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Gardner Denver L55, User And Service Manual

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Gardner Denver L55 User And Service Manual Download Page 6

4 

August 20, 2018 

PROHIBITION/MANDATORY ACTION 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 

task 

 

Opening pressure relief valve = xx bar (value "xx" see 
sticker on compressor)

 

 

 

 

Handle package at forklift points only 

 

Before disassembling the tube bundle, the intake union 
must be disassembled! (Only for water-cooled units) 

 

Summary of Contents for L55

Page 1: ...Original User and Service Manual Screw Air Compressor L55 L75 L55RS L75RS USA 13 21 605 VERSION 00...

Page 2: ......

Page 3: ...e 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 essential t...

Page 4: ...erence 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 Labels are used w...

Page 5: ...f 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 converter between the DC terminal and the...

Page 6: ...r operate the unit with open doors or loose access panels Read the operator s manual before proceeding with this task Opening pressure relief valve xx bar value xx see sticker on compressor Handle pac...

Page 7: ...__________________________________________________________________________ _____________________________________________________________________________________ _______________________________________...

Page 8: ...mpressor fulfills the requirements made of it Therefore it is essential that the prescribed maintenance intervals are adhered to and that maintenance and upkeep are done thoroughly especially under di...

Page 9: ...nver replacement parts alterations to the equipment The warrantee or liability terms of Gardner Denver s Terms and Conditions are not expanded by the foregoing Any independent alterations to the compr...

Page 10: ...er cooled units 20 5 2 System Schematic 21 5 3 Oil circuit 22 5 4 Air circuit 22 5 5 System control 22 5 5 1System control L55 80 22 5 5 2System control L55RS L75RS 23 6 Transport and installation 26...

Page 11: ...ol transformer setting 49 10 10 Screw connections 51 10 11 General maintenance and cleaning 51 10 12 Clean change filter with cool air intake and control box filter pads 51 10 13 Clean dirt intercepto...

Page 12: ...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 comp...

Page 13: ...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 no...

Page 14: ...g 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 the...

Page 15: ...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 nec...

Page 16: ...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 meas...

Page 17: ...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 oil...

Page 18: ...ressurized or moving parts Only carry out inspection maintenance and repair work when the screw compressor system is at a standstill and is not under pressure The system must be secured from being swi...

Page 19: ...t 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 liability...

Page 20: ...18 August 20 2018 5 Design and functioning 5 1 Design of the unit 5 1 1 Design of air cooled units...

Page 21: ...ture regulator 17 Cooling fan 18 Cool air inlet filter mat 19 Compressed air outlet 20 Base frame 21 Control panel 22 Emergency stop button 23 Switch cabinet 24 Feed cable entry 25 Final compression t...

Page 22: ...ter mat 19 Compressed air outlet 20 Base frame 21 Control panel 22 Emergency stop button 23 Switch cabinet 24 Feed cable entry 25 Final compression temperature sensor 26 System pressure sensor 27 Fina...

Page 23: ...ervoir 7 Fine separator 8 Oil draining 9 Pressure relief valve 10 Oil filter monitor S5 11 Oil filter 12 Oil cooler 13 Throttle 15 Minimum pressure and non return valve 16 Compressed air after cooler...

Page 24: ...e 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 consumer network 5 5 System control See also o...

Page 25: ...pressure control valve 2 2 in the suction regulator 2 closes and the pressure reservoir is unloaded to atmospheric pressure After 30 seconds the drive motor 3 and the cooling fan motor 25 are shut do...

Page 26: ...perature only air cooled units The cooling water solenoid valve 34 Y6 is opened and closed depending on the compression end temperature only water cooled units When the pressure at the system pressure...

Page 27: ...August 20 2018 25 Fig 5...

Page 28: ...oose parts or parts which can swing freely must be safely secured before the unit can be lifted It is strictly prohibited to stand in the danger zone of a lifted load Ensure that the transport load ap...

Page 29: ...mpressor 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 so that...

Page 30: ...tated 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 screens etc please c...

Page 31: ...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 operating instructions Automatic drain fa...

Page 32: ...efore being reinstalled In the case of even the slightest damage replace the pipe bundle Always use new seals when carrying out assembly work The cooling water circuit is completely installed in the s...

Page 33: ...0 0 Conductivity 50 800 S cm 50 200 S cm 7 4 Electrical connection USA CANADA Version only DANGER Risk of strong damages and fire on the electric power components 1 The power supply to the compressor...

Page 34: ...ambient temperature Compressor type Supply voltage Installed nominal motor power Main supply type 1 Fuse s protection slow blow fuse class J Line cross section conductor rated 140 F 167 F 194 F V hp...

Page 35: ...k to the trouble free operating of the system Checking the setting of the control transformer is part of commissioning and part of regular inspection maintenance because the supply voltage can change...

Page 36: ...the transparent plastic tube on the pressure reservoir 2 Fig 14 The oil level must lie between the maximum oil level 3 Fig 14 and minimum oil level 4 Fig 14 marks on the oil container If required top...

Page 37: ...ctrical control Open isolator valves between the screw compressor reservoir and pipe Ensure cooling water supply in accordance with Chapter 7 3 only water cooled units Turn on the main power supply sw...

Page 38: ...ction of rotation for compressor direction of rotation may deviate from this representation NOTICE For switching the compressor off normally use only the stop push button 3 Fig 16 but not the EMERGENC...

Page 39: ...d Before commissioning make sure that no one is located in the danger zone of the motor screw compressor After doing work Check that all safety equipment is reinstalled and that all tools have been ta...

Page 40: ...menu After the acknowledgement the message READY TO START appears on the display unless another fault is present Press START button I 2 Fig 16 8 6 Shutoff To switch off the compressor use the O key 3...

Page 41: ...sible 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 should be...

Page 42: ...ional information refer to the motor manufacturer s instructions The following procedure should be used in regreasing 1 Stop the unit 2 Disconnect lockout and tagout the unit from the power supply 3 R...

Page 43: ...aning intervals have to be shortened as required For order numbers see the spare parts list 10 3 1 Service Check List Every 8 hours operation Check air oil reservoir oil level add oil if required See...

Page 44: ...enge line if necessary 5 Inspect the inlet valve service if necessary see parts list for repair kit part number 6 Inspect minimum pressure check valve operation repair if necessary See Fig 2 Minimum D...

Page 45: ...ssary scavenge line replace check valve Inspect service if necessary Inlet Valve Inspect re grease if necessary Motor Bearings Inspect replace if necessary Drive Belts if app Inspect replace if necess...

Page 46: ...months 20000 hours 66 months 22000 hours 72 months 24000 hours 78 months 36000 hours 84 months 28000 hours 90 months 30000 hours 96 months 32000 hours 102 months 34000 hours 108 months 36000 hours 114...

Page 47: ...are based on intake air which is normally available and if foreign substances dust steam gases are not present in large amounts When changing the oil the old oil must be drained as fully as possible b...

Page 48: ...filter cartridge properly it is hazardous waste Look for leaks Fig 18 1 Oil filter cartridge The changing intervals can be found in the maintenance schedule Replace the oil filter cartridge as follow...

Page 49: ...e 10 3 If the fine oil separator is monitored optional then a differential pressure that is too high will be shown in the control panel of the GD Pilot TS compressor control When the corresponding war...

Page 50: ...depressurized and secured from being switched on again NOTICE Never operate the screw compressor system without an air filter even briefly removing it can cause considerable damage to the machine Fig...

Page 51: ...lief valve may result in pressure that is too high breaking open parts of the system and causing serious or fatal injury Never operate a screw compressor system with a defective pressure relief valve...

Page 52: ...ch the unit off as described in Chapter 8 6 Change the control transformer setting as follows if the output voltage is not correct Change the control transformer setting accordingly Set the on site ma...

Page 53: ...ler components Fittings Air end block Cooler Electric motor Remove and clean the dirt trap strainer only for water cooled units 10 12Clean change filter with cool air intake and control box filter pad...

Page 54: ...Only perform checks and carry out work on the screw compressor when the unit is out of operation depressurized and secured from being switched on again Fig 27 1 Dirt interceptor 2 Cooling water soleno...

Page 55: ...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 characteristic...

Page 56: ...he prescribed pressure L55RS L75RS 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 bui...

Page 57: ...System doesn t discharge 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...

Page 58: ...ad current max IP55 200V 230V 460V 575V Amps 255 223 112 88 371 323 162 130 Motor protection type TEFC IP55 EPACT Drive motor speed rpm 3600 Fan motor power hp kW 1 9 1 4 3 4 2 5 Suggested cable size...

Page 59: ...5 55 Nominal voltage tolerance frequency 460V 10 60Hz Full load current max at 460V Amps 105 Motor protection type TEFC IP55 EPACT Drive motor speed min max rpm 750 3000 Fan motor power hp kW 1 9 1 4...

Page 60: ...hp kW 100 75 Nominal voltage tolerance frequency 460V 10 60Hz Full load current max at 460V Amps 141 Motor protection type TEFC IP55 EPACT Drive motor speed min max rpm 650 4050 Fan motor power hp kW...

Page 61: ...r intake 6 Cool air intake of switch cabinet only L55RS L75RS 9 water inlet cold only for water cooled variant inside thread EN 10226 1 Rp 1 Adaptor 1 11 1 2 NPT for CDN USA variant 10 water outlet ho...

Page 62: ...60 August 20 2018 Fig 29 all dimensions in mm...

Page 63: ......

Page 64: ...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...

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