Gardner Denver L30RS, User And Service Manual

Page 1: ...Original User and Service Manual Screw Air Compressor L30 L50 L30RS L45RS V2 USA Id no ZS1133367 00 April 2015...

Page 2: ......

Page 3: ...nd before the compressors are serviced New and edited publications can be obtained from your local Gardner Denver distributor or service center In any communication concerning the compressor it is ess...

Page 4: ...stment Careful adherence to these instructions will result in economical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety...

Page 5: ...voltage at the system terminal strip of the frequency converter by measuring this between the DC and DC terminals the exact position can be found in the supplied operating manual of the frequency con...

Page 6: ...REQUIREMENTS Asphyxiation Hazard Never breathe in compressed air from this system Never operate the unit with open doors or loose access panels Read the operator s manual before proceeding with this t...

Page 7: ..._______________________________________________________________________ ______________________________________________________________________________________ _________________________________________...

Page 8: ...horoughly especially under difficult operating conditions Service If you encounter a fault or require spare parts please contact your Gardner Denver representative Trained expert staff will quickly an...

Page 9: ...ndent alterations to the compressor equipment station or installing components which have not been approved by the manufacturer e g separator will result in the loss of the CE mark or other factory ce...

Page 10: ...d functioning 19 5 1 Design of the unit 19 5 2 System Schematic 20 5 3 Oil circuit 21 5 4 Air circuit 21 5 5 System control 21 5 5 1 Manner of operation of the suction regulator 23 6 Transport and ins...

Page 11: ...ransformer setting 44 10 10 Screw connections 45 10 11 General maintenance and cleaning 45 10 12 Clean change filter with cool air intake and switch cabinet inlet 45 10 13 Inspection intervals for pre...

Page 12: ...ake sure that only authorized personnel use the machine Define who is responsible for operating the machine and authorize him her to ignore instructions from third parties if these instructions could...

Page 13: ...ded that this safety device should be used for pressures above 58 PSI The steel wire has a diameter of 0 315 and is firmly clamped to the hose at least every 20 Both ends are fitted with cable lugs Do...

Page 14: ...ting it up make sure that nobody can be injured by the machine installation as it starts up Compressed air may contain substances that may damage your health if inhaled The compressed air produced by...

Page 15: ...nd irritated and after a longer period of time our nervous system can suffer serious damage We recommend a separate machine room in order to keep the noise of the machine away from the workshop Where...

Page 16: ...be isolated from external lines and hoses The system must be set up on a level surface with full contact between its base frame and the supporting surface 4 6 General workplace dangers Danger Safety m...

Page 17: ...in the system are in good condition firmly fixed and do not chafe Replace hydraulic hose lines at the stated or at reasonable intervals even if no defects of relevance to safety are apparent Spurting...

Page 18: ...from the power supply and wait another 10 minutes before touching the electrical components The power condensers require this time in order to discharge Check the DC bus voltage at the system termina...

Page 19: ...be protected from the ingress of water steam or detergents for safety and or functional reasons in particular electric motors and switch cabinets After cleaning remove the covers masking completely M...

Page 20: ...that parts and special accessories not supplied by us are not approved by us Installing or using such products may thus adversely affect active and or passive safety The manufacturer accepts no liabil...

Page 21: ...n return valve 14 Air cooler 15 Fine oil separator extraction 16 Oil temperature regulator 17 Cooling fan 18 Cool air inlet filter mat 19 Compressed air outlet 20 Base frame 21 Control panel 22 Emerge...

Page 22: ...10 Oil filter monitor S5 11 Oil filter 12 Oil cooler 13 Throttle 14 Non return valve 15 Minimum pressure and non return valve 16 Compressed air after cooler 18 Final compression pressure sensor B2 19...

Page 23: ...oir 6 After pre separation and subsequent fine separation by the separator element 7 the compressed air with a low oil content is fed via the minimum pressure valve 12 and the air cooler 14 into the c...

Page 24: ...the upper control chamber is bled via the solenoid valve 20 Y4 The pressure reservoir 6 is unloaded to off load pressure residual pressure The screw compressor 4 is now running in the offload mode Th...

Page 25: ...of the actuator The suction regulator valve opens the lower control chamber is bled through the pipe 22 by the solenoid valve 7 Y1 Fig 4 Idling mode As soon as mains pressure has been attained both s...

Page 26: ...forks see Fig 6 and their length in mind when transporting the compressor All loose parts or parts which can swing freely must be safely secured before the unit can be lifted It is strictly prohibite...

Page 27: ...the compressor station Fig 8 The screw compressor unit has to be leveled The system may not be run while on the transport pallet A minimum distance from walls other machines etc should be maintained...

Page 28: ...ft 2 NOTICE The stated minimum cross section refers to a maximum duct length of 16 4 ft and a maximum of one bend In the event of differing values over 16 4 ft more than one bend filter cartridges sc...

Page 29: ...ts to drain collected liquids These facilities have to be fitted to allow the observance of the draining of such liquids Hand operated drain facilities have to be actuated in accordance with the opera...

Page 30: ...ctrical components The power capacitors need this time to discharge WARNING If local regulations are stricter than the values given below observe the stricter regulations WARNING If the electrical con...

Page 31: ...e in UL508A Rubber sheathed cable at 86 F and max 55 yd cable length If conditions differ cable length temperature and accumulation the gauge must be determined according to UL508A The cable type must...

Page 32: ...erent specifications If the compressor system is delivered without oil oil must first be filled into the pressure reservoir up to the maximum oil level mark For oil filling also see Sections 10 4 and...

Page 33: ...hten all connecting terminals of the electrical control Open isolator valves between the screw compressor reservoir and pipe Turn on the main power supply switch After the power supply was switched on...

Page 34: ...compressor direction of rotation may deviate from this representation NOTICE For switching the compressor off normally use only the stop push button 3 Fig 17 but not the EMERGENCY STOP push button Af...

Page 35: ...that all tools have been taken out Only operate the screw compressor with the coverings closed For routine commissioning proceed as follows Check the oil level in the pressure reservoir also see Sect...

Page 36: ...menu After the acknowledgement the message READY TO START appears on the display unless another fault is present Press START button I 2 Fig 17 8 6 Shutoff To switch off the compressor use the O key 3...

Page 37: ...t possible to specify a maximum permissible standstill time which will apply in all cases NOTICE The following aspects must be taken into account for storage of storing compressors The compressor shou...

Page 38: ...utes before touching electrical components The power capacitors need this time to discharge WARNING Some parts of the system will still be pressurized after the system has been switched off Small part...

Page 39: ...Every 4000 hours operation or 12 months 1 Visually check for leakage on the shaft seal replace as required See the parts lists for the kit part number and for the tool kit part number The tool kit is...

Page 40: ...rator Inspect clean if necessary scavenge line replace check valve Inspect service if necessary Inlet Valve Inspect re grease if necessary Motor Bearings Inspect replace if necessary Min Pressure Chec...

Page 41: ...ny spilled oil NOTICE Catch the old oil do not let it drain onto the floor Dispose of it properly Do not spill any oil Look for leaks With these compressors the frequency of the oil changes is closely...

Page 42: ...es until the oil has settled i e until the air has bubbled out Check the oil level see Section 7 4 The oil level must lie between the maximum oil level 4 Fig 18 and minimum oil level 5 Fig 18 If neces...

Page 43: ...e Section 7 4 If necessary top up the oil Changing times for oil filter cartridges Operating conditions e g coolant temperatures the type of operation and the quality of the intake air e g dust conten...

Page 44: ...is lifted off by some mm Pivot the reservoir cover 180 Remove the used fine oil separator 1 Fig 20 Clean all seals and if necessary remove and clean the O ring Install a new fine oil separator Pivot t...

Page 45: ...outward and remove housing base Detach air filter cartridge while slightly turning it Carefully insert new air filter cartridge in the housing Close air filter with housing base The snap latches must...

Page 46: ...his time to discharge NOTICE Making incorrect settings to the control transformer poses a risk to the trouble free operating of the system Checking the setting of the control transformer is part of co...

Page 47: ...s do not aim the compressed air at people especially Controller components Fittings Air end block Cooler Electric motor Remove and clean the dirt trap strainer only for water cooled units 10 12Clean c...

Page 48: ...the filter pad Insert the new filter pad into the louver grille Ensure that the smooth side A Fig 28 of the filter pad faces the air inlet side Place the louver grille back onto the filter housing Ch...

Page 49: ...ote that proper lubrication can significantly increase the lifespan of your compressor system In accordance with valid accident prevention regulations lubricating oils should be used whose characteris...

Page 50: ...or the prescribed pressure L30RS L45RS 8 Wait until the mains pressure has fallen below the lower switching point Unit stops during the start up phase 1 Suction regulator only closes part way pressure...

Page 51: ...2 Check the suction regulator and solenoid valve Oil in the compressed air 1 Fine oil separator is defective 1 Replace the fine oil separator cartridge 2 Oil foams 2 Replace the oil 3 Oil level is too...

Page 52: ...55 200V 230V 460V 575V Amps 143 124 63 50 170 148 75 59 Standard drive motor detail TEFC IP55 EPACT Drive motor speed rpm 3600 Fan motor rating hp kW 1 2 0 86 IP 54 Suggested cable size 200V 230V 460V...

Page 53: ...40 30 Nominal voltage frequency 460V 10 60Hz Full load current max at 460V Amps 57 Standard drive motor detail TEFC IP55 EPACT Drive motor speed min max rpm 800 2960 Fan motor rating hp 1 2 0 86 IP 5...

Page 54: ...ng hp kW 50 37 Nominal voltage frequency 460V 10 60Hz Full load current max at 460V Amps 71 Standard drive motor detail TEFC IP55 EPACT Drive motor speed min max rpm 800 3600 Fan motor rating hp 1 2 0...

Page 55: ...max IP55 200V 230V 460V 575V Amps 207 180 90 73 Standard drive motor detail TEFC IP55 EPACT Drive motor speed rpm 3600 Fan motor rating hp kW 2 0 1 5 IP 54 Suggested cable size 200V 230V 460V 575V 167...

Page 56: ...ting hp kW 60 45 Nominal voltage frequency 460V 10 60Hz Full load current max at 460V Amps 84 Standard drive motor detail TEFC IP55 EPACT Drive motor speed min max rpm 800 4050 Fan motor rating hp 2 1...

Page 57: ...T 1 1 2 11 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 o...

Page 58: ...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 r...

Page 59: ...12 Annex 57 Fig 31 all dimensions in mm...

Page 60: ...essor 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 Fa...