The context does not provide the flow rate for the AERZEN GM 35S 00 model. However, it gives the following specifications:

- Width: 1500 mm
- Depth: 1800 mm
- Height: 1980 mm
- Nominal diameter: 150 mm
- Weight without acoustic hood and motor: 770 kg
- Weight with acoustic hood, without motor and belt drive: 1100 kg

Flow rate information is not included.

This answer is automatically generated

Summary of Contents for AERZEN GM 3 S Series

Page 1 OPERATING INSTRUCTIONS POSITIVE DISPLACEMENT BLOWER VACUUM OPERATION DELTA BLOWER Read the instructions prior to performing any task! Keep for future reference! G4-008 M Translation of the original operating instructions Material no.:2000020150 Doc content: 01.04.2017 Series: : GM 3 S - GM 400 L...
Page 2 Aerzener Maschinenfabrik GmbH Reherweg 28 31855 Aerzen Germany Telephone: +49 (0) 5154 81-0 Fax: +49 (0) 5154 81-9191 Email: info@aerzener.de Internet: www.aerzen.com G4-008 M, 1, en_GB This manual was created by: Technical documentation department of Aerzener Maschinenfabrik GmbH Technical editing and illustration Heiko Nickel / Angela Pedack ©...
Page 3: Table Of Contents
Table of contents Table of contents General Information............8 1.1 Information about these instructions......8 1.2 Explanation of symbols..........8 1.3 Copyright protection............ 10 1.4 Addresses..............11 1.4.1 Manufacturer............11 1.4.2 Customer service............. 11 Safety................. 12 2.1 Residual risks and fundamental risks......12 2.1.1 Electrical hazards............
Page 4 Table of contents 3.3 Overview of assemblies..........55 3.4 Operating principle............56 3.5 Operating modes............56 3.6 Operating methods............. 57 3.6.1 Operating information for pneumatic conveyance... 57 3.6.2 Operating information for air-separation systems..57 3.6.3 Description of assemblies........57 3.7 Control elements (optional)......... 61 3.7.1 Factory-installed control element......
Page 5 Table of contents 5.5 Connecting an exhaust silencer/relief line....97 5.6 Connecting the drive motor......... 98 5.6.1 Preparing the connection......... 98 5.6.2 Routing cables............99 5.6.3 Connecting the drive motor........99 5.7 Connecting the drive motor........100 5.7.1 Preparing the connection........100 5.7.2 Routing cables............
Page 6 Table of contents 7.8.1 Setting the vacuum regulator......... 130 7.8.2 Commissioning after adjustments......131 Maintenance..............132 8.1 Safety instructions............ 132 8.2 Maintenance schedule..........134 8.2.1 Maintenance schedule for normal operation..135 8.3 Maintenance work............. 137 8.3.1 First oil filling............138 8.3.2 Checking the oil level..........
Page 7 Table of contents 11.6 Noise emissions............188 11.7 Operating materials..........189 11.7.1 Lubricant oil specifications........189 11.7.2 Lubricant oil in the food and pharmaceutical industry ..............191 11.7.3 Grease specifications........... 192 11.7.4 Lubricant quantities..........193 11.8 Coating..............195 11.9 Electrical details............196 11.9.1 Voltage fluctuations..........
Page 8: General Information
General Information Explanation of symbols General Information 1.1 Information about these instructions These instructions allow for the safe and efficient handling of this machine. These instructions are an integral part of the machine and must be kept in the immediate vicinity of the machine so that it is accessible for personnel at all times.
Page 9 General Information Explanation of symbols CAUTION! This combination of symbol and signalling word points to a potentially dangerous situation that could lead to minor injuries if it is not avoided. NOTICE! This combination of symbol and signalling word points to a potentially dangerous situation that could lead to material damage if it is not avoided.
Page 10: Copyright Protection
General Information Copyright protection Warning signs Type of danger Warning – automatic start-up. Warning – hand injuries. Warning – high-voltage. Warning – flammable sub- stances. Warning – danger zone. Additional designations To draw attention to operating guidelines, events, listings, refer- ences and other elements in this manual, the following designa- tions are used: Designation...
Page 11: Addresses
General Information Addresses > Customer service 1.4 Addresses 1.4.1 Manufacturer Tab. 1: Manufacturer Address Aerzener Maschinenfabrik GmbH Reherweg 28 31855 Aerzen Germany Telephone +49 (0) 51 54 8 10 +49 (0) 51 54 8 1 9191 E-mail info@aerzener.de Internet www.aerzen.com 1.4.2 Customer service...
Page 12: Safety
Safety Residual risks and fundamental risks Safety This section gives an overview of all important safety aspects rele- vant to the protection of persons and to safe and trouble-free oper- ation. Further task-based safety instructions are contained in the section on the individual phases of the machine’s service life. Non-compliance with the handling and safety instructions provided in this manual can lead to serious hazards.
Page 13: Electrical Hazards
Safety Residual risks and fundamental risks > Electrical hazards 2.1.1 Electrical hazards Electric current DANGER! Risk of fatal injury from electric current! Coming into contact with live parts poses an imme- diate and potentially fatal risk of an electric shock. Damage to insulation or individual components can prove fatal.
Page 14 Safety Residual risks and fundamental risks > Electrical hazards Stored charges DANGER! There is a risk of fatal injury from stored charges! Electrical charges can be stored in electronic com- ponents and maintained even after the deactiva- tion and separation of the electric power supply. Coming into contact with these components can lead to fatal injuries.
Page 15: Hazards Associated With The Acoustic Hood
Safety Residual risks and fundamental risks > Hazards associated with the acoustic hood 2.1.2 Hazards associated with the acoustic hood Inside the acoustic hood DANGER! Risk of injury if the acoustic hood is open during operation! By opening the acoustic hood while the machine is in operation there is a risk of direct contact with hazardous zones, e.g.
Page 16 Safety Residual risks and fundamental risks > Hazards associated with the acoustic hood Noise WARNING! Risk of injury from noise! The noise level present at the installation area can cause hearing damage. The magnitude of the noise level is dependent on operational data, among other factors.
Page 17 Safety Residual risks and fundamental risks > Hazards associated with the acoustic hood Risk of fire and injury WARNING! Risk of fire from easily-flammable materials that are sucked into the machine! Easily-flammable material, fluids or gases can be sucked into the machine and cause it to catch fire. This can lead to serious or fatal injuries.
Page 18: Risks Of Machines With Belt Guard
Safety Residual risks and fundamental risks > Risks of machines with belt guard 2.1.3 Risks of machines with belt guard Lärm WARNING! Risk of injury from noise! The noise level present at the installation area can cause severe hearing damage. The magnitude of the noise level is dependent on operational data, among other factors.
Page 19 Safety Residual risks and fundamental risks > Risks of machines with belt guard Risk of fire and injury WARNING! Risk of fire from easily-flammable materials that are sucked into the machine! Easily-flammable material, fluids or gases can be sucked into the machine and cause it to catch fire. This can lead to serious or fatal injuries.
Page 20: Hazards At The Installation Site And Operating Site
Safety Residual risks and fundamental risks > Hazards at the installation site and operating site 2.1.4 Hazards at the installation site and operating site Securing the machine against restarting DANGER! An unauthorised or unregulated restart can have fatal consequences. An unauthorised or unregulated restart of the machine can lead to serious or fatal injuries.
Page 21 Safety Residual risks and fundamental risks > Hazards at the installation site and operating site Unexpected machine start WARNING! Risk of injury or personal shock if the machine starts suddenly! For example, a superordinate control system could send a start command to the machine so that it starts operating.
Page 22 Safety Residual risks and fundamental risks > Hazards at the installation site and operating site Sudden draw-in of gas CAUTION! Risk of injury from sudden draw-in of gas! Components such as intake pressure valves and vacuum pressure regulators may open suddenly during operation and suck in ambient air.
Page 23: Mechanical Hazards
Safety Residual risks and fundamental risks > Mechanical hazards 2.1.5 Mechanical hazards Rotating components WARNING! Risk of injury from rotating components! Rotating components may cause serious injury. – During operation never reach into or perform work on rotating components. – Never open covers during operation.
Page 24: Thermal Hazards
Safety Residual risks and fundamental risks > Risks from pressurised components 2.1.6 Thermal hazards Hot surfaces WARNING! Risk of injury from hot surfaces! Component surfaces may become very hot during operation. Skin contact with hot surfaces causes serious burns. – For all work performed in the vicinity of hot sur- faces, always wear protective work clothing and protective gloves.
Page 25: Risks From Hazardous Substances
Safety Residual risks and fundamental risks > Risks from hazardous substances Noise during disassembly CAUTION! Risk of injury from noise during the disas- sembly of pressurised gas pipes! For the disassembly of pressurised components, such as pipes, containers, hoses or valves, hot conveying material is released, resulting in noise.
Page 26: Risks From Flammable Substances
Safety Residual risks and fundamental risks > Risks from flammable substances Hazardous dust WARNING! Risk of injury from rising dust! Dust deposits may rise during machine operation. Inhaling this dust may, in the long term, lead to lung damage or other health problems. –...
Page 27: Risks Associated With Conveyance Of Nitrogen
Safety Residual risks and fundamental risks > Risks associated with conveyance of nitrogen Improper fire protection WARNING! There is a risk of injury and material damage from limited or improper fire protection! If, in the event of fire, the fire extinguisher is not operational or not suited to the specific class of fire, there is a risk of serious or fatal injury and con- siderable material damage.
Page 28: Intended Use
Safety Intended use Leaking gases during machine downtime DANGER! Risk of suffocation from build-up of leaking gases during machine downtime! Depending on the type of sealing used, gaseous nitrogen can escape into the environment during machine downtime. This can lead to a build-up of gases inside the acoustic hood or at the installation site.
Page 29: Foreseeable Misuse
Safety Foreseeable misuse The positive displacement blower machine is intended for operation with non-flammable gases in a non-explosive atmos- phere. The positive displacement blower machine has been designed and constructed solely for its “intended use” in the industrial field, as described here. Observe and comply with the job-based operating data and opera- tional limits! This intended use also includes compliance with all information in...
Page 30 Safety Foreseeable misuse Serious material damage NOTICE! Danger in case of misuse! Dangerous situa- tions could occur that may lead to serious machine damage! – Never disregard the instructions for “intended use”. – Never operate the machine in an operating area other than the one intended.
Page 31: Responsibility Of The Operator
Safety Responsibility of the operator Operation: – outside the scope of intended use. – outside the scope of the intended operating data. – using gases other than those originally intended. – with the machine operating in the incorrect direction of rota- tion.
Page 32 Safety Responsibility of the operator Operator’s obligations The machine is used for commercial purposes. The operator of the machine is thus subject to the applicable legal obligations for occu- pational safety. Alongside the safety instructions in this manual, the safety, occupa- tional and environmental regulations relevant to the field of applica- tion for the machine must also be complied with.
Page 33 Safety Responsibility of the operator Observe all warnings and notices displayed on the machine and make sure they are legible. You must replace any loose or illegible signs. Ask the manufacturer for replacements. Install the separately provided components listed in the scope of delivery on the machine and incorporate these in the safety concept.
Page 34: Replacement Parts
Ä on page 11. Customer service Replacement parts Replacement parts that have not been provided by AERZEN have not been tested or approved. They do not correspond to the orig- inal components. The use of such products can potentially have an effect on the default design characteristics of the system.
Page 35 Safety Requirements for personnel > Qualifications For the purposes of all work with this machine, only allow persons who are expected to carry out their work reliably to do so. Persons whose reaction times have been impaired, e.g. through drug or alcohol consumption or medication, must not be permitted to work.
Page 36 Safety Requirements for personnel > Qualifications Depending on the designated job, the person must have additional qualifications: Operation and handling of compressors. Parameterisation of compressors. Optimisation work within the persmissible operating data range. Skilled staff for industrial waste Skilled staff for industrial waste posses comprehensive, field-spe- cific expertise relating to the disposal and recycling of industrial waste.
Page 37: Unauthorised Personnel
Safety Requirements for personnel > Unauthorised personnel 2.6.2 Unauthorised personnel Unauthorised personnel in the installation area WARNING! Risk of fatal injury for unauthorised persons in the installation area! Unauthorised persons who do not fulfil the require- ments described here, are not familiar with the hazards in the installation area.
Page 38: Training
Safety Requirements for personnel > Training 2.6.3 Training The operator must regularly provide safety training for personnel. For tracking purposes, a training report must be drafted with the following mandatory content: Date of training Name of the training participant Content of the training Name of the training instructor Signatures of the participant and instructor Date...
Page 39: Personal Protective Equipment
Safety Personal protective equipment 2.7 Personal protective equipment Personal protective equipment serves to protect persons from breaches of safety and health hazards when working. Personnel, when working near or with the machine, must wear the personal protective equipment described separately in the various sections of this instruction manual.
Page 40: Safety Devices
Safety Safety devices > EMERGENCY STOP function Safety shoes Safety shoes protect feet from being crushed, from falling objects and from slipping on slippery surfaces. 2.8 Safety devices Correct functioning of safety devices WARNING! Risk of fatal injury from non-functioning safety devices! Non-functioning or deactivated safety devices may cause serious or fatal injury.
Page 41 Safety Safety devices > EMERGENCY STOP function EMERGENCY STOP control device An EMERGENCY STOP control device includes a special com- mand unit which is connected to the control system. The EMERGENCY STOP function allows for the machine to be shut down safely and immediately in case of a potential or existing hazard.
Page 42 Safety Safety devices > EMERGENCY STOP function Notes on installation by the oper- The EMERGENCY STOP facility must: ator be installed and integrated into the safety line of the system controller. be clearly recognisable, highly visible and quickly accessible. shut down dangerous operation quickly without causing any additional risks.
Page 43: Hinged Support With Lifting Device
Safety Safety devices > Acoustic hood 2.8.2 Hinged support with lifting device The hinged support serves to protect against mechanical hazards. The hinged support holds the motor hinge in place during transport and assembly. It prevents uncontrolled movement of the motor hinge. When operating the machine, the hinged support must be released and positioned accordingly.
Page 44: Belt Guard
Safety Safety classification Fig. 7: Acoustic hood, rear view (example) 2.8.5 Belt guard The belt guard serves to protect against rotating components. A belt guard is always used in machines without an acoustic hood. It serves to protect against rotating components. Fig.
Page 45 Safety Safety classification Unreadable signage WARNING! There is a risk from unreadable signage! There is a risk of injury resulting from dirty or unreadable signs. It may be impossible to recog- nise hazards and to follow the necessary operating information. –...
Page 46 Safety Safety classification Placement of the sticker set on the intake silencer. Fig. 12: Position on the belt guard model Access for unauthorised persons forbidden Only persons given authorisation by the operator may enter the hazard area. Electrical voltage Only qualified electrical personnel may work in the signposted working area.
Page 47: Instruction Signs
Safety Instruction signs Gas emission Risk from sudden gas emission. The opening of the safety valve results in the emission of gas and accompanying noise emissions. There is a risk of hearing damage and injuries to eyes or skin. Pressure in the piping Pipelines may be placed under pressure.
Page 48: Hazards In The Operating And/Or Display Area
Safety Hazards in the operating and/or display area 2.11 Hazards in the operating and/or display area Hazard area Operating and/or display area The hazard area is located in the marked zone (in the acoustic hood interior zone). The opening of acoustic hood elements and protective covers during operation is not permissible.
Page 49: Securing The Machine Against Restarting
Safety Securing the machine against restarting 2.12 Securing the machine against restarting Sudden restart DANGER! An unauthorised or unregulated restart can have fatal consequences. An unauthorised or unregulated restart of the machine can lead to serious or fatal injuries. There may be people located in the hazard zone.
Page 50: Environmental Protection
Safety Environmental protection Place a sign on the machine and (where applicable) remote station that notifies persons of the work being carried out in the hazard area and forbids activation of the machine. The sign must contain the following information: Shut-down on: Shut-down at: Shut-down by:...
Page 51 Safety Environmental protection Lubricants Lubricants such as greases and oils contain poisonous sub- stances. They must not be released into the environment. Disposal must be carried out by a certified waste management company. AERtronic batteries Batteries contain poisonous heavy metals. They require special waste treatment and must be deposited at local collection points or disposed of by specialist companies.
Page 52: Design And Operation
Design and operation Overview of assemblies Design and operation 3.1 Overview of assemblies Fig. 15: Acoustic hood with oil system Intake side Oil system Machine stage Drive system G4-008 M 10.04.2017...
Page 53 Design and operation Overview of assemblies Discharge side 10.04.2017 G4-008 M...
Page 54: Overview Of Assemblies
Design and operation Overview of assemblies 3.2 Overview of assemblies Fig. 16: Acoustic hood without oil system Intake side Drive system Machine stage Discharge side G4-008 M 10.04.2017...
Page 55: Overview Of Assemblies
Design and operation Overview of assemblies 3.3 Overview of assemblies Fig. 17: Overview Intake side Drive system Machine stage Discharge side 10.04.2017 G4-008 M...
Page 56: Operating Principle
Design and operation Operating modes 3.4 Operating principle The medium to be conveyed is connected using an elastic rubber sleeve or the compensator of the intake-side connection. The medium to be conveyed enters through the intake silencer. There is an intake strainer located inside the intake silencer. The intake silencer also contains an intake valve.
Page 57: Operating Methods
Design and operation Operating methods > Description of assemblies 3.6 Operating methods 3.6.1 Operating information for pneumatic conveyance Pneumatic conveyance When the machine is being used for the purposes of pneumatic conveyance, pressure surges must not occur when switching between different delivery lines. Pressure surges can be prevented by making the switching process for the intake-side and discharge-side valves take at least five seconds.
Page 58 Design and operation Operating methods > Description of assemblies 3.6.3.1 Intake side 3410 Intake silencer, housing 3470 Intake silencer, filter strainer The intake side assembly comprises the components of the con- veying system's intake side. The intake side assembly includes all components located upstream of the machine stage gas inlet.
Page 59 Design and operation Operating methods > Description of assemblies 3.6.3.3 Oil system The oil system contains all components necessary for providing lube oil to the machine stage. Fig. 21: Oil system 3.6.3.4 Drive system 1810 Motor 2110 Belt drive The drive system comprises the drive motor and the drive ele- ments, e.g.
Page 60 Design and operation Operating methods > Description of assemblies Base support 2710 Flexible pipe connection The discharge-side assembly represents the components of the discharge-side conveying system. The discharge-side assembly includes all components fitted downstream from the machine stage gas outlet. All components are pressurised during operation and have hot surfaces.
Page 61: Control Elements (Optional)
Design and operation Control elements (optional) > Customer-installed control element 3.7 Control elements (optional) 3.7.1 Factory-installed control element Factory-installed control element Observe the AERtronic instruction manual. The AERtronic instruction manual is included with the product. Fig. 25: Operator interface Information menu Service display Local/ LOCATION / START Local/ LOCATION / STOP...
Page 62: Accessories
Design and operation Accessories > Drive motor 3.8 Accessories The accessories are the total collection of components belonging to the machine or to the supplementary equipment. 3.8.1 Drive motor Motor connection requirements The cable and lead sheathing must be resistant to the normal wear expected due to the movement of the hinged motor support and the effects of con- taminants in the atmosphere.
Page 63 Design and operation Accessories > Drive motor Requirements for the electricity network NOTICE! There is a risk of material damage from voltage fluctuations / drops! Voltage fluctuations / drops beyond the tolerance interval may lead to serious damage to the drive system.
Page 64: Aertronic
Observe the operating manual for the purposes of commissioning and operation! AERZEN reserves the right to change, expand or improve the hardware and software of this product as required. This does not include any obligation to update units already shipped.
Page 65: Frequency Converter
Design and operation Accessories > Frequency converter NOTICE! The switching points of the switches/sensors are fixed and must not be changed. Pressure and temperature switches If, to safeguard the machine, an intake pressure, discharge pres- sure or discharge temperature switch is used, it must also be ensured that the drive motor switches off when the limit switch is triggered.
Page 66: Machine Terminal Box
Design and operation Accessories > Machine terminal box For machine use, observe the fol- Take into account the electrical and mechanical properties of lowing the drive motor. The minimum frequency must always be fixed. This frequency must never fall below the fixed minimum during operation. The maximum frequency is to be set by taking into account the maximum rotational speed of the motor and the maximum machine speed.
Page 67: Intake Pressure Gauge
Design and operation Accessories > Intake silencer 3.8.6 Intake pressure gauge Vacuum pressure mode The gauge displays the intake pressure. It is a display instrument without a switching function. The gauge is connected on the intake side. Fig. 27: Gauge 3.8.7 Discharge pressure gauge Positive pressure mode The gauge displays the discharge pressure of the compressed...
Page 68: Discharge Silencer
Fig. 31: Discharge silencer 3.8.11 Intake pressure valve AERZEN intake pressure valve The intake pressure valve is installed at the factory and designed in accordance with the operating data. The intake pressure valve is NOT a control component and is not to be used as such.
Page 69: Non-Return Flap
Design and operation Accessories > Vacuum regulator NOTICE! Risk of premature wear and tear and breakdown! The valve is not intended for controlling the oper- ating data! The deactivation of the valve, e.g. by increasing the opening pressure, may lead to serious damage! Risk of total machine damage! The valve inlet must not be made narrower or closed.
Page 70: Exhaust Silencer
Design and operation Accessories > Starting strainer Operating principle Valve Lower diaphragm chamber Upper diaphragm chamber Valve Control valve Set screw System Nozzle The vacuum pressure can be adjusted by moving the set screw (pos.6). Fig. 36: Vacuum regulator diagram In the rest position the valves (pos.1 and pos.4) are closed.
Page 71: Belt Drive
It is extremely important that only original replace- ment parts be used for the purposes of belt-pulley operation! Only use replacement parts that are recommended and approved by AERZEN! Original replacement parts NOTICE! Risk of material damage! Pulleys must only come from one manufacturer and from one production batch.
Page 72: Acoustic Hood
Design and operation Accessories > Acoustic hood 3.8.17 Acoustic hood Acoustic hood The acoustic hood serves to reduce noise and acts as an isolating safety device. The acoustic hood is a component for product safety with lockable door elements. Always keep the acoustic hood closed during operation. The key must only be accessible for authorised personnel.
Page 73: Required Tools
Design and operation Required tools This prevents damage to the machine by heating up the housing and preheating the lube oil and medium to be conveyed. 3.9 Required tools The following tools are required: Auxiliary materials, aids including collection containers for oil, drain hose, cleaning rags. Conveyor rails The conveyor rails must be made of steel.
Page 74 Design and operation Required tools Tools for authorised electricians Basic electrical engineering equipment, e.g. multimeter, voltage detector, insulated tools. Transport equipment for transporting packaged units and the machine, e.g. with lift trucks, forklifts. G4-008 M 10.04.2017...
Page 75: Transport, Packaging And Storage
Transport, packaging and storage Transport > Safety instructions Transport, packaging and storage 4.1 Transport 4.1.1 Safety instructions Improper transport WARNING! Risk of injury and damage from improper trans- port! Improper transport may result in personal injury. – Proceed with caution upon delivery and unloading of the machine and during in-house transport.
Page 76 Transport, packaging and storage Transport > Safety instructions Suspended loads WARNING! There is a risk of fatal injury from suspended loads! During lifting work, loads may swing out and fall. This can result in serious or fatal injury. – Never walk under or into the range of a sus- pended load.
Page 77 Transport, packaging and storage Transport > Safety instructions Risk of slipping CAUTION! Risk of injury due to slipping on the packaging foil! The packaging foil features a slippery surface that can cause persons to slip on it. Moisture, creases, edges and tension straps on the packaging foil entail a risk of slipping or stumbling.
Page 78: Delivery Method
Transport, packaging and storage Transport > Delivery method Special tools Requirements for transport: NOTICE! Risk of damage to the machine! Chains, steel cables and similar equipment are not suitable lifting equipment. Special tool: Lifting equipment Transport equipment Special tool: Lifting beams Locking key Conveyor rails Dimensions of the conveyor rails...
Page 79: Packaging
Transport, packaging and storage Transport > Packaging Transport on a truck Strap the packaged unit to the truck in accordance with the diagram. Always use appropriate edge protection to avoid damage to the packaged unit. Fig. 41: Transport on a truck 4.1.3 Packaging 4.1.3.1 Symbole auf der Verpackung...
Page 80 Transport, packaging and storage Transport > Packaging Transport on a truck Strap the packaged unit to the truck in accordance with the diagram. Always use appropriate edge protection to avoid damage to the packaged unit. Fig. 44: Transport on a truck Explanations Comply with the order (pos.1-pos.3) of the work stages.
Page 81 Transport, packaging and storage Transport > Packaging Removing packaging Packaging materials made of solid wood (e.g. wooden palettes, wooden crates) comply with the IPPC standard. They are re-usable. When dis- posing of the material, national and local require- ments must be complied with. From the machine CAUTION! Risk of injury from rough packaging material...
Page 82: Transport Inspection
Transport, packaging and storage Transport > Transport inspection 4.1.4 Transport inspection Completeness Checking for completeness Check the goods for completeness immediately after delivery. Register missing parts and contact the manufacturer. Check the delivery for completeness on the basis of the packing slip.
Page 83: Transport Of Packaged Units
Transport, packaging and storage Transport > Transport of packaged units 4.1.5 Transport of packaged units 4.1.5.1 Transport using industrial vehicles NOTICE! Risk of toppling loads! The transport of pack- aged units may only be carried out using lifting equipment that reaches under the machine and fits into the transport palette fully.
Page 84 Transport, packaging and storage Transport > Transport of packaged units Transport the machine so that it is balanced. The packaged unit must not lean to one side. 4.1.5.3 Transport using industrial vehicles NOTICE! Risk of toppling loads! The transport of pack- aged units may only be carried out using lifting equipment that reaches under the machine and fits into the transport palette...
Page 85: Transport To The Installation Site
Transport, packaging and storage Transport > Transport to the installation site 4.1.6 Transport to the installation site 4.1.6.1 Transport using industrial vehicles Completely remove packaging material. Open the operating side of the acoustic hood (pos.1). Open the rear side of the acoustic hood (pos.2). Separate the machine from the transport palette by removing the holding screws.
Page 86 Transport, packaging and storage Transport > Transport to the installation site 4.1.6.2 Transport using a crane Completely remove packaging material. Remove the front and rear elements of the acoustic hood and store them safely. Guide the conveyor rails through the openings of the forklift tunnel.
Page 87: Storage And Preservation
Transport, packaging and storage Storage and preservation > Storage Take into account the centre of gravity! See the labelling on the packaging. DANGER! Risk of fatal injury from toppling components! Determine the machine’s centre of gravity by raising it care- fully.
Page 88 Transport, packaging and storage Storage and preservation > Storage Storage information for periods of Additional measures: over 12 months Packaging with VPI paper. Sealed in PVC foil. Storage information for periods of Additional measures: over 12 months in a tropical climate Drying agent (VPI power in a bag) inside the packaging.
Page 89: Preservation
Transport, packaging and storage Storage and preservation > Preservation 4.2.2 Preservation Preservation Factory preservation protects the product for a certain time period in accordance with the relevant storage and packaging information. Factory preservation/standard Conveying chamber BIO-CHEM food biodegradable, does tech oil not contaminate groundwater Oil chamber...
Page 90 Transport, packaging and storage Storage and preservation > Preservation Carrying out preservation treat- ment Preservation measures: Open the packaging. Check the machine for good accessi- bility. WARNING! Risk of poisoning from inhaling oil vapour! Preservation treatment of the conveying chamber: spray suitable preservative oil over the intake nozzle at the machine stage.
Page 91: Set-Up And Installation
Set-up and installation Safety instructions Set-up and installation 5.1 Safety instructions Improper set-up/installation WARNING! Risk of injury from improper set-up and instal- lation! Improper set-up and installation can result in serious injury or damage. – Before beginning any work, ensure there is suf- ficient space for installation.
Page 92 Set-up and installation Safety instructions Personnel: Authorised electricians Set-up and installation of mechanical components Personnel: Service personnel Protective equipment Requirements for set-up and installation: Protective equipment: Protective work clothing Safety shoes Protective gloves Safety goggles Industrial hard hat Special tools Requirements for set-up and installation: Special tool: Tools for authorised electricians...
Page 93: Requirements For The Installation Site
Set-up and installation Requirements for the installation site 5.2 Requirements for the installation site Ground properties Inspect the ground properties. These should be as follows: stable even free of vibrations without any incline without holes NOTICE! Risk of deformation of the acoustic hood substruc- ture! Do not install or mount the machine on “hollow”...
Page 94 Set-up and installation Requirements for the installation site Installation with belt guards The machine is only suitable for indoor installation. Machine installation site Comply with the overall dimensions for maintenance work. Observe the installation drawing. Provide measures for sound insulation. Take the following precautionary measures: –...
Page 95: Installation
Set-up and installation Installation 5.3 Installation Models with acoustic hoods; aligning and dowelling Carefully align the machine. Position it so that it is balanced. Fig. 55: Spirit level alignment NOTICE! Risk of total machine damage! Installing a machine at an angle may, as a result of an undefined oil level, can lead to a total machine loss.
Page 96: Connecting The System Pipeline
Set-up and installation Connecting the system pipeline Models without acoustic hoods; aligning and dowelling Carefully align the machine. Position it so that it is balanced. NOTICE! Risk of irreversible machine failure! Installing a machine at an angle may, as a result of an undefined oil level, can lead to a total machine loss.
Page 97: Connecting An Exhaust Silencer/Relief Line
Set-up and installation Connecting an exhaust silencer/relief line Remove the sealing cover from the connection openings. Bushings/2 clamps Connect the system pipeline. ð Make sure that the clamps are offset by 180° to one another. Fig. 59: 2 clamps Bushings/4 clamps Connect the system pipeline.
Page 98: Connecting The Drive Motor
Set-up and installation Connecting the drive motor > Preparing the connection Connecting the relief line Align the operator’s pipeline. Connect the relief line to the base support’s pipe connection. 5.6 Connecting the drive motor 5.6.1 Preparing the connection Preparation with acoustic hood Ä...
Page 99: Routing Cables
Set-up and installation Connecting the drive motor > Connecting the drive motor 5.6.2 Routing cables Routing the connection cable Route the connection cable in accordance with the installa- tion drawing. NOTICE! Risk of damage! The minimum bending radius must not be undershot! Observe the bending radii.
Page 100: Connecting The Drive Motor
Set-up and installation Connecting the drive motor > Routing cables 5.7 Connecting the drive motor 5.7.1 Preparing the connection Preparation with belt guards Ä Chapter 3.8.1 „Drive motor“ on page 62. DANGER! Risk of fatal injury in the case of incorrect electrical connection data! Compare the electrical connection data of the drive motor with those of the grid operator.
Page 101: Connecting The Drive Motor
Set-up and installation Connecting the machine’s terminal strip 5.7.3 Connecting the drive motor Motor connection Fig. 69: Connection layout Star-delta connection Delta connection Star connection Thermal winding shield Open the motor terminal box. Check the alignment of the terminal box. ð...
Page 102: Connecting The Earthing
Set-up and installation Connecting the earthing Connection layout according to the AERZEN wiring scheme! Guide the external connecting cable to the terminal box. Guide the connecting cable correctly through the cable entry (dummy cover) to the terminals. The cable entry (dummy cover) can be equipped on site with screwed cable glands.
Page 103: Laying The Insulation Mat
Set-up and installation Laying the insulation mat 5.11 Laying the insulation mat Laying the insulation mat Depending on the scope of delivery, the insulation mat is deliv- ered separately. Lay the insulation mat in the exhaust duct of the acoustic hood. Fig.
Page 104: Initial Start-Up
Initial start-up Safety instructions Initial start-up 6.1 Safety instructions Improper commissioning WARNING! Risk of injury from improper commissioning! Improper commissioning may lead to serious injury and considerable material damage. – Before commissioing, ensure that all installa- tion work has been carried out and completed in accordance with the information and notes in this instruction manual.
Page 105: Preparation For Commissioning
Initial start-up Preparation for commissioning Special tool: Ratchet wrench Oil funnel Test pump General tool kit General measurement tools and equip- ment Tools for authorised electricians Special tool: Locking key 6.2 Preparation for commissioning Preparation Check that the machine has been correctly installed. See Ä...
Page 106 Initial start-up Preparation for commissioning Ventilating the manometer Prepare the manometer in line with its specific design. Cut off the rubber connections on the upper section. Turn the bleeder flap to OPEN. Fig. 74: Ventilating the manometer Aligning the sheaves Check the alignment of the sheaves.
Page 107 Initial start-up Preparation for commissioning Checking the acoustic hood fan Check the fan wheel for smooth movement and contact-free operation. If necessary, adjust the cover plate. Fig. 77: Fan cover Connecting the vacuum regulator Connect the control pressure to the vacuum system line using a hose.
Page 108 Initial start-up Preparation for commissioning Preparing the hinged motor sup- port Handling without lifting device Disassemble the transport safety lock. Remove the safety screws for transport. Fig. 79: Example: DN50 Disassemble the transport safety lock. 1.) Remove the split pin. 2.) Disassemble the safety rod for transport.
Page 109: Performing Commissioning
Initial start-up Performing commissioning > Filling oil, version featuring oil system Preparing the hinged motor sup- port Handling with lifting device Remove counternut the (pos.1) and locking sleeve (pos.2). Fig. 81: Hinged motor support prepa- ration 6.3 Performing commissioning 6.3.1 Filling oil, version featuring oil system Open the maintenance elements of the acoustic hood.
Page 110 Initial start-up Performing commissioning > Filling oil, version featuring oil system Checking the acoustic hood’s oil level. Check the lube oil level on the acoustic hood’s oil level dis- play and adjust as necessary. Fig. 83: Acoustic hood oil level display Check the machine stage’s oil level Fig.
Page 111: Filling With Oil, Models Without Oil System
Initial start-up Performing commissioning > Establishing an electrical connection 6.3.2 Filling with oil, models without oil system Fig. 86: Machine stage GM3S-GM80L When working with operating materials such as lube oil, wear personal protective equip- ment. ENVIRONMENT! Environmental risks from incorrect handling of lubricants! Fig.
Page 112 Initial start-up Performing commissioning > Establishing an electrical connection Checking direction of rotation/ models with acoustic hood WARNING! Risk of injury from rotating components! NOTICE! Risk of machine damage from incorrect direction of rotation! Check the direction of rotation without belts in place. Fig.
Page 113: Handling The Hinged Motor Support With Lifting Device
Initial start-up Performing commissioning > Handling the hinged motor support with lifting device Checking the direction of rotation/ models without acoustic hood WARNING! Risk of injury from rotating components! NOTICE! Risk of machine damage from incorrect direction of rotation! Fig. 90: Direction of rotation Check the direction of rotation without belts in place.
Page 114 Initial start-up Performing commissioning > Handling the hinged motor support with lifting device Loosening the self-locking nut NOTICE! Prevention of wear and tear on belts. Screw the self-locking nut (pos.4) all the way downwards. ð The hinged motor support can be adjusted to the correct position.
Page 115: Handling Hinged Motor Support Without Lifting Device
Initial start-up Performing commissioning > Handling hinged motor support without lifting device Tensioning the belts CAUTION! Risk of injury from moving and rotating com- ponents! Tension the belts. Secure the guide bushing (pos.3) with the self-locking nut (pos.4). The hinged motor support is supported entirely by the belt drive.
Page 116 Initial start-up Performing commissioning > Handling hinged motor support without lifting device Raising the hinged motor support of the DN80 Insert the lifting bracket in the motor’s attachment rail. NOTICE! Only use hydraulic lifts on solid, level ground. Position the hydraulic lift securely. Fig.
Page 117: Carrying Out A Test Run
Initial start-up Performing commissioning > Carrying out a test run Completely remove the hydraulic lift and other auxiliary equipment and store them safely for future maintenance pur- poses. NOTICE! Risk of damage to the belt drive! The hinged motor support must not rest on the base sup- port, the transport securing rod or similar equipment.
Page 118 Initial start-up Performing commissioning > Carrying out a test run CAUTION! Risk of injury from moving components! Carry out a test run of the belt drive and check that it is oper- ating correctly. Characteristics: quiet, even operation. even load. no excessive vibrations.
Page 119 Initial start-up Performing commissioning > Carrying out a test run Assembling and adjusting the pro- tective cover/models without acoustic hood WARNING! Risk of injury from rotating components! Assemble the protective cover after tensioning the belts. The protective cover should be at a distance of approx. 10 mm from the motor drive shaft.
Page 120 Initial start-up Performing commissioning > Carrying out a test run Starting briefly WARNING! Risk of injury from rotating components! WARNING! Risk of injury from pressurised components! Do not loosen or remove any locking screws or pipe connections. Switch on the drive motor. After approx.
Page 121 Initial start-up Performing commissioning > Carrying out a test run Acoustic hood protection WARNING! Risk of injury if protective equipment is not present. Correctly close the elements of the acoustic hood. Store the acoustic hood key safely. Only allow access for authorised personnel. Belt protection WARNING! Risk of injury if protective equipment is not...
Page 122: Performing Checks After Commissioning
Initial start-up Performing checks after commissioning 6.4 Performing checks after commissioning Inspection After the first 3 op. After the first 25 op. Screws after the machine has cooled down, re- tighten if necessary Intake pressure Check for correct valve operation Oil level check and, if neces- check and, if neces-...
Page 123: Operation
Operation Safety instructions Operation 7.1 Safety instructions Improper operation WARNING! Risk of injury from improper operation! Improper operation may lead to serious injury and considerable material damage. – Carry out all activities in accordance with the information and notes in this instruction manual.
Page 124: Shut-Down In Case Of Emergency
Operation Shut-down in case of emergency Explosion and fire hazards DANGER! There is a risk of explosion and fire from igni- tion hazards! Avoid allowing ignition hazards (open flames, flying sparks, weld spatter) into the vicinity of the machine. Sparks and incandescent or flammable objects could be sucked in through the supply air openings on the acoustic hood or through the intake silencer.
Page 125: Switching On
Operation Switching on > On-site operation Shut-down in case of emergency In an emergency, proceed as follows: Activate the EMERGENCY STOP immediately. Inform the responsible staff. Switch off the main circuit breaker and secure it against restarting. Assign qualified personnel the task of rectifying the fault. WARNING! An unauthorised or unregulated restart can have fatal consequences.
Page 126: Remote Operation
Operation Switching on > Automatic operation 7.3.2 Remote operation Via remote station DANGER! Risk of fatal injury if protective equipment is missing! WARNING! Risk of injury if the machine starts suddenly! Activate the starter switch in the remote station. ð The machine is started remotely and comes on stream. Remote station with AERtronic Remotely via potential-free contact Remotely via MODBUS RTU...
Page 127: Displaying Operating Parameters
Operation Switching off > On-site operation 7.4 Displaying operating parameters AERtronic (optional) A detailed explanation is contained in the separate operating manual AS-002. Fig. 105: AERtronic display Analogue instruments (optional) Depending on their deisgn, analogue instruments display the given operating data, e.g. discharge pressure, discharge temperature, oil pressure.
Page 128: Remote-Controlled Operation
Operation Switching off > Switching off in nitrogen operation 7.5.2 Remote-controlled operation Via remote station WARNING! Risk of injury from unbraked shut-down! Activate the cut-out switch in the remote station. ð The machine is switched off and shuts down. The machine does not stop immediately.
Page 129: Decommissioning
Operation Adjusting valves 7.6 Decommissioning Decommissioning means the shut-down of a machine for a longer period. Measures Switch off the machine properly and secure it against an unintentional start. Disconnect fuses. Close the shut-off valves of the delivery lines. Prevent condensate from entering the machine. For a downtime of over six weeks: preserve the conveying chamber.
Page 130: Setting The Vacuum Regulator
Operation Adjusting valves > Setting the vacuum regulator Preparation/models with acoustic Agree adjustments with the responsible staff at the location. hood Switch off the machine. Activate the EMERGENCY STOP function. Switch off the main circuit breaker and secure it against restarting.
Page 131: Commissioning After Adjustments
Operation Adjusting valves > Commissioning after adjustments NOTICE! Risk of damage! Observe the starting fre- quency of the drive motor! Start the machine. Check the closing time. If the closing time is in the permissible adjustment range: ð adjustments are complete. If the closing time is not in the permissible adjustment range: ð...
Page 132: Maintenance
Maintenance Safety instructions Maintenance 8.1 Safety instructions Improperly performed maintenance work WARNING! Risk of injury from improperly performed main- tenance work! Improperly performed maintenance may lead to serious injury or material damage. – Only perform maintenance work when the machine has been decommissioned. –...
Page 133 Maintenance Safety instructions Rotating or moving components WARNING! Risk of injury from rotating or moving compo- nents! Rotating or moving components can cause serious injuries. – Never touch rotating or moving components. – Never reach into the clamping area of the belts, for example.
Page 134: Maintenance Schedule
Maintenance Maintenance schedule Protective equipment For maintenance, the following is necessary: Protective equipment: Protective work clothing Safety shoes Protective gloves Safety goggles Industrial hard hat Special tools For maintenance the following is necessary: Special tool: Ratchet wrench Oil funnel General tool kit General measurement tools and equip- ment Auxiliary materials, aids...
Page 135: Maintenance Schedule For Normal Operation
Maintenance Maintenance schedule > Maintenance schedule for normal operation 8.2.1 Maintenance schedule for normal operation Interval Maintenance work Personnel After the first 500 op. Check the differential pressure or intake Service personnel strainer. Ä 8.3.12 „Checking the starting strainer“ on page 163 Replace the lube oil.
Page 136 Maintenance schedule > Maintenance schedule for normal operation Interval Maintenance work Personnel When using AERZEN special rotary piston oil with a gas-tight shaft seal, replace the grease at a discharge temperature of Ä Chapter 8.3.4 „Replacing the grease on gas- over 140 °C.
Page 137: Maintenance Work
Maintenance Maintenance work op. hrs = operating hours 8.3 Maintenance work Preparation Agree maintenance work with the responsible staff at the location. Switch off the machine. Activate the EMERGENCY STOP function. Switch off the main circuit breaker and secure it against restarting.
Page 138: First Oil Filling
Maintenance Maintenance work > First oil filling 8.3.1 First oil filling 8.3.1.1 Version with oil system Filling with oil Check the drain valve for firm seating. Check that the sealing cap of the drain valve is firmly in place. Open the oil container. Ensure that the ventilation pipe in the oil filling container is unobstructed.
Page 139 Maintenance Maintenance work > First oil filling Fig. 109: Machine stage sight glasses Check the lube oil level on the machine stage’s oil level dis- plays (item 2) and adjust as necessary. Fill the rest of the lube oil up to the mark on the acoustic hood’s sight glass.
Page 140 Maintenance Maintenance work > First oil filling Check the drain valves (pos. 3) for firm seating. Check the sealing caps of the drain valves (pos. 3) for firm seating. Open the oil fill openings (pos.1) – the RED-marked locking screws. Observe the oil quantity distribution.
Page 141: Checking The Oil Level
Maintenance Maintenance work > Checking the oil level 8.3.2 Checking the oil level 8.3.2.1 Version with oil system Version with oil system Oil fill opening (oil filling container) Oil level display Oil drain Fig. 114: Oil system Checking the oil level Check the lube oil level and correct it if necessary.
Page 142 Maintenance Maintenance work > Checking the oil level 8.3.2.2 Version without oil system Version without oil system Oil fill openings, marked in red Oil level displays Drain valves Fig. 118: GM 3S - GM 80L Fig. 119: GM 90S - GM 400L Checking the oil level Check the lube oil level and correct it if necessary.
Page 143: Correcting The Oil Level
Maintenance Maintenance work > Correcting the oil level 8.3.3 Correcting the oil level 8.3.3.1 Oil level too high Draining oil/version with oil system WARNING! Risk of scalding from hot lube oil! NOTICE! Material damage to the drain hose from lube oil temperatures over 60°C! Allow the lube oil to cool down to the ambient temperature.
Page 144 Maintenance Maintenance work > Correcting the oil level Observe and check the oil level. If the permissible oil level is reached, remove the drain hose. ð The drain valve closes automatically. Screw the sealing cap onto the drain valve. Close the oil fill opening. ENVIRONMENT! Risk of environmental damage from waste oil!
Page 145 Maintenance Maintenance work > Correcting the oil level CAUTION! Risk of skin irritation from old lube oil! A locking screw or a shut-off valve can be used as an alternative to the drain valve. The oil chamber can be opened by: –...
Page 146 Maintenance Maintenance work > Correcting the oil level If the oil level has been corrected, remove the drain hose. ð The drain valve closes automatically. A locking screw or a shut-off valve can be used as an alternative to the drain valve.
Page 147 Maintenance Maintenance work > Correcting the oil level CAUTION! Risk of skin irritation from lube oil! ENVIRONMENT! Environmental risks from incorrect handling of lubricants! Ä Chapter 11.7.1 „Lubricant oil specifica- Specifications tions“ on page 189 Fill the lube oil in stages and in small quantities. Observe the oil level.
Page 148 Maintenance Maintenance work > Correcting the oil level Close the oil filling container. ENVIRONMENT! Risk of environmental damage from incorrect storage of lube oil! Clean the workspace thoroughly. Dispose of residual lube oil in an environmentally-friendly way. Clean all auxiliary equipment. Filling oil/version without oil system Oil fill openings, marked in red...
Page 149: Replacing The Grease On Gas-Tight Drive Shafts
Maintenance Maintenance work > Replacing the grease on gas-tight drive shafts Observe the oil level. Wait 5 - 10 minutes. The lube oil con- tinues to flow. ð The oil level regulates itself in the oil system and in the oil chambers.
Page 150: Changing Oil
Maintenance Maintenance work > Changing oil Pressing the grease WARNING! Risk of burning from hot housing surfaces! Allow the housing surfaces to cool down to ambient tempera- ture. Press the grease by turning the Stauffer lubricator. Fig. 133: Stauffer lubricator CAUTION! Risk of skin irritation from escaping grease! Ä...
Page 151 Maintenance Maintenance work > Changing oil Open the oil opening on the oil filling container. ð Lube oil flows out more evenly from the oil drain. Feed the drain hose into the receptacle. CAUTION! Risk of skin irritation from old lube oil! Remove the sealing cap from the drain valve.
Page 152 Maintenance Maintenance work > Changing oil Filling with oil Check the drain valve for firm seating. Check the sealing cap of the drain valve for firm seating. Open the oil filling container. Ensure that the ventilation pipe in the oil filling container is unobstructed.
Page 153 Maintenance Maintenance work > Changing oil Fig. 138: Machine stage sight glasses Oil fill openings, marked in red Oil level displays Drain valves Check the lube oil level on the machine stage’s oil level dis- plays (item 2) and adjust as necessary. If the lube oil level is between the min.-/max.
Page 154 Maintenance Maintenance work > Changing oil 8.3.5.2 Draining oil/version without oil system Draining oil/version without oil system WARNING! Risk of scalding from hot lube oil! Allow the lubricating oil to cool down to ambient temperature. Observe the volume of the waste oil and the Ä...
Page 155 Maintenance Maintenance work > Changing oil CAUTION! Risk of slipping from oil spillage! Guide all emerging lube oil into the receptacle. Remove the drain hose. ð The drain valve closes automatically. A locking screw or a shut-off valve can be used as an alternative to the drain valve.
Page 156 Maintenance Maintenance work > Changing oil Check the drain valves (pos. 3) for firm seating. Check the sealing caps of the drain valves (pos. 3) for firm seating. Open the oil fill openings (pos.1), the RED-marked locking screws. Observe the oil quantity distribution. Guide value: 1/3 of the entire lube oil quantity in the driving side.
Page 157: Checking The Sheaves
Maintenance Maintenance work > Moving and checking the protective cover of the sheaves 8.3.6 Checking the sheaves For wear and tear and damage Check for unusual wear and tear or obvious damage. Check for correct alignment and stability. If necessary, replace the sheaves. Assemble the sheaves.
Page 158: Replacing Belts, Version With Lifting Device
Maintenance Maintenance work > Replacing belts, version with lifting device 8.3.8 Replacing belts, version with lifting device Raising the hinged motor support WARNING! Risk of injury from moving or rotating compo- nents! Lift the hinged motor support using the hinge jig. Turn guide bushing (pos.3) anti-clockwise using the ratchet wrench.
Page 159 Maintenance Maintenance work > Replacing belts, version with lifting device Pre-tensioning belts CAUTION! Risk of injury from tensioning components! Turn guide bushing (pos.3) clockwise with the ratchet wrench until the belts are pre-tensioned. ð The hinged motor support is partly held by the belt drive and rests lightly on the guide bushing (pos.3).
Page 160: Replacing Belts, Version Without Lifting Device
Maintenance Maintenance work > Replacing belts, version without lifting device Checking the protective cover Check the spacing of the protective cover of the motor shaft. The protective cover should be at a distance of approx. 10 mm from the motor drive shaft. By loosening the fastening screws, the protective cover can be moved.
Page 161 Maintenance Maintenance work > Replacing belts, version without lifting device Raising the hinged motor support of the DN80 Insert the lifting bracket in the motor’s attachment rail. NOTICE! Only use hydraulic lifts on solid, level ground. Position the hydraulic lift securely. Fig.
Page 162: Checking The Intake Pressure Valve
Maintenance Maintenance work > Checking the intake pressure valve NOTICE! Risk of damage to the belt drive! The hinged motor support must not rest on the base sup- port, the transport securing rod or similar equipment. Completely remove the hydraulic lift, transport safety rod and other auxiliary equipment and store them safely for future maintenance purposes.
Page 163: Checking That Sealing Plugs Have Been Removed
Maintenance Maintenance work > Checking the starting strainer Remove the side-mounted sealing screws. Guide screwdrivers through the holes. Raise the valve bell carefully. Ensure correct operation, correct movability and exact align- ment! An intact valve can be moved and closes correctly. After the check, remove the screwdrivers and seal the holes with sealing screws.
Page 164: Checking The Non-Return Flap
Maintenance Maintenance work > Checking the non-return flap NOTICE! Risk of machine damage from suctioned grease! Ensure the inside of the pipe is clean. If resistance does increase during the first 500 operating hours and the starting strainer remains clean, it can be removed.
Page 165: Checking The Inlet And Exhaust Air Openings On The Acoustic Hood
Maintenance Maintenance work > Checking the inlet and exhaust air openings on the acoustic hood If no damage and/or hardening is visible, the sealing is acceptable. ð Re-use the non-return flap. If damage and/or hardening is visible, the sealing is not acceptable.
Page 166: Checking The Belt Guard
Maintenance Maintenance work > Checking pipelines for tightness Pull the fan from the shaft and replace it. Seal the screw for attaching with liquid thread locker. Screw on the fan. Close the maintenance elements of the acoustic hood. Check the cooling air flow during machine operation. 8.3.15 Checking the belt guard Damage and stability...
Page 167: Cleaning After Maintenance
Maintenance Commissioning after maintenance 8.4 Cleaning after maintenance Cleaning after maintenance work NOTICE! Risk of damage! Do not used high pressure cleaners, steam jet pumps, grease removal agents, thinners, compressed air etc. as cleaning methods. Dust and dirt must be cleaned with suitable cloths. Clean components susceptible to scratches, display units and touch panels of control systems, gauges etc.
Page 168: Checks After Maintenance Work
Maintenance Checks after maintenance work 8.6 Checks after maintenance work Inspection After the first 3 op. After the first 25 op. Intake pressure Check for correct valve operation Oil level check and, if neces- check and, if neces- sary, correct sary, correct Aligning the check, if necessary...
Page 169: Malfunctions
Malfunctions Safety instructions Malfunctions The following chapters describe possible causes of faults and steps to be taken to rectify them. If faults cannot be rectified using the following instructions, contact the manufacturer. 9.1 Safety instructions Improper fault rectification WARNING! Risk of injury due to improper operation fault rectification! Improper fault rectification may lead to serious injury or material damage.
Page 170 Malfunctions Safety instructions Securing the machine against restarting WARNING! An unauthorised or unregulated restart can have fatal consequences. An unauthorised or unregulated restart of the machine can lead to serious or fatal injuries. There may be people located in the hazard area. –...
Page 171: Fault Displays
Malfunctions Fault diagnosis and troubleshooting Behaviour in the event of faults DANGER! Risk of injury during fault rectification! In the event of a malfunction, activate the EMERGENCY STOP immediately. Switch off the main circuit breaker and secure it. Immediately inform the responsible staff on location about the fault.
Page 172 Malfunctions Fault diagnosis and troubleshooting Fault description Cause Remedy Personnel Abnormal running Sheaves are not Check and, if necessary, correct align- Service per- Ä Chapter 8.3.6 „Checking the sounds aligned properly. ment. sonnel sheaves“ on page 157 Bearing damage. Replace bearings. Manufacturer’s customer service division...
Page 173: Status And Error Messages (Component Suppliers)
Malfunctions Commissioning after malfunction rectification Fault description Cause Remedy Personnel Mechanical damage. Replace malfunctioning components. Service per- sonnel Belts are vibrating. Wear and tear on belts. Ä Chapter Service per- Replace the belts. 8.3.8 „Replacing belts, version with sonnel lifting device“ on page 158 Ä...
Page 174: Checks After Malfunction Rectification
Malfunctions Checks after malfunction rectification Inform the responsible on-site person about the result of the work carried out 9.6 Checks after malfunction rectification Inspection After the first 3 op. After the first 25 op. Intake pressure Check for correct valve operation Oil level check and, if neces-...
Page 175: Disassembly And Disposal
Safety instructions Disassembly and disposal Protecting the environment and conserving resources are among AERZEN’S foremost priorities. Once the machine’s service life is over, it must be disassembled and disposed of in an environmentally-friendly way. The following is a set of recommendations for environmentally-friendly disposal.
Page 176 Disassembly and disposal Safety instructions Disassembling the delivery line WARNING! Risk of injury from compressed conveyed materials! For the disassembly of pressurised components such as pipes, containers, hoses or valves, hot conveying material escapes with a strong gas flow. This can result in serious injury. –...
Page 177: Disassembly
Disassembly and disposal Disposal Protective equipment: Protective work clothing Safety shoes Hearing protection Protective gloves Safety goggles Industrial hard hat Special tools Requirements for disassembly: Special tool: General tool kit Tools for authorised electricians Auxiliary materials, aids Lifting equipment Transport equipment Special tool: Locking key 10.2...
Page 178 Disassembly and disposal Disposal Proper disposal In as far as no agreement has been made on the return or disposal of the machine, send dismantled components for recycling: Scrap metals. Send plastics for recycling. Sort and dispose of other components according to material composition.
Page 179 Disassembly and disposal Disposal Requirements for personnel Disposal requirements: Personnel: Skilled staff for industrial waste Protective equipment Disposal requirements: Protective equipment: Protective work clothing Safety shoes Hearing protection Protective gloves Safety goggles Industrial hard hat Special tools Disposal requirements: Special tool: Lifting equipment Categories for sorting Scrap iron...
Page 180 Disassembly and disposal Disposal Scrap iron Non-ferrous metal Insulation material Electronic waste Auxiliary mate- (except for scrap (encoder elec- rials and chemi- iron) tronics) cals Heat insulation AERtronic batteries materials This does not Valve disposal This does not Solvents, include: include: cleaning agents Remove the...
Page 181: Technical Specifications
Technical specifications Dimensions and weights Technical specifications 11.1 Dimensions and weights General information The following dimensions and weights relate to standard variants and can vary depending on the specific design. Exact details can be found on the installation drawing. Information on weight can be found on the packing note and the designation on the type plate.
Page 182: Dimension Specifications Sheet
Technical specifications Dimension specifications sheet Vacuum operation Size Width (W) Depth (D) Height (H) Nominal Weight Weight with diameter without acoustic acoustic hood, hood, without excluding motor and motor and without belt belt drive drive approx. kg approx. kg GM 80 L 1900 2200 2344...
Page 183: Operating Data
Technical specifications Operating data 11.3 Operating data 10.04.2017 G4-008 M...
Page 184: Technical Performance Data
Technical specifications Technical performance data 11.4 Technical performance data Tab. 4: Operating and application limits Vacuum operation Size Differential pressure volume flow Motor rating max. mbar max. kW max. m GM 3 S -500 GM 4 S -500 GM 7 L -500 GM 10 S / DN80 -500...
Page 185: Type Plate(S) And Placement
Technical specifications Type plate(s) and placement Environmental limits Data Value Unit Temperature range -10 to 40 °C Mounting of acoustic hood heating less than -10 °C Relative humidity 0 to 80 % Chemical-free atmosphere operating period Data Value Unit Maximum continuous operating period 24 hrs Pause until next operation / hrs...
Page 186 Technical specifications Type plate(s) and placement Type plate - pos.2 Fig. 164: Type plate Pos.1 Machine type Pos.2 Factory/serial number Pos.3 Order no. Pos.4 Machine rotational speed Pos.5 Power consumption Pos.6 Year of manufacture Pos.7 Weight Pos.8 Motor rotational speed Pos.9 Conveyed amount Pos.10 Intake pressure (absolute) - p1...
Page 187 Technical specifications Type plate(s) and placement Manufacturer and type plate - pos.1 Fig. 166: Acoustic hood manufacturer/performance data plate Pos.1 Manufacturer, including address Pos.2 Designation Pos.3 Machine type Pos.4 Customer order no. Pos. 5 Serial number Pos.6 Year of manufacture Item 7 max.
Page 188: Noise Emissions
Technical specifications Noise emissions 11.6 Noise emissions Information on noise emissions This information is determined in accordance with the performance Ä Chapter 11.4 „Technical performance data“ on page 184. data. No-load operation or operation below the maximum performance values reduces noise emissions. Machines without an acoustic hood have considerably higher noise emissions.
Page 189: Operating Materials
Low-load operation Using these machines for "low-load operation with minor pres- sure differences" requires prior consultation with AERZEN Cus- tomer Service or the sales company. To select a suitable lubricant, the operating conditions, load and operating data need to be taken into account.
Page 190 Final compression temperature (machine stage) over 140°C Ambient temperature* no constraints Example: ESSO Glycolube 220, ARAL Degol GS 220 11.7.1.2 Changing oil types Delta Lube 06, AERZEN special rotary piston oil --> fully syn- thetic PAO lubricants G4-008 M 10.04.2017...
Page 191: Lubricant Oil In The Food And Pharmaceutical Industry
Only oil of the same type should be used for topping up. Delta Lube 06, AERZEN special rotary piston oil, fully syn- thetic PAO lubricants --> polyglycol oils (PAG) The AERZEN lubricants (Delta Lube 06, AERZEN special rotary piston oil) as well as PAO lubricants are not compatible with poly- glycol oils (PAG) or perfluorinated polyether oils, e.g.
Page 192: Grease Specifications
Only for the gas-tight version of the drive shaft! Tab. 13: Greases for the gasket of the drive shaft Grease KHC-2P-30 Using the lubricating oils according to AERZEN lubricating oil specification, excluding polyglycols Filling at the factory KLÜBER PETAMO GHY 133 N...
Page 193: Lubricant Quantities
Technical specifications Operating materials > Lubricant quantities 11.7.4 Lubricant quantities Machine lube oil levels The following values for lube oil levels are guide values. The main factor in determining the oil fill quantity is the displays of the relevant oil level pointer.
Page 194 Technical specifications Operating materials > Lubricant quantities Total oil quantity Oil level at centre of sight glasses on machine stage Operating material Machine type Filling quantity, approx. Unit GM 25 S 1.20 GM 30 L 1.20 GM 35 S 3.00 GM 50 L 3.50 GM 60 S...
Page 195: Coating
Technical specifications Coating Stauffer lubricators Tab. 16: Grease amount per Stauffer lubricator for each rotation Stauffer lubricator size Rotation Grease amount in Fig. 167: Stauffer lubricator Drive motor grease quantity Observe the separate motor documentation and the information on the type plate of the motor. Filling quantity, Operating material Motor size...
Page 196: Electrical Details
Technical specifications Accessory information > Balancing grade 11.9 Electrical details 11.9.1 Voltage fluctuations Permissible voltage fluctuations Permissible voltage fluctuations are described in the international standard IEC 60038 subject to country-specific supply voltage tol- erances. Machine use only in a stable three-phase power supply. Voltage fluctuations or drops beyond the tolerance level may cause serious damage to the drive system.
Page 197: Notes On The Declaration Of Conformity
Fax: +49 5154 81-9191 Phone: +49 5154 81-0 E-mail: info@aerzener.de Fax: +49 5154 81-9191 Internet: www.aerzen.com E-mail: info@aerzener.de Reherweg 28 Internet: www.aerzen.com 31855 Aerzen, Germany Reherweg 28 31855 Aerzen, Germany Product Designation Type Serial no. Order no. Year of construction We hereby declare that the above product complies with all applicable provisions of the Machinery Directive 2006/42/EC.
Page 198: Glossary
Glossary Glossary ·Bar chart display A bar chart display is a display method which uses a scale to represent the size of a signal with a representative bar that changes in length depending on the signal size. ·Belt run The belt section between two sheaves is termed a “belt run”. ·Discharge temperature Temperature measured at the discharge sockets of the machine stage.
Page 199: Index
Index Index Safety instructions ....104 Control elements ......61 Accessories .
Page 200 Index Lubricants ......51 Lubricants Filling quantities ..... 193 Exhaust silencer .
Page 201 Index Overview Switching off Assemblies ....52, 54, 55 Operating mode ..... 127 Switching on .

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