Edition: 1.12.

2009 · BA 883-EN

Original Operating Instructions

C-KLR
C-KLR 80 | 140

C-Serie
C-Series
Klaue
Claw
Table of contents

Table of contents

1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Zulieferdokumentation und mitgeltende Dokumente . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Directives, standards, laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Symbols and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Technical terms and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Warning instruction markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Unacceptable operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Personal qualifications and training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Safety-conscious work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Safety notes for the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.8 Safety instructions for installing, commissioning and maintenance . . . . . . . . . . . . . . . . . . . . . . 9
2.9 Guarantee conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Transport, storage and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.1 Unpack and check the delivery condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1.2 Lifting and transporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Ambient conditions for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Set up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1.1 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Areas of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Connecting pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4 Relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5 Filling with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.6 Connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6 Commissioning and decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.1 Checking the rotation direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Decommissioning/ storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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 Table of contents

7 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7.1 Ensuring operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.1 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2.2 Air filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2.3 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.3 Reparatur/ Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.4 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

8 Malfunctions: Causes and elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Foreword

1 Foreword
1.1 Principles

These operating instructions:

• are a part of the following contact free running
claw vacuum pumps, models C-KLR 80 and
C-KLR 140.
• describe how to use them safely and properly in
all life phases.

• must be available where the equipment is used.

1.2 Target group

The target group for these instructions is technically

trained specialists.

1.3 Zulieferdokumentation und mitgeltende Dokumente

Document Contents No.

Operating Instructions BA 883-EN
Supplier documentation Declaration of Conformity C 0078-EN
Declaration of harmlessness 7.7025.003.17
Spare parts‘ list Spare parts‘ document E 883
Data sheet Technical data D 883
Info sheet Storage guidelines for machines I 150
Manufacturer’s declaration EU Directive 2002/95/EG (RoHS) —

1.4 Abbreviations

Fig. Figure
C-KLR Pressure vacuum pump
3
m /h Flow rate Compressed air/ intake air
bar Excess pressure/ negative pressure

1.5 Directives, standards, laws

See Conformity Declaration

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 Foreword

1.6 Symbols and meaning

Symbol Explanation
Condition, pre-requisite
#### Instructions, action
a), b),... Instructions in several steps
Results
[-> 14] Cross reference with page number
Information, note

Safety symbol
Warns of potential risk of injury
Obey all the safety instructions with this symbol in order to avoid injury
and death.

1.7 Technical terms and meaning

Terms Explanation
Machine Pump and motor combination ready to be connected
Motor Pump drive motor
In combined use the machine may produce a vacuum and excess pres-
Pressure vacuum pump
sure at the same time.
Claw Machine's design or active principle
Volume flow A pressure vacuum pump’s suction air or compressed air.
Overpressure (pressure) Difference in pressure compared with atmospheric pressure. The corre-
sponding working pressure is greater than the atmospheric pressure.
Under pressure (vacuum) Difference in pressure compared with atmospheric pressure. The corre-
sponding working pressure is lower than the atmospheric pressure.
The noise emitted at a specific loading given as a figure, sound pressure
Noise emission
level dB(A) as per EN ISO 3744.

1.8 Copyright

Passing on or copying this document, using and

providing information on its contents are prohibited
unless expressly permitted. Contraventions will lead
to claims for damages.

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Safety

2 Safety
The manufacturer is not responsible for damage if
you do not follow all of this documentation.

2.1 Warning instruction markings

Warning Danger level Consequences if not obeyed

DANGER immediately imminent danger Death, severe bodily injury

WARNING possible imminent danger Death, severe bodily injury

CAUTION possible hazardous situation Slight bodily injury

NOTICE possible hazardous situation Material damage

2.2 General

These operating instructions contain basic instruc-

tions for installation, commissioning, maintenance
and inspection work which must be obeyed to en-
sure the safe operation of the machine and prevent
physical and material damage.
The safety instructions in all sections must be taken
into consideration.
The operating instructions must be read by the
responsible technical personnel/ operator before
installing and commissioning and must be fully un-
derstood. The contents of the operating instructions
must always be available on site for the technical
personnel / operator. Instructions fixed directly onto
the machine must be obeyed and must always re-
main legible. This applies for example to:
• Symbols for connections
• Data and motor data plate
• Instruction and warning plates
The operator is responsible for observing local regu-
lations.

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 Safety

2.3 Designated use

The machine must only be operated in such areas

as are described in the operating instructions:
• only operate the machine in a technically perfect
condition
• do not operate the machine when it is only par-
tially assembled
• the machine must only be operated at an ambi-
ent temperature and suction temperature of
between 5 and 40°C. Please contact us for
temperatures outside this range.
• the machine may convey, compress or extract
the following media:
• all non-explosive, non-inflammable, non-ag-
gressive and non-poisonous dry gases and
gas air mixtures

2.4 Unacceptable operating modes

• extracting, conveying and compressing explo-

sive, inflammable, aggressive or poisonous me-
dia, e.g. dust as per ATEX zone 20-22, solvents
as well as gaseous oxygen and other oxidants,
water vapour, liquids or solid materials
• using the machine in non-commercial plants if
the necessary precautions and protective meas-
ures have not been taken in the plant
• installing in environments that are at risk of ex-
plosions
• using the machine in areas with ionising radia-
tion
• modifications to the machine and accessories

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Safety

2.5 Personal qualifications and training

• Ensure that people entrusted with working on

the machine have read and understood these
operating instructions before starting work,
particularly the safety instructions for installation,
commissioning, maintenance and inspection
work.
• Manage the responsibilities, competence and
monitoring of staff
• all work must only be carried out be technical
specialists:
• Installation, commissioning, maintenance
and inspection work
• Working with electricity
• personnel being trained to work on the ma-
chine must be supervised by technical special-
ists only

2.6 Safety-conscious work

The following safety regulations apply in addition

to the safety instructions and intended use listed in
these instructions:
• Accident prevention regulations, safety and op-
erating regulations
• the standards and laws in force

2.7 Safety notes for the operator

• hot parts of the machine must not be accessible

during operation or must be fitted with a guard
• People must not be endangered by the free
extraction or discharge of pumped media
• Risks arising from electrical energy must be
eliminated.

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 Safety

2.8 Safety instructions for installing, commissioning and maintenance

• The operator will ensure that any installation,

commissioning and maintenance work is car-
ried out by authorised, qualified specialists who
have gained sufficient information by an in-depth
study of the operating instructions.
• Only work on the machine when it is idle and
cannot be switched on again
• Ensure that you follow the procedure for decom-
missioning the machine described in the operat-
ing instructions.
• Fit or start up safety and protective devices
again immediately after finishing work.
• Conversion work or modifications to the ma-
chine are only permissible with the manufactur-
er’s consent.
• Only use original parts or parts approved by the
manufacturer. The use of other parts may invali-
date liability for any consequences arising.
• Keep unauthorised people away from the ma-
chine

2.9 Guarantee conditions

The manufacturer’s guarantee or warranty will no

longer apply in the following cases:
• Improper use
• Not complying with these instructions
• Operation by insufficiently qualified staff
• Using spare parts that have not been approved
by Gardner Denver Schopfheim GmbH
• Unauthorised modifications to the machine or
the accessories supplied by Gardner Denver
Schopfheim GmbH

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Transport, storage and disposal

3 Transport, storage and disposal

3.1 Transportation

3.1.1 Unpack and check the delivery condition

a) Unpack the machine on receipt and check for

transport damage.
b) Notify the manufacturer of transport damage im-
mediately
c) Dispose of the packaging in accordance with the
local regulations in force.
3.1.2 Lifting and transporting

WARNING

Death or limbs crushed as a result of the items

being transported falling or tipping over.

When transporting with the lifting device remem-

ber:
a) Select the lifting device suitable for the total
weight to be transported.
b) Ensure that the machine cannot tip and fall.
c) Do not stop under a suspended load.
d) Put the goods to be conveyed on a horizontal
base.
Lifting device/ Transporting with a crane

WARNING

Bodily injury resulting from improper operation

a) Loads crosswise to the ring level are not per-
mitted.
b) Avoid impact stress.
1

a) Tighten the eyebolts (Fig. 1/1) firmly.

b) The machine must be suspended on the eyebolt
using the lifting device for lifting and transport-
ing.

Fig. 1 Lifting and transporting

1 Eyebolt

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 Transport, storage and disposal

3.2 Storage

NOTICE

Material damage caused by improper storage.

Ensure that the storage area meets the following

conditions:
a) dust free
b) vibration free

3.2.1 Ambient conditions for storage

Ambient conditions Value

Relative humidity 0% to 80%
Lagertemperatur -10°C to +60°C

The machine must be stored in a dry environment

with normal air humidity. It should not be stored for
more than 6 months.
see Info “Machine storage guidelines”, Page 4

3.3 Disposal

WARNING

Danger from inflammable, corrosive or poison-

ous substances.
Machines that come into contact with hazard-
ous substances must be decontaminated before
disposal.

When disposing ensure the following:

a) Collect oils and grease separately and dispose
of in accordance with the local regulations in
force.
b) Do not mix solvents, limescale removers and
paint residues
c) Remove components and dispose of them in
accordance with the local regulations in force.
d) Dispose of the machine in accordance with the
national and local regulations in force.
e) Parts subject to wear and tear (marked as such
in the spare parts list) are special waste and
must be disposed of in accordance with the
national and local waste laws.

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Set up and operation

4 Set up and operation

4.1 Setup

S1 S ZUV R Q ZBD

E
F

P P1 J O M N H

F
E

F
K I

Fig. 2 Pressure vacuum pump C-KLR 80

A Vacuum connection O Rotation direction plate
B Pressure connection P Drive motor
E Cooling air inlet P1 Motor data plate
F Cooling air outlet R Compressed air aftercooler
H Oil filling point S Suction filter ‘ suction air
I Oil sight glass S1 Suction filter’ Interim charging
J Plug-connector Q hot surfaces > 70°C
K Oil discharge point ZBD Pressure relief valve
M Oil recommendation plate ZUV Vacuum relief valve
N Data plate

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 Set up and operation

4.1.1 Data plate

1 Type/ Size (mechanical version)

1 2 3 4 5
2 Year of construction
Bauj./Nr. 09 3~ Mot. 3 Motor design
2843970
4 Serial number
Typ KTR 100 (01) 1027630137
+0,60 / -0,60 bar 5 Item no.
100 / 120 m³/h
6 Overpressure / Vacuum
7 Pumping capacity 50 Hz/60 Hz
EN 60034
8 Speed 50 Hz/60 Hz
S1 5,50/ 6,50 kW 1460 / 1745 min-1
9 Motor output 50 Hz/60 Hz
10 9 8 7 6 10 Operating mode

Fig. 3 Data plate (example)

4.2 Description

The ZEPHYR C-KLR is a double shaft rotary piston pressure vacuum pump in which the claws roll off
against each other contact free and dry. The counter-rotating claw rotors are synchronised by a gear pair
in the gearbox. The synchronous gearbox gear wheels and the bearing on the motor side are lubricated
with oil. These components are in a gearbox that also contains the oil supply. Oil conveying devices always
ensure that the bearings and the gear wheels are sufficiently supplied with oil at all permissible speeds. The
feed chamber has no sealants or lubricants. The gearbox and the compression chamber are separated from
each other by special seals. The gearbox is sealed from the outside with piston sealing rings and O rings,
the compressor chamber with piston rings.
The ZEPHYR C-KLR is enclosed in an insulation hood. In order to dissipate compression heat, the cooling
air is sucked through between the machine and the hood using drum fan that sucks in the fresh cooling air
(Fig. 2/E) and discharges the heated air out of the cooling air outlet (Fig. 2/F). The compressed air aftercooler
(Fig. 2/R) provides a low blowing air temperature.The ZEPHYR C-KLR is driven by standard flanged three-
phase motors via a coupling (with an elastomer component).
Relief valves (Fig. 2/ZUV) and (Fig. 2/ZBD) are installed as standard to protect against overload..

4.3 Areas of application

These contact free running claw pressure vacuum pumps models C-KLR 80 and C-KLR 140 are suitable for
creating pressure and vacuum at the same time. Constant operation is permissible.
The nominal flow rate is 80 and 140 m3/h at 50 Hz. The load limits (bars) on the intake and pressure sides
are specified on the data plate (Fig. 2/N). Data sheet D 883 shows the dependency of the flow rate on the
excess pressures.
If the unit is switched on more frequently (at regular
intervals of about 12 times (C-KLR 80) or 10 times
(C-KLR 140) per hour or at higher ambient tem-
peratures and intake temperatures, the excess tem-
perature limit of the motor winding and the bearings
may be exceeded.Please contact the manufacturer
should the unit be used under such conditions.
If it is installed in the open air the unit must be pro-
tected from environmental influences, (e.g. by a pro-
tective roof).

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Installation

5 Installation
5.1 Preparing for installation

Check the following points:

• Machine freely accessible from all sides
• Do not close ventilation grids and holes
• Sufficient room for installing and removing pipes
and for maintenance work, particularly for install-
ing and dismantling the machine
• No external vibration effects
• Do not suck any hot exhaust air from other ma-
chines into the cooling system.

The oil filling point (Fig. 2/H), oil sight glass (Fig. 2/I) and the oil outlets (Fig. 2/K) must be easily
accessible. The cooling air inlets (Fig. 2/E) and the cooling air outlets (Fig. 2/F) must be at least
20 cm away from adjacent walls. Cooling air coming out must not be sucked in again.
For maintenance work there must be a minimum of 40 cm in front of the inlet filters (Fig. 2/S, 2/S1).

5.2 Installation

NOTICE

The machine may only be operated when it is

set up horizontally.

Material damage resulting from the machine

tipping over and falling.
When installed at more than 1000 m above sea
level a reduction in power is noticeable. In this
case we would ask you to contact us.

Ensure that the foundation complies with the follow-

ing conditions:
• Even and level
• The bearing surface must be designed to be
able to take the weight of the machine

It is possible to install the machine on a firm base without anchoring. When installing on a sub-
structure we recommend fixing with flexible buffers.

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 Installation

5.3 Connecting pipes

a) Vacuum connection at (Fig. 2/A) and pressure

connection at (Fig. 2/B).

NOTICE

Material damage resulting from the forces and

torques of the pipes on the unit being too high.
Only screw pipes in by hand.

The pumping capacity of the machine is redu-

ced if the suction pipe is too narrow and/or too
long.

b) Check to ensure the intake line and pressure

connection are connected correctly.

NOTICE

Length of the connection pipes

With connection pipes that have the same pipe
cross section as the machine connection and are
more than 3m long, a non-return valve especially
for the purpose must be installed in order to avoid
reverse operation when the machine has stopped.

5.4 Relief valves

As a protection against overload safety valves

(Fig. 2/ZUV) and (Fig. 2/ZBD) are installed as stand-
ard.

NOTICE

Do not operate without standard relief valves.

If the permissible final compression pressure and
the permissible vacuum are exceeded (see data
plate) the machine may be damaged.

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Installation

5.5 Filling with lubricating oil

a) Fill the lubricating oil (for suitable types see

„Maintenance“) for the gear wheels and bearings
at the oil filling point (Fig. 2/H) up to the middle
of the sight glass (Fig. 2/I).
b) Close the oil filling point.
5.6 Connecting the motor

DANGER

Danger of death if the electrical installation has

not been done professionally.
The electrical installation must only be done by a
qualified electrician observing EN 60204. The ope-
rating company has to provide the main switch.

a) The motor‘s electrical data is given on the data

plate (Fig. 2/N) or on the motor data plate (Fig. 2/
P1). The motors comply with DIN EN 60034
and are in protection class IP 55 and insulation
class F. The appropriate connection diagram is
located in the motor‘s terminal box (not for the
plug connection version). The motor data must
be compared with the data of the existing mains
network (current type, voltage, network frequen-
cy, permitted current value).
b) Connect the motor via the plug connection
(Fig. 2/J) or a motor protection switch (for safety
reasons a motor protection switch is required
and cable fitting must be provided to provide
strain relief for the connection cable). We recom-
mend using motor protection switches with de-
layed switch off, depending on possible excess
current. Temporary excess current may occur
when the machine is started cold.

NOTICE

Power supply
The conditions at the installation location must
match the information on the motor data plate.
Without derating the following is permissible:
• ± 5% Voltage deviation
• ± 2% Frequency deviation

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 Commissioning and decommissioning

6 Commissioning and decommissioning

6.1 Commissioning

WARNING

Improper use
May lead to severe or fatal injuries. Therefore be
sure to obey the safety instructions.

CAUTION

Hot surfaces
When the machine is at operating temperature the
surface temperatures on the components (Fig. 2/
Q) may go above 70°C.
You must avoid touching the hot surfaces (mar-
ked with warning plates).

CAUTION

Noise emission
The highest noise pressure levels measured as
per EN ISO 3744 are given in Section 9.
When spending a long time in the vicinity of the
running machine use ear protectors to avoid per-
manent damage to your hearing.

NOTICE

Wait until the machine stops.

The machine must only be switched on again
after it stops.

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Commissioning and decommissioning

6.1.1 Checking the rotation direction

The intended direction of rotation of the drive

shaft is shown by the rotary direction arrow
(Fig. 2/O) on the motor flange.
a) Start the motor briefly (max. two seconds) to
check the direction of rotation. When looking at
the motor fan, it must rotate anti-clockwise.

NOTICE

Incorrect direction of rotation

Running in reverse for a long time may damage the
machine.
Use a phase sequence indicator to check the direc-
tion of rotation (clockwise rotating field).

6.2 Decommissioning/ storing

Stop the machine

a) Switch the machine off.
b) If available close the cut off device in the
suction and pressure pipe.
c) Disconnect the machine from the electricity
source.
d) Depressurise the machine: Open the pipes
slowly. The pressure reduces slowly.
e) Remove the pipes and hoses.
f) Seal the connections for suction and pressure
nozzles using adhesive foil.
g) Insert the desiccant bag into the filter housing.
see also Section 3.2.1, Page 11
6.3 Re-commissioning

a) Check the condition of the machine (cleanliness,

cabling etc.).
b) Remove the desiccant bag from the filter hous-
ing.
For installation see Section 5 Page 14
For commissioning see Section 6.1 Page 17

18 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Maintenance and repair

7 Maintenance and repair

DANGER

Danger of death from touching live parts.

Before maintenance work disconnect the machine
by pressing the main switch or unplugging it and
ensure that it cannot be turned on again.

WARNING

Hot surfaces
During maintenance work there is the danger of
getting burnt on hot components (Fig. 2/Q) of the
machine.
Wait for the machine to cool down.

7.1 Ensuring operational safety

Regular maintenance work must be carried out in order to ensure operational safety.
Maintenance intervals also depend on the operational demands on the machine.
With any work observe the safety instructions described in Section 2.8 “Safety notes for installation, com-
missioning and maintenance”.
The whole unit should always be kept in a clean condition.

7.2 Maintenance work

Interval Maintenance to be carried out Section

monthly Check the pipes and screws for leaks and to ensure they are —
seated properly and if necessary seal again or tighten up.
monthly Check the terminal box and cable inlet holes for leaks and if —
necessary re-seal.
monthly Clean the regulating valves and ventilation slots on the ma- —
chine and the motor cooling ribs.
monthly Check the oil level 7.2.1
5.000 h Changing the oil
monthly/ every 6 months Clean or replace filter cartridge 7.2.2
at least once a year Check for coupling wear 7.2.3

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Maintenance and repair

7.2.1 Changing the oil

M H

K I

Fig. 4 Changing the oil

NOTICE
H Oil filling point
Always change the oil when the machine is at
I Oil sight glass operating temperature and in an atmospherically
K Oil discharge point ventilated area.
If it is not completely emptied the amount that can
M Oil recommendation plate be refilled is reduced.

The waste oil must be disposed of in compliance with

the local environmental protection regulations.
If you change the type of oil, empty the oil tank
completely.

The oil level in the sight glasses (Fig. 4/I) must be

checked every month.
The machine must be switched off and vented to at-
mospheric pressure to top up the oil.With clean op-
erations the oil must be changed after every 5,000
operating hours..
The oil viscosity must comply with ISO VG 150 as
per DIN 51519.
Designation as per DIN 51502: CLP HC 150.
We recommend the following oil brand: GEAR-
LUBE 150 or equivalent oils by other manufacturers
(also see oil recommendation plate (Fig. 4/M)).

20 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Maintenance and repair

7.2.2 Air filtering

NOTICE

Insufficient maintenance on the air filter

The power of the machine lessens and damage may
occur to the machine.

The filter cartridges (Fig. 5/e) for intake air and

e (Fig. 5/f) for interim charging must be cleaned by
s1 blowing through from the inside out depending on
f
how dirty they are. In spite of cleaning the filter its
g2 separation efficiency will continue to deteriorate.
Therefore the filters should be replaced every six
months.
g1 The filter cartridge (e) can be removed for cleaning
after removing the screws (Fig. 5/s1) and the filter
housing lid (Fig. 5/g1). The filter cartridge (f) can be
Fig. 5 Suction filter removed for cleaning after unscrewing the suction
filter cover (Fig. 5/g2).
e Filter cartridge for inlet air
Clean the filter housing chambers too.
f Filter cartridgeinterim charging
NOTICE
g1 Filter housing cover
Do not damage the filter cartridges when cleaning
g2 Suction filter cover
them.
s1 Screws

No dirt must get into the machine when cleaning

the filter housing chambers.

WARNING
1 Danger of injury when dealing with com-
pressed air.
When blowing through with compressed air, solid
particles may be carried along or powder dust swir-
ling around may cause injury to the eyes. Therefore,
when cleaning with compressed air always wear
goggles and a dust mask.
2

Fig. 6 Purging filter cartridge

1 Filter cartridge
2 Compressed air

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Maintenance and repair

7.2.3 Coupling
The coupling sprocket (Fig. 7/k, 8/k)) is subject to
s4 n2 wear and must be checked regularly (at least once a
year).

CAUTION
v
Defective coupling sprocket.
q Defective sprockets may lead to the rotor shaft
m k breaking.

To check the coupling switch the motor

(Fig. 7/m, 8/m) off and ensure that it cannot be
switched on again.
C-KLR 80
Fig. 7 Coupling C-KLR 80 Undo the screws (Fig. 7/s4) on the motor flange.
k Coupling sprocket Remove the motor with the coupling half on the mo-
tor side (Fig. 7/q) from the fanhousing (Fig. 7/n2) axi-
m Motor ally and suspend using a lifting tool. If the sprocket
n2 Fan housing (Fig. 7/k) is damaged or worn, then replace it. The
fan (Fig. 7/v) should also be checked for damage
q Coupling half on the motor side from time to time and replaced if necessary.
s4 Screws C-KLR 140
Undo the hexagonal nuts (Fig. 8/s6) on the motor
v Fan flange. Remove the motor with the coupling half
on the motor side (Fig. 8/q) from the fan housing
(Fig. 8/n2) axially and suspend using a lifting tool.
If the sprocket (Fig. 8/k) is damaged or worn, then
replace it. The fan (Fig. 8/v) should also be checked
n2 for damage from time to time and replaced if neces-
sary.

NOTICE
v
Frequent starting up and high ambient tempe-
q rature
k The service life of the sprocket (Fig. 7/k, 8/k) is
m s6 reduced.

Re-assemble in reverse order.

Fig. 8 Coupling C-KLR 140

k Coupling sprocket
m Motor
n2 Fan housing
q Coupling half on the motor side
s6 Hexagonal nut
v Fan

22 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Maintenance and repair

7.3 Reparatur/ Service

a) For on site repair work the motor must be
disconnected from the mains by a qualified
electrician so that it cannot be started up again
accidentally. For repairs use the manufacturer,
its branch offices or authorised dealers. Please
contact the manufacturer for the address of the
service centre responsible for you (see Manufac-
turer‘s address).

NOTICE

For each machine that is sent to an Elmo Riet-

schle Service centre for inspection, maintenance
or repair, a fully completed, signed declaration of
harmlessness must be enclosed.
The declaration of harmlessness is part of the
supplier‘s documentation.

b) After a repair or re-commissioning, the actions

listed under „Installation“ and „Commissioning“
must be carried out as for initial commissioning.

Fig. 9 Clearance certificate 7.7025.003.17

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Maintenance and repair

7.4 Spare parts

Order spare parts in accordance with the:

• Spare parts list :

E 883/1 ➝ C-KLR 80
E 883/2 ➝ C-KLR 140
• Download the PDF file:
http://www.gd-elmorietschle.com
➝ Downloads
➝ Product Documents
➝ C-Series ➝ Spare Parts
• Parts subject to wear and gaskets are indi-
cated separately on the list.
• Web site:
http://www.service-er.de
• Select the type, size and design.

NOTICE

Only use original spare parts or parts approved by

Fig. 10 Spare parts list (example) the manufacturer. The use of other parts may lead to
malfunctions and invalidate liability or the guarantee
for any consequences arising.

Fig. 11 Web site

http://www.service-er.de

24 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Malfunctions: Causes and elimination

8 Malfunctions: Causes and elimination

Fault Cause Troubleshooting Important

Machine is switched Mains voltage/ Frequency Check by qualified electrician Section 5.5
off by the motor pro- does not correspond with the
tection switch motor data
Connection to motor terminal
board is not correct
Motor protection switch is not
set correctly
Motor protection switch is Use a motor protection switch
triggered too quickly with an overload-dependent
delayed switch off that takes
into consideration the short
term excess current at start
up (version with short circuit
and overload trigger as per
VDE 0660 Part 2 orIEC 947-4)
The suction filter cartridges Clean or replace the filter Section 7.2.2
are dirty cartridges Section 7.4
The relief valves are dirty so Clean or replace the regulat- Section 7.2
that the permissible pressure ing valves Section 7.4
and/or vacuum values have
been exceeded.
Intake or blowing The suction filter cartridges Clean or replace the filter Section 7.2.2
power is not suf- are dirty cartridges Section 7.4
ficient
Lines are too long or too nar- Check the hose or the pipe Section 5.3
row
Machine or system leaking Check the pipework and Section 7.2
screw connections for leaks
and to ensure that they are
firmly seated.

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Malfunctions: Causes and elimination

Fault Cause Troubleshooting Important

Excess pressure or Machine or system leaking Check the pipework and Section 7.2
vacuum not achieved screw connections for leaks
and to ensure that they are
firmly seated.
Machine gets too hot Ambient or intake temperature Ensure it is being used prop- Section 2.3
is too high erly
Cooling air supply is ob- Check environmental condi- Section 5.1
structed tions
Clean ventilation slots Section 7.2
The suction filter cartridges Clean or replace the filter Section 7.2.2
are dirty cartridges Section 7.4
The relief valves are dirty so Clean or replace the regulat- Section 7.2
that the permissible pressure ing valves Section 7.4
and/or vacuum values have
been exceeded.
The machine makes Deposits on the rotary piston Clean the working space and Elmo Rietschle
an abnormal noise the rotary piston Service
A relief valve is vibrating Replace the valve Section 7.4

Please contact Elmo Rietschle Service for other malfunctions or those that cannot be eliminated.

26 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Technical Data

9 Technical Data

C-KLR 80 140

Sound pressure level (max.) 50 Hz 83 85

EN ISO 3744 dB(A)
Tolerance± 3 dB(A) 60 Hz 88 88

50 Hz 94 97
Sound power level dB(A)
60 Hz 99 99

Weight * kg 120 160

Length * mm 778 1016

Width mm 387 355

Height mm 415 500

Vacuum connection G 11/4 G 11/2

Pressure connection G 11/4 G 11/2

Correct amount of oil l 0,55 0,60

* The length and the weight may differ from the information listed here depending on the motor manufac-
turer.

You will find more technical data on the data sheet

D 883

• Download the pdf file:

D 883 ➝ C-KLR 80 / C-KLR 140
• Download the pdf file:
http://www.gd-elmorietschle.com
➝ Downloads
➝ Product Documents
➝ C-Series ➝ Data Sheets

NOTICE

Subject to technical changes.

Fig. 12 Data sheet (example)

www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH | 27

 www.gd-elmorietschle.com
[email protected]

Gardner Denver
Schopfheim GmbH
Roggenbachstraße 58
79650 Schopfheim · Deutschland
Tel. +49 7622 392-0
Fax +49 7622 392-300

Elmo Rietschle is a brand of

Gardner Denver‘s Industrial Products
Division and part of Blower Operations.
 EC - declaration of conformity 2006/42/EC
Hereby the manufacturer Gardner Denver Schopfheim GmbH
confirms: Postfach 1260
D-79642 Schopfheim
that the machine: Claw pressure/vacuum pump
of the: Series: C-KLR
Type: C-KLR 80, C-KLR 85, C-KLR 100,
C-KLR 110, C-KLR 115, C-KLR 140
is conform to the regulations of the guideline indicated above.

The following harmonized and national standards and specifications are applied:
EN 1012-1:2010 Compressors and vacuum pumps — Safety requirements — Part 1:
Compressors
EN 1012-2:1996+A1:2009 Compressors and vacuum pumps — Safety requirements — Part 2:
Vacuum pumps

These declarations of conformity are invalid when the machine has been modified without prior ap-
proval by us and the approval has been documented in writing.

Name and address of the EC person in Gardner Denver Schopfheim GmbH

charge for documentation Postfach 1260
D-79642 Schopfheim

Gardner Denver Schopfheim GmbH

Schopfheim, 01.8.2010

Dr. Friedrich Justen, Director Engineering

C_0078_EN
 Safety declaration form 7.7025.003.17
for vacuum pumps and components
Page 1 of 1

Gardner Denver Schopfheim GmbH

Roggenbachstr. 58, 79650 Schopfheim Phone: +49/(0)7622/392-0 Fax: +49/(0)7622/392-300
Repairs and/or maintenance of vacuum pumps and components will only be carried out if a declaration has been
filled in correctly and completely.
If not, the repair work cannot be started and delays will result.
This declaration must only be filled in and signed by authorised qualified staff.

1. Type of vacuum pumps/ components 2. Reason for the submission

Type description:
Machine number
Order number:
Delivery date:

3. Condition of vacuum pumps/ components 4. Contamination of the vacuum pumps/

Was this being operated? YES ‰ NO ‰ components when in use
Which lubrication was used? Toxic YES ‰ NO ‰
Corrosive YES ‰ NO ‰
Was the pump/ component emptied? Microbiological*) YES ‰ NO ‰
(Product/Consumables) YES ‰ NO ‰ Explosive*) YES ‰ NO ‰
Has the pump/ component been cleaned and decontaminaRadioactive*) YES ‰ NO ‰
other YES ‰ NO ‰
YES ‰
Cleaning agent:
Cleaning method:

*) Microbiological, explosive or radioactively contaminated vacuum pumps/ components will only be accepted
with proof that they have been cleaned properly.
Type of toxic substance or process-related, dangerous reaction products with which the vacuum pumps/
components came into contact:
Trade name, manufacturer's Chemical Hazard Action to be taken if toxic First aid in the event of
product name name class substances are released accidents
1
2
3
4
Personal protection measures:

Hazardous decomposition products when subjected to thermal load YES ‰ NO ‰

Which?
5. Legally binding declaration
We swear that the information in this declaration is accurate and complete and that I, the undersigned, am in a
position to judge this. We are aware that we are liable to the contractor for damage caused by incomplete and
inaccurate information. We undertake to release the contractor from any damage claims from third parties arising
from incomplete or incorrect information. We are aware that, regardless of this declaration, we are directly liable
to third parties including in particular the contractor's staff entrusted with handling or repairing the product.

Company:
Street: Post code/ Town:
Phone: Fax:
Name (in capitals) Position:

Date: Company stamp:

Legally binding signature:
TOS no. / Index: 7.7025.003.17 / 03 Office responsible: GS File management: ..\7702500317.xl
Gardner Denver Schopfheim GmbH Postfach 1260 D-79642 Schopfheim