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Appendix

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America

January 2017

min. 29.5

26.1

35.5

36.6

35.5

26.1

34.3

35.4

min. 29.5

Fig. 9-4: L160 - L290 RS water-cooled

[A]

Compressed air connection

[F]

Motor cooling air inlet

[B]

Compressor suction duct

[G]

Motor cooling air outlet

[C1]

Cooling water inlet

[H]

Switch cabinet cooling air inlet

[C2]

Cooling water outlet

[J]

Switch cabinet cooling air outlet

[E]

Cover for supply cable

[K]

Condensate drain outlet

Содержание L160 110A V2

Страница 1: ...User manual Screw compressor L160 L290 V2 L160RS L290RS V2 America ZS1149274 03 January 2017...

Страница 2: ...connection 30 5 4 Cooling water connection 32 6 Commissioning and operation 34 6 1 Initial commissioning 34 6 2 Normal operation 36 6 3 Routine commissioning 37 6 4 Commissioning after extended downti...

Страница 3: ...Contents January 2017 America 3 72 9 6 3 L160 RS 60Hz air cooled A water cooled W 60 9 6 4 L200 RS 60Hz air cooled A water cooled W 62 9 6 5 L290 RS 60Hz air cooled A water cooled W 63 9 7 Installatio...

Страница 4: ...its qualified and experienced personnel is responsible for all repair work that exceeds typical maintenance and requires specialized technical knowledge All pressure values in these operating instruct...

Страница 5: ...t these operating instructions in any case 1 3 Intended use The compressor uses the best available technology and meets applicable safety requirements at the time of sale in the context of correct usa...

Страница 6: ...otective and safety devices Operation with defective deactivated or manipulated protective and safety devices or safety values or operation with other safety related defects Use by private users or us...

Страница 7: ...Foreword 1 January 2017 America 7 72 1 6 Rating plate Fig 1 1 Rating plate...

Страница 8: ...d warning signs on and near the compressor must be checked regularly for completeness and legibility Missing hazard warning signs must be replaced immediately The time frames from tests and inspection...

Страница 9: ...r is placed in a safe condition 2 Rectify the fault that was the cause of the emergency stop See the Troubleshooting chapter 3 Unlock Emergency Stop button Turn the pushbutton anticlockwise 4 Start up...

Страница 10: ...situation that if not prevented can result in death or extreme irreversible injury CAUTION Indicates a potential dangerous situation that if not prevented can result in slight or minor reversible inj...

Страница 11: ...rking on rotating parts Secure against being switched back on again during repair work Use hearing protection Label for areas with elevated sound pressure level Enter the area only with suitable heari...

Страница 12: ...vers enclosures guards fences during transport Working at the labeled workstations requires increased vigilance Do not go beneath the load Do not go beneath a suspended load The driver is not allowed...

Страница 13: ...monitoring of the cooling water by mainte nance personnel Caution hot liquid Warning of hot oil or hot coolant Allow the compressor to cool before opening the fluid cir cuit lines Chart 2 1 Safety sym...

Страница 14: ...work Organizational The maintenance work and intervals are specified in the operating manual including information about replacing parts partial equipment Maintenance and repair work may be performed...

Страница 15: ...repair work Also check all the other bolt connections Before releasing the compressor for operation after maintenance and repair work ensure that the operating pressures temperatures and time setting...

Страница 16: ...The compressor stages consist of a main rotor and a secondary rotor with spiral teeth that mesh with each other Compression chambers bounded by the flanks of the teeth and by the compressor housing a...

Страница 17: ...t 1 1 Suction filter 20 Base frame 2 Intake regulator 21 Control system control panel 3 Electric motor 22 EMERGENCY Off button 4 Screw compressor 23 Electrical enclosure 6 Fine precipitator 25 Compres...

Страница 18: ...oled 5 Pressure vessel 14 Air cooler 7 Oil fill 17 Oil cooler cooling air fan 8 Oil drain 18 Cooling air inlet filter pad 9 Oil level indicator 19 Compressed air outlet 11 Oil cooler 24 Aftercooler co...

Страница 19: ...ter cooled 5 Pressure vessel 14 Air cooler 7 Oil fill 17 Cooling air fan 8 Oil drain 18 Cooling air inlet filter fleece 9 Oil level indicator 19 Compressed air outlet 11 Oil cooler 26 Line pressure se...

Страница 20: ...5 B1 16 15 24 S6 9 8 7 6 S12 22 29 4 13 33 5 R2 12 21 11 10 S5 34 R1 3 32 E5 E4 31 28 Y6 27 Fig 3 4 Functional schematic Compressed air Oil Control air Cooling water Chart 3 1 Lines Components No Desi...

Страница 21: ...cator 9 Safety valve 23 Suction filter monitoring S7 optional Switching point 50mbar 20 in H2O 10 Oil filter monitoring S5 optional Switching point 2 2 bar 32 psi 24 Fine separator monitor ing S6 opti...

Страница 22: ...ressor due to the drop in pressure between the pressure vessel and the injection point in the screw compressor When switching the drive motor to operation the solenoid valve 19 Y1 switches as it is be...

Страница 23: ...eset lower switching point within the set motor run on time the solenoid valve 19 Y1 is supplied with current again and the blow off valve 20 Y4 is shut The unit goes back to on load operation 3 7 Lub...

Страница 24: ...efer to the operating instructions for the compressor control GD Pilot TS If the lubricant pipe is blocked the drive unit increases the pressure to 6bar 87psi If the max pressure is reached the lubric...

Страница 25: ...ons 1 1 Cooling water connection Switching heat recovery on and off 1 2 3 A B 1 Connection from oil cooler 2 Connection to compressor 3 Connection from heat exchanger WRG A Heat recovery switched on B...

Страница 26: ...to life from tipping or falling parts A suitable forklift with sufficiently long forks must be used to transport the compressor Use forks only at the labeled lifting points The compressor even in its...

Страница 27: ...rty Damage to property due to exceeding the permissible temperature range Where there is a risk that the permissible temperature limits of 2 65 C 36 149 F could be exceed or underrun contact Gardner D...

Страница 28: ...h as possible Cover ventilation openings with screens in order to prevent dirt from entering the compressor room The design of ventilation system is based primarily on the required amount of cooling a...

Страница 29: ...d and flat The compressor must be installed with full contact on a foundation with sufficient structural strength The compressor must not be operated on the transport pallet No flammable or explosive...

Страница 30: ...nnection 2 Condensate connection 3 Electrical connection WARNING Risk of injury If incorrectly connected the connection can come loose and the open connection can cause severe personal injury When con...

Страница 31: ...ighting heating or the like that are not disconnected by the main disconnect switch then these excepted electrical circuits must be labeled and run separately per EN 60204 Warning labels must also be...

Страница 32: ...nsformer settings can cause problems in operation Checking the control transformer settings is part of commissioning and periodic inspection and maintenance because grid voltage conditions can change...

Страница 33: ...ement at maximum power and T 10K T Cooling water outlet temperature Cooling water inlet temperature T p Cooling water outlet pressure Cooling water inlet pressure p The values are based on freshwater...

Страница 34: ...r Denver Perform initial commissioning as follows 1 Check the oil level 2 Check the settings of the fan motor protection switch 3 Check the settings of the control transformer 4 Check all connection t...

Страница 35: ...to the compressor may occur even if it only operates very briefly 8 Switch off the main disconnect switch 9 Correct the direction of rotation Change the rotating field on the compressor 10 Mount the p...

Страница 36: ...button I on the control panel The compressor switches on The compressor runs automatically automatic mode See the sequence description in the Sequence section of the chapter Structure and function Ope...

Страница 37: ...id switching on the compressor multiple times without clearing the fault as this can lead to significant machine damage Switch on the compressor only after the fault has been cleared Recommissioning a...

Страница 38: ...Acknowledge a fault in the electronic controller Pressure vessel not depressurised Wait for depressurisation Screw compressor does not start up when the vessel pressure is greater than the preset valu...

Страница 39: ...Make the intake regulator moveable replace if needed Check solenoid valves Y1 and pressure reducing valve 14 and replace if necessary Chart 7 3 Fault cleared by Unit does not reach the set network pre...

Страница 40: ...ause Remedy Safety valve defective Replace safety valve Network pressure sensor defective Replace network pressure sensor Final compression pressure sensor defective Replace final compression pressure...

Страница 41: ...the white triangle on the drive is fully visible Lubrication system is in pressure cut off OL Counter pressure to lubrication point 87 psi Flush lubrication point manually or special dispensing PURGE...

Страница 42: ...0 of Gardner Denver Display not working despite volt age being supplied Internal drive fault Replace entire lubrication system Lo message on the display Lo Weak backup battery of the drive Change the...

Страница 43: ...7 January 2017 America 43 72 NOTE Also note the fault messages on the display of the operator panel The corresponding actions to clear the faults are described in the operating instructions for the el...

Страница 44: ...restarting WARNING Risk of injury from hot bleeder valve The outlet temperature of the compressed air can be as high as 90 C 194 F Allow the compressor system to cool down before opening the bleeder v...

Страница 45: ...its please observe the following points In case of leakage a part of the oil in oil water coolers may penetrate into the cooling water circuit Cooling water must not be discharged into public sewage s...

Страница 46: ...s listed All maintenance repairs and service work performed on the compressor must be documented Service and maintenance work should be performed by the local Gardner Denver representative Cleanliness...

Страница 47: ...Control Panel Check for fault mes sages report if any User Chart 8 1 Maintenance plan every 8 operating hours Maintenance plan Maintenance every 125 operating hours Components Measure Required qualifi...

Страница 48: ...rtridge Maintenance personnel Safety valve Function test at least once a year Maintenance personnel Hoses and piping Check for leaks or any dam age Maintenance personnel Condensate Drain Aftercooler f...

Страница 49: ...icing kits To identify the correct servicing kit see the following table Part numbers for servicing kits Model number Service Part number L160 L290 2000 4000 operating hours 302KGA6032 L160 RS L290 RS...

Страница 50: ...service life of the filter elements The filter elements should be inspected for dust accumulation at least weekly daily if possible If usage scenarios transpire with for example a high rate of dust ac...

Страница 51: ...permitted duration of use of the oil must be checked with the help of an oil analysis NOTE Collect the used oil Do not let it drain into the soil Dispose of the oil in accordance with regulations Do...

Страница 52: ...n the compressor is relieved of pressure the aftercooler remains pressurized Release pressure manually prior to performing maintenance work in the aftercooler and pressure retaining valve area 1 Switc...

Страница 53: ...6 Close the enclosure 8 6 7 Connection terminals in the switch cabinet control transformer setting DANGER Electric shock Deadly electrical voltage Exercise extreme caution when working with electrica...

Страница 54: ...controls with the message Warning Mot Lubricator see also the operating instructions for the electronic controller Replacing the grease cartridge 1 2 3 4 Fig 8 12 Lubricator 1 Socket for connection c...

Страница 55: ...ops blinking 8 6 10 Checking intervals for pressure vessel and electrical installation Pressure vessel The checking intervals for the compressed air vessel and the safety valve have to be coordinated...

Страница 56: ...fety data sheets must be adhered to Lubricating oil AEON 9000SP Lubricating grease MOBIL POLYREX EM 9 3 Disassembly WARNING Damage to health Risk of damage to health from consumables and auxiliary mat...

Страница 57: ...point 4 Seal off the lubrication point 5 Close the enclosure Remove the air filter 1 Remove all filter elements and filter mats Dispose of filter elements and filter mats Air filter cartridge Filter m...

Страница 58: ...dissolved matter 9 6 Technical data 9 6 1 L160 L200 60Hz air cooled A water cooled W L160 L200 60Hz air cooled A water cooled W L160 L200 Maximum operating pressure psig 110 130 190 110 130 190 Minimu...

Страница 59: ...ions W 1 1 2 11 1 2 NPT Total oil volume gal 31 7 Compressed air connection Flange ANSI B16 5 3 125lbs Weight lb A 9229 W 9083 A 9733 W 9456 Dimensions L x W x H in 114 5 x 81 5 x 86 3 Chart 9 2 Techn...

Страница 60: ...32 34 Residual pressure at ambient temper ature A Torr 0 38 0 08 95 F 113 F 0 53 0 15 95 F 113 F Cooling water quantity T 10 K W gal min 52 8 p 19 psi 60 7 p 34 psi Cooling water inlet temperature W...

Страница 61: ...0 3 0 IE3 Rated capacity of fan motor W hp kW 0 4 0 3 IE 3 Recommended cable cross section 460V 2 x 3 x AWG3 0 Recommended fuse size time delay 460V A 2 x 3 x 175 Air cooler oil cooler cooling air vo...

Страница 62: ...ctric motor TEFC IP55 EISA 2007 IE 3 Nominal speed of drive motor rpm 500 2419 Nominal power of fan motor A hp kW Air cooler 3 0 2 2 IE3 oil cooler 4 0 3 0 IE3 Rated capacity of fan motor W hp kW 0 4...

Страница 63: ...er outlet temperature above ambient temperature A F W F 10 18 Sound pressure level ISO 2151 A dB A W dB A 81 83 79 80 Nominal power of drive motor hp kW 340 250 Total current consumption during load o...

Страница 64: ...emperatures other than 30 C 86 F and then selecting the wire that has sufficient ampacity after correction to meet the load requirements shown in the NEC Package Amps 30 C column above Wire ampacity i...

Страница 65: ...3 3 33 8 8 7 39 5 8 7 23 8 29 2 79 5 86 3 10 8 14 4 15 6 19 1 13 6 81 5 7 1 8 1 13 16 7 45 6 59 3 11 6 5 7 8 9 114 4 28 5 40 2 16 7 17 8 5 2 2 8 1 7 12 7 3 2 59 32 4 56 3 27 4 4 8 28 7 28 7 2 4 18 1...

Страница 66: ...air cooled A Compressed air connection F Motor cooling air inlet B Compressor suction shaft G Motor cooling air outlet C Air and oil cooler cooling air inlet H Frequency converter cooling air inlet on...

Страница 67: ...33 8 8 7 39 5 8 7 23 8 79 5 86 3 2 2 27 4 2 8 117 2 11 5 11 5 29 63 40 9 53 6 46 5 59 3 13 17 8 9 5 7 11 6 13 2 15 6 19 2 13 6 5 6 3 7 12 1 81 5 57 2 12 2 1 3 12 2 4 1 1 6 RS 18 1 8 5 11 9 10 2 13 4 3...

Страница 68: ...E F C1 C2 A J G Fig 9 4 L160 L290 RS water cooled A Compressed air connection F Motor cooling air inlet B Compressor suction duct G Motor cooling air outlet C1 Cooling water inlet H Switch cabinet coo...

Страница 69: ...Appendix 9 January 2017 America 69 72...

Страница 70: ...9 Appendix 70 72 America January 2017...

Страница 71: ...Appendix 9 January 2017 America 71 72...

Страница 72: ...Gardner Denver Compressor Division 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9868 Fax 217 224 7814...

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