Gardner Denver L Series Guide de dépannage

13-25-640 v00 Page 1

L-SERIES FRAME 6

BASE MOUNTED COMPRESSOR

OriginalUserandServiceManual

MODELS:

L160-290C

215, 270, 335, 400 HP

LRS160-290C

160, 200, 250, 290 kW

13-25-640

Version 00

November 12, 2020

13-25-640 v00 Page 2

TABLE OF CONTENTS

1FOREWORD ...................................................................................................................... 4

1.1 About these Operating Instructions..............................................................................................4

1.2 Notes.............................................................................................................................................4

1.3 Intended Use.................................................................................................................................5

1.4 Foreseeable Misuse ......................................................................................................................6

1.5 Service...........................................................................................................................................7

1.6 Rating Plate ...................................................................................................................................7

2SAFETY REQUIREMENTS ................................................................................................... 8

2.1 General Safety Instructions ..........................................................................................................8

2.2 Warnings about Special Types of Hazard......................................................................................8

2.3 Protective and Safety Devices......................................................................................................9

2.4 Residual Risks..............................................................................................................................10

2.5 Labeling of Safety Instructions...................................................................................................10

2.6 Safety Symbols............................................................................................................................11

2.7 Transport and Installation ..........................................................................................................14

2.8 Normal Operation.......................................................................................................................14

2.9 Special Work................................................................................................................................15

2.10 Modifications and Changes to the Machine...............................................................................16

3DESIGN AND FUNCTION ................................................................................................. 16

3.1 General Description ....................................................................................................................16

3.2 Construction of the Compressor.................................................................................................17

3.3 System Schematic .......................................................................................................................21

3.4 Oil Circuit.....................................................................................................................................23

3.5 Air Circuit.....................................................................................................................................23

3.6 System Control............................................................................................................................23

3.7 Heat Recovery L160-L290 ...........................................................................................................25

4TRANSPORT AND INSTALLATION..................................................................................... 26

4.1 Transport.....................................................................................................................................26

4.2 Storage........................................................................................................................................28

4.3 Installation ..................................................................................................................................28

5PREPARING FOR COMMISSIONING................................................................................. 30

5.1 Piping...........................................................................................................................................30

5.2 Compressed Air Connection.......................................................................................................31

5.3 Cooling Water Connection..........................................................................................................32

5.4 Electrical Connection ..................................................................................................................35

5.5 Check the Setting of the Fan Overload Protection Switch(es). ......................................................37

5.6 Check the Oil Level......................................................................................................................37

13-25-640 v00 Page 3

6COMMISSIONING AND OPERATION................................................................................ 38

6.1 First Commissioning....................................................................................................................38

6.2 Check the Direction of Rotation of the Drive Motor ..................................................................39

6.3 Normal operation .......................................................................................................................40

6.4 Display of the Compressor Controller.........................................................................................40

6.5 Routine Commissioning ..............................................................................................................41

6.6 Commissioning after extended downtime .................................................................................42

6.7 Commissioning after a fault........................................................................................................42

7CLEARING A FAULT ......................................................................................................... 42

8MAINTENANCE AND SERVICE......................................................................................... 45

8.1 General Notes .............................................................................................................................45

8.2 Service.........................................................................................................................................47

8.3 Inspection of Protective and Safety Devices...............................................................................47

8.4 Routine Maintenance..................................................................................................................49

8.5 Maintenance Schedule ...............................................................................................................50

8.6 Maintenance Work.....................................................................................................................52

8.6.1

Filter Mats

..................................................................................................................................52

8.6.2

Switch Cabinet Inlet Filter

..........................................................................................................53

8.6.3

Oil Change

..................................................................................................................................54

8.6.4

Changing the Oil Filter Cartridge

..............................................................................................55

8.6.5

Oil Fine Separator

......................................................................................................................57

8.6.6

Air Filter

......................................................................................................................................59

8.6.7

Pressure Relief Valve

.................................................................................................................60

8.6.8

Connecting Terminals in the Switch Cabinet

............................................................................62

8.6.9 Maintenance Instructions and Lubricant Recommendations for Fixed Compressors................62

9APPENDIX....................................................................................................................... 64

9.1 Decommissioning........................................................................................................................64

9.2 Consumables and Auxiliary Materials.........................................................................................64

9.3 Disassembly.................................................................................................................................65

9.4 Disposal.......................................................................................................................................66

9.5 Installation Plan ..........................................................................................................................67

13-25-640 v00 Page 4

1 FOREWORD

Gardner Denver screw compressors are the result of many years of research and development. This

background and a high-quality standard ensure that the screw compressors we manufacture have long

service lives with higher reliability and economic operation. Naturally, we also ensure that strict

environmental protection requirements are met.

1.1 About these Operating Instructions

These operating instructions are written for operating and maintenance personnel.

These operating instructions are part of the compressor and must be stored near the compressor such

that they are available at all the times.

These operating instructions contain all of the documentation required for safe operation and maintenance

of the compressor. These include:

Installing and connecting the compressor Commissioning andoperating the compressor

Replacing wear parts and consumable materials, such as filters and oil

Identifying faults and clearing system malfunctions

Performing regular visual inspections for damage

Cleaning, maintenance, and repair of the compressor

The dealer's or manufacturer's shop, with 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 instructions are gage pressures (positive pressure).

Target groups

The target groups for these operating instructions are the operators, maintenance personnel, and

electrical technicians.

After training, the operator is permitted to start up and shut down the compressor and activate the

emergency-stop.

Maintenance personnel may, in conjunction with the information in these operating instructions,

maintain the compressor, repair it, start it up and shut it down and activate the emergency-stop.

Electricians may electrically install the compressor, carry out direction of rotation checks and carry out

electrical maintenance work.

Safety requirements

In addition to all the other information in these operating instructions, the general safety instructions in

the Chapter “Safety Requirements” must absolutely be read.

1.2 Notes

General notes

The operating instructions must be read and applied by any person assigned to work with and on the

compressor.

Regardless of these operating instructions, the laws, regulations, directives, and standards in force in

the installed location and the country of use must be followed.

Training

Operator training at site is performed by authorized service technicians. These operating instructions

serve as training documents, along with the repair instructions, which are provided only in conjunction

with service training.

These measures ensure that the assigned work can be completed reliably.

13-25-640 v00 Page 5

Guarantee

Gardner Denver is not liable for the functional safety of the compressor if any actions are taken that are

contrary to the intended use, or if used for any other purpose than those listed in the operating

instructions.

Gardner Denver refuses any guarantee or liability for cases of:

Operating errors.

Use of the compressor other than as intended.

Damages resulting from foreseeable misuse or failure to follow the operating instructions.

Damages or injuries caused by third party components.

Use of replacement or wear parts or consumable materials that are not provided or recommended by

Gardner Denver.

Inadequate maintenance. Modifications to the compressor.

The guarantee and liability conditions of the general terms and conditions of Gardner Denver are not

expanded by the notes above.

Warranty

Conditions and exclusions to the warranty by Gardner Denver are indicated in our general terms and

conditions, which were provided with the compressor. The document can also be sent again upon

request.

These operating instructions are subject to copyright law and may be used solely for the agreed purpose,

that is, as a reference for internal purposes.

Propagation or reproduction of this document, or the sale and impartation of its contents, are prohibited

unless expressly allowed. Infringement is liable to compensation. All rights are reserved with respect to

registration of a patent, utility patent, or design patent.

Resale

If the compressor is resold, these operating instructions must be provided to the new operator along with

the compressor. If necessary, the operating instructions must be reordered from Gardner Denver by

providing the order confirmation number. The compressor may not be resold without 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 usage.

The design cannot prevent foreseeable misuse, nor all other residual risks, without limiting the

functionality of correct usage.

The compressor is designed for the compression of atmospheric air (compressed air for driving

pressure equipment). The compressor is not suitable for the compression of other gases.

The compressor is considered to be used correctly if the following points are also covered:

The compressor is used in accordance with these operating instructions.

The operator’s work procedures and operating instructions are followed.

Any other use, or use exceeding these limits, is considered to be improper. The manufacturer is not

liable for any resulting damages. The user alone bears the entire risk.

Correct usage also includes following the operating instructions and complying with the inspection and

maintenance instructions.

13-25-640 v00 Page 6

Other provisions

The use of the compressor can cause hazards to life and limb of the user or third parties, or damage

to the compressor or other property, if the compressor:

Is not used properly.

Is operated by untrained personnel. Is modified or altered.

The safety instructions are not followed.

The following apply in addition to these operating instructions:

Applicable accident prevention regulations. Generally recognized safety rules.

Country-specific regulations.

Installation Site / Altitude

The compressor is intended to be installed in a suitable compressor room.

The compressor is not suitable for outdoor installation.

Depending on the operating pressure, ambient humidity, and ambient temperature at which the

compressor is operated, the permissible altitude of the installation site is limited. The permissible site

altitude is determined by Gardner Denver for each individual case in consultation with the customer.

Pressure equipment

A pressure safeguard (pressure relief or the like) that conforms to the applicable specifications must be

provided for the pressure equipment and systems installed in the compressed air supply network,

considering the weakest pressurized component.

Work environment

The lighting intensity in the area of the compressor must be ≥ 200 lx in normal operation.

The lighting intensity must be ≥ 500 lx for inspection and maintenance work.

The ambient temperature for operation: See “Technical data”.

1.4 Foreseeable Misuse

Incorrect usage and abuse

The following rationally foreseeable applications (incorrect usage) do not comply with the intended use:

Compressing gases other than atmospheric air.

Operation outside of the permissible operating limits, even if exceeded for only a short time, or if not

immediately detectable.

Operation outside of the permissible ambient temperatures.

Intake of non-atmospheric air (over pressure or under pressure).

Use as a respiratory air compressor. Manipulation of sensor signals.

Changing signals from sensors.

Operation without protective and safetydevices.

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 users without technical training.

Operation outside of industrial premises.

Failure to comply with maintenance intervals.

Failure to perform maintenance and repairs.

Incorrectly executed maintenance and repairs.

Limitations on use

Operation of the compressor is not permitted:

Outside of the permissible ambient temperatures.

Above the permissible elevation of the installation site.

On a foundation that does not have sufficient load capacity.

In areas with explosive atmosphere.

13-25-640 v00 Page 7

1.5 Service

In case of questions or problems with compressor, consult your Gardner Denver representative.

Trained technicians provide fast, technically accurate assistance.

For questions

In case of questions or spare parts orders, please provide the model, identification, and year built, as

indicated on the model rating plate. Providing these data ensures that you will receive the correct

information or spare parts.

Your Gardner Denver representative

Use the following table to record data about your local Gardner Denver representative.

Name:

Contact person:

Address:

Telephone

Fax

Email:

Table 1 Local Gardner Denver Representative

1.6 Rating Plate

Figure 1-1 Rating Plate

13-25-640 v00 Page 8

2 SAFETY REQUIREMENTS

Every person involved with the operation, maintenance, and repair of the compressor must read and

follow the safety requirements.

Gardner Denver accepts no responsibility for material damage or injuries that arise from non- observation

of safety conditions or the failure to observe normal levels of care and attention, even where this is not

expressly stated in these operating instructions.

2.1 General Safety Instructions

Organizational measures

The following organizational measures support the safe operation of the compressor:

Only assigned personnel may work on the compressor. Personnel are trained and instructed on the

compressor.

Personnel must have read the operating instructions and particularly the Chapter “Safety

Requirements”. During the assignment is too late. This applies in particular to personnel who are in

action only occasionally, such as for maintenance.

The responsibilities of personnel foroperation, maintenance, and repair must be clearly defined.

Personnelshouldbecheckedregularto ensuretheyareconsciousof safetyandhazardswhenworking.

Personnel in training, under instruction, being taught, or taking part in a general training program

may work with the compressor only under the continuous supervision of an authorized person.

For safety-related changes to the compressor or its operating behavior, the compressor must be

stopped immediately and the fault must be reported to the responsible area orperson.

Faults, especially those that can compromise safety, must be corrected immediately.

Otherwise the compressor must not be operated.

All hazard 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 inspections must be adhered to.

The operating instructions must be updated to include instructions for supervisory or reporting

obligations in reaction to special operating conditions, such as with respect to work organization,

process flows, responsibilities, etc.

2.2 Warnings about Special Types of Hazard

Electricity

DANGER

Electric shock

Deadly electrical voltage

Exercise extreme caution when working with electrical equipment.

Before starting maintenance work, disconnect the compressor and lock it out to prevent

restarting.

For all work on the compressor’s electrical equipment, the 5 safety rules for working on electrical

systems must be followed.

The following instructions must also be followed:

Work on the electrical equipment of the compressor may be done only by an electrician in

accordance with electrical rules.

The electrical equipment of the compressor must be inspected regularly. Defects, such as loose

connections or scorched cables, must be corrected immediately.

Only original fuses with the specified current rating may be used.

Only for units with Variable Frequency Drives:

Due to residual voltage in the capacitors, the electrical enclosure must not be opened until at least 10

minutes after disconnecting (main disconnect switch OFF). Follow the hazard warning sign on the

electrical enclosure! See the “safety symbols” table.

13-25-640 v00 Page 9

Noise

The sound pressure level without the sound-proofing enclosure is approx. 95 dB(A). Remaining for

long periods alongside the compressor without its sound-proofing enclosure can result in irreversible

hearing impairment.

Only operate the compressor without the sound- proofing enclosure during test runs. Wear personal

hearing protection.

The sound pressure level with sound-dampening enclosure is about: (See "Technical data".)

During normal operation the compressor may only be operated with a closed acoustic hood.

Oil, Grease, and other chemical substances

Follow the applicable safety requirements when handling oils, greases, and other chemical

substances.

Use caution when handling hot materials, as there is a risk of burning or scalding.

DANGER

Explosion hazard

The compressor is not designed for operation in explosion hazard areas.

Operation of the compressor in explosion hazard areas is not permitted!

2.3 Protective and Safety Devices

The compressor is equipped with the following protective and safety equipment.

Prior to commissioning, particularly after maintenance and repair work, all protective and safety devices

must be installed and checked for proper function.

In addition, the inspection intervals required in the country of use must be complied with.

NOTICE

Operation ofthe compressor is permitted only with complete, functional protective and safety devices in

place.

Emergency Stop

The emergency stop button can be used tobring the compressor to a safe condition in dangerous

situations.

Emergency stop buttons are mounted:

On the control panel of the compressor.

Optional in a pedestal (control console).

Using the Emergency Stop

1. Press the <Emergency stop> pushbutton. The compressor is placed in a safe condition.

2. Rectify the fault that was the cause ofthe emergency-stop. See the "Troubleshooting" chapter.

3. Unlock <Emergency-Stop>button. Turn the pushbuttoncounter-clockwise.

4. Start up the compressor. See section "Commissioning after a fault" in the chapter "Commissioning and

operation".

Pressure Relief Valve / Check valve

Thecompressor isprotected fromexceedingthe permissible operating pressure by a pressure relief valve.

The pressure relief valve opens at 15 bar / 218psi.

Thecompressor is protected against backpressure from the compressed air network by means of a check

valve on the pressure side.

13-25-640 v00 Page 10

Protective covers and enclosure panels

The cooling air fans are covered with protective mesh.

The coupling between the drive and the compressor is protected by a mesh guard.

The housing of the compressor is designed so that any broken parts that may be thrown off are retained

within the compressor.

The compressor housing serves as a sound protection cover.

2.4 Residual Risks

Hot surfaces

Some parts of the compressor become hot in operation (up to 120°C / 248°F). A hazard warning sign

on the compressor enclosure warns of this danger.

Before beginning maintenance and repair work, the compressor must have cooled off sufficiently.

Personal protective equipment

We recommend wearing the following personal protective equipment:

Safety shoes

Safety glasses whenever working with compressed air and open enclosure

Hearing protection when the sound protection cover is open

2.5 Labeling of Safety Instructions

Safety instructions are used as special warning notices in the operating instructions, using the following names

and symbols.

These special warning notices serve to protect against hazards and are close to the potential hazard in space

and time:

On the system, near the source of hazard

In the operating instructions, before a sequence of actions or activities to be performed is described

Structure of safety instructions

The special warning notices in the operating instructions are structured as follows:

Components of safety instructions

Hazard (consequences of hazard): The hazard sequence tells the type of hazard.

Description of the hazard (hazard source): The hazard source indicates the cause of the hazard.

Protective measure (protection against hazard): The protection against the hazard describes the

measures for preventing the hazard.

Alert word: Thealert word classifies the severity of the hazard into four levels, emphasized graphically

with different colors. The alert word is used in the safety instructions as described below.

DANGER Indicates an immediate dangerous situation that, if not prevented, will result in death or

extreme (irreversible) injury.

WARNING Indicates a potential dangerous 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) injury.

CAUTION Indicates information or recommendations that directly or indirectly relate to the safety of

persons or equipment protection.

ALERT WORD

Safety symbol

Hazard (consequences of hazard)

Description of the hazard (source)

Protective measure (protection against hazard)

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