Related Manuals for Gardner Denver ESM 30
Summary of Contents for Gardner Denver ESM 30
- Page 1 Original User Manual Screw Air Compressor ESM 30-ESM 50 ● ● ● Id. no. ZS1064358 / 00 - January 2010...
-
Page 3: General Information
Genuine Gardner Denver parts will be used. Warranty The conditions of the Gardner Denver Warranty are set out in the Company’s standard Conditions of Sale available from the Gardner Denver Company or Distributor supplying the machine. - Page 4 Data sheet for users Fig. 1 The values on the type plate are maximum values. Your Gardner Denver distributor Name: Address: ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Telephone: Fax: Contact: Spare Parts: Service:...
-
Page 5: Foreword
Maintenance Notes on the compressor Carefully performed maintenance is imperative, this Gardner Denver screw compressors are the result of ensures that your screw compressor can meet all the many years of research and development. These requirements placed upon it. It is therefore imperative to... - Page 6 Operate this compressor only if you have an exact knowledge of the machine taking into respect these instructions. Gardner Denver cannot be held responsible for the safe operation of the machine/unit if it is used in a manner which does not correspond to the intended use, or for other applications which are not mentioned in these instructions.
- Page 7 4.3 Oil circuit..................................23 4.4 Air circuit..................................23 4.5 System control ................................23 4.5.1 System control ESM 30 (Fig. 3 a) ........................23 4.5.2 System control ESM 37-ESM 50 (Fig. 3 b)....................24 4.5.3 Manner of operation of the suction regulator ESM 45-ESM 50 ..............26 5 Transport and installation ..............................27...
- Page 8 10 Annex....................................49 10.1 Technical Data ................................49 10.1.1 EUROPE version ESM 30-ESM 37........................49 10.1.2 EUROPE version ESM 45-ESM 50........................50 10.1.3 North America version ESM 30-ESM 37 .......................51 10.1.4 North America version ESM 45-ESM 50 .......................52 10.2 Layout plan..................................53 10.3 Declaration of conformity............................55...
-
Page 9: Safety Regulations
General safety instructions Identification of safety guidelines Organizational measures Gardner Denver is not liable for any damage or injury resulting from the non-observance of these safety The operating instructions must always be at hand at instructions or negligence of the usual care and... -
Page 10: Changes And Modifications To The Machine
3. Safety regulations For the execution of maintenance work, tools and The manufacturer is not liable for damage resulting workshop equipment adapted to the task on hand are from the use of non-original parts or special accessories. This applies also to the installation and absolutely indispensable. - Page 11 3. Safety regulations If a remote control is used, the system must carry a If the room temperature can fall below zero, the clearly visible sign with the following note: Attention! condensation drain system must be protected from This installation is operated by remote control and can freezing, e.g.
-
Page 12: Special Work/Maintenance
3. Safety regulations Before blowing through a hose or an air pipe ensure Brief the operating personnel prior to starting special that the open end is positively held. A free end whips operations or maintenance work! Appoint a person to and can cause injuries. - Page 13 3. Safety regulations Avoid damage to the safety valves and other pressure Maintenance/rectification of faults reducing components. Check in particular for clogging The employer has to inform the employee of the caused by paint, oil carbon or the accumulation of dust, dangers possibly arising during the repair and which could deteriorate the effectiveness of these maintenance of the machine/unit as well as on how to...
-
Page 14: Warning Of Special Dangers
3. Safety regulations If the set-up, maintenance or repair require the Observe any existing national regulations if work is to demounting of safety equipment, this equipment has to be carried out in small rooms. be remounted and checked immediately after these Always check a correct power supply to the compressor activities. -
Page 15: Storage Of Compressors
3. Safety regulations Oils, greases and other chemical substances When handling oils, greases and other chemical substances, observe the safety regulations for this product! Be careful when handling hot fuels and consumables (danger of burning or scalding)! Rooms subject to explosion hazards Danger Compressor units must never be operated in areas subject to explosion hazards! -
Page 16: Symbols And Explanations
3. Safety regulations Symbols and explanations Carefully read the operating manual before commissioning or servicing this compressor. Never breathe in compressed air from this system. Never operate the unit with open doors or loose access panels. - Page 17 3. Safety regulations Warning: Hot surface Warning: Pressurized part or system Warning: This system can start up by means of a remote control or automatically after a power failure.
- Page 18 3. Safety regulations Warning: The system continues to run for 30 seconds after pressing the O-key Warning: Danger of electric shock Attention: Lifting point...
- Page 19 3. Safety regulations Attention: Check and, if required, re-tighten connection terminals. For further details, see the operating instructions. Attention: Opening pressure safety valve = xx bar (value "xx" see sticker on compressor)
-
Page 20: Design And Functioning
4. Design and functioning Desig n a n d f un cti oni ng Design of the unit Fig. 2 1 Intake filter 16 Oil temperature regulator 29 Fan protection panel 2 Intake regulator 17 Cooling air ventilator 30 Pressure relief for cooler 3 Electric motor 18 Cooling air inlet filter mat 31 Filter mat, cooling-air inlet, dryer... -
Page 21: Schematic Diagram
4. Design and functioning Schematic diagram 4.2.1 Schematic diagram ESM 30 Fig. 3 1 Intake filter 9 Safety valve 23 Oil level indicator 2 Intake regulator 10 Oil filter monitor (S5) 24 Intake filter monitor (S7) 2.1 Actuator 11 Oil filter 25 Fine separator monitor (S6) 2.2 Pressure control valve... -
Page 22: Schematic Diagram Esm 37-Esm 50
4. Design and functioning 4.2.2 Schematic diagram ESM 37-ESM 50 reacting pressure 50 mbar reacting pressure 50 mbar residual pressure: ca. 1.5 bar throttle diameter: 1,1 mm operating temperature: 55 °C [70 °C] Fig. 3 b 1 Intake filter 8 Oil drain ball valve 20 Control/blow-off valve(Y4) 2 Intake regulator 9 Safety valve... -
Page 23: Oil Circuit
System control The oil flows from the pressure reservoir (- 6 - Fig. 3) 4.5.1 System control ESM 30 (Fig. 3 a) into the oil thermostat (- 22 - Fig. 3). With oil tempera- (See also operating instructions for the compressor tures <... -
Page 24: System Control Esm 37-Esm 50 (Fig. 3 B)
4. Design and functioning Automatic operation (open-close operation) 4.5.2 System control ESM 37-ESM 50 (Fig. 3 b) When the pressure reaches the upper switching • point set on the network pressure sensor (-28 - (See also operating instructions for the compressor (B1)), solenoid valve (- 30 - (Y1)) is deenergised. - Page 25 4. Design and functioning Stopping the system To de-energise the solenoid valves (- 19 - (Y1) and • - 20 - (Y4)) press the OFF push-button on the keypad of the compressor control GD Pilot MK. The pressure control valve (- 2.2 -) in the intake •...
-
Page 26: Manner Of Operation Of The Suction Regulator Esm 45-Esm 50
4. Design and functioning 4.5.3 Manner of operation of the suction regulator ESM 45-ESM 50 Load running mode When switching over to delta connection the two upper control area of the operating cylinder. The suction solenoid valves are supplied with power (7 (Y1) and regulator valve opens, the lower control area is bled 9 (Y4)). -
Page 27: Transport And Installation
Weights The values listed below are approximate values, they refer to a screw compressor unit including oil fill: Fig. 6 ESM 30 923 kg / 2061 lbs ESM 37 966 kg / 2157 lbs ESM 45... -
Page 28: Installation
5. Transport and installation Installation A = 1m/39,4“ B = 1m/39,4 “ Fig. 8 Danger The weight carrying capacity of the foundation • has to be taken into account when installing the compressor. Provide for a solid and plane base. •... -
Page 29: Preparations For Commissioning
5 m/16.4 ft, more than one bend, filter cartridges, screens, etc.), please contact your technical adviser. Gardner Denver screw compressors are rated for ambient temperatures and cooling temperatures of +1°C/ 33.8°F to +45°C/113°F. In the case of temperatures other than the above limiting values,... -
Page 30: Compressed Air Connection
6. Preparations for commissioning In the case of connections by means of connecting Compressed air connection hoses, take appropriate measures to prevent whipping of the loose end in the event that the hose connection tears off. Electrical connection 6.3.1 Electrical connection (EUROPE- Version only) Compressor units are finished in the factory according to standard EN60204 (industrial machinery). - Page 31 6. Preparations for commissioning To establish an electrical connection, proceed as Danger follows: When carrying out adjustment work on the control Route the supply cable through the cable gland power transformer, the unit must be electrically (-1 - Fig. 12) on the control cabinet and tighten screws. isolated and locked off.
- Page 32 Recommended supply cable cross-sections and fuses Installed nominal Fuse protection Line cross section Compressor type Supply voltage motor power (slow-blow fuse) at 30°C [kW] [AgL] 50-Hz-Compressors 220V 3x70PE35 ESM 30 380V 4G35 400V 4G25 220V 3x95PE50 ESM 37 380V 4G35 400V 4G35 220V 3x95PE50...
-
Page 33: Electrical Connection (Usa/Canada-Version Only)
6. Preparations for commissioning 6.3.2 Electrical connection (USA/CANADA-Version only) Danger The power supply to the compressor side has to be fitted for industrial equipment and fulfilling the requirements of EN60204-1/IEC60204-1. To avoid strong damages and fire on the power electric components, any kind of operation outside of the stated limits of EN60204-1/IEC60204-1 is inadmissible. - Page 34 (slow-blow fuse) class J 140°F 167°F 194°F [hp] 60-Hz-compressors 200V AWG4/0 AWG3/0 AWG2/0 230V AWG3/0 AWG2/0 AWG1/0 ESM 30 460V AWG3 AWG4 AWG4 575V AWG4 AWG6 AWG6 200V MCM250 AWG4/0 AWG3/0 230V AWG4/0 AWG3/0 AWG2/0 ESM 37...
-
Page 35: Oil Level Check
± 3 dB(A)): compressor unit is out of operation and 50 Hz compressors dB(A) depressurized! ESM 30 The pressure reservoir can be under pressure and the oil hot. Warning: Danger of scalding! ESM 37 ESM 45 Do not spill oil! Check for leakage! -
Page 36: Commissioning
The factory setting of the setpoint value for the • network pressure (upper and lower switching point) Although every Gardner Denver screw compressor is saved in the compressor control GD Pilot MK and has been subjected to a test run at the factory and... - Page 37 7. Commissioning Fig. 15 1 Drive motor‘s direction of rotation for geared compressor Fig. 15 c 1 Cooling air intake 2 Cooling air outlet 3 Arrow “direction of rotation for compressor“ (direction of rotation may deviate from this representation) Note For switching the compressor off “normally”, use only Fig.
-
Page 38: Routine Commissioning
7. Commissioning To switch off the compressor in the usual way use Display of the compressor control GD Pilot MK • the STOP button (- 3 - Fig. 16) and not the emergency STOP button (- 1 - Fig. 16). After shutdown the compressor has a run on time of 30-50 seconds (soft-stop). -
Page 39: Service And Maintenance
In order to facilitate this task, the scope of supply of the screw compressor unit comprises the “Maintenance and inspection manual for Gardner Denver compressors”, in which you can list your performed maintenance work at the specified intervals. -
Page 40: Maintenance Schedule
8. Service and maintenance The screw compressor unit must therefore be • Maintenance schedule depressorized prior to any maintenance work by slowly opening the lock (oil filler cap) with Danger integral vents When performing control, adjusting and mainte- The customer-installed main switch is set to "O" •... -
Page 41: Oil Change
8. Service and maintenance intake air from a normal environment without a high Oil change content of foreign matter (dusts, vapours, gases). When changing the oil, the waste oil is to be drained completely, since used oil reduces the service life of the new oil fill considerably. -
Page 42: Change Of Oil Filter Cartridge
8. Service and maintenance Check oil level (see chapter 6.4) • Change of oil filter cartridge If required, top up oil. • Changing intervals for oil filter cartridge The operating conditions (e.g. coolant temperatures), the operating modes and the quality of the intake air (e.g. -
Page 43: Change Of Air Intake Filter
8. Service and maintenance If the oil fine separator is monitored (option), too high a Turn cheese head screw (- 8 - Fig. 19 a) • differential pressure is indicated on the keypad of the counterclockwise until the reservoir cover is loosely compressor control GD Pilot MK. -
Page 44: Safety Valve
8. Service and maintenance Danger Safety valve Only perform checks and carry out work on the screw compressor when the unit is out of operation and depressurized! Important Never operate the screw compressor unit without the air filter (even a short operating time without this filter can result in considerable damage to the machine)! As a standard, the air filter is provided with a visual in-... -
Page 45: Connecting Terminals In The Switch Cabinet/Control Transformer Setting
8. Service and maintenance Connecting terminals in the switch 8.12 Clean / change filter mat with cooling cabinet/control transformer setting air inlet and control cabinet inlet Danger In the case of electric voltage: Actuate STOP button at the operating panel •... -
Page 46: Maintenance Information And Lubricant Recommendations For Stationary Compressors
8. Service and maintenance Cleaning: Clean the filter mat by brushing or washing. Important Never install the filter mat in a wet or moist state! Changing times for the filter mat The operating modes and the quality of the suctioned air (e.g. -
Page 47: Trouble-Shooting
9. Trouble-shooting Tr ou ble -s ho oti ng In the case of faults or warnings that are detected by the compressor control GD Pilot MK, please refer to the chapter “Fault/warning table” in the operating instructions of the GD Pilot MK. Malfunction Possible cause Remedy... - Page 48 9. Trouble-shooting Malfunction Possible cause Remedy Unit switches off Ambient temperature too high Ventilate compressor room Electric motor defective Check electric motor and thermistor Fan defective Check/replace fan Sensor, connections or lines defective Check sensors, connections and lines Cross section of the electric supply Measure power requirement, lines too small if necessary, replace lines...
-
Page 49: Annex
10. Annex Ann ex 10.1 Technical Data 10.1.1 EUROPE version ESM 30-ESM 37 ESM 30 ESM 37 Technical Data 50Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C 1...45°C Flow /min 5.75 5.11 4.36 6.17 After-cooler outlet temperature above ambient temp. -
Page 50: Europe Version Esm 45-Esm 50
10. Annex 10.1.2 EUROPE version ESM 45-ESM 50 ESM 45 ESM 50 Technical Data 50Hz Maximum operating pressure Minimum operating pressure Ambient temperature °C 1...45°C Flow / min 6.11 8.67 7.55 After-cooler outlet temperature above ambient temp. °C Sound pressure level (to ISO 2151) dB(A) Nominal motor rating Full-load current max. -
Page 51: North America Version Esm 30-Esm 37
10. Annex 10.1.3 North America version ESM 30-ESM 37 Technical Data 60Hz North America ESM 30 ESM 37 Nominal pressure psi g Maximum working pressure psi g Minimum working pressure psi g Ambient temperature - min / max °F 34...113 FAD at nominal pressure 203.7... -
Page 52: North America Version Esm 45-Esm 50
10. Annex 10.1.4 North America version ESM 45-ESM 50 Technical Data 60Hz North America ESM 45 ESM 50 Nominal pressure psi g Maximum working pressure psi g Minimum working pressure psi g Ambient temperature - min / max °F 34...113 FAD at nominal pressure 278.7 160.8... -
Page 53: Layout Plan
10. Annex 10.2 Layout plan Fig. 23 (all dimensions in mm) Compressed air connection Europe version: male screwed thread DIN 2999 - R 1 1/2 Canada USA version: male screwed thread NPT 1 1/2 - 11 ½ Condensate connection (only for dryer option or for integrated water-separator option) outer-∅... - Page 54 10. Annex Fig. 24 (all dimensions in mm)
-
Page 55: Declaration Of Conformity
10. Annex 10.3 Declaration of conformity 1. EC Declaration of conformity in accordance with the EC Machinery Directive 2006/42/EC, Supplement II A 2. We, hereby declare Gardner Denver Deutschland GmbH Argenthaler Str.11 D-55469 Simmern that the product: Kompressor type: trade mark: manufacturer no.:... - Page 60 Gardner Denver Compressor Division, 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Fax: (217) 224-7814 Gardner Denver Deutschland GmbH Argenthaler Str. 11 55469 Simmern Deutschland Tel. ++49 (0)6761 832-0 Fax ++49 (0)6761 832-409...