Gardner Denver Reavell H5000 Series, Operator'S Handbook Manual

Page 1: ...Fax 44 0 1527 838438 Service 44 0 1527 838632 www reavell com e mail reavellenquiries gardnerdenver com Gardner Denver Ltd OPERATOR HANDBOOK For a 5217 2 IA Water cooled Air Compressor In any correspo...

Page 2: ......

Page 3: ...1 1 7 7 PRECAUTIONS IN THE EVENT OF FIRE WITHIN THE COMPRESSOR 12 1 8 PURGING INSTRUCTIONS FOR GAS INSTALLATIONS 12 1 8 1 PURGING 12 1 9 HAZARDOUS AREA OPERATION 13 1 9 1 ELECTRICAL CONNECTIONS 13 1 9...

Page 4: ...4 CONNECTIONS PIPEWORK AND FITTINGS 28 6 5 DRIVE RECOMMENDATIONS 28 6 6 COOLING 29 6 7 ELECTRICAL CONNECTIONS 29 6 8 RECOMMENDED ANCILLARIES SUMMARY 30 7 COMMISSIONING OR RECOMMISSIONING 31 7 1 BEFORE...

Page 5: ...LOW OIL PRESSURE 47 11 8 OVERHEATING 47 11 9 UNUSUAL NOISE ON LOAD 47 11 10 UNUSUAL NOISE UNLOADED 47 12 PARTS LIST 49 12 1 CRANKCASE PARTS 51 12 2 RUNNING GEAR PARTS 53 12 3 1ST STAGE CYLINDER PARTS...

Page 6: ...13 2 SAFETY VALVE APP167 81 13 3 SOLENOID VALVE DDV APP138 83 13 4 ANTI VIBRATION MOUNTS APP003 84 13 5 WATER PUMP DRIVE APP074 85 13 6 EXPANSION TANK COOLING WATER SYSTEM APP076 5217 86 13 7 PRESSURE...

Page 7: ...by Reavell Ipswich or the failure to maintain this equipment in accordance with the maintenance instructions may invalidate the WARRANTY cause equipment failure create unsafe or hazardous conditions o...

Page 8: ...ouse Road Ipswich IP1 5PB ENGLAND Notes Sales Contact Names Telephone Fax 44 0 1473 242000 44 0 1473 745451 Parts Contact Names Telephone Fax 44 0 1527 838499 44 0 1527 838438 Service Contact Names Te...

Page 9: ...d CONTRACT reference in order that the correct information is supplied It is important that this Manual is retained with the compressor for reference and that it should remain with the compressor if i...

Page 10: ...ust only be carried out by competent persons under the control of a qualified supervisor The compressor safety relates to the document EN1012 1 Compressors and vacuum Pumps Safety Requirements and the...

Page 11: ...from clothing Never direct compressed gas onto your skin or at other people Before releasing compressed air or gas through a flexible hose make sure the free end is held securely so that it cannot wh...

Page 12: ...etent personnel under a qualified supervisor Ensure that all instructions concerning operation and maintenance are strictly followed and that the complete installation with all accessories and safety...

Page 13: ...e models will have desiccant bags in valve covers and distance pieces which must be removed prior to start up Handling components such as seals gaskets and diaphragms should not present a personal haz...

Page 14: ...ot breathe mists Ensure clean water and soap is readily available Protect components and exposed openings by covering with clean cloths or tape during repair or maintenance work Protect all items as n...

Page 15: ...om the separators to the unloader valves and from the first stage to unloaders and water valve if fitted can be purged by disconnecting them at their far end allowing the purge gas to pass through and...

Page 16: ...likely to be thrown into suspension 1 9 3 IGNITING CLASSIFICATIONS The flammable gases are also given a classification according to the spark energy or strength required to ignite the most easily ign...

Page 17: ...d solenoid valves There are varying degrees of protection in this category which are described below Flameproof EExd A type of protection in which the parts which can ignite an explosive atmosphere ar...

Page 18: ...SAFETY PAGE 16...

Page 19: ...AMENDMENTS PAGE 17 2 AMENDMENTS ISSUE No REASON DATE SECTION 1 MAY 2003 ALL 2 SERVICE PLAN UPDATED APRIL 2009 9 6 3 SAFETY SECTION UPDATED STANDARD WIRING TERMINAL NUMBERS ADDED MAY 2012 1 14...

Page 20: ...AMENDMENTS PAGE 18...

Page 21: ...MORE SERVICE PLAN NUMBER COMPRESSOR LOG SHEET INSTALLED AT DATE INSTALLED DELY PRESS BAR PSI STAGE PRESSURES BAR PSI 5 4 3 PRIME MOVER TYPE POWER DRIVE 2 1 DELY TEMP C STAGE TEMP C COMPRESS0R TYPE SPE...

Page 22: ...COMPRESSOR LOG SHEET PAGE 20 REMARKS DATE REMARKS DATE...

Page 23: ...e oils It may be possible to extend oil change periods in some cases Wear rates are reduced These oils being produced to close tolerances have properties and performance which are consistent from batc...

Page 24: ...GENERAL DESCRIPTION AND OPERATION PAGE 22 4 6 LUBRICATION SCHEMATIC FLOW DIAGRAM...

Page 25: ...e When the compressor is stationary these valves one connected to each separator are open About 10 seconds after the compressor starts the solenoid valve opens and allows first stage pressure to pass...

Page 26: ...GENERAL DESCRIPTION AND OPERATION PAGE 24...

Page 27: ...PEEDS Minimum speed 750 rpm Maximum speed 1800 rpm 5 5 PRESSURES Maximum inlet pressure 0 14 bar Minimum working pressure 10 bar Maximum working pressure 40 bar Maximum water pressure 5 1 bar Water ja...

Page 28: ...and Rotors 0 13 Coupling Face Distance For Direct Coupled Sets 2 4 4 5 11 TORQUE WRENCH SETTINGS 5 11 1 CLASS A CRITICAL All figures 5 ASSEMBLY OPERATION SIZE NEWTON METRE Nm Big End Bearing Bolts M10...

Page 29: ...n works in a cool clean direct air flow and that there is a reasonable air gap around the radiator or it is fixed into a wall As a large percentage of the compressor cooling water heat is dissipated v...

Page 30: ...oreign substance The system must be suitably braced to prevent vibration and coupling strain on the compressor Flexible suction piping should be suitable to withstand suction collapse If suction is fr...

Page 31: ...d without water flow before shutting down During freezing weather conditions cooling water should be drained from the system if the compressor is not being used mains or anti freeze added to radiator...

Page 32: ...STALLATION PAGE 30 6 8 RECOMMENDED ANCILLARIES SUMMARY Flexible pipe at final delivery Overload trips Water inlet and outlet thermometers Water flow control Separators and drain traps Non return valve...

Page 33: ...pework is clean before reassembling IMPORTANT For first commissioning run or following overhaul or after compressor has stood idle for an extended period MINERAL oil of the recommended grade must be u...

Page 34: ...ing joints are correctly seated Close drain valves and or replace plugs Restart the compressor and bring slowly onto load Build up to full pressure within 1 hour If appropriate set the compressor for...

Page 35: ...compressor and ancillary equipment are clear of all loose equipment and tools Ensure that there is adequate water in the cooling system radiator sets or supply from the mains Operate main control or...

Page 36: ...OPERATION AND ROUTINE MAINTENANCE PAGE 34...

Page 37: ...ve an indication of impending problems 9 2 DAILY Check oil level in crankcase and top up if necessary Check stage pressures oil pressure and temperatures 9 3 WEEKLY Check for oil air or water leaks re...

Page 38: ...filter 1 X X X X X X 8 Replace water pump impellor Impellor kit 1 X X 9 Remove 2nd stage valve covers Cover O ring 4 X 12 9 Service 2nd stage valves Valve kit 2 X 13 9 Replace 2nd stage valves Valve a...

Page 39: ...gasket 1 X 30 27A IF FITTED Replace water pump drive chain chain 1 X 31 27A IF FITTED Service water pump seal impellor kit 1 Joint water pump bracket 1 Joint water pump 1 Joint water pump IN OUT 2 X X...

Page 40: ...1500 3000 4500 6000 7500 9000 Task Preparatory Task Task Description Parts Provided Qty X 1st stage 1 X 2nd stage 1 X DDV 1 X Test pressure gauges 1st stage 1 X 2nd stage 1 X Oil 1 X Test temperature...

Page 41: ...ed 1 10th of the plate thickness If the seats show severe wear or indentations the complete valve assembly must be renewed The remaining components should be checked for cracks distortion or other dam...

Page 42: ...e beds properly as a slight misfit will entail the loss of air Check valve cover for cleanliness before reassembly Renew O rings lightly greasing before fitting There should be at least a 2mm gap betw...

Page 43: ...e Test for correct operation by ensuring free movement of suction and delivery valve plates Lightly smear new O ring 10 with silicon grease and fit to groove in upper body 11 10 6 2 SECOND STAGE CONCE...

Page 44: ...DISMANTLING AND REASSEMBLY OF VALVES PAGE 42...

Page 45: ...IS IS DANGEROUS If safety valve opens or appears faulty shut down compressor immediately and investigate If fault appears immediately or shortly after a service first examine those parts disturbed dur...

Page 46: ...DENLY 9 Check override timer setting High inlet air gas pressure switch operating 9 See fault STOPS SUDDENLY Diesel engine fault 9 Check diesel engine handbook 11 3 LOW OUTPUT Inlet filter dirty or bl...

Page 47: ...ge safety valve blowing 9 Check 2nd stage safety valve operating pressure 9 Check 3rd stage concentric valve for damage to seats springs and or plates 9 Check for damage to o rings and or seats on 3rd...

Page 48: ...rect operation of air gas inlet solenoid valve 9 Check correct operation of air gas inlet non return valve 9 Check condition of air gas inlet filter High air gas inlet pressure switch operating 9 Chec...

Page 49: ...eck for restrictions or blockages to cooling air supply Water pump 9 Confirm correct operation and rotation of pump 9 Check for restrictions in pump connections due to sludge deposits etc Insufficient...

Page 50: ...FAULT GUIDE PAGE 48...

Page 51: ...RY DELAY PLEASE QUOTE 1 Complete invoicing and shipping address 2 Machine Model Reference No 3 Machine No 4 Item Reference 5 Part No 6 Description 7 Quantity required Due to our policy of continuous i...

Page 52: ...PARTS LIST PAGE 50 01 1 3 2 4 05 7 02 03 5 2 5 1 5 05 3 05 4 05 9 05 6 05 1 05 2 05 3 05 5 05 11 05 10 05 8 04 4 3 2 1 4 9 6 8 7 3 02 03 05 7 05 8 01 09 CRANKCASE...

Page 53: ...asher Fibre with item e 1 8 Oil level Label 98381 1013 1 002 9 Seal 98660 1156 1 002 04 BEARING HOUSING O E D101670 1 1 Bush C200020 1 004 2 Joint D100356 1 004 3 Bearing Housing E60003 1 004 4 Dowel...

Page 54: ...PARTS LIST PAGE 52 10 19 RUNNING GEAR 13 1 2 1 1 1 2 2 2 3 2 1 14 2 2 2 2 2 1 1 1 1 13 1 2 16 2 16 2 1 1 2 1 1 2 15 11 12 1 2 16 1 16 5 16 3 16 4 15 11 12 1 1 14 15 16 6 16 7...

Page 55: ...ton Ring 1st Stage 98477 1058 4 013 14 PISTON 2nd STAGE D101680 2 1 Piston D100015 2 020 1 1 Gudgeon Pin C200032 2 1 2 Circlip 95650 25 4 2 Piston Ring Set 98477 1140 2 2 2 Oil Control Ring 98477 1052...

Page 56: ...PARTS LIST PAGE 54 20 29 1ST STAGE CYLINDER 25 3 25 4 25 1 25 2 21 22 6 1 23 2 8 21 22 2 1 2 2 2 2 3 6 9 21 22 7 5 3 4 1 21 22 24 1 24 3 24 2...

Page 57: ...021 4 Seal PS 1322 3 4 021 5 Setscrew 95018 272 3 021 6 Nut 95111 6 23 021 7 Dowel 95504 472 2 021 8 Eyebolt 98086 1001 2 021 9 Seal Copper 98660 1156 1 021 23 VALVE COVER 1st STAGE C200004 100 2 1 V...

Page 58: ...PARTS LIST PAGE 56 30 39 2ND STAGE CYLINDER 36 3 36 2 36 1 31 32 6 1 35 2 3 33 1 2 2 1 9 2 2 2 31 32 5 1 4 3 3 1 34 2 3 31 9 31 8...

Page 59: ...8 031 7 Nut 95111 7 9 031 8 Dowel 95504 472 2 031 9 Eyebolt 98086 1001 2 031 33 CYLINDER LINER 2nd STAGE C200015 100 2 1 Liner C200015 2 033 2 O Ring Lower 95602 91 2 033 3 O Ring Upper 95602 93 4 033...

Page 60: ...1ST 2ND STAGE COOLERS 45 17 45 23 45 14 45 23 45 1 45 7 45 13 45 21 45 5 45 11 45 4 45 12 43 4 6 7 43 3 8 1 2 1 8 45 17 45 23 45 15 45 24 45 16 44 4 6 45 6 45 22 45 16 45 24 45 2 45 9 45 3 45 10 45 2...

Page 61: ...95602 95 2 044 45 2 JOINT C200682 1 045 45 3 JOINT C200683 1 045 45 4 JOINT C200688 1 045 45 5 JOINT C200689 1 045 45 6 FUSIBLE PLUG IF FITTED C202557 3 1 045 45 7 COOLER COVER O E 1st STAGE D100034...

Page 62: ...PARTS LIST PAGE 60 50 59 TYPICAL STANDARD PRESSURE TEMPERATURE GAUGES 58 6 58 10 58 1 58 9 58 7 58 2 58 4 58 13 58 12 58 11 58 5 58 8 56 57 1 3 2 51 52 53 4 2 3 1 5...

Page 63: ...1967 11 1 1 Adaptor 4mm X 1 4 BSP 98156 1294 1 053 2 Tube Nut 4mm 98156 1315 2 053 3 Tube Sleeve 4mm 98156 1386 2 053 4 CU Tube 4mm X 450mm M3201 0403 1 053 5 Seal 98660 1153 1 053 56 1 SWITCHED THERM...

Page 64: ...PARTS LIST PAGE 62 60 69 LUBRICATION 67 4 67 6 67 5 67 1 67 2 67 11 67 3 67 8 67 7 67 10 67 9 2 3 66 1 4 2 3 a 65 64 1 2 3 1 2 62 63 2 61 1 1 6 65 5...

Page 65: ...el Assembly C85737 3 1 1 Joint C200900 1 065 2 Drive Fitting C85737 1 1 065 3 Dowel Pin 95504 424 2 065 4 Tension Pin 4 x 22mm 95540 165 1 065 5 Oil Filter 98262 1009 1 065 6 Oil Pump C85737 2 1 065 6...

Page 66: ...PARTS LIST PAGE 64 DRAIN VALVE PIPING 70 79 74 6 74 6 74 4 74 1 74 3 74 5 1 2 3 72 3 2 73 1 3 4 3 72 2 1 74 8 74 7 74 8 4 2 71 1 3 71 4 74 2...

Page 67: ...el 10mm X 1000mm M 3089 1008 1 072 2 Coupling 98156 1049 2 072 3 Seal 98660 1155 2 072 73 SERVICE PIPE ASSY 1st STG to PUV C203893 1 1 Pipe Steel 6mm X 1300mm M3206 0602 1 073 2 Coupling 98156 1042 1...

Page 68: ...PARTS LIST PAGE 66 80 89 EXTERNAL COMPONENTS 83 4 84 1 83 5 83 6 83 3 83 2 83 1 4 2 81 1 3 4 82 4 2 1 3 4...

Page 69: ...98156 1061 1 081 4 Seal 3 4 BSP 98660 1156 2 081 82 WATER TRANFER PIPE ASSY C203885 1 1 Copper 20mm X 500mm M3201 2017 1 082 2 Coupling 20mm X 3 4 BSP 98156 1245 1 082 3 Elbow Swivel 2 0mm X 3 4 BSP...

Page 70: ...GE 68 91 TYPICAL DRIVE ARRANGEMENTS 91 14 91 19 91 20 91 22 91 18 91 26 91 27 91 28 91 15 91 21 91 17 91 16 91 8 91 9 91 7 91 3 91 1 91 10 91 2 91 6 91 4 91 5 91 11 91 12 91 13 91 11 91 12 91 13 91 23...

Page 71: ...IBRATION MOUNTS 98418 1040 4 91 12 NUT 95111 7 4 91 13 SPRING WASHER 95179 3 4 91 14 ANTI VIBRATION MOUNTS 98418 1014 3 91 15 MOTOR PLATE C200783 2 91 16 MOTOR ADJUSTING BLOCK C86469 2 91 17 MOTOR ADJ...

Page 72: ...PARTS LIST PAGE 70 93 95 1ST STAGE CONCENTRIC VALVE 9 8 6 5 4 2 1 3...

Page 73: ...E 1st Stage 98650 1841 2 b VALVE MAINTENANCE KIT 98650 1842 2 1 O Ring 98504 1006 1 2 O Ring 98504 1193 1 3 Nut 98650 1040 1 4 Suction Plate Small 98651 1026 1 5 Lift washer 98651 1027 1 6 Lift washer...

Page 74: ...PARTS LIST PAGE 72 96 97 2ND STAGE CONCENTRIC VALVE 2 1 3 4 5 6 5...

Page 75: ...96 1 CONCENTRIC VALVE 2nd Stage 98650 1099 2 a VALVE MAINTENANCE KIT 98650 1578 2 1 O Ring 98504 1005 1 2 Nut 98650 1050 1 3 Suction Plate Small 98650 1103 1 4 Spring Plate Small 98650 1104 3 5 Deliv...

Page 76: ...74 98 99 1ST 2ND STAGE DIAPHRAGM DRAIN VALVE OPTIONAL 98 8 98 7 98 5 98 6 98 7 98 8 98 5 C 3 a 1 1 4 1 3 1 2 1 1 3 C 2 1 2 2 2 3 2 4 2 b 3 4 C C 3 4 99 7 99 8 99 6 99 5 99 2 99 3 1 1 1 2 1 3 1 4 1 a...

Page 77: ...te C201978 1 2 4 Screw 95028 112 1 c SERVICE KIT 98650 1535 2 3 Joint C200722 4 4 Diaphragm 98210 1002 2 98 5 DRAIN VALVE BODY C203190 1 2 98 6 CENTRE COVER C200841 1 98 7 BACKNUT PS1290 4 2 98 8 BOLT...

Page 78: ...RING 1st STAGE VALVE COVER 95602 103 4 O RING 2nd STAGE LINER 95602 91 2 O RING 2nd STAGE LINER 95602 93 2 O RING 2nd STAGE VALVE COVER 95602 94 4 O RING 2nd STAGE COOLER 95602 95 2 O RING 1st STAGE C...

Page 79: ...1 12 18 SERVICE KIT FOR DDV S DESCRIPTION PART N N OFF SERVICE KIT 98650 1535 2 Diaphragm 98210 1002 1 Diaphragm Joint C200722 2 12 19 SERVICE TOOLS DESCRIPTION PART N N OFF SERVICE TOOLS Valve Withdr...

Page 80: ...PARTS LIST PAGE 78...

Page 81: ...POINTER RUN COMPRESSOR TO ESTABLISH NORMAL RUNNING TEMPERATURE OF BLACK POINTER A WHEN READING IS STABLE REMOVE ADJUSTING KEY B FROM REAR OF SWITCH AND INSERT INTO FRONT OF CENTRAL KNOB ADJUSTER C ROT...

Page 82: ...120 WATERCOOLED 5000 SERIES CONTROLLER PART No WHERE FITTED USED ON COMPRESSOR MODEL 98288 1093 1st 5th STG DELIVERY 5450 5470 98288 1094 FINAL DELIVERY 5450 5470 98288 1215 THE PURPOSE OF THIS SWITCH...

Page 83: ...outlet pipe Discharge pipes should be as short as possible and of such a size that the pressure developed therein not reduce the relieving capacity Ensure arrows indicating the direction of the flow a...

Page 84: ...ent type valve arrangement from this information the valve set pressure can be obtained examples 98650 2073 is the base unit number 98650 2073 16 2 16 2 being to the setting in bar g wire locked 98650...

Page 85: ...etails Current consumption Part No Voltage Hz Current Inrush Hold PS2197 1 230 50 AC 26 VA 16 VA PS2197 2 110 50 AC 26 VA 16 VA PS2197 3 220 60 AC 26 VA 16 VA PS2197 4 110 60 AC 26 VA 16 VA PS2197 5 2...

Page 86: ...g on usage i e regular usage every 3 months Note This dimension may only change a small amount during the life of the mount approximately 1mm 4 Any oil or paint contact with the rubber mount will affe...

Page 87: ...over 1 4 C85739 1 Sprocket water pump 2 5 C85740 1 Pillar chain tensioner If fitted 2 6 D100253 Cover outer end 1 7 E60003 Housing outer end bearing 1 8 PS2062 Chain roller 1 9 M3201 2017 Tube 22mm 22...

Page 88: ...FOR FILLING COMPRESSOR 5215 5217 5217 MK2 ILLUSTRATED FRESH WATER COOLING SYSTEM FILLER CAP VENT PIPE EXPANSION TANK FRESH WATER COOLING PIPES SEA WATER INLET OUTLET CONNECTION STOP VALVES EMERGENCY S...

Page 89: ...resh water 4 Replace filler cap 5 Start compressor run for 2 minutes and stop 6 Gently release filler cap remove and top up 7 With filler cap removed start compressor and slowly fill with water until...

Page 90: ...o remove a pressurised gauge The pressure system must be totally relieved if the gauge can not be isolated otherwise The remainder of the pressure medium contained in the element may be hazardous or t...

Page 91: ...FAILS REPLACE THE WHOLE UNIT CHECK OTHERS REPLACE AS NECESSARY PREVENTIVE MAINTENANCE 1 2 3 4 Every 3 months check the following 1 Outer casing for cracks defects and leaks 2 Crimped connections for...

Page 92: ...ANCILLARY PARTS PAGE 90...

Page 93: ...V2 W2 NOT USED 43 44 FINAL DELIVERY PRESSURE SWITCH CONTROL 1 2 CRANKCASE SUMP HEATER 45 46 LOW OIL PRESSURE 3 4 MOTOR ANTI CONDENSATION HEATER 47 48 4TH STAGE TEMPERATURE 5 6 DRYER 1phase L 49 N 50 S...

Page 94: ...STANDARD WIRING TERMINAL NUMBERS PAGE 92...

Page 95: ......

Page 96: ...has no control Such hazardous conditions may lead to accidents that can be life threatening cause substantial bodily injury or result in damage to the equipment Reavell can bear no responsibility for...