Gardner Denver L4-5C Original User Manual Download

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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

Summary of Contents for 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...

Page 2: ...ors 3 Repair and maintenance kits designed with the necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and skilled in compressor maint...

Page 3: ...nomical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriat...

Page 4: ...a low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not...

Page 5: ...ressor air or oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFP...

Page 6: ...ection 3 Starting Operating Procedures 17 Section 4 Controls Instrumentation 22 Section 5 Lubrication Oil Cooler Oil Filter Separator 40 Section 6 Heat Exchangers Oil Air 48 Section 7 Air Filters 51 S...

Page 7: ...B As meshing continues more of the main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression...

Page 8: ...13 25 629 v03 Page 8 Figure 1 2 COMPRESSOR ILLUSTRATION EXTERNAL DETAILS 302ECA797 A Ref Drawing Page 1 of 2...

Page 9: ...13 25 629 v03 Page 9 Figure 1 3 COMPRESSOR ILLUSTRATION INTERNAL DETAILS 302ECA797 A Ref Drawing Page 2 of 2...

Page 10: ...13 25 629 v03 Page 10 Figure 1 4 COMPRESSOR ILLUSTRATION TOTAL SYSTEM L4 5 Base Model with 120 gallon receiver and XGNC dryer shown 307ECA804 A Ref Drawing Page 1 of 2...

Page 11: ...pressor air oil reservoir separator chamber and all piping and tubing may be at high temperature during and after operation LOCATION Figure 2 1 The compressor must be installed where it is protected f...

Page 12: ...screw compressor requires no special foundation but should be mounted on a smooth and solid surface Whenever possible install the unit near level Mounting bolts are not normally required However inst...

Page 13: ...removed Any of the enclosure panels may be removed by opening the latch and lifting it up slightly Do not operate the compressor with the fan and belt guard removed Exposed fan and belts may cause in...

Page 14: ...ovided with an optional stand alone combination moisture separator and trap that is field installed downstream of the after cooler CONTROL PIPING Control piping is not necessary since the rotary screw...

Page 15: ...erage Perform all wiring in accordance with the National Electrical Code NFPA 70 and any applicable local electrical codes Wiring must be performed only by qualified electricians Electrical shock can...

Page 16: ...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 packag...

Page 17: ...and extended drain intervals of AEON 4000 lubricant Use only genuine Gardner Denver filters designed and specified for this compressor Always stop the unit and release air pressure before removing oi...

Page 18: ...acuum pressure but this may damage the compressor by prolonged operation under reverse rotation If motor reverse rotation is confirmed follow the appropriate lockout tagout procedure to isolate the pa...

Page 19: ...ent o Display info 2nd row Menus Total Running Hrs default menu o Display info 3rd row Status Fault and Warning messages Load status default menu Setting the Cut out Pressure o Navigate to the Control...

Page 20: ...n cause injury or death Open lockout and tagout main disconnect and any other circuits before servicing the unit The enclosure doors must be closed and latched to keep the compressor package from over...

Page 21: ...n press the I key to start the unit 4 Run for approximately several minutes until the temperature stabilizes 5 The unit is equipped with a minimum 70 psig pressure check valve No special procedure is...

Page 22: ...the GD Pilot controller which integrates all the control functions under microprocessor control see Figure 4 1 for general detail of the controller keypad and display Controller functions include saf...

Page 23: ...ction for the main drive motor as well as limited compressor speed modulation NOTICE Read the Operator s Manual before operating the compressor It is critical that the detailed instructions for the co...

Page 24: ...13 25 629 v03 Page 24 FIGURE 4 2 WIRING DIAGRAM 208 230 460V 60 Hz 306ECA546 B Ref Drawing Page 1 of 3...

Page 25: ...13 25 629 v03 Page 25 FIGURE 4 3 WIRING DIAGRAM 208 230 460V 60 Hz 306ECA546 B Ref Drawing Page 2 of 3...

Page 26: ...13 25 629 v03 Page 26 FIGURE 4 4 WIRING DIAGRAM 208 230 460V 60 Hz 306ECA546 B Ref Drawing Page 3 of 3...

Page 27: ...13 25 629 v03 Page 27 FIGURE 4 5 WIRING DIAGRAM 380V 60 Hz 303ECA546 B Ref Drawing Page 1 of 3...

Page 28: ...13 25 629 v03 Page 28 FIGURE 4 6 WIRING DIAGRAM 380V 60 Hz 303ECA546 B Ref Drawing Page 2 of 3...

Page 29: ...13 25 629 v03 Page 29 FIGURE 4 7 WIRING DIAGRAM 380V 60 Hz 303ECA546 B Ref Drawing Page 3 of 3...

Page 30: ...13 25 629 v03 Page 30 FIGURE 4 8 WIRING DIAGRAM 575V 305ECA546 A Ref Drawing Page 1 of 3...

Page 31: ...13 25 629 v03 Page 31 FIGURE 4 9 WIRING DIAGRAM 575V 305ECA546 A Ref Drawing Page 2 of 3...

Page 32: ...13 25 629 v03 Page 32 FIGURE 4 10 WIRING DIAGRAM 575V 305ECA546 A Ref Drawing Page 3 of 3...

Page 33: ...13 25 629 v03 Page 33 Figure 4 11 WIRING DIAGRAM 230V 1 Phase 307ECA546 D Ref Drawing Page 1 of 4...

Page 34: ...13 25 629 v03 Page 34 Figure 4 12 WIRING DIAGRAM 230V 1 Phase 307ECA546 D Ref Drawing Page 2 of 4...

Page 35: ...13 25 629 v03 Page 35 Figure 4 13 WIRING DIAGRAM 230V 1 Phase 307ECA546 D Ref Drawing Page 3 of 4...

Page 36: ...13 25 629 v03 Page 36 Figure 4 14 WIRING DIAGRAM 230V 1 Phase 307ECA546 D Ref Drawing Page 4 of 4...

Page 37: ...aerosol oil stream in the compressed air exiting the inertial separation process within the oil sump Oil Filler Cap 8 Oil fill port on the oil sump Oil drain 9 28 Ball valve 9 drains the oil from the...

Page 38: ...also trigger a shutdown event in case an exceedingly high is detected The following items are provided with the Total System variant Receiver 21 Provides storage of compressed air and serves as a sup...

Page 39: ...13 25 629 v03 Page 39 Figure 4 15 PIPING AND INSTRUMENTATION ILLUSTRATION 301ECA797 01 Ref Drawing Page 1 of 1...

Page 40: ...ed with one of several Gardner Denver AEON lubricants These lubricants are formulated to the highest quality standards and are factory authorized tested and approved for use in rotary screw compressor...

Page 41: ...tubing may be at high temperature during and after operation Use of improper lubricants will cause damage to equipment Do not mix different types of lubricants or use inferior lubricants Improper equi...

Page 42: ...e at the bottom of the oil sump and remove the single drain plug at the bottom of the oil core tank Once the oil has been drained reinstall the drain plug and close the drain valve Remove and drain oi...

Page 43: ...nges may indicate excessive oil carry over and should be investigated Excessive oil carry over can damage equipment Never fill oil reservoir above the FULL marker OIL CHANGE INTERVAL Recommended oil c...

Page 44: ...new element gasket with clean lubricant used in the unit Screw each new element on the filter body and tighten by hand Tighten 1 2 turn more after gasket makes contact DO NOT OVERTIGHTEN ELEMENT 5 Wip...

Page 45: ...element 85 185 F does not prevent water condensation consult your application with Gardner Denver The standard thermostatic element may be replaced with a high temperature one 98 C 208 F and the oil...

Page 46: ...is equivalent to the difference between the two 2 pressure sensors in use The pressure differential value may be calculated by subtracting the system pressure value from the compressor discharge press...

Page 47: ...190 200 210 220 230 240 250 260 30 40 50 60 70 80 90 100 110 120 130 Ambient Temp oF Discharge PDP oF 100psig 125psig 150psig 175psig Pressure Dew Point Trend 100 r h 30 35 40 45 50 55 60 65 70 75 80...

Page 48: ...fan located behind the fresh air inlet grille delivers an air stream to a cool the exterior of the main electric motor and b meet the cooling demands of the air oil combination heat exchanger on its...

Page 49: ...the unit is completely off and that oil reservoir is depressurized 2 Open and or remove enclosure door panel adjacent the cooler assembly see Figure 6 2 for details 3 Inspect core area If blocked wit...

Page 50: ...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...

Page 51: ...ot oil this element Do not wash in inflammable cleaning fluids Do not use solvents other than water Improper cleaning may damage the element Never operate the unit without the element Never use elemen...

Page 52: ...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 3 Replace...

Page 53: ...mitted 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 det...

Page 54: ...age 4 Check alignment of the sheave set and make sure that v belts are properly seated in sheave grooves 5 Screw out adjusting bolt 6 and secure with jam nut 2 to allow motor weight to rest on v belts...

Page 55: ...ts 2 Remove the belts 3 Carefully sketch or photograph the orientation of each sheave bushing pair as they sit on their respective shaft You ll need this information to re install each pair 4 Loosen a...

Page 56: ...ne by venting to atmosphere the gas trapped underside of the piston via check valve 19 and orifice 18 During the unloaded state a two way solenoid valve feeds pressurized air underneath the piston 2 1...

Page 57: ...3 Close when provided valve isolating compressor package from air system 4 Refer to Figure 9 1 for hardware details 5 Loosen and remove the air filter element 6 Remove four bolts securing inlet flange...

Page 58: ...in personal injury or death Never paint lubricate or alter a relief valve Do not plug vent or restrict Operation of the unit with improper relief valve setting can result in severe personal injury or...

Page 59: ...supply to the starter 3 Unscrew the minimum pressure valve assembly from compressor housing and remove 4 Inspect the valve seat surface on the valve itself Cleanse or replace Also inspect the mating s...

Page 60: ...tting temperature it is stamped on the valve seat area 5 Immerse the valve body in a bath of compressor oil heat the oil slowly and note the temperatures at which seat first starts moving and at it fi...

Page 61: ...13 25 629 v03 Page 61 Figure 9 5 Compressor Module Hardware...

Page 62: ...6 in Figure 9 6 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 f...

Page 63: ...n 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 3 Remove the cooling fan module Disconnect the individual plug connector...

Page 64: ...r Model GSRN Dryer Model L4 XGNC25 GSRN25 L5 XGNC32 GSRN40 Installation Package must installed in a location with an ambient temperature range of 40 F to 110 F 3 C to 43 C Consult Gardner Denver for o...

Page 65: ...nd the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan...

Page 66: ...l Separator Check Reservoir Oil Level Check for Proper Load Unload Check Dirt Accumulation on Cooler Change Oil Filter Element Clean Oil Return Orifice Change Compressor Lubricant AEON 4000 Check Reli...

Page 67: ...se of overload 4 Fast pressure buildup due to open inlet valve 4 Inspect inlet valve and unloader valve operation Replace if faulty 5 High oil viscosity 5 Review oil type for ambient temperature or pr...

Page 68: ...ooler is frozen 10 Thaw out This machine cannot operate in temperatures below 32 F 0 C High discharge air temperature 1 Dirty or clogged cooler core or fins 1 Clean cooler 2 Insufficient cooling air f...

Page 69: ...ter condensate in oil 8 Check oil reservoir temperature and if low change thermal mixing valve element to one with higher temperature setting Excessive water in air delivery line 1 Water separator dra...

Page 70: ...oltage Operation with lower voltages will reduce motor life and load capacity As voltages get further below the design range other symptoms may show up Low voltages may lead to high motor currents The...

Page 71: ...WITHIN 30 DAYS AFTER THE DATE UPON WHICH THE PRODUCT IS CLAIMED NOT TO HAVE BEEN AS WARRANTED ANY ACTION FOR BREACH OF THIS WARRANTY MUST BE COMMENCED WITHIN ONE YEAR AFTER THE DATE UPON WHICH THE CA...

Page 72: ...For additional information contact your local representative or visit www contactgd com compressors 2021 Gardner Denver Inc Printed in U S A...

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