structure and function Ope...

Page 37: ...id switching on the compressor multiple times without clearing the fault as this can lead to significant machine damage Switch on the compressor only after the fault has been cleared Recommissioning a...

Page 38: ...Acknowledge a fault in the electronic controller Pressure vessel not depressurised Wait for depressurisation Screw compressor does not start up when the vessel pressure is greater than the preset valu...

Page 39: ...Make the intake regulator moveable replace if needed Check solenoid valves Y1 and pressure reducing valve 14 and replace if necessary Chart 7 3 Fault cleared by Unit does not reach the set network pre...

Page 40: ...ause Remedy Safety valve defective Replace safety valve Network pressure sensor defective Replace network pressure sensor Final compression pressure sensor defective Replace final compression pressure...

Page 41: ...the white triangle on the drive is fully visible Lubrication system is in pressure cut off OL Counter pressure to lubrication point 87 psi Flush lubrication point manually or special dispensing PURGE...

Page 42: ...0 of Gardner Denver Display 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...

Page 43: ...7 January 2017 America 43 72 NOTE Also note the fault messages on the display of the operator panel The corresponding actions to clear the faults are described in the operating instructions for the el...

Page 44: ...restarting WARNING Risk of injury from hot bleeder valve The outlet temperature of the compressed air can be as high as 90 C 194 F Allow the compressor system to cool down before opening the bleeder v...

Page 45: ...its please observe the following points In case of leakage a part of the oil in oil water coolers may penetrate into the cooling water circuit Cooling water must not be discharged into public sewage s...

Page 46: ...s listed All maintenance repairs and service work performed on the compressor must be documented Service and maintenance work should be performed by the local Gardner Denver representative Cleanliness...

Page 47: ...Control Panel Check for fault mes sages report if any User Chart 8 1 Maintenance plan every 8 operating hours Maintenance plan Maintenance every 125 operating hours Components Measure Required qualifi...

Page 48: ...rtridge Maintenance personnel Safety valve Function test at least once a year Maintenance personnel Hoses and piping Check for leaks or any dam age Maintenance personnel Condensate Drain Aftercooler f...

Page 49: ...icing kits To identify the correct servicing kit see the following table Part numbers for servicing kits Model number Service Part number L160 L290 2000 4000 operating hours 302KGA6032 L160 RS L290 RS...

Page 50: ...service life of the filter elements The filter elements should be inspected for dust accumulation at least weekly daily if possible If usage scenarios transpire with for example a high rate of dust ac...

Page 51: ...permitted duration of use of the oil must be checked with the help of an oil analysis NOTE Collect the used oil Do not let it drain into the soil Dispose of the oil in accordance with regulations Do...

Page 52: ...n the compressor is relieved of pressure the aftercooler remains pressurized Release pressure manually prior to performing maintenance work in the aftercooler and pressure retaining valve area 1 Switc...

Page 53: ...6 Close the enclosure 8 6 7 Connection terminals in the switch cabinet control transformer setting DANGER Electric shock Deadly electrical voltage Exercise extreme caution when working with electrica...

Page 54: ...controls with the message Warning Mot Lubricator see also the operating instructions for the electronic controller Replacing the grease cartridge 1 2 3 4 Fig 8 12 Lubricator 1 Socket for connection c...

Page 55: ...ops blinking 8 6 10 Checking intervals for pressure vessel and electrical installation Pressure vessel The checking intervals for the compressed air vessel and the safety valve have to be coordinated...

Page 56: ...fety data sheets must be adhered to Lubricating oil AEON 9000SP Lubricating grease MOBIL POLYREX EM 9 3 Disassembly WARNING Damage to health Risk of damage to health from consumables and auxiliary mat...

Page 57: ...point 4 Seal off the lubrication point 5 Close the enclosure Remove the air filter 1 Remove all filter elements and filter mats Dispose of filter elements and filter mats Air filter cartridge Filter m...

Page 58: ...dissolved matter 9 6 Technical data 9 6 1 L160 L200 60Hz air cooled A water cooled W L160 L200 60Hz air cooled A water cooled W L160 L200 Maximum operating pressure psig 110 130 190 110 130 190 Minimu...

Page 59: ...ions W 1 1 2 11 1 2 NPT Total oil volume gal 31 7 Compressed air connection Flange ANSI B16 5 3 125lbs Weight lb A 9229 W 9083 A 9733 W 9456 Dimensions L x W x H in 114 5 x 81 5 x 86 3 Chart 9 2 Techn...

Page 60: ...32 34 Residual pressure at ambient temper ature A Torr 0 38 0 08 95 F 113 F 0 53 0 15 95 F 113 F Cooling water quantity T 10 K W gal min 52 8 p 19 psi 60 7 p 34 psi Cooling water inlet temperature W...

Page 61: ...0 3 0 IE3 Rated capacity of fan motor W hp kW 0 4 0 3 IE 3 Recommended cable cross section 460V 2 x 3 x AWG3 0 Recommended fuse size time delay 460V A 2 x 3 x 175 Air cooler oil cooler cooling air vo...

Page 62: ...ctric motor TEFC IP55 EISA 2007 IE 3 Nominal speed of drive motor rpm 500 2419 Nominal power of fan motor A hp kW Air cooler 3 0 2 2 IE3 oil cooler 4 0 3 0 IE3 Rated capacity of fan motor W hp kW 0 4...

Page 63: ...er outlet temperature above ambient temperature A F W F 10 18 Sound pressure level ISO 2151 A dB A W dB A 81 83 79 80 Nominal power of drive motor hp kW 340 250 Total current consumption during load o...

Page 64: ...emperatures other than 30 C 86 F and then selecting the wire that has sufficient ampacity after correction to meet the load requirements shown in the NEC Package Amps 30 C column above Wire ampacity i...

Page 65: ...3 3 33 8 8 7 39 5 8 7 23 8 29 2 79 5 86 3 10 8 14 4 15 6 19 1 13 6 81 5 7 1 8 1 13 16 7 45 6 59 3 11 6 5 7 8 9 114 4 28 5 40 2 16 7 17 8 5 2 2 8 1 7 12 7 3 2 59 32 4 56 3 27 4 4 8 28 7 28 7 2 4 18 1...

Page 66: ...air cooled A Compressed air connection F Motor cooling air inlet B Compressor suction shaft G Motor cooling air outlet C Air and oil cooler cooling air inlet H Frequency converter cooling air inlet on...

Page 67: ...33 8 8 7 39 5 8 7 23 8 79 5 86 3 2 2 27 4 2 8 117 2 11 5 11 5 29 63 40 9 53 6 46 5 59 3 13 17 8 9 5 7 11 6 13 2 15 6 19 2 13 6 5 6 3 7 12 1 81 5 57 2 12 2 1 3 12 2 4 1 1 6 RS 18 1 8 5 11 9 10 2 13 4 3...

Page 68: ...E F C1 C2 A J G Fig 9 4 L160 L290 RS water cooled A Compressed air connection F Motor cooling air inlet B Compressor suction duct G Motor cooling air outlet C1 Cooling water inlet H Switch cabinet coo...

Page 69: ...Appendix 9 January 2017 America 69 72...

Page 70: ...9 Appendix 70 72 America January 2017...

Page 71: ...Appendix 9 January 2017 America 71 72...

Page 72: ...Gardner Denver Compressor Division 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9868 Fax 217 224 7814...