Gardner Denver L Series Service Manual
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Gardner Denver L Series Service Manual

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L-SERIES FRAME 4
BASE MOUNTED COMPRESSOR
Service Manual
MODELS:
L55-75F
75 & 100 HP
LRS55-75F
55 & 75 kW
13-25-638
Version 03
January 12, 2021

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  • Page 1 L-SERIES FRAME 4 BASE MOUNTED COMPRESSOR Service Manual MODELS: L55-75F 75 & 100 HP LRS55-75F 55 & 75 kW 13-25-638 Version 03 January 12, 2021...
  • Page 2 Gardner Denver parts will be used. Warranty The conditions of the Gardner Denver Warranty are set out in the company's standard Conditions of Sale available from the Distributor supplying the machine. USE ONLY GARDNER DENVER GENUINE PARTS. USING NON-GENUINE PARTS FOR SERVICING OR REPAIRS WILL INVALIDATE YOUR WARRANTY.
  • Page 3 Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment.
  • Page 4 Check and, if required, re-tighten connection terminals. Check the DC bus voltage at the system terminal strip of For further details, see the operating instructions. the frequency converter by measuring this between the Danger of electric shock from loaded condensers! +DC and -DC terminals (the exact position can be found Please always first disconnect the system from the in the supplied operating manual of the frequency...
  • Page 5 NOTICE Indicates a property damage message. PROHIBITION/MANDATORY ACTION REQUIREMENTS Asphyxiation Hazard – Never breathe in compressed air Never operate the unit with open doors or loose access from this system. panels. Read the operator’s manual before proceeding with this Opening pressure relief valve = xx bar (value "xx" see task sticker on compressor) Handle package at forklift points only...

  • Page 6: Preface

    Fig. 1 Your Gardner Denver distributor Name: Address: Telephone: Fax: Contact: Spare Parts: Service: 13-25-638 v03 Page 6...

  • Page 7: Compressor Information

    Therefore, it is essential that the prescribed Gardner Denver will not guarantee the safe operation of maintenance intervals are adhered to and that the machine/equipment if it is not handled in a way...
  • Page 8 Gardner Denver replacement parts • alterations to the equipment. The warranty or liability terms of Gardner Denver’s Terms and Conditions are not expanded by the foregoing. Any independent alterations to the compressor equipment/station or installing components which have not been approved by the manufacturer (e.g., separator) will result in the...

  • Page 9: Table Of Contents

    Warning -Prohibition - Mandatory Label Information ..................... 3 Preface ..................................6 Compressor Information .............................. 7 Intended Use ................................7 Maintenance and Care ..............................7 Notes .................................... 7 Table of contents ..............................9 Safety regulations ..............................11 General safety regulations ............................11 Particular dangers associated with compressed air ....................
  • Page 10 10 Service and maintenance ............................39 10.1 Maintenance recommendations ..........................39 10.2 Maintenance Electric Motor ............................. 39 10.2.1 Motor Lubrication……………………………………………………………………………………………………… . 39 10.3 Maintenance and inspection schedule........................39 10.3.1 Service Check List ............................40 10.4 Oil change ................................42 10.5 Change oil filter cartridge............................

  • Page 11: Safety Regulations

    4.1 General safety regulations Danger Safety measure required Working with compressors involves Everyone working with the machine must have first read and understood the operating manual. Don’t leave this until you start work – it’s too late. dangers that are not immediately apparent.

  • Page 12: Particular Dangers Associated With Compressed Air

    4.2 Particular dangers associated with compressed air Danger Safety measure required Never play with compressed air. Compressed air is very powerful. It can be used, for example, to break open concrete but can also put lives at risk. Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution and compressed air can penetrate the skin always wear suitable eye protection.
  • Page 13 Danger Safety measure required Compression results high The system should be set up such that hazardous mixtures (flammable solvent temperatures. Risk of explosion from vapors etc., but also dusts and other dangerous or toxic materials) cannot be drawn-in materials. drawn in. The same applies to flying sparks. Never use the machine in environments where the possibility cannot be ruled out that flammable or toxic vapors may be taken in.

  • Page 14: Particular Dangers Associated With Machines

    4.3 Particular dangers associated with machines Danger Safety measure required Risk of electric shock. Electrical connections must meet local regulations. Power units must be connected to earth and protected from short-circuits by means of fuses. Insufficient power quality could Always check a correct power supply to the compressor before commissioning. The voltage supply has to fulfill the requirements of NFPA70-NEC f o r this type of have a strong effect on health &...

  • Page 15: Dangers Present When Loading/Moving Machines

    Dangers present when loading/moving machines Danger Safety measure required Loose parts may fall off when lifting. All loose parts must first be removed or secured; parts fitted so that they can turn like doors etc. must be secured and made immobile. Parts to be removed for transport purposes must be carefully refitted and fixed again before putting the machine/installation back into operation.

  • Page 16: General Workplace Dangers

    General workplace dangers Danger Safety measure required This manual only describes how to work Please note and pass on general statutory and other binding regulations that safely with the compressor itself. But may supplement the operating manual for the prevention of accidents and the other dangers will arise during work.

  • Page 17: Dangers During Maintenance And Repairs

    Contact your Gardner Denver agent. removed. If you maintain the compressor and have not been trained by Gardner Denver, you will put yourself and others at risk. Incorrectly installed spare parts may Spare parts must meet the technical requirements laid out by the manufacturer.
  • Page 18 Danger Safety measure required Never weld any pressure reservoir or modify it in any way. During the course of maintenance and repairs, parts can be damaged which If work which produces heat, flames, or sparks has to be carried out on a are important for safety.

  • Page 19: Dangers Resulting From Conversion Work/Modifications On The Machine

    Gardner Denver. Installing or using such products will adversely affect active and/or passive safety. The manufacturer accepts no liability whatsoever for damage resulting from the use of non-original parts or special accessories.

  • Page 20: Design And Functioning

    Design of the unit - Air cooled Fig. 2a 13. Minimum Pressure Valve & 24. Final Compression Temperature Intake Filter Non-Return Valve Sensor Suction Regulator 14. Fine Oil Separator Extraction 25. System Pressure Sensor Electric Motor 15. Oil Temperature Regulator 26.
  • Page 21 5.1 Design of the unit - Water cooled Fig. 2b 13. Minimum Pressure Valve & 24. Final Compression Temperature 1. Intake Filter Non-Return Valve Sensor 2. Suction Regulator 14. Fine Oil Separator Extraction 25. System Pressure Sensor 3. Electric Motor 15.

  • Page 22: System Schematic

    System Schematic Fig. 3 Intake filter 25 Flow throttle adjustable 12 Oil filter Intake regulator 26 Fine separator monitor (S6) 13 Oil temperature regulator 2.1 Pressure valve control 27 Fine separator 14 Oil cooler 2.2 Actuator 28 Pressure holding and check valve 15 Oil flow throttle 29 Network pressure sensor (B1) Check valve...

  • Page 23: Oil Circuit

    Oil circuit System control The oil flows from the pressure reservoir (-22-) into the (See also operating instructions for the compressor oil thermostat (-13-). With oil temperatures < 131°F the controller) oil flows via the by-pass of the oil cooler directly into the oil filter (-12-) and is then injected into the screw compressor (-4-).
  • Page 24 Stopping the system  The pressure reservoir (-20-) is unloaded  Solenoid valve (-5-(Y1)) is de-energized when the to atmospheric pressure by means of the STOP button on the operating panel of the solenoid valve (-4- (Y4)) and the actuator compressor controller is pressed.
  • Page 25  Stopping the system When the demand for compressed air rises, the motor speed is increased in order to keep the  To de-energize the solenoid valves (-5- (Y1) and - preset setpoint pressure constant. 4- (Y4)) press the OFF push-button on the keypad of ...

  • Page 26: Transport And Installation

    Transport DANGER The compressor or parts of it may fall if mistakes are made when lifting, and this will put your life at risk. Safety devices may be damaged if lifted incorrectly.  Always observe the safety notes in Section 4.5 of the user manual. ...

  • Page 27: Installation

    The screw compressor unit has to be leveled. The Installation system may not be run while on the transport pallet. DANGER A minimum distance from walls, other machines, etc. should be maintained so that there is sufficient Always observe the safety notes in Section clearance for maintenance and repair work (Fig.

  • Page 28: Preparations For Commissioning

    Cooling air volume/minimum cross Fig. 9 a Cool air intake Cool air exhaust Control cabinet cool air intake (L55RS-L75RS only) The figures below show the recommended ventilation sections arrangement: The cooling air volume required by these screw compressors is as follows: Air-cooled 60 Hz Compressors: L55, L55RS: 4308 cfm L75, L80, L75RS: 6003 cfm...

  • Page 29: Compressed-Air Connection

    Compressed-air connection WARNING Fig. 10 Fig. 11 Compressed-air connection Thread identification of compressed-air connection Cooling-water inlet (option) Cooling-water outlet (option) The compressed-air line system is connected at the compressed air supply of the screw compressor (-1- Fig. 11). For this you should use a flexible connection (e.g., compressed air hose, compensator).

  • Page 30: Water Connection For Water-Cooled Units

    This data is based on fresh water and the cooling-water The following items must be noted for quality recommended by Gardner Denver (see operation of water-cooled screw Section 7.3.1). Please contact Gardner Denver if the cooling-water data diverges from this. compressor systems:  Cooling water must not be discharged...
  • Page 31 7.3.1 Limit values of the constituent elements in water Constituent elements of Pass- Circulating water / characteristic through water values water pH value 6 – 9 6 – 9 (at 77°F) Carbonate CaCO < 100 mg/l < 50 mg/l hardness (5.6 °dH) (2.8 °dH) Total hardness...

  • Page 32: Electrical Connection (Usa/Canada Version Only)

    To establish an electrical connection, proceed as Electrical connection follows: (USA/CANADA Version only) Route the supply cable (-1- Fig. 12) through the cable gland on the switch cabinet and tighten screws. DANGER Connect the supply line to the connecting terminals as Risk of severe damages and fire on the shown in the circuit diagram.

  • Page 33: Checking The Oil Level

    (- 3 - Fig. 13) and “minimum oil level” (- 4 - Fig. 13) marks on the oil gauge.  If required, top up oil. Use Gardner Denver oil only.  Close the oil filler cap (-1- Fig. 13) firmly.

  • Page 34: Commissioning

    First commissioning is carried out as follows: First commissioning  Remove transport guards, if fitted. DANGER  Check the oil level in the pressure reservoir (also see Section 7.5 Fig. 13) The rotational direction of the motor can only be checked with the casing open. ...
  • Page 35 Fig. 14 a 1 Drive motor direction of geared compressors Fig. 14 d - Water-cooled units Cooling air intake Cooling air outlet Arrow “direction of rotation for compressor“ (direction of rotation may deviate from this representation) Fig. 14 b 1 Drive motor direction with direct drive Temperature start-up protection The screw compressor unit will not start up if the ambient temperature is lower than 34 °F.

  • Page 36: Putting A Decommissioned Compressor Back Into Operation

    Routine commissioning Putting a decommissioned compressor back into operation WARNING Before commissioning the compressor all the electrical and electronic components and units should be checked for the ingress of water or condensation. If the electronic control system was removed during shut down, it must be re-installed.

  • Page 37: Commissioning After Malfunction

    Commissioning after malfunction Re-start after an automatic shutdown due to a malfunction as follows:  Faults are shown as text in the compressor controller Alarms menu. Turn master switch off and secure it from being switched on again.  Eliminate fault. ...

  • Page 38: Storage Of Compressors

    Decommissioning All compressors are protected against corrosion at the factory for transport and for brief storage before commissioning. If the compressors are to be stored for period exceeding six months, additional precautions must be taken. Compressors which are to be shut down for a lengthy period must also be protected from corrosion.

  • Page 39: Service And Maintenance

    10 Service and maintenance 10.1 Maintenance recommendations WARNING 10.2 Maintenance Electric Motor 10.2.1 Motor Lubrication Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The following chart show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions.

  • Page 40: Service Check List

    Valve" and "Compressor Oil System Check". 2. An oil sample will need to be taken and sent to the Gardner Denver oil lab. Refer to oil change 7. Inspect, replace if necessary the drive coupling procedure in section 10.4 for proper oil draining spider (coupling element).
  • Page 41 Maintenance Schedule - L Series Check air/oil reservoir oil level  Check operation of the machine, is it loading and  unloading properly Check discharge pressure and temperature  Check control panel for advisory text messages  Inspect, Clean if necessary Cooler / Fan ...

  • Page 42: Oil Change

    10.4 Oil change DANGER Air/oil under pressure will cause severe personal injury or death.  Shut down the compressor, relieve the system of all pressure, disconnect, lockout and tagout the power supply to the compressor package before removing valves, caps, plugs, fittings, bolts and filters.

  • Page 43: Change Oil Filter Cartridge

     The oil level must lie between the “maximum oil level” (-4- Fig. 16) and “minimum oil level” (-5- Fig. 16).  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 SO and solvent vapors) have a strong influence on...

  • Page 44: Changing The Fine Oil Separator

    10.6 Changing the fine oil separator DANGER Air/oil under pressure will cause severe personal injury or death.  Shut down the compressor, relieve the system of all pressure, disconnect, lockout and tagout the power supply to the compressor package before removing valves, caps, plugs, fittings, bolts and filters.

  • Page 45: Change Of Air Intake Filter

     Pivot the reservoir cover back to the starting position.  Screw the cheese-head screws (-8- Fig. 19) 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 MPV (Minimum Pressure Valve).

  • Page 46: Pressure Relief Valve

    10.8 Pressure relief 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.

  • Page 47: Connecting Terminals In The Switch Cabinet

    DANGER A defective pressure relief valve may result in pressure that is too high, breaking open parts of the system and causing serious or fatal injury. Never operate a screw compressor system with a defective pressure relief valve or without pressure relief valve! 10.9 Connecting terminals in the switch cabinet DANGER...

  • Page 48: Screw Connections

    10.10 Screw connections 10.12 Clean / change filter with cool air intake and switch cabinet inlet The screw connections of the air, oil, and water circuits have to be checked and, if required, re-tightened DANGER according to the maintenance schedule. Only perform checks and carry out work on Check the hose and piping for unsealed areas.
  • Page 49 Fig. 23 Fig. 24 Perform filter mat change as follows:  Open the louver grilles of the inlet filter (Fig. 23).  Remove the filter pad.  Insert the new filter pad into the louver grille. Ensure that the smooth side (-A- Fig. 24) of the filter pad faces the air inlet side.

  • Page 50: Maintenance Notes And Lubricant Recommendations For Stationary Compressors

    The exact oil change schedule according to the actual operating conditions should 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 1(800) 682-9868.

  • Page 51: Trouble-Shooting

    11. Trouble-shooting In the case of faults or warnings that are detected by the compressor controller, please refer to the chapter “Fault/warning table” in the operating instructions of the controller. Malfunction Possible cause Remedy Unit cannot be started No operating or control voltage Check fuses, main switch and supply line Malfunction not acknowledged Acknowledge fault message...
  • Page 52 11 Trouble-shooting Malfunction Possible cause Remedy Ambient temperature is too high Ventilate the compressor room Unit switches off Electric motor is defective Check the electric motor and PTC thermistor Faulty fan Check/exchange fan Faulty sensor, connection or cable Check the sensor, connection and cable Electrical cable gauge too small Measure the current draw and...

  • Page 53: Annex

    12.1 Layout plan Fig. 25 Feed cable entry Cool air outlet Compressed air connection with male screwed thread CANADA/USA version: 2-11 1/2 NPT Cool air intake Cool air intake of control cabinet (only L55RS-L75RS) Water inlet (cold) (only for water-cooled variant) inside thread EN 10226-1 Rp 1"...
  • Page 54 Fig. 26 (all dimensions in mm) 13-25-638 v03 Page 54...
  • Page 55 NOTES: 13-25-638 v03 Page 55...
  • Page 56  For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2021 Gardner Denver, Inc. Printed in U.S.A.

This manual is also suitable for:

L55-75fLrs55-75f

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