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ENGLISH
Operating- and installation instructions Positive displacement blower unit
AERZENER MASCHINENFABRIK GMBH G4-006 F EN G4-006 F EN
174 676 000
09-2007
ENGLISH
Die INFO-Seite ist vor der Inbetriebnahme durchzulesen. Dort evtl. vermerkte Hinweise und Änderungen sind durchzuführen. Read the 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 modifications. De INFO-Bladzijde moet voor de inbedrijfname worden doorgelezen. Daar eventueel opgeschreven aanwijzingen en modificaties moeten worden uitgevoerd. Prima della messa in esercizio leggere la pagina INFO, ed eseguire eventuali istruzioni o modifiche indicate. Antes de proceder a la puesta en marcha, leer detenidamente la página informativa y cumplir eventuales indicaciones y modificaciones indicadas en la misma. A página de informações deve ser lida antes da colocação em funcionamento. As eventuais 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, 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 modifications techniques. Drukfouten, vergissingen en technische wijzigingen voorbehouden. Salvo error u omisión. Reservado el derecho a realizar modificaciones técnicas. Salvo errori di stampa, incorrettezze e modifiche 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 huomioon
G4-006 F EN
ENGLISH
Konformitäts-Erklärung
C o n t e n t s
Declaration of Conformity Certificat de conformité EG-Verklaring van over-eenstemming voor machines Declaración de conformidad Dichiarazione di conformità
Leistungsdaten
Performance data Performances Capaciteitsgegevens Datos de servicio Dati di esercizio
Ersatzteil-Liste
/
Spare parts list Pièces de rechange Reservedelen Repuestos para tamaños de soplantes Parti di ricambi
Verschleißteilzeichnungen
I n h a l t
Wearing parts drawings Plans des pièces d'usure Tekening waarop aangegeven Disegno parti soggette ad usura Dibujo de pieza de desgaste
ENGLISH 1 - 48
49
Aerzener Maschinenfabrik
Abteilung Technische Dokumentation Technische Illustration & Redaktion H.Nickel Technischer Autor
INFO - Seite
Information sheet Page infos Info bladzijde Pagina Informativa Informazioni
50 - 51
G4-006 F EN
ENGLISH
G4-006 F EN
Konformitäts-Erklärung Declaration of Conformity Certificat de conformité
EC-Conformiteitsverklaring Declaración de conformidad Dichiarazione di conformità
deutsch
ENGLISH
Hiermit bestätigen wir, dass diese Maschine den folgenden EG-Richtlinien entspricht: EG-Maschinen-Richtlinie 98/37 EG Anhang II A EMV-Richtlinie 89/336 EG Druckgeräte-Richtlinie 97/23 EG Niederspannungs-Richtlinie 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 liegt vor. english
We herewith confirm that this machine is in accordance with the following EC guidelines: EC machine guideline 98/37 EG Appendix II A for machines to be installed EMV guideline 89/336 EG pressure device guideline 97/23 EG low-voltage guideline 2006/95/EG 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 all relevant technical information is provided and available. The operating manual pertaining to the machine is provided and available. français
Nous déclarons par la présente que cette machine est conforme aux directives CE suivantes : Directive machine CE 98/37 CE Annexe II A Directive CEM 89/336 CE Directive équipements sous pression 97/23 CE Directive basse tension 2006/95/EG La machine a été conçue, fabriquée et documentée en accord avec les normes d’harmonisation des directives CE indiquées, par la société : Aerzener Maschinenfabrik GmbH, D-31855 Aerzen Une documentation technique complète est disponible. Le présent document comprend la notice d’instructions de la machine. nederlands
Hiermee bevestigen we, dat deze machine aan de volgende EG-richtlijnen voldoet: EG-Machinerichtlijn 98/37 EG Bijlage II A EMC-richtlijn 89/336 EG Drukapparatuurrichtijn 97/23 EG Laagspanningsrichtlijn 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 GmbH, D-31855 Aerzen Een technische documentatie is compleet aanwezig. De bij de machine behorende bedieningshandleiding ligt ter inzage. español
Nos aseguramos de esta forma, que la máquina cumple con las siguientes Directivas de la CE: Directiva de máquinas CE 98/37 CE Anexo II A Directiva EMV 89/336 CE Directiva de dispositivos de presión 97/23 CE Directiva de baja tensión 2006/95/CE 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 GmbH, D-31855 Aerzen Se encuentra disponible una documentación técnica completa. Existe un manual de instrucciones de la máquina. italiano
Con la presente si conferma che la presente macchina è conforme alle seguenti direttive CEE: Direttiva macchine CEE 98/37 EG Anhang II A Direttiva EMV 89/336 EG Direttiva per apparecchi ed impianti a pressione 97/23 EG Direttiva bassa tensione 2006/95/EG 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.
(Herr Seidel)
G4-006 F EN
L e i t e r Te c h n . A b t e i l u n g Head of the dept. Directeur technique Hoofd technische 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
Ersatzteile,
spare parts, pièces dé tachée, onderdelen, repuestos, pezzi di ricambio - AERZENER MASCHINENFABRIK -
ENGLISH
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 beeinflussen. Für Schäden, die 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 by us are also not inspected and released by us. Therefore, the installation and application of such products might influence under certain circumstances constructively 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. L’intégration ou le montage ainsi que l’utilisation de telles pièces peut influencer sous certaines conditions les caractéristiques et performances de la machine. Pour tout dommage causé du fait de pièces 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. De in of aanbouw alsmede de toepassing van zulke producten kan derhalve onder zekere omstandigheden constructief gegeven eigenschappen van de installatie beïnvloeden. Voor schaden, die door gebruik van niet originele delen en accessoires ontstaan, is iedere aansprakelijkheid jegens de 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 influenze sul cattivo funzionamento 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, que aquellos repuestos y/o accesorios no suministrados por nosotros no están comprobados ni homologados por Aerzen. Su montaje, así como su utilización pueden tener incidencia en las características prefijadas 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.
G4-006 F EN
Aerzener Maschinenfabrik Leistungsdaten
ENGLISH
Performance data
G4-006 F EN
Aerzener Maschinenfabrik Ersatzteilliste / spare parts list
Auftrags-Nr.
Typ
Fabrik-Nr.
Kundenbestell-Nr.
order no.
type
Customer‘s order no.
ENGLISH
serial no.
Lieferanschrift
Dispatch address
Rechnungsanschrift Invoice address
Pos.
Stückzahl / quantity
Pos.
Stückzahl / quantity
10
150
20
160
30
170
Aerzener Maschinenfabrik Abteilung Technische Dokumentation / TN Technische Illustration & Redaktion H.Nickel Technischer Autor
DN 50
40
180
50
190
60
200
70
210
80
220
90
230
100
240
110
250
120
260
130
270
140
280
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
G4-006 F EN
DELTA BLOWER
ENGLISH
Verschleißteilzeichnung / Wearing parts drawing
Diese Abbildung ist eine Beispiel-Darstellung und dient der Ersatzteilbestellung. Abweichungen zu der ausgelieferten Maschine sind möglich. Detaillierte Informationen enthält die auftragsbezogene Zeichnung.
This figure is an example-presentation and serves for spare part order. Deviations to the machine supplied are possible. The drawing gives detail information according to the order number.
G4-006 F EN
DELTA BLOWER
Verschleißteilzeichnung / Wearing parts drawing
ENGLISH Diese Abbildung ist eine Beispiel-Darstellung und dient der Ersatzteilbestellung. Abweichungen zu der ausgelieferten Maschine sind möglich. Detaillierte Informationen enthält die auftragsbezogene Zeichnung.
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This figure is an example-presentation and serves for spare part order. Deviations to the machine supplied are possible. The drawing gives detail information according to the order number.
G4-006 F EN
DELTA BLOWER
ENGLISH
Verschleißteilzeichnung / Wearing parts drawing
Diese Abbildung ist eine Beispiel-Darstellung und dient der Ersatzteilbestellung. Abweichungen zu der ausgelieferten Maschine sind möglich. Detaillierte Informationen enthält die auftragsbezogene Zeichnung.
This figure is an example-presentation and serves for spare part order. Deviations to the machine supplied are possible. The drawing gives detail information according to the order number.
G4-006 F EN
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Table of contents
ENGLISH
Title page.....................................................................................1 Notes on information page..........................................................2 Overview of contents...................................................................3 Declaration of conformity.............................................................5 Information about spare parts.....................................................6 Performance data........................................................................7 Spare parts list............................................................................8 Drawings of wearing parts and replacement parts...............9 - 11 Table of contents.......................................................................12
1.......... Suitability, general information..................................... 13 2.......... Construction, function................................................... 14 - 15 3.......... Precautions..................................................................... 16 - 18 4.......... Inadmissible operating methods................................... 19 5.......... Transport / installation................................................... 20 - 23 6.......... Drive motor...................................................................... 24 - 25 7.......... Commissioning............................................................... 26 - 27 8.......... Switch off / shutdown..................................................... 28 9.......... Frequency converter operation ............ Pole change..................................................................... 29 10........ Maintenance 10.1..... Inspections / inspection schedule..................................... 30 10.2..... Maintenance schedule...................................................... 31 10.3..... Lubricating oil specifications............................................. 32 - 33 10.4..... Lube oil quantities............................................................. 34 10.5..... Lubricant change on drive shaft, gas-tight........................ 35 10.6..... Lubricant change.............................................................. 36 - 39 10.7..... V-belt installation / replacement........................................ 40 10.8..... Intake filter........................................................................ 41 10.9..... Starting strainer................................................................ 41 10.10... Pressure valve.................................................................. 42 11......... Accessories..................................................................... 43 - 45 12........ Malfunction / Possible cause / Repairs......................... 46 - 47 13........ Spare parts overview of blower stage.......................... 48 14........ Recycling......................................................................... 49 15........ INFORMATION page....................................................... 50 – 51
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G4-006 F EN
Suitability/General information
1
Aerzener rotary piston machines are suitable for the oil-free conveying and compression of air and, if specially modified versions are used, various other types of gas.
ENGLISH
The technical performance limits must be observed if perfect operation of the equipment is to be ensured in the long term. The intake temperature t1 specified on the order confirmation serves as the installation site ambient temperature. 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 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“.
G4-006 F EN
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Construction, function
ENGLISH
Unit: The standard unit is delivered with mounted accessories, ready to operate. However, the following additional work must be carried out: • Connect the delivery pipes. • Check the oil level. • Adjust the level, if necessary. • Install the electrical connection. • Install special accessories which are supplied separately, if necessary. Service package: An Aerzen service package is available for the delta blower unit. It includes auxiliary equipment and material for filling with oil and lifting the hinged motor mounting plate, for example. Generation 5/Initial quantity of operating oil: „Fifth generation“ series units with acoustic hoods are supplied with an initial quantity of operating oil. The lubricating oil is stored in suitable containers located inside the acoustic hood/on the unit. Please take note of the machine type specifications on the lubricating oil container. The initial oil supplied is the exact quantity required by the blower. This means that the oil container may not be completely full. Please observe the machine‘s oil filling quantity and check the level using the markings on the sight glasses found either on the blower and on the acoustic hood, as appropriate. Please retain the lubricating oil container until the first oil change so that it can be used for catching and collecting the waste oil. Motor connection: Electrical installation has to be performed by an authorised electrical fitter. The terminal diagram for the motor can be found in the cover of the terminal box as well as in the accompanying documentation. Connect the motor and control circuit voltage to a common, stable network to ensure that the locking of the power contactor will be disabled if the power supply fails. Avoid voltage fluctuations and dips. Alternative: Install an electronic monitoring relay in parallel with the driving motor which will disable the locking of the power contactor if the power supply fails. A restart should only be possible after a complete machine standstill. Base support: The base support is a torsion-stable, cylindrical container that serves as both an absorption-free discharge silencer and as a foundation for the installation of a blower with intake silencer, belt drive, belt guard, hinged motor mounting plate and connection housing. The base support rests on flexible machinery mountings and is to be placed on an even, non-sloping foundation. A pressure valve appropriate to the size of the blower is also mounted on the base support to protect the blower against overload. Filter silencer: This silencer is a combination of intake-side silencer and intake filter. The filter material is easy to access and, therefore, easy to replace. The degree of contamination/the specifications in the maintenance schedule determine when the filter material is to be replaced.
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G4-006 F EN
2
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Connection housing: The connection housing contains a non-return valve that prevents the blower from running in reverse after shut-down. Additionally, a device for no-load start can be mounted on the connection housing. A pressure valve appropriate to the size of the blower is also mounted on this housing to protect the blower against overload. Connect the discharge-side piping to the housing via a rubber sleeve or a compensator. Function: Aerzen positive displacement blowers are twin-shaft rotating piston machines whose pistons turn against each other uniformly. Timing gears guarantee contact-free running of the rotary pistons. The direction of rotation determines the blower‘s direction of flow, which means there is a discharge-side and an intake-side flange. During operation the conveying medium flows through the intake flange into the housing and is forced into the conveying chambers, which are formed by the pistons and the blower cylinder, towards the discharge side. Pulsation is reduced by means of interference (patented). The conveying chamber (cylinder) is sealed from the oil chambers (housing cover and gear case) by piston ring labyrinth seals and the driving shaft is sealed by means of one or two radial seal rings. If the oil level is too high, oil can penetrate the conveying chamber in an uncontrolled manner. The compression process creates compression heat. The heat is partly released into the surrounding air via the outer surfaces of the blower and the delivery pipes. Outer surfaces and delivery pipes reach temperatures which can cause unprotected skin to burn.
G4-006 F EN
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3
Precautions prior to and during operation CAUTION!
Identifies all hazardous situations.
WARNING!
Indicates immediate danger to personnel.
ENGLISH
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. Erst lesen dann bedienen!
Read the INFORMATION sheet prior to commissioning. Any notes and changes indicated herein must be carried out.
Read first, then operate !
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. 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 to 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 defined 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.
G4-006 F 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 must be free of excessive dust, acid, steam and explosive or inflammable gas. 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 first 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 fluctuations/ 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 modified 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! G4-006 F EN
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•
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3
• • • •
ENGLISH
•
• •
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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 specified in the operating data. Therefore, a sound pressure level 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 insufficiently ventilated, there is a risk of poisoning. The installation site must 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.
G4-006 F EN
Inadmissible operating methods
• • •
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. Overfilling the maximum oil level. Operation without oil.
G4-006 F EN
ENGLISH
• • • • • • • • • • • •
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5
Transport / installation
When transporting the machine the following points must be observed: •
ENGLISH
• • • • • • • • •
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The hinged motor support on the belt-driven unit is to be fastened for transport by means of transport securing bolt. The V-belts are to be removed from the belt pulleys. The unit must not be subjected to impact loads. The unit must be transported by means of a crane, fork lift, load platform or similar. The unit must be suspended only in accordance with the sketch. Expander braces suitable for the load must be used. This is to avoid the risk of injury and damage to the equipment! The lifting tackle, ropes, chains, or similar, must be designed for the load. Units without an acoustic hood are transported by fixing the transport tackle to three or four lifting eyes (hinged motor support / base fame) or under transport timbers. The lifting tackle is to affixed according to the machine’s centre of gravity. The lifting tackle must not exert any kind of force on the machine which could lead to damaging the machine. For “Delta Blower Generation 5“ units the cover sheet, if not loosely included, is to be removed from the base of the acoustic hood for transport.
G4-006 F EN
During installation the following points must be observed:
• • • • • •
≥ DN 150
•
The positive displacement machines are preserved for a period 12 months when leaving the factory. When stored for over 12 months the preservation is to be repeated; observe storage and preservation regulation TNO 1175. During storage observe proper preservation, packaging and, if necessary, nitrogen filling according to TNO 1175. Inspection interval is every six weeks. Negative effects are to be rectified immediately, to ensure continuous preservation. Intermediate storage in dry, clean and vibration-proof rooms. The oil chambers are adequately preserved for one year. In case of belt-driven machines, the V-belt is to be relieved during storage. When shutting the machine down for over 6 weeks the conveying chamber, piston and bare components are to be preserved. For installation and assembly the respective acoustic hood elements are to be opened.
ENGLISH
•
5
•
The unit is to be installed on a level, vibration-free and slant-free foundation. Depending on the foundation it is recommended that the unit is firmly secured on the 4 mounting boreholes with dowels and bolts. Only one anchor bolt per machine foot / borehole is required.
G4-006 F EN
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5
• • • • • • •
ENGLISH
• • • • •
• • • • • •
Completely remove packing materials. When designing the protective guard for the coupling provide for adequate ventilation. Provide for adequate ventilation at the installation site / incoming and outgoing air. The following conditions for installation are to be observed: Ambient temperature : -10°C to 40°C Relative humidity : 0% to 80% Atmosphere free from chemicals The positive displacement machine is to be checked for freedom of movement. Binding indicates distortion or foreign matter. When conveying air, the plastic plugs are to be removed from the condensate boreholes on the blower. This allows a minimal warm air current to flow out and flush the condensate boreholes. When conveying “industrial gases” the condensate boreholes are closed. If the conveyed medium tends to the formation of condensate, then, depending on the operation, the condensate is to be drained by means of residual gas pipes or brief opening of the lower boreholes. ATTENTION ! Hot gas or condensate can escape from the boreholes! To avoid electrostatic charging of the unit, the motor, acoustic hood and base frame are to be earthed via the connecting points provided.
Discharge-side and intake-side piping are to be separately fixed in order to obtain a stable connection. Connection to the piping should be made with via a flexible sleeve or compensator. Flanges and connections must not be subjected to forces and / or stress of any kind. Only in this way can an optimum layout of the drive unit be guaranteed. Provide noise protection! Sound radiation can induce natural vibration in pipes and bases. When designing the plant yourself, additionally observe the safety instructions and technical data of the component suppliers. The oil level is to be checked and adjusted prior to start-up, if necessary.
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G4-006 F EN
• •
G4-006 F EN
5
ENGLISH
•
DELTA BLOWER Generation 5 The “Delta Blower Generation 5” unit must be aligned with care and must be completely level; if necessary, bearing plates should be placed underneath in accordance with the oil level indicated by the individual sight glasses. The unit must be aligned so that the sight glasses indicate the same average oil level between the minimum and maximum marks. Please also note the contents of the section entitled “Lubricant change”. The unit should be aligned using the bearing plates included in the service package. Operational safety/reliability will be affected in accordance with the extent of any misalignment. ATTENTION ! A slanting unit can sustain total damage due to an undefined oil level. Design with acoustic hood Install exhaust air sealing strips in the exhaust air duct. Install exhaust air baffle plate(s).
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6
Driving motor Observe the Aerzen operating instructions when using driving motors with an Aerzen type plate.
ENGLISH
Motor connection • • • • • •
• • • • • • • • • • • • •
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Connect and operate the driving motor in accordance with the manufacturer‘s operating and connection instructions. Electric motor connection: Refer to the type plate, the inside of the terminal box or the information attached to the motor housing for technical data relating to the motor. Observe the motor operating manual, supplied separately. You must ensure that the nominal electrical data is complied with during operation. Only authorised electrical fitters may perform the connection. Observe the tightening torques of the terminal screws. Install connecting cables for the electric motor so that they cannot be damaged by movement of the hinged motor mounting plate, if installed. Observe also the following instructions: Motor cable installation for belt-driven units. Generation 5: If your unit has an acoustic hood, it may be necessary to remove the intake console and the acoustic hood cover to connect the motor, depending on the size and output of the unit. Electricians must observe all applicable regulations when connecting the motor. EN 60204-1 must be observed. Secure all connections against accidental loosening. The connecting hardware must be suitable for the cross-section and type of the connecting leads. Cables, leads and connections must not be subjected to excessive bending and tensile forces. Install the connecting cables via a stayed cable bridge to prevent the terminal box being subjected to forces or stress. Install cables and leads in such a way that they cannot sustain any external damage. Avoid contact with the machine, excessive friction and excessive radiant heat. The cable and lead sheathing must be resistant to normal wear which is to be expected due to the movement of the hinged motor mounting plate and the effects of contaminants in the atmosphere. Fine-core cable is recommended for the connecting leads. Connect the motor and control circuit voltage to a common, stable network to ensure that the locking of the power contactor will be disabled if the power supply fails. Avoid voltage fluctuations and dips. Prerequisites for operating positive displacement machines with electric induction motors in a three-phase AC supply system: Only use the machine in a stable three-phase supply system. Observe the voltage and frequency limits specified in EN 60034-1. Voltage fluctuations/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. If excessive voltage fluctuations arise in the system, Aerzener Maschinenfabrik recommends the following in order to prevent the blower, compressor or motor from sustaining damage: - Use suitable protective equipment that will shut the motor down and safeguard it against an automatic restart if impermissible operating data is detected. Observe also EN 60034-1 and EN 60 204-1. G4-006 F EN
6
Motor assembly performed by the customer
• • • •
If the motor is to be assembled by the customer, sufficient motor cooling must be ensured. Observe the specifications and paperwork provided by the motor manufacturer. Observe and comply with the centre distances and clearances to the positive displacement machine specified by Aerzener Maschinenfabrik. Observe the maximum permissible motor weight. Install and align the motor in line with the drive. Place shims underneath the motor, if necessary. The magnitude of any misalignment affects the service life of the drive elements.
ENGLISH
•
Permissible starting frequencies of the driving motors • • •
Up to 160 kW = 6 starts per hour From 200 kW = 3 cold starts or 2 warm starts Refer to the paperwork provided by the motor manufacturer for further specifications and information.
VDE 0298
Kabel
Kunststoffkabel
cable
plastic-instulated cable
Uo = 0,6 kV
Uo > 0,6 kV
einadrig
15 x d
15 x d
12 x d
15 x d
single core
mehradrig multi core
G4-006 F EN
25
7
Commissioning
ENGLISH
1.
The blower unit is to be set up and installed in accordance with these instructions.
2.
Initial commissioning Fill unit with lube oil, if not filled ex factory. Check lube oil level and correct if necessary. Check oil filler screw and drain valve for correct seating and leakage. Check the fan of the acoustic hood ventilation for free and smooth movement. If necessary, the blower cover is to be readjusted, to guarantee contactless running!
Oil level sight glass on blower stage
26
Pressure gauge bleeding
Oil level sight glass on the acoustic hood, ‘generation 5’
Fan cover, acoustic hood design
3.
Observe commissioning instructions and lubricating intervals of drive motor manufacturer!
4.
Depending on design, cut off rubber nipple on the upper side of the pressure gauge (if fitted) or turn bleeder flap to OPEN.
5.
Set maintenance indicator on “ZERO”.
6.
Check rotational direction. See also red directional plate on the blower. There must be no V-belts on the motor pulley for this. Remove the axial locking bolt between belt pulley and the motor housing, if fitted. Start drive motor briefly / approx. 1 – 2 seconds. See also the instructions of the supplier of electrical components or plant manufacturer! ATTENTION! Incorrect rotational direction destroys the blower. From the viewing position the blower turns left on the drive shaft. The rotational direction of drive motor and blower must be identical.
G4-006 F EN
When rotational direction is correct: Remove the transport securing bolt on the hinged motor support plate. Check the alignment of the belt pulleys. Lift the hinged motor support plate with the aid of a hydraulic lifter. Install the V-belts. Relieve the hinged motor support plate / remove the hydraulic lifter. The weight of the motor automatically tensions the V-belts. Close the openings on the motor drive shaft in the belt guard with the pre-i nstalled, adjustable protective covers. Push the protective covers up to a maximum of 2 cm toward the motor drive shaft and secure.
8.
Connect the pipes to the operational unit.
9.
Labels with safety instructions must be legible and safety devices tested.
ENGLISH
7.
7
10. Open valves on the system side. The machine can be started. 11.
Switch on drive motor! Switch off after approx. 20 seconds and monitor blower for ease of run-down. If the pressure relief valve blows, shut the system down immediately and remove the cause.
12. Switch on again. Check EMERGENCY-OFF button! 13. The unit is now ready for operation.
G4-006 F EN
27
8
Switch off / shutdown • • •
ENGLISH
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.
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G4-006 F 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 fixed. This frequency must never fall below the fixed 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 converter type… etc. a motor throttle / motor filter 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 soecificationa 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.
ENGLISH
•
9
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.
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.
G4-006 F EN
29
10
Maintenance Maintenance is to ensure that all functions are maintained or that they can be restored after a breakdown. Maintenance includes specifications about inspection, service and repairs.
ENGLISH
Maintenance includes instructions for trained and qualified personnel. 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 flange with blind cover. • Seal open connections. • Also observe instructions in chapter “Transport”.
Inspections / inspection schedule
10.1
30
A general inspection should be carried out by a service technician from 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.
G4-006 F EN
10.2
Maintenance schedule
After every 20,000 Oh Or after 3 years
After every 8000 Oh Or yearly
After every 4000 Oh or half-yearly
After every 1000 Oh Half-yearly in clean environment -monthly in dusty environment
After the first 500 Oh
Weekly
After the first 25 Oh
We recommend carrying out maintenance on the blower at the intervals specified below. The operating hours refer to normal operating conditions. Other intervals could apply depending on operating specifications and environmental conditions. In this case please consult Aerzener Maschinenfabrik.
After the first 3 Oh
Maintenance intervals
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Retaining screws and fittings • retighten after machine has cooled
●
Starting strainer, if installed • check, if no more contaminant it can be removed
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Intake filter • check filter for contamination, replace if necessary, max. -45 bar • replace filter insert
● ●
Air intake / air exhaust openings • of acoustic hood, check and clean Condition of V-belt • check, replace if necessary V-belt pulley alignment • check, correct if necessary
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Pressure valve • check function
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Oil level • check
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●
●
●
●
●
●
●
● ●
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Lubricating oil • exchange • *at end temperatures above 120°C
●
Grease, only for gas-tight shaft seal • exchange • *at end temperatures above 120°C
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*● *●
● ● ●
Non-return valve • check for wear and leakage Main inspection / maintenance • check / replace wearing parts • overall check of machine
●
Drive motor • carry out maintenance • observe grease replacement intervals
Please observe maintenance intervals and specifications of motor manufacturer! In case of Aerzener motors observe Aezerner operating and maintenance instructions!
Have the positive displacement machine checked by Aerzener service at the specified intervals or yearly at the latest. Or: Take out a maintenance contract with Aerzener Maschinenfabrik. Through regular and proper maintenance Aerzener Machinenfabrik guarantees maximum safety for your operation.
G4-006 F EN
31
ENGLISH
Whenever carrying out work on the positive displacement machine, it must be switched off and disconnected from the supply net! This is to avoid the risk of injury and damage to the equipment! To guarantee long service life and optimum operating conditions, the maintenance work listed in the following table must be carried out at the specified intervals.
10.3
Lube oil specifications 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.
ENGLISH
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) 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 fluorine-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-Olefin, 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
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G4-006 F EN
10.3
ENGLISH
4. Lube oil in the food and pharmaceutical industries Lube oils approved according to USDA H1 specifications 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. 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 : Overpressure operation Lubricating oil : 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.
G4-006 F EN
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10.4
Lube oil quantities Total oil quantity,
in approximate litres / oil level up to middle of gauge glass on the blower stage
ENGLISH
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
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
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1.00 l
G4-006 F EN
10.5
Change of lubricant on the drive shaft > Only on drive shaft of gas-tight design