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Gardner Denver L15 User Manual

Gardner Denver L15
60 pages
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Original Operating and Service Manual
Screw Air Compressor
L15 - L22
L15 RS - L22 RS
USA
Id. no. ZS1138156 / 00 - April 2015

Table of Contents

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Gardner Denver L15 Specifications

General IconGeneral
ModelL15
CategoryAir Compressor
TypeRotary Screw
Voltage208-230/460V
Phase3
LubricationOil Lubricated

Summary

General Information

Maintenance

Details on periodic maintenance and servicing schedules.

Warranty

Information on warranty terms and the importance of genuine parts.

1. Warning -Prohibition - Mandatory Label Information

DANGER Hazard Symbols

Illustrates critical hazards with symbols for pressurized parts and electric shock.

Hazard Level Explanations

Warning and CAUTION Symbols

Details hazards with medium/low risk, burn hazards, and electrical safety.

Safety Action Requirements

Prohibition and Notice Labels

Mandatory safety actions, prohibitions, and property damage notices.

2. Preface

Company Contact Information

Contact details and address for Gardner Denver Deutschland GmbH.

Nameplate Data Explanation

Explanation of fields and values found on the compressor's nameplate.

Preface - Key Sections

Compressor Information

Overview of Gardner Denver screw compressors, their design, and benefits.

Intended Use

Defines the proper application and limitations of the machine.

Maintenance and Care

Emphasizes the importance of proper maintenance for performance and longevity.

General Notes

Provides general guidance on using the manual and safety regulations.

Preface - Warranty and Safety

Warranty Terms and Conditions

Details conditions under which the warranty is valid and invalid.

Safety Regulations Overview

Highlights the importance of observing safety regulations in Section 4.

4. Safety regulations

General Safety Regulations

Fundamental safety rules and principles for operating the compressor.

Safety Regulations - Specific Dangers

Dangers Associated with Compressed Air

Details specific risks and safety measures related to compressed air.

Safety Regulations - Machine Dangers

Dangers Associated with Machines

Outlines risks related to electric shock, noise, and remote operation.

Safety Regulations - Loading and Workplace

Dangers During Loading/Moving Machines

Safety precautions for lifting, moving, and securing the compressor unit.

General Workplace Dangers

Addresses general site safety, fire prevention, and handling chemicals.

Safety Regulations - Maintenance and Modifications

Dangers from Neglecting Maintenance

Highlights risks from wear, leaks, electrical faults, and sensor failures.

Safety Regulations - Maintenance Risks

Dangers During Maintenance and Repairs

Covers risks like electric shock, pressure, and component damage during servicing.

Safety Regulations - Modifications

Dangers from Conversion Work/Modifications

Warns against unauthorized modifications and the use of non-original parts.

5. Design and functioning

Design of the Unit

Provides a detailed diagram and list of components for the compressor unit.

Design and Functioning - Schematics

Schematic Diagram

Presents the system schematic showing air and oil circuits.

Oil Circuit

Explains the flow and function of the oil circulation system.

Design and Functioning - System Control

System Control

Describes the control system's operation and components.

System Control L15-L22

Details the standstill and starting procedures for the L15-L22 models.

System Control L15 RS-L22 RS

Details the standstill and starting procedures for the L15 RS-L22 RS models.

Design and Functioning - Unit Components

Design of the Unit

Provides a detailed diagram and list of components for the compressor unit.

System Schematic

System Schematic Diagram

Visual representation of the compressor's system interconnections.

Oil Circuit and System Control

Oil Circuit Description

Explains the oil flow from the reservoir through the filter and cooler.

System Control L15-L22

Details the standstill, starting, and automatic operation modes for L15-L22.

System Control Modes

Automatic Operation

Describes how the compressor operates automatically based on pressure.

Stopping the System

Instructions on how to properly shut down the compressor unit.

System Control L15 RS-L22 RS

Details operation modes, starting, and stopping for L15 RS-L22 RS models.

Speed Control and Hood Operation

Speed Control Operation

Explains how speed is adapted to demand for compressed air.

Hood (Opening/Closing)

Instructions for accessing the compressor unit by opening and closing the hood.

6. Transport and installation

Transport Safety

Safety notes and procedures for safely lifting and transporting the compressor.

Unit Weights

Lists the approximate weights of different compressor models.

Installation Requirements

Installation Guidelines

Provides requirements for compressor placement, ventilation, and leveling.

Explosion Risk Warning

Alerts to explosion risks from hazardous mixtures and flying sparks.

7. Preparations for commissioning

Cooling Air Volume Requirements

Specifies required cooling air volume and duct dimensions.

Ambient Temperature Limits

Defines the operational temperature range for the screw compressor.

Compressed Air Connection

Compressed Air Connection Procedure

Instructions for safely connecting the compressor to the compressed air system.

Condensate Drainage

Notes on equipping lines with drain facilities and handling condensate.

7.3 Electrical connection

Electrical Connection Procedure

Guidelines for making electrical connections, including safety warnings.

Recommended Cable and Fuse Sizes

Table of recommended cable diameters and fuse sizes based on temperature.

Control Transformer Setting

Checking Control Transformer Setting

Procedure for verifying the control transformer's output voltage under load.

Electric Motor Fasteners

Instructions for removing transport fasteners from the electric motor.

Oil Level Check and Sound Pressure

Oil Level Check Procedure

Steps for checking and topping up the oil level in the pressure reservoir.

Sound Pressure Levels

Provides measured sound pressure levels for different compressor models.

8. Commissioning

First Commissioning Steps

Detailed procedure for initial setup and startup of the compressor.

Drive Motor Rotation Check

Procedure for verifying the correct rotational direction of the drive motor.

Commissioning Procedures

Routine Commissioning

Steps for standard commissioning and operation of the compressor.

Start-up Protections

Information on motor start-up protection related to temperature and pressure.

Commissioning After Malfunction

Procedure for restarting the compressor after an automatic shutdown.

9. Control system

General Control System Overview

Introduction to the control system and its display functions.

Control System Keys

Explanation of the function of each key on the control panel.

Control System Display and Settings

Status Indicator and Light Signals

Describes the three-row display and the meaning of indicator lights.

Displaying and Changing Values

How to navigate menus and modify system parameters.

Control System Default Settings

Selecting Language

Instructions for changing the display language of the control system.

Setting Network Pressure

Procedure for setting cut-in and cut-out pressures for L15-L22 models.

Control System Line Pressure and Timer

Setting Line Pressure

Procedure for setting pressure for L15 RS-L22 RS models.

Setting Time/Date (Timer)

Instructions for setting the system's internal clock and date.

Control System Operation Modes

Starting the Unit

Steps for safely starting the compressor unit.

Switching Off the Unit

Procedure for normal shutdown and the function of the soft-stop.

Emergency Off Button

Information on the emergency stop button for immediate shutdown.

Control System Messages

Acknowledging Warning/Fault Messages

How to view and acknowledge warning and fault messages on the display.

Warning Messages

Details on warning messages and how to clear them.

Fault Messages

Explanation of fault messages that cause shutdown or prevent startup.

Menu Structure

Menu Structure L15-L22

Diagram showing the menu navigation and options for L15-L22 models.

Menu Structure L15 RS-L22 RS

Menu Structure L15 RS-L22 RS

Diagram showing the menu navigation and options for L15 RS-L22 RS models.

10. Service and maintenance

Maintenance Recommendations

General advice on performing maintenance work carefully and at specified intervals.

Maintenance Electric Motor

Guidance on servicing the electric motor as per its operating instructions.

Maintenance and Inspection Schedule

Maintenance and Inspection Schedule Overview

General warnings and cautions related to maintenance tasks.

Service Check List

Every 8 Hours Operation Checks

List of checks to perform during the first 8 hours of operation.

Every 125 Hours Operation Checks

List of checks to perform every 125 hours of operation.

Service Check List Intervals

Every 2000 Hours/6 Months Checks

Tasks to perform every 2000 hours or 6 months.

Every 4000 Hours/12 Months Checks

Tasks to perform every 4000 hours or 12 months.

Service Check List - Extended Intervals

Every 8000 Hours/24 Months Checks

Tasks to perform every 8000 hours or 24 months.

Oil Change

Oil Change Procedure

Step-by-step instructions for draining oil and replacing the oil filter cartridge.

Oil Change Intervals

Factors influencing oil change frequency and analysis.

Oil Filter and Fine Separator

Change of Oil Filter Cartridge

Procedure for replacing the oil filter cartridge, including safety precautions.

Change of the Fine Separator Cartridge

Instructions for replacing the fine separator cartridge, including safety.

Air Filter and Maintenance Schedule

Change of Air Intake Filter

Procedure for replacing the air intake filter, with warnings about operating without one.

Maintenance Schedule - L Series

Overview of maintenance tasks and their recommended intervals.

Filter Mat Cleaning and Pressure Reservoir Testing

Cleaning Filter Mats

Instructions for cleaning and replacing filter mats in air intake and outlet.

Test Period for Pressure Reservoir

Requirements for periodic inspection of the pressure reservoir.

Maintenance Notes and Lubricant Recommendations

Guidance on lubrication and recommended oil types for compressors.

11. Trouble-shooting

Unit Cannot Be Started

Troubleshooting steps for when the compressor fails to start.

Unit Stops During Start-up Phase

Diagnosing and resolving issues causing the unit to stop during startup.

Trouble-shooting - Unit Operation

Unit Does Not Reach Set Mains Pressure

Troubleshooting steps for low pressure issues.

Unit Switches Off

Diagnosing and resolving causes for unexpected unit shutdown.

Trouble-shooting - Oil and Pressure Issues

Excessive Idling Pressure

Troubleshooting steps for excessive pressure during idling.

Oil in Compressed Air

Diagnosing and resolving issues causing oil in the compressed air.

Oil in the Air Filter

Troubleshooting steps for oil found in the air filter.

Trouble-shooting - Valve Issues

Pressure Relief Valve Opens

Troubleshooting steps when the pressure relief valve activates.

12. Annex

Technical Data USA/Canada L15-L22 60 Hz

Detailed technical specifications for L15-L22 models in US/Canada.

Technical Data L15 RS

Technical Data USA/Canada L15 RS

Detailed technical specifications for the L15 RS model.

Technical Data L18 RS

Technical Data USA/Canada L18 RS

Detailed technical specifications for the L18 RS model.

Technical Data L22 RS

Technical Data USA/Canada L22 RS

Detailed technical specifications for the L22 RS model.

Layout Plan

Layout Plan L15 - L22, L15 RS - L22 RS

Diagram showing component layout and dimensions for L15/L22 series.

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