Rotary piston blower stage
Installation, assembly and operating instructions
H S I L G N E
for rotary piston blower stage
AERZENER MASCHINENFABRIK GMBH G4-001 I EN
G4-001 I EN
168 39 397 00 000
06-2007
1
E N G L I S H
Die INFO-Seite ist vor der Inbetriebnahme durchzulesen. durchzulesen. Dort evtl. vermerkte Hinweise und Änderungen sind durchzuführen. Read the INFORMATION INFORMATION sheet prior to commissioning. Possible notes and changes indicated herein are to be effected. La page INFO est à lire avant la mise en route. Y apporter éventuellement des annotations et modications.
De INFO-Bladzijde moet voor de inbedrijfname worden doorgelezen. Daar eventueel opgeschreven aanwijzingen en modicaties moeten worden uitgevoerd.
Prima della messa in esercizio leggere la pagina INFO, ed eseguire eventuali istruzioni o modiche indicate.
Antes de proceder a la la puesta en marcha, leer detenidamente la página informativa y cumplir eventuales indicaciones y modicaciones indicadas en la misma.
A página de informações informações deve ser lida antes da colocação colocação em funcionamento. As eventuais indicações indicações e alterações aí mencionadas devem ser respeitadas. INFO-siden skal læses igennem inden idriftsættelsen. Evt. anvisninger og ændringer der står dér skal gennemføres. Les INFO-siden før igangsetting. Anvisninger og endringer som står oppført der, skal utføres. Läs igenom INFO-sidan före idrifttagning. Eventuellt angivna anvisningar eller förändringar skall genomföras. Pidätämme oikeuden painovirheisiin, erehdyksiin sekä teknisiin muutoksiin..
Druckfehler, Druckfehler, Irrtümer sowie technische Änderungen sind vorbehalten. We are not liable for misprints, errors, and we reserve the right to make technical changes. Sous réserve de fautes d‘impression, d‘erreurs et de modications techniques.
Drukfouten, vergissingen en technische wijzigingen voorbehouden. Salvo error u omisión. Reservado el derecho a realizar modicaciones técnicas. Salvo errori di stampa, incorrettezze e modiche tecniche.
Reservamo-nos o direito a erros de impressão, enganos e alterações técnicas. Der tages forbehold for trykfejl, fejl og tekniske ændringer. Med forbehold om trykkfeil, feiltagelser og tekniske endringer. Tryckfel, övriga fel samt tekniska förändringar förbehålles. INFO-sivu on luettava ennen käyttöönottoa. Siellä ilmoitetut mahdolliset muutokset tai lisäykset on otettava otettava huomioon
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G4-001 I EN
Hersteller-Erkärung Manufacturer Declaration Certificat du constructeur Verklaring van fabrikant Declaración de fabricante Dichiarazione del produttore
H S I L G N E
s t n e t
Leistungsdaten Performance data Performances Capaciteitsgegevens Datos de servicio Dati di esercizio
n o C
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Ersatzteil-Liste Spare parts list Pièces de rechange Reservedelen Repuestos para tamaños de soplantes Parti di ricambi
Verschleißteilzeichnungen Wearing parts drawings Plans des pièces d'usure Tekening waarop aangegeven Disegno parti soggette ad usura Dibujo de pieza de desgaste
t l a h n I
ENGLISH
1 - 46
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n o n i t o a t i t n k e a d m k u e i r k R b o & a D f n n e o i r e h t o n c a t i u r A s t h i r c n s h e s h l u c s l a c I i n e h M T e c e r g h T c l e n s e n u i k e l i n i c z e h r t c N e b e . H A A T
INFO - Seite Information sheet Page infos Info bladzijde Pagina Informativa Informazioni
44 - 45
G4-001 I EN
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E N G L I S H
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G4-001 I EN
Hersteller-Erklärung Manufacturer Declaration Certicat du constructeur
Verklaring Verklaring van fabrikant Declaración de fabricante Dichiarazione del produttore
deutsch
Hiermit bestätigen wir, dass diese Maschine den folgenden EG-Richtlinien entspricht: EG-Maschinen-Richtlinie 98/37 EG Anhang II B für einzubauende Maschinen EMV-Richtlinie Niederspannungs-Richtlinie
89/336 EG
2006/95/EG Die Maschine wurde konstruiert, gefertigt und dokumentiert, in Übereinstimmung mit den harmonisierten Normen der genannten EG-Richtlinien, von Firma: Aerzener Maschinenfabrik GmbH, D-31855 Aerzen Eine technische Dokumentation ist vollständig vorhanden. Die zur Maschine gehörende Betriebsanleitung Betriebsanleitung liegt vor. Die Inbetriebnahme dieser Maschine ist so lange untersagt, bis festgestellt wurde, dass die Maschine/Anlage, in die sie eingebaut werden soll, den Bestimmungen der EG-Richtlinie entspricht !
H S I L G N E
english
We herewith conrm that this machine is in accordance with the following EC directives: 98/37 EG Appendix II B for machines to be installed EMV directive 89/336 EG low-voltage directive 2006/95/EG
ective EC machine dir ective
The machine was designed, manufactured and documented in accordance with the harmonized standards of the stated EC-guidelines of: Aerzener Maschinenfabrik GmbH, D-31855 Aerzen A copy of of all relevant technical technical information is provided and and available. The operating operating manual pertaining to the the machine is provided and available. Commissioning Commissioning of this machine must not be carried out until it is determined that the unit/plant in which the machine is to be installed corresponds to the regulations of the EC guideline! français
Nous déclarons par la présente que cette machine est conforme aux directives CE suivantes: 98/37 CE Annexe II B pour les éléments destinés à être incorporés Directive machine CE Directive CEM Directive basse tension
89/336 CE
2006/95/CE La machine a été conçue, fabriquée et documentée en accord avec les normes d’harmonisation des directives CE indiquées, par la société : Aerzener Maschinenfabrik Maschinenfabrik GmbH, D-31855 D-31855 Aerzen Une documentation technique complète est disponible. Le présent document comprend la notice ’instructions de la machine. Il est interdit de mettre la présente machine en service tant que la machine/installation dans laquelle elle doit être incorporée n’aura pas été déclarée conforme aux dispositions de la directive CE. nederlands
Hiermee bevestigen we, dat deze machine aan de volgende EG-richtlijnen voldoet: 98/37 EG Bijlage II B voor in te bouwen machines EG-Machinerichtlijn EMC-Richtlijn Laagspanningsrichtlijn
89/336 EG
2006/95/EG De machine werd geconstrueerd, vervaardigd en gedocumenteerd in overeenstemming met de geharmoniseerde normen van de genoemde EG-richtlijnen door de: Aerzener Maschinenfabrik Maschinenfabrik GmbH, D-31855 D-31855 Aerzen Een technische documentatie documentatie is compleet aanwezig. De bij de machine behorende bedieningshandleiding bedieningshandleiding ligt ter inzage. De inbedrijfname van deze machine is zo lang verboden totdat is vastgesteld, dat de machine/installatie waarin ze ingebouwd zal worden aan de voorschriften van de EG-richtlijn voldoet! español
Nos aseguramos de esta forma, que la máquina cumple con las siguientes Directivas de la CE: 98/37 CE Anexo II B para máquinas que serán montadas Directiva de máquinas CE
Directiva EMV Directiva de baja tensión
89/336 CE
2006/95/EG La máquina fue construida, concluida y documentada en conformidad con las normativas harmonizadas de las Directivas de la CE mencionadas, por la empresa: Aerzener Maschinenfabrik Maschinenfabrik GmbH, D-31855 D-31855 Aerzen Se encuentra disponible una documentación técnica complet a. Existe un manual de instrucciones de la máquina. ¡La puesta en marcha de esta máquina se encuentra interdicto, hasta que se haya detectado que la máquina/ sistema donde esta será montada, está de acuerdo con las determinaciones de las Directivas de la CE! italiano
Con la presente si conferma che la presente macchina è conforme alle seguenti direttive CEE: Direttiva macchine CEE 98/37 CEE Appendice II B per macchine da installare Direttiva EMV Direttiva bassa tensione
89/336 CEE
2006/95/CEE La macchina è stata costruita, prodotta e documentata, in conformità alle norme armonizzate delle succitate direttive CEEdalla ditta: Aerzener Maschinenfabrik GmbH, D-31855 Aerzen É disponibile la documentazione tecnica completa. Le istruzioni per l‘uso necessarie alla macchina sono allegate. La messa in servizio di questa macchina è vi etata no a che non vi ene accertato che, che la mac china/l‘impianto china/l‘impianto in cui deve essere installata sia conforme alle disposizioni della direttiva CEE !
(Herr Seidel)
G4-001 I EN
Leiter Techn. Abteilung Head of the dept. Directeur technique Hoofd tec hnische afdeling Director Dpto, Técnico Responsabile reparto tecnico
Unterschrift des Herstellers Signature of the manufacturer Signature du constructeur Handtekening van de fabrikant Firma del fabricante Firma del fornitore
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Ersatzteile,
spare parts, pièces dé tachée, onderdelen, repuestos, pezzi di ricambio - AERZENER MASCHINENFABRIK -
Ersatz- und Zubehörteile Es wird darauf hingewiesen, dass nicht von uns gelieferte Originalteile und Zubehör auch nicht von uns geprüft und freigegeben sind. Der Einbau oder Anbau sowie die Verwendung solcher Produkte kann daher unter Umständen konstruktive vorgegebene Eigenschaften der Anlagen beeinussen. Für Schäden, die
E N G L I S H
durch Verwendung von nicht Originalteilen und Zubehör entstehen, ist jede Haftung des Herstellers ausgeschlossen. Spare parts and accessories We draw your attention to the fact that original parts and accessories not supplied supplied by us are also not inspected and released by us. Therefore, the installation and application of such products might inuence under
certain circumstances constructively stipulated stipulated properties of the plants. Consequential damages due to application of non-original parts and accessories release the manufacturer from any warranty and liability. Accessoires et pièces de rechange Nous attirons votre attention sur le fait que les accessoires et pièces d’origine n’étant pas de notre fourniture ne peuvent être controlés et pris en considératoin lors d’une réclamation. réclamation. L’intégration ou le montage ainsi que l’utilisation de telles pièces peut inuencer sous certaines conditions les caractéristiques et performances
de la machine. Pour tout dommage causé du fait de pièces n’étant n’étant pas d’origine ou de montage erroné, nous déclinons toute responsabilité. Reservedelen en toebehoren Er wordt uitdrukkelijk op gewezen dat niet door ons geleverde originele delen en toebehoren ook niet door ons getest en vrijgegeven zijn. zijn. De in of aanbouw alsmede alsmede de toepassing toepassing van zulke producten kan derhalve onder zekere omstandigheden constructief constructief gegeven eigenschappen eigenschappen van de installatie beïnvloeden. Voor schaden, die door gebruik van niet originele delen en accessoires ontstaan, is iedere aansprakelijkheid jegens de fabrikant fabrikant uitgesloten. Ricambi e accessori Facciamo presente che i pezzi e ricambi originali non forniti da noi, non sono da noi controllati e accettati. Il montaggio o l’impiego di questi prodotti può in certe circostanze provocare inuenze sul cattivo funziona mento dell’impianto. Danni causati dall’impiego di parti e ricambi non originali esonerano il fornitore da ogni garanzia. Piezas de repuesto y accesorios Indicamos expresamente, expresamente, que aquellos repuestos y/o accesorios no suministrados suministrados por nosotros no están comprobados ni homologados por Aerzen. Aerzen. Su montaje, así como su utilización pueden tener incidencia en las características prejadas de la instalación. Por lo tanto no asumimos garantía ni responsabilidad alguna
sobre éstas piezas y de los eventuales daños posteriores y/o alteraciones de las calidades y prestaciones de origen. Para daños originados por la utilización de piezas y accesorios no originales, se excluye cualquier responsabilidad por parte del fabricante.
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G4-001 I EN
Aerzener Maschinenfabrik Leistungsdaten Performance data H S I L G N E
G4-001 I EN
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Aerzener Maschinenfabrik 3SG-4648 3SG-4647
Ersatzteilliste / spare parts list Auftrags-Nr.
Typ
order no.
type
Fabrik-Nr.
Kundenbestell-Nr. Customer‘s order no.
serial no.
E N G L I S H
Lieferanschrift Dispatch address
Rechnungsanschrift Invoice address
Pos.
Stückzahl /
Pos.
Stückzahl /
quantity
quantity
10
150
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160
30
170
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180
50
190
60
200 GM 3S-30L
N T / n o n i t o a t i t n k e a d m u e r k k R o i r o t & u b D a n A f r e i o e n h e c t h a n c r i s t s h i n s i c h u n s c l l h I a e c T e e M r g h T l e n c s e n l u i k e i n i c z e h r t N e b c e . A A T H
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70
210
80
220
90
230
100
240
110
250
120
260
130
270
140
280
GM 35S-50L
Bitte richten Sie Ihre Bestellung, an die für Sie zuständige Aerzener Vertretung / -Gesellschaft. Abruf unter (++49) 0 51 54 81 192 Please send your ordering to the Aerzen representation / -company responsible for your country. Fax polling ++49 (0) 515481192
G4-001 I EN
Notizen note
H S I L G N E
G4-001 I EN
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Gebläsestufe / Rotary piston - blower stage Verschleißteilzeichnung / Wearing parts drawing
E N G L I S H
Diese Abbildung ist eine Beispiel-Dar Beispiel-Darstellung stellung und dient der Ersatzteilbestellung. Ersatzteilbestellung. Abweichungen zu der ausgelieferten Maschine sind möglich. Detaillierte Informationen enthält die auftragsbezo auftragsbezogene gene Zeichnung. This gure is an example-presentation and serves for spare part or der.
Deviations to the machine supplied are possible. The drawing gives detail information according to the order number.
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Gebläsestufe / Rotary piston - blower stage Verschleißteilzeichnung / Wearing parts drawing
H S I L G N E
Diese Abbildung ist eine Beispiel-Dar Beispiel-Darstellung stellung und dient der Ersatzteilbestellung. Ersatzteilbestellung. Abweichungen zu der ausgelieferten Maschine sind möglich. Detaillierte Informationen enthält die auftragsbezo auftragsbezogene gene Zeichnung. This gure is an example-presentation and serves for spare part or der.
Deviations to the machine supplied are possible. The drawing gives detail information according to the order number.
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Table of contents E N G L I S H
Front page ..................................................................................1 Note on information sheet ..........................................................2 Overview of contents ..................................................................3 Manufacturer declaration ............................................................5 Note on spare parts ....................................................................6 Performance data .......................................................................7 List of spare parts ................................................................. 8 - 9 Wearing and spare parts drawings ....................................10 - 11 Table of contents ......................................................................12
1. 2. 3. 4. 5. 6. 7. 8. 9. 9.1 9.2 9.3
9.4. 9.5 9.6 9.7 10. 11. 12. 13. 14.
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Suitability/General information.................................13 Construction, function ...................................... 14 - 15 Care ..................................................................... 16 - 18 Inappropriate operation.............................................19 operation.............................................19 Transport/Installation Transport/Installation ........................................ 20 - 23 Commissioning .................................................. 24 - 25 Shut-down/Taking Shut-down/Taking out of operation..........................26 Frequency converter operation Pole changing ............................................................27 Maintenance Inspection/Inspection schedule ....................................28 Maintenance schedule .................................................29 ........................ ............. .......... .... 30 - 31 Oil lubrication specication ................. Lubricating oil volumes ................................................32 Lubricant change: driving shaft, gas-tight ....................33 Lubricant change ................................................. 34 - 35 Drive, belt drives, couplings ................................. 36 - 38 Accessories ................................................................39 Fault diagnosis/Troubleshooting diagnosis/Troubleshooting advice/ Repairs ................................................................ 40 - 41 Overview of spare parts for blower stage ...............42 Recycling ....................................................................43 INFORMATION INFORMATION sheet ......................................... 44 - 45
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Suitability/General Suitability/General information
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Aerzener rotary piston machines are suitable for the oil-free oil-fre e conveying conveyin g and compression compres sion of air and, if specially modied versions are used, various other types of gas.
The technical performance limits must be observed if perfect operation of the equipment is to be ensured in the long term. The intake temperature t 1 specied on the order conrmation serves as the ins tallation site ambient temperature.
H S I L G N E
Non-observance of the technical performance limits or the safety information shall absolve Aerzener Maschinenfabrik of its warranty obligations and its liability to pay damages or compensation as a result of any consequential damage. The same shall apply to defects that can be traced back to recommended inspections not being performed correctly or on time. The vibration behaviour of blowers and compressors with mounted belt pulleys or couplings is largely determined by the balance quality of the pistons/rotors as well as the balance of the driving elements. At Aerzener Aer zener Maschinenfabrik Maschine nfabrik,, the piston/rotor piston/ rotor driving shafts are balanced using the „half-key balancing“ technique. The belt pulleys/couplings must be used in accordance with the requirements of balancing type „H“.
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Construction, function Blower stage: The blower stage is supplied as a fully assembled unit. The following additional work must be carried out: • Correct installation/assembly in the relevant unit/system • Connect the conveying piping. • Check lubricating oil level. • Adjust level, if necessary. necessary. • Install driving elements, ensuring that safety devices are in place! • Install special accessories which are supplied separately, if necessary. necessary.
E N G L I S H
Service package: An Aerzener service package is available for the blower stage. Depending on the option selected, this includes auxiliary equipment and material, e.g. for lling with oil,
draining oil, etc. Motor connection: Electrical installation of the driving motor must only be carried out by an authorised electrical tter.
The motor and control voltage must be connected to a stable common network and the power contactor unlocked in the event of an interruption of circuit. Voltage uctua -
tions and dips must be avoided. Alternative: An electronic monitoring relay must be installed parallel to the driving motor so that the power contactor can be unlocked in the event of an interruption of circuit. A restart should only be possible once the machine has come to a complete halt. Requirements for operating rotary piston machines with asynchronous electric motors on a 3-phase AC system: The machine should only be used on stable three-phase systems. The voltage and frequency limits must be observed. These are specied in
EN 60034-1. Voltage uctuations/dips beyond the tolerance zone can seriously damage all the ele -
ments that make up the drive system, e.g. couplings, V-belts, V-belt pulleys, shafts, gear wheels, etc. . If the supply system is subject to signicant voltage uctuations.
Aerzener Maschinenfabrik recommends the following measures to avoid damaging the blower, compressor or motor: - Use a suitable protective device that will shut down the motor and denitely prevent
an automatic restart when impermissible operating data is detected. Please also observe EN 60034-1 and EN 60 204-1 in this respect. Unit/System: The blower stage must be installed/assembled in a unit/system in the correct way so that it is safe to operate. No forces or moments that could distort the blower housing are permitted to act on the ange.
A distortion-resistant form of assembly/installation must be ensured. The blower stage must be installed at (without any slopes).
Operational safety/reliability will be affected in accordance with the extent of any misalignment. We recommend that you install a pressure valve in the piping on the discharge side to protect the blower against overload. No shut-off valves must be installed between the pressure valve and blower stage.
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G4-001 I EN
With a suction pressure version, we recommend that you install a suction valve in the piping on the intake side. No shut-off valves must be installed between the suction valve and blower stage. Suitable valves are available from Aerzener Maschinenfabrik. The valves are not intended to control the operating data!
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Filter silencer/Starting strainer A lter lter (or in the case of intake from from a pipeline, pipeline, a starting strainer) should should be used used to
ensure the blower stage‘s operational reliability. We recommend that you use an Aerzener intake silencer. This silencer is a combina-
H S I L G N E
tion of intake-side silencer and intake lter. The lter element is easily exchanged due
to its easy access. The degree of contamination or the specications in the maintenance schedule deter mine when the lter element is to be replaced.
Accessories: A non-return valve is required on the discharge side to prevent the blower from running in reverse after shutdown. Additionally, Additionally, a start-up relief can be installed on the discharge side. This provides relief from any existing discharge pressure during start-up. With a suction pressure version, various components must be used accordingly. All accessory components are available from Aerzener Maschinenfabrik. Function: Aerzener rotary piston blowers are dual-shaft rotary piston machines whose pistons turn uniformly against each other. Timing gear wheels guarantee contact-free running of the rotary pistons. The rotational direction determines the conveying direction of the blower, which means there is a discharge-side and intake-side ange. During opera tion, the medium to be conveyed ows through the intake ange into the housing.
From there, it is forced through the conveying chambers (consisting of the pistons and the blower cylinder) to the discharge side. Pulsation decrease on the basis of interference (patented). The conveying chamber (cylinder) is sealed against the oil chambers (casing cover and gear case) by square piston ring labyrinth seals and the driving shaft is sealed by means of one or two radial seal rings.
G4-001 I EN
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Erst lesen dann bedienen!
E N G Read frst, L then operate ! I S H
Precautions prior to and during operation CAUTION!
Identies all hazardous situations.
WARNING!
Indicates immediate danger to personnel.
Check the positive displacement machine against the delivery note and the order for completeness and for transport damage on receipt/acceptance. Observe health and safety regulations, safety information and the relevant operating instructions. Read the INFORMATION sheet prior to commissioning. Any notes and changes indicated herein must be carried out. The steps described below must only be carried out by skilled personnel who are familiar with the functions of the positive displacement machine and its components and have been instructed in the safety information to be observed.
Hinweis: Angaben zur SchallSchallhaube können je nach Aggregat- / Anlagenausführung variieren. Instruktionen des Anlagenbauers beachten ! Note: Details concerning acoustic hood can vary depending on unit- /plant design. Pay attention to instruc- tions of plant manufac- turer! Remarque: Les indications concernant capot d‘insonorisation peuvent varier selon exécution du groupe / de l‘usine. Les instructions du constructeur de l‘usine sont à observer.
This positive displacement machine complies with the relevant European safety regulations. However, unavoidable technical residual risks may still pose a danger to personnel and property. In order to prevent any damage, operators must observe the following safety information:
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You must not attempt t o commission this machine before reading and understanding this operating manual. Everyone involved in installing, operating, maintaining and repairing the unit must have read and understood the operating manual. Only personnel with the requisite expertise may commission the unit. Only trained and authorised personnel may operate the unit. Operator responsibilities must be clearly dened in order to prevent any confusion
in this regard. Observe the warnings and notices attached to the machine. They provide important information for ensuring safe operation. Operators must be competent and have been instructed in and authorised to perform the relevant tasks. Observe general, statutory safety and accident prevention regulations as well as the information provided in the operating manual. Any operation that impairs machine safety is prohibited. The user has an obligation to only operate the machine in its perfect, original condition. Prior to commissioning, ensure that the machine is undamaged and that all screwed connections are fully tightened. Operators must have read this manual and, therefore, be familiar with all protective, operator control and monitoring elements before the device is switched on. Use the machine appropriately and correctly and observe its performance limits. Documents provided by accessories suppliers must also be observed. Observe the safety, operating and maintenance instructions provided by the drive motor manufacturer. When operating a machine with an acoustic hood, all hood elements are to be closed before starting operation and are only to be opened after the motor has been shut down and the fuses removed or switched off. The acoustic hood is also a structural safety component. The acoustic hood prevents the risk of injury from rotating and hot components.
G4-001 I EN
• • • • •
If the acoustic hood is opened during operation of the machine, there is a risk of serious injury! Do not perform any improper repairs or changes on the unit. If you have any problems, please contact Aerzen After-Sales Service for assistance. Disconnect the power supply and secure the machine against start-up before carrying out any conversion, servicing or maintenance work that requires protective equipment to be removed. It is the operating company‘s responsibility to use and operate the machine in accordance with its intended use and local conditions. Only operate the machine at a suitable, well-ventilated site. The installation site
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H S I L G N E
must be free of excessive dust, acid, steam and explosive or inammable gas.
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Remove all solids, liquids and powders from the intake area. Protective equipment such as the belt guard/coupling guard, fan cover, hood elements, electrical protective elements, pressure valves, motor protection/emergency stop device, etc. must be in place when the machine is running and their operational reliability must not be restricted. Risk of injury! Do not operate the machine if electrical, mechanical or hydraulic connections are faulty or missing. Only retighten or open lubricating and regulating oil lines when the machine is depressurised. Only retighten screwed connections when the machine is depressurised. Risk of burns! Do not touch delivery pipes or components on the discharge side without appropriate protection. The pipes and components can reach temperatures of over 70°C. Risk of burns! Depressurise delivery pipes before attempting to remove them. If industrial gases are used, you must rst rinse the delivery pipes with a neutral
•
• • • •
gas. Never look into or touch the discharge opening/side of the pressure valve. There is a risk of injury since hot, decompressing gas escapes at high speed when the pressure valve is drained. Residual contaminant pieces, dust particles, etc. can also be carried along in this gas. The motor must be securely disconnected from its power supply before commencing any work on the unit. Only trained, authorised, skilled personnel may work on current-carrying components. The unit must be de-energised before such work is performed. Remove fuses. Do not operate the unit if electrical connections are damaged, faulty or not properly connected. Only use the machine in a stable three-phase supply system. Voltage uctuations/
dips beyond the accepted tolerances can lead to serious damage to all drive system elements, such as couplings, V-belts, V-belt pulleys, shafts, gear wheels, etc. • • • • • •
The safety devices serve to protect against injury and must not be modied or
bypassed. Do not operate the unit if protective equipment, such as the belt or coupling guard, acoustic hood elements, pressure valve, etc. is faulty or missing. It is strictly forbidden to remove or modify the machine‘s protective equipment, to use it for anything other than its intended purpose, or to attach third-party protective equipment. Do not operate the machine with open inlet or discharge sockets, as rotating piston machines are positive displacement machines which carry a risk of injury in the area around the conveying chamber. Wear protective gloves if the acoustic hood is open or missing and the surface of the housing is at operating temperature. Risk of burns! Loose clothing must not be worn, as rotating components could pose a danger. Risk of injury! G4-001 I EN
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Ear protection must be worn during blower operation. Depending on the operational state of the machine, the sound pressure level may differ from that specied in the operating data. Therefore, a sound pressure level
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•
greater than 85 dB(A) may arise for a brief period. Observe the oil temperature when changing the oil; it must not exceed 60°C. If the oil temperature is above 60°C, there is a risk of burns. Only use suitable tools that comply with the respective standards and designs of the screws, nuts and screwed connections. If the machine is driven by diesel or petrol motors and the room is not ventilated, or is insufciently ventilated, there is a risk of poisoning. The installation site must
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be adequately ventilated. Observe also the information provided in the motor manufacturer‘s operating manual. When using detergents or sprays there is a risk of poisoning from breathing them in and a risk of chemical burns from touching them. Observe the manufacturer‘s instructions, those provided with the accessories and all general safety guidelines.
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Inadmissible operating methods • • • • • • • • • • • • • • •
4
Installation on uneven and / slanting foundations. Securing transport devices to the acoustic hood. Non-observance of operating data. Non-observance of maintenance intervals. Incorrect direction of rotation. Switching on - during run-down. - during reverse rotation. Inadmissible increase in pressure. Remaining under or exceeding maximum rotational speed. Exceeding the maximum temperature / see type plate. Pole change to lower rotational speed before motor has come to a standstill. Operating the screw compressor without a properly connected fault indicator / control is not permited. Risk of total machine damage! Operation without assemblies or with damaged assemblies which serve for the protection of persons and machine.
H S I L G N E
Overlling the maximum oil level.
Operation without oil.
G4-001 I EN
19
5
Transport/Installation When transporting the machine, the following key points must be observed: • • • •
E N G L I S H
• • •
Do not expose the blower to impact loads. Transport the blower using a crane, fork-lift truck, lift trolley or similar. Only suspend the blower as shown in the sketch. Use suitable hoisting gear that is appropriate for the load concerned. Failure to observe this point could result in damage or injury! The hoist, cable, chains, etc. must be designed for the load concerned. The hoist must be a rranged in accordance with the machine‘s centre of gravity. The hoist must not be able to exert any forces on the machine that could result in damage.
During installation the following points must be observed: •
• • • • • • • •
•
Prior to delivery, rotary piston machines are treated and packaged to allow for a 12-month storage period. If they are to remain in storage following this 12-month period, they will need to be retreated; see storage and mothballing guidelines TN0 1175. Whilst the units are in storage, please ensure that they are correctly preserved, packaged and if necessary that they undergo nitrogen replenishment in accordance with TN0 1175. They must be checked every six weeks. You must eliminate any adverse inuences immediately to ensure ongoing preser vation of the units. Intermediate storage in dry, clean rooms that are free of vibrations. The oil chambers have been sufciently preserved for one year.
In the case of belt-driven machines, the V-belts should be slackened during storage. If the unit is to be taken out of operation for longer than six weeks, the conveying chamber, piston and bright work must be preserved. The blower must be installed on an a foundation, base and connections that are even, non-vibrating and slope-free. CAUTION! If the blower is installed with a tilt, this will result in irreparable damage to the machine due to the uneven oil level. The machine‘s operational safety/reliability and service life will be affected in accordance with the extent of any misalignment. Remove all packaging material. If your machine features an acoustic hood, ensure that the inlet and exhaust air louver proles can be accessed.
20
G4-001 I EN
• •
• •
• • • • •
Ensure that the installation site is adequately ventilated. The following standard installation conditions must be observed: Ambient temperature : -10°C to 40°C Rel. air humidity : 0% to 80% Atmosphere free of chemicals Check that the rotary piston machine can run easily. Sluggishness indicates the presence of distortion or foreign bodies. For the purpose of conveying air, the plastic plugs must be removed from the condensation holes on the blower. This enables a small amount of warm air to escape in order to clear the condensation holes. For the purpose of conveying „industrial gases“, the condensation holes must remain sealed. If the medium to be conveyed has a tendency to produce condensation, then the condensate should be discharged by means of collecting basins or residual gas pipelines or by temporarily opening the lower holes (depending on the application). CAUTION! Hot gas or condensate can escape through the holes!
5
H S I L G N E
To avoid electrostatic charging of the units, the motor, acoustic hood and base frame must be earthed via the relevant connections. Fasten the piping on the discharge side and the piping on the intake side separately to ensure a stable connection. No forces and/or moments are permitted to act on the ange and connections.
Check that the blower can run easily prior to installation. Sluggishness indicates the presence of foreign bodies inside the conveying chamber. Remember to remove the sealing covers from the intake-side and discharge-side anges prior to installation!
G4-001 I EN
21
5
•
There must be no distortion of the blower as a result of alignment or tightening operations.
•
Assemble the blower xing screws in the correct correct manner. manner.
- Please observe the foot assembly drawing 139 006. - According to drawing 139 006, the length of the bush should be determined within the context of assembly. - The screw, disc spring and bush must be tightened as far as the stop. E N G L I S H
Skt.-Schraube
Lospunkt
movable point
hexagon screw
GM 220 L GM 315 L GM 400 L
Tellerfeder(n) disc spring(s)
Buchse bush
Festpunkt fxes point
•
• •
Check that the blower can run easily following installation. Sluggishness indicates the presence of foreign bodies inside the conveying chamber or distortion. Take noise protection into consideration. Piping and foundations may be stimulated into producing natural vibrations along with the inevitable sound emissions. If you are planning the system in-house, the safety information, maintenance information and technical documentation provided by your component suppliers must also be observed.
Check oil level prior to commissioning and correct if necessary.
22
G4-001 I EN
5
Piping
• • • •
When installing the piping on the intake side, ensure that it is clean. Foreign bodies and dirt will damage the blower. Any piping that is to be connected must be carefully cleaned and must be free from foreign bodies. Piping on the intake side must be supported/propped up. No forces and/or moments are permitted to act on the blower housing. A starting starting strainer strainer should be installed for the the rst 500 operating operating hours hours to prevent prevent
H S I L G N E
damage as a result of impurities. Install the starting strainer together with a seal on the intake side. • • • • • •
• • • • •
Prior to tightening, the piping and seals must sit on the blower housing ange
without any stresses. The maximum distance in the sealing surface area is 0.05 mm on one side. Once it has been tightened, the blower stage should be able to rotate easily without any resistance. Please note that piping and foundations may be stimulated into producing vibrations and sound emissions when the blower is in operation. Therefore, insulation and soundproong measures should be taken into account
right from the planning stage. If you are planning a system in-house and/or plan to install the blower stage yourself, the safety information and technical documentation provided by your component suppliers should also be observed. Coolant connections for oil cooling (special accessories) Install shut-off valves in the feed piping. The coolant must ow through the refrigerating chambers from bottom to top. A ow ow indicator should should be installed installed in order order to monitor water throughput. throughput.
A drain valve must be provided for the purpose of emptying the cooling system completely. Caution! Risk of frost in the case of winter operation.
starting strainer
G4-001 I EN
23
6
Commissioning 1. Install and assemble the blower stage in accordance with these instructions. Assemble the driving elements correctly. CAUTION! Do not establish any connection connection with the driving motor yet. 2. On rst commissioning top up lubricating oil on empty machines. Check lubricating oil level and correct if necessary.
E N G L I S H
Check that the oil lling plug and the drain valve are seated securely and do not
leak. Ölstandschaugläser Ölstandschaugläser an der Gebläsestufe oil level sight glasses on the blower stage verres-regard au niveau de l’étage de soufante
max. min.
3. Observe the commissioning instructions and lubrication intervals provided by the driving motor manufacturer. Observe the requirements for operating rotary piston machines with asynchronous electric motors on a 3-phase AC system. See under Construction and function. 4. Check the direction of rotation. See also the red direction plate on the blower. There must not be any V-belts on the motor pulley/the drive coupling between the blower and motor must not be connected. Briey start the driving motor (approx. 1 - 2 seconds).
See also the instructions provided by the electronics supplier/system manufacturer. CAUTION! The blower will be destroyed if it is operated in the wrong direction. The blower‘s direction of rotation must match that of the driving motor.
24
G4-001 I EN
5. With the correct direction of rotation: The alignment of the belt pulleys/drive coupling should be checked. The V-belts should be attached/the drive coupling should be connected using connecting elements.
6
Tension the V-belts. Observe the specications regarding the belt tensioning force.
6. Ensure that protective equipment is in place for the belt drive/drive coupling. 7. Safety information stickers must be legible and protective equipment must have been checked.
H S I L G N E
8. Open the slide on the system side. Operation can now start. 9. Switch the driving motor on. Switch it off after approx. 20 seconds and monitor the blower to ensure it coasts down smoothly smooth ly.. If the pressure valve blows off, switch the blower off immediately and remove the cause. 10. Switch on again. Check the EMERGENCY STOP switch. 11. The unit is now ready for operation.
G4-001 I EN
25
7
Switch off / shutdown • • •
E N G L I S H
Switch off is effected via the power switch on the motor. To shut the unit down completely the fuses must be removed after the blower has come to a standstill. The valves on the conveying pipes must be closed. Avoid possible entry of condensate into the blower stage. In case of a shutdown for more than six weeks the conveying chamber is to be preserved and the blower turned regularly by hand to avoid damage due to standstill. Observe also the TN01175 regulations governing storage and preservation.
In case of danger: Press EMERGENCY - OFF button. For details refer to the instructions of the supplier of electrical components or the plant manufacturer.
26
G4-001 I EN
Frequency converter operation •
With the addition of a frequency converter the electrical and mechanical characteristics of the drive motor are to be taken into account.
•
The minimum frequency must always be xed. This frequency must never fall below the xed minimum during operation.
•
The maximum frequency is to be set by taking into account the maximum rotational speed of the motor and the maximum speed of the blower / compressor. The run-up time of the drive motor from standstill up to minimum speed may be 3 to 6 seconds. The frequency converter must be designed with a constant load moment for operation with a working machine. Rotational speeds must no fall below minimum nor exceed maximum. The highest admissible voltage increase speed of the motor converter is 1200 V/ms. When exceeding the value, e.g. due to excessively long cables, frequency conver-
• • • • •
8
H S I L G N E
ter type… etc. a motor throttle / motor lter coil to match the frequency converter is
• • • •
to be used. If these components are not used, this can lead to damage of the motor isolation and to a motor breakdown. The maximum rotational changeover speed on positive displacement blowers / screw compressors, after run-up to minimum speed, amounts to 1 Hz per second for upward and downward control time. Minimum frequency = 20 Hz // maximum frequency = 50 Hz results in a control time of 30 seconds from minimum to maximum. The maximum current limit of the motor must not be exceeded. Observe the soecicationa on the motor name plate.
•
To prevent operational faults the function “Interception circuit” must not be parameterised in the control of the frequency converter. When the frequency converter is switched off, a restart should only be possible after a complete standstill of the blower or compressor. Only applies to screw compressors
•
At a speeds below 50% the oil pressure sinks to approximately 0.6 bar (ü). To enable the machine to run at speeds up to 25% the ain oil pressure switch, setting value of 1.8 bar (ü), is bridged with a threshold switch. A further switch, setting value of 0.5 bar (ü), is installed for oil pressure safety. safety.
Operation with pole-changing motor Between a changeover of motor speed • from a high to a low speed, the motor must have reached zero rotational speed each time. • from a low to a high speed, changeover can take place instantaneously.
G4-001 I EN
27
9
Maintenance Maintenance is to ensure that all functions are maintained or that they can be restored after a breakdown. Maintenance includes specications about inspection, service and repairs. Maintenance includes instructions for trained and qualied personnel.
E N G L I S H
If anything is unclear consult Aerzener customer service. During inquiries please state: • order and serial number • prevailing faults / malfunctions as accurately as possible • steps taken to rectify faults. Is the machine sent back to the supplier, the following measures are to be carried out: • Completely drain oil, otherwise it is transport of hazardous goods. • Treat bare components with preservative. • Seal ange with blind cover. • Seal open connections. • Also observe instructions in chapter “Transport”.
Inspections / inspection schedule
9.1
28
A general inspection should be carried out by a service technician from Aerzener Aerzener after 3 years or 20,000 operating hours. This includes the preventive maintenance of wearing and replacement parts such as bearings, seal, etc. We recommend maintaining a stock of replacement and wearing parts to avoid or reduce waiting times and downtimes.
G4-001 I EN
9.2
Maintenance schedule
Whenever work is carried out on the rotary piston machine, it must be switched off and isolated from the electrical mains supply. Failure to observe this point could result in injury or damage. To ensure a long service life and optimum operating conditions, various steps should be taken including observance of the maintenance operations and intervals specied in this table.
Maintenance intervals We recommend that you maintain your rotary piston machine in accordance with the specied intervals. The
operating hours represent average operating conditions. The actual life of the equipment may vary depending on environmental conditions and operating data. If you think this situation applies to you, please contact Aerzener Maschinenfabrik.
t s r s r h e . h t p r o e t f 3 A
Fixing screws and screwed connections • Re-tighten once the machine has cooled down
t s r s r h e . h p t r o e 5 t f 2 A
y l k e e W
- . e p s s r b o a u 0 e s 0 s y 0 r y r , u 3 r e 0 o e v 2 h t f e t r n a r e e t f u O q A
●
V-belt condition (part of the unit) • Check; replace if necessary
•
r - s e u s o b h u . y s p l o r y r 0 a e e 0 y v 0 r e 8 O r e t n t f e A u q
●
Intake lter (part of the unit) Check level of lter soiling and if necessary replace • lter cartridge, max. -45 mbar Replace lter cartridge •
Belt pulley/coupling alignment
r s - s e u h s o t b h n u . s p o o m y r 0 6 e 0 y v 0 r e 4 e r v e t n e t f e r A u o q
●
Starting strainer, if tted • Check; if dirt is no longer accumulating, it can be removed
●
(part of the unit)
t s s r r h e . p h t o r 0 e t f 0 5 A
g f o n r i - s e u m e s a s o u i r r c i b h s a e a t u . s a t h n t n , e s p s e n i o t i y b i b r 0 h h n m m t e 0 o a n a v 0 m n o y e 1 6 a m t s r y l e u e t r c y r d n t e f e e v v A u E E q - -
●
●
●
● ●
●
●
●
●
Check; correct if necessary
Pressure valve (part of the unit) • Check function
●
Oil level • Check
●
● ●
●
Lubricating oil • Replace • *at discharge temperatures of over 120°C
●
Lubricating grease, only with gas-tight shaft seal • Replace • *at discharge temperatures of over 120°C
●
● *● ● *●
Non-return valve (part of the unit) • Check for wear and leaks
●
Main inspection/maintenance • Check/replacement Check/replacement of spare and wearing parts • Check of entire machine
●
Driving motor (part of the unit) • Carry out maintenance • Observe deadlines for renewal of lubrication
Please observe the maintenance intervals and specications
of the motor manufacturer. In the case of Aerzener motors, the Aerzener operating and maintenance instructions must be observed.
Arrange for the rotary piston machine to undergo a complete check by the Aerzener Service department at the specied
intervals and certainly at least once a year. Or: Take out a maintenance contract with Aerzener Maschinenfabrik. Assuming that maintenance work is carried o ut regularly and professionally, Aerzener Maschinenfabrik is condent that your machine will offer maximum reliability for your application.
G4-001 I EN
29
H S I L G N E
9.3
Lube oil specications for positive displacement blowers For the selection of lube oil, the additives and the viscosity class are important. Depending on the application, the following oil types with corresponding viscosity and additives are to be used. General requirements for lube oil characteristics Kinematics viscosity at 100°C : > 13 cSt (mm2/s) Kinematic viscosity at 100°C : > 28 cSt (mm2/s) Only for constant oil temperatures in excess of 120°C See item 4 Kinematic viscosity at -10°C : > 3500 cSt (mm2/s)
E N G L I S H
Minimum characteristics of oil additives • EP anti-wear additive for application in gear boxes with roller bearings • Oxidative stability up to 110°C oil sump temperature, at constant oil temperatures above 120°C = oxidative stability up to 220°C oil sump temperature • Foam inhibitor • Detergents for dissolving deposits • Neutrality towards sealing materials made of uorine-propylene-methyl (Viton) • Neutrality towards single-component synthetic resin primers 1. Single or two-shift operation / intermittent interruption of operation Intake temperature up to 60°C Discharge temperature up to 140°C Ambient temperature that could fall below 10°C SAE 5W-40 / fully synthetic high-performance motor oil API CF or higher ACEA B3 / E3 or higher Example Aerzener special rotary piston oil, part no. for ordering: 160 754 or 160 755 2. Continuous operation / 24 hours per day Intake temperature up to 60°C Discharge temperature up to 140°C Ambient temperatures throughout the year > +10°C SAE 5W-40 / fully synthetic high-performance motor oil API CF or higher ACEA B3 / E3 or higher Example Aerzener special rotary piston oil, part no. for ordering: 160 754 or 160 755 ISO VG 150 / fully synthetic (PAO) Poly-Alpha-Olen, gearbox oil or compressor oil. Example MOBIL SHC 629 3. Operation with constant oil temperatures above 120°C Constant oil temperature > 120°C ISO VG 220 / synthetic lube oil with a base oil of type polyglycol Example ESSO Glycolube 220 ARAL Degol GS 220
30
G4-001 I EN
4. Lube oil in the food and pharmaceutical industries
9.3
Lube oils approved according to USDA H1 specications can be used for positive
displacement blowers. Experience in practice is available only for the following lube oils. Aerzener Maschinenfabrik does not approve the use of any other oils. It is recommended that an oil analysis is carried out after 1000 operating hours in consultation with the lube oil manufacturer.
H S I L G N E
Conveying temperatures up to 100°C ISO VG 100 Klüberoil 4UH1-100 Conveying temperatures 0f 100°C to 140°C ISO VG 220 Klüberoil 4UH1-220
5. Lube oil for conveying of oxygen or gases that are corrosive or reactive
Application : Lubricating oil :
Overpressure operation Fomblin Y 45 or Fomblin Y 25 / Solvay Solexis
Changing oil types • High-performance motor oils and PAO oils can be fully mixed. • No special measures are required when changing over from one type of oil to another. • However, in order to retain the performance characteristics of the new oil, the oil to be replaced should be completely drained after an operating period of 24 hours and replaced with new oil. • Only the same oil type must be used for topping up. • Oils on the basis of polyglycol are not miscible with motor oil or PAO oils. In case of doubt, open the oil chambers and flush them.
G4-001 I EN
31
9.4
Lube oil quantities Total oil quantity, in approximate litres / oil level up to middle of gauge glass on the blower stage
E N G L I S H
GM 3S
0.55 l
GM 4S
0.55 l
GM 7L
0.55 l
GM 10S
0.86 l
GM 15L
0.86 l
GM 25S
1.2 l
GM 30L
1.20 l
GM 35S
3.00 l
GM 50L
3.50 l
GM 60S
6.50 l
GM 80L
6.50 l
GM 90S
11.50 l
GM 130L
11.50 l
GM 150S
11.00 l
GM 220L
11.00 l
GM 240S
17.50 l
GM 315L
17.50 l
GM 400L
22.00 l
Total oil quantity / only applies to generation 5 units with acoustic hood in approximate litres / oil level up to mark on the gauge glass of the acoustic hood GM 3S
0.55 l
GM 4S
1.00 l
GM 7L
1.00 l
GM 10S
1.40 l
GM 15L
1.40 l
GM 25S
1.75 l
GM 30L
1.75 l
GM 35S
3.75 l
GM 50L
4.50 l
GM 60S
7.50 l
GM 80L
7.50 l
GM 90S
12.50 l
Generation 5 units with acoustic hood
32
G4-001 I EN
9.5
Change of lubricant on the drive shaft > Only on drive shaft of gas-tight design <
Changing lubrication on a gas-tight drive shaft is carried out by means of re-lubrication on the drive shaft. Schmierstoffwechsel an der Antriebswelle •
Depending on the sealing method, a lube oil or grease block is used.
• •
If an oiler is used the oil level is to be checked weekly and topped up if necessary. The maximum oil level should be in the middle of the oiler.
•
If a grease bush or grease nipple is used, the grease quantities listed below, according to the intervals listed in the maintenance schedule, are to be used for re-greasing. Please note! The grease is to be pressed in / changed several operating hours before the lube oil change. In this way the used, excess grease reaches the oil chamber of the blower and can then be drained together with the lube oil.
• •
H S I L G N E
Grease specications When using lube oils according to Aerzener lube oil specications, except polyglycol oils, grease type KHC-2P-30 is used.
• •
Filled at factory:
•
When using polyglycol oil according to Aerzener lube oil specication, grease type
KLÜBER PETAMO GHY 133 N
MPG2K-40 is used KLÜBER SYNTHESO PROBA 270
• • • •
Mixing of different greases is to be avoided. Re-lubrication is admissible only with the same grease. If these greases are not available, they are to be removed completely and replaced with other greases according to KHC-2P-30 or MPG2K-40. Observe sealing consistency with Viton.
Re-lubrication quantities Type
GM 3S - GM 30L GM 35S - GM 130L GM 150S - GM 400L
Prole 10 - 12 13 - 15 16 - 18 19 - 21
Oiler Grease nipples Grease bush ≈ 5 cm3 ≈ 10 cm 3 ≈ 20 cm 3 ≈ 5 cm3 ≈ 10 cm3 ≈ 20 cm3 ≈ 40 cm3
G4-001 I EN
33
9.6
Lubricant change •
Filling up oil
• • •
Drainage valves must be closed/check for proper seating. Open oil reservoir. The specied oil quantity must be divided proportionately between both oil
chambers according to the oil level indicator. Correct oil level = middle of sight glass, observe maximum and minimum markings.
E N G L I S H
•
It is very important that each of the oil chambers is lled and drained separately
•
and that they are checked using the relevant sight glasses. Fill oil with a suitable funnel. Please ensure that the oil temperature is at least 20°C.
• • • •
The lling process should be carried out in stages. First ll with approximately ¾ of the specied oil quantity.
After a brief interval, the oil level adjusts itself in the oil chambers. The oil level should now be checked and adjusted in line with the markings on the sight glass. Oil level can move between the minimum and maximum marks. The oil level should be checked after the rst 3 and 25 operating hours and then at
weekly intervals, and adjusted if necessary.
Ölstandschaugläser an der Gebläsestufe oil level sight glasses on the blower stage verres-regard au niveau de l’étage de soufante
max. min.
Oil level too high, oil in conveying
GM 3S - GM 80L
a Connection for measuring instruments
GM 90S - GM 400L
Oil level during machine standstill
b Oil ller c Oil drainage
/ drain valve d Oil level level
34
G4-001 I EN
Oil level too low, mechanical damage to bearings and gear wheels
•
9.6
Draining oil
The initial operating oil container can be used as a collecting container. The waste oil can be collected in this container in the proper manner and disposed of in an environmentally-friendly way at an appropriate collecting station. Please observe capacity. capacity. a) b)
Unscrew cap (1), threaded plug (1) from the drain valve. If the cap (1) and threaded plug (1) have been screwed in too tight, hold the
H S I L G N E
valve rmly with an
a) a) a) b) a) b)
a)
b)
a) a) b)
open-jaw wrench and loosen position (1) with a second wrench. Screw on the hose, which is supplied. The drain valve opens automatically. Position the end of the hose in a collecting container. Open manual valve, drain the waste oil into a container. The waste oil must be disposed of in the proper manner. Remove the hose from the drain valve Close manual valve, screw in threaded plug (1) while gripping the valve rmly. rmly.
Screw cap (1) hand-tight onto drain valve. If the drain valve becomes loose or completely detached in the thread, it must be replaced together with a new seal.
Observe oil temperature when changing the oil. The oil temperature must not exceed 60°C, due to the thermal load capacity of the “drain hose”. If the oil temperature exceeds 60°C there is a risk of burns.
Beispiel / example a)
b)
Design without acoustic hood c - Oil drainage / drain valve
G4-001 I EN
35
9.7
Drive,belt drives, couplings • • • •
E N G L I S H
• • • •
Before installing the driving elements, clean the shaft journals to remove the preserving oil. Gently break off (debur) any sharp edges on the drive shaft, coupling or belt pulley. Push the coupling/belt pulley onto the shaft journal using a xture, threaded rod...
In the case of belt pulleys with Taper Taper Lock bushes, refer to the manufacturer‘s assembly instructions. The xture, threaded rod ... must be screwed into the metric tapped centre hole on
the driving shaft. The driving elements mustNOT be be driven onto the shaft journal with a hammer. This would risk damaging the blower bearings. Following assembly and alignment, the belt pulley/coupling half must be secured to prevent axial displacement. At Aerzener Maschinenfabrik, the piston/rotor driving shafts are balanced using the „half-key balancing“ technique. The belt pulleys/couplings must be used in accordance with the requirements of balancing type „H“.
Notes on V-belts, V-belt pulleys, V-belt tensioning Whenever work is carried out on the belt drive, the machine must be taken out of operation and correctly isolated from the mains supply. Measures must be implemented to prevent the machine from starting up/being operated. Caution: The belt drive is potentially dangerous and can sever and/or crush body parts. Changing V-belts V-belt replacement/life depends on the unit version and on the operating conditions. Please refer to the information provided by the unit manufacturer. V-belt pulley alignment The belt pulleys should be aligned as precisely as possible with the aid of a standard or gauge. The life of the driving elements will be affected in accordance with the extent of any misalignment. The standard/gauge must make contact with the belt pulleys at points A, B, C and D. Min. belt pulley Ø (mm)
Max. belt pulley width (mm)
GM 3S/4S/7L
160
70
GM 10S/15L
165
85
GM 25S/30L
140
115
GM 35S/50L
170
115
GM 60S/80L
230
150
GM 90S/130L
360
180
GM 150S/220L
425
225
GM 240S/315L
/
/
GM 400L
/
/
Machine type
Minimum perm. belt pulley diameter and maximum perm. belt pulley width for the relevant frame size
36
G4-001 I EN
9.7 e = Distance between pulley centres E = Depth of indentation per 100 mm distance between pulley centres Ea = Strand depth of indentation f = Test force Ea = E · e 100
Prole
Test force f per V-belt (daN)
Diameter dk (mm)
2.5
≥ 56 - 71
SPZ/3V XPZ/3VX
> 71 - 90 > 90 - 125 > 125
SPA XPA
5.0
SPB/5V XPB/5VX
7.5
SPC XPC
12.5
≥ 71 - 100
> 100 - 140 > 140 - 200 > 200 ≥ 112 - 160
> 160 - 224 > 224 - 355 > 355 ≥ 180 - 250
> 250 - 355 > 355 - 560 > 560
H S I L G N E
Depth of indenta- Depth of indentation tion E (mm) per E (mm) per 100 mm 100 mm Strand length on Strand length initial assembly during operation after run-in
2.20 1.95 1.50 1.20
2.45 2.20 2.00 1.70
2.80 2.50 2.20 2.15
3.20 2.85 2.55 2.40
2.40 2.10 1.70 1.40
3.00 2.65 2.22 1.90
2.30 1.90 1.65 1.60
2.65 2.30 1.90 1.70
1. Specifying the test force f from from the table on the basis of the V-belt prole used. 2. Determine the smallest pulley diameter dk on the drive and take the corresponding depth of indentationE from the table. 3. Using the formula, the depth of indentation Ea should be calculated with the available distance between pulley centres e 4. The test force f must must be applied to the V-belts in the middle of the distance be tween pulley centres e and must act vertically in relation to the strand. Pretension the drive until the calculated depth of indentation Ea is achieved. Pretensioning calculation Example:
Prole = SPZ; dk = 100 mm; e = 380 mm; f = 2.5 daN;
E = 2.00 mm; Ea = 7.6 mm
Check the tension of the V-belt after an operating time of approx. 30 minutes. The belts may need to be retightened depending on the tensioning unit. Subsequent checks are to be made in accordance with the maintenance schedsc hedule. G4-001 I EN
37
9.8 Drive coupling/alignment notes Whenever work is carried out on the drive coupling, the machine must be taken out of operation and correctly isolated from the mains supply. Measures must be implemented to prevent the machine from starting up/being operated. Caution: The coupling is potentially dangerous and can sever and/or crush body parts.
E N G L I S H
Changing the coupling elements Driving element replacement/life depends on the unit version and on the operating conditions. Please refer to the information provided by the unit manufacturer. Coupling alignment Use dial gauges/hairline squares for alignment purposes. The life of the driving elements will be affected in accordance with the extent of any misalignment. Use dial gauges/hairline squares to check the axial and radial run-out. The coupling must be pushed onto the driving shaft in the correct way so that it provides full bearing support.
Coupling running tolerances: Radial : max. 0.05 mm parallel shaft misalignment/0.1 mm on turnover Axial : max. 0.05 mm on turnover - Dimensions apply to a distance r = 100 mm from the centre of the shaft. - In the case of other distances, the tolerances will need to be adapted accord ingly.
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Accessories 1. Filter silencer 2. Service indicator for monitoring lter soiling 3. Starting strainer 4. Pressure gauge for monitoring the intake and discharge pressure 5. Pressure valve 6. Discharge silencer 7. Pressure switch 8. Non-return valve 9. Start-up relief 10. Acoustic hood 11. Thermometer for indicating the discharge temperature 12. Compensators 13. Driving motor 14. Maintenance accessories (V-belts, intake lter, oil, etc.)
H S I L G N E
The scope of supply can be expanded to include the accessories listed above. For enquiries and orders, simply contact the Aerzener After-Sales Service department (also responsible for spare parts).
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11
Malfunction / Possible cause / Remedy Repairs on positive displacement blowers must be carried out only by authorized and qualied personnel. Improper repairs can lead to considerable
damage for the user / persons. Malfunction Faults What to do, when . . ? ... abnormal running • noises occur? • •
E N G L I S H
• •
... the blower gets too hot?
Remedy . . .
Belt not properly aligned
•
Bearing damage Rotary pistons contact each other or in the conveying chamber Pistons contact due to contamination Foreign particles in gear wheels
• •
•
Shaft deection
• •
Intake lter contaminated contaminated
Ambient temperature too high
Check and adjust if necessary Exchange bearings Check clearance adjustment/check for cracks
• •
Clean conveying chamber Check wheels, clean, exchange if necessary
•
Measure deection,
change rotary piston if necessary • •
Replace lter Ensure sufcient room
Hood slots clogged Ventilator defective Oil level or viscosity too high Rotary piston clearances too large Overloaded
• • •
... oil appears in • conveying medium? •
Oil level too high Worn seals
• •
ventilation inlet-/exhaust air Clean ventilation slots Replace ventilator Correct oil level, observe viscosity Replace damaged components Check and observe operating data Adjust oil level Replace seals
... the intake volume • is too low? • •
Anfahrsieb bzw. Ansaug-
•
reinigen ggf. ersetzen
• •
Leitungen abdichten Auslegung prüfen
•
beschädigte Bauteile austauschen Check and observe operating data Replace damaged components Adjust power, refer to motor instructions
• • • • •
• ... motor requires too much power?
• • •
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Possible Causes . ..
• •
lter verschmutz
undichte Leitungen Gebläse falsch dimensioniert beschädigte(r) Drehkolben / Zylinder Operating data differ from order data Mechanical blower or motor damage Motor voltage drop
G4-001 I EN
• • •
Malfunction Faults What to do, when . . ? ... the side of belt vibrates?
11 Possible Causes . ..
Remedy . . .
• •
V-belt is worn Belt not properly aligned
• •
... the blower runs • in reverse direction after shutdown? ... machine damage • occurs due to faulty electrical connection?
Non-return valve defective or leaky
•
Motor and control system are connected to two different networks
•
Replace belt Check and correct if necessary Replace valve
H S I L G N E
Connect motor and control voltage to one supply network • Alternative: Installation of a power monitoring relay After the correction of each malfunction, the following is to be checked: • Freedom of movement of the machine • Non-contact turning • Lube oil level • Proper function and connection • Adherence to safety and warning instructions
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12
Overview of spare parts First-rated parts Are to be replaced at each disassembly and therefore these parts must always be available. The package includes: bearings, seal rings, bushing sleeves, adjusting elements and repair instruction.
E N G L I S H
Second-rated parts Are replaced at disassemblies depending on their condition. They should also be available.The package includes: gear wheels, ttingkeys, seal rings, oil level indicators,
nuts, bushes, retainers, oil splashers and oil throwers.
Third-rated parts Are parts not normally associated with wear but could need replacement following a major failure through misuse.
Spare parts and accessories We expressly draw your attention to the fact that replacement parts and accessories not supplied by us are not tested and approved by us. The integration or installation, as well as the use of such products can, under certain circumstances, alter the original design characteristics of the equipment. We exempt ourselves from any liability for damages resulting from the use of parts and accessories not supplied by us.
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Recycling / Disposal • • •
All waste products are to be disposed of or treated not harmful to the environment. Used lubricants are to be disposed of properly. Contaminated components and auxiliary material are to be packed and decontaminated.
H S I L G N E
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E N G L I S H
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INFO - SEITE
Information sheet Info - bladzijde Info - side Info - side
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Page infos PaginaInformativa Info - sida Info - sivu H S I L G N E
Gegenüber Darstellungen und Angaben dieser Betriebsanleitung sind technische Änderungen, die zur Verbesserung Verbesserung der Drehkolbenmaschinen Drehkolbenmaschinen notwendig werden, vorbehalten. This operating- and installation manual is subject to engineering changes necessary for the compressor advancement. Nous nous réservons le droit dans les instructions de service procéder à toutes modications techniques u tiles visant à améliorer la qualité des compresseurs.
Wat de betrft de tekeningen en gegevens in deze bedienings- en opstellings-hanleiding verbetering van de schroefcompressor noodzakelijk worden, voorbehouden. Nos reservamos el derecho de efectuar, frente a las representaciones e indicaciones de esta instrucciones de montage servicio modicaciones técnicas necesarias para perfeccionar. Rispetto all'illustrazione ed alle indicazioni di questa Istruzioni di Esercizio ci si riserva quelle modiche tecniche che sono necessarie per migliorare i compressori.
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E N G L I S H
Aerzener Maschinenfabrik GmbH Reherweg 28
31855 Aerzen
Postfach 1163 Telefax e-mail
31849 Aerzen 0 51 54 / 81-191
[email protected]
undenservice K undenservice 0 51 54 / 81-529
Aerzener International Rental B.V. www.airental.nl phone +31 (0) 26 44 64 723 Telefax +31 (0) 26 44 63 570 e-mail
[email protected]
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Aerzen im I nternet nternet www.aerzener.com
