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Summary of Contents for GD P Series
- Page 1 PARTS LIST OPERATING AND SERVICE MANUAL BLOWERS/VACUUM PUMPS 7CDL – P SERIES 37-1-614 Version 03 September 8, 2010...
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Page 2: Maintain Blower Reliability And Performance
MAINTAIN BLOWER RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Factory genuine parts, manufactured to design tolerances, are developed for optimum dependability - - - specifically for your blower. Design and material innovations are born from years of experience with hundreds of different blower applications. -
Page 3: Gardner Denver Lubricant Order Information
GARDNER DENVER LUBRICANT ORDER INFORMATION Re-order Part Numbers for Factory-Recommended Lubricants. AEON PD Synthetic Lubricant or AEON PD-Food Grade Synthetic Lubricant AEON PD Synthetic Lubricant Description Part Number 1 Quart 28G23 Case/ 12 Quarts 28G24 5 Gallon Pail 28G25 55 Gallon Drum 28G28 AEON PD-Food Grade Synthetic Lubricant Description... -
Page 4: Foreword
FOREWORD CycloBlower blowers are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. -
Page 5: Table Of Contents
TABLE OF CONTENTS Maintain Blower Reliability And Performance ....................2 Gardner Denver Lubricant Order Information ....................3 Foreword ............................... 4 Index................................6 List Of Illustrations............................7 Safety Precautions ............................8 Introduction Your Key To Trouble Free Service.................... 9 Section 1 Equipment Check.......................... 9 Section 2 Installation ........................... -
Page 6: Index
INDEX Altitude .............22 Safety Devices ..........15 Blower Startup Checklist ........24 Check Valve ............. 15 Relief Valve ............15 Discharge Piping ..........16 Safety Devices ..........15 Drive Installation..........12 Safety Precautions..........8 Emergencies ............23 Section 1 ............9 Foundations .............11 Equipment Check..........9 Section 2 ............ -
Page 7: List Of Illustrations
LIST OF ILLUSTRATIONS FIGURE 2-1 – OPERATING PRINCIPLE ........................10 FIGURE 2-2 – ACCESSORIES AND SAFETY DEVICES ...................11 FIGURE 2-3 – BELT DRIVE OVERHUNG LOAD CALCULATIONS................14 FIGURE 2-4 – OUTLINE DIMENSIONS ........................18 FIGURE 2-5 – OUTLINE DIMENSIONS ........................18 FIGURE 3-1 – MAXIMUM RATING..........................19 FIGURE 3-2–... -
Page 8: Safety Precautions
SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel. -
Page 9: Introduction Your Key To Trouble Free Service
INTRODUCTION YOUR KEY TO TROUBLE FREE SERVICE Although Gardner Denver blowers are sturdy, precision-engineered machines, there are several relatively simple but basic installation and maintenance procedures that must be observed to assure optimum performance. As there is no guesswork in the manufacture of these highly advanced units, there must be none in preparing them to get the job done in the field. -
Page 10: Section 2 Installation
SECTION 2 INSTALLATION FIGURE 2-1 – OPERATING PRINCIPLE GENERAL – The CycloBlower® is a compact, rotary lobe type axial flow blower. The meshing of two screw type rotors synchronized by timing gears provides controlled compression of the air for maximum efficiency and pulsation free discharge. -
Page 11: Figure 2-2 - Accessories And Safety Devices
FIGURE 2-2 – ACCESSORIES AND SAFETY DEVICES LOCATION – Select a clean, dry, well-ventilated area for installing blower and allow ample room for normal maintenance. Proper ventilation is necessary for blower cooing and cool air intake. Do not electric weld on the blower or base; bearings can be damaged by the passage of current. FOUNDATIONS –... - Page 12 Inlet Filter or Filter-Silencer – For pressure service handling air, the blower inlet must be protected by a filter of suitable size to allow full flow of air to the blower inlet. The filter must be of adequate efficiency to trap any foreign materials which may be in the general area of the air inlet.
- Page 13 NOTICE When a simple V-belt drive is not available, to stay within the maximum allowable moment, a jackshaft V-belt drive is required. Belt drives must be carefully aligned. Motor and blower pulleys must be parallel to each other and in the same plane within 1/16 inch.
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Page 14: Figure 2-3 - Belt Drive Overhung Load Calculations
7CDL Maximum Drive Dimensions Allowable Shaft (Inches) Moment Location (LB-IN) (Max) Discharge 8.64 3.65 5,985 (Standard) Gear 10.12 5.30 5,985 (Optional) MAXIMUM ALLOWABLE MOMENT DRIVE SHAFT ILLUSTRATION 0.000 1.000 0.250 0.966 0.500 0.926 0.750 0.879 1.000 0.823 1.250 0.751 0.025 0.997 0.275 0.962... - Page 15 Bypass Valve – Installation of a bypass valve at the blower discharge ( , page 11) will allow FIGURE 2-2 the blower to be started under no-load. Bypass line may be discharged at atmosphere or to blower inlet depending on local requirements or material being handled. Heat Exchanger –...
- Page 16 DISCHARGE PIPING – In general, the type of system used will govern the piping arrangement. However, the following suggestions should be followed for blower protection and efficiency. An expansion joint should be installed as close to the blower opening as possible to protect the blower housing from stresses.
- Page 17 37-1-614 Page 17...
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Page 18: Figure 2-4 - Outline Dimensions
37-1-614 Page 18... -
Page 19: Section 3 Operation
SECTION 3 OPERATION Future operating problems can be avoided if proper precautions are observed when the equipment is first put into service. Before starting under power, the blower should be turned over by hand to make certain there is no binding or internal contact. -
Page 20: Figure 3-2- Inlet Water Injection Diagram
FIGURE 3-2– INLET WATER INJECTION DIAGRAM TYPE OF SERVICE – The blower can be operated in either pressure or vacuum service. Pressure – Never operate the blower above the maximum pressure shown in FIGURE 3-1, page 19. Excessive pressure may cause overheating and blower failure, it is therefore most important to have an accurate pressure gauge in the discharge line as close to the blower discharge as possible. -
Page 21: Figure 3 4 - Water Quality Requirements
pH Range at 25° C ............6.5 – 8.0 Conductivity at 25°C (MICROMHO/cm) ......Less than 250 Total hardness as CaCo (ppm) ........Less than 100 Total Alkalinity as CaCo (ppm)........Less than 70 Chloride ion; CI (ppm)............ Less than 30 –2 Sulfate ion SO (ppm) .......... -
Page 22: Figure 3-5 - Altitude - Pressure/Vacuum
Altitude Maximum Maximum (Feet above Discharge Inlet See Level) Pressure* Vacuum* 1000 19.3 PSIG 16.4 Inches Hg. 2000 18.6 PSIG 15.8 Inches Hg. 3000 17.9 PSIG 15.3 Inches Hg. 4000 17.3 PSIG 14.7 Inches Hg. 5000 16.7 PSIG 14.2 Inches Hg. Gauge readings are taken as close as possible to blower openings. -
Page 23: Figure 3-6 - Minimum Speed, Maximum Pressure Or Vacuum
EMERGENCIES – In event of system failures, shutdown the blower immediately. Inspect the blower for foreign material backflow. If materials are found inside the blower housing, a thorough cleaning is necessary before restarting. Do not operate a blower which is noisy, vibrating, or heating excessively. Minimum Speed (RPM) –... - Page 24 BLOWER STARTUP CHECKLIST This startup procedure should be followed during the initial installation and after any shutdown periods or after the blower has been worked on or moved to new location. It is suggested that the steps be followed in sequence and checked off (√) in the boxes provided. Check the unit and all piping for foreign material and clean if required.
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Page 25: Section 4 Maintenance
SECTION 4 MAINTENANCE GENERAL – Blower efficiency and life depend on the quality of maintenance the blower receives. Maintenance must be done regularly and with care. Clean work space, tools, solvents and wiping rags are necessary to avoid transferring dirt into the unit. A maintenance chart listing each blower and scheduling regular maintenance of the unit is valuable. -
Page 26: Figure 4-3 - Non Synthetic Lubricant Chart
Ambient Temperatures Blower Discharge Less than 10° F 10°F to 32° F** 32°F to 90° F Greater than 90° F Temperature Less than 32°F ISO 100 ISO 100 (0° C) 32°F to 100° F ISO 100 ISO 100 ISO 150 (0°... - Page 27 Check the oil level at both ends of the blower daily. The oil change period is governed by operating conditions, such as load, temperature, dirt, humidity, fumes and the quality of oil used. Under severe operating conditions the oil should be changed every 1000 hours or more often. Under ideal operating conditions oil may extend the change interval up to 6000 hours based on a good oil analyzes program.
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Page 28: Figure 4-4 - Oil Bath Filter
Oil Bath Filter (FIGURE 4-4, page 27) – The following instructions also apply when the filter is equipped with a silencing chamber: Remove cover, screen and bowl form the base. Wash the screen and bowl. Fill the bowl to oil level bead with oil listed. Place the end of the screen bonded with felt down into the oil. - Page 29 ROTOR SHAFT SEALS – Rotors have a labyrinth type shaft air seal to minimize air leakage along the shaft from the compression chamber. More air will leak through the seals at the discharge end since they are under higher air pressure. Excessive air leakage indicates shaft seal failure. The air seal consists of two parts, a hardened steel bearing spacer with grooves cut into the outside diameter, and a steel-backed babbitt ring (shaft seal) pressed into the bearing carrier.
- Page 30 BLOWER OVERHAUL – Refer to Disassembly Section, page 36, and Assembly Section, page 40. REPAIR PARTS – When ordering parts, specify Blower Model, Size and Serial Number. Reference numbers shown in the left hand column of the parts list are used to help locate parts shown on the drawing and sectional view.
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Page 31: Section 5 Parts List
SECTION 5 PARTS LIST GEAR END DISCHARGE END 4060 (Ref. Drawing) FOR LIST OF PARTS SEE PAGES 33 AND 34. 37-1-614 Page 31... - Page 32 37-1-614 Page 32...
- Page 33 Order by Part Number and Description. Reference Numbers are for your convenience only. Models Models Models Ref. Qty. 7CDL11P 7CDL14P 7CDL17P Name of Part Part No. Part No. Part No. HOUSING ..........300CBL002 301CBL002 302CBL002 ROTOR GROUP (Includes Items 2 & 3) 200CBL010A 202CBL010A 204CBL010A...
- Page 34 Order by Part Number and Description. Reference Numbers are for your convenience only. Models Models Models Ref. Qty. 7CDL11P 7CDL14P 7CDL17P Name of Part Part No. Part No. Part No. 42** KEY – SQUARE ......... 8500121 8500121 8500121 43** PIN – DOWEL ........62M3 62M3 62M3...
- Page 35 OVERHAUL KIT – 302CBL6010 Description Qty. Part No. Installation Sleeve for Oil Seal ........300CBL074 Installation Sleeve for Oil Seal ........300CBP074 Installation Sleeve for Oil Seal ........301CBL074 Bearing Spacer ............8500036 Bearing Spacer ............8504493 Shaft Air Seal ............... 8500389 Shaft Air Seal ...............
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Page 36: Section 6 Disassembly Instructions
SECTION 6 DISASSEMBLY INSTRUCTIONS FIGURE 6-2 – EARING PRESS PLATE FIGURE 6-1 – ADAPTOR PLATE NOTICE Illustrations for Disassembly Instructions are taken from various sizes of CycloBlower. Minor variations in construction of some parts need cause no concern. 1. Provide adaptor plates, (Figure 6-1), and bearing press plate, (Figure 6-2), for pulling the gear hub and pinion, and for installing bearings. -
Page 37: Figure 6-2 - Alternate Adaptor Plates
FIGURE 6-5 – ADAPTOR PLATE 3. Place the unit in a horizontal position, on a solid blocking, so the gear end bearing carrier hangs free. Drain oil from both carriers. At the gear end remove the cover, hub retainer plate, gear (slip fit on hub) and pinion locknut. -
Page 38: Figure 6-3 - Bearing Carrier
FIGURE 6-8 – BEARING CLAMP PLATE FIGURE 6-7 – BEARING CARRIER NOTICE Never reuse shaft seals that have been in operation. Refer to “Rotor Shaft Seals,” page 29. 8. Remove the discharge end carrier cover, oil slinger, clamp plate, bearing locknut and bearing clamp plates. -
Page 39: Figure 6-6 - Rotor Removal
FIGURE 6-10 – ROTOR REMOVAL FIGURE 6-11 – BEARING CARRIER 37-1-614 Page 39... -
Page 40: Section 7 Assembly Instructions
SECTION 7 ASSEMBLY INSTRUCTIONS NOTICE The fastener & locknut torque values required during assembly are shown in FIGURE 7-33 NOTICE Illustrations for Assembly Instructions are taken from various sizes of Cycloblower minor variations in construction of some parts should not cause concern. Numbers in parentheses ( ) refer to key numbers in assembly drawings on pages 31 and 32. -
Page 41: Figure 7-1 - Rotor Shaft Seal
2. To ease assembly in later steps, fit the bearing spacers (16, 17) to the seals (18, 19) (FIGURE 7-2, page 41). Be sure there are no burrs on the spacer O.D. and seal I.D. Spacer should be SLIP FIT in the seal. A sloppy fit will cause excess air leakage and decrease blower efficiency. -
Page 42: Figure 7-5 - Angular Contact Bearing Assembly
FIGURE 7-6 – BEARING INSTALLATION FIGURE 7- 5 – ANGULAR CONTACT BEARING ASSEMBLY NOTICE If rotors are installed in reverse of above instructions, the gate rotor bearing spacer O.D. may drag on the main rotor lobe and be damaged. The CycloBlower is designed for no metal-to-metal contact with parts within the housing. To achieve this, some preliminary measurements are necessary before completing the assembly. -
Page 43: Figure 7-8 - Rotor End Clearnace Chart (Unit Cold)
Total End Clearance Suction Discharge Models (Suction & Discharge 7CDL11 .021 .014 .007 7CDL14 .025 .018 .007 7CDL17 .028 .021 .007 Dimensions are for Ideal Clearances. Allow +/- for Tolerance FIGURE 7-8 – ROTOR END CLEARNACE CHART (UNIT COLD) 8. To the micrometer reading add discharge end clearance shown in clearance chart, FIGURE 7-8, page 43, and .002”... -
Page 44: Figure 7-11 - Discharge Opening
FIGURE 7-11 – DISCHARGE OPENING FIGURE 7-12 – DIAL INDICATOR 10. Select the correct thickness of aluminum shims (21) to give the shim set established in Step 9. Check the thickness of the shims with an outside micrometer (FIGURE 7-10, page 43). Place the shims on the end of the housing, matching the pointed section of the shims with the contour of the housing. -
Page 45: Figure 7-13 - Seal Installation Guide
FIGURE 7-13 – SEAL INSTALLATION GUIDE With the hydrodynamic seals, the bearing carrier must be lowered over the shaft first. The installation sleeves must be used to cover keyways and to provide smooth transitions onto the diameter changes. NOTICE Seals must stay on the shipping rings until it is time to install them. Otherwise the lips will deform. -
Page 46: Figure 7-15 - Bearing Shims
FIGURE 7-15 – BEARING SHIMS FIGURE 7-16 – BEARING SHIMS 17. Lightly coat the shaft extension and bearing bore with oil. Assemble bearings (29, 30), as shown in (FIGURE 7- 5, page 42), on the shaft. Assemble the press plate (refer to Error! Reference source not found., Disassembly page 36), on the bearing and install the jack screws, (FIGURE 7-17). -
Page 47: Figure 7-17 - Bearing Press Plate
FIGURE 7-18 – BEARING CLAMP PLATES FIGURE 7-17 – BEARING PRESS PLATE FIGURE 7-20 – OIL SLINGER FIGURE 7-19 – DISCHARGE END CLEARANCE CHECK 19. Check the discharge end clearance of the rotor with a feeler gauge through the discharge opening, (FIGURE 7-19, page 47). -
Page 48: Figure 7-21 - End Cover Assembly
21. Check the shaft extension and keyway for burrs. Cover the shaft and keyway with a thin protective installation sleeve. Push the oil seal (26) into the seal adaptor (25). Install the seal adaptor gasket (52), seal and adaptor to the end cover (14) using four screws (46) and two dowels (43). -
Page 49: Figure 7-24 - Oil Seal On Gate Rotor Shaft Assembly
22. Turn the unit end for end, gear end up. With a depth micrometer on a perfectly flat parallel bar across the bearing bore, measure the distance to the shoulder in the bearing bore, FIGURE 7-22. 23. Remove tape from the shaft holding the bearing spacers in place. Tap the spacer to be sure it is solidly against the end of the rotor. -
Page 50: Figure 7-25 - Slide Shims Over Shaft Assembly
FIGURE 7-25 – SLIDE SHIMS OVER SHAFT ASSEMBLY Tighten the nuts on the jack screws evenly to prevent cocking of the race. On the gate rotor, a ball bearing (32) is used. Coat the shaft and bearing bore with oil. Slide the bearing over the shaft. -
Page 51: Figure 7-28 - Smallest Minus Reading
FIGURE 7-29 – SMALLEST PLUS READING FIGURE 7-28 – SMALLEST MINUS READING The final check to be made for running clearances is dividing the interlobe clearance of the rotors to prevent metal-to-metal contact. This is referred to as “TIMING OF ROTORS” and is accomplished in the following steps. -
Page 52: Figure 7-30 - Setting The Interlobe Clearance
FIGURE 7-30 – SETTING THE INTERLOBE FIGURE 7-31 – HOLD GEAR & SHAFT FROM CLEARANCE TURNING TIGHTEN FIVE GEAR TO HUB 31. SETTING THE INTERLOBE CLEARANCE – (FIGURE 7-31 page 52). The interlobe clearance is divided with 2/3 on the discharge side and 1/3 on the suction side. Hold the gear from turning. Move the shaft counterclockwise with a wrench just enough to obtain 1/3 of the indicator reading obtained is Step 29. -
Page 53: Figure 7-33 - Fasteners & Locknut - Torque Values Chart
FASTENERS & LOCKNUTS (Ref. No.) TORQUE VALUES (ft-lb except as noted) Locknut (33) 130 – 150 Locknut (34) 64 – 90 Capscrew (46) 38 – 41 Capscrew (47) 75 – 80 Capscrew (48) 75 – 80 Socket Head Capscrew (44) 65 –... -
Page 54: Warranty
WARRANTY GARDNER DENVER® CDL SERIES CYCLOBLOWERS GENERAL PROVISIONS AND LIMITATIONS Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty is made with respect to: Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely. - Page 55 For additional information, contact your local representative or Gardner Denver Compressor Division 1800 Gardner Expressway, Quincy, Illinois 62301 Phone: (800) 682-9868 ● Fax (217) 221-8780 E-mail: pd.blowers@gardnerdenver.com Visit our web site: www.gardnerdenver.com Specifications subject to change without notice © Copyright 2010 Gardner Denver, Inc. Litho in U.S.A. Sales and Service in all major cities...
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