Gardner Denver Reavell 5236 Operating & Maintenance Manual
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Gardner Denver Reavell 5236 Operating & Maintenance Manual

Gardner Denver Reavell 5236 Operating & Maintenance Manual

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INDUSTRIALS GROUP
Operating & Maintenance Manual
5236 Compressor M-V-A-M
Sales Order No. 4072412
Publication No. 98407.5877
v2.0 En
www.gdhighpressure.com

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Summary of Contents for Gardner Denver Reavell 5236

  • Page 1 INDUSTRIALS GROUP Operating & Maintenance Manual 5236 Compressor M-V-A-M Sales Order No. 4072412 Publication No. 98407.5877 v2.0 En www.gdhighpressure.com...
  • Page 3 AMENDMENTS ISSUE DESCRIPTION DATE SECTION 09/10/2019 ALL UPDATE GA-VERSION B 15/04/2020 3...
  • Page 5 TABLE OF CONTENTS Section 1 General Section 2 Compressor Section 3 Drawings Section 4 Motor Section 5 Control Panel Section 6 Equipment Data Sheet...
  • Page 7 Section 1 General Information...
  • Page 9 General Safety Information WARNING The use of replacement parts or lubricating oils not supplied, recommended or approved by Gardner Denver, or the failure to maintain this equipment accordance with maintenance instructions, may invalidate the WARRANTY, cause equipment failure, create unsafe or hazardous conditions or result in damage to the equipment.

  • Page 10: Table Of Contents

    MAINTENANCE WARNING ......................2 STANDARDS, TESTING AND DOCUMENTATION ..............2 OWNERSHIP DATA ........................3 TECHNICAL DATA ......................3 GARDNER DENVER CONTACT DETAILS ................. 3 WARNINGS, CAUTIONS & NOTES ................... 4 HEALTH AND SAFETY PRECAUTIONS ..................5 GENERAL PRECAUTIONS ....................5 INSTALLATION PRECAUTIONS ..................

  • Page 11: Disclaimer

    2 FOREWORD The standard build of all Gardner Denver products are not intended for use in either Explosive or Potentially Explosive Atmospheres as defined in Directive 2014/68/EU. An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases, vapours, hazes or dusts in which, after ignition has occurred, combination propagates to the entire unburned mixture and may cause a hazard.

  • Page 12: Warranty

    Warranty. Similarly, the Warranty does not cover running adjustments. Gardner Denver are well known in the market place for the design, manufacture and supply of high- quality air compressor equipment. These compressors are constructed from the highest quality materials and are designed and built according to the latest manufacturing techniques.

  • Page 13: Ownership Data

    6 OWNERSHIP DATA 6.1 TECHNICAL DATA It is recommended that details taken from the compressor nameplates are recorded below. 6.2 GARDNER DENVER CONTACT DETAILS Address Gardner Denver Ltd Claybrook Drive Redditch Worcestershire B98 0DS Telephone +44 (0) 1527 838600 +44 (0) 1527 838630 Email highpressure@gardnerdenver.com...

  • Page 14: Warnings, Cautions & Notes

    7 WARNINGS, CAUTIONS & NOTES The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred to in Machinery Directive 2006/42/EC. Warnings call for attention to operating procedures involving specific hazards which could cause injury or death and are identified by the following RISK OF DANGER RISK OF HIGH PRESSURE RISK OF GAS EXHAUST...

  • Page 15: Health And Safety Precautions

    Gardner Denver, then they must ensure that the unit will not be damaged or made unsafe and that there is no risk to persons or property.

  • Page 16: Installation Precautions

    They must be suitably sized for the pressure and flowrate of the gas involved. For specific details, contact Gardner Denver. To minimse the risk of Legionnaires Disease, Gardner Denver advise caution with the use of cooling towers for water cooling the compressor. Potable water should be used, and treated where necessary to prevent harmful bacteria from entering the compressed air.

  • Page 17: Operational Precautions

    Beware of burns from hot oil and water (if applicable) when working on a unit recently shut-down. Use only lubricating oils and greases approved by Gardner Denver to avoid potential hazards especially the risk of explosion or fire and the possibility of decomposition or generation of hazardous gases.

  • Page 18: Maintenance & Repair Precautions

    8.4 MAINTENANCE & REPAIR PRECAUTIONS Maintenance, repair and modifications must only be carried out by competent persons under a “PERMIT TO WORK” system.. Pressure gauges, temperature switches and other protection devices should be checked at least every 12 months and thoroughly examined at least every 48 months. They must be renewed or service exchanged if acceptable tolerances are exceeded or if they are not functioning correctly.

  • Page 19: Purging Instructions For Gas Installations

    It is assumed that the compressor is situated in a well ventilated area with suitable gas leakage detection equipment to minimise possible risks. Due to the unknown nature of the plant processes involved, Gardner Denver cannot be held responsible for any heath risk arising from leakage of gas into the atmosphere.

  • Page 20: Disposal Of Condensate And Used Parts

    10 DISPOSAL OF CONDENSATE AND USED PARTS Whilst recyclable materials are used as far as possible, please ensure when disposing of condensate, spent oil, used filter elements and any discarded parts or waste material of any kind make sure that there is no pollution to any natural water-course, drain system and that no burning of waste takes place which could cause pollution of the atmosphere.
  • Page 21 Section 2 Compressor...
  • Page 23 INSTALLATION, OPERATION & MAINTENANCE MANUAL C5236.MK2 WATER-COOLED COMPRESSOR C5236.MK2 COMPRESSOR V14.0, En...
  • Page 24 2) Technical Support Service Gardner Denver Technical Support covers the whole of the United Kingdom and provides its customers with one simple port of call for product support, for all brands and all models. Please note currently Gardner Denver technical support system is only for English speakers.
  • Page 25 Spare Kits Running 1000 2000 3000 4000 Hours* Kit Number HSK1503 HSK6556 HSK6564 HSK6556 HSK6572 *The above service schedule repeats after the final service listed. Recommended oil Oil Type GD Oil Brand Working Temperature Synthetic oil SYNTECK S + 5 to 45°C Synthetic oil SYNTECK W - 5 to -10°C...
  • Page 26 TABLE OF CONTENTS C5236.MK2 COMPRESSOR WATER-COOLED OPERATING & MAINTENANCE MANUAL CONFIGURATION ....................... 1 LUBRICATION ........................1 LUBRICATION SCHEMATIC FLOW DIAGRAM ..............1 COOLING ..........................2 DRIVE ..........................2 RUNNING GEAR ......................... 2 VALVES ..........................2 CONDENSATE DRAINAGE SYSTEM................. 2 SUCTION UNLOADING ....................... 3 1.10 AUTOMATIC STOP/START CONTROL ................
  • Page 27 STANDING IDLE ........................18 GENERAL ...........................19 DAILY ..........................19 WEEKLY ..........................19 AFTER THE FIRST 100 HOURS RUNNING TIME ON MINERAL OIL......19 CHANGING OVER FROM MINERAL TO SYNTHETIC LUBRICANT........19 SERVICE PLAN ........................20 GENERAL ...........................25 CLEANING AND INSPECTION – ALL STAGES ..............25 FIRST STAGE VALVES – WITH SUCTION UNLOADERS ..........26 REMOVAL ........................26 DISMANTLING ......................26 REASSEMBLY ......................26...
  • Page 28 4.11 ADDED, 13.13 ALTERNATIVE WATER VALVE ADDED STANDARD WIRING TERMINAL NUMBERS ADDED MAR 2012 UPDATE TO GARDNER DENVER VERSION NOV 2014 ADD FRONT PAGE, REVIEW CONENT, REMOVE APR 2015 SAFTEY SECTION AND ACCILIARY PARTS SECTION UPDATE PISTION DIAMETER AT 2.10 AUG 2015 2.10...

  • Page 29: Configuration

    Recommendations are the result of extensive research at Gardner Denver Works and all responsibility for the use of an oil other than that recommended is placed on the purchaser and his oil company.

  • Page 30: Cooling

    1.4 COOLING Cooling is by water flowing through the jackets and passages, either from the mains or a closed circuit system using a radiator or cooling tower. A bursting disc is fitted to prevent excessive pressure build up in the water spaces if a leak should occur from the coolers. Electrolytic corrosion of the cooler tubes and fittings is prevented by the provision of a sacrificial anode (corrosion rod) in the water jacket which will be chemically attacked before the machine components.

  • Page 31: Suction Unloading

    This system comprises a pilot unloader valve, (PUV), and two diaphragm drain valves, (DDV's). The PUV comprises a three way air valve operated by a solenoid in one direction and a combination of air and spring pressure in the opposite direction and is automatically actuated by a signal from the motor starter or a electronic timer.

  • Page 32: Automatic Stop/Start Control

    WARNING! SUCTION UNLOADERS MUST ONLT BE USED BY HAND TO SUPPLIMENT AUTOMATIC DDV SYSTEM AND RELEASED IMMEDIATELY THE DDV'S ARE ACTIVATED TO LOAD COMPRESSOR. FAILURE TO OBSERVE THIS PROCEDURE CAN LEAD TO UNACCEPTABLE HIGH SECOND STAGE TEMPERATURES. 1.10 AUTOMATIC STOP/START CONTROL On initial starting the compressor is unloaded by the diaphragm drain valves and first stage suction unloaders.

  • Page 33: Unit Designation

    2 LEADING PARTICULARS 2.1 UNIT DESIGNATION Model ........................C5236 Mk2 For Air compressors: This compressor is designed for use compressing Air. This compressor is NOT designed to compress any other gases. 2.2 TECHNICAL DATA – GENERAL Type ................Four cylinder, 2 stage, vee configuration Cooling ..........................

  • Page 34: Connections

    2.9 CONNECTIONS Suction connection .......................Rp3 Final stage delivery connection ....................Rp1 Water inlet and outlet connections ................... Rp1 2.10 RUNNING CLEARANCES Description Stage As Fitted (mm) Max Permissible (mm) Piston vertical clearance 0.5/1.2 0.25/1.35 1.35 Piston ring gaps 0.2/0.45 1.43 0.07/0.1 Piston ring axial width 0.05/0.1 0.15...

  • Page 35: Torque Wrench Settings

    2.11 TORQUE WRENCH SETTINGS CLASS A – CRITICAL (All figures ± 5%) NEWTON ASSEMBLY OPERATION SIZE METRE Big End Bearing Bolts First, Second Stage Cylinders to Crankcase First Stage Cooler Cover – Floating End First Stage Cooler Cover – Fixed End Second Stage Cooler Cover –...
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  • Page 37: Handling Of Unit

    3 INSTALLATION 3.1 HANDLING OF UNIT When using the compressor and motor eyebolts as the slinging attachment, it is essential that a spreader is used. The lift should always be made vertical, as inclined loadings drastically reduce the eyebolts' strength. Suitable shackles should be used for this operation. 3.2 LOCATION Compressor should be installed in a cool, level, well ventilated position, clear of fumes, heat or high humidity, to ensure efficient performance and also to prevent temperature problems.

  • Page 38: Mounting

    Maximum allowable ambient cooling air temperature for radiator cooled sets is dependant on many variables eg, pressure, speed and type of oil. Contact Gardner Denver Works to ascertain allowable temperature for operating conditions. 3.3 MOUNTING Under normal circumstances a special foundation is unnecessary but verification must be obtained that the support floor is structurally adequate as well as flat and level.

  • Page 39: Electrical Connections

    Prevent overcooling by shutting off flow when compressor is not running (mains). A Gardner Denver Ltd automatic water valve can be fitted to control water supply when stopping or starting the compressor (mains). If one has been ordered, details will be found in section 10.
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  • Page 41 4 COMMISSIONING OR RECOMMISSIONING WARNING! BEFORE OPERATING THIS EQUIPMENT USERS SHOULD BE MADE AWARE OF AND ENSURE COMPLIANCE WITH THE HEALTH AND SAFETY REGULATIONS APPROPRIATE TO THIS CLASS OF WORK. ATTENTION OF U.K. USERS IS DRAWN TO THE HEALTH AND SAFETY AT WORK ACT, 1974. &...

  • Page 42: Before Starting

    4.1 BEFORE STARTING Ensure familiarity with safety devices and type of control. Ensure suction filter is in good condition and filter element is fitted. Make sure that any protective blank fitted to the first stage suction is removed. Check that silencer bore (if fitted) and any suction pipework is clean before reassembling.
  • Page 43 Close drain valves and/or replace plugs. Restart the compressor, unscrew the first stage suction unloaders and bring slowly onto load. Build up to full pressure within 1 hour. If appropriate, set the compressor for automatic operation. Check and adjust the control equipment settings, if applicable (for example, pressure switch). Continue to check that machine is functioning correctly and not over-heating.
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  • Page 45: Operation And General Maintenance

    5.3 RUNNING ON LOAD Set automatic timer (when fitted) to vent diaphragm drain valves every 30 minutes for 5 seconds duration, or more frequently if high humidity prevails. Contact Gardner Denver Ltd for more details. Monitor gauges for normal pressures and temperatures.

  • Page 46: Stopping

    After one week standing idle, turn the machine over by hand before starting to ensure it turns freely. If the compressor is to stand idle for more than four weeks or shorter period if ambient conditions are unfavourable, it is advised to consult Gardner Denver Ltd for correct inhibition procedure. P a g e...

  • Page 47: General

    6 MAINTENANCE SCHEDULE WARNING! 1. BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED AND ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES DISPLAYED. 2. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE SUPPLY AND STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF.

  • Page 48: Service Plan

    SERVICE PLAN Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided Change air intake Suction filter element (air element compressor only) Inspect Belt Tension Inspect Drive Coupling Inspect corrosion rods Replace corrosion rods Corrosion rod assy Remove crankcase Door joints...
  • Page 49 Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided Replace 2nd stage big Bearing Shells end bearings Pairs Big end bolts Remove 1st stage Cover O ring valve covers Service 1st stage Valve kit valves Replace 1st stage...
  • Page 50 Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided Oil pump with Replace oil pump coupling & gasket Replace water pump chain FITT drive chain Service water pump seal & impellor kit FITT Joint-water pump bracket...
  • Page 51 Service Kit Number Service Plan - 5236 12 Months From Installation/Last Service Or Task Description Parts Provided 1st stage 2nd stage Surge vessel Test pressure gauges 1st stage 2nd stage Test temperature 1st stage switches Final stage Test low oil pressure L.O.P switch Test non return valve...
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  • Page 53: General

    7 DISMANTLING AND REASSEMBLY OF VALVES 7.1 GENERAL Keep a spare oiled and maintained set of valves in store for quick compressor servicing. Valves should have a thin carbon layer and be slightly moist with oil. Valve removal is a simple procedure but the following guidelines should be observed. 7.2 CLEANING AND INSPECTION –...

  • Page 54: First Stage Valves - With Suction Unloaders

    7.3 FIRST STAGE VALVES – WITH SUCTION UNLOADERS REMOVAL Remove the first stage suction unloader pipework and the nuts securing each of the two valve covers and withdraw the covers from the locating studs using forcing screws in the tapped holes provided in each cover.
  • Page 55 Automatic unloader 1st STAGE CONCENTRIC VALVE 98650.1520 Lower Valve Body Delivery plate Delivery plate springs Suction plate springs Middle lift washer Suction Valve Plate Lower lift washer Location pegs Location pegs 'O' ring Unloader Cap Unloader Fork Unloader Spring Upper Body Washer 1st STAGE CONCENTRIC VALVE Note: Valve is shown inverted for ease of assembly...

  • Page 56: First Stage Valves - Without Suction Unloaders

    7.4 FIRST STAGE VALVES – WITHOUT SUCTION UNLOADERS REMOVAL Remove the nuts securing each of the two valve covers from the locating studs using forcing screws in the tapped holes provided in each cover. Screw valve lifters to each valve and lift from the cylinders. A gentle rocking action pulling at the same time will help to free the valve if necessary.

  • Page 57: Second Stage Valves

    7.5 SECOND STAGE VALVES REMOVAL As 7.3 A. i) except for removal of suction unloader pipework. DISMANTLING Remove and discard 'O' ring (7). Unscrew and remove nut (8) whilst holding the valve in a soft jawed vice with just sufficient force to prevent it from turning. The valve can then be removed from the vice and the upper valve body half (9) can be lifted clear of the stud.
  • Page 58 2nd STAGE CONCENTRIC VALVE 98650.1039 Lower Body Delivery Valve/Backing Plates Delivery Spring Plates Suction Valve Plates Suction Plate Springs 'O' ring Upper Valve Body 2nd STAGE CONCENTRIC VALVE Note: Valve is shown inverted for ease assembly P a g e | 30...
  • Page 59 8 FAULT GUIDE WARNING! 1. BEFORE PROCEEDING WITH MAINTENANCE ON THE COMPRESSOR IT MUST BE STOPPED AND ISOLATED ELECTRICALLY AND MECHANICALLY AND VISIBLE WARNING NOTICES DISPLAYED. 2. IN ADDITION ALL INTERNAL PRESSURE MUST BE RELEASED WITH THE UNIT ISOLATED FROM THE SUPPLY AND STORAGE RESERVOIR AND THE WATER SUPPLY SHUT OFF.
  • Page 60 FAULT PROBABLE CAUSE RECOMMENDATION(S) Intake filter element dirty or blocked Remove, clean and renew element. LOW FIRST STAGE First stage suction/delivery valve Remove and service valves. PRESSURE fault. Gas leakage from compressor Renew parts, joints and seals as necessary. system. Unloader/drain valves not closing.
  • Page 61 FAULT PROBABLE CAUSE RECOMMENDATION(S) Star/Delta timer. Full speed should be obtained by star before switching to delta. Extend timer period to suit. Low oil pressure switch operating. Consult fault symptom 'LOW OIL PRESSURE' or reset star/delta timer. Loose components. Trace and rectify. UNUSUAL NOISE (ON Gas leaks (usually hissing or Trace, stop compressor, depressurise, renew...
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  • Page 63 9 DRAWINGS The following drawings contain all items used in the construction of the compressor. Number Drawing Ref Description C5236.MK2 5236 MK2 AIR COMPRESSOR C204482 PIPE ASSY-WATER TRANSFER D100973.4 2ND STG SUCTION PIPE ASSY D100973.5 PIPE ASSY-WATER TRANSFER D101719 1ST STG RUNNING GERA D101849 OIL PUMP ASSY-NOT WATER PUMP VERSION D102229...
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  • Page 65 10 APPENDIX 5236.MK2 COMPRESSOR P a g e | 37 V14.0, En...
  • Page 66 LOGSHEET...
  • Page 68 Customer Order No: Maximum Cost Approved: This form is to be completed & emailed to Gardner Denver Central Quality Department. Email: quality.redditch@gardnerdenver.com. All parts to be returned to Gardner Denver unless otherwise instructed. Should failed parts not be returned within 60 days of the date of the claim, Gardner Denver shall reserve the right to charge for the parts replaced.
  • Page 69 Precise details of work done: (Including time taken) (If details are incomplete, replacements parts could be delayed and the claim rejected) For Gardner Denver Internal use only. Warranty claim code, original cause of warranty claim: Warranty Claim Code: Failures of GD product where reasons cannot be allocated to others.
  • Page 70 STANDARD TERMINAL WIRING NUMBERS WHEN THE MOTOR AND / OR STANDARD COMPRESSOR CONTROL DEVICES HAVE BEEN PRE-WIRED INTO LOCAL MARSHALLING BOXES OR DIRECTLY INTO A STARTER / CONTROL PANEL, THE FOLLOWING TERMINAL NUMBERS ARE USED. ALL OTHER TERMINALS ARE AS SPECIFIC CONTRACT DRAWINGS STANDARD TERMINAL IDENTIFICATION FOR SET WIRING TERMINAL TERMINAL...
  • Page 72 Perfect With Pressure Compact, maintainable, and designed for integration. Perfect your start with Reavell Single Source Solutions For more than 155 years, Gardner Denver has been a Compact Footprint leading global provider of compressors, blowers and • Best in class footprint and weight per vacuum pumps.
  • Page 73 Section 3 Drawings...
  • Page 75 THIS DRAWING IS THE COPYRIGHT MANUFACTURING TOLERANCES TO BE AS FOLLOWS UNLESS OTHERWISE STATED SCALE T.Chaplin 09/04/2020 THIRD ANGLE APPROVED WASHFORD INDUSTRIAL ESTATE PROPERTY OF GARDNER DENVER Ltd. MACHINED ` 0.3 ANGULAR ` 0.5 ~ (A0 PLOT) REDDITCH PROJECTION AND MUST NOT BE COMMUNICATED SHT No.
  • Page 76 Reference Drawings General Arrangement A42506 Single Line Diagram D74711 Connection Details Description Terminal Point Connection Compressor Inlet Filter/Silencer Final Delivery Outlet 1" NPT (F) Water In " BSP.P hose adptor to suit 32mm bore hose Water Out " BSP.P hose adptor to suit 32mm bore hose Condensate Outlet "...
  • Page 79 Section 4 Motor...
  • Page 81 Motors | Automation | Energy | Transmission & Distribution | Coatings Low and high voltage electric motors Instructions manual for installation, operation and maintenance of electric motors...
  • Page 82 ENGLISH TABLE OF CONTENTS 1. FOREWORD ......................... 3 2. SHIPMENT, STORAGE AND HANDLING ..............3 3. INSTALLATION......................4 4. OPERATION........................5 5. MAINTENANCE ......................5 6. ADDITIONAL INFORMATION ..................5 7. EC DECLARATION OF CONFORMITY ............... 5 8. WARRANTY TERM ...................... 6 1.

  • Page 83: Installation

    Periodically and mainly before the initial star-up, measure the insulation resistance of the motor winding. Check the recommended values and the measuring procedures in the website. 3. INSTALLATION During the installation, the motors must be protected against accidental energization. Check the motor direction of rotation, turning it without load before it is coupled to the load.

  • Page 84: Operation

    the power supply and investigate the cause of the thermal protector tripping. Wmagnet motors must be driven by WEG variable frequency drives only. For more information about the use of variable frequency drives, follow the instructions in the motor manual on the website www.weg.net and in the manual of the variable frequency drive.

  • Page 85: Warranty Term

    WEGeuro – Industria Electrica SA Rua Eng Frederico Ulrich, Apartado 6074 4476-908 – Maia – Porto – Portugal hereby declare that the products: WEG induction motors and components for using in these motors: Three-phase IEC frames 63 to 630 Nema frames 42, 48, 56 and 143 to 9610 ……………...
  • Page 87 Section 5 Starter Control...
  • Page 89 Cable Colours. AC Power Circuits. Black. AC Control Circuits. Red. Interlock Control Circuits Supplied. Orange. Protective Conductor. Green/Yellow. Cable Spec & Sizes. Cable LSF. All Power Cable 2.5mm² UNLESS STATED. All Control Cable 0.75mm ² UNLESS STATED. AUTOMATED POWER & DISTRIBUTION ELECTRICAL MANUFACTURER &...
  • Page 90 LK1 - REMOVE LINK IF REQUIRED LK2 - REMOVE LINK IF REQUIRED AUTOMATED POWER & DISTRIBUTION ELECTRICAL MANUFACTURER & SUPPLIER 12A WILLIE SNAITH ROAD NEWMARKET, SUFFOLK, CB8 7SU TEL +44 (0) 1638 669399 FAX +44 (0) 1638 669926 www.apd.ltd.uk email sales@apd.ltd.uk...
  • Page 91 AUTOMATED POWER & DISTRIBUTION ELECTRICAL MANUFACTURER & SUPPLIER 12A WILLIE SNAITH ROAD NEWMARKET, SUFFOLK, CB8 7SU TEL +44 (0) 1638 669399 FAX +44 (0) 1638 669926 www.apd.ltd.uk email sales@apd.ltd.uk...
  • Page 92 AUTOMATED POWER & DISTRIBUTION ELECTRICAL MANUFACTURER & SUPPLIER 12A WILLIE SNAITH ROAD NEWMARKET, SUFFOLK, CB8 7SU TEL +44 (0) 1638 669399 FAX +44 (0) 1638 669926 www.apd.ltd.uk email sales@apd.ltd.uk...
  • Page 93 AUTOMATED POWER & DISTRIBUTION ELECTRICAL MANUFACTURER & SUPPLIER 12A WILLIE SNAITH ROAD NEWMARKET, SUFFOLK, CB8 7SU TEL +44 (0) 1638 669399 FAX +44 (0) 1638 669926 www.apd.ltd.uk email sales@apd.ltd.uk...
  • Page 94 K12T K13T K14T K10A K11T ESR1 POWER ON LOW OIL 1ST STAGE FINAL MOTOR COMPRESSOR PRESSURE HIGH TEMP DELIVERY OVERLOAD HIGH TEMP STOP START RESET I ON Enclosure ST6.825 - 600W x 800H x 250mmD AUTOMATED POWER & DISTRIBUTION ELECTRICAL MANUFACTURER & SUPPLIER 12A WILLIE SNAITH ROAD NEWMARKET, SUFFOLK, CB8 7SU TEL +44 (0) 1638 669399...
  • Page 95 Section 6 Equipment Data Sheets (APPs)
  • Page 97 5236.4072412 Component number Object description 98418.1015 AV MOUNT 2 YELLOW 1 WHITE SPOT U334.L DIAPHRAGM DRAIN VALVE 98650.1759 PRESSURE MAINTAINING VALVE 0-70 BAR 98524.1042 LOW OIL PRESS SWITCH Blue Dot 98288.1089 TEMP CONT 50-250 deg 1 mtr capillary 98288.1121 TEMP SWITCH (0 to 120 Deg.C) 1 mtr Capil PS2197.4 SOLENOID VALVE (110V,60HZ) 98650.1754...
  • Page 98 AVA TYPE PART NUMBERS VARIOUS PREVENTIVE MAINTENANCE After installation and initial running in. Record height dimension (H) of each mount. After a week or 100 hours running time recheck and record dimension (H) Check this dimension every 3 to 6 months depending on usage i.e. regular usage every 3 months.
  • Page 99 DRIVE RECOMMENDATIONS (V-BELT TRANSMISSION) Details of drive arrangements and non isolation pad mountings are available from Reavell Works, Ipswich. An overload device must always be fitted to motors. Manufacturer’s terminal box wiring instructions must be observed. It is recommended that for efficient maintenance scheduling an hours run meter be incorporated on the diesel engine or fitted to the motor starter.
  • Page 100 BELT DEFLECTION MEASUREMENT Required Deflection Force "P" at Centre of Span For Compressor Speed Ranges (Newtons) Above follows current BS3790 practice. RECOMMENDED TENSIONING FORCE Centre Distance Belt tension indicator applied to mid-span Straight edge ADJUSTMENT METHOD If the belt tension is incorrect, correct it by using the adjusting screws provided, using a suitable straight edge (long enough to span both pulleys) or by use of the second belt, release motor holding down screws enough to allow the adjustment screws to be free to slide the motor on its adjustment slots without it being loose.
  • Page 101 TABLE Force required to deflect belt 16 mm per metre of span Basic setting force New Belt setting force Belt Small Pulley Newton Kilogram Newton Kilogram Section Ø mm force force (kgf) (kgf) 58 to 71 75 to 90 XPZ & QXPZ 95 to 125 Over 125 80 to 100...
  • Page 102 DIAPHRAGM DRAIN VALVES ASSEMBLY INSTRUCTIONS Assemble drain valve seat(s) (3 - 14) to valve body(s) (2) using silicon sealant on joint faces, tighten lock nut (1). Assemble diaphragm (8) and joints (4) to cover (9) and body(s) (2). Assemble complete assembly tighten setscrews (10) nuts (15) finger tight. Tighten setscrews (10) nuts (15) evenly to the correct torque setting of 27Nm.
  • Page 103 PARTS LIST FOR STANDARD SINGLE AND DOUBLE UNITS - U334 J to M Item No Part No Description PS 1290.4 LOCK NUT 2 & 9 C 203190.1 DOUBLE DRAIN VALVE BODY ASSEMBLY 2 & 9 C 203190.2 SINGLE DRAIN VALVE BODY ASSEMBLY C 201159 VALVE SEAT (HP) C 201417...
  • Page 104 PRESSURE MAINTAINING VALVE (BACK PRESSURE REGULATING VALVE) 98650.1759 Maximum Pressure 40 bar Temperature Range - 10 to 100°C Flow Rate 300m³/hr Connections 1" BSPP This valve is fitted to maintain a back pressure through the separators, filters and the dryers (if fitted). This ensures that these items of equipment reach their optimum working pressure as soon as possible, to give long filter life, good oil separation and low oil consumption.
  • Page 105 LOW OIL PRESSURE SWITCH PART NO: 98524.1042, .1122, .1140, .1169, .1170 & .1176 OPERATION Located in the crankcase on water-cooled & large air-cooled compressors, in the oil filter body on air-cooled, the pressure switch stops the compressor when the oil pressure drops to pre-set pressure setting. Part No.
  • Page 106 3. Rotate key to adjust red pointer [D] to 10°c above running temperature pointer [A]. 4. Adjustment of trip pointer must be within range that has been pre-set at Gardner Denver ltd before despatch, but may be adjusted within this range depending on ambient conditions.
  • Page 107 CONTROLLER TRIP POINTER USED ON PART No STOP SETTING °C COMPRESSOR MODEL C202960.3 WATER OUTLET C202960.4 5207,5209,5213 C202960.5 5417N,5436N C202964.1 5280,5281,5282,5283, DELY C202964.2 5450,5470 DELY CONTROLLER TEMPERATURE RANGE USED ON PART No °C COMPRESSOR MODEL 50 – 250 °C,1M 98288.1089 WATER-COOLED 5000 SERIES 0 - 120°C, 1M 98288.1121...
  • Page 108 3 WAY SOLENOID VALVE PS2197 OPERATION 3 way normally closed energise to open, continuous duty. On starting the solenoid valve opens (energised) this operates the diaphragms which in turn closes the valves within the D.D.Vs. (Diaphragm Drain Valves) thus allowing pressure to build up in the system to the desired pressure.
  • Page 109 3 WAY SOLENOID VALVE OPERATION 3 way normally open energise to close, continuous duty. On starting the solenoid valve closes (energised) this stops the air from the receiver to the hand/automatic 1st stage valve unloaders which in turn allows the compressor to come on to load, at the same time another solenoid valve (PS2197) opens to close the diaphragm Drain Valves On shutdown the solenoid valve opens allowing air onto the 1st stage valve unloaders which unloads the compressor at the same time the other solenoid valve (PS2197) closes to unload and...
  • Page 110 The inlet line to the safety valve should have an effective area of flow, at least equal to that of the safety valve inlet. Gardner Denver Limited should be consulted if the safety valve is to be mounted in any position other than vertically.
  • Page 111 FUNCTIONAL TESTING Once installed in service. Valves should be tested at least once every six months to ensure free movement of parts. This should be carried out by operating the easing gear when the valve is under a pressure of not less than 75'% of the set pressure.
  • Page 112 GARDNER DENVER APP457 Technical information Notes on equipment protection per EN/IEC 60529 and NEMA For Bourdon tube or diaphragm pressure gauges WIKA data sheet IN 00.18 General information This technical information describes the measures to prevent both the formation of condensation within a hermetically sealed case, and also the intrusion of water into cases vented to the atmosphere.
  • Page 113 GARDNER DENVER APP457 Degrees of protection against water, defined by the second index number Second Degree of protection index num- Code designation Definition Not protected – Protected against dripping water Perpendicularly falling drops must have no damaging effects Protected against dripping water when the case is Perpendicularly falling drops must have no damaging effects, when inclined to 15°...
  • Page 114 GARDNER DENVER APP457 4. Measures against the formation of condensation Different filling liquids depending on the ambient temperature and the electrical conductivity In order to avoid the formation of condensation in the case, If the ambient temperature drops below -20 °C, then we WIKA recommends filling the instruments with glycerine.
  • Page 115 GARDNER DENVER APP457 Temperature errors in hermetically sealed, filled Bourdon tube pressure gauges Filled to 90 % with glycerine Illustration 5 Temperature in °C Filled to 90 % with silicone oil Temperature in °C Illustration 6 Page 4 of 6...
  • Page 116 GARDNER DENVER APP457 5.2 Temperature error with unfilled and filled diaphragm pressure gauges With model 4, 5 and 7 hermetically sealed diaphragm For instrument models 73x.14, 702.01/02/03, 700.01/02 pressure gauges, the temperature error for scale ranges and 7x2.15, due to their mechanical design, there are no ≥...
  • Page 117 GARDNER DENVER APP457 Plastic diaphragm Illustration 10: Rear wall of case with pressure compen- sation diaphragm for contact gauges, nominal size 160 Blow-out rear wall with pressure compensation Case with solid Window diaphragm Pressure element baffle wall Dial Laminated safety glass...
  • Page 118 Mechatronic GARDNER DENVER APP457 pressure measurement OEM compact pressure switch With settable hysteresis Model PSM02 WIKA data sheet PV 34.82 Applications Hydraulics and mobile hydraulics ■ Pneumatics ■ Plastics injection moulding machines ■ General machine building and plant construction ■...
  • Page 119 GARDNER DENVER APP457 Standard version Switch contacts High-quality snap-action switch, self-cleaning Case Switching function Steel, galvanised Selectable: Normally open, normally closed, change-over contact Reproducibility ±2 % of full scale value Electrical rating Permissible temperature Current Voltage Cur- Ambient: -20 … +80 °C...
  • Page 120 GARDNER DENVER APP457 Options Factory setting of switch point and hysteresis ■ Case and process connection from stainless steel ■ Other process connection ■ Other materials on request ■ Electrical connection M12 x 1 or cable ■ Permissible ambient and medium temperature ■...
  • Page 121 APP704 U231.K Page 1 APP704 PNEUMATIC WATER VALVE FOR U231.K PART NUMBERS: PORT SIZE BODY MATERIAL 98650.2584.1 1” BSP BRONZE 98650.2584.2 1” BSP STAINLESS STEEL 98650.2585.1 ¾” BSP BRONZE 98650.2585.2 ¾” BSP STAINLESS STEEL 98650.2612 1 ½” BSP BRONZE DESCRIPTION A 2-port pneumatically actuated on/off valve for use on water, air, oil and gasses.
  • Page 122 GARDNER DENVER APP850 This manual will be used on these parts below: WIKA reference number: 213.53.63 Gardner Denver Part Number: 98288.1001 98288.1002 98288.1003 98288.1004 98288.1005 98288.1026 98288.1027 98288.1028 98288.1031 98288.1032 98288.1077 98288.1104 98288.1129 98288.1130 98288.1137 98288.1161 98288.1301 98288.1302 98288.1303...
  • Page 123 GARDNER DENVER APP850 Operating Contents 1. Safety 2. Description models 1 and 213 per directive 94/9/EC (ATEX) 4. Commissioning II 2 GD c TX 5. Maintenance and cleaning Appendix 1: Declaration of conformity for models 111.xx, 113.53, 213.40 and 213.53 WIKA Alexander Wiegand SE &...
  • Page 124 GARDNER DENVER APP850 Sealing in the thread to OPEN. (+20 °C): Ingress protection per EN 60529 / IEC 529 Model 111.xx: IP 42 Model 111.xx: -40 ... +60 °C +60 °C Attention! Materials Model 111.11: Steel Model 213.40: Forged brass...
  • Page 125 GARDNER DENVER APP850 Permissible vibration load at the installation site 4. Commissioning 5. Maintenance and cleaning personnel. WARNING! Appendix 1: Declaration of conformity...
  • Page 126 GARDNER DENVER APP851 This manual will be used on these parts below: WIKA reference number: 232.30.63 Gardner Denver Part Number: 98288.1139,98288.1140,98288.1141,98288.1142,98288.1143,98288.1144, 98288.1145,98288.1147, 98288.1150 WIKA reference number: 232.50.63 Gardner Denver Part Number: 98288.1086 WIKA reference number: 233.50.63 Gardner Denver Part Number: 98288.1242 98288.1246...
  • Page 127 GARDNER DENVER APP851 Operating Contents instructions 1. Safety 2. Description Pressure gauge model 2 NS 63 3. Specifications and intended use per directive 94/9/EC (ATEX) 4. Commissioning II 2 GD c TX 5. Maintenance and cleaning Appendix 1: Declaration of conformity for models 23x.50/53.063 and 23x.30.063...
  • Page 128 GARDNER DENVER APP851 Spanner flats the thread CLOSE to OPEN. Temperature effect IP Ingress protection Operating temperature Attention! Temperature class of the ambient Maximum permissible medium temperature (in atmosphere (ignition temperature) the measuring system) Models 232 Models 233 Materials Installation...
  • Page 129 GARDNER DENVER APP851 Permissible vibration load at the installation site 4. Commissioning 5. Maintenance and cleaning personnel. WARNING! Appendix 1: Declaration of conformity...
  • Page 130 THERMOMETER – SLIM LINE DIAL TYPE TECHNICAL DATA Supplier: SM GAUGE COMPANY Gardner Denver Part Number: 98288.1014 Description Thermometer- Slim Line Dial Type REF No. 98288.1014 Range C to +60 To be supplied with brass pocket, pressure tested to 500lb.f./in...
  • Page 131 INSTALLATION & OPERATION MATERIALS. Standard stainless steel bulbs and thermowells are suitable for air, oil, water and other non-corrosive fluids. HVAC Thermometers must be used with their brass or stainless steel thermowell. For corrosive fluids, alternative materials e.g. PTFE and Hastalloy etc. should be specified. Environmental conditions should be taken into account when considering suitable materials for cases, capillary etc.
  • Page 132 OIL FILTER – EFL89 Technical Data Gardner Denver Part Number: 98262.1009 Description Oil Filter REF No. EFL89 Filtration 15/20 Micron Plate Number 1404 Illustration Plate, No. 1404 All dimensions in mm’s except where otherwise stated. Operating and Maintenance Replace every 1000 hours, and when changing compressor oil.
  • Page 134 Perfect With Pressure Compact, maintainable, and designed for integration. Perfect your start with Reavell Single Source Solutions For more than 155 years, Gardner Denver has been a Compact Footprint leading global provider of compressors, blowers and • Best in class footprint and weight per vacuum pumps.

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