Professional Documents
Culture Documents
Manual de Operacion y Mantenimiento Del Compresor
Manual de Operacion y Mantenimiento Del Compresor
11 1
1111 1111
Paquetes Hidroneumáticos de Servicios Agua de Mar y Agua Potable, Paquetes de Aire de Planta E Instrumentos,
Bombas Contra Incendio y Bombas Jockey, Trampas de Grasa, Filtros de Carbón Activado, Paquetes lnhibidores de Corrosión.
Translation of the original operating
instructions
Screw compressor
075 .. 0160 V2
0110RS .. 0160RS V2
1.4 Foreseeable misuse .................................. 6 6.1.1 Cooling water adjustment for water-cooled
compressor systems ............................... 42
1.5 Service ...................................................... 6
6.2 Normal operation .................................... 43
1.6 Rating plate ............................................... 7
6.3 Routine commissioning ........................... 44
9 Appendi:x: ...................................................... 68
4 Transport .and installation .......................... 33
9.1 Decommissioning .................................... 68
4.1 Transport ................................................. 33
9.2 Consumables and auxiliary materials ..... 68
4.2 Storage .................................................... 33
9.3 Disassembly ............................................ 68
4.3 lnstallation ............................................... 33
9.4 Disposal. .................................................. 69
5 Preparing for commissioning .................... 36 9.5 Limit val u es of dissolved matter .............. 70
-----·---------- ·----------
August 2013 USA 3/100
1 Foreword CompAir
These operating instructions apply to the following ~ Replacing wear parts and consumable materi-
compressors from Gardner Oenver: als, such as filters and oil
~ 075-BA V2 ~ ldentifying faults and clearing system malfunc-
tions
~ 075-10A V2
&ii Performing regular visual inspections for dam-
~ 090-BA V2 age
~ 090-10A V2 ~ Cleaning, maintenance, and repair of the com-
~ 0110-BA V2 pressor
USA
41 100
CompAir Foreword 1
------- ---·----·--
Regardless of these operating instructions, the Propagation or reproduction of this document, or
laws, regulations, directives, and standards in the sale and impartation of its contents, are pro-
force in the installed location and the country of hibited unless expressly allowed. lnfringement is li-
use must be followed. able to compensation. All rights are reserved with
respect to registration of a patent, utility patent, or
Training design patent.
Operator training at site is performed by autho-
rized service technicians. These operating instruc- Resale
tions serve as training documents, along with the lf the compressor is resold, these operating in-
repair instructions, which are provided only in con- structions must be provided to the new operator
junction with service training. along with the compressor. lf necessary, the oper-
These measures ensure that the assigned work ating instructions must be reordered from Gardner
can be completed reliably. Denver by providing the arder confirmation num-
ber. The compressor may not be resold without
Guarantee these operating instructions in any case.
Gardner Denver is not liable for the functional
1.3 Correct usage
safety of the compressor if any actions are taken
that are contrary to the intended use, or if used for The compressor uses the best available technol-
any other purpose than those listed in the operat- ogy and meets applicable safety requirements at
ing instructions. the time of sale, in the context of correct usage.
Gardner Denver refuses any guarantee or liability The design cannot prevent foreseeable misuse,
for cases of: nor all other residual risks, without limiting the
functionality of correct usage.
~ Operating errors.
The compressor is designed for compressing oil-
e11 Use of the compressor other than as intended. free atmospheric a ir (compressed air for powering
~ Damages resulting from foreseeable misuse or pressure equipment); the compressor is not suit-
failure to follow the operating instructions. able for compressing other gases.
~ Damages or injuries caused by third party com- The compressor is considered to be used correctly
ponents. if the following points are al so cave red:
* Use of replacement or wear parts or consum- Efl The compressor is used in accordance with
able materials that are not provided or recom- these operating instructions.
mended by Gardner Denver.
o The operator's work procedures and operating
e lnadequate maintenance. instructions are followed.
e Modifications to the compressor. Any other use, or use exceeding these limits, is
The guarantee and liability conditions of the gen- considered to be improper. The manufacturer is
eral terms and conditions of Gardner Denver are not liable for any resulting damages. The user
not expanded by the notes above. alone bears the entire risk.
Correct usage also includes following the operat-
Warranty ing instructions and complying with the inspection
Conditions and exclusions to the warranty by and maintenance instructions.
Gardner Denver are indicated in our general terms
and conditions, which were provided with the com- Other provisions
pressor. The document can also be sent again The use of the compressor can cause hazards to
upon request. life and limb of the user or third parties, or damage
to the compressor or other property, if the com-
Copyright
pressor:
These operating instructions are subject to copy-
• ls not used properly.
right law and m ay be used solely for the agreed
purpose, that is, as a reference for interna! pur- • ls operated oy untrained personnel.
poses. • ls modified or altered.
• The safety instructions are not followed.
The following apply in addition to these operating ti Operation with detective, deactivated, or ma-
instructions: nipulated protective and safety devices, or
~t Applicable accident prevention regulations. safety values, or operation with other safety-re-
lated defects.
~t Generally recognized safety rules.
11 Use by prívate users or users without technical
Country-specific regulations. training.
~ Operation outside of industrial premises.
lnstallation site 1 altitude
Failure to comply with maintenance intervals.
The compressor is intended to be installed in a
suitable compressor room. The compressor is not ti Failure to perform maintenance and repairs.
suitable for outdoor installation.
~~; lncorrectly executed maintenance and repairs.
Depending on the operating pressure, ambient hu-
midity, and ambient temperature at which the com- limitations on use
pressor is operated, the permissible altitud e of the
installation site is limited. The permissible site alti- Operation of the compressor is not permitted:
tude is determined by Gardner Denver for each in- e Outside of the permissible ambient tempera-
dividual case in consultation with the customer. tures.
Work: environment
e Above the permissible elevation of the installa-
tion site.
The lighting intensity in the area of the compressor
must be ;::: 200 lx in normal operation.
e On a foundation that does not have sufficient
load capacity.
The lighting intensity must be ;::: 500 lx for inspec-
tion and maintenance work.
e In areas with explosive atmosphere.
The ambient temperature for operation: See 1.5 Service
"Technical data"
In case of questions or problems with compressor,
Pressure equipment consult your Gardner Denver representative.
A pressure safeguard (safety valve or the like) that Trained technicians provide fast, technically accu-
conforms to the applicable specifications must be rate assistance.
provided for the pressure equipment and systems
installed in the compressed air supply network, For questions
considering the weakest pressurized component. In case of questions or spare parts orders, please
provide the model, identification, and year built,
1.4 Foreseeable as indicated on the model rating plate. Providing
lncorrect usage ami abuse these data ensures that you will receive the cor-
rect information or spare parts.
The following rationally foreseeable applications
(incorrect usage) do not comply with the intended Your Gardner Denver representative
use: Use the following table to record data about your
• Compressing gases other than atmospheric air. local Gardner Denver representative.
·------~-----
6/100 USA August 2013
CompAir Foreword 1
Noise
The sound pressure level without a sound-damp-
ening enclosure is about 11 O dB(A). Long-term ex- Operation of the compressor is permitted only
posure to the compressor without a sound-damp- with complete, functional protective and safety
ening enclosure can cause irreversible hearing devices in ace.
damage.
The compressor may be operated without a Emergency stop
sound-dampening enclosure only for test runs.
The emergency stop button can be used to bring
Wear personal hearing protection.
the compressor to a safe condition in dangerous
The sound pressure level with sound-dampening situations.
enclosure is about: See "Technical data"
For normal operation, the compressor may be run Emergency stop buttons are mounted:
only when the sound protection cover is closed. e On the control panel of the compressor
Oil, grease, and other chemical substances 1111 Optionally in a pedestal (control console)
Follow the applicable safety requirements when
Using the emergency stop
handling oils, greases, and other chemical sub-
stances. 1 Press the <E-stop> button.
The compressor is brought to a safe condition.
Use caution when handling hot materials, as there
is a risk of burning or scalding. 2 Correct the fault that was the reason for the
emergency stop.
Explosive hazard areas See the "fault correction" chapter.
3 Unlock the <E-stop> button.
Turn the button counterclockwise.
4 Start up the compressor.
See the paragraph "Commissioning after a
The compressor is not designed for op-
fault" in the chapter "Commissioning and oper-
eration in explosion hazard areas.
ation."
~ Operation of the compressor in ex-
plosion hazard areas is not permit- Safety valves 1 check valve
ted!
Safety valves protect the compressor against ex-,
ceeding the permissible operating pressure. The
Legionella growth in water-cooled compres-
safety valves open at 3.5 bar (1st compressor
sors with open-loop cooling circuits
stage) and 11.4 bar (2nd compressor stage).
The compressor is protected against backpressure
from the compressed air network by means of a
Contamination with Legionella check valve on the pressure side.
Health hazard with open-loop cooling
systems. Protective covers and enclosure
~ Continuous monitoring of water The cooling air fans are covered with protective
quality and germ count in the cool- mesh.
circuit. The coupling between the drive and the compres-
sor is protected by a mesh guard.
2.3 Protective and safety devices The housing of the compressor is designed so that
The compressor is equipped with the following any broken parts that may be thrown off are re-
protective and safety equipment. tained within the compressor.
Prior to commissioning, particularly after mainte- The compressor housing serves as a sound pro-
nance and repair work, all protective and safety tection cover.
devices must be installed and checked for proper
function. 2.4 Residual risks
In addition, the inspection intervals required in the Hot surfaces
country of use must be complied with. Some compressor components become very hot
during operation (up to 235 oC). A hazard warning
sign on the compressor enclosure warns of this
danger.
Do not operate with open lt is not permitted to run the compressor with open doors
doors or loase clothing. or loase clothing, except for test runs. High sound pres-
sure level, risk of injuryl
Normal operation requires the enclosure to be closed.
Do not breathe in the lt is not permitted to use the compressed air produced by
compressed air from this this compressor for breathing. lndrawn materials can be
unit dangerous to health.
Do not use compressed airas breathing air.
System continues to run compressor continues to run for 30 second after the
button <O> is pressed.
not open the compressor enclosure until the com-
pressor has stopped.
Follow the instructions Labeling of instructions to the user that additional infor-
for use mation can be found in the (manufacturer's) operating
instructions.
Befare the machine is operated, the user (operator)
must have read and understood the instructions for use
(manufacturer's instructions for use).
Use hearing protection Label for areas with elevated sound pressure leve!.
Enter the area only with suitable hearing protection.
Warning about industrial Warning of industrial trucks traveling within the plant
trucks (e.g., forklifts) when transporting.
Do not perform any work in traffic lanes with limited visi-
bility that are not secured or blocked off. Use or crossing
of this traffic lane requires great caution.
Warning of suspended Warning of suspended loads during transport.
loads During transport, no persons may be present in the haz-
ard area. In particular, do not reach in or allow the feet to
pass beneath the suspended compressor.
1-------------·---··¡----
1 Warning of automatic In normal operation the compressor can start automati-
1 l~art cally at any time. Operational readiness of the compres-
sor is indicated by the green LEO on the control panel.
---·-----------+-----~-------------\
Suffocation warning Suffocation hazard dueto insufficient ventilation and
0
~-~-~f--i
movements of an industrial truck.
~rtyv~ Opening pressure of the safety valve (for val ue "xx" see
the sticker on the control panel).
XX bar 1
'·-------------------+------------------------------+---------------------·---------------
1Check connection ter- Warning of loosened clamp connections. Clamping pres-
f minals and retighten if su re can fade after so m~ time.
1needed. For additional Check the clamps regularly according to the safety
1instructions, see the guidelines and tighten as needed.
¡operating instructions.
Chart 2-1: Safety symbol
Electrical voltage
Residual voltage on the Warning of stored energy in the form of capacitors. They
capacitors carry deadly electrical voltage.
Do not open the electrical enclosure (RS compressor) for
1O minutes after disconnecting the compressor.
Check the OC bus voltage of the frequency inverter
at the grid terminal strip of the frequency inverter. The
exact position of the "OC+" and "OC-" terminals can be
found in the included operating instructions for the fre-
quency inverter.
Work on the electrical equipment of the compressor may
be done only by an electrician in accordance with electri-
cal rules.
lnsert the forks only at the lifting points provided. No flammable or explosive materials may be
stored near the compressor.
The compressor, even in its packed state, may not
be transported by crane. Non"f\al operation
During transport, no persons may be present in
The compressor may be used only if it is in a tech-
the hazard area. In particular, do not reach in or
nically pristine state, and it must be used as in-
allow the feet to pass beneath the suspended
tended, with awareness of safety and hazards, by
compressor.
following the operating instructions.
Operate the compressor only if all protective and Maintenance and repair work may be performed
safety devices, sound dampeners, ventilation and only under supervision, or by a person qualified for
exhaust devices, and cooling water supply (for this work.
water-cooled compressors only) are present and Secure an ample working area, if needed.
functional.
Workshop equipment suitable for the work is ab-
Check regularly that: solutely required to perform maintenance and re-
~ All hoses and pipelines are in good condition pairwork.
and securely attached.
Safety measures
there are no leaks (oil, coolant, or cooling wa-
Personnel must not wear open, long hair, loose
ter).
clothing, or jewelry, including rings. When the
~ The electrical connection lines are in good con- compressor is running, there is an injury hazard,
dition. such as dueto jamming or drawing in. lf needed
~ cooling water supply is provided (for wa- or required by regulations, use personal protective
ter-cooled compressors only). equipment!
Perform only those maintenance and repair works
Behavioral rules for using compressed air.
for which yo u have sufficient training and where
~ Do not use any method that involves question- you feel comfortably su re of your ability.
able safety.
Do not use machine parts as climbing aids. For
~ Never play around with compressed air. maintenance work at greater heights, use fall pro-
~ Never direct compressed air at the skin or at tection.
other person.
Maintenance/fault clearing
~ Never use compressed air to clean clothing.
Perform any maintenance and repair work only
~ When using compressed air to clean equip- when the compressor is switched off and the
ment, use great care and also wear safety power grid supply is disconnected. Secure the
glasses as eye protection. compressor against being turned on accidentally.
-----------
14/100 USA August 2013
CompAir Safety requirements 2
-----------
Weight /lifting gear Damage arising from the use of non-original parts
Carefully attach and secure heavy individual com- or special equipment precludes the liability of the
ponents and assemblies when replacing, so that manufacturer. This also applies to the installa-
they do not presenta hazard. Use only suitable tion and adjustment of safety devices and valves,
lifting gear that is in technically perfect condition, and for the welding of load-bearing or pressurized
and a load handling device with sufficient load ca- parts.
pacity. Do not stand or work beneath suspended
loads.
Spare parts
Use only original spare parts.
Spare parts must comply with the technical re-
quirements stipulated by the manufacturer. This
is guaranteed only when original spare parts are
u sed.
----------- ·-----·-----
August 2013 USA 15 /i 00
3 Design and function CompAir
'o
13
4 5 6 7
[1] Condensate drain (intermediate cooler) [10] Sound barrier with filter mesh
[2] Oil/water cooler [11] Aftercooler
[3] Oil filter [12] lntermediate cooler
[4] Pulsation/noise suppressor [13] Water cooler
[5] Air service unit [14] Blow-off sound damper
[6] Compressor unit [15] Condensate trap (intermediate cooler)
[7] Control air filter [16] Safety valves (intermediate pressure)
[8] Ultrafine filter [17] Compensating tank (coolant)
[9] Pulsation damper
----------
August 2013 USA 17/100
3 Design and...........
-----·-·-·-·---- function
_____
, __ ____________________________________________________________ CompAir
,
18 18 17 16 15
14
13
7 8 9 10 11 12
Water-cooled
14 13
6 7
[1] Condensate drain (intermediate cooler) [10] Sound barrier with filler mesh
[2] Oil/water cooler [11] Cooling water header
[3] Oil filler [12] Aftercooler
[4] Pulsation/noise suppressor [13] lntermediate cooler
[5] Air service unit [14] Cooler (interna! cooling circuit)
[6] Compressor unit [15] Blow-off sound damper
[7] Control air filler [16] Condensate trap (intermediate cooler)
[8] Ultrafine filler [17] Safely valve (intermediate cooler)
[9] Pulsation damper [18] Compensating tank (coolant)
--------------·------
August 2013 USA 19 /100
3 Design and function CompAir
16 15
.
----~~-~ ---~~·---------
S1e't~ ' 27
R7
E:B 28
B7
IT7I
k:::c.:J
air Water
Charl3-1: Unes
Components
1
--
8 Compressor, second Air service unit i?Q IULÜr
---
stage IV'""
9 8ound and pulsation 19 , Vacuum generator 30 1Speed control (inverter)
damper 1
J
_.,._,,_,_.,,m_._,,,_., .. .................. ,
,..__, ._ __ ...... ................ ...- .. -·-·----·-···....-..-.....
._
S18 y
~
R8
.
Ci"i
~
..... ,.•:
1Jb~0
'Z!
' rz[IL]M
Y4
Qb:.
R1
EB
B7
C2J
Components
No.
exchanger
2 13 trap (aftercooler)
r-----+------------------------+--------r---------------------+------~-----------------
3 Compressor, first stage 14 valve (final pres- Cooler, infernal cooling
su re) water circuit
4 Pulsation damper i5 Filtered water trap 26 :r~~~-~~;1~~~----~-~~-~;~;~;¡~~-1
(interna! cooling water cir-
cuit)
5 lntermediate cooler 27 Compensation tank
------
6 Water trap (intermediate damper 28 Cooling water pump
cooler)
7 29 Orive motor
valve (externa!
circuit)
Temperature at outlet
from first compressor
stage
Pressure al inlet to first R3 Temperature at inlet S12 Oillevel
compressor stage to second compressor
stage
82 Pressure at outlet from R4 Temperature al outlet 818 Water level
first compressor stage from second compressor
stage
83 Pressure at inlet to sec- R5 Network temperature Orive motor PTC thermis-
ond compressor stage tor
Air circuit
3
4
2
6
Air is drawn in through an intake filter and passes through the intake regulator into the first compres-
sor stage. Here the air is compressed to the intermediate pressure and then cooled in the intermediate
cooler. lt is then compressed in the second stage to the final compression pressure desired by the cus-
tomer. The compressed air passes through the aftercooler and into the compressed air network. The con-
densate produced during cooling is precipitated by automatic condensate traps.
When the compressor is running in idle mode, the compressed air outlet of the second stage is released
to atmosphere vi a a blow-off valve integrated in the intake regulator.
A pulsation damper after the first compressor stage ensures that the air flows smoothly to the second
stage and the reduces pressure variations. After the second compressor stage, a combined sound and
pulsation damper reduces pressure variations and dampens the sound.
To protect the machine components and for safety reasons, safety valves are installed downstream of the
intermediate cooler and the aftercooler.
To protect the compressor against backflow from the compressed air network, a check valve is installed in
the pressure line within the compressor. •
Scalding hazard from escaping steam and escaping hot cooling water.
The intermediate cooler, aftercooler, and heat exchanger (interna! water circuit) are supplied with cooling
water vía the externa! cooling water circuit.
The two compressor stages are cooled by the interna! cooling water circuit in the housing, and the lubri-
cating oil is cooled in the oil/water cooler.
The water pump circulates the water to the second compressor stage, the first compressor stage, the oil/
water cooler, and then back to the water/air cooler.
Temperature control is provided by the cooling water temperature control valve. Variations in the water
are compensated for the by the compensation tank.
circuit
The gearbox and bearings are lubrícated by the compressor stage unit.
Oil is drawn in from the oíl pan and círculated through the oíl cooler or bypass (temperature control),
through the oíl fílter, and ínto the gearbox and bearíngs of the compressor stage unít. The used oíl returns
to the oíl pan. Q
Sequence
111 Switch on the cooling water supply (for wa-
ter-cooled compressors only).
Fig. 3-1 O: Air vent system ejector
• Press the start button < 1 > on the control
[1] Condensate trap for the second stage paneL
(aftercooler water trap) The compressor switches on.
[2] Compressed air connection, air vent • The electronic controller checks the starting pa-
system ejector rameters (temperatures, pressures, sensors,
·. [3] Solenoid valve Y3 cooling water leve!).
[4] Air service unit (water trap, pressure 111 lf the starting parameters have been met, the
regulator, pressure gag e) cooling water pump and oil pump are switched
on in sequence; the water and oil start to circu-
[5] Ejector (vacuum generator)
late.
[6] Exhaust
• At the same time, the solenoid valve Y3 is actu-
[7] Ultrafine filter ated. This starts the venting system ejector.
[8] Oil return 111 lf the water and oil pressure are OK, the drive
motor is started.
The ejector bleeding system generales a defined • After the drive motor runs up to speed, the so-
vacuum pressure in the area of the compressor lenoid valves Y1 and Y2 are switched on after
stage unit that is lubricated with oil, and thus pre- a delay. The intake regulator opens. The two
vents oil from escaping to the environment fans are switched on. The compressor is now
The ejector venting system uses compressed air running under load.
from the compressed air network. The air passes 111 The compressor runs under load until the max-
through the air service unit to the vacuum genera- imum network pressure [max. network pres-
ter. sure] is reached.
The air drawn off from the oil system is filtered and 111 When the maximum network pressure [max.
discharged to the atmosphere, and the precipi- network pressure] has been reached, the so-
tated oil is returned to the oil pan. lenoid valves Y1 and Y2 are deenergized. The
intake regulator is closed, the blow-off valve
3.10 Controls (automatic mode) is opened, and the compressor is relieved of
Prerequisites pressure. Tl;le compressor is in idle mode. Fan
2 is switched off.
The following prerequisites must be met for auto-
111 The compressor runs in id le mode until the net-
matic operation:
work pressure falls below the mínimum network
111 All preparations for commissioning are met pressure [min. network pressure] or until the
e The compressor is correctly connected to the programmed idle time has expired.
power grid.
Receiving
When received, check for sliipping damagé.
1 Check the delivery for visible damage.
Fig. 4-1: Lifting points
2 Use the packing list to check the delivery for
completeness. 1 Remove bolts from the transport pallet.
3 lmmediately inform the freight forwarder, insur- 2 Lift the compressor off of the transport pallet.
ance, and Gardner Denver of any missing parts
or damage.
3 Transport the compressor to the destination
are a.
Weight 4 Align the compressor and place it down.
The compressor weighs up to 3,800 kg (gross),
depending on the model. The weight is shown on Storage
the rating plate and is visible from the exterior. Storing compressors.
Transport The compressor should be stored in a dry area,
heated if possible. This applies especially to the
winter months.
Danger to life
.,.~
"ElE Danger to life from tipping or falling
Damage to property
parts.
Damage to property dueto exceeding the per-
e:> A suitable forklift with sufficiently
missible temperature range
long forks must be used to transport
the compressor. e:> lf there is a risk that the temperature will
be outside of the permissible limits of +2 ...
e:> Use forks only at the labeled lifting
+65 oc, consult Gardner Denver.
points.
e:> The compressor, even in its packed Corrosion protection
state, may not be transported by All compressors are protected at the factory
crane. against corrosion for shipping and short-term stor-
e:> During transport, no persons may age prior to commissioning. lf compressors are
be present in the hazard area. In stored for longer than 6 months, additional preven-
particular, do not reach in or allow tive measures must be taken.
the feet to pass beneath the sus- Compressors that will be out of service for an
ded ressor. extended period of time must also be protected
against corrosion.
lnstaliation
Requirements 'for the installation site
The compressor must be installed with full contact
on a foundation with sufficient structural strength.
Deviation from flat must not be greater than 3 mm.
The installation site (compressor room) should lf local conditions are unfavorable, insta!! air duct-
be of sufficient size that there is clearance of 1 m ing. The flow speed of the cooling air should not
("A" and "B") on al! sides, and clearance of 1.5 m exceed 5 m/s. We recommend a mínimum pas-
above the compressor. There should also be ap- sage cross section of about 1.2 m2 (for air-cooled
propriate access space for maintenance work. compressors) and 0.45 m2 (for water-cooled com-
pressors).
Danger of asphyx:iation
Danger from asphyxiation dueto insuffi-
=
~_ti==~==~~==~--~
cient ventilation and exhaust.
r:::> The operator must provide sufficient
ventilation and exhaust of the com-
room.
Risk of injury
Danger from improper installation
~ Consider the permissible load ca-
pacity of the foundation.
~ Make su re the foundation is salid
and flat
~ The compressor must be installed
with full contact on a foundation with
sufficient structural strength.
r:;> The compressor must not be oper-
ated on the transport pallet
~ No flammable or explosive materials
may be stored near the compressor.
1 Place the compressor down at the correct loca-
tion.
2 Ensure that the support surface is flat, within a
tolerance of 3 mm. (The compressor does not
have any leveling features.)
A shutoff valve should be installed in the supply [1] Compressed air connection
line, so that the compressor can be isolated for [A 1] Automatic aftercooler condensa te drain
maintenance purposes. No additional check valve
may be installed. An additional check valve would [A2] Aftercooler condensate drain via ball valve
prevent the vacuum generator from being supplied (used if the automatic condensate drain is
with air. not working)
lf excessive condensate is expected, then the [A3] Automatic intermediate cooler condensate
compressed air connection for the vacuum gen- drain
erator ejector must be connected to a conden- [A4] lntermediate cooler condensate drain
sate-free compressed air supply. In case of doubt, vi a ball valve (u sed if the automatic
consult Gardner Denver. condensate drain is not working)
The two automatic condensate drains must be
provided with separate lines that run to waste-
water discharge orto a collecting tank.
The drain lines running away from the condensate Burst hazard
connections must be pitched at no greater than 5 The outlet temperature of the com-
m. pressed a ir can be as high as 95°C.
An air tank of sufficient volume should be installed 9 The pressure rating of the down-
(as a buffer) between the compressor and the stream components in the supply
compressed air network. As a guideline for the line (customer network) must be
tan k capacity, selecta size that is 10% of the sup- suitable for these res.
ply volume. For example, a compressor with a
supply vol ume of 1O m3/min requires a tank with a
volurne of 1 m 3 .
Lb. WARNING
Risk of injury dueto hot supply line
The outlet temperature of !he com-
pressed air can be as high as 95°C.
9 The supply line must be protected
contact.
Risk of injury
lf incorrectly connected, the connection
can come loase and the open connec-
tion can cause severe personal injury.
e:> When connecting the compressor
to the compressed air network, in
addition to the operating tempera-
tu res and pressures, the connection
flange requires special
. .
inspection.
. ......
e:> When connecting hoses, suitable 2
measures must be taken to prevent
dangerous "whipping" of a free end.
DN80, PN16
1 Read the connection ID.
2 Ensure that the connection and the flange Contamination with Legionella
match each other. Health hazard with open-loop cooling
systems.
Connect the compressor to the compressed
air network. e:> Continuous monitoring of water
quality and germ count in the cool-
The compressor is fully assembled at the factory.
circuit.
The connection to the compressed air network
should be made with a flexible line, that is, a com- Connect the compressor to the cooling water
pressed air hose or compensator. network
Use only hose couplings and connectors of the The compressor is fully assembled at the fac-
corred type and size. tory. The connection to the cooling water network
1 Ensure that the supply line can be connected should be made with a flexible line, that is, a com-
with no tension. pressed air hose or compensator.
2 Connect the connection line to the compressed Use only connections that are the correct size.
air connection of the compressor. 1 Ensure that the lines can be connected with no
3 Secure hose lines. tension.
2 Connect the connection line to the cooling wa-
ter inlet and outlet of the compressor.
3 Shutoff valves must be installed at the cooling
water inlet and cooling water outlet.
4 Secure hose lines.
.. M in. cooling water inlet temperature: The compressor system is completely finished at
5 oc 141 OF the factory according to EN 60204 (Industrial Ma-
" Max. cooling water inlet temperature: chinery).
42 oc 1 107 OF ® The power supply to the compressor must be
" Max. cooling water outlet temperature: suitable for industrial equipment and mus! meet
57°C/134°F all requirements of EN60204-1 /IEC60204-1.
lf the installation conditions deviate from the
conditions as described in EN 60204, consult
Cooling water requirement at maximum power and Gardner Denver.
(.llT = 15 K, .6.p = 0.7 bar 113 psi) ® Provide the electrical connection and protec-
.. 75KW = 89 1/min./ 23 gal/min tive measures according to VDE, BS, or local
requirements. As a rule, additional regulations
.. 90KW = 111 1/min 1 29 gal/min from the corresponding power company must
" 11 OKW = 132 1/min 1 35 gal/min also be complied with.
.. 132KW = 155 llmin 141 gallmin ® A main disconnect switch (if not already in-
" 160KW = 170 1/min 1 45 gallmin stalled as a special option at the factory) must
be connected ahead of the compressor (DI N
EN 1012 - 1). The main disconnect switch must
.6.T: meet the requirements of the safety standard
EN 60 204-1 (Eiectrical Equipment for Machin-
Cooling water outlet temperature =
ery) andEN 60947-2 (Low Voltage Equipment).
Cooling water inlet temperature + 11T
® The compressor must be protected by suitable
Llp: line fuses according to EN 60269-1 (Low Volt-
Cooling water outlet pressure = age Directive).
Cooling water inlet pressure -/1p ® lf other electrical circuits are run to the elec-
tronic controller afterward, such as lighting,
The values are based on freshwater quality with-
heating, or the like, that are not disconnected
out additives (e.g., antifreeze). lf the cooling water
by the main disconnect switch, then these ex-
quality deviates from this, please consult Gardner
cepted electrical circuits must be labeled and
Denver.
run separately per EN 60204. Warning labels
Adjust the volume of cooling water according to must also be installed near the main disconnect
the description "Cooling water adjustment for wa- switch and near these circuits.
ter-cooled compressor systems".
® lf the electrical connection is made to a non-
grounded three-phase grid (IT grid), then follow
the instructions in the included documentation
for the frequency inverter (only RS compres-
The cooling water outlet temperature should be
sors).
below 57 oc, if possible, in arder to preven! ex-
cessive lime sediment.
5 Electrical cormection
Electrically connect the compressor Check the settings of the control transformer
Electric shock
Deadly electrical voltage
2 e:> Work on the electrical equipment
may be performed only by autho-
3 rized electrical technicians.
e:> For models 011 ORS- D160RS
there is a risk of electrical shock
from charged capacitors.
Disconnect the compressor and wait
1O minutes befo re touching electri-
cal components.
e:> Check the OC bus voltage.
Fig. 5-3: Supply fine openings
e The control transformer is preset to the rated
[1] Compressed air connection voltage at the factory.
[2] Cooling air inlet filter e In practice, it has been found that the actual
[3] Condensate drain supply voltage can deviate from the rated volt-
age.
[4] lnlet cover
e In arder to adapt to local conditions, the cor-
rect setting must be made on the control trans-
former when the compressor is under load, by
measuring the control transformer output volt-
ages and adjusting them as needed.
e Severa! taps are provided for this purpose (see
Work on the electrical equipment wiring diagram).
may be performed only by autho-
rized electrical technicians.
1 Remove the factory cover.
Property damage
2 lnstall a customer supply line cover.
lncorrect control transformer settings can cause
3 Run the supply lines through the openings in
problems in operation.
the electrical enclosure.
e:> Checking the control transformer settings is
4 Connect the supply lines; see wiring diagram.
part of commissioning and periodic inspec-
5 Tighten the cable screws. tion and maintenance, because grid voltage
conditions can
Check the setting of the fan circuit breaker.
Electric shock
Deadly electrical voltage
e:> Work on the electrical equipment
may be performed only by autho-
rized electrical technicians.
1 Check the setting of the circuit breakers for the
two fan motors; see wiring diagram.
2 Set the circuit breakers for the correct grid volt-
age and frequency; see wiring diagram.
(
1 Switch off the main disconnect switch.
2 Open the enclosure.
3 Remove the protective cover from the coupling.
4 Switch on the main disconnect switch.
5 Press the start button < 1 >.
6 Check the direction of rotation.
7 lf the direction of rotation is incorrect: lmmedi-
ately shut down the compressor by means of
the emergency stop button <emergency stop>,
not the stop button <O>, because otherwise
severe damage can occur to the compressor,
even for a very brief period.
8 Switch off the main disconnect switch.
9 Correct the direction of rotation. Change the ro-
tating field on the compressor.
10 Mount the protective cover on the coupling.
11 Glose the enclosure. Fig. 6-3: Check the direction of rotation of the fan motor
(water-coo/ed systems)
Check the direction of rotation of the fan mo- The direction of rotation of the fan motors can be
tors (for RS compressors ) checked while the enclosure is closed.
1 Place a suitable ladder next to the compressor
and climb up.
Falling hazard 2 Check the direction of rotation.
The direction of rotation of the fan mo- The direction of rotation arrow can be seen
tors can be checked only "from above." through the protective cover.
>==:> Provide a safe means of climbing 3 lf the direction of rotation is incorrect: Switch off
u p. the compressor.
4 Switch off the main disconnect switch.
5 Correct the direction of rotation. Change the ro-
tating field on the compressor.
Switching on
1 Press the start button < 1 > on the control
panel.
- The compressor switches on.
- The compressor runs automatically (auto-
matic m ode). Se e the sequence descrip-
tion in the "Sequence" section of the chapter
"Structure and function."
Operating sta\es
11 Partially loaded operation (running under load 6.4 Commissioning after extended
at reduced speed, only for RS compressors ) downtime
[O n-Load]
For commissioning after an extended idle period,
® ldle [Off-Load]
consult Gardner Denver.
Observations during operations
6.5 Commissioning after a fauit
During operation, the compressor should be
checked regularly for seal tightness in the cooling
water circuit and the oil circuit.
Property damage
Condensate drain
Avoid switching on the compressor multiple
The condensate drains for the intermediate cooler times without clearing the fault, as this can lead
and aftercooler are actuated by sensors. to significant machine damage.
ing
Routine commissioning includes commissioning
after maintenance.
1 Open the shutoff valves between the compres-
sor and the compressed air network.
2 Then proceed as described in the "lnitial com-
missioning" section.
7 CLEARING A FAULT
lnstructions for clearing a fault
Potential causes and solutions are listed in the fol- Property damage
lowing tables. Property damage dueto incorrect/unsuitable
The measures listed in these operating in- meas u res for fault clearing.
structions for clearing faults may be performed ti> lf the solutions listed he re are not sufficient
only by specially trained personnel. Any other to clear the fault. Contact Gardner Denver.
work beyond thís must be performed by the ti> For fault and warning messages that are
manufacturer's service personnel! Work on the displayed on the display of the electronic
electrícal equípment may be performed only by au- controller, follow the instructions in the
thorized electrical technícians. chapter ."Fault clearing" in the operating in-
Solutíons are described in detaíl in repair ínstruc- for the electronic controller.
tions, which are transmitted as part of the operator
traíning.
not acknowledged
Compressor detective
Ambient temperature < +2 oc Ensure that the ambient temperature is
otherwise provide idle heaters
Chart 7-1: Fault cleared by: Unit wi/1 not start
detective fuses.
Loase terminal connections terminal connections and tighten if needed.
Switching on and off by hand has exceed the maxi- switching on and off frequently by han d.
mum number of motor switching cycles.
Chart 7-2: Fault cleared by: Unit remains stopped during the run-up phase.
Too much aír captured Throttle the removal, or switch on and use addi-
compressors.
Chart 7-3: Fau/t cleared by: Unit does not reach the set network pressure.
regulator does not open completely Make the intake regulator mni!P.Oih
needed.
Check solenoid valves (Y1 and
Charl 7-3: Fault cleared by: Unit does not reach the set network pressure.
does not give relief lnspect intake regulator, blow-off noise damper,
check valve, and replace if needed.
regulator does not close completely Make the intake regulator moveable,
needed.
Check solenoid valves (Y1 and Y2).
Charl 7-5: Fau/t cleared by: Id/e pressure too high
lntake regulatar daes nat clase campletely Check membrane in intake regulatar.
Check salenaid valves (Y1 and Y2).
Check the changeaver valve befare entry inta the
twa salenaid valves.
Check that the blaw-aff valve apens.
e Cable broken
Lubrication system signals "Sys- ~ "VOL" switch settings full grease cartridges.
tem working" (green LEO), even
~ Partially filled grease car-
though the grease cartridges are
tridge, installed
empty.
Lubrication system signals e Line and/or connection paint
"Fault" (red LEO) clogged
e Counterpressure is too
The lubricatian system signals ·e "VOL" switch settings full grease cartridges.
"end of dispensing" (red and
e Nearly empty grease car-
green LEO), although the grease
tridges replaced with partially
cartridges are nat empty.
filled grease cartridges.
Chart 7-7: Troubleshooting and clearing faults on the lubricator
Also note the fault messages on the display of the aperatar panel.
The corresponding actions ta clear the faults are described in the operating instructions for the elec-
tronic contrals.
Safety
F ollow the safety instructions in the safety require-
ments chapter.
1
Deadly electrical voltage
9 Exercise extreme caution when
working with electrical equipment.
9 Befare starting maintenance work,
disconnect the compressor and lock
it out to revent restartin
Fig. 8-2: Bleeder va/ve position for water-cooled com-
pressor systems
8 Follow instructions regarding hazardous materi- Checking the OC bus voltage of the frequency
als. inverter
The OC bus voltage is measured at the grid termi-
Manual pressure relief
nal of the frequency inverter. The exact position of
the "OC+" and "OC-" terminals can be found in the
included operating instructions for the frequency
Pressurized components inverter.
Even when the compressor is relieved of 1 Measure the voltage between terminals OC+
pressure, the aftercooler remains pres- and OC-.
surized. 2 Measure the voltage between the terminal OC+
e:> Perform pressure relief manually, and the chassis.
befare maintenance work is per- 3 Measure the voltage between the terminal OC-
formed near the aftercooler. and the chassis.
1 Clase the shutoff valve (customer provided) in The voltage must be zero for all three measure-
the supply line. ments.
2 Switch off the m ain disconnect switch.
8.2 Service
3 Open the enclosure, create access.
The worldwide spare parts and field service net-
4 Unscrew the sealing screw on the closed vent
work of Gardner Oenver is available to our cus-
valve (ball valve on the aftercooler).
tomers.
5 Relieve the pressure in the aftercooler by care- For any spare parts needed, the local Gardner
fully opening the pressure relief valve. Denver branch or representative retailer is avail-
6 Clase the vent valve and screw in the sealing able.
screw. lt is important to provide the model name and se-
7 After maintenance work is complete, open the rial number of the compressor in all communica-
shutoff valve in the supply line. tions.
Cleanliness
The compressor room and the environment of the
compressor must always be kept clean.
The compressor must be checked regularly for
damage and excessive wear.
Spilled oil must be wiped up immediately. Oil • lf a leak is suspected, check the appropriate
traces must be removed immediately. area for leaks.
• lmmediately repair or replace damaged or leak-
ing pipe and hose connections.
Never allow oil to enter the air intake, the com-
Emission or leakage of consumable materials
ponents, or the pipelines of the compressed air
Üne~~~------·-----------~---1 The following consumables are used in the com-
pressor:
Electrical connections e Cooler corrosion protectant and antifreeze
The condition of cables and terminals must be (hazardous to health)
checked regularly. • Lubricating oil (non-hazardous for normal han-
• Watch for loose connections or worn wires. dling)
• All connections must be clean and tight. In case of accident orextended contact with con-
sumable materials, follow the instructions on the
• Replace worn or damaged wires or cables im-
material safety data sheets.
mediately.
Avoid leaking consumable materials.
Leak points lmmediately clean up any discharged consum-
ables.
Follow the instructions on the material safety data
sheets.
>=:.> Do not use the hand to search for Oil coking in the lubricating oil system.
leaking points in the system. High oil temperatures reduce the service life of the
>=:.> Always use paper or cardboard for oil, which can lead to oil coking in the oillubrica-
this se. tion system. Deposits of oil coke can cause dam-
age to bearings and gearboxes.
Lubricating oil
needed.
Maintenance plan: Maintenance A - every 4,000 hours or 6 months, weekly inspections plus the
following tasks:
Meas ure
Check and preserve operating
parameters.
Check error statistics.
Air filter Check air filter and filter car-
tridge, replace if needed.
Hoses and piping Check for leaks or any dam-
age.
----~---···--··-··-······-··-·---···----·---l-----------------------··-----+-··----"·"·--·"-·-··------·------1·----··-"·--····---··-···-i
~--------------·----...L....----------------L-------·----L.....---·-----__)
irt catche. r (for water-coole ve and clean the personnel
ompressors only)
Chart 8-2: Maintenance plan: Maintenance A
Maintenance plan: Maintenance B- every 8,000 hours or 12 months, weekly inspections plus
Maintenance A, plus the following tasks:
Components
Maintenance personnel
Replace oil filter. Maintenance
Replace filter element. Maintenance
Replace membrane (1st com- Trained service person-
pressor stage). nel
Replace membrane (2nd com- Trained service person-
pressor stage). nel
Maintenance personnel
Maintenance personnel
Electronic controls stop func- Operator
Maintenance plan: Maintem.mce C- every 16,000 hours or 24 months, weekly inspections plus
Maintenance A and B, plus the following tasks:
Notes
Operating parameters: The current settings, such as the maximum network pressure [max. network
pressure] and mínimum network pressure [min. network pressure] should be documented in the customer
operating log. The operating log should also contain records and results of maintenance work and inspec-
tions. This will enable Gardner Denver to determine the specific service that your compressor needs.
Maintenance word:The individual maintenance tasks that the maintenance personnel are permitted to
perform are described in detail in the next chapter. All other maintenance work must be performed by
trained service personnel using the repair manual.
Maintenance schedules:The earlier time applies in each case. That is, if the operating hours are
reached befare the calendar date, the maintenance task is due.
Oil change intervals: Oil change intervals can be extended to 16,000 operating hours or 24 months, if
the oil analysis permits. Oil analyses are performed in a lab contracted by Gardner Denver throughout the
warranty period.
Coolant change:The coolant (cooling fluid) for the interna! cooling circuit must be changed every 32,000
operating hours or after 48 months. The mixing ratio is 33% glycol (Havoline XLC- ethylene glycol (ba-
sis)) to 67% water.
Maintenance kits: To identify the corree! maintenance kit, see the following table, "part numbers for
maintenance kits."
CK8135RS-1
0 NOTE
The compressor is supplied with Renolin AC68.
The following types of oil can be used as an alternative:
,. Shell Turbo T68
Mobil Rarus 426
Es so T eresso 68
Castrol Perfecto T68
Electronic controls
lnformation regarding maintenance points for the electronic controller are found in the operating instruc-
tions for the electronic controller.
---------------
541 100 USA August 2013
CompAir Maintenance and service 8
-----------------------------------------------------------------·--------·
The condition of the filter mat must be checked
with regular visual inspections.
1 Loasen the fastening screws.
2 Remove the filter mat.
4
3 Check the condition of the filter mat.
5 - Replace the filter mat if damaged.
4 Clean the filter mat.
- Brush off the filter mat.
- Wash out the filter mat with a mild cleaning
solution.
Thoroughly rinse the filter mat and allow to
dry.
5 Replace the filter mat.
Fig. 8-5: Access 4 - 5
6 lnstall the fastening screws.
[4] Access 4
[5] Access 5
8.6.3 Electrical enclosure intake air filter
(RS compressor)
Access 4 provides access to:
11 Air filter
11 Aftercooler
11 Check valve
2
Fig. 8-7: lntake filler (only RS compressors)
3
5
4
6
3
7
2 8
- Add oil if the oil level is too low. 3 Remove the cover from the oil filler neck.
4 Add oil in small quantities and wait until the oil
4 Glose the enclosure.
in the system has settled.
This will prevent overfilling.
5 Place the cap on the oil filler neck and clase it.
6 Clase the enclosure.
Oil can be drained out vía the oil drain. Fresh oil is
added through the oil filler neck.
Drain out the oil when it is warm, if possible, so
that it can flow out easily.
NOTE
Drain out the used oil as completely as possi-
ble, because the used oil will severely reduce
the serví ce life of the added oil.
---·-------
58 /100 USA August 2013
CompAir Maintenance and service 8
6
7
8
7 Set the pressure regulator so that -5 mbar is 4 Unscrew the filler holder with the filter element.
displayed on the vacuum sensor. 5 Remove the deflector plate and the housing
8 Glose the enclosure. gasket.
6 Remove the filter element.
7 Loasen the knurled screw and remove the float
leve! of vacuum generated in the oil system arrester in the bottom of the housing.
depends on the flow rate in the vacuum gener- 8 Clean the bottom of the housing and the float
ator. Therefore, the vacuum cannot be set pre- arrester with mild cleaning agent and then blow
in advance using the pressure regula- out with compressed air.
described setting is sufficient for trou-
&,WARNING
Change the filter element in the a ir service Risk of injury
unit
Eye injury hazard.
e:> Wear safety glasses.
'---·----J.-------~--~~----~~------1
·----------·-----
601 i 00 USA August 2013
CompAir Maintenance and service 8
6
7
8
9
Fig. 8-18: Air vent system ejector Fig. 8-19: Solenoid va/ve Y3
[1] lntake regulator [1] Condensate trap for the second stage
{ [2] Blow off val ve (aftercooler water trap)
\
[2] Compressed air connection
[3] Air service unit
[3] Solenoid valve Y3
[4] Control a ir filler
[5] Vacuum sensor The so len oid valve Y3 in the ejector vent system
[6] Solenoid valve Y1 must be changed regularly.
4 Add cooling water until the required filllevel Adding cooling water
has been reached. 1 Remove the cap from the compensation tank.
Add cooling water in small quantities and wait
until the cooling water in the system has set- 2 Add cooling water until the required filllevel
tled. This will prevent overfilling. has been reached.
Add cooling water in small quantities and wait
5 Place the cap on the compensation tank. until the cooling water in the system has set-
6 Clase the enclosure. tled. This will prevent overfilling.
3 Place the cap on the compensation tank.
Changing the cooling water
4 Switch on the main disconnect switch.
5 Press the start button < 1>.
Allow the compressor to run under load for
about 5 minutes, until the cooling water has
been distributed in the system.
6 Press the stop button <O>.
7 Check filllevel.
8 Add cooling water if needed.
9 Clase the enclosure
Scalding hazard
Scalding hazard from escaping hot cool-
ing water. 2
9 Do not open the cap of the compen-
sation tank until the interna! cooling
water system has ca oled off suffi- 3
ciently.
9 Carefully open the cap slightly to let
off some pressure.
9 Do not open the cap completely until
then.
Property damage
Operating the compressor without an air filter,
even for a short time, can cause severe damage 6
7
to the compressor. 8
e> Never operate the compressor without an 9
air filter.
e> Dirt must not be allowed to enter the clean
air si de of the air filter!
1 Switch off the main disconnect switch.
2 Open the enclosure, create access.
3 Remove the air filter cover.
4 Change out the filter element.
5 lnstall the air filter cover.
6 Clase the enclosure.
Risk of injury
Eye injury hazard.
e> Wear safety glasses.
8 lnstall the new filter element. 9 Remove the seal plug from the grease car-
9 Replace the deflector plate and the housing tridge.
gasket. 1O Screw the lubricator into the lubrication point
10 Screw on the top of the housing and tighten by and tighten by hand.
hand. 11 1nsert the plug into the drive.
11 Clase the enclosure.
Functional check of the lubricator
8.6.11 Orive motor /lubricator
The drive motor is equipped with an automatic mo-
tor lubrication system.
Maintenance of the motor lubrication system is
limited to replacing the grease cartridges. Empty
grease cartridges ora fault in the lubricator are in- 3
dicated on the electronic controls with the mes-
sage [Warning: Mot.Lubricator] (see also the oper-
ating instructions for the electronic controller). 4
2
Replacing the grease cartridge
!'J.
DlJ
1
1 1/'~o ""·· 3
'-~~-~/ / \
/ í \
1 / \
\
6 5 4 7
---·-----------
August 2013 USA 67 /100
9 Appendix CompAir
·--··----...--w~--~~·~--~-•.,__._ _____,0__ ~--·---w-----~o-~-~--.--·----~-~--~---•VH•---~·--~·-~·~---·--------
Electric shock
Oeadly electrical voltage
e> Work on the electrical equipment
may be performed only by autho-
rized electrical technicians.
/
1 Disconnecl the feed cables. See wiring dia- - Air filler cartridge
f
1 gram. - Filter mat
2 Remove lhe feed cables. - Electrical enclosure cooling air inlake filter
3 Apply sea! plugs to the feed line openings. (only RS compressors)
- Control air filter
Removing the pipework
1 Disconnect the compressed air connection. 9.4 Disposal
2 Disconnect the condensate drain lines. General
3 Allow the condensate to drain out completely. The compressor must be dismantled and removed
4 Clean up any escaped condensate immedi- by technicians. The applicable local safety and en-
ately. vironmental protection regulations must be com-
plied with.
Draining the cooling water
When disposing of materials that are hazardous to
1 Open the enclosure, creale access. health, the instructions on the corresponding ma-
2 Place a suitable container below the cooling terial safety data sheets must be followed.
water drain. Packaging materials, cleaning agents, and used or
3 Open the drain valve and allow cooling water residual consumables must be fed to recycling in
to drain out completely. Dispose of the cooling accordance with the regulations applicable at the
water. installation site.
4 Clase the drain valve. WEEE Directive
5 Clase the enclosure. In accordance with the WEEE Directive (2002/96/
EG), Gardner Denver agrees to support the recla-
Draining the lubricating oil
mation and recycling electrical and electronic de-
1 Open the enclosure, create access. vices. Consult Gardner Denver.
/ 2 Place a suitable container below the oil drain.
\ Disposal
3 Open the drain valve and allow oil to drain out
completely. Dispose of the lubricating oil. The compressor should be dismantled into its
componen! parts for disposal "according to con-
4 Clase the drain valve. slituent materials", such as base metals, plastics,
5 Clase the enclosure. and textile products.
Biodegradable parts should be fed to the normal
Remove the oil filter
industrial wasle disposal process. Plastics, rubber,
1 Remove all oil filters in the lubrication system. or composile materials must not be disposed of by
Dispose of the filters. incineration.
- Oil filler Allliquid waste materials, such as lubricating oils
- Ultrafine filter and greases, antifreeze agents, cooling fluids, or
corros ion inhibitors must be disposed of sepa-
Remove the drive motor lubricator grease rately through licensed waste disposal or recycling
cartridges system. lt must be ensured that these materials do
1 Open the enclosure, creale access. not enter the wastewater system.
2 Pul! the plug from the lubrication system. The following table gives an overview of the dis-
posal of used substances and materials.
3 Unscrew the lubricator (grease cartridge with
drive and cover) from the lubrication point.
4 Sea! off the lubrication point.
5 Glose the enclosure.
ofdisposal
Recycling Resíd~ Haz~
ual wasté ardous
waste
1 lf possible
2 Dispose of in accordance with the material
safety data sheet or manufacturer's infor-
mation
The data listed below are guidelines that may deviate under certain operating conditions.
composition and operating temperature are the critica! factors. This cannot be used to
claim.
6-9
< 50 mg/1 (2.8 °dH)
<50 mg/1
<50 mg/1
< 4 mg/1
< 2 mg/1
----··········-····-····---·-···········-----·--··----···-··--+----·----!-·~--------------·-·-·--··----+-----··--------------·i
Ammonia < 1mg/l
Ammonia
Conductivity
Chart 9-2: Limit va/ues of dissolved matter
.ozs ..
•··.···· ·. " p?,l . .· :Ji),~O)
50.ti~~Ait:~;().olec;Arf:~~~·F~~tl1~at~f,.cooled .. :;.::x,··¡:·
!'¿J; '
··,!·.~,§··;: •.
~;::~:~~;:
. .. ; > .. :; ~ .•
·. [[bar] 10,0 8.0 10,0
Minimum operating pressure [[bar] 4,0
·-·------~---.- --·--·--·--
Ambient temperature ¡¡oc¡ 2 1 45 2 14 1 45 2 1 40
Volumetric flow rate [m 3/min] 12.91 10.63 15.65 13.79
Aftercooler outlet temperature above ambient "A" ¡oc¡ 7 8
temperature
---·----------·N---·------·~-~·-·N~·---·~~0 --·---·---·-----·---
Aftercooler outlet temperature above ambient "W"[oC] 7 8
temperature
Sound pressure level (ISO 2151) "A" [dB(A)] 1 75 74 76 75
-¡ -
Sound pressure level (ISO 2151) "W" [dB(A)] 72 70 73 72
1 Nominal power of drive motor [kW] 75 90
·-·---
Total current draw at load max. (400V) [A] 175 199
~~-~----~------~~·-·--·~•M·~·-·~·~·-~--··~~"~-·--b~O-·-·-·-----~-·-·-~·-~·~--·--·-··-
Residual pressure at ambient temperature "A" [Pa] 45/20 45/35 40/15 40/30
[35.°C 1 (35 oc 1 [35 oc 1 (35 oc 1
45 °Cj 40 °Cj 40 oc] 40 oc]
---·
Interna! cooling fluid volume [1] "A" = 30 ; "W" = 20
Externa! cooling water volume (@6.T=15K) [1/min] 89 @6.p=0.7 bar 111 @6.p=0.9 bar
Chart 9-3: Technica/ data; 075 + 090, 50Hz, air-cooled "A" and water-coo/ed "W" (European version)
min. = 5 ; max. = 42
57
8
EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
24
Flange EN 1092-1 1131
81 /DN80x8/PN16
5xG1/2"
Chart 9-3: Technica/ data; 075 + 090, 50Hz, air-coo/ed "A" and water-coo/ed "W' (European version)
9.6.2 011 O + 0132, 50Hz, air-cooled "A" and water-cooled "W" (European version)
. ·---·-··-·--
0110 + 0132,
50Hz, air~cooled "A" and water-cooled
0110
¡ 0132
Chan' 9-4: Technical data; 0110 + 0132, 50Hz, air-coo/ed "A" and water-cooled "W" (European version)
Cooling air volumetric flow rate [m 3/min] ("A"= 338) ; ("W" = 85)
Cooling air outlet temperature above ambient "A"= 22 "A"= 25
temperature
Residual pressure at ambient temperature "A"[Pa] 120 1 40 120 1 85 11 o 1 80
[35 oc 1 [35 oc 1 [35 oc 1
45 OC] 40 OC] 40 oc]
9.6.3 0160, 50Hz, air-cooled "A" and water-cooled "W" (European version)
Chart 9-5: Technical data; 0160, 50Hz, air-cooled "A" and water-coo/ed "W" (European version)
------------------~--------------·-··----------
August 2013 USA 73/100
9 Appendix CompAir
ID11 0160
¡soHz, ... _, "A" and water~cooled
"W" (European versíon)
Cooling air volumetric flow rate [m3, 1] ("A"= 338) ; ("W' = 85)
9.6.4 0110 RS, 50Hz, air-cooled "A" ami wa.ter-cooled "W" (European version)
RS 0110 RS
air-cooled "A" and water-cooled
versfon)
~.tlrotlP-:l'n
Chart 9-6: Technica/ data; D 11 O RS, 50Hz, air-coo/ed "A" and water-cooled "W" (European version)
Charl 9-6: Technica/ data; 0110 RS, 50Hz, air-coo/ed "A" and water-coo/ed "W" (European version)
9.6.5 0132 RS, 50Hz, airmcooled "A" and water-cooled "W" (European version)
D132 RS, D132 RS D132 RS
150Hz, air-cooled "A" and wateN:;ooled
I"W" (European version) 1
Maximum operating pressure [b; r] 8.0
Minimum operating pressure [bar] 4.0
Ambient temperature [o, ;¡ 2145 2140
~··-·-
~;__
Min. Max. Max.
speed speed
·-·~~eed speed
-•w••.,.._..-~·---·
V! flow rate 1 Final pressure [bar] l[m 3/min] 9.13/6 22.8216 10.81 16 21.02/6
Volu1 flow rate 1 Final pressure [bar] l[m 3lmin] 9.03 1 7 22.7517 10.66/8 20.93 1 8
·-··-··----···----··-·'"·"·~·-······
Chart 9-7: Technica/ data; 0132 RS, 50Hz, air-coo/ed "A" and water-coo/ed "W" (European version)
Weight
Dimensions L x W x H
Chart 9-7: Technical data; 0132 RS, 50Hz, air-cooled "A" and water-cooled "W" (European version)
9.6.6 0160 RS, 50Hz, air~cooled "A" and water-cooled "W" (European version)
160
---------------·-------·-·-·-----+---------+-----------..-------------·-------1
Total current draw at load max. (380V /400V) [A] 304/289
---------··------------..---·--..-----------+--·------t-·-........._.,______,..........._,,________. ,________.________. ,____ -1
Electric motor IP55 (IE3)-
60034-2-1 ECA
3 x 150 PE95
EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[1] 24
---..·--·--··------·-·-·-----------------·-·--·-----·--·--+---..-----""'"'-+---·-"·--·--------.. - .......,,_.____"""'_'_"_____________...¡
Flange EN 1092-1/13/
B1/DN80x8/PN16
drain 5 x G1/2"
"A"=3688 ; "W"=3888
Chart 9-8: Technica/ data; 0160 RS, 50Hz, air-coo/ed "A" and water-coo/ed "W" (European version)
9.6.7 075 + 090, 60Hz, air-cooled "A" and water-cooled "W" (European version)
075 090
. ~ir~<;><>l~d "A" ~nd wate.r~ooler.t .
europeanverslon)
[bar] 8.0 10.0 10.0
Chart 9-9: Technical data; 075 + 090, 60Hz, air-cooled "A" and water-cooled "W' (European version)
Externa! cooling water vol ume (@LlT=15K) 89 @Llp=0.7 bar 111 @Llp=0.9 bar
"W"=3223
Dimensions L x W x H [mm] 2597 X 1744 X 2001
'-·-·---------------------'------'-------------------------·------'
Cha/19-9: Technical data; 075 + 090, 60Hz, air-coo/ed "A" and water-cooled "W'' (European version)
9.6.8 D110 + D132, 60Hz, air-cooled "A" and water-cooled "W" (European version)
./
~~~:~~:~~led . ~'
'· ... ·.
·. P11 P132 ~-· .:
_:.~e- · . :. -.. -'
-::;- - .. ;_:~ i'?t: - -- f:
_ Wú _(European verJ;ion) ... : .... ·..
·.
Maximum operating pressure [bar] 8.0 10.0 8.0 1
-··
Minimum operating pressure (bar] 4.0
·---~~--~--~--·-··-·----~~----·-·M-•---
Chart 9-10: Technica/ data; 0110 + 0132, 60Hz, air-coo/ed "A" and water-coo/ed "W' (European version)
------------·"·------------·-----
801 100 USA August 2013
CompAir Appendix 9
min. = 5 ; max. = 42
8
EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
Chart 9-10: Technical data; 0110 + 0132, 60Hz, air-coo/ed "A" and water-coo/ed "W" (European version)
9.6.9 0160, 60Hz, air-cooled "A" and water-cooled "W" (European version)
Chart 9-11: Technical data; 0160, 60Hz, air-cooled "A" and water-coo!ed "W' (European version)
9.6.10 0110 RS, 60Hz, air-cooled "A" andwater-cooled "W" (European version)
10.0
4.0 4.0
2/45 2/40
Min. Max. Min.
speed speed speed
Chart 9-12.· Technical data; 0110 RS, 60Hz, air-cooled "A" and water-coo/ed "W' (European version)
--------------------
82/100 USA August 2013
CompAir Appendix 9
9.6.11 0132 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)
Volume flow rate 1 Final pressure [bar] 1 [m 3/min] 9.13 1 6 22.82 1 6 10.81 16 21.02 /6
Volume flow rate 1 Final pressure [bar] [m 3/min] 9.03/7 22.7517 ..,_10.6618
..______ ,. ____ 20.93/8
,_,.,,.. ,,.,,,_,., __ M•>••<•""'-''-"''''''''''"'"''"''''-' ...................... ...... ... ........... ............................................... ............
._ ._
••mm'"''''''''"'"'"' ---····-··-------·-··-· -~·•~•~••m~-··-• ~ .. -•-•u<o-••u•••w .. -•••--•
3
Volume flow rate 1 Final pressure [bar] [m /min] ' 8.9518 22.6818 10.51 1 20.851
10 10
f-·
Aftercooler outlet temperature above ambient ·"A" ¡oc¡ 12 10
tempera tu re
1
Aftercooler outlet temperature above ambient "W"(oC] 8 9
1
temperature
--------------~--------···------- _
..... -._..... ...,.,,_,,.................. .......................... ..............................................
~ ~----------·· ............ _.
. --~~-~---- ... ·-~·--»>--- . - ···--·--··
Sound pressure level (per ISO 2151) at 70% "A" [dB(A)] 77/79 77/79
load /1 00% load
-~------ - --
Soundpressure level (ISO 2151) al 70% load 1 "W' [dB(A)] 74/79 72176
100% load
Total curren! draw at load max. (380V /460V) [A] 302 1226 /227
-----------···---·--..........-----·--·-...
Electric motor IP55 , EISA 2007 (IE3)
rN·;;;al speed min./max. [rpm] 1550
Chart 9-13: Technica/ data; 0132 RS, 60Hz, air-coo/ed "A" and water-coo/ed "W' (European version)
8
EN 10226-1 1/4 Rp 1
1/4 (DIN 2999-R 1 1/4)
[1] 24
EN 1092-1 1131
1 DN80x8 1 PN16
5 x G1/2"
kg] "A"=3476 ; "W"=3676
[mm] 2597 X 1744 X 2001
Chart 9-13: Technical data; 0132 RS, 60Hz, air-cooled '~" and water-coo/ed "W" (European version)
9.6.12 0160 RS, 60Hz, air-cooled "A" and water-cooled "W" (European version)
[m 3/min]
outlet temperature above ambient "A" [°C] 10
9.6.13 075 + 090, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
Total current draw at load max. (460V /575V) [A] 152/128 173 /155
Recommended cable cross section (460V 1 AWG 3/01 AWG AWG 4/01 AWG
575V) 2/0 (Single Supply) 3/0 (Single Supply)
Cooling air volumetric flow rate cfm] ("A"= 7946); ("W" = 3354)
Chart 9-15: Technica/ data; 075 + 090, 60Hz, air-cooled "A" and water-coo/ed "W" (USA version)
9.6.14 0110 + 0132, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
Chart 9-16: Technica/ data; 0110 + 0132, 60Hz, air-cooled "A" and water-coo/ed "W" (USA version)
. ··.
º1 i[""'lj, [~s,,~%l~l~~J
1 ·.·.··..·
0119; 132, .
"..L.'" .í."' ·:~·¡·
~~~~{Jl:;t'"': ~ ·' and ; • .},' '!'!
·,~. -~ii" . .··· ;. '· i •. ,.· .· .~·; •
""''"uvu¡
36~
•••
Am temperature [oF] ···•·· 36/113 /1
~~~~~~
fuse size (time-delay) (460V 1 [A] 150/125 175/150
c. ing air volumetric flow rate .[cfm] ("A"= 12325); ("W" = 3354)
-----~-----······---
Residual pressure at ambient temperature "A" [Pa] 120/40! 120/85 11 o125 11 o /80
[95 °F 1 [95°F 1 [95 OF 1 [95°F 1
113 °F] 104°F] 113 °F] 104 °F]
---~-
__
,Cooling water outlet temperature -
[of] 134
Charl 9-16: Technica/ data; O 11 O + O 132, 60Hz, air-coo/ed '1'\" and water-cooled "W" (USA version)
Chart 9-16: Technical data; 0110 + 0132, 60Hz, air-cooled "A" and water-cooled "W' (USA version)
9.6.15 0160, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
¡o~~~~~~-" ·. . _,. .·.,. .· .-.•. . '·r .::.ii:i:fi[''} '.~:, .•.
~~c7 ·;; • ;
'·
ll1!d wat.r·cooled
.·· .. ',. ¡;~:,~il~.:,,,x. ,.,·, . . · ¡~·• · i h
i.. ¡i•.
6.4
+---------------------------
Flange 3" ANSI 816.5
5x1/2NPT
Weight [lbs] "A"=8034; "W"=8475
--------------------------·----·----l---------·-·--i--------------------------·--·--·--·---·--------·----1
Dimensions L x W x H [in eh] 102.2 X 68.7 X 78.8
Chart 9-17: Techníca/ data; 0160, 60/-/z, aír-coo/ed "A" and water-coo/ed "W" (USA version)
9.6.16 011 O RS, 60Hz, air~cooled "A" and water~cooled "W" (USA version)
145
58 58
Ambient temperature 36 /113 36/104
M in. Max. Min. Max.
speed speed speed
Volume flow rate 1 Final pressure 320 1 87 686 1 87 380 1 87
·~~--------
1.5(1P-54)
-------------------------+------¡.....-------------·---------1
Recommended cable cross section (380V + MCM 250 (Single Supply)
400V)
Chart 9-18: Technícal data; 0110 RS, 60Hz, aír-cooled "A" and water-coo/ed "W" (USA version)
Cooling air volumetric flow rate [cfm] ("A"= 12325); ("W' = 3354)
9.6.17 0132 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
58 58
Ambient temperature 36 /113 36/104
Volume flow rate 1 Final pressure [psíg] 1 102 8 03 1 102 376 1 116 739 1 116
----------4---------+-------·---l----l------i---~
Volume flow rate 1 Final pressure [psíg] [cfm] 316/116 /116 371 /145¡736/1451
Aftercooler outlet temperature above ambíent "A" [°F] 21.5 18
temperature
9.6.18 0160 RS, 60Hz, air-cooled "A" and water-cooled "W" (USA version)
um operatíng pressure
-------------~--------~-----------------------------~
m operatíng pressure [psig]
[oF]
Chart 9-20: Technica/ data; 0160 RS, 60Hz, air-cooled "A" and water-cooled "W' (USA version)
------------------------
92 1 100 USA August 2013
CompAir Appendix 9
[gallmin] 45 @llp=19psi
s]
Chart 9-20: Techníca/ data; 0160 RS, 60Hz, aír-coo!ed "A" and water-cooled "W" (USA versíon)
Chart 9-20: Technical data; 0160 RS, 60Hz, air-coo/ed "A" and water-cooled "W'' (USA version)
D7&D160(RS)·A
. 141(A)
-..l---1-----
t·,·'¡
1 11
i 1¡
[1
i Jt
-~11 ~-
;:_¡r,x 1
o~
m
r--'2
$
N
!.~\ o
f¿'-}- ..
o
.,....
D
-=r 1210(8) ~
l317(B)
1
~~,
105(E) f+ 92(E)
.---,---/'··--,_
.
D
f
B
E
[A] Compressed air connection, 3" DIN flange [E] Opening for feed cables
[B] Cooling air inlet [F] Condensate drain, G %"
[C] Cooling air outlet [CG] Center of gravity
[D] Cooling air inlet (speed control) [Option]
D75-D160(RS)-W
)\ \
1'~ "1
1 i
1'
'1
l.
¡:u
45(A) . 1265(CG)
---'--'--; -- ---------¡
¡' . ---;::::¡-¡-
0560
81
~-
1
-------¡ :?51
1
! .,¡-j
1--T--~+-~--~ ~~
.,..-¡
1
¡
1
H,~=i=¡='=45=5EO(C="')=~>==c=::=:::=;:=:::l5ii----L
1 e
---+--------·t--·-~-
A
\
\
[A] Compressed air connection, 3" DIN flange [E] Opening for feed cables
[B] Cooling air inlet [F] Condensate drain, G Yz"
[C] Cooling air outlet [G] Cooling water connection
[O] Cooling air inlet (speed control) [Option] [CG] Center of gravity
i
. . . ~----·-····· .---+-··-~T
1
81
D75-D160(RS)·A
-++-~.6(~L
'¡··
. i
. 1
1 l
. 1
-r-· 1
i 1
----1
D
F
B
E
[A] Compressed air connection, 3 NPT flange [E] Opening for feed cables
[8] Cooling air inlet [F] Condensate drain, female 1/2 NPT
[C] Cooling air outlet [CG] Center of gravity
[D] Cooling air inlet (speed control) [Option]
----------·-----------
August 2013 USA 97 /100
9 Appendix CompAir
5.6(A)
¡-+---·-
,.
''
~~ 49.8(CG)
-~---¡
O' '
022 Lñ'!
r---~
j
o)j
---~ ._ N'
---~-
¡-...'
ro·' 1
(.()'
i··~='"l='=~==:-5:fu:::=c::::::=:=:=:;;==~
: 1 i7.9(C)
-~--------r-~-
L--~--- 102.3___________ .!
A
[A] Compressed air connection, 3 NPT flange [E] Opening for feed cables
[B] Cooling air inlet [F] Condensate drain, female 1/2 NPT
[C] Cooling air outlet [G] Cooling water connection
[O] Cooling air inlet (speed control) (Option] [CG] Center of gravity
==--==-=--=-===·==·
min. 39.4
---
--r-----r
¡
·:_l? i
. 1
E.
!
j_
EUROPE
Gardner Denver
Argenthaler Str. 11
55469 Simmern
Germany
Telephone: ++49 (0)6761 832-0
Homepage: www.compair.com
e-mail.: [email protected]