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11 Troubleshooting

Troublesh ooting

For faults or warnings which were diagnosed by the GD Pilot compressor control, please read the
section “Table of Faults/Warnings” in the GD Pilot user manual.

Fault

Possible Cause

Remedy

The system will not start.

Missing operating or control voltage

Check fuses, main switch and supply
cable

Fault has not been acknowledged

Fault message must be acknowledged

Pressure reservoir is not depressurized 3.

Wait for discharge

Screw compressor will not start if the
reservoir pressure is > 11.6 PSI for
L23-L29 and > 29.0 PSI for L23RS-
L29RS

Electric motor is defective

Check connections, winding, etc.

Compressor is defective

Turn the compressor by hand
possibly replace

Ambient Temp < 33.8 °F

Make sure that the ambient
temperature is at least 33.8 °F,
possibly provide an idle heater

Remote operation via the connection
terminal is active

Deactivate remote operation

The system pressure is above the
lower switching point

Wait until the system pressure has
fallen below the switching point

The system stops during
the start-up phase

Suction regulator only closes part way,
pressure builds up too quickly in the
pressure reservoir

Make the suction regulator viable,
replace if necessary, check the
solenoid valve

System short

Determine cause and remedy, replace
defective fuses

Connection terminal in switch cabinet
is loose

Check and tighten

Oil is too viscous

Choose type of oil which suits the
environmental conditions or install an
idle heater

Maximum motor cycles exceeded due
to manually switching off and on too
often

Avoid frequent manual on and off
switching, let the electric motor cool

System pressure sensor set too low

Check, reset

System doesn

t reach

the system pressure set

Suction regulator only opens partially

Make the suction regulator viable,
replace if necessary, check the
solenoid valve

Air bleed too large

Throttle the bleed or attach additional
compressors

Fine oil separator is dirty

Replace the fine oil separator
cartridge

Air filter is dirty

Replace air filter cartridge

Large leaks in the compressor system

Check the unit

Содержание L23

Страница 1: ...Original Operating and Service Manual Screw Compressor L23 L29 L23RS L29RS V1 USA Id No ZS1137206 01 November 2015 ...

Страница 2: ......

Страница 3: ...and 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 essential to quote the MODEL and SERIAL NUMBER In this manual all pressures quoted are gauge pressures unless otherwise stated Maintenance To ensure the continued trouble free operation of the compresso...

Страница 4: ...ustment 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 Safety Labels are used within this manual and affixed to the appropriate areas of the compressor package to alert users of the following conditions DANGER Indicates a hazard with a high level of risk which...

Страница 5: ...the 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 operating manual between the DC terminal and the chassis as well as between the DC terminal and the chassis The voltage must read zero in all three measurements WARNING Indicates a hazard with a medium level...

Страница 6: ...CTION REQUIREMENTS Asphyxiation Hazard Never breathe in compressed air from this system Never operate the unit with open doors or loose access panels Read the operatorʼs manual before proceeding with this task Opening pressure relief valve xx bar value xx see sticker on compressor Handle package at forklift points only ...

Страница 7: ...Address _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Telephone Fax Representative Replacement parts Service ...

Страница 8: ...e thoroughly especially under difficult 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 genuine Gardner Denver replacement parts Genuine Gardner Denver replacement parts are manufactured with state of the art technology and guarantee reliable operation For...

Страница 9: ...endent alterations to the compressor 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 consequence all liability and warrantee claims against the manufacturer will be terminated Safety Regulations DANGER Always observe the safety regulations in Section 4 of the user m...

Страница 10: ...ork modifications on the machine 18 5 Assembly and Operation 19 5 1 Assembling the System 19 5 2 System Schematic 20 5 3 Oil Circuit 21 5 4 Air Circuit 21 5 5 Regulation 21 5 5 1 Regulator L23 L29 21 5 5 2 Regulator L23RS L29RS 22 6 Transportation and Installation 24 6 1 Transportation 24 6 2 Installation 25 7 Preparation for Commissioning 26 7 1 Cooling Air Volume Minimum Channel Diameter 26 7 2 ...

Страница 11: ... Maintenance 40 10 1 Maintenance suggestions 40 10 2 Electric Motor Maintenance 40 10 3 Maintenance schedule and test schedule 40 10 3 1 Service Check List 41 10 4 Oil change 43 10 5 Change oil filter cartridge 44 10 6 Changing the fine oil separator 45 10 7 Change air filter 46 10 8 Pressure relief valve 47 10 9 Connection terminals in the switch cabinet control transformer settings 48 10 10 Scre...

Страница 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 compromise safety Symbols on the machine indicating dangers may become dirty or disappear Ensure that all safety and danger notices on the machine system stay fully legible Faults and modifications ...

Страница 13: ...ded 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 Do not use chafed damaged or poor quality hoses Only use the correct type and size of hose coupling and connection The compressed air line connected at the air exit of the unit must not be under stra...

Страница 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 must not be used as breathable air unless it has been processed specially for such an application in accordance with the Safety requirements for breathable air When breathing apparatus with cartridges i...

Страница 15: ...ithout 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 working on it For this a label with a corresponding warning notice has to be attached to the remote control equipment Noise even when it is not very loud can make us nervous and irritated and after a l...

Страница 16: ...ck into operation The compressor may fall if mistakes are made when lifting Only use lifting tackle approved for the weight in question Observe the operating manual for the lifting tackle When heavy loads are being conveyed by means of hoisting gear it is imperative to keep well clear of the load in order to avoid accidents The person giving the instructions must be within sight or voice contact w...

Страница 17: ...ulations Instructions including supervisory responsibility and duty of notification for taking account of special in plant factors for example regarding work organization sequences of operations personnel assigned to certain tasks are to be added to the operating manual Before starting work make yourself familiar with the working environment at the installation site The location and operation of f...

Страница 18: ... damaged parts to be replaced Risk of electric shock Have the electrical equipment on a machine system checked regularly Have defects like loose connections or charred cables rectified immediately Use only original fuses with the specified current rating In the event of faults with the electrical power supply switch the machine system off immediately and secure it from being switched on again In t...

Страница 19: ... repair work when the screw com pressor system is at a standstill and is not under pressure The system must be secured from being switched on Before removing or opening pressurized components positively isolate any source of pressure and depressurize the entire system During the course of maintenance and repairs parts can be damaged which are important for safety Never weld any pressure reservoir ...

Страница 20: ...ed especially for the machine Modifications may interfere with safety equipment or give rise to new dangers for which protection is not provided No alterations additions or modifications to the machine may be carried out without the approval of the manufacturer Unauthorized modifications to the machine are prohibited for reasons of safety Original parts are specially designed for our machines We m...

Страница 21: ...cooler 12 Pressure relief valve 13 Minimum pressure and non return valves 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 Control panel controls 22 Emergency stop button 23 Switch cabinet 24 Feed cable entry 25 Final compression temperature sensor 26 System pressure sensor 27 Final com...

Страница 22: ...ain 9 Pressure relief valve 10 Oil filter 11 Oil cooler 12 Throttle 13 Minimum pressure and non return valve 14 After cooler 15 Oil temperature regulator 16 Oil level indicator 17 Cooling air fan 18 Discharge pressure sensor B2 19 Air outlet pressure sensor B1 20 Motor temperature R1 21 Frequency converter only for L23RS L29RS 22 Integr waste heat recovery option 22 1 Plate heat exchanger 22 2 Man...

Страница 23: ...of approx 22 PSI residual pressure in the vessel 5 4 Air Circuit Incoming air is passes through a suction filter 1 Fig 3 and the intake regulator 2 Fig 3 into the screw compressor 4 Fig 3 It is cooled during compression by the injected oil and the resulting mixture of compressed air and oil flows tangentially into the pressure reservoir 6 Fig 3 After pre separation and the following fine separatio...

Страница 24: ... 2 Regulator L23RS L29RS System Idle See 5 5 1 System Idle Starting the System The motor control accelerates the electric motor 3 Fig 4 to the maximum rotational speed At the beginning of the acceleration phase the suction regulator is open In a few seconds a pressure of approximately 22 PSI is created in the demister vessel 6 Fig 4 This pressure travels through the open solenoid valve Y1 Fig 4 to...

Страница 25: ...ed down to adjust the delivered quantity to match the actual compressed air consumption If the minimum motor speed is reached and system pressure continues to rise power is cut to the solenoid valve Y1 Fig 4 and the suction regulator is closed The reservoir pressure is relieved to approximately 22 PSI In this way no additional compressed air is delivered to the distribution system If system pressu...

Страница 26: ...it width see Section 12 1 Keep the distance between see Fig 5 and length of the forks in mind when transporting the compressor All loose 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 approach is performed properly according to the user manual of the lif...

Страница 27: ...aust for the compressor station The screw compressor must be placed so that it lies level The system may not be run while on the transport pallet Maintain distance from walls other machines etc so that enough free space is available for maintenance and repairs see Fig 7 When running the screw compressor system heat is created by the electric motor and the compression process A part of this heat is...

Страница 28: ...ever a cooling airflow rate of 17 ft sec should not be exceeded We recommend a minimum channel diameter of approximately 6 ft 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 more than one bend using filters grills etc please consult with your expert advisor The screw compressor is designed for amb...

Страница 29: ... check that the necessary operating temperatures operating pressures as well as the necessary connecting flange or connecting thread are appropriate and in perfect working order see Fig 12 For connections with hoses take steps so that if an end breaks free it wonʼt whip around dangerously Fig 12 The compressed air distribution system is connected to the external threaded connector of the screw com...

Страница 30: ...s need this time to discharge Make electrical connections as follows Feed the supply cable through the opening M50 Fig 13 in the switch cabinet and screw tight Connect the supply cable to the connection terminal following the circuit diagram Fig 13 CAUTION If local regulations are stricter than the values given below the stricter of the two should be used Recommended supply cable diameters and fus...

Страница 31: ... of Shock Burn or Death The electrical connection should be made by a qualified electrician 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 NOTICE Incorrectly setting the control transformer poses a risk to the trouble free operating of the system Checking the setting of the control transformer ...

Страница 32: ... 13 Fig 15 1 Oil filler cap R1 2 Oil level indicator 3 Maximum oil level 4 Minimum oil level Check the oil level as follows Shut off the compressor with the STOP button Wait at least 5 minutes until the oil has settled i e until 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 ...

Страница 33: ...ing see Sections 7 3 1 and 10 13 Check the oil level in the pressure reservoir also see Section 7 3 1 Fig 15 Check of the fan motor circuit breaker setting only L23RS L29RS also see Section 7 3 1 Check the control transformer setting also see Section 7 3 2 Check and tighten all connecting terminals on the electrical control system Open the isolating valves between the screw compressor reservoir an...

Страница 34: ... direction of rotation might be different than shown here NOTICE In general use the Stop button to shut off the compressor Fig 20 page 34 and not the large EM STOP button above the control panel After switching off the screw compressor unit it will continue to run for 30 50 seconds SOFT STOP Start protection temperature The screw compressor will not start if the ambient temperature is less than 33...

Страница 35: ...rvoir and pipework Turn on the main power supply switch Once the power supply has been switched on the POWER LOSS fault appears This fault must be acknowledged using the button Fig 20 page 34 Press the Start button I Fig 20 page 34 In general use the Stop button to shut off the compressor Fig 20 page 34 and not the large EM STOP button at the control panel The compressor is cooled for 30 seconds a...

Страница 36: ...ton 9 3 Status indicator display LEDs The controller is equipped with a three row display 1 Row This always shows the final compression temperature final compression pressure and system pressure Final compression temperature the temperature measured downstream of the compressor stage Final compression pressure the pressure measured downstream of the compressor stage System pressure the pressure wi...

Страница 37: ...ge You can change the language by simultaneously pressing the or buttons Press these buttons at the same time until the right language appears 9 5 2 Setting system pressure except for L23RS L29RS Max system pressure The system pressure is set in the CONTROL MENU sub menu To do so press the or buttons at the same time You are then taken to the main menu Use to switch to the CONTROL MENU sub menu Th...

Страница 38: ...mall TARGET PRESSURE In the CONTROL MENU sub menu use to go to the TARGET PRESSURE menu item Pressing the button causes the value to flash You can now change increase or decrease this value by pressing or Then confirm the value set by pressing the button 9 5 4 Setting time date timer The GD Pilot battery can bridge a loss of power lasting around two weeks If power is lost for longer periods the ti...

Страница 39: ...same time You will find a table containing messages and suggested ways of remedying problems in the separate DELCOS Pro operating instructions 9 9 1 Warning messages When there are warnings the red LED flashes slowly The unit does not automatically shut down when there are warnings However ignored warnings may cause faults Rectify what is causing the warning and press the button to acknowledge the...

Страница 40: ...00 00 00 7_______ 00 00 00 00 02 EM STOP 123456 h 01 EM STOP 123000 h CUT OUT POINT 189 PSI CUT IN POINT 181 PSI 2 CUT OUT POINT 152 PSI 2 CUT IN POINT 145 PSI AUTOMATIC OPERATION ENABLE REMOTE START ON TIMER CONTROL OFF 2 TIMER CONTROL OFF AUTO RESTART ON POWER LOSS TIME 2 s START UP DELAY 5 s DRYER PRE RUN 0 min RS485 PROTOCOL ModBus RS485 BAUDRATE 19200 RS485 ADRESS 1 MAINTENANCE SCHED TIMER CO...

Страница 41: ...NTROL MENU TOTAL RUNNING 12345 h LOADED HOURS 10987 h AIR FILTER IN 2000 h OIL FILTER IN 2000 h SEPARATOR IN 4000 h OIL CHANGE IN 4000 h SHUTDOWN OFF 02 EM STOP 12345 h 01 EM STOP 12300 h FAULT MEMORY TH 08 02 07 13 55 41 1 ______________ 00 00 00 00 7 ______________ 00 00 00 00 p21 ____________ 00 00 00 00 p27 ____________ 00 00 00 00 TIMER CONTROL DESIGN PRESS 189 PSI START PROTECT 12 PSI EXT LI...

Страница 42: ...nents The 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 penetrate the skin or destroy an eye Only perform checks and maintenance after observing the following Press the STOP button on the control panel and wait until the screw compressor comes t...

Страница 43: ... 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 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 lubricant every 8000 hours Under adverse conditions change more frequently refer to Oil...

Страница 44: ...if 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 necessary Min Pressure Check Valve Check pressure relief valve Inspect repair if necessary the Condensate Drains Inspect replace if necessary Solenoid Valves Vacuum Switch Inspect replace if necessar...

Страница 45: ...any 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 related to how dirty the circulating oil is Pay close attention that no foreign substances which can damage the oil dust steam gases make it through the air intake filter into the compressor unitʼs ...

Страница 46: ... oil has settled i e until the air has bubbled out Check the oil level see Section 7 3 1 The oil level must lie between the maximum oil level and minimum oil level 5 Fig 21 If necessary top up the oil Oil Change interval Operating conditions 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 ...

Страница 47: ...atures 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 the filter lifespan air filter oil filter fine separator In these cases the intervals between changes may be shorter 10 6 Changing the fine oil separator DANGER Air oil under pressure will cause severe personal injury or death...

Страница 48: ...ll seals and if necessary remove and clean the O ring 6 Fig 23 Install a new fine oil separator Pivot the reservoir cover back to the starting position Screw the cheese head screws 5 Fig 23 counter clockwise until the reservoir cover is lying loosely on the pressure reservoir flange Screw in and tighten crosswise all hex screws except for the two screws in the pivot area of the PMV Pivot the PMV b...

Страница 49: ...elief valve DANGER When checking pressure relief valve there is an explosive release of pressure Failure to perform this operation in a safe manner or without safety equipment may result in personal injury or death Use the appropriate safety equipment hearing and eye protection and use safety precautions when performing this PRV check on an operating machine 2 1 Fig 26 1 Pressure relief valve 2 Va...

Страница 50: ...hecking the setting of the control transformer is part of commissioning and part of regular inspection maintenance because the supply voltage can change The connecting terminals in the switch cabinet have to be checked and if required re tightened during first commissioning and afterward according to the maintenance schedule Fig 27 Check the control transformer setting as follows Switch the unit o...

Страница 51: ...own off with compressed air at the given intervals do not aim the compressed air at people especially Controller components Fittings Air end block Cooler Electric Motor 10 12Clean replace cool air intake and control box filter pads DANGER 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 28 1 ...

Страница 52: ...r grille Ensure that the smooth side A Fig 31 of the filter pad faces the air inlet side Place the louver grille back onto the filter housing Changing times for filter pads Type of operation and the quality of the intake air e g dust content have a strong influence on the filter padʼs life span The filter pad should be checked at least once a week and possibly daily for dust accumulation In these ...

Страница 53: ...ld be set by performing oil tests Material Safety Data Sheets MSDS are available for all Gardner Denver lubricants from your authorized Gardner Denver distributor or by calling Gardner Denver USA at 937 498 2500 The following oil types should be used a AEON 9000SP For further information please contact your local Gardner Denver Distributor or Gardner Denver USA at 937 498 2500 10 14 Test period fo...

Страница 54: ...nt 8 Wait until the system pressure has fallen below the switching point The system stops during the start up phase 1 Suction regulator only closes part way pressure builds up too quickly in the pressure reservoir 1 Make the suction regulator viable replace if necessary check the solenoid valve 2 System short 2 Determine cause and remedy replace defective fuses 3 Connection terminal in switch cabi...

Страница 55: ...valve Oil in the compressed air 1 Fine oil separator is defective 1 Replace the fine oil separator cartridge 2 Oil foams 2 Replace the oil 3 Oil level is too high 3 Drain the oil 4 Faulty minimum pressure non return valve 4 Check the minimum pressure non return valve 5 Oil extractor orifice is plugged 12 Fig 3 5 Remove and clean the orifice Oil in the air filter 1 Faulty suction regulator non retu...

Страница 56: ...1 47 56 Max full load current IP55 575V A 33 38 48 Motor protection TEFC IP55 EISA 2007 IE 3 Rated motor speed 1 min 3600 Rated fan power hp 0 67 IP54 1 15 IP54 Recommended cable gauge 200V AWG 1 AWG 1 0 AWG 2 0 Recommended cable gauge 230V AWG 2 AWG 1 AWG 1 0 Recommended cable gauge 460V AWG 6 AWG 6 AWG 4 Recommended cable gauge 575V AWG 8 AWG 8 AWG 6 Recommended fuse rating 220V 230V A 110 90 12...

Страница 57: ...g to ISO 2151 dB A 70 Drive motor rated power hp 30 Voltage frequency V 460V 10 60Hz Max full load current 380V 400V 460V A 45 Motor protection TEFC IP55 EISA 2007 IE3 Rated speed 1 min 1500 3620 Rated fan power hp 0 67 IP54 Recommended cable gauge 460V AWG6 Recommended fuse rating 460V A 50 Ventilation fan air flow rate cfm 2331 Cooling air exhaust temperature above ambient F 38 Residual pressure...

Страница 58: ...according to ISO 2151 dB A 72 Drive motor rated power hp 35 Voltage frequency V 460V 10 60Hz Max full load current 460V A 51 Motor protection TEFC IP55 EISA 2007 IE3 Rated speed 1 min 1200 4230 Rated fan power hp 0 67 IP54 Recommended cable gauge 460V AWG6 Recommended fuse rating 460V A 63 Ventilation fan air flow rate cfm 2463 Cooling air exhaust temperature above ambient F 41 Residual pressure a...

Страница 59: ...ding to ISO 2151 dB A 73 Drive motor rated power hp 40 Voltage frequency V 460V 10 60Hz Max full load current 380V 400V 460V A 58 Motor protection TEFC IP55 EISA 2007 IE3 Rated speed 1 min 1200 4790 Rated fan power hp 1 15 IP54 Recommended cable gauge 460V AWG4 Recommended fuse rating 460V A 70 Ventilation fan air flow rate cfm 3143 Cooling air exhaust temperature above ambient F 38 Residual press...

Страница 60: ...lation diagram Fig 32 All dimensions in inches A Compressed air connection External threaded connector 1 inch USA NPT E Cool air intake F Cool air exhaust K Electrical connection R Switch cabinet cool air intake only L23RS L29RS ...

Страница 61: ...12 Appendix 59 Fig 33 All dimensions in inches ...

Страница 62: ...12 Appendix 60 Fig 34 All dimensions in inches ...

Страница 63: ......

Страница 64: ...mpressor Division 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9868 Fax 217 224 7814 Gardner Denver Deutschland GmbH Argenthaler Str 11 55469 Simmern Germany Tel 49 0 6761 832 0 Fax 49 0 6761 832 409 ...

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