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Gardner Denver L30RS User Manual

Gardner Denver L30RS
60 pages
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Original User and Service Manual
Screw Air Compressor
L30 - L50
L30RS - L45RS
V2
ā—
USA
Id. no. ZS1133367 / 00 - April 2015

Table of Contents

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Gardner Denver L30RS Specifications

General IconGeneral
ModelL30RS
TypeRotary Screw
Power30 hp
Flow Rate125 cfm
Max Pressure125 psig
Phase3
Noise Level69 dB(A)

Summary

General Information

Maintenance

Ensures trouble-free operation through periodic maintenance and servicing as per manual guidelines.

Warranty

Conditions for warranty claims, emphasizing use of genuine parts for servicing to avoid invalidation.

Warning - Prohibition - Mandatory Label Information

DANGER Symbol Explanation

Indicates a hazard with a high level of risk, potentially resulting in death or serious injury if not avoided.

Specific Hazard Warnings

Details warnings for electric shock from condensers, burn hazards, and general cautionary notes.

Prohibitions and Actions

Covers safety prohibitions like asphyxiation and mandatory actions like reading manuals and proper handling.

Preface

Your Gardner Denver distributor

Section for filling in distributor contact information for service and parts.

Compressor Information

Details on the design and manufacturing of Gardner Denver screw compressors for long service life and reliability.

Intended Use

Specifies the machine's intended use for compressing atmospheric air and hazards if misused or operated improperly.

Maintenance and Care

Emphasizes the importance of proper maintenance for ensuring compressor performance and longevity.

General Notes

Provides general notes on operating the compressor safely, economically, and increasing its service life.

Service

Guidance on contacting Gardner Denver for faults, spare parts, and repairs with genuine parts.

For important questions

Instructions on providing specific unit information (model, serial number) for inquiries or parts orders.

Warranty Claims

Lists conditions under which warranty claims are void, such as user errors or unauthorized modifications.

Safety Regulations

Highlights the DANGER of not observing safety regulations and refers to Section 4.

Technical Changes

Statement reserving the right to make technical changes without prior notice.

Safety regulations

4.1 General safety regulations

General safety rules for working with compressors, emphasizing manual adherence and trained personnel.

4.2 Particular dangers associated with compressed air

Details dangers of compressed air, including high speed, connections, hoses, and expansion, with safety measures.

4.3 Particular dangers associated with machines

Covers dangers like electric shock, power quality issues, unexpected remote startups, and noise.

4.4 Particular dangers associated with water-cooled units

Addresses dangers from bacteria (legionella) in cooling water and oil leakage into the cooling circuit.

4.5 Dangers present when loading/moving machines

Details dangers during lifting and moving, like falling parts and incorrect hoisting.

4.6 General workplace dangers

Covers general workplace safety, including adherence to regulations, fire safety, and handling chemical substances.

4.7 Dangers resulting from neglecting to perform maintenance

Highlights dangers from wear of safety components, line perishability, oil spurting, electric shock, and faulty sensors.

4.8 Dangers during maintenance and repairs

Covers dangers during maintenance, such as pressurized parts, incorrect spare parts, electric shock, and unexpected startups.

4.9 Dangers resulting from conversion work/modifications on the machine

Explains dangers of unauthorized modifications, use of non-genuine parts, and operating with non-functioning protective equipment.

Design and functioning

5.1 Design of the unit

Illustrates and labels the main components of the screw compressor unit.

5.2 System Schematic

Presents a schematic diagram of the compressor's system with labeled components and functions.

5.3 Oil circuit

Details the flow and operation of the oil circuit within the compressor, including temperature-dependent routing.

5.4 Air circuit

Explains the path of intake air through the compressor, its cooling, separation, and delivery to the network.

5.5 System control

Describes the system control logic, including standstill conditions and starting procedures.

Stopping the system

Provides steps for stopping the compressor system normally and its automatic shutdown sequence.

Automatic operation (open-close operation)

Explains the compressor's automatic operation cycle, including load, offload, and standby modes.

5.5.1 Manner of operation of the suction regulator

Details the operation of the suction regulator in both load running mode and idling mode with diagrams.

Transport and installation

6.1 Transport

Provides safety instructions and guidelines for transporting the compressor unit, including lifting and securing.

6.2 Installation

Outlines installation requirements, including leveling, ventilation, safety notes, and placement considerations.

Preparations for commissioning

7.1 Cooling air volume/minimum cross

Specifies cooling air requirements and minimum duct cross-sections for optimal heat dissipation and performance.

7.2 Compressed-air connection

Details the compressed-air connection procedure, safety warnings, and requirements for hoses and fittings.

7.3 Electrical connection (USA/CANADA Version only)

Provides instructions and safety warnings for making the electrical connection for USA/CANADA versions.

Recommended supply cable cross-sections and fuses

Table listing recommended cable sizes and fuse ratings for various compressor types and supply voltages.

7.3.1 Check setting of the fan protection switch

Instructions for checking and setting the fan motor protection switch for specific models.

7.3.2 Checking the setting of the control-power transformer

Guidance on checking and setting the control-power transformer for proper system operation.

7.4 Checking the Oil Level

Detailed procedure for checking the oil level, including safety warnings and oil specifications.

7.5 Sound pressure level

Presents sound pressure level data for different compressor models according to ISO 2151.

Commissioning

8.1 First commissioning

Step-by-step guide for the initial commissioning of the screw compressor unit.

8.2 Putting a decommissioned compressor back into operation

Procedure for recommissioning a compressor after it has been decommissioned or stored.

8.3 Display of the compressor control GD Pilot TS

Explanation of the GD Pilot TS control display elements and indicators.

8.4 Routine commissioning

Steps for routine commissioning and startup procedures for the compressor unit.

8.5 Commissioning after malfunction

Procedure for restarting the compressor after an automatic shutdown due to a malfunction.

8.6 Shutoff

Instructions for normally shutting down the compressor, emphasizing the use of the stop button.

8.7 Emergency stop

Information on the function and usage of the emergency stop button.

Service and maintenance

10.1 Maintenance recommendations

Guidelines for performing maintenance work at specified intervals for optimal compressor satisfaction.

10.2 Maintenance Electric Motor

Details on the maintenance of the electric motor, noting it is permanently lubricated.

10.3 Maintenance and inspection schedule

Overview of the maintenance and inspection schedule, with safety warnings for electrical work.

10.3.1 Service Check List

A detailed checklist for service and maintenance tasks categorized by operating hours.

10.4 Oil change

Detailed procedure and safety precautions for changing the compressor oil.

Maintenance Schedule - L Series

A comprehensive maintenance schedule table for the L Series compressors, indicating intervals for various tasks.

10.5 Change oil filter cartridge

Step-by-step guide on how to change the oil filter cartridge, including safety warnings.

10.6 Changing the fine oil separator

Instructions for replacing the fine oil separator, with safety warnings and disposal information.

10.7 Change of air intake filter

Procedure for changing the air intake filter, including safety warnings and filter replacement steps.

10.8 Pressure relief valve

Information on checking and testing the pressure relief valve, with critical safety warnings.

10.9 Connecting terminals in the switch cabinet/control transformer setting

Guidance on checking and setting connecting terminals and the control transformer, with high voltage warnings.

10.10 Screw connections

Instructions for checking and re-tightening screw connections in air, oil, and water circuits.

10.11 General maintenance and cleaning

General advice on cleaning system parts with compressed air, emphasizing safety and avoiding oil residue.

10.12 Clean / change filter with cool air intake and switch cabinet inlet

Procedure for cleaning or changing filters for cool air intake and switch cabinet inlet.

10.13 Inspection intervals for pressure reservoir and electrical installations

Details inspection intervals for pressure reservoirs and electrical installations as per regulations.

10.14 Maintenance notes and lubricant recommendations for stationary compressors

Provides notes on lubrication for compressor lifespan and recommends specific oil types.

c) Switch cabinet inlet filter (-4- Fig. 26)

Specific instructions for changing the switch cabinet inlet filter, including filter pad replacement.

Trouble-shooting

Unit cannot be started

Troubleshooting steps for when the compressor unit fails to start, listing possible causes and remedies.

Unit stops during the start-up phase

Diagnosing and resolving issues where the unit stops during the start-up phase.

Unit does not reach the set mains pressure

Troubleshooting for the unit failing to reach the set mains pressure, covering sensor and regulator issues.

Unit switches off

Addresses causes and solutions for the unit switching off unexpectedly, including temperature, motor, and sensor faults.

Idle pressure too high

Troubleshooting steps for when idle pressure is too high, focusing on suction regulator and system discharge.

Oil in the compressed air

Diagnosing and rectifying causes of oil contamination in the compressed air.

Oil in the air filter

Troubleshooting for oil found in the air filter, relating to suction regulator and separator issues.

Pressure relief valve opens

Resolving issues where the pressure relief valve opens, often related to sensor faults or regulator problems.

Annex

12.1 Technical specifications

Presents technical specifications for North America version L30-L37 compressors.

12.1.1 North America version L30RS

Technical specifications for the L30RS model in the North American market.

12.1.2 North America Version L37RS

Technical specifications for the L37RS model in the North American market.

12.1.3 North America version L45-L50

Technical specifications for L45 and L50 models in the North American market.

12.1.4 North America version L45RS

Technical specifications for the L45RS model in the North American market.

12.2 Layout plan

Provides layout plans and dimensional drawings for L30-L50 compressor models.

L30RS-L45RS

Layout plans and dimensional drawings specific to L30RS-L45RS compressor models.

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