Related Manuals for Gardner Denver L90 7.5A V4
Summary of Contents for Gardner Denver L90 7.5A V4
- Page 1 Translation of the original operating instructions Screw compressor L90 - L132 V4 L90e - L132e V4 L90RS - L132RS V4...
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Page 2: Table Of Contents
CONTENTS Foreword..........4 Commissioning and operating....33 About these operating instructions..4 Initial commissioning......33 Notes...........5 Normal operation........ 35 Intended use........5 Routine commissioning.......36 Intentional misuse....... 6 Commissioning after a long shutdown 36 Service..........6 Commissioning after a fault....36 Name plate......... 7 Troubleshooting........ - Page 3 Technical Specification......62 9.6.1 L90-L110 + L90e - L110e, 50Hz, air- cooled "A", water-cooled "W"....62 9.6.2 L90-L110, 60Hz, air-cooled "A", water-cooled "W”........ 63 9.6.3 L132 + L132e, 50 Hz, air-cooled "[A]", water-cooled "W"........ 65 9.6.4 L132, 60Hz, air-cooled "A", water- cooled "W".......... 66 9.6.5 L90 RS, 50Hz + 60Hz, air-cooled "A", water-cooled "W"........
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Page 4: Foreword
FOREWORD Gardner Denver screw compressors are the prod- L132 RS 13W V4 uct of years of research and development. This L90e 7,5A V4 experience in conjunction with high quality require- L90e 7,5W V4 ments ensures that the manufactured screw com-... -
Page 5: Notes
Warranty Intended use Gardner Denver will not be held liable for the safe functioning of the compressor if it used other than The compressor conforms to the state of the art for its normal use or for purposes not listed in the and the applicable safety conditions at the time of operating instructions. -
Page 6: Intentional Misuse
The illumination for inspection and repair work must be ≥ 500 lx. in areas with an explosive atmosphere. Ambient temperature for operation: see "Technical Service data". If you have any questions about or problems with the compressor please contact your responsible Gardner Denver agency. -
Page 7: Name Plate
Your Gardner Denver agency Please enter the details of your local Gardner Denver agency in the following table. Name: Contact: Address: Phone Email: Chart 1-1: Local Gardner Denver agency Name plate Fig. 1-1: Name plate... -
Page 8: Safety Conditions
The operating instructions must be supple- Gardner Denver accepts no responsibility for ma- mented with instructions for the observation of terial damage or injuries that arise from non-obser- operating peculiarities including monitoring and vation of safety conditions or the failure to observe reporting obligations, e.g. -
Page 9: Protection And Safety Equipment
Moreover, the following instructions must be ob- All protective and safety equipment must be at- served: tached and checked for trouble-free operation be- fore every commissioning, in particular after main- Only a qualified electrician following elec- tenance and repair work. trotechnical regulations may carry out work on the electrical equipment of the compressor. -
Page 10: Residual Hazards
Residual hazards DANGER WORD Hot surfaces Danger (danger sequence) Some parts of the compressor become hot in op- Description of the danger (danger eration (up to 120 °C / 248 °F). A danger warning Safety sign source) sign on the compressor enclosure warns of the Protective measure (danger pre- danger. - Page 11 Safety sign Significance Use / Behaviour Pressurised part or sys- Identification of devices or rooms in which there is per- manently or occasionally a significantly higher air pres- sure than in the normal atmosphere. Do not open the devices or rooms before pressure equalisation has taken place.
- Page 12 Safety sign Significance Use / Behaviour Warning against sus- Warning of suspended loads being transported. pended loads No person may remain in the danger area during trans- port. In particular, do not encroach into the area under the raised compressor or place your feet beneath it. Warning against moving During maintenance work it is necessary to check some machine parts...
- Page 13 Safety sign Significance Use / Behaviour Lifting point Identification of the lifting points. Only the indicated lifting points may be used for trans- port. Safety valve Opening pressure of the safety valves (values "xx" see sticker on the control panel). Check the connecting Warning against loosened connecting terminals.
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Page 14: Transport And Positioning
NOTE All danger signs must be complete and legible. Check regularly and replace if necessary. Transport and positioning Rules for working with compressed air: Forbid all working practices that could pose a Transport risk to safety A suitable forklift with forks of adequate length Never 'play around' with compressed air. -
Page 15: Conversions And Changes To The Machine
Do not make any changes or additions to or re- build the compressor without prior consultation Cleanliness with Gardner Denver. During maintenance and repair work always check Unauthorised changes to the machine are not au- for cleanliness. Keep dirt away by covering parts thorised for safety reasons. -
Page 16: Design And Function
DESIGN AND FUNCTION General description Compression principle The compressor stages comprise a main rotor and The compressor is an oil-lubricated, compressing, an auxiliary rotor with intermeshing spiral toothing. single-stage screw compressor with one sound- Compression chambers are delimited by the flanks proofed enclosure. -
Page 17: Compressor Design
Compressor design Air-cooled Fig. 3-1: Overview part 1 (air-cooled) Suction filter [17] Cooling air fan [18] Suction regulator Cooling air inlet filter pad Electric motor [19] Compressed air outlet [20] Screw compressor Base frame Pressure vessel [21] Control system control panel Fine separator [22] EMERGENCY-Off button... - Page 18 [15] [31] Fine separator, suction Heat recovery connection (optional) [16] Oil temperature regulator [32] Moisture sensor...
- Page 19 Fig. 3-2: Overview part 2 (water-cooled) Suction filter [20] Base frame [21] Suction regulator Control system control panel Electric motor [22] EMERGENCY-Off button [23] Screw compressor Switch cabinet Pressure vessel [24] Supply cable, cable inlet Fine separator [25] Final compression temperature sensor [26] Oil fill Line pressure sensor...
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Page 20: System Scheme Air-Cooled Compressor
[16] [35] Oil temperature regulator Cooling water solenoid valve (only Lxx W) [17] Cooling air fan [36] Throttle valve (only Lxx W) [18] Cooling air inlet filter pad [37] Cooling water temperature monitor (only Lxx [19] [38] Compressed air outlet Moisture sensor System scheme air-cooled compressor E5 E4... -
Page 21: Oil Circuit
Components Designation Designation Designation Suction air filter Final compression pres- 3/2-way solenoid valve sure sensor (B2) (regulator valve) (Y1) Suction regulator; resid- Pressure-retention and Blow-off valve (Y4) ual pressure 1.5 bar / non-return valve 22 psi Opening pressure 4.5 bar / 65 psi Adjusting cylinder Line pressure sensor Throttle;... -
Page 22: Air Circuit
System with speed control (RS) / e variant Air circuit Depending on ambient conditions (relative humid- The air drawn in reaches the screw compressor ity, intake temperature and ambient pressure), the (-4-) via the suction filter (-1-) and the suction reg- oil temperature level is regulated using an elec- ulator (-2-). -
Page 23: Lubricant System
• The supply of compressed air to the load net- • If the line pressure drops to the pre-set lower work begins. switching point within the set motor run-on time, the solenoid valve (-24-(Y1)) is supplied • The unit is in on-load operation. with current again and the blow-off valve (-25- (Y4)) is shut. -
Page 24: Heat Recovery L90-L132
Function display on lubricator (*) When the lubricator issues this signal, the fol- lowing message is output on the compressor con- trol: [Warning: mot.lubr. sys] (also refer to the op- erating instructions for the compressor control DELCOS XL). If the lubricant pipe is blocked, the drive unit in- creases the pressure to 6 bar / 87psi. - Page 25 Function schematic of heat recovery Switching heat recovery on/off Connection from oil cooler Heat recovery Connection to compressor Temperature regulator with switch-off Connection from heat exchanger function Heat recovery switched on Heat exchanger Heat recovery switched off Cooling water connection Turning the hex screw clockwise to the stop (max.
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Page 26: Transport And Positioning
TRANSPORT AND POSITIONING Transport Transporting the compressor Delivery The compressor is screwed onto a transport pallet and packaged with a film cover. The centre of gravity and lifting points are marked on the packaging. Receipt of goods Upon receipt of goods check for transport dam- age. -
Page 27: Storage
To be able to dissipate the heat generated during +149 °F could be over or undershot, contact operation, the compressor room must be of suffi- Gardner Denver. cient size and have adequate ventilation. The recommended minimum size of the compres-... - Page 28 Positioning the compressor In the event of unfavourable local conditions, in- stall air ducts in which the flow velocity of the cool- DANGER ing air must not exceed 5 m/s / 16.5 ft/sec. We recommend a minimum channel cross section of Risk of injury 1.8 m / 19 sq ft (air-cooled compressor).
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Page 29: Preparations For Commissioning
PREPARATIONS FOR COMMISSIONING Pipelines WARNING Remove all blank flanges, plugs, caps and des- Risk of injury iccant containing pouches before fitting the pipelines. If an incorrect connection is made, the connector could come loose and the free Manifolds and pipe connections must be of the connection result in severe personal in- correct size and be suitable for the operating tem- jury. - Page 30 The compressor power supply must be suitable for industrial equipment and must fulfil all the requirements of EN60204-1/IEC60204-1. Con- tact Gardner Denver if the positioning condi- tions differ from the conditions as they are de- scribed in EN 60204. Implement the electrical connection and the protective measures in accordance with VDE, BS or the appropriate local regulations.
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Page 31: Cooling Water Connection
Check the setting of the control transformer Cooling water connection DANGER Electric shock Life-threatening electric shock ➯ Work on the electrical equipment must only be carried out by autho- rised electricians or electrical techni- cians. ➯ With the speed-controlled type- s (RS) there is a risk of electric shocks due to charged capacitors! Switch the compressor voltage-free... - Page 32 • Cooling water inlet temperature max.: 35°C • Cooling water outlet temperature max.: 55°C P [KW] Δp [bar] V [l/min] ΔT [K] 90 RS Chart 5-1: Cooling water requirement at maximum power ΔT: Cooling water outlet temperature = Cooling water inlet temperature + ΔT Δp: Cooling water outlet pressure = Cooling water inlet pressure - Δp...
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Page 33: Commissioning And Operating
If the compressor has been stored for longer than 2 years, consult Gardner Denver. Carry out the initial commissioning as follows 1. Check the oil level. 2. Check the settings of the fan motor overload switch. - Page 34 Check the direction of rotation of the fan mo- tors (for RS compressors ) CAUTION Risk of falling The rotational direction of the fan motors can only be checked "from above". ➯ Ensure safe climbing means are provided. Fig. 6-1: Check the drive motor rotational direction Protective cover (removed) Fig.
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Page 35: Normal Operation
Normal operation Electronic control unit Fig. 6-4: Control panel Touchscreen display Start button < I >. Stop button < O > red LED flashing slowly: warning or maintenance Fig. 6-3: Check direction of rotation of fan motor (wa- ter-cooled system) flashing rapidly: Fault Cooling air inlet yellow LED... -
Page 36: Routine Commissioning
1. Open the shut-off valves between the compres- sor and compressed air network. 2. Thereafter proceed as described in the section "Initial commissioning". Commissioning after a long shutdown If commissioning after a long shutdown, contact Gardner Denver. -
Page 37: Troubleshooting
TROUBLESHOOTING Troubleshooting instructions Remedies are described in detail in the repair manual, which is provided as part of operator The following tables list possible fault causes and training. remedies. The troubleshooting measures listed in these op- NOTICE erating instructions may only be carried out by specially trained personnel. - Page 38 Possible Cause Remedy Suction regulator does not close completely Provide access to the suction regulator, replace if necessary. Check solenoid valves (Y1) and pressure reducing valve (12). Chart 7-2: Troubleshooting upon: The system remains stationary during the start-up phase Fault: System does not reach the set line pressure Possible Cause Remedy Line pressure sensor defective...
- Page 39 Fault: Off-load pressure too high Possible Cause Remedy Compressor does not discharge Check suction regulator, blow-off solenoid valve (Y4) and pressure-retaining and non-return valve, and replace if necessary. Suction regulator does not close completely Provide access to the suction regulator, replace if necessary.
- Page 40 • Pressure check if necessary • Acknowledge fault by pressing the SET key. Lubricant cartridge empty, but no LC unit too small for the drive. Use original LC unit MLS 120 from “LC” message. Gardner Denver. Chart 7-7: Troubleshooting and fault rectification for lubricator...
- Page 41 Remedy Message “LC” even though lubri- LC unit too big for the drive. Use original LC unit MLS 120 from cant cartridge is not completely Gardner Denver. emptied. Display not working despite volt- Internal drive fault. Replace entire lubrication system age being supplied.
- Page 42 NOTE Observe the fault messages on the operating panel display. The corresponding measures for fault clearance are described in the operating instructions of the elec- tronic control unit.
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Page 43: Maintenance And Service
MAINTENANCE AND SERVICE Maintenance and service are decisive for ensur- ing that the compressor can fulfil the requirements made of it for fault-free operation and running time. Therefore the adherence to the prescribed maintenance schedule and the careful execution of all maintenance and service work are indispens- able. -
Page 44: Service
Electrical components The global spare parts and customer service net- DANGER work of Gardner Denver is available worldwide. The local Gardner Denver subsidiary or the re- Electric shock sponsible dealer is available for any spare parts Life-threatening electric shock requirements. -
Page 45: Inspection Of Protection And Safety Equipment
➯ Wear ear defenders. Service and maintenance work must be carried out by the local Gardner Denver agency. Cleanliness The compressor room and the compressor sur- roundings must always be kept clean. -
Page 46: Maintenance Plan With 2000 Hour Service Package
The maintenance plan should always be used as a guideline. However, if based on experience a change is necessary, then this should be discussed with Gardner Denver. Maintenance plan: Maintenance every 8 operating hours... - Page 47 Maintenance plan: Maintenance every 125 operating hours Component Measure Necessary qualification Carried out Cooler / fan Check and clean if nec- Maintenance personnel essary Oil tank Drain condensate Maintenance personnel Chart 8-2: Maintenance plan, very 125 operating hours Maintenance plan: Service interval A - every 2000 hours run, but no less than annually Component Measure Necessary qualification Carried out...
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Page 48: Maintenance Plan Without 2000 Hour Service Package
The maintenance plan should always be used as a guideline. However, if based on experience a change is necessary, then this should be discussed with Gardner Denver. Maintenance plan: Maintenance every 8 operating hours... - Page 49 Maintenance plan: Service interval A - every 2000 hours run, but no less than annually Component Measure Necessary qualification Carried out Filter mats cooling air inlet Check, clean and replace as Maintenance personnel necessary. Condensate drain Aftercooler, function check. Maintenance personnel Electronic control unit Check for displayed mainte- Operator...
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Page 50: Service Plan Assure
Component Measure Necessary qualification Executed Suction regulator pressure Replace. Maintenance personnel regulator Blow-off valve diaphragm Replace Maintenance personnel Chart 8-10: Maintenance plan: Service D Inspection every 4 years: Have electrical installation inspected by an electrician. Inspection every 5 years: Internal inspection of the pressure vessel by a competent individual Inspection every 10 years: Strength test of the pressure vessel by appointed body Electronic control unit... -
Page 51: Maintenance Work
Maintenance work 8.8.2 Switch cabinet inlet filter 8.8.1 Filter mats Fig. 8-4: Switch cabinet inlet filter, air-cooled system Cooling air inlet Fig. 8-3: Filter mats Switch cabinet cooling air inlet (only Cooling air inlet speed-controlled system) Switch cabinet cooling air inlet (only speed-controlled system) Replacement times for the filter pad The operating modes and the quality of the suction... -
Page 52: Oil Change
8.8.3 Oil change Fig. 8-6: Filter element replacement Change inlet filter Fig. 8-7: Oil filter 1. Pivot open the louvred grille of the inlet filter. Oil filler neck 2. Remove dirty filter. Oil drain 3. Insert new filter. Oil level indicator 4. -
Page 53: Oil Filter
When changing oil, drain used oil as completely as 18.Check the oil level. If necessary, correct oil possible, as used oil greatly reduces the service level. life of the new oil charge. 19.Shut enclosure. You must refrain from mixing different lubrica- 8.8.4 Oil filter tion oils. -
Page 54: Oil Fine Separator
8.8.5 Oil fine separator 5. Detach suction pipe (3). 6. Remove vessel cover screws. 7. Raise vessel cover using the lifting device (4). 8. Turn vessel cover by 180°. 9. Lift oil fine separator (5) out of the vessel. 10.Replace sealing rings. 11. -
Page 55: Moisture Sensor Protective Cap
8.8.7 Moisture sensor protective cap 3. Check the filter element. – Replace the filter element if it is heavily con- taminated. 4. Shut enclosure. Replace the air filter element NOTICE Material damage Operation of the compressor without air filters, even briefly, can result in considerable damage to the compressor. -
Page 56: Connection Terminals In The Switch Cabinet / Control Transformer Setting
Performance of a protective cap change Checking the setting of the control transformer forms part of commissioning and periodic in- 1. Switch main switch OFF and secure to prevent spection/maintenance, as the mains voltage switching back on. conditions may have changed. 2. -
Page 57: Drive Motor / Lubricator
8.8.9 Drive motor / Lubricator – You must ensure that the triangular marks on the drive housing are fully visible. Replacing a grease cartridge – If these marks are not fully visible, release the union nut and put the drive back on again. -
Page 58: Checking Intervals For Pressure Vessel And Electrical Installation
3. Reset the fault message. To do this press the button [RESET] on the tab "Fault log" in the electronic control unit. – The "Fault log" tab stops flashing. 8.8.11 Checking intervals for pressure vessel and electrical installation Pressure vessel After five years, a person qualified to do so must check the pressure vessel internally in accordance with Pressure Equipment Directive 97/23/EC. -
Page 59: Appendix
Shutdown for a longer period valid operating instructions/haz- For shutdowns longer than six months, contact ardous substance data sheets. Gardner Denver. ➯ Avoid direct contact with lubricants Final shutdown and additives. Wear personal pro- tective equipment! To prevent restarting of the compressor or misuse ➯... -
Page 60: Disposal
1. Open the enclosure, create access. In accordance with the WEEE directive (2002/96/ 2. Position a suitable container beneath the oil EC), Gardner Denver undertakes to support the drain. recovery and reuse of electrical and electronic de- vices. Contact Gardner Denver for advice. -
Page 61: Limit Values Of Dissolved Matter
Material / Disposal type substance Recycling Landfill Haz- ardous waste Metals Cable Seals Plastics Filters Operating fluids Chart 9-1: Substances and materials used and their dis- posal Where possible Disposal according to the safety data sheet or manu- facturer's information Limit values of dissolved matter NOTE The following data are guidelines, which may deviate under certain operating conditions. -
Page 62: Technical Specification
Dissolved matter / specific values Circulating water Through-flow water Manganese < 0.1 mg/l < Sulfide Ammonia Conductivity > 50 < 800 µS/cm > 50 < 200 µS/cm Chart 9-2: Limit values of dissolved matter Technical Specification 9.6.1 L90-L110 + L90e - L110e, 50Hz, air-cooled "A", water-cooled "W" L90-L110 L90e-L110e L90 + L90e L110 + L110e... -
Page 63: L90-L110, 60Hz, Air-Cooled "A", Water-Cooled "W
L90-L110 L90e-L110e L90 + L90e L110 + L110e 50Hz, air-cooled "A” + water- cooled "W" Cooling air outlet temperature above "A" [°C] ambient temperature Residual pressure at ambient temper- "A" [Pa] 110 / 80 80/ 40 ature [35 °C / 45 °C] [35 °C / 45 °C] Cooling water quantity "W"... - Page 64 L90-L110 L110 60Hz, air-cooled "A” + water- cooled "W" Total current consumption during load 205 / 166 247 / 201 operation (380V / 460V) Electric motor IP55 (IE3) - IEC 60034-2-1 ECA Qualifying Rated speed of drive motor [rpm] 3000 Rated speed of fan motor "A"...
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Page 65: L132 + L132E, 50 Hz, Air-Cooled "[A]", Water-Cooled "W
9.6.3 L132 + L132e, 50 Hz, air-cooled "[A]", water-cooled "W" L132 + L132e L132 + L132e 50Hz, air-cooled "A” + water- cooled "W" Maximum operating pressure [bar] Maximum operating pressure (ver- [bar] sion e) Minimum operating pressure [bar] Ambient temperature [°C] 1 / 45 Volume flow... -
Page 66: L132, 60Hz, Air-Cooled "A", Water-Cooled "W
L132 + L132e L132 + L132e 50Hz, air-cooled "A” + water- cooled "W" Cooling water connections "W" EN 10226-1 Rp 11/4 (DIN 2999-R 1 1/2) Total oil quantity Compressed air connection EN 10226 R 2 1/2 (DIN 2999-R 2 1/2) Weight [kg] "A"... -
Page 67: L90 Rs, 50Hz + 60Hz, Air-Cooled "A", Water-Cooled "W
L132 L132 60Hz, air-cooled "A” + water- cooled "W" Cooling air volume flow "A" [m /min] Cooling air volume flow "W" [m /min] Cooling air outlet temperature above "A" [°C] ambient temperature Residual pressure at ambient temper- "A" [Pa] 70/ 40 ature [35 °C / 45 °C] Cooling water quantity... - Page 68 L90 RS, L90 RS, 50Hz, air-cooled "A” + water-cooled "W" Aftercooler outlet temperature above ambient "A" = [°C] temperature "W" = [°C] Sound pressure level (ISO 2151) "A" [dB(A)] 72 / 74 (50Hz) ; 72 / 75 (60Hz) "W" [dB(A)] 72 / 74 (50Hz) ;...
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Page 69: L110 Rs, 50Hz + 60Hz, Air-Cooled "A", Water-Cooled "W
Measured in an open area as per ISO 2151, tolerance 3 dB(A). At CompAir, our philosophy is to continually improve our products. We therefore reserve the right to alter technical data without prior notice. 9.6.6 L110 RS, 50Hz + 60Hz, air-cooled "A", water-cooled "W" L110 RS, L110 RS, 50Hz + 60Hz, air-cooled "A"... -
Page 70: L132 Rs, 50Hz + 60Hz, Air-Cooled "A", Water-Cooled "W
L110 RS, L110 RS, 50Hz + 60Hz, air-cooled "A" + water-cooled "W" Cooling water inlet temperature "W" [°C] min. 5 / max. 35 Cooling water outlet temperature "W" [°C] max. 55 Cooling water pressure "W" [bar] max. 10 Cooling water connections "W"... - Page 71 L132 RS, L132 RS, 50Hz + 60Hz, air-cooled "A" + water-cooled "W" Electric motor IP55 (IE3) - IEC 60034-2-1 ECA Qualifying Rated speed of drive motor [rpm] 650 / 2980 Rated speed of fan motor "A" [kW] 2.6 (50Hz) ; 6.6 (60Hz) Rated speed of fan motor "W"...
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Page 72: Installation Plan
Installation plan 90-132kW Fixed Speed 1225 210 162 210 90-132kW Fixed Speed 1374 2290... - Page 74 min. 1100 min. 800 Compressed air connection [EN] Water outlet (heat recovery) Cooling air inlet Electrical connection Water inlet (heat recovery) Cooling water inlet (water-cooled system) [CA] Cooling air outlet (air-cooled system) Cooling water outlet (water-cooled system) [CW] Cooling air outlet (water-cooled system) Switch cabinet cooling air inlet (only speed- controlled system RS)
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Page 75: Declaration Of Conformity
Declaration of conformity 1. EC Declaration of Conformity Pursuant to the EC Machinery Directive 2006/42/EC, Annex II A Gardner Denver Deutschland GmbH Argenthaler Str. 11 D-55469 Simmern hereby declare that the product: Compressor Type: L90; L110; L132; L90 RS; L110 RS; L132 RS... - Page 76 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Germany Tel. ++49 (0)6761 832-0 Homepage: www.compair.com e-Mail: [email protected]...