Gardner Denver L15 User Manual Download

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Original Operating and Service Manual

Screw Air Compressor
L15 - L22
L15 RS - L22 RS

●

USA

Id. no. ZS1138156 / 00 - April 2015

Summary of Contents for L15

Page 1: ...Original Operating and Service Manual Screw Air Compressor L15 L22 L15 RS L22 RS USA Id no ZS1138156 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: ...djustment 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 Saf...

Page 5: ...he DC bus 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 frequency converter operatin...

Page 6: ...TION 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 t...

Page 7: ...ddress _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________...

Page 8: ...essor 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 diffi...

Page 9: ...t 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 compressor equipment...

Page 10: ...version work modifications on the machine 17 5 Design and functioning 18 5 1 Design of the unit 18 5 1 1 Design of the unit L15 L22 L15 RS L22 RS 18 5 2 Schematic diagram 19 5 3 Oil circuit 20 5 4 Air...

Page 11: ...tor 38 10 3 Maintenance and inspection schedule 38 10 3 1 Service Check List 39 10 4 Oil change 41 10 5 Change of oil filter cartridge 42 10 6 Change of the fine separator cartridge 43 10 7 Change of...

Page 12: ...Make 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: ...ed that this safety device should be used for pressures above 58 PSI The steel wire has a diameter of 8 mm and is firmly clamped to the hose at least every 500 mm Both ends are fitted with cable lugs...

Page 14: ...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 these compressors mus...

Page 15: ...thout 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 wo...

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 5 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: ...ted Ensure that the power unit cannot be switched on inadvertently The system must be secured from being switched on Seal off the main switch and remove the key and or attach a warning sign to the mai...

Page 19: ...operly 4 8 Dangers resulting from conversion work modifications on the machine Danger Safety measure required Genuine parts are designed especially for the machine Modifications may interfere with saf...

Page 20: ...Oil drain 10 Oil level indicator 11 Oil filter 12 Oil cooler 13 Pressure relief valve 14 Minimum pressure and non return valve 15 Air cooler 16 Oil fine separator extractor 17 Oil temperature regulat...

Page 21: ...r 8 Oil filler cap 9 Oil drain 10 Oil level indicator 11 Oil filter 12 Oil cooler 13 Pressure relief valve 14 Minimum pressure and non return valve opening pressure 65 PSI 15 Air cooler 16 Oil fine se...

Page 22: ...me time 5 4 Air circuit The intake air passes through the intake filter 1 Fig 3 and the suction regulator 2 Fig 3 into the screw compressor 4 Fig 3 During the compression process the intake air is coo...

Page 23: ...compressor extracts a certain volume of air via a start valve 2 1 Fig 4 Pressure builds up in the reservoir and closes the regulator This way constant pressure of approx 58 to 65 PSI is maintained in...

Page 24: ...alve Y1 Fig 4 is de energized closed Reservoir pressure is reduced to approx 58 to 65 PSI and the pressure maintenance valve 8 Fig 4 closes This way no more compressed air will be supplied to the main...

Page 25: ...compressor The fork length of the fork lift must correspond to the unit width see Section 12 5 Keep the distance between see fig 6 and length of the forks in mind when transporting the compressor All...

Page 26: ...propriately protected from being touched and labeled NOTICE The operator must always provide sufficient ventilation and exhaust for the compressor station The screw compressor unit has to be leveled A...

Page 27: ...a minimum duct cross section of approx 310 in 2 NOTICE The minimum channel diameter is based on a duct with a maximum length of 16 4 ft and a maximum of one bend For different values over 16 4 ft mor...

Page 28: ...screw compressor 1 Fig 9 For this you should use a flexible connection e g compressed air hose compensator Connection sleeve G 1 1 NPT NOTE After coolers separators collecting reservoirs and the compr...

Page 29: ...supply cable through the cable gland 1 Fig 10 on the switch cabinet and tighten screws Connect the supply line to the connecting terminals as shown in the circuit diagram Fig 10 CAUTION If local regul...

Page 30: ...ge However practice has shown that the actual supply voltage often differs from this value Before first commissioning set the measured supply voltage on the control transformer Fig 11 illustrates an e...

Page 31: ...l mark For oil filling also see Sections 10 4 and 10 15 Fig 13 1 Oil filler cap R1 2 Oil level indicator 3 Maximum oil level 4 Minimum oil level Check the oil level as follows Switch off the screw com...

Page 32: ...ed out as follows Remove transport guards see Section 7 4 Fig 12 Fill oil in the pressure vessel up to maximum oil level mark This applies to compressor systems which are delivered without having been...

Page 33: ...een the screw compressor reservoir and pipe Switch on the power supply master switch Once the power supply has been switched on the POWER LOSS fault appears This fault must be acknowledged using the k...

Page 34: ...system is fitted with a three row display 1st row The final compression temperature final compression pressure and network pressure are permanently displayed here Final compression temperature is the...

Page 35: ...Press these keys at the same time until the right language appears 9 5 2 Setting network pressure only L15 L22 Max network pressure The network pressure is set in the CONTROL MENU sub menu The keys h...

Page 36: ...2 more than the TARGET PRESSURE You may therefore have to first set the TARGET PRESSURE To prevent your compressor suffering from excess wear the difference between the CUT OUT POINT and TARGET PRESSU...

Page 37: ...y always use the key 9 9 Acknowledging warning fault messages Warning and fault messages are shown in the third row of the display The red light signal flashes at the same time You will find a table c...

Page 38: ...0 00 00 p27 ___________00 00 00 00 02 EM STOP 12345h 01 EM STOP 12300h CUT OUT POINT 13 0bar CUT IN POINT 12 5bar p2 CUT OUT POINT 10 5bar p2 CUT IN POINT 10 0bar AUTOMATIC OPERATION ENABLE REMOTE STA...

Page 39: ...02 EM STOP 12345h 01 EM STOP 12300h CUT OUT POINT 13 0bar TARGET PRESSURE 12 5bar p2 CUT OUT POINT 10 5bar p2 TARGET PRESSURE 10 0bar AUTOMATIC OPERATION DISPLAY UNITS m3 min ENABLE REMOTE START OFF T...

Page 40: ...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 parts propelled at high speed by compressed air can...

Page 41: ...ction 10 13 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...

Page 42: ...f necessary 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...

Page 43: ...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 44: ...evel see Section 7 5 The oil level must be between the maximum level 4 Fig 16 and minimum level 5 Fig 16 marked on the oil reservoir If required top up oil Oil Change interval The operating conditions...

Page 45: ...ridge The operating conditions e g coolant temperatures the operating modes and the quality of the intake air e g content of dust content of gaseous foreign matter such as SO2 solvent vapours etc have...

Page 46: ...ressor when the unit is out of operation depressurized and secured from being switched on again NOTICE Never operate the screw compressor system without an air filter even briefly removing it can caus...

Page 47: ...e cap one or two turns and retightening it or by pulling the valve lifting lever DANGER A defective pressure relief valve may result in pressure that is too high breaking open parts of the system and...

Page 48: ...There is a risk of electric shock from charged capacitors Disconnect the system from the mains and wait 10 minutes before touching electrical components The power capacitors need this time to dischar...

Page 49: ...the user manual The screw compressor should be blown off with compressed air at the given intervals do not aim the compressed air at people especially Controller components Fittings Air end block Coo...

Page 50: ...inted body must perform a strength test on the pressure reservoir after ten years Electrical installation After four years or after each intervention the electric installation must be tested by an ele...

Page 51: ...rvoir 1 Fix suction regulator or if required replace check solenoid valves 2 Short circuit in the unit 2 Determine and eliminate cause replace defective fuses 3 Connecting terminals in the switch cabi...

Page 52: ...d air 1 Oil fine separator defective 1 Replace oil fine separator cartridge 2 Oil foams 2 Change oil 3 Oil level too high 3 Drain off oil 4 Minimum pressure valve defective 4 Check minimum pressure va...

Page 53: ...ps 63 56 77 68 93 81 Full load current max 460V 575 V Amps 30 23 37 27 42 32 Motor protection type IP55 EPAct Nominal speed rpm 3600 Nominal fan motor power no separate fan motor Recommended cable siz...

Page 54: ...dB A 72 Nominal motor rating hp kW 20 15 Voltage frequency V 460V 10 60 Hz Full load current max at 460V Amps 37 Motor protection type TEFC IP55 EPAct Nominal speed rpm 1146 2950 Nominal fan motor po...

Page 55: ...dB A 73 Nominal motor rating hp kW 25 18 5 Voltage frequency V 460V 10 60 Hz Full load current max at 460V Amps 44 Motor protection type TEFC IP55 EPAct Nominal speed rpm 1500 2945 Nominal fan motor p...

Page 56: ...B A 73 Nominal motor rating hp kW 30 22 Voltage frequency V 460V 10 60 Hz Full load current max at 460V Amps 45 Motor protection type TEFC IP55 EPAct Nominal speed rpm 955 3000 Nominal fan motor power...

Page 57: ...RS Fig 24 A Compressed air connection G 1 B Cool air intake C Cool air outlet D Oil drain E Cool air outlet of switch cabinet only L15 RS L22 RS F Cool air intake of switch cabinet only L15 RS L22 RS...

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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...

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