Operating Instructions V-KTR
Contents
1. Section 5 3 Machine or system leaking Check the pipework and screw connections for leaks and to ensure that they are firmly seated Section 7 2 Discs are damaged Replace discs 26 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH Section 7 2 2 Section 7 4 Elmo Rietschle A Gardner Denver Product Fault Cause Malfunctions Causes and elimination Troubleshooting Important Overpressure or vac uum not achieved Machine or system leaking Check the pipework and screw connections for leaks and to ensure that they are firmly seated Section 7 2 Discs are worn or damaged Replace discs Section 7 2 2 Section 7 4 Machine gets too hot Ambient or intake temperature is too high Ensure it is being used prop erly Section 2 3 Cooling air supply is ob structed Check environmental condi tions Section 5 1 Clean ventilation slots Section 7 2 The blow out filter cartridge is dirty Clean or replace the filter cartridges Section 7 2 3 Section 7 4 The regulating valves are dirty so that the permissible pres sure and or vacuum values have been exceeded Clean or replace the regulat ing valve Section 7 2 Section 7 4 The machine makes a abnormal noise The compressor housing is worn chatter marks Repair by manufacturer or authorised workshop Elmo Rietschle Service A r2. cannot be started and delays will result This declaration must only be filled in and signed by authorised qualified staff 1 Type of vacuum pumps components 2 Reason for the submission Type description Machine number Order number Delivery date 3 Condition of vacuum pumps components 4 Contamination of the vacuum pumps Was this being operated YES O NO QO components when in use Which lubrication was used Toxic YES NO Corrosive YES NO Was the pump component emptied Microbiological YES NO Product Consumables YES NO U Explosive YES NO Has the pump component been cleaned and decontamingRadioactive YES NO other YES NO OOOOOO YES OU Cleaning agent Cleaning method Microbiological explosive or radioactively contaminated vacuum pumps components will only be accepted with proof that they have been cleaned properly Type of toxic substance or process related dangerous reaction products with which the vacuum pumps components came into contact Trade name manufacturer s Chemical Hazard Action to be taken if toxic First aid in the event of product name name class substances are released accidents Personal protection measures Hazardous decomposition products when subjected to thermal load YES NO DO Which 5 Legally binding declaration We swear that the information in this declaration is accurate and complete and that the undersigned am ina position to judge this We are aware that
3. deviation Elmo 25 Rietschle A Gardner Denver Product 6 Commissioning and decommissioning 6 1 Commissioning Elmo LB Rietschie ene bo Ped A Commissioning and decommissioning Improper use May lead to severe or fatal injuries Therefore be sure to obey the safety instructions Hot surfaces When the machine is at operating temperature the surface temperatures on the components Fig 2 Q may go above 70 C You must avoid touching the hot surfaces marked with warning plates Noise emission The highest noise pressure levels measured as per EN ISO 3744 are given in Section 9 When spending a long time in the vicinity of the running machine use ear protectors to avoid permanent damage to your hearing NOTICE Wait until the machine stops The machine must only be switched on again after it stops www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 17 Commissioning and decommissioning 6 1 1 Checking the rotation direction The drive shaft direction of rotation is shown by the rotation direction arrow Fig 2 0 on the mo tor flange Start the motor briefly max two seconds to check the direction of rotation When looking at the motor fan it must rotate clockwise A NOTICE Incorrect direction of rotation Running the machine in reverse for a long time may cause damage to the blades which may lead to the blades breaking Use a phase sequence indicator to check
4. ensure that it cannot be switched on again Undo the screws Fig 9 ss on the motor flange Fig 9 n Remove the motor axially with the half of the coupling on the motor side Fig 5 q and sus pend with the lifting device If the sprocket Fig 9 k is damaged or worn then replace it The fan Fig 9 v should also be checked for damage from time to time and replaced if necessary NOTICE Do not operate without the flywheel mass Abb 9 n Frequent starting up and high ambient tempera ture The service life of the sprocket Fig 9 k is re duced Re assemble in reverse order www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 23 Maintenance and repair 7 3 Repair Service a For on site repair work the motor must be disconnected from the mains by a qualified electrician so that it cannot be started up again accidentally For repairs use the manufacturer its branch offices or authorised dealers Please contact the manufacturer for the address of the service centre responsible for you see Manufac turer s address NOTICE For each machine that is sent to an Elmo Rietschle Service centre for inspection maintenance or repair a fully completed signed declaration of harmless ness must be enclosed L The declaration of harmlessness is part of the sup A plier s documentation in Pasame Snes Vider es Pr nae be U tera gesse
5. plate a Thread hole s Screws w Slotted nut 7 2 2 Blades 20 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH A bearing motor side The A bearing motor side has life long lubrication and is therefore maintenance free After 20 000 op erating hours or 2 years 3 shift operation the A bearing must be replaced by a qualified professional or by our authorised workshops B bearing side facing away from the motor The B bearing on the side facing away from the mo tor must be lubricated on the grease nipple Fig 4 L with 4g of grease after 3 000 operating hours but no later than after one year To lubricate the inlet grating Fig 4 G must be unscrewed NOTICE Do not overfill the grease reservoir Fig 5 c on the B bearing We recommend the following brands of grease Kl berPetamoGY193 or other equivalent greases see also grease recommendation plate Fig 4 M Blade check V KTR models have 7 carbon blades that gradually wear out during operation First check after 3 000 operating hours and then every 1 000 operationg hours or depending on the height Fig 5 X earlier Remove inlet grating Fig 4 G as well as screws Fig 5 s To lift the housing lid Fig 5 b from the housing two screws Fig 5 s must be screwed into the two tapped holes Fig 4 a on the housing lid evenly Remove the blades Fig 5 d to be checked All blades on the machine mu
6. 1 1 Lifting and transporting 1 Transport shackle 2 Fixing screw 10 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH LD Rietschle Transport storage and disposal 3 2 Storage NOTICE Material damage caused by improper storage gt Ensure that the storage area meets the following conditions a dust free b vibration free 3 2 1 Ambient conditions for storage Ambient conditions Value Relative humidity 0 to 80 Lagertemperatur 10 C to 60 C The machine must be stored in a dry environment with normal air humidity It should not be stored for more than 6 months see Info Machine storage guidelines Page 4 Danger from inflammable corrosive or poison ous substances Machines that come into contact with hazard ous substances must be decontaminated before disposal 3 3 Disposal gt When disposing ensure the following a Collect oils and grease separately and dispose of in accordance with the local regulations in force b Do not mix solvents limescale removers and paint residues c Remove components and dispose of them in accordance with the local regulations in force d Dispose of the machine in accordance with the national and local regulations in force e Parts subject to wear and tear marked as such in the spare parts list are special waste and must be disposed of in accordance with the national and local waste laws El 25 Rie
7. Edition 1 12 2009 BA 461 EN Operating Instructions Elmo Vesp Rietschle V KTR 100 140 A Gardner Denver Product V Serie V Series Drehschieber Rotary Vane Table of contents 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 1 3 2 3 3 4 2 4 3 5 1 5 2 5 3 5 4 5 5 6 1 6 2 6 3 Table of contents ele WEE 4 Pririclples iii A as Sed ade Rah a FE eae A EUG pau Ue al dade Bk 4 Target grouDuauss ssec cpi a het Ie onde RBEGHe Re haer ee a DRY RUBY dae Pai EG gor pe d 4 Supplier documentation and accompanying documents 4 Abbreviations 2 onda ce eme Sia ea e e dac e NEEN RE 4 Directives standards laws llle hs 4 Symbols and meaning xa bene eed eee ew wae en en nn 5 Technical terms and meaning oooooooccrn ln 5 Copyright zx SNE Ee ue x RR ERE EA shales iR Ree BA e he Ced nt Raed QE RE dpa 5 Sadfely suit A A A AA AAA 6 Warning instruction markings 6 General 22 mex RR REREIRA E Re3 ee Seed Pee et eee eee eevee edt E 6 DD sigriated Se s ax tet dose biden a O ob ated a a ales 7 Unacceptable operating mode 7 Personal qualifications and training 2 0 00 eee 8 Salety CONSCIOUS WOK iE E RERO Pix bx RUE OES re mae eS ued ad dred eS 8 Safety notes for the operato eee 8 Safety instructions for installing commissioning and maintenance ulsss 9 Guarantee Conditions xiii SINT dk Rue Gee ee ce ee ee EE 9 Transport s
8. Ensuring operational safely 00 eee 19 Maintenarice work 22 253 omie Goad a ans bee ed o ta Fon Rope Doe ieee Bes 19 7 2 1 PSCC ATION eii postor TE REEL OU EE 20 7 2 2 BIAS ci a en AA eee A ERA BS re 20 7 2 3 Ait filtering lt lt lt ER AA tee AR 22 7 2 4 reel P een a aaah eee 23 Repair Service iii a a we te a 24 Sparo DEE ee SE ne etf eene 25 Malfunctions Causes and elimination eee ee 26 Technical Data i 226 dE N NN Ne n RR ER ana a ce ea a a ee en 28 El 25 Rietschle www gd elmorietschle com O Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 3 A Gardner Denver Product Foreword 1 Foreword 1 1 Principles 1 2 Target group These operating instructions are a part of the following dry running ro tary vane pressure vacuum pumps models V KTR 100 and V KTR 140 describe how to use them safely and properly in all life phases must be available where the equipment is used The target group for these instructions is technically trained specialists 1 8 Supplier documentation and accompanying documents Document Contents No Supplier documentation Operating Instructions BA 461 EN Declaration of Conformit C 0001 EN Declaration of harmlessness 7 7025 003 17 Spare parts list Spare parts document E 461 Data sheet Technical data and graphs D 461 Info sheet Storage guidelines for machines 1 150 Manufacturer s de
9. chine in non commercial plants if the necessary precautions and protective meas ures have not been taken in the plant installing in environments that are at risk of ex plosions using the machine in areas with ionising radia tion back pressures on the outlet side of more than 0 1bars modifications to the machine and accessories www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 7 Safety 2 5 Personal qualifications and training 2 6 Safety conscious work 2 7 8 Ensure that people entrusted with working on the machine have read and understood these operating instructions before starting work particularly the safety instructions for installation commissioning maintenance and inspection work Manage the responsibilities competence and monitoring of staff all work must only be carried out be technical specialists e Installation commissioning maintenance and inspection work e Working with electricity personnel being trained to work on the ma chine must be supervised by technical special ists only The following safety regulations apply in addition to the safety instructions and intended use listed in these instructions Safety notes for the operator www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH Accident prevention regulations safety and op erating regulations the standards and laws in force hot par
10. claration 1 4 Abbreviations 1 5 Directives standards laws 4 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH EU Directive 2002 95 EG RoHS Fig Figure V KTR Pressure vacuum pump m h Volume flow compressed suction air bar Overpressure vacuum See Conformity Declaration Elmo 25 Rietschle A Gardner Denver Product Foreword 1 6 Symbols and meaning Explanation gt Condition pre requisite THHHE Instructions action a b Instructions in several steps gt Results gt 14 Cross reference with page number re N Information note eo Safety symbol Warns of potential risk of injury Obey all the safety instructions with this symbol in order to avoid injury and death 1 7 Technical terms and meaning Term Explanation Machine Pump and motor combination ready to be connected Motor Pump drive motor In combined use the machine may produce a vacuum and excess pres Pressure vacuum pum pump sure at the same time Rotary vane Machine s design or active principle Volume flow A pressure vacuum pump s suction air or compressed air Overpressure pressure Difference in pressure compared with atmospheric pressure The corre sponding working pressure is greater than the atmospheric pressure Under pressure vacuum Difference in pressure compared with atmospheric pressure The corre sp
11. e separated by an integral filter if necessary A fan between the compressor housing and the motor provides intensive air cooling The compressor housing is located in a sound cover The compressed air is cooled by a cooling segment The machines are driven by standard flanged three phase motors using a coupling Pressure and vacuum can be adjusted to the required levels however they are limited to a maximum point 4 3 Areas of application These dry running rotary vane pressure vacuum pumps models V KTR 100 and V KTR 140 are suitable for creating pressure and vacuum at the same time Constant operation is permissible All models have nominal capacities of 100 and 140 m hr operating at 50 cycles The pressure and vacuum limits bar are indicated on the data plate Fig 2 N The tables showing capacity against pressure and vac uum can be seen in data sheet D 461 These dry running machines are suitable for conveying air with a relative humidity of 30 9096 If the unit is switched on more frequently at regular intervals of about 10 times an hour or at A higher ambient temperatures and intake temperatures the excess temperature limit of the motor amp y winding and the bearings may be exceeded i Please contact the manufacturer should the unit be used under such conditions O If it is installed in the open air the unit must be protected from environmental influences e g by a protective roof El 25 Rietschle www gd elmorietsch
12. egulating valve is vibrating Replace the valve Section 7 4 Discs are damaged Replace discs Section 7 2 2 Section 7 4 Please contact Elmo Rietschle Service for other malfunctions or those that cannot be eliminated Elmo Rietschle A Gardner Denver Product www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 27 Technical Data 9 Technical Data V KTR Sound pressure level max EN ISO 3744 Tolerance 3 dB A Sound power level Weight Length Width Height Vacuum connection Pressure connection Die Lange sowie das Gewicht k nnen je nach Motorfabrikat von den hier aufgef hrten Angaben abwei chen You will find more technical data on the data sheet Bir PB tiene ES ES e Download the PDF file D461 gt V KTR 100 V KTR 140 e Download the PDF file ttp www gd elmorietschle com Downloads Product Documents gt V Series Data Sheets NOTICE Subject to technical changes Fig 13 Data sheet example 28 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Ricischle A Gardner Denver Product Elmo Rietschle A Gardner Denver Product Gardner enver Elmo Rietschle i
13. er Product Installation 5 5 16 Connecting the motor www gd elmorietschle com O Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH A M Danger of death if the electrical installation has not been done professionally The electrical installation may only be done by a spe cialist electrician observing EN 60204 The operating company has to provide the main switch 8 The motor s electrical data is given on the data plate Fig 2 N or on the motor data plate The motors comply with DIN EN 60034 and are in protection class IP 55 and insulation class F The appropriate connection diagram is located in the motor s terminal box not for the plug connec tion version Compare the motor data with the data of the existing mains network current type voltage network frequency permitted current value Connect the motor via plug connector if fitted or via the motor protection switch for safety reasons a motor protection switch is required and the connecting cable must be installed via a cable fitting to provide strain relief We recommend using motor protection switches with delayed switch off depending on possible excess current Temporary excess current can occur when the machine is started cold NOTICE Power supply The conditions at the installation location must match the information on the motor data plate Without derating the following is permissible e 5 voltage deviation e 2 frequency
14. haft passes through the housing lid Otherwise this grease would get into the compressor housing and would mix with the blade wear debris to form a paste like coating that could cause the blades to jam in the rotor slots When screwing the housing lid on the grease free screws should be tightened alternately and evenly so that the lid does not get jammed on the locating pins As soon as the lid is almost resting on the front of the housing it is advisable to turn the fan to and fro using a screw driver or similar while you finish screwing in the screws This will prevent the corners of the blades getting jammed and breaking away Screw in the inlet grating Fig 4 G NOTICE Ensure that no dirt gets into the bearing At each blade change check the grease reservoir Fig 5 c on the B bearing and top up if necessary www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 21 Maintenance and repair 7 2 3 Air filtering Fig 7 Air filtering e Filter cartridge suction air f Filter cartridge exhaust air g Filter housing cover h Filter screw in knobs Fig 8 Purging filter cartridge 1 Filter cartridge 2 Compressed air NOTICE Insufficient maintenance on the air filter The power of the machine lessens and damage may occur to the machine The filter cartridges Fig 7 e and Fig 7 f must be cleaned by blowing through from the inside out once a mon
15. le com O Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 1 3 A Gardner Denver Product Installation 5 Installation 5 1 Preparing for installation Check the following points e Machine freely accessible from all sides e Do not close ventilation grids and holes e Sufficient room for installing and removing pipes and for maintenance work particularly for install ing and dismantling the machine e No external vibration effects e Do not suck any hot exhaust air from other ma chines into the cooling system The cooling air inlets Fig 2 E and the cooling air outlets Fig 2 F must be at least 30 cm away from adjacent walls Cooling air coming out must not be sucked in again or maintenance work there must be a minimum of 40 cm in front of the filter housing Fig 2 S and the inlet grating Fig 2 G O The filter housing Fig 2 S should be easily accessible 5 2 Installation NOTICE The machine may only be operated when it is set up horizontally Material damage resulting from the machine tipping over and falling When installed at more than 1000 m above sea level a reduction in power is noticeable In this case we would ask you to contact us Ensure that the foundation complies with the follow ing conditions e Level and straight e The bearing surface must be able to bear the weight of the machine Te It is possible to install the machine on a firm base without anchoring When installi
16. le on site for the technical personnel operator Instructions fixed directly onto the machine must be obeyed and must always re main legible This applies for example to e Symbols for connections e Data and motor data plate e Instruction and warning plates The operator is responsible for observing local regu lations El 6 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle Ganar Der Product 2 3 Designated use Safety The machine must only be operated in such areas as are described in the operating instructions 2 4 Unacceptable operating modes Elmo 25 Rietschle A Gardner Denver Product only operate the machine in a technically perfect condition do not operate the machine when it is only par tially assembled the machine must only be operated at an ambi ent temperature and suction temperature of between 5 and 40 C Please contact us for temperatures outside this range the machine may convey compress or extract the following media e convey air with a relative humidity of 30 90 e all non explosive non inflammable non ag gressive and non poisonous dry gases and gas air mixtures extracting conveying and compressing explo sive inflammable aggressive or poisonous me dia e g dust as per ATEX zone 20 22 solvents as well as gaseous oxygen and other oxidants extremely damp air water vapour traces of oil oil vapour and grease using the ma
17. manufacturer The use of other parts may lead to malfunctions and invalidate liability or the guarantee for any consequences arising www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Malfunctions Causes and elimination 8 Malfunctions Causes and elimination Fault Cause Troubleshooting Important Machine is switched off by the motor pro tection switch Mains voltage Frequency does not correspond with the motor data Connection to motor terminal board is not correct Motor protection switch is not set correctly Check by qualified electrician Motor protection switch is triggered too quickly Use a motor protection switch with an overload dependent delayed switch off that takes into consideration the short term excess current at start up version with short circuit and overload trigger as per VDE 0660 Part 2 orlEC 947 4 Section 5 5 The blow out filter cartridge accessory is dirty Clean or replace the filter cartridges Section 7 2 3 Section 7 4 The regulating valves are dirty so that the permissible vacu um value is exceeded Clean or replace the regulat ing valves Section 7 2 Section 7 4 Blowing capacity is insufficient Intake filter and or blow out filter are dirty Clean or replace the intake filter Section 7 2 3 Section 7 4 The pressure line is too long or too narrow Check the hose or the pipe
18. nce intervals also depend on the operational demands on the machine With any work observe the safety instructions described in Section 2 8 Safety notes for installation com missioning and maintenance The whole unit should always be kept in a clean condition 7 2 Maintenance work Interval Maintenance to be carried out Section monthly Check the pipes and screws for leaks and to ensure they are seated properly and if necessary seal again or tighten up monthly Check the terminal box and cable inlet holes for leaks and if necessary re seal monthly Clean the regulating valves and ventilation slots on the ma chine and the motor cooling ribs If there is a great deal of dust in the spaces on the cooling ribs and cooling pipes after removing the inlet grating Fig 2 G and the protective cover Fig 5 G1 clean by blowing through 20 000 h Change the bearing on the motor side 3 000 h Lubricate the bearing on the side facing away from the motor 3 000 h 1 000 h Check blades Replace blades monthly every 6 months Clean or replace filter cartridges at least once a year Check for coupling wear 25 Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 19 A Gardner Dany Prot Maintenance and repair 7 2 1 Lubrication ard ecu Fig 4 Lubrication Discs G Inlet grating L Grease nipple M Grease recommendation
19. negjieme or schaute I q a I E b After a repair or re commissioning the actions listed under Installation and Commissioning must be carried out as for initial commissioning Fig 10 Clearance certificate 7 7025 003 17 El 24 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH I Rietschle A Gardner Denver Product 7 4 Spare parts ji rn Fig 11 Spare parts list example ae Klicken Sie hier wenn Sie den Katalog ohne Zugangskennung benutzen m chten keine Bestellmogichkeit Click here if you wart to acess the catalog without using e password no ordering possible Bitte w hlen Sie Ihre Sprache Please choose your language a a amp Keen a n RE D p Fig 12 Web site http www service er de Elmo Rietschle A Gardner Denver Product Maintenance and repair Order spare parts in accordance with the Spare parts list E461 gt V KTR100 V KTR 140 e Download the PDF file tp www gd elmorietschle com Downloads Product Documents gt V Series Spare Parts e Parts subject to wear and gaskets are indi cated separately on the list Web site http www service er de e Select the type size and design NOTICE Only use original spare parts or parts approved by the
20. ng on a substruc v L ture we recommend fixing with flexible buffers EI 14 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle A Gardner Denver Product Installation 5 3 Connecting pipes a Vacuum connection at Fig 2 A and pressure connection at Fig 2 B NOTICE Material damage resulting from the forces and torques of the pipes on the unit being too high Only screw pipes in by hand Long and or small bore pipework should be avoided as this tends to reduce the capacity of the machine b Check to ensure the intake line and pressure line are connected correctly NOTICE Length of the connection pipes With connection pipes that have the same pipe cross section as the machine connection and are more than 3 m long a non return valve especially for the purpose must be installed in order to avoid reverse operation when the machine has stopped 5 4 Control and relief valves The required pressure and vacuum ranges can be set with the pressure regulating valve Fig 2 D and the vacuum regulating valve Fig 2 C as shown on the symbol plate attached to the rotary knob NOTICE Do not operate without the standard control and relief valves If the permissible final compression pressure is exceeded see data plate the machine may be damaged 2 Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 15 A Gardner Denv
21. onding working pressure is lower than the atmospheric pressure The noise emitted at a specific loading given as a figure sound pressure Noise emission level dB A as per EN ISO 3744 1 8 Copyright Passing on or copying this document using and providing information on its contents are prohibited unless expressly permitted El 25 Rietschle www gd elmorietschle com O Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 5 A Gardner Denver Product Safety 2 Safety 2 1 Warning instruction markings Danger level The manufacturer is not responsible for damage if you do nat follow all of this documentation Consequences if not obeyed immediately imminent danger Death severe bodily injury possible imminent danger Death severe bodily injury possible hazardous situation Slight bodily injury NOTICE 2 2 General possible hazardous situation Material damage These operating instructions contain basic instruc tions for installation commissioning maintenance and inspection work which must be obeyed to en sure the safe operation of the machine and prevent physical and material damage The safety instructions in all sections must be taken into consideration The operating instructions must be read by the responsible technical personnel operator before installing and commissioning and must be fully un derstood The contents of the operating instructions must always be availab
22. peration by insufficiently qualified staff Using spare parts that have not been approved by Gardner Denver Schopfheim GmbH Unauthorised modifications to the machine or the accessories supplied by Gardner Denver Schopfheim GmbH www gd elmorietschle com O Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 9 Transport storage and disposal 3 Transport storage and disposal 3 1 Transportation 3 1 1 Unpack and check the delivery condition 3 1 2 Lifting and transporting Unpack the machine on receipt and check for transport damage Notify the manufacturer of transport damage im mediately Dispose of the packaging in accordance with the local regulations in force Death or limbs crushed as a result of the items being transported falling or tipping over When transporting with the lifting device remem ber Select the lifting device suitable for the total weight to be transported Ensure that the machine cannot tip and fall Do not stop under a suspended load Put the goods to be conveyed on a horizontal base Lifting device Transporting with a crane Bodily injury resulting from improper operation a Loads crosswise to the ring level are not per mitted b Avoid impact stress a Tighten the fixing screw Fig 1 2 tightly to the transport shackle Fig 1 1 b The machine must be suspended on the trans port shackle using the lifting device for lifting and transporting Fig
23. s a brand of Gardner Denver s Industrial Products Division and part of Blower Operations Gardner enver EC declaration of conformity 2006 42 EC Hereby the manufacturer Gardner Denver Schopfheim GmbH D 79642 Schopfheim that the machine Dry running pressure vacuum pump of the Series V KTR Type V KTR 100 V KTR 140 is conform to the regulations of the guideline indicated above The following harmonized and national standards and specifications are applied EN 1012 1 2010 Compressors and vacuum pumps Safety requirements Part 1 Compressors EN 1012 2 1996 A1 2009 Compressors and vacuum pumps Safety requirements Part 2 Vacuum pumps These declarations of conformity are invalid when the machine has been modified without prior ap proval by us and the approval has been documented in writing Name and address of the EC person in Gardner Denver Schopfheim GmbH charge for documentation Postfach 1260 D 79642 Schopfheim Gardner Denver Schopfheim GmbH Schopfheim 1 8 2011 Dr Friedrich Justen Director Engineering C_0001_EN Safety declaration form 7 7025 003 17 for vacuum pumps and components Page 1 of 1 Gardner Denver Schopfheim GmbH Roggenbachstr 58 79650 Schopfheim Phone 49 0 7622 392 0 Fax 49 0 7622 392 300 Repairs and or maintenance of vacuum pumps and components will only be carried out if a declaration has been filled in correctly and completely If not the repair work
24. st have a minimum height Fig 6 X of more than 26 mm V KTR 100 and 32 mm V KTR 140 and a minimum thickness Fig 6 W of more than 2 5 mm The blades must only be changed as a set Elmo L Rietschie Ae beta Fig 5 Lubrication Blades G Protective cover Housing lid Grease store Blade Screws on OG o o Fig 6 Blades Direction of rotation Minimum thickness Minimum heigh Slanting side of the blade N lt x S oO Drilled holes in the housing Elmo 25 Rietschle A Gardner Denver Product Maintenance and repair Changing blades If the minimum height or the minimum thickness has already been reached or if the blades have fallen below these levels the whole blade set must be changed NOTICE Do not undo the slotted nuts Fig 4 w on the housing lid Fig 5 b Only the screws Fig 4 s need to be removed to change the blades Blow out the housing and rotor slot Insert the blades into the rotor slot BWhen doing this you must ensure that the blades with the sloping side Fig 6 Y point outwards and the direction of rota tion of these sloping sides Fig 6 01 matches that of the drilled holes for the housing Fig 6 2 Before putting the housing cover Fig 5 b back onto the shaft end the excess grease in the grease store Fig 5 c of the B bearing must be completely removed from the bearing cage Also grease residue should be wiped off the end of the shaft and where the s
25. th or more often depending on the level of contamination In spite of cleaning the filters their separation efficiency will continue to deteriorate Therefore the filters should be replaced every six months The filter cartridges Fig 7 e and Fig 7 f can be removed for cleaning after undoing the filter screw knobs Fig 7 h and the filter housing cover Fig 7 Clean the filter housing chambers too NOTICE Do not damage the filter cartridges when clean ing them No dirt must get into the machine when cleaning the filter housing chambers Danger of injury when dealing with com pressed air When blowing through with compressed air solid particles may be carried along or powder dust swirl ing around may cause injury to the eyes Therefore when cleaning with compressed air always wear goggles and a dust mask El 22 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH I Rietschle A Gardner Denver Product 7 2 4 Coupling Fig 9 Coupling k Coupling sprocket m Motor n Motor flange n Flywheel mass q Coupling half on the motor side S5 Screws v Fan Elmo L Rietschie Marar oann Ped Maintenance and repair The coupling sprocket Fig 9 k is subject to wear and must be checked regularly at least once a year Defective coupling sprocket Defective sprockets may lead to the rotor shaft breaking To check the coupling switch the motor Fig 9 m off and
26. the direction of rotation anti clockwise rotating field 6 2 Decommissioning storing Stop the machine 8 b 6 3 Re commissioning Switch the machine off If available close the cut off device in the suction and pressure pipe Disconnect the machine from the electricity source Depressurise the machine Open the pipes slowly c The pressure reduces slowly Remove the pipes and hoses Seal the connections for suction and pressure nozzles using adhesive foil Insert the desiccant bag into the filter housing see also Section 3 2 1 Page 11 Check the condition of the machine cleanliness cabling etc Remove the desiccant bag from the filter hous ing For installation see Section 5 Page 14 For commissioning see Section 6 1 Page 17 EI 1 8 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle A Gardner Denver Product Maintenance and repair T Maintenance and repair A E Danger of death from touching live parts Before maintenance work disconnect the machine by pressing the main switch or unplugging it and ensure that it cannot be turned on again A heey as Hot surfaces During maintenance work there is the danger of getting burnt on hot components Fig 2 Q of the machine Wait for the machine to cool down 7 1 Ensuring operational safety Regular maintenance work must be carried out in order to ensure operational safety Maintena
27. torage and disposal 0000 eee ee 10 Transportation uses kh el Sewn PO RO EN ee eee dae See A eae 10 3 1 1 Unpack and check the delivery condition 10 3 1 2 Lifting and transporting 22 ENNEN RR AEN NEEN BARRE NEE es 10 Sore IM 11 3 2 1 Ambient conditions for storage 11 Disposal orante pueia AERE Pe RE a ae PEE EE 11 Setup and Operation seiss NNN x ara xh mh RR hx RIRs eee Rm RU dob RR 12 SUD errar nung ee EE a 12 4 1 1 Data plate ass ae rn er nr ea 13 DESECFIPEION a e ean e en EE RRE MEAG a en BR ee ee 13 Areas OF application rn deed eres SE Ute eee RA 13 Installation 5 eege 0 0020 Eae ci mc c wa A nein 14 Preparing for installation 0 0 2220 seen rennen RII IR A t 14 Installation co coi a EE ee a Diba E eddie wed ER 14 Connecting pID8S som fa ancora a Ree ees ias ARR peo ol aene RAR 15 Control and relief valves ssr ersi E RR n RR Eer DEELER E ENN EROR E RA S ia 15 Connecting the Motor isi ui epe ka pF ERIS ERE RR ra A 16 Commissioning and decommissioning sees nn nn nn 17 COMMISSIONING eiii dara Dek REO S Rus Pon C EGRE a Kec Run gue we 17 6 1 1 Checking the rotation direction 22222 seen rennen nennen 18 Decommissioning stong 18 El ei UL ENEE 18 El www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle Ganar Denver Product 7 1 7 2 7 3 7 4 Table of contents Maintenance and repair o ooocooconn ee 19
28. ts of the machine must not be accessible during operation or must be fitted with a guard eople must not be endangered by the free ex traction or discharge of pumped media Risks arising from electrical energy must be eliminated Elmo LB Rietschie Ar Do Pete Safety 2 8 Safety instructions for installing commissioning and maintenance 2 9 Guarantee conditions Elmo 25 Rietschle A Gardner Denver Product The operator will ensure that any installation commissioning and maintenance work is car ried out by authorised qualified specialists who have gained sufficient information by an in depth study of the operating instructions Only work on the machine when it is idle and cannot be switched on again Ensure that you follow the procedure for decom missioning the machine described in the operat ing instructions Fit or start up safety and protective devices again immediately after finishing work Vor Wie derinbetriebnahme die aufgef hrten Punkte f r die Inbetriebnahme beachten Conversion work or modifications to the ma chine are only permissible with the manufactur er s consent Only use original parts or parts approved by the manufacturer The use of other parts may invali date liability for any consequences arising Keep unauthorised people away from the ma chine The manufacturer s guarantee or warranty will no longer apply in the following cases Improper use Not complying with these instructions O
29. tschle www gd elmorietschle com O Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 11 A Gardner Denver Product Set up and operation 4 Setup and operation 4 1 Setup Fig 2 Pressure vacuum pump V KTR 100 V KTR 140 Vacuum connection Greasing plate Pressure connection Data plate Vacuum regulating valve Rotation direction plate Drive motor hot surfaces gt 70 C Filter housing Pressure regulating valve Cooling air inlet Cooling air outlet o nm oo mp S e o on oz S Inlet grating Maintenance plate EI 12 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle A Gardner Denver Product Set up and operation 4 1 1 Data plate 1 Type Size mechanical version 1 2 3 4 5 2 Year of construction Gardner Ce Bauj NrS09 3 Mot 3 Motor design A Denver enver en 4 Serial number Typ KTR 100 01 1027630137 0 60 0 60 bar 5 ltem no 100180 miy 6 Overpressure Vacuum 7 Pumping capacity 50 Hz 60 Hz en 8 Speed 50 Hz 60 Hz S1 5 50 6 50 kW 1460 1745 min eg 9 Motor output 50 Hz 60 Hz 10 9 8 7 6 10 Operating mode Fig 3 Data plate 4 2 Description The V KTR range has a connecting thread on the pressure side and on the suction side The aspirated air is cleaned by an inbuilt fine micro filter The carbon dust caused by the scoring of the discs can also b
30. we are liable to the contractor for damage caused by incomplete and inaccurate information We undertake to release the contractor from any damage claims from third parties arising from incomplete or incorrect information We are aware that regardless of this declaration we are directly liable to third parties including in particular the contractor s staff entrusted with handling or repairing the product Company Street Post code Town Phone Fax Name in capitals Position Date Company stamp Legally binding signature TOS no Index 7 7025 003 17 0 Office responsible GS File management 7702500317 xl Gardner Denver Schopfheim GmbH Postfach 1260 D 9642 Schopfheim
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