Gardner Denver Wittig RFW 150 DV, Operating And Service Manual

Page 1: ...PARTS LIST OPERATING AND SERVICE MANUAL RFW 150 260 BA 45 01 0 US Version 00 January 23 2015 ...

Page 2: ... Oil level monitoring 4 6 4 4 10 Rotation speed monitoring 4 6 Water cooling 4 6 Drive 4 7 4 6 1 Hydromotor drive 4 7 4 6 2 Drive by flexible coupling 4 7 4 6 3 Drive by drive shaft 4 8 4 6 4 V belt drive 4 8 5 Initial operation 5 1 Checking the system 5 1 Cooling water 5 1 Lubricating oil 5 1 Shut off slides and valves 5 2 Rotating direction 5 2 Drive 5 2 Checking the rotation speed vacuum and pr...

Page 3: ...authorized service centers using original spare parts as our guarantee otherwise loses its validity We wish you much satisfaction with the rotary compressor or compressor and vacuum pump that has been supplied to you by Gardner Denver If your questions are not satisfactorily answered we will be pleased to assist you at any time Yours sincerely Gardner Denver Compressor Division 1800 Gardner Expres...

Page 4: ...ble compression ratio POUT PIN is limited by the final compression temperature The operating principle of a rotaryvane compressor or a compressor vacuum pump Machine versions The various versions differ in their method of lubrication and of cooling Oil lubricated machines are fed by means of an automatic lube oil pump in the oil well The rotor shaft directly drives the lubricating pump Dry running...

Page 5: ...100 100 Max operating pressure gauge in compressor operation2 in compressor operation with V belt drive2 bar g 2 0 2 0 2 0 1 5 2 0 0 5 Max Power requirement at max operating pressure gauge kw 50 70 92 Suction pressure 400 mbar abs Volume flow Final overpressure Power requirement at drive shaft m3 h bar g kW 820 0 0 23 0 1180 0 0 34 0 1540 0 0 41 0 Suction pressure 1000 mbar Volume flow Final overp...

Page 6: ...tor 9 Oil drain cock 10 Vacuum intake filter suction filter point 11 Non return valve Figure 1 2 Dimensions RFW 150 RFW 260 Lubrication Lubrication is carried out by the built in fixed drive lube oil pump Lubricating oil specification Single grade oils of the following classes API CC SF CD SF MIL L 2104 B 2104 C See section 5 8 Lubrication Oils or the lubrication oil selection table Rotary vane co...

Page 7: ... until ca litre oil has been drawn into the machine Note the noises produced by the machine The additional oil intake volume of Iitre has been reached when the oil level in the oil sight glass has fallen ca 1 cm 1 Suction line 2 Oil well 3 Regulating tap 4 Additional oil vessel 1 Extreme operating conditions exist for example in the following circumstances Surrounding temperature 35 C Continuous o...

Page 8: ...dimensions R1 R1 R1 Recommended equalizing tank l 10 10 10 These data apply for Surrounding temperature 30 C Continuous operation Winter operation with anti freezing compound Summer operation without anti freezing compound If the anti freezing compound remains in the cooling system during summer operation it is necessary to increase the volume flow of the cooling water by ca 15 Otherwise the lower...

Page 9: ...n of particular interest to the operator of the machine Points to note The rotary compressor compressor and vacuum pump has been constructed according to the latest technological standards and safety regulations However during use of the machine it is still possible that the health and life of the operator or other persons may be endangered or that damage to the machine or to other property may be...

Page 10: ... drive prevention device must only be removed when the machine is at a standstill The contact prevention guard must only be removed when the machine and the pressure pipe are cool Before switching on the machine ensure that all safety devices are correctly in place For the sake of environmental protection all liquids which come from the machine during maintenance work e g lubricating oil must be c...

Page 11: ...nsport protection mechanisms must be removed Storage Before assembly the machine should be stored in a dry heated room The covers on the pressure nozzle should remain in place until the machine is finally installed The protective coating on the bare parts remains effective for approximately 1 year If the machine is stored for a longer period it must be renewed Delivery contents The contents of the...

Page 12: ...4 8 Contact prevention 4 4 9 Oil level monitoring 4 4 10 Rotation speed monitoring 4 5 Water cooling 4 6 Drive 4 6 1 Hydromotor drive 4 6 2 Drive by flexible coupling 4 6 3 Drive by drive shaft 4 6 4 V belt drive 1 Ventilation valve 2 Vacuum filter 3 Compressor and vacuum pump 4 Non return valve 5 Compensator 6 Safety valve 7 Manometer 8 Thermometer 9 Silencer oil separation vessel 10 Four way tap...

Page 13: ...the oil reservoir It may be necessary to use a different oil intake suction pipe Please contact us your after sales service center will be pleased to help you adapt the appliance to your installation requirements Traverse mountings on the vehicle chassis must be strong enough thin profiles and flat metal sheets must not be used The mounting points supports for the machine feet must be exactly bala...

Page 14: ...al vehicles To preserve these values when the machine is installed the low noise installation is necessary 4 3 1 Air noise suppression by noise suppressing oil separator 4 1 9 The combined silencer and oil separator suppresses the exhaust noise of the compressor and vacuum pump and it also removes 80 to 90 of the lubricating oil The silencer is installed between the machine and the four way tap or...

Page 15: ...V belt drive 1 Rubber metal cup element 2 Buffer stop 3 Counterstop Compensators in the suction line and in the pressure line effect the isolation of the body noise and prevent thermal stresses 4 Compensator for pressure line Kompaflex axial compensator type F temperature and compression proof DN 100 PN 16 for RFW 150 DN 125 PN 16 for RFW 200 and 260 Type W for high grade steel pipelines for weldi...

Page 16: ...e 4 1 1 The ventilation valve is the regulator for the appliance and the safety feature in the suction pipe It is absolutely essential If the intake suction vacuum falls below the pre set minimum value the ventilation valve opens and the machine draws in atmospheric air This serves to limit the suction pressure to the permitted minimum pressure e g 200 mbar If the ventilation valve is mounted or f...

Page 17: ...on must be checked each week by activating the manual ventilation 4 4 7 Manometer 4 1 7 For continuous pressure monitoring Measurement range conforming to the operating pressure Mounted directly behind the pressure nozzle 4 4 8 Contact prevention The drive of the machine and the hot pressure pipe must be provided with a contact prevention mechanism Accidental touching of rotating or moving machine...

Page 18: ...compressor compressor and vacuum pump and an operating notice must be fitted for the vehicle operator Drive by means of combustion engines must only be used with controlled rotation speed engines Axial thrust from the drive must not be transferred to the rotor shaft The drive elements should be fitted to the rotor shaft with the existing thread M12 The drive elements must not be hammered onto the ...

Page 19: ...d directly to the free end of the shaft Rotary compressor vacuum pump Type RFW 150 DV RFW 200 DV RFW 260 DV Belt profile SPB SPB SPB Belt pulley diameter DW mm 250 250 250 Max operating pressure for V belt drive barg 2 0 1 5 0 5 Max operating vacuum for V belt drive mbar 200 200 200 Number of belts 4 4 4 Between the V belt pulley and the housing at least 12 mm gap should be allowed as the intake o...

Page 20: ...the holes and insert the screws loosely 2 Push the disk with the bush onto the shaft align it and tighten the screws evenly and tightly Dismantling 3 Take out the screws then screw one of them as a leverage screw into the hole with a half thread in the bush and tighten it This releases the taper lock bush 4 Remove the loose pulley unit by hand without knocking it or damaging the machine ...

Page 21: ...an be turned by hand Cooling water Fill cooling water only to the highest mark on the equalising tank or cooler Determine the quantity according to the cooler volume and line volume Use only clean tap water Observe the instructions in section 1 4 Water cooling If frost danger exists add antifreezing compound as instructed by the manufacturer generally 33 Lubricating oil For the oil type see 5 8 ta...

Page 22: ...data Check manually whether safety valve expels air Lubrication oils for rotary compressor compressor vacuum pumps The permissible oils are single range oils of the specifications API CD SF or higher MIL L2104 C or higher Summer oils SAE 40 Make Type ARAL Basic Turboral BP Vanellus C3 DEA Cronos Super ELF Performance XR ESSO Essolube X 301 FUCHS Titan Universal HD MOBIL Delvac 1340 SHELL Rimulla X...

Page 23: ... the condensate and safety tanks The tank must not be under pressure when the condensate is drained In the winter the condensate may freeze Rotating speed Check the operating rotation speed Permitted speed range Drive by cardan shaft 1200 1500 min 1 Other drive systems 1000 1500 min 1 Cooling water temperature Upon return to the cooler the maximum cooling water temperature is 60 C Oil level Check ...

Page 24: ...tilation valve 6 2 2 Clean machine Clean inlet outlet aperture for cooling air Check fixing of ventilator cowl and covering plates The vacuum must not fall below the permitted vacuum of 200 mbar cf section 1 1 Possible operating errors Operating errors can lead to machine failure The following must be avoided Too low or too high rotation speed Too high pressure Expelling of the entire volume flow ...

Page 25: ...e operated without vacuum or pressure Switch machine on and with slightly reduced speed fill in approx Iitre petrol diesel or a diesel oil mixture through the bore hole in the intake flange Switch off machine screw in the locking screw and maintain pre lubrication according section 5 3 before restarting the machine Intermediate positions of the four way changeover valve are not allowed during the ...

Page 26: ...e to dirt intake Incorrect rotation speed Altered pressure Altered vacuum Balance machine exactly Have bearing replaced Refill with oil clean oil reservoir and suction filter Fill out oil in accordance with 5 8 lubrication oil table Replace rotor vanes Have housing re bored and honed in authorized repair workshop If intake air is strongly contaminated fit a fine filter Adhere to rotation speed lim...

Page 27: ...ank blocked Clean oil tank and suction filter Safety valve blows out air Closed valves in pressure pipe Blockage in pressure system Blockage in exhaust silencer Open valves Remove blockage Replace exhaust silencer Ventilation valve is activated Closed valves in suction pipe Suction filter blocked Open valves Clean suction filter replace cartridge if necessary Compressed air blows from shaft end an...

Page 28: ...nd largely on correct maintenance The below table contains timing checking and maintenance information for normal operation of the machine The maintenance intervals given are based on an operating time of approx 5 hours per day If this operating time is not reached the maintenance intervals can be extended accordingly Because of the differing operating conditions it cannot be predicted how often c...

Page 29: ...et Check the fine filter cartridge for damage Damaged cartridges must be replaced When cleaning the filter housing under no circumstances must dirt cleaning pad remnants or liquid be allowed to get into the compressor vacuum pump This can cause the vanes to fracture Type SFA Type SFD 1 Cover 2 Cone clamp SFA type 3 Cross clamp SFA type Figure 7 1 Vacuum filter SFA and SFD Assembly of the filter In...

Page 30: ... cleaning check the valve seating for the quality of the seal If there is a leak grind the valve seating afresh with grinding paste Before assembly which is carried out in reverse order the sliding surfaces of the cylinder pin 4 should be coated with MOLYKOTE oil type M 55 manufacturer DOW CORNING 7 2 7 Ventilation valve If incorrectly installed the vent hole C used for pressure compensation of th...

Page 31: ... oblong hole which becomes visible Measure the depth to the rotor surface by means of a depth gauge see Figure 7 4 Figure 7 4 Check rotor vanes for height wear The depth must not be more than 5 mm If the wear limit of 5 mm is reached the rotor vanes must be replaced See the separate instruction manual Make the first wear check after about 6 months then every 3 months if the machine run time is abo...

Page 32: ...information Example Commission No Year of construction Machine type Machine No Parts list No Item No Order No Quantity Designation 77 303 793 1993 RFW 260 DVR 961 016 9 ETB 40 01 0 5 342 607 00 6 Rotor vanes The information marked with can be found on the machine s rating plate Wearing parts We recommend storage of the following spare parts Order number for type Item No RFW 150 RFW 200 RFW 260 Qua...

Page 33: ...BA 45 01 0 US 01 15 9 1 9 Parts List Figure 9 1 RFW exploded view ...

Page 34: ...OSE LINE 58 8 10 42543100 SLEEVE 2 1 90399400 COVER RFW B END PLATE 3 1 90399300 COVER RFW A END PLATE 5 1 90399700 FLANGE SHAFT 6 1 90398900 FLANGE B 9 1 98230700 COVER PLATE 10 1 90399500 INTERMEDIATE OIL TANK 11 1 90399600 OIL TANK 15 2 42640600 GLASS SIGHT 16 1 47201900 CAP OIL FILL 17 1 42537300 SLEEVE SUCTION 18 2 51055100 TUBE CLIP 20 1 99355900 VALVE NON RETURN 22 2 41123000 BEARING 23 2 4...

Page 35: ...UT HEX 48 16 45113200 WASHER 55 1 6200700 PIPE OIL INTAKE LINE 59 4 58741500 CONICAL STOPPER 60 2 42171600 RING SEALING 61 4 42170300 SEALING RING 62 1 46454000 GASKET 63 1 46454200 GASKET INTAKE FLANGE 64 1 46563500 GASKET 65 2 46629000 CASING GASKET 67 1 45588600 NAME PLATE FOR OIL TYPES 68 1 45589900 NAME PLATE 69 4 45301900 TRUSS HEAD RIVET 70 2 44331700 BOLT CHEESE HEAD SP9039502 KIT SERVICE ...

Page 36: ...SE LINE 58 8 10 42543100 SLEEVE 2 10 90399400 COVER RFW B END PLATE 3 1 90399300 COVER RFW A END PLATE 5 1 90399700 FLANGE SHAFT 6 1 90398900 FLANGE B 9 1 98230700 COVER PLATE 10 1 90399500 INTERMEDIATE OIL TANK 11 1 90399600 OIL TANK 15 2 42640600 GLASS SIGHT 16 1 47201900 CAP OIL FILL 17 1 42537300 SLEEVE SUCTION 18 2 51055100 TUBE CLIP 20 1 99355900 VALVE NON RETURN 22 2 41123000 BEARING 23 2 4...

Page 37: ...9300 NUT HEX 48 16 45113200 WASHER 55 1 6200700 PIPE OIL INTAKE LINE 59 4 58741500 CONICAL STOPPER 60 2 42171600 RING SEALING 61 4 42170300 SEALING RING 62 1 46454000 GASKET 63 1 46454200 GASKET INTAKE FLANGE 64 1 46563500 GASKET 65 2 46629000 CASING GASKET 67 1 45588600 NAME PLATE FOR OIL TYPES 68 1 45589900 NAME PLATE 69 4 45301900 TRUSS HEAD RIVET 70 2 44331700 BOLT SP9039502 KIT SERVICE 300FWA...

Page 38: ...SE LINE 58 8 10 1 42543100 SLEEVE 2 1 90399400 COVER RFW B END PLATE 3 1 90399300 COVER RFW A END PLATE 5 1 90399700 FLANGE SHAFT 6 1 90398900 FLANGE B 9 1 98230700 COVER PLATE 10 1 90399500 INTERMEDIATE OIL TANK 11 1 90399600 OIL TANK 15 2 42640600 GLASS SIGHT 16 1 47201900 CAP OIL FILL 17 1 42537300 SLEEVE SUCTION 18 2 51055100 TUBE CLIP 20 1 99355900 VALVE NON RETURN 22 2 41123000 BEARING 23 2 ...

Page 39: ... 16 45019300 NUT HEX 48 16 45113200 WASHER 55 1 6200700 PIPE 59 4 58741500 CONICAL STOPPER 60 2 42171600 RING SEALING 61 4 42170300 SEALING RING 62 1 46454000 GASKET 63 1 46454200 GASKET INTAKE FLANGE 64 1 46563500 GASKET 65 2 46629000 CASING GASKET 67 1 45588600 NAME PLATE FOR OIL TYPES 68 1 45589900 NAME PLATE 69 4 45301900 TRUSS HEAD RIVET 70 2 44331700 BOLT SP9039702 KIT SERVICE 300FWD6010 KIT...

Page 40: ...E 4 WAY 1 300FLA345 HANDLE USED WITH 4 WAY VALVE 2 CALL FACTORY CAPSCREW AND WASHER FOR HANDLE 3 CALL FACTORY COVER 4 CALL FACTORY CAPSCREW AND WASHER FOR COVER 4 REQ 5 522001245 O RING STEM BUNA 6 522001244 O RING COVER BUNA 7 CALL FACTORY SPRING 8 CALL FACTORY INTERNAL VANE 9 CALL FACTORY VALVE BODY 10 CALL FACTORY TOGGLE SCREW 11 CALL FACTORY SEAL NUT ...

Page 41: ...1 301FLA238 VALVE 4 WAY 2 302FWA286 MANIFOLD KIT W O 4 WAY VALVE 3 303FWA286 MANIFOLD INTAKE SIDE 4 301FLA6017 KIT VALVE 4 WAY W 2 4 NPT FLANGES 5 300FLA715 GASKET MANIFOLD TO 4 WAY VALVE 6 300FLA345 HANDLE 7 300FLA578 O RING 8 540033209 MANIFOLD ACCESS PLATE KIT W HDWR 9 300FLA1100 HARDWARE KIT 286 10 46482900 GASKET FILTER TO MANIFOLD ITEMS NOT SHOWN IN DRAWING ...

Page 42: ... Compressor Division 1800 Gardner Expressway Quincy Illinois 62301 Customer Service Department Phone 800 682 9868 Fax 217 221 8780 Visit our web site www gardnerdenver com E mail pdblowers gardnerdenver com Specification subject to change BA 45 01 0 US 1 15 2015GardnerDenver Inc ...