Related Manuals for Gardner Denver EnviroAire 15
Summary of Contents for Gardner Denver EnviroAire 15
- Page 1 Original Operating and Service Manual 15 - 22 kW ● Id. no. ZS1093133 / 00 - June 2012...
- Page 3 Gardner Denver parts will be used. Warranty The conditions of the Gardner Denver Warranty are set out in the company's standard Conditions of Sale available from the Distributor supplying the machine.
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Page 4: Warning -Prohibition - Mandatory Label Information
1 Warning -Prohibition - Mandatory Label Information Warning -Prohibition - Mandatory Label Information Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. - Page 5 1 Warning -Prohibition - Mandatory Label Information Check and, if required, re-tighten connection terminals. Danger of electric shock from loaded condensers! Please For further details, see the operating instructions. always first disconnect the system from the power supply and wait another 10 minutes before touching the electrical components.
- Page 6 1 Warning -Prohibition - Mandatory Label Information NOTICE Indicates a property damage message. PROHIBITION/MANDATORY ACTION REQUIREMENTS Asphyxiation Hazard – Never breathe in compressed air Never operate the unit with open doors or loose access from this system. panels. Read the operator’s manual before proceeding with this Opening pressure pressure relief valve = xx bar (value task "xx"...
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Page 7: Preface
2 Preface Preface Fig. 1 Your Gardner Denver distributor Name: Address: _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ Telephone: Fax: Contact: Spare Parts: Service:... -
Page 8: Compressor Information
Therefore, it is essential that the prescribed maintenance intervals are adhered to and that Gardner Denver will not guarantee the safe operation of maintenance and upkeep are done thoroughly, the machine/equipment if it is not handled in a way especially under difficult operating conditions. - Page 9 Gardner Denver replacement • parts alterations to the equipment. • The warrantee or liability terms of Gardner Denver’s Terms and Conditions are not expanded by the foregoing. Any independent alterations to the compressor equipment/station or installing components which have not been approved by the manufacturer (e.g.,...
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Page 10: Table Of Contents
3 Table of contents Table of conte nts 1 Warning -Prohibition - Mandatory Label Information ....................2 2 Preface ....................................5 Compressor Information..............................6 Intended Use................................6 Maintenance and Care ..............................6 Notes ....................................6 3 Table of contents .................................8 4 Safety regulations ................................10 General safety regulations ............................10 Particular dangers associated with compressed air ....................11 Particular dangers associated with machines......................13 Particular dangers associated with water-cooled units ...................13... - Page 11 3 Table of contents 10 Service and maintenance..............................35 10.1 Maintenance recommendations ..........................35 10.2 Maintenance electric motor.............................35 10.3 Maintenance and inspection schedule ........................35 10.4 Change of air intake filter ............................38 10.5 Change water filter ..............................38 10.6 Replace prefilter RO unit ............................39 10.7 Change the RO membrane cartridge ........................40 10.8...
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Page 12: Safety Regulations
4 Safety regulations Safety re gulations General safety regulations Danger Safety measure required Working with compressors involves Everyone working with the machine must have first read and understood the dangers that are not immediately operating manual. Don’t leave this until you start work – it’s too late. apparent. -
Page 13: Particular Dangers Associated With Compressed Air
4. Safety regulations 4.2 Particular dangers associated with compressed air Danger Safety measure required Compressed air is very powerful. It can Never play about with compressed air. be used for example to break open concrete but can also put lives at risk. Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution compressed air can penetrate the skin... - Page 14 4 Safety regulations Danger Safety measure required Compression results in high The system should be set up such that hazardous mixtures (inflammable solvent vapors etc. but also dusts and other dangerous or toxic materials) temperatures. cannot be drawn in. The same applies to flying sparks. Never use the machine in environments where the possibility cannot be ruled out that inflammable or toxic vapors may be taken in.
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Page 15: Particular Dangers Associated With Machines
4. Safety regulations 4.3 Particular dangers associated with machines Danger Safety measure required Risk of electric shock. Electrical connections must meet the local regulations. Power units must be connected to earth and protected from short-circuits by means of fuses. Insufficient power quality could have Always check a correct power supply to the compressor before commissioning. -
Page 16: Dangers Present When Loading/Moving Machines
4 Safety regulations 4.5 Dangers present when loading/moving machines Danger Safety measure required Loose parts may fall off when lifting. All loose parts must first be removed or secured; parts fitted so that they can turn like doors etc. must be secured and made immobile. Parts to be removed for transport purposes must be carefully refitted and fixed again before putting the machine / installation back into operation. -
Page 17: Dangers Resulting From Neglecting To Perform Maintenance
Contact your Gardner Denver agent. removed. If you maintain the compressor and have not been trained by Gardner Denver, you will put yourself and others at risk. Incorrectly configured spare parts may Spare parts must meet the technical requirements laid down by the jeopardize safety, e.g., tear when... - Page 18 4 Safety regulations Danger Safety measure required Risk of electric shock. Work on the electrical systems of the machine / installation may only be carried out by a trained electrician in accordance with electrical regulations. The system must be secured from being switched on. Seal off the main switch and remove the key and/or attach a warning sign to the main switch.
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Page 19: Dangers Resulting From Conversion Work/Modifications On The Machine
4. Safety regulations 4.9 Dangers resulting from conversion work/modifications on the machine Danger Safety measure required Genuine parts are designed especially No alterations, additions, or modifications to the machine may be carried out for the machine. Modifications may without the approval of the manufacturer. Unauthorized modifications to the interfere with safety equipment or give machine are prohibited for reasons of safety. -
Page 20: Design And Functioning
5 Design and functioning Design a nd functioning Design of the unit Fig. 2 1 Intake filter 10 Water connection 19 Opening for lifting gear 2 Suction inlet 11 Cooling air ventilator 20 Water cooler 3 Electric motor 12 Cooling air inlet filter mat 22 Water level indicator 4 Screw compressor 13 Compressed air outlet... -
Page 21: Schematic Diagram
5. Design and functioning Schematic diagram Fig. 3 1. Intake filter 15. Blow-off valve 27. 2/2-directional solenoid valve 2. Intake controller 16. Pressure holding valve (water stop Y6) 3. Electric motor (residual pressure) 28. 2/2-directional solenoid valve 4. Compressor block 17. -
Page 22: Water Circuit
5. Design and functioning The water supply of the screw compressor (- 4 -) is • Water circuit provided by the drop in pressure between the pressure tank (-6-) and the injection site in the The water flows from the pressure tank (-6- Fig. 3) screw compressor. - Page 23 5 Design and functioning This way, no more compressed air will be supplied • to the mains. If the mains pressure does not drop to the target • value within the programmed follow-up time, then the system will shut down. If the target value is achieved before the expiration •...
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Page 24: Transport And Installation
6. Transport and installation Trans port and installation Transport DANGER The compressor or parts of it may fall if mistakes are made when lifting, and this will put your life at risk. Safety devices my be damaged if lifted incorrectliy. •... -
Page 25: Installation
6 Transport and installation The screw compressor unit has to be levelled. The Installation system may not be run while on the transport pallet. DANGER A minimum distance from walls, other machines, etc. should be maintained so that there is sufficient Always observe the safety notes in Section clearance for maintenance and repair work (Fig. -
Page 26: Preparations For Commissioning
(over 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 35.6 °F to 104 °F. In the case of temperatures other than the above limiting values, please consult your technical adviser. -
Page 27: Compressed-Air Connection
7 Preparations for commissioning Compressed-air connection WARNING A defective connection to the compressed- air system may jeopardize safe operation of the compressed-air system. When connecting the compressor outlet to the customer’s existing compressed-air system, check that the necessary operating temperatures, operating pressures as well as the necessary connecting flange or connecting thread are appropriate and in perfect working order. -
Page 28: Electrical Connection (Usa/Canada Version Only)
7. Preparations for commissioning To establish an electrical connection, proceed as Electrical connection follows: (USA/CANADA Version only) Route the supply cable through the cable gland (-1- Fig. 10) on the control cabinet and tighten screws. DANGER Connect the supply line to the connecting terminals as Risk of strong damages and fire on the shown in the circuit diagram. -
Page 29: Check Setting Of The Fan Motor Protection Switch
7 Preparations for commissioning 7.3.1 Check setting of the fan motor protection switch Check the setting of the motor protection switch in accordance with the enclosed circuit diagram for the compressor. Set the protection switch to the value stated in the table corresponding to the mains voltage and frequency (see circuit diagram). -
Page 30: Water Supply
Fill with water up to the fill level marking "Above" • Ammonium (NH4+) < 0.3 mg / L (-5- Fig. 12). The Gardner Denver water analysis set can be used to Close manual valve – water in. Start system and • determine the water quality. monitor the water level. -
Page 31: Demineralisation Unit
7 Preparations for commissioning Fill water up to the fill level marking "Above" (-5- Fig. • Demineralisation unit 12). This process may take up to 90 minutes. The following points are to be considered when using Close manually operated valve – water on (-1- Fig. 12); •... -
Page 32: Sound Pressure Level
7. Preparations for commissioning Sound pressure level Sound pressure levels are measured in dB(A) according to PN8NTC 2.2 under a 70% load at an 11-yard distance (tolerance: ± 3 dB(A)): air-cooled unit: 70 dB(A) Subject to technical revision. -
Page 33: Commissioning
8 Commissioning Commiss ioning After the power supply was switched on, all LEDs • First commissioning on the compressor control GD Pilot TS light up for a display test. The fault shown on the display [power DANGER supply fault] must be acknowledged in the fault memory menu item prior to starting the unit. -
Page 34: Routine Commissioning
8. Commissioning Display of the compressor control GD Pilot TS Routine commissioning WARNING Rotating parts inside the unit may lead to injuries, e.g., cutting of finger or hand. • Before commissioning make sure that no one is located in the danger zone of the motor/screw compressor! •... -
Page 35: Commissioning After Malfunction
8 Commissioning Commissioning after malfunction NOTICE Do not switch the screw compressor on repeatedly without having rectified the malfunction, since this may cause considerable damage to the machine. Re-start after an automatic shutdown due to a malfunction as follows: Faults are shown as text in the compressor control •... -
Page 36: Storage Of Compressors
9. Storage of compressors Stora ge of com press ors Decommissioning All compressors are protected against corrosion at the factory for transport and for brief storage before commissioning. If the compressors are to be stored for period exceeding six months, additional precautions must be taken. -
Page 37: Service And Maintenance
You can also have this maintenance work components. The power capacitors need performed by our trained technicians. Please this time to discharge. ask your Gardner Denver distributor for a maintenance contract. WARNING Some parts of the system will still be pressurized after the system has been 10.2 Maintenance electric motor... - Page 38 For your own benefit, put a cross on the servicing schedule against maintenance work when performed. We recommend that you have the work on these parts be performed by a Gardner Denver company or by an authorised dealer.
- Page 39 10 Service and maintenance ...
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Page 40: Change Of Air Intake Filter
10. Service and maintenance Changing intervals for air filter cartridge 10.4 Change of air intake filter The operating conditions (e.g., coolant temperatures), DANGER the operating modes and the quality of the intake air (e.g., content of dust, content of gaseous foreign Only perform checks and carry out work on substances such as SO and solvent vapors, etc.) have... -
Page 41: Replace Prefilter Ro Unit
10 Service and maintenance Let cooling water drain off via the extraction site • Perform the prefilter change as follows: (-2- Fig. 17) and drain screw on the water filter Turn off compressor, secure it from being switched • housing (-1- Fig. 17). on again, and make sure that it is depressurized Open filter housing and remove filter elements. -
Page 42: Change The Ro Membrane Cartridge
10. Service and maintenance 10.7 Change the RO membrane cartridge DANGER WARNING A defective pressure relief valve may result in pressure that is too high, breaking open Air/water under pressure may cause severe parts of the system and causing serious or personal injury. -
Page 43: Connecting Terminals In The Switch Cabinet/Control Transformer Setting
10 Service and maintenance 10.9 Connecting terminals in the switch cabinet/control transformer setting DANGER High voltage – Hazard of shock, burns, or death • Only qualified electricians may work on the control cabinet. • Only perform checks and carry out work on the screw compressor when the unit is out of operation, depressurized, and secured from being switched on again! -
Page 44: Screw Connections
10. Service and maintenance 10.10 Screw connections 10.12 Clean / change filter with cooling air inlet and control cabinet inlet The screw connections of the air and water circuits have to be checked and, if required, re-tightened DANGER according to the maintenance schedule. Only perform checks and carry out work on Check the hose and piping for unsealed areas. -
Page 45: Inspection Of The Compressor Stage
10 Service and maintenance b) Control-cabinet inlet filter (-4- Fig. 21) 10.13 Inspection of the compressor stage DANGER Only perform checks and carry out work on the screw compressor when the unit is out of operation, depressurized, and secured from being switched on again! CAUTION Caution when draining hot water: risk of scalding! -
Page 46: Inspection Intervals For Pressure Reservoir And Electrical Installations
10. Service and maintenance Attach the side cover with a new seal. Insert the • screws to a torque of 18.5 lbf ft. Check the water level on the water level indicator • (-6- Fig. 12) and add water if necessary (see Chapter 7.4 Water supply). -
Page 47: Trouble-Shooting
11 Trouble-shooting Trouble-s hooting In the case of faults or warnings that are detected by the compressor control GD Pilot TS, please refer to the chapter “Fault/warning table” in the operating instructions of the GD Pilot TS. Malfunction Possible cause Remedy Unit cannot be started No operating or control voltage... - Page 48 11. 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 lines Measure power requirement, if too small necessary, replace lines...
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Page 49: Annex
12 Annex Annex 12.1 Technical specifications EnviroAire VS 15 EnviroAire VS 22 Maximum operating pressure psig Minimum operating pressure psig Ambient temperature min./max. °F 36 to 113 36 to 104 min. 11.1 15.4 27.2 max. 77.9 64.5 117.9 103.6 Discharge temp. of air above ambient temp. °F Free field noise level dB(A) -
Page 50: Layout Plan
12. Annex 12.2 Layout plan (all dimensions in Inches) Fig. 27 Water inlet inner thread G 3/8” (3/8” NPT) Water outlet inner thread G 3/8” (3/8” NPT) Drain water separator inner thread G 1/4” (1/4” NPT) (not available) Drain RO unit inner thread G 1/4” (1/4” NPT) Compressed air connection: external threaded connector R 1”... - Page 51 12 Annex (all dimensions in Inches) Fig. 28 Water inlet inner thread G 3/8” (3/8” NPT) Water outlet inner thread G 3/8” (3/8” NPT) Drain water separator inner thread G 1/4” (1/4” NPT) (not available) Drain RO unit inner thread G 1/4” (1/4” NPT) Compressed air connection: external threaded connector R 1”...
- Page 52 12. Annex (all dimensions in Inches) Fig. 29...
- Page 56 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...