Related Manuals for Gardner Denver DRUM XK Series
Summary of Contents for Gardner Denver DRUM XK Series
- Page 1 Installation, Operating & Maintenance Manual (Original Instructions) XK SERIES SCREW COMPRESSOR Models XK12 XK12HD 4990140010 2015...
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Page 2: Table Of Contents
Contents Chapter Page Health & Safety Health & Safety Issues ............3 General Product general description .........4 Drive options ..............4 Available packages ............5 Dimensions, performance data, and operating environment ..........6 Installation General mounting considerations ......7 Lifting ..................7 Mounting ................8 Lubrication................9 PTO and prop. shaft drive alignment ...... 10 Pipe work ................ -
Page 3: Health & Safety
This procedure should be carried out every month to clear the valve seat and check the valve is functional. (Ear protection is recommended) Noise Gardner Denver Drum Ltd’s own tests show maximum noise levels for the XK12 should typically not exceed 94 dB(A) in the worst case (1600rpm 2.5bar g). -
Page 4: General
General Product general description The XK12 is a robust, medium ow, oil free, contactless, low maintenance screw compressor designed for the contaminant free discharge of dense bulk powder products (e.g. cement, our and lime), usually at 1.5-2.5 bar g pressure in 3” pipework. The machine is generally comprised of synchronised screw rotors, combined main body/step up gearcase assembly and inlet bearing carrier. -
Page 5: Available Packages
General Available packages - see g 1 The following packages are available as standard: Package 1 - Loose ancillaries with absorptive discharge silencer Standard ancillaries supplied as separate items including the absorptive type discharge silencer and cyclonic inlet lter/kit Package 2 - Loose ancillaries with reactive discharge silencer Standard ancillaries supplied as separate items including the reactive type discharge silencer and cyclonic inlet lter/kit Fully assembled package (5) -
Page 6: Dimensions, Performance Data, And Operating Environment
General Dimensions, Performance data & Operating Environment NOTE Dimensions The dimensions of the basic XK12 are shown in gure 2 below. High speed machine is dimensionally identical to the standard machine. Performance The performance details and power requirements of the compressor are shown on the product data sheet. -
Page 7: Installation
Installation General When selecting the machine mounting position, the following points should be considered: • Access to oil ll/level and drain plugs • Adequate clearance to allow the cooling air to circulate around the machine • Install away from sources of heat, e.g. vehicle exhaust air or hot pipes that could e ect the compressor temperature in any way. -
Page 8: Mounting
Installation Mounting NOTE The XK12 should be installed vertically utilising all three mounting feet on one side of the machine and can be driven in both rotations by using either The compressor has three end of the input shaft. mounting feet on each side Additionally, the machine has discharge anges on both sides. -
Page 9: Lubrication
Installation NOTE Description NOTE M16 stud (short) Short Spacer Alternative mounting channels M16 Stud (long), Grade 8 maybe neccesary due to other Long Spacer vehicle ancillaries (e.g. fuel Mounting channels tank). These should provide M16 Flanged Self locking nut, Grade 8 comparative strength to the con guration shown. -
Page 10: Pto And Prop. Shaft Drive Alignment
Installation PTO and prop. shaft drive alignment Shaft cover The compressor can be driven from either end of the input shaft (see section 3.3 for further details of the orienations possible). The clockwise end of the compressor input shaft is protected with a shaft cover. - Page 11 Installation PTO and prop. shaft drive alignment (cont.) Drive Couplings (cont.) € ‚ ƒ „ … † „ ‡ ˆ ‰ … ‘ ’ “ ” • – ‰ ‡ — ‰ ˜ … — ™...
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Page 12: Pipe Work
Installation PTO and prop. shaft drive alignment (cont.) Alignment - See Figure 8 The axis on majority of PTO’s is mounted at approximately 2° - 5° to the horizontal, which re ects the angle of the engine and gearbox. NOTE The compressor should be mounted so that its drive axis is parallel to the The compound prop.shaft PTO’s drive axis. -
Page 13: Ancillaries
Installation Ancillaries (relating to gures 10a - 10b) Inlet Air Filter and Flexible Induction Kit Should be located so that the inlet air is cool and clean. Do not mount close to exhausts or other warm air sources. Ensure screw-on cu s are sealed onto inlet hose using suitable high- temperature silicone sealant, such as DOW CORNING Silicone AP. -
Page 14: Package 1 Layout/Parts
Installation Installation Package 1 - Separate ancillaries with absorptive discharge silencer CAUTION Compressors should never be started against pressurised discharge lines or tanks. - Indicates locally supplied item. - Indicates customer supplied pipework. Ref. No. Description Ref. No. Description XK-12 Basic M/C (or high speed unit) Outlet Flange (S0W) - 77mm Bore 10”... -
Page 15: Package 2 Layout/Parts
Installation 3.10 Package 2 - Separate ancillaries with reactive discharge silencer CAUTION Compressors should never be started against pressurised discharge lines or tanks. - Indicates locally supplied item. - Indicates customer supplied pipework. Ref. No. Description Ref.No. Description XK-12 Basic M/C - (or high speed unit) Outlet Flange (S0W) - 70mm Bore 10”... -
Page 16: Pre-Commissioning Check List
These should be removed and replaced with a temperature probe and a pressure probe for commissioning only. (see Fig. 11) If Gardner Denver Drum supplied anges are not used, the installer must provide 2 x 1/4” BSP tappings adjacent to the inlet and outlet ports for the commissioning test probes. -
Page 17: Commissioning Procedure
Re-check for oil leaks test immediately and contact 9 Increase the pressure beyond this to operate the relief valve. the Gardner Denver Drum Representative. 10 The relief valve should crack (begin to open/blow o ) at a pressure not exceeding 2.5 bar g and then fully open (full Max. - Page 18 Commissioning Description Pressure Manometer Temperature Gauge Pressure Tapping (Inlet depression) Temperature Tapping (Inlet) Commissioning Filter Pressure Gauge Pressure Tapping (Discharge) Temperature Tapping (Discharge) Figure 12. Commissioning Tests 4990140010 Date:03/15 XK12 Installation, Operating & Maintenance Manual XK12 Installation, Operating & Maintenance Manual Page 18 Page 18...
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Page 19: Driver Operating Instructions
Commissioning Driver Operating Instructions The input speed should be between 1000 and 1600 rpm (1810 and 2896 rpm for high speed machine) and the maximum pressure should not exceed 2.5 bar gauge. Where the operator will be subjected to prolonged exposure to noise, it is recommended that ear protection is provided. -
Page 20: Driver Training
Commissioning XK12 Driver training Driver training should be given when ever possible and should include:- Safety Instruct the driver regarding: • Rotating parts • Hot Pipework • Safety valve • Safety coupling Operation Instruct the driver regarding: • Speed range •... -
Page 21: Commissioning Test Sheet
Commissioning 4990140010 Date:03/15 XK12 Installation, Operating & Maintenance Manual XK12 Installation, Operating & Maintenance Manual Page 21 Page 21... -
Page 22: Maintenance
Maintenance Schedule Daily • Check Air Filter blockage indicator and clean or replace lter element if required. 40 - 60 hours from new • Change the gearcase oil; see section 5.2 Weekly • Where the compressor is mounted on a vehicle and located outside, it should be operated for at least 15 minutes each week (twice a week In damp/cool conditions). -
Page 23: Valves
Maintenance Valves Check Valve The check (non-return) valve should be removed, visually checked for signs NOTE of wear. If in any doubt, replace the entire valve. New gaskets may be required Relief Valve when inspecting the check The screwed top of the relief valve (lifting screw) can be used to check/clear valve. -
Page 24: Air Inlet Filter - Cyclonic
Maintenance Air Inlet Filter - Cyclonic The blockage indicator is designed to show/hold the maximum inlet blockage encountered. It is set to show 100% blockage when the inlet depression reaches 37mbar. The lter element should be replaced/cleaned before the indicator enters the red portion of the blockage scale. If the indicator valve has entered the red portion of the scale: Press the reset button and re-check with the compressor operating. -
Page 25: Service Maintenance Sheet
Service Maintenance Record for XK12 Compressor Serial Number Monthly For the monthly check, simply initial the boxes as the check is completed. Year starting the month of MONTH Oil Level Relief valve Air Filter Security MONTH Oil Level Relief valve Air Filter Security MONTH... - Page 26 Contact Us Americas Australia Belgium Gardner Denver, Inc. Gardner Denver Ind. Australia Pty Ltd Gardner Denver Belgium N.V. Industrial Products Group - Americas 30 Bearing Road Luithagen 7A 1800 Gardner Expressway Seven Hills Haven 200 Quincy, IL. 62305 New South Wales...