Gardner Denver EnviroAire 15, Original Operating Manual

Page 1: ...Original Operating and Service Manual 15 22 kW USA Id no ZS1093133 00 June 2012...

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Page 3: ...nd before the compressors are serviced New and edited publications can be obtained from your local Gardner Denver distributor or service center In any communication concerning the compressor it is ess...

Page 4: ...stment Careful adherence to these instructions will result in economical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety...

Page 5: ...voltage at the system terminal strip of the frequency converter by measuring this between the DC and DC terminals the exact position can be found in the supplied operating manual of the frequency con...

Page 6: ...REQUIREMENTS Asphyxiation Hazard Never breathe in compressed air from this system Never operate the unit with open doors or loose access panels Read the operator s manual before proceeding with this t...

Page 7: ...________________________________________________________________________ _____________________________________________________________________________________ _________________________________________...

Page 8: ...horoughly especially under difficult operating conditions Service If you encounter a fault or require spare parts please contact your Gardner Denver representative Trained expert staff will quickly an...

Page 9: ...ndent alterations to the compressor equipment station or installing components which have not been approved by the manufacturer e g separator will result in the loss of the CE mark or other factory ce...

Page 10: ...unctioning 18 5 1 Design of the unit 18 5 2 Schematic diagram 19 5 3 Water circuit 20 5 4 Air circulation 20 5 5 Control 20 6 Transport and installation 22 6 1 Transport 22 6 2 Installation 23 7 Prepa...

Page 11: ...8 Pressure relief valve 40 10 9 Connecting terminals in the switch cabinet control transformer setting 41 10 10 Screw connections 42 10 11 General maintenance and cleaning 42 10 12 Clean change filte...

Page 12: ...ake sure that only authorized personnel use the machine Define who is responsible for operating the machine and authorize him her to ignore instructions from third parties if these instructions could...

Page 13: ...or operating pressures above 102 PSI it is in fact recommended that this safety device should be used for pressures above 58 PSI The steel wire has a diameter of 0 315 and is firmly clamped to the hos...

Page 14: ...that nobody can be injured by the machine installation as it starts up Compressed air may contain substances that may damage your health if inhaled The compressed air produced by these compressors mus...

Page 15: ...s checking the system or working on it For this a label with a corresponding warning notice has to be attached to the remote control equipment Noise even when it is not very loud can make us nervous a...

Page 16: ...be isolated from external lines and hoses The system must be set up on a level surface with full contact between its base frame and the supporting surface 4 6 General workplace dangers Danger Safety m...

Page 17: ...for damaged parts to be replaced Risk of electric shock Have the electrical equipment on a machine system checked regularly Have defects like loose connections or charred cables rectified immediately...

Page 18: ...r or change it in any way If work which produces heat flames or sparks has to be carried out on a machine the adjacent components have to be protected by means of non inflammable material Motor air fi...

Page 19: ...that parts and special accessories not supplied by us are not approved by us Installing or using such products may thus adversely affect active and or passive safety The manufacturer accepts no liabil...

Page 20: ...Pressure holding valve 10 Water connection 11 Cooling air ventilator 12 Cooling air inlet filter mat 13 Compressed air outlet 14 Base frame 15 Control keypad 16 EMERGENCY OFF push button 17 Control ca...

Page 21: ...sure holding valve residual pressure 17 Throttle 18 Manual valve 20 Ventilator 22 Non return valve 23 Throttle 24 Mud flap 25 2 2 directional solenoid valve discharge Y4 26 2 2 directional solenoid va...

Page 22: ...the pressure holding non return valve 7 still remains closed at this pressure level The water supply of the screw compressor 4 is provided by the drop in pressure between the pressure tank 6 and the...

Page 23: ...ins pressure does not drop to the target value within the programmed follow up time then the system will shut down If the target value is achieved before the expiration of the programmed motor follow...

Page 24: ...ft must correspond to the unit width see Section 12 2 Keep the distance between the forks see Fig 4 and their length in mind when transporting the compressor All loose parts or parts which can swing f...

Page 25: ...uched and labeled NOTICE The operator must always provide sufficient ventilation and exhaust for the compressor station Fig 5 The screw compressor unit has to be levelled The system may not be run whi...

Page 26: ...CE The stated minimum cross section refers to a maximum duct length of 16 4 ft and a maximum of one bend In the event of differing values over 16 4 ft more than one bend filter cartridges screens etc...

Page 27: ...drain facilities at their lowest points to drain collected liquids These facilities have to be fitted to allow the observance of the draining of such liquids Hand operated drain facilities have to be...

Page 28: ...g and delay may be used To establish an electrical connection proceed as follows Route the supply cable through the cable gland 1 Fig 10 on the control cabinet and tighten screws Connect the supply li...

Page 29: ...tched on again NOTICE Incorrectly setting the control transformer poses a risk to the trouble free operating of the system Checking the setting of the control transformer is part of commissioning and...

Page 30: ...2 Close manual valve water in 1 Fig 12 Start system and monitor the water level Once the fill level marking Below 4 Fig 12 has been reached turn off system via the emergency off Open manual valve wate...

Page 31: ...water on 1 Fig 12 start the system and observe the water level When the fill level marking Below 4 Fig 12 is reached switch system off via the emergency stop Open manually operated valve water on 1 Fi...

Page 32: ...commissioning 30 7 7 Sound pressure level Sound pressure levels are measured in dB A according to PN8NTC 2 2 under a 70 load at an 11 yard distance tolerance 3 dB A air cooled unit 70 dB A Subject to...

Page 33: ...compressor reservoir and pipe Turn on the main power supply switch After the power supply was switched on all LEDs on the compressor control GD Pilot TS light up for a display test The fault shown on...

Page 34: ...in the pressure reservoir see also chapter 7 4 Open shut off valves between the screw compressor reservoir and pipe Turn on the main power supply switch After the power supply was switched on all LED...

Page 35: ...menu After the acknowledgement the message READY TO START appears on the display unless another fault is present Press START button I 2 Fig 15 8 5 Shutoff To switch off the compressor use the O key 3...

Page 36: ...t possible to specify a maximum permissible standstill time which will apply in all cases NOTICE The following aspects must be taken into account for storage of storing compressors The compressor shou...

Page 37: ...wered There is a risk of electric shock from charged capacitors Disconnect the system from the mains and wait 10 minutes before touching electrical components The power capacitors need this time to di...

Page 38: ...witch cabinet and checking of the control transformer setting Checking tightening screw connections Checking cleaning water level sensor Replace pressure holding non return valve General maintenance c...

Page 39: ...44 000 h 46 000 h 48 000 h 50 000 h 52 000 h 54 000 h 56 000 h 58 000 h 60 000 h 62 000 h 64 000 h 66 000 h 68 000 h 70 000 h 72 000 h 74 000 h 76 000 h 78 000 h 80 000 h 33 m 36 m 39 m 42 m 45 m 48...

Page 40: ...aintenance work make sure that no dirt gets to the clean air side of the air filter Changing intervals for air filter cartridge The operating conditions e g coolant temperatures the operating modes an...

Page 41: ...before removing valves caps plugs fittings bolts and filters Make sure that system is leak tight Fig 18 1 RO membrane cartridge 2 Prefilter RO unit 3 Permeate pump Perform the prefilter change as foll...

Page 42: ...equipment may result in personal injury or death Use the appropriate safety equipment hearing and eye protection and use safety precautions when performing this PRV check on an operating machine DANG...

Page 43: ...em Checking the setting of the control transformer is part of commissioning and part of regular inspection maintenance because the supply voltage can change The connecting terminals in the switch cabi...

Page 44: ...r at people especially Controller components Fittings Air end block Cooler Electric motor Dirt trap strainer 10 12Clean change filter with cooling air inlet and control cabinet inlet DANGER Only perfo...

Page 45: ...intervals between changes may be shorter 10 13Inspection of the compressor stage DANGER Only perform checks and carry out work on the screw compressor when the unit is out of operation depressurized a...

Page 46: ...ed on again CAUTION Caution when draining hot water risk of scalding Allow the unit to cool down first 1 Fig 25 1 2 Fig 26 Check if the water level indicator on the GD Pilot TS display deviates greatl...

Page 47: ...been activated 7 Deactivate remote control timer 8 Excessive mains pressure 8 Wait until the mains pressure has fallen below the lower switching point Unit stops during the start up phase 1 Intake re...

Page 48: ...8 Water injection pressure too low 8 Clean replace water filter cartridge and clean water circuit Excessive idling pressure 1 Intake regulator does not close correctly 1 Check intake regulator Check...

Page 49: ...l fan motor power hp 1 2 Suggested cable cross section 400V AWG 8 AWG 6 Suggested fuse size 400V Amps 40 50 Cooling Cooling air flow through ventilator cfm 3125 3125 Heat rejected by ventilating fan a...

Page 50: ...ter outlet inner thread G 3 8 3 8 NPT C Drain water separator inner thread G 1 4 1 4 NPT not available D Drain RO unit inner thread G 1 4 1 4 NPT E Compressed air connection external threaded connecto...

Page 51: ...read G 3 8 3 8 NPT C Drain water separator inner thread G 1 4 1 4 NPT not available D Drain RO unit inner thread G 1 4 1 4 NPT E Compressed air connection external threaded connector R 1 1 NPT F Cool...

Page 52: ...12 Annex 50 Fig 29 all dimensions in Inches...

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Page 56: ...essor Division 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9868 Fax 217 224 7814 Gardner Denver Deutschland GmbH Argenthaler Str 11 55469 Simmern Deutschland Tel 49 0 6761 832 0 Fa...