Gardner Denver L Series User Manual Download

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L-SERIES FRAME 5

BASE MOUNTED COMPRESSOR

Original User and Service Manual

125, 150, 180 HP

MODELS:

L90-132E

LRS90-132E

50/60Hz

13-25-639

Version 00

September, 2019

Summary of Contents for L Series

Page 1: ...L SERIES FRAME 5 BASE MOUNTED COMPRESSOR Original User and Service Manual 125 150 180 HP MODELS L90 132E LRS90 132E 50 60Hz 13 25 639 Version 00 September 2019...

Page 2: ...ore 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...

Page 3: ...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 within this manu...

Page 4: ...lectrical components The power condensers require this time in order to discharge Check the DC bus voltage at the system terminal strip of the frequency converter by measuring this between the DC and...

Page 5: ...with open doors or loose access panels Read the operator s manual before proceeding withthis task Opening pressure relief valve xx bar value xx see sticker on compressor Handle package at forklift poi...

Page 6: ...13 25 639 v00 Page 5 Fig 1 Your Gardner Denver distributor Name Address Telephone Fax Contact Spare Parts Service...

Page 7: ...t operating conditions Service If you encounter a fault or require spare parts please contact your Gardner Denver representative Trained expert staff will quickly and properly make repairs with genuin...

Page 8: ...pressor 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 certifications As a consequenc...

Page 9: ...ign of the unit 19 5 1 1 Design of air cooled units 19 5 1 2 Design of water cooled units 20 5 2 System Schematic 21 5 3 Oil circuit 22 5 4 Air circuit 22 5 5 System control 22 6 Transport and install...

Page 10: ...of air intake filter 48 10 8 Pressure relief valve 49 10 9 Connecting terminals in the switch cabinet 50 10 10 Screw connections 51 10 11 General maintenance and cleaning 51 10 12 Clean change filter...

Page 11: ...at 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 compromise...

Page 12: ...ed 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 13: ...ing 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 t...

Page 14: ...hout prior warning As an additional safety measure persons who start remotely controlled systems have to take sufficient safety precautions in order to ensure that nobody is checking the system or wor...

Page 15: ...o that they can turn like doors etc must be secured and made immobile Parts to be removed for transport purposes must be carefully refitted and fixed again before putting the machine installation back...

Page 16: ...to perform maintenance Danger Safety measure required Components of importance to safety wear over time Observe the setting maintenance and inspection work and intervals stipulated in the operating m...

Page 17: ...or attach a warning sign to the main switch L90RS L132RS only Danger of electric shock from loaded condensers Always first disconnect the system from the power supply and wait another 10 minutes befor...

Page 18: ...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 Mo...

Page 19: ...at 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 liabilit...

Page 20: ...Minimum pressure and non return valve 14 Air cooler 15 Fine oil separator extraction 16 Oil temperature regulator 17 Cooling fan 18 Cool air inlet filter pad 19 Compressed air outlet 20 Base frame 21...

Page 21: ...d 19 Compressed air outlet 20 Base frame 21 Control panel 22 Emergency stop button 23 Switchcabinet 24 Feed cable entry 25 Final compression temperature sensor 26 System pressure sensor 27 Final compr...

Page 22: ...ler block 17 Oil filter 33 Cooling water solenoid valve Y6 3 Electric motor 18 Cooling fan only water cooled units 4 Air end block 19 Motor lubrication system E4 E5 34 Manual regulating valve 5 Final...

Page 23: ...to the pressure reservoir oil reservoir 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...

Page 24: ...itched on or off in dependence upon the final compression temperature only air cooled units The cooling water solenoid valve 33 Y6 is opened and closed depending on the compression end temperature onl...

Page 25: ...ll if mistakes are made when lifting and this will put your life at risk Safety devices may be damaged if lifted incorrectly Always observe the safety notesin Section 4 5 of the user manual Never lift...

Page 26: ...mance of a compressor Once the compressor has been installed the R clips 1 Fig 7 can be removed from the hinge pins 2 Fig 7 The R clips prevent the doors from falling off while being transported from...

Page 27: ...m duct cross section of approx 9 8 ft2 Fig 8 b 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 f...

Page 28: ...ry connecting flange or connecting thread are appropriate and in perfect working order For connections with hoses take steps so that if an end breaks free it won t whip around dangerously NOTICE After...

Page 29: ...ever possible the cooling water outlet temperature should be below 122 F in order to prevent excessive precipitation of limestone fur CAUTION Environmental hazard As a result of leakage in oil water c...

Page 30: ...nformation set out below is intended for guidance and may differ under certain conditions of operation The total composition and the operating temperature are always decisive Warranty claims may not b...

Page 31: ...be utilized to terminate the supply conductors to the line side of the VFD The final installation is up to the discretion of the installer s certified electrical contractor and local electrical codes...

Page 32: ...level mark For oil filling also see Sections 10 4 and 10 15 CAUTION Fire hazard and slip hazard Do not spill any oil Look for leaks Immediately take care of any spilled oil Air oil under pressure wil...

Page 33: ...ntil the air has bubbled out The oil level should be checked at each pause in operation and at regular intervals using the transparent plastic tube on the pressure reservoir 2 Fig 13 The oil level mus...

Page 34: ...toring the screw compressor system or in the event of a longer period of downtime if there is the risk of frost t 34 F the cooling water should be completely discharged CAUTION The rotational directio...

Page 35: ...r fault is present The factory settings of the Load Target and Unload set points are saved in the compressor controller and depend on the pressure variant of the compressor see nameplate fig 1 stage p...

Page 36: ...13 25 639 v00 Page 35 Fig 14 a 1 Drive motor direction with direct drive Fig 14 b Air cooled units...

Page 37: ...entation Temperature start up protection The screw compressor unit will not start up if the ambient temperature is lower than 34 F NOTICE For switching the compressor off normally use only the stop pu...

Page 38: ...commissioning 8 3 Display of the compressor controller Fig 15 1 Touchscreen Display 2 Start push button I 3 Stop push button O 4 Emergency stop NOTICE Only for L90RS L132RS If the compressor has been...

Page 39: ...ay use the STOP button 3 Fig 15 and not the emergency STOP button 4 Fig 15 After shutdown the compressor has a run on time of 30 50 seconds soft stop The time remaining is counted down on the display...

Page 40: ...t stop 8 7 Emergency stop The EMERGENCY STOP button is situated next to the compressor controller It is used to immediately shut down the unit Only use the EMERGENCY STOP button 4 Fig 15 to shut down...

Page 41: ...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 stored i...

Page 42: ...ditional 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...

Page 43: ...es to a stop and the screw compressor unit is depressurized The pressure gauge shows no morethan 4 4 PSI Shortly after shutting off the screw compressor unit a small residual pressure may remain There...

Page 44: ...rts lists for the kit part number and for the tool kit part number The tool kit is required to change the oil seal If the oil seal is a lip seal the wear sleeve must always be replaced 2 Replace lubri...

Page 45: ...or 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 Check V...

Page 46: ...be drained as fully as possible because the used oil strongly decreases the life span of the new oil Different lubricating oils must not be mixed When changing this type of oil the oil must be comple...

Page 47: ...Slowly open the oil screw plug 2 Fig 16 to relieve the screw compressor of any residual pressure in the system Remove the oil screw plug Open the oil drain 6 Fig 16 from the pressure reservoir Drain t...

Page 48: ...nditions e g coolant temperatures the type of operation and the quality of the intake air e g dust content ratio of gaseous foreign substances such as SO2 and solvent vapors have a strong influence on...

Page 49: ...oir and the oil extractor which have been removed Changing times for the fine oil separator Operating conditions e g coolant temperatures the type of operation and the quality of the intake air e g du...

Page 50: ...such conditions exist the filter element may require changing more frequently Change the air filter asfollows Pull snap latch outward and remove housing base Detach air filter cartridge while slightl...

Page 51: ...d and secured from being switched onagain Push the STOP button on the compressor controller After the soft stop time 30 sec set the on site main switch to 0 OFF and secure it against being switched on...

Page 52: ...only L90RS L132RS a Filter mat cool air intake 1 Fig 23 Perform filter mat change as follows Remove the mounting screws 2 Fig 23 Take out the filter mat 1 Fig 23 and clean it replace it if damaged Cle...

Page 53: ...between changes may be shorter Fig 26 1 Dirt interceptor 2 Cooling water solenoid valve 3 Manual regulating valve Lock water inflow and water outflow on the compressor Provide a suitable container in...

Page 54: ...proper lubrication can significantly increase the lifespan of your compressor system In accordance with valid accident prevention regulations lubricating oils should be used whose characteristics corr...

Page 55: ...re has fallen below the lower switching point Unit stops during the 1 start up phase Suction regulator only closes part way pressure builds up too quickly in the pressure reservoir 1 Make the suction...

Page 56: ...alve 2 System doesn t discharge 2 Check the suction regulator and solenoid valve Oil in the compressed 1 air Fine oil separator is defective 1 Replace the fine oil separator cartridge 2 Oil foams 2 Re...

Page 57: ...ns in inches A Compressed air connection Canada USA Version male screwed thread NPT 1 11 B Cool air intake C Hot air discharge D Cooling air inlet Variable speed machines only E Feed cable entry F Coo...

Page 58: ...13 25 639 v00 Page 57 Fig 28 all dimensions in inches...

Page 59: ...NOTES...

Page 60: ...Gardner Denver Compressor Division 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9868 Fax 217 224 7814...

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