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1. oa Doe 26 VIII Surge in Centrifugal BIOWGFS ccce eroe ctc eren ect repe ced tene ebd ehe cedet he Ed t ehe cedet ehe e ES CES CRESCE ONCE 28 APPENDIX A Warranty Repair amp Technical Field Services and Material Poly ed adeat cB capo oS cS oS chen Eee tes 30 APPENDIX B Terms and Conditions ee o es e e ee eee o s 31 CF0996001 iii FOREWORD Gardner Denver blowers exhausters marketed under the Hoffman Lamson and Gardner Denver brand names are the result of advanced engineering and skilled manufacturing To be assured of receiving maximum service from this machine the owner must exercise care in its operation and maintenance This book is written to give the operator and maintenance department essential information for day to day operation maintenance and adjustment Careful adherence to these instructions will result in safe economical operation and minimum downtime Danger is used to indicate the presence of a hazard that will cause severe personal injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard that will cause severe personal injury death or substantial property damage if the warning is ignored Caution is used to indicate the presence of a hazard that will or can cause severe personal injury or property damage if the warning is ignored
2. 0 mod hi ment A Do rmi Pay mes U S Fu ith collec ts sole discre orders over 100 000 wi bject to app all be su petition i may de herein means GAR his proposal i haser s assent solely itu ssible nds by wi jon accept tati D plie a f 0 da TI o TERMS AND CONDITIONS n oft and nce and subject to c ncluding without lim material alteration a wri ce is quoted and or acknow now on by the amou ment action ter 3 ng the above ei ity obligations o minimum order value is 100 00 nder any ci narily carried in stock d and profi nimum rei based on the fo rials on Order are sophi promptly provide all nd accurate ing support r purpose and o he design engi ded purpose on use any unapproved egative criteria will ill be ns drawi made in I be enti ht desig purpose of thi mprovements ies ra re ion 5 Purchaser s business Seller may de ms and condi nge discontinue ledged edgement and the nt of any sa or modi n a shipment of Equipme nd claims for shortages nt or thirty contract hereunder d Purchas in connec dispute or b 0 days after date o mus h this Contract in the event suc n Arbitration As her party shall to se ransfer its ri es or excise G THESE TERMS AND CON his agreement and rights o ER DENV
3. OPERATING AND SERVICE MANUAL I GARDNER DENVER MULTISTAGE CENTRIFUGAL BLOWERS EXHAUSTERS CF0996001 Version 04 March 2008 IMPORTANT INSTALLATION INFORMATION To ensure that you get the best expected service life from this equipment there are specific blower and motor installation and alignment procedures that must be observed These instructions are outlined in this comprehensive Operating amp Service Manual Blowers are low pressure compressors and they operate at elevated discharge temperatures due to the heat of compression occurring through multiple stages This results in the outlet end of the blower having more thermal growth than the inlet end This uneven growth requires careful offset of the blower to the motor to ensure that when the blower and motor reach operating temperatures normally 1 2 hours after start up the correct hot alignment be achieved Our scope of supply including the blower motor and applicable accessories are covered by Gardner Denver s and our sub vendor s standard warranties against defects in material and workmanship These warranties do not cover failures caused by improper installation alignment or operation and maintenance or by normal wear and tear As such proper installation alignment and operation and maintenance of this equipment are necessary to insure the warranty is not voided If you feel you do not have the training or instrumentation to perform these start up
4. When Smartmeter Multiguard or MDOCS systems are purchased specific user manuals for these controls will be furnished CF 0996001 Page 20 SECTION IV Bearing Lubrication Proper maintenance and lubrication are extremely important to ensure long reliable service from your Gardner Denver machine Gardner Denver centrifugals are lubricated using grease or oil The most common causes of overheating noise and premature bearing failure are over lubricating use of the wrong type of lubricant or use of contaminated lubricant A Oil Lubrication Gardner Denver centrifugal blowers are supplied with sight glasses as standard or optional oilers Gardner Denver blowers use Gardner Denver AEON CF 46 Lubricant Use of any other oil without explicit approval of the Gardner Denver Service Department will automatically VOID THE MACHINE WARRANTY Prior to starting the oil reservoirs must be filled to the proper level AEON CF 46 is the standard lubricant and is recommended for most applications AEON CF 150 may be used for those applications with a blower discharge air gas temperature of 250 F or higher Gardner Denver Blowers Exhausters that are grease lubricated are shipped with the bearings pre lubricated Oil Lubricated Blowers Exhausters must have oil added to the bearing reservoirs prior to start up Do not overfill Fill only to full mark on sight glass GD AEON CENTRIFUGAL BLOWER LUBRICANTS Hydraulic and circulation
5. be a part o CF 0996001 Page 32 in or with any atomic installation or activity this Contract Seller will fu f Purchaser or the ul jmate user of these products intends nish Purchaser with a copy of its Terms for uclear Sales upon Gardner nver Specifications subject to change without notice For additional information contact your local representative or Gardner Denver Engineered Products Division 100 Gardner Park Peachtree City GA 30269 Toll Free 800 543 7736 Phone 770 632 5000 Fax 770 486 5629 E mail blowersmktg gardnerdenver com Visit our web site www gardnerdenver com For Parts Information Contact Gardner Denver Engineered Products Division Customer Service Toll Free 800 982 3009 Phone 770 632 5000 Fax 770 486 5530 Copyright 2008 Gardner Denver Inc Litho in U S A
6. 3 Plan ahead Ample room is required for maintenance lubrication and the removal of the machine or driver for servicing B Handling The unloading and handling of Gardner Denver equipment is the users responsibility and should be performed by personnel experienced in handling heavy machinery HEY uL FIGURE 1 NOTICE Eye bolts can fail due to mishandling improper use alteration excessive heat paint or wear Always stand clear of load when handling and lifting The complete assembly can be lifted from beneath the steel base Figure 1 or with lifting eyes if provided Figure 2 For bare machines use slings located as close as possible to inlet head and outlet head Figure 3 Never lift with a sling around the shaft or flange as damage may occur to the machine The slings should be located under the tie rods to prevent damage Eyebolts are NOT supplied with the machine If eyebolts will be used to lift the blower Gardner Denver recommends the use of drop forged weldless shoulder pattern eyebolts using full size flat washers and nuts screwed all the way down and properly seated 2 FIGURE 2 FIGURE 3 CF0996001 Page 2 C Foundation The structural design of this unit and the smooth operation inherent in the centrifugal machinery eliminates the need for massive foundations and costly site preparation The blower should rest on a solid level flat smooth surface such that
7. Materials shipped in to Gardner Denver must bear an authorized return number supplied by the Gardner Denver Engineered Products Division and must be clearly marked with all pertinent information Any shipment made to Gardner Denver Engineered Products Division without due authorization will incur a further charge of 100 00 for handling and processing CF 0996001 Page 30 APPENDIX B EXCEPT AS OTHERWISE AGREED IN WR QUOTATIONS AND ESTIMATES ARE NOT OFFERS CAPABLE OF ACCEPTANCE BY YOU A CONFIRMATIO GENERAL PROMSIONS 1 The defi Produc 2 only on conditio hereund Un in no inc ompli otice clai onco 5 5 writi BE authori Com hea Purc of no effect The CANCELLATION Purc canc canc over purc The Equi 1 all such Fully to c Um s Not unde Purc l AllofSe consumptio which he is quiremen The Design the De ny inve eithe 2 3 4 l reduce payme d to ntsh Seller may sole discreti Shipments and deliveries sh or not payment is yet due a Purchaser s business Selle Purchaser satisfactory secu signs ntions party shall di SHIPMENT PAYMENT AND CREDIT edit Terms 0 nition of te Seller when used ts means All quotations are for immediate accep accepted by an au erms set forth in ned on P urc er shall be erms and conditio ess otherwise agreed voice price after the pri quotation is issue
8. NOTICE Notice is used to notify people of installation operation or maintenance information that is important but not hazard related CF0996001 iv SAFETY PRECAUTIONS Safety is everybody s business and is based on your use of good common sense All situations or circumstances cannot always be predicted and covered by established rules Therefore use your past experience watch out for safety hazards and be cautious Some general safety precautions are given below Failure to observe these notices could result in injury to or death of personnel Keep fingers and clothing away from inlet and discharge ports rotating belts openings in bearing housings sheaves drive coupling etc Do not use the air discharge from this unit for breathing not suitable for human consumption Do not loosen or remove the oil filler plug drain plugs covers or break any connections etc in the air or oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Unit must be grounded in accordance with the National Electrical Code Open main disconnect switch tag and lockout before working on the control Disconnect the unit from its power source tag and lockout before working on the unit the machine may be automatically controlled and may start at any time Failure to observe these notices could result in damage to equipment Stop the unit if any repairs or adjustments on or
9. in less than 30 seconds e Allow machine to reach its operating temperature see next page and readjust flow rates as they may have decreased due to temperature variations e Adjust bypass valves if present e Monitor vibration and temperature levels at the bearing housings and note any drastic or constant increases Although they may vary depending on size of unit and application normal operating levels are Vibration Less than 0 28 IPS 1 5 mils in the vertical and horizontal plane at each end of blower It is important to note that Gardner Denver tests each machine prior to shipping Vibration acceptance criteria for testing are 0 24 IPS 1 25 mils vertical horizontal and axial planes on each bearing housing Testing is done under ideal conditions In actual job site operating conditions this value may not be attainable NOTICE It is normal to hear clacking of the check valve during coast down NOTICE Motor starting amperage draw will momentarily indicate full scale on ammeter if supplied 1 Shutdown normal and emergency Press stop button Open bypass valves if present In the event of an electrical malfunction during an emergency shutdown de energizing the control panel is recommended Do not restart blower after a shutdown or momentary power interruption until motor blower shafts have stopped rotating completely Rolling restart can cause severe damage 2 Oper
10. 271 870 80 356 240 1068 160 712 500 678 250 339 250 339 742 100 445 250 1112 200 890 500 678 250 339 250 339 751 120 534 300 1334 240 1068 600 813 300 407 300 407 1260 100 445 300 1334 200 890 700 949 350 475 350 475 752 140 623 350 1557 280 1246 700 949 350 475 350 475 1270 150 667 450 2002 300 1334 900 1220 450 610 450 610 761 140 623 350 1557 280 1246 700 949 350 475 350 475 1400 200 890 600 2669 400 1779 1200 1627 600 813 600 813 1600 180 801 450 2002 360 1601 1050 1424 525 712 525 712 1870 200 890 660 2936 440 1957 1400 1898 700 949 700 949 2000 200 890 660 2936 440 1957 1400 1898 700 949 700 949 2400 240 1068 720 3203 480 2135 1500 2034 750 1017 750 1017 OUTLET FLANGE F1 F2 F3 M1 M2 M3 PARALLEL TO HORIZONTAL 90 TO VERTICAL TO HORIZONTAL 90 Ib N Ib N Ib N ft Ib N m ft Ib N m ft Ib N m 310 30 133 90 400 60 267 100 136 50 68 50 68 400 40 178 120 534 80 356 200 271 100 136 100 136 510 40 178 120 534 80 356 200 271 100 136 100 136 725 50 222 125 556 100 445 250 339 125 169 125 169 550 50 222 120 534 80 356 200 271 100 136 100 136 42 60 267 150 667 120 534 300 407 150 203 150 203 732 60 267 150 667 120 534 300 407 150 203 150 203 850 60 267 180 801 120 534 400 542 200 271 200 271 741 80 356 200 890 160 712 400 542 200 271 200 271 870 80 356 180 801 120 534 400 542 200 271 200 271 742 80 356 200 890 160 712 400 542 200 271 200 271 751 120 534 300 1334 240 1068 600 813 300 407 300 407 1260 100 445 300 1334 200 890 700 949 350 475 350 475
11. 3 Excessive lubrication or lack of lubrication 4 Improper assembly e Correct number of bearing shims e Wavy washer positioned properly e Oil and grease slingers positioned properly e All gaskets to original thickness specs 5 Bearing housings worn excessively shaft journal worn 6 Coupling alignment e Coupling manufacturer specs followed for a hub to hub spacing b shaft to shaft axial clearance c lubrication if required 7 Shafts not rotated weekly on idle units 8 NOTE Many non mechanical problems can lead to frequent or repeated bearing failure They may include improper installation application or operation of machine PROBLEM Surge 1 Restricted inlet piping 2 Blocked outlet piping 3 Increased fluid level in aeration tank or process differential pressure 4 System imbalance 5 Incorrect valving or valve timing Page 27 SECTION VIII Surge in Centrifugal Blowers Surge is a phenomenon that happens when maximum pressure point is reached As airflow through a centrifugal blower is flow is further reduced pressure then drops reduced to a point beyond the maximum below this peak point and the downstream peak pressure of the blower pressure blows back into the blower This creates a pulsation inside the machine a As flow is reduced pressure rises until the very unstable condition PRESSURE PSI SURGE SURGE LINE NOTE INCREASING AMPS AS FLOW INCREASE
12. FAX 770 486 5530 parts FAX 770 631 0765 service CF0996001 vi SECTION EQUIPMENT CHECK Immediately upon receipt thoroughly examine the equipment Both motor and blower shafts should rotate freely There should be no evidence of damage cracked castings bent tie rods or any other unusual conditions Most equipment is shipped Ex Works factory meaning that the purchaser is responsible for the machine when it leaves the factory If damage has occurred or any material is missing note on the delivering carrier s freight bill and make sure the driver signs same on the receiving copy Notify the delivering carrier at once and also notify your Gardner Denver representative Do not return the blower to the factory until you have recorded the discrepancy with the driver and have notified your representative and the factory and have received return authorization approval NOTE FREIGHT DAMAGE IS THE RESPON SIBILITY OF THE DELIVERING CARRIER SHIPMENTS ARRIVE DAMAGED CUSTOMER OR RECEIVING PARTY MUST CONTACT CARRIER AND SUBMIT A CLAIM Customers are cautioned to provide adequate protection warning and safety equipment necessary to protect personnel against hazards involved in installation and operation of this equipment in the system or facility STORAGE Short Term Storage Your Gardner Denver centrifugal blower should be stored in a clean dry well ventilated area Keep equipment covered and out of the
13. FIGURE 8 FIGURE 9 failure resulting from a shifting or hunting of the motor rotor about its magnetic center due to variable load conditions Belt Drive Alignment Aligning a belt drive is much simpler than aligning a direct coupled drive To check alignment place a straightedge across the face of the driving and driven sheaves If properly aligned see fig 10 the straight edge will contact both sheave faces squarely Figures 8 and 9 show incorrect alignment Keep sheave as close to blower as possible Excessive distance between sheave and blower can reduce bearing life significantly Belt drive units should receive regular inspections to detect improper belt tension See following paragraph for instructions This is particularly important a few days after initial installation Belts that are too tight will result in excessive bearing stresses and loose belts will slip and fail prematurely When replacing belts in a multiple set ALL belts should be replaced Tensioning of new belts should be increased by approximately 2 Ibs at calculated deflection to allow for stretching and then rechecked after an eight hour run in Belt tension can be checked as follows Divide the center distance L in inches by 64 to arrive at a deflection dimension The belts should have approximately 5 7 lbs tension at this deflection See Figure 11 Belt tension measuring devices are available from most belt manufacturers and usual
14. PARTS Any parts used for service will be billed at the prevailing prices unless repair is being covered under warranty All parts are shipped Ex Works factory MATERIAL RETURN POLICY Request to return merchandise must be in writing listing full identification and quantities for each item Reference must be made to the invoice number as well as the purchase order number against which the merchandise in question was purchased Only standard materials or equipment will be considered for return Sales of customized or modified equipment are final and not subject to return Material approved for return must be in a new or unused condition Quantities as verified by the Gardner Denver Engineered Products Division Receiving Department will be accepted as final Terms of shipment must be prepaid FOB destination Any damage incurred in transit will be charged to the account of the shipper There will be a minimum 25 handling and restocking charge for materials returned and accepted in first class condition Minimum charge of 100 00 No credit memorandum will be issued where the net amount involved is less than 100 00 except where an error made by Gardner Denver Engineered Products Division is being corrected In the event that material returned does not satisfy the criteria established for acceptance the customer will be given the option of accepting a reduced allowance for the material or having it returned to them at their expense PROCEDURE
15. around the blower are required Disconnect the unit from its power source tag and lockout before working on the unit the machine may be automatically controlled and may start at any time Do not exceed the rated maximum speed shown on the nameplate Do not operate unit if safety devices are not operating properly Check periodically Never bypass safety devices 0996001 v GARDNER DENVER S QUALITY POLICY Gardner Denver is committed to provide on time delivery of competitively priced products and services that meet or exceed our customers requirements We will achieve this by maintaining a quality system devoted to the prevention of quality deficiencies and to continuous improvement INTRODUCTION Thank you for investing in Gardner Denver quality The Gardner Denver reputation for rugged dependability has been earned by over 100 years of service in demanding industrial operations where downtime cannot be tolerated and efficient blower performance is expected Your Gardner Denver blower is a precision blower that has been carefully manufactured and thoroughly tested at the state of the art Gardner Denver Inc blower factory in Peachtree City Georgia As with other precision machinery there are several relatively simple installation operation and maintenance procedures that you must observe to assure optimum blower performance There is no guesswork in the manufacture of your highly advanced Gardner Denver blower and
16. elements canvas preferred over plastic The storage area should be heated to prevent condensation and it must be free of ambient or transient vibration Rotate the blower and motor shaft at least once a week to prevent bearings from developing flat spots and to keep lubrication evenly distributed in bearings during idle periods Be sure to keep a log of shaft rotations to ensure machine warranty protection Long Term Storage For storage periods longer than 90 days the same instructions apply In addition the following steps must also be considered A Blower Maintenance Every six months one protective flange cover should be removed to inspect internal surfaces of the machine Renew vapor phase inhibitors if evidence of rust is visible Inspect exterior surfaces and coat with a rust inhibitor primer where necessary e g exposed shaft surfaces B Motor Maintenance Use only lubricant specified in motor O amp M Manual Note that this lubricant may be different than that used in the blower Please review motor O amp M Manual for complete lubrication and maintenance procedures Rotating components will cause severe injury in case of personal contact Keep hands away from blower inlet and discharge ports CF0996001 Page 1 SECTION INSTALLATION amp HANDLING A Location 1 The location selected should be clean dry properly drained and adequately ventilated 2 Heated indoor locations are preferable
17. grouted in 2 Isolation pads e Positioned incorrectly e Improperly sized e Poor condition 3 Expansion joints e Machine must be isolated from system piping by flexible sleeves or expansion joints NEVER bolt piping directly to blower 4 Misalignment e The number one cause of excessive vibration in Gardner Denver equipment CF 0996001 5 Foundation e blower shall rest on a solid level flat surface such that it will support the weight of the unit 6 Unsupported piping e The piping system must be adequately supported above the flexible connections T Loose hold down bolts e The motor and machine hold down bolts may have loosened 8 Foreign material in machine e Liquids such as water etc e Hardware such as bolts filter pieces etc 9 Surge e Operating in the surge range e Blocked inlet or outlet piping 10 Motor vibration e Improper voltage e Failing motor bearings e Imbalance within motor such as broken fan etc 11 Blower Exhauster bearings e Damaged during replacement e Over lubrication or wrong type of lubricant e Wrong type of bearings e Inadequate storage maintenance 12 Coupling e Improper lubrication e Incorrect shaft spacing e Imbalance such as damaged coupling or wrong size key e Loosened set screws 13 Imbalance e Motor due to rotor bearings or fan e Coupling e Rotor due to impellers shaft or bearings PROBLEM Oil Leakage 1 level too high e Operato
18. maintenance procedures will help prolong the life of your Gardner Denver blower A Periodically inspect foundation and G correct if deficiencies are found Check for level condition and correct as necessary B Check condition of isolation pads and replace as necessary recommended H every 3 years C Periodically check all valves in the system A stuck or broken valve can cause severe damage to equipment Lubrication Frequency Every 6 months or 3000 hrs Every 3 months or 1500 hrs Every month or 750 hrs Alignment should be checked and corrected yearly twice yearly in northern climates Check pipe supports and adjust if necessary Keep equipment clean If machine is oil lubricated be sure to keep oiler bottle or sight glass clean so oil or lack of can be seen Keep oil breather clean to prevent leaks Review motor Operating amp Maintenance manual for all pre start up requirements including lubrication Follow motor manufacturer s recommendations for motor maintenance Vibration readings and bearing tempera ture readings should be taken periodi cally to monitor the condition of the machine bearings which are the most critical component in the machine If necessary equipment is not available consult Factory Service Department CF 0996001 Page 24 SECTION VI Service There are some service functions that can be performed easily on your Gardner Denver centrifugal blower These include beari
19. nuts on the foundation studs is not recommended for several reasons It is better to dampen vibration than to mask it in structural bases Any piece of rotating machinery will introduce energy into the structure to which itis mounted This energy is measured as vibration Vibration energy will create internal stresses in structural members or be transferred out of the system by heat and sound A rigid structure keeps more of the vibration energy trapped in the system Vibration pads allow vibration energy to escape from the system Vibration isolators under the base are a way to transfer vibration energy out of the system in the form of heat When a nut is tightened on a foundation stud the vibration pads are rendered ineffective E Piping The inlet and discharge connections on all blowers should be large enough to handle maximum volume with minimum friction loss Reducing the pipe diameter on either the inlet or discharge will create additional line loss and increase the overall pressure differential causing inefficient operation and wasted energy The excessive weight of piping and fittings on blower flanges will cause internal misalignment and premature wear Never allow the blower to carry the weight of the piping A spool or sleeve type expansion joint should be installed between the unit and the piping These expansion joints should not be used to compensate for pipe misalignment Control or restraining rods are not normal
20. oils with corrosion foaming oxidation and rust inhibitors Namee e E a Ud Miedo dos Specific gravity ASTM D 4052 15 15 POU DOU E Viscosity index ASTM D 2270 VISCOS MY eree TET Available in Bottle 1 quart Case of 12 quarts AEON oil may be purchased from your Blower Exhauster supplier or directly from Gardner Denver Peachtree City Georgia 770 632 5000 GD AEON CF 46 GD AEON CF 150 0 85 0 86 48 C 54 F 45 C 49 F 135 144 48 cSt 40 C 143 cSt 40 C Part No Part No BC3018120000 300RGA786 BC3018220000 303RGA786 CF 0996001 Page 21 Add the oil slowly so it can drain off the internal parts DO NOT OVERFILL OIL RESERVOIR WITH WINDOW SIGHTS AND FILLER FIGURE 12 1 To check the sight glass oil level a Stop the unit and allow it to come to a complete stop b Sight glasses are located on both sides of the reservoir The oil level is at the proper level when it is within the center of the glass c To add oil to the reservoir housing remove the filler breather filter located on top of the reservoir Add oil through this hole until the oil has reached the proper level as indicated by the sight glass See Figure 12 B Grease Lubrication Over greasing can be more danger ous than under greasing For this reason Gardner Denver does not recommend use of permanently in stalled grease fittings which invite
21. rules regulations building code or ordinance relating to the installation or operation of the Equipment 4 Ifthe Purchaser informs the Seller of a defect after the Warranty Period has expired then Seller may offer advice free of charge and may offer repair or replacement at Purchaser s expense Any dispute as to whether a defect is covered by the Warranty shall be immediately referred to an expert to be agreed by Seller and Purchaser whose decision shall be final and binding upon the parties 5 There are no third party beneficiaries of the Warranty granted by Seller herein WARRANTY OF OTHER MANUFACTURER S PRODUCTS Seller makes no warranties or representations of any kind whatsoever either expressed implied or statutory on any component parts or accessories sold hereunder which are not manufactured by Seller Seller hereby extends the manufacturer s warranty or guaranties if any given to Seller by the manufacturer of said component parts and accessories but only to the extent Seller is able to enforce such warranty or guaranties Seller does not guaranty warranties of other manufacturers products Claims under any manufacturer s warranty shall be made in accordance with the manufacturer s requirements regarding the return repair or replacement of the goods Seller agrees to use its best efforts and will cooperate with Purchaser in enforcing any claims against manufacturer s for defects that may occur Seller has not authorized any party to make a
22. there must be none in preparing the blower to get the job done in the field The purpose of this manual is to help you properly install operate and maintain your blower It is essential that you review all sections of this manual in preparation for installing your blower Follow the instructions carefully and you will be rewarded with trouble free Gardner Denver service year in and year out OPERATING PRINCIPLES The Gardner Denver centrifugal blower is a dynamic type compressor It uses an impeller within a casing called a diffuser As the impeller rotates air enters the eye of the impeller The rotational speed of the impeller imparts a high velocity to the air as it moves radially outward into the diffuser which converts part of the velocity head into a static pressure head By employing a number of impellers in series multi staging will produce high pressure Air that has left the diffuser of a previous section or stage moves radially inward to the eye of the next impeller and the process is repeated increasing pressure with each stage WHERE TO CALL FOR GARDNER DENVER BLOWER ASSISTANCE For prompt professional Gardner Denver service always contact your Customer Service Representative first If you do not know your Customer Service Representative please refer to the following contact information Gardner Denver Engineered Products Division 100 Gardner Park Peachtree City GA 30269 Phone 770 632 5000 Toll Free 800 982 3009
23. wiring MUST be done by a licensed electrician in accordance with the National Electric Code and local regulations For turbine diesel gasoline and natural gas drivers read and follow the manufacturer s instructions On direct coupled units the adjustment and lubrication of couplings to the specifications of the coupling manufacturer 15 very important When mounted drives are sup plied from the factory preliminary alignment has been established before shipment However during shipping handling and in stallation it is likely that the alignment will be disturbed and final adjustment must be made before start up To reduce vibration the coupling must be aligned to within 0 002 for both offset and angular alignment Final alignment is the responsibility of the owner and or installer Laser alignment is recommended 7 Flexible Couplings Units coupled through flexible couplings should be aligned as accurately as possible As a suggested limit the two halves should indicate correct alignment within 0 002 on both the circular concentric peripheral surfaces and the separation between faces Although most flexible couplings will withstand greater misalignment than rigid couplings misalign ment can cause vibration possibly resulting in failure of motor bearings and or the blower bearings CF 0996001 Page8 G Alignment Procedures The alignment procedure used is based on the motor being the moveable component a
24. 752 100 445 250 1112 200 890 500 678 250 339 250 339 1270 100 445 300 1334 200 890 700 949 350 475 350 475 761 140 623 350 1557 280 1246 700 949 350 475 350 475 1400 200 890 450 2002 300 1334 900 1220 450 610 450 610 1600 180 801 450 2002 300 1334 900 1220 450 610 450 610 1870 200 890 600 2669 400 1779 1200 1627 600 813 600 813 2000 200 890 600 2669 400 1779 1200 1627 600 813 600 813 2400 240 1068 660 2936 440 1957 1400 1898 700 949 700 949 CF 0996001 Page 5 Accessories minimum blower The following are the recommended accessories for protection and reliable operation 1 Throttle Valve This is normally a butterfly valve located on the inlet of the blower that is used to control the flow through the blower When starting the blower the throttle valve should be in a fully closed position and slowly opened within 10 15 seconds after start up Occasionally due to a long valve response time or the system process it may be necessary to start the blower with the throttle valve at a minimum start position in lieu of starting the blower with the throttle valve fully closed As soon as the blower reaches full speed the throttle valve should be adjusted to allow sufficient airflow through the blower to reach the design operation point Throttling the inlet on a pressure blower is preferred and more efficient than throttling on the discharge The throttle valve is used to adjust the airflow through the machine
25. ER INC drawings data or other property or services describe hdrawal without no be changed or vari Terms and Conditi limitation t terms a hereby objected to and rej ing Seller s prices are subj itatio to the terms of proposal includi Such assent Any additio nd is to ta invoi jons are subj fy the Purc hange or wit he Seller This proposal cannot parties here when used n naser n these ng without nal and or differen ect to change with e account of any ce so adjusted sha ectto Seller and o n in a shipmen ship be commenced within one year after ny failure by Seller to enforc be resolved by a good h negotiations do not reso socia er shall be enforceable A jon wi shall nave ment whichever occ ion Each party sha he right to seek a te file suit to compe ghts rcu t l lowi 50 he informa spare parts f good engi ineering ins spare egate ora n to Seller ngs indica good fait led 0 vary 5 Contract echni Nett eina ny thereof paymen be subj urther s er urther s mstances wi such agreement sha n addition for special Equipment i e mburse Seller for all expenses incurred i ng schedule of minimum values whichever ue Fabrication Started sticated engineeri con and in acco of purchase order va tio ne ta
26. IR PARTS For pricing and delivery information contact your local Sales Representative or our Customer Service team at our Peachtree City factory When ordering parts specify the Blower Model Serial Number see data plate on unit and sales order number if available Rely upon the knowledge and experience of your local sales representative or our customer service team and let them assist you in making the proper parts selection for your blower NOTE This manual is applicable for the following models Current catalog models 260 310 400 510 725 550 42 732 850 741 870 742 751 1260 752 1270 761 1400 1600 1870 2000 and 2400 Non catalog models 250 383 40 41 600 642 650 652 671 691 772 781 791 810 860 1210 and 1250 Please consult factory with any questions CF0996001 ii TABLE OF CONTENTS FPO 15012 tede Scr ce Ss eG sc Sessa A eMe iv Safety Precautions rrr V l Equipment Check arid Storage eruit ernannt rea a ede rae aerea edad e ed adest es toda a ed oaa 1 ll installation amp Hana ling isa eite treo eto reto otro terat a ere i occus 2 lll SperaliOb a Ee te viai ador ERR SR DEC An A 16 IV Bearing ei ts 21 V tette gu et eet eet ete Ie Ur 24 Vla ASer T 25 VII SIFOUDISS MO OUI CUS hd ons hn
27. S MOTOR AMPS we ee PRESSURE MAX FLOW MOTOR OVERLOAD SAFE OPERATING RANGE AIRFLOW As the illustration shows when flow is reduced to the area left of the surge line pressure and flow drop creating an unstable condition CF 0996001 Page 28 The following things happen to blowers in surge 1 Pulsation of air in and out of blower causes undue stress on rotor and bearings Thrust loading on bearings is greatly increased Instability when severe enough can cause rotor displacement movement Bearing failure can also cause rotor to become eccentric causing failure axially and radially Damage caused by surge is usually indicated by one or more of the following Severe damage to impellers Collision of the aluminum and cast iron surfaces is catastrophic Bearing failure Possible shaft damage discoloration scoring deflection Discoloration of blower components due to high temperatures Aluminum in the inlet head of blower Loss of flow through the machine and higher pressure increases heat inside the machine As pressure approaches peak heat increases due to heat of compression Lower flow or no flow inhibits machine s ability to carry internal heat out of machines Increase in heat can compromise close radial clearances of impeller diameters Impellers can actually hit casing causing severe damage Some things that can cause surge are Dirty or plugged inta
28. Seller s sole responsibility under this warranty shall be to either repair or replace at Seller s option any part which fails during the Warranty Period because of a defect in workmanship and material Such replacement parts shall be provided at no cost to Purchaser at the business establishment of Seller or a repair facility authorized by Seller during regular working hours No Equipment may be returned by Purchaser without Seller s prior written consent and Seller will not be liable for costs incurred by Purchaser in connection with returning equipment or parts or otherwise without Seller s prior written consent Seller s obligation under this warranty shall not include any transportation charges cost of installation duty taxes or any other charges whatsoever 2 Seller shall be under no liability for breach of the warranty set forth herein i unless the Equipment has been properly installed used maintained and serviced ii unless Purchaser has promptly informed Seller in writing of the defect alleged within the Warranty Period and within 7 days of the discovery thereof iii with respect to wearing and consumable parts iv if Purchaser places Products in long term storage and fails to perform proper long term storage preparations per Seller s instructions and or v to Equipment or component parts or accessories thereof not manufactured by Seller 3 Seller makes no representation regarding compliance with any state provincial or local law
29. al growth of the outlet in thousandths of an inch Height of shaft A x Change in temperature At x 000006 COE CF 0996001 Page 13 INLET OUTLET ji Hot Shaft Position MOTOR SHAFT a eee a ee ee co oco 0m 9 Hom ooo o t I vie SE Cold Shaft G F Position miet Outlet Temperature Temperature Thermal Offset Calculations for Inlet Drive Blowers Note Motor is lower than blower Offset will be negative number On an inlet drive blower it is necessary to set the motor shaft lower than the blower shaft when cold to compensate for thermal growth on the non drive end of the unit To find the offset for the motor feet From zero in the cold position subtract Inlet drive motor front feet F C B x E Inlet drive motor rear feet G C D B x E F and G are measured in thousandths of an inch This is the amount to subtract from the feet of the motor once the alignment is zeroed under cold conditions CF 0996001 Page 14 OUTLET INLET ee 4 Position Hot Shaft Inlet Position Temperature Outlet Temperature Thermal Offset Calculations for Outlet Drive Blowers Note Motor is higher than blower Offset will be positive number On an outlet drive blower it is necessary to set the motor shaft higher than the blower shaft when cold to compensate for thermal growth on the drive end of the blower To find the offset for the motor feet From
30. at the current transformer has been installed with the number of turns identified on the control panel drawing NOTICE Ship loose current transformers that provide surge overload protection are supplied with control systems Please consult control panel drawings to determine the correct number of turns of the motor lead through the current transformer Gardner Denver recommends installing current transformers in the motor control center Consult factory if current transformer installation information is not readily available CF 0996001 Page 19 2 Primary Turns Current Transformer 1 Primary Turn Installation Drawing for Current Transformer Amperage Test Check reading Compare actual amperage draw of the motor with that registered on the meter With machine in full operation use a clamp on ammeter to measure actual amperage draw at motor or motor starter This amount should be reasonably close to that registered on the meter within 5 meter for correct amperage Surge is defined as the unstable flow of air through a machine It can be caused by a lack of air into or a restriction of air out of a blower or exhauster Surge is harmful to centrifugal machines because the heat of compression within the blower is not allowed to be carried off resulting in the aluminum impellers expanding to touch the inside walls of the cast iron housing The heavy pulsating action of a unit in surge will cause
31. ating temperatures It is the nature of centrifugal compressors to run hot due to heat of compression and internal friction caused by movement of air The higher temperatures will be on the discharge end of the machine The following information will serve as a guide in determining acceptable temperature limitations under normal operating conditions For specific applications or operating tempera tures outside the figures shown contact the factory 3 Bearing temperatures Bearings used in your Gardner Denver centrifugal blower designed to operate continuously in temperatures in excess of 200 F 93 C If bearing temperature moni tors are not supplied check bearing housing temperatures periodically CF 0996001 Page 18 and notify Gardner Denver Service if readings exceed 220 F 104 C Normal operating temperatures for bearings are under 200 F 93 C when operated with inlet gas temperature of 100 F and below 4 Discharge air temperature Under normal operating conditions using ambient or atmospheric air typical discharge air temperatures can also exceed 200 F 93 C measured in the discharge air stream or on the surface of the discharge outlet head Use only discharge pipe and piping accessories rated for high temperature 300 F 149 C Discharge temperature is affected by many factors including efficiency flow pressure altitude etc so it is difficult to determine the exact dis charg
32. c type couplings Whether mounted by Gardner Denver or by the end user couplings must be installed and maintained in accordance with the manufacturer s instructions supplied with the equipment Final coupling alignment is the responsibility of the owner or installer Gear type couplings installed by Gardner Denver are not lubricated prior to shipment Any gear type coupling must have the gear teeth thoroughly hand packed with the proper grease before placing the blower in service If equipped with lube holes in the sleeve hubs inject grease into the hubs until approximately half full grease begins to overflow through sleeve hubs Follow manufacturers instructions for lubrication type and frequency The spacer type coupling is also acceptable and provides distinct benefits It is however an extension of a standard coupling and is therefore not treated separately Motors Ball Bearing Motors A ball bearing motor can be direct coupled to the blower using an approved flexible coupling Sleeve Bearing Motors When sleeve bearing motors are used extreme care must be taken in establishing proper magnetic center alignment Special selected couplings are available for this service and should be used to restrict the axial float of the motor rotor The coupling manufacturer s installation instructions must be followed closely Periodically inspect the blower s thrust bearing inlet end to prevent Page 11 Incorrect len Gap
33. d the order ac ease without no ance with any govern sales under all o he Seller reserves to the Purcha ms by Purchaser for shortages i nforming E qui ays after receipt of shipme ny action for breach of the ng signed by Seller a disputes arising under or zed to settle any suc mercial Arbitration Rules of the America rbitrator Notwithstandi compliance with confidentia haser may not assign novate or otherwi haser cannot cancel orders u catalogue equipment elled orders to cover o ellation charges must head and profi hase order va ENGINEERING CRITERIA pment furn That it has provide information That all premises p use of the Products 0 operate To use the Produc r any circums agrees that any breach of haser further agrees that it w DRAWINGS DESIGNS AND CONFIDENTIALITY ler s specifi ns tS he ini relying a 5 includi other maximum pe all be in due any costs associated w ms used interpre hose articles sup horized employee deemed to cons ns shall be deem by Seller i e n ificati d these to cha ders the ri ser an igh pmenta n h ordi verhea atami nd wi Mate t a ue ished b and wi is full a ant en are fit with Seller in ts for the inten ances to hese y Selle d ginee or thei n cations desig the Designs are nd Seller sha ng all copyri than for the ifications i sclose to tl
34. e body of the blower to allow smooth air entry into the blower The rush of air should never be directed toward the first stage impeller NOTE ISOLATION SLEEVE EXPANSION JOINT OMITTED FROM FIGURE FOR CLARITY UNIT MUST BE PROPERLY ISOLATED FROM PIPING SYSTEMS INCORRECT VALVE OPENING AND LOCATION Always start blower with inlet valve closed or at a minimum start position Open slowly after machine comes up to speed Not to exceed 10 seconds CF 0996001 6 3 Check Valve A check valve must be installed in the discharge piping to prevent reverse airflow from other blowers in the piping system on pressure service On vacuum systems the check valve must be located in the inlet line to the blower On pressure systems the check valve must be located downstream of any blow off valves and on vacuum systems it must upstream of all bleeding devices Installation maintenance and operation of check valves The installation of a check valve in a pipeline is as simple as installing a section of pipe Prior to installation the interior of the valve should be checked carefully for debris of any kind Such debris if not removed may render the check valve inoperative The internal assembly of the check valve should move freely from the open to closed position without binding Even in the largest valves the internals should operate easily by hand The check valve may appear not to close tightly when so operated bu
35. e temperature the user can expect Generally speaking Gardner Denver discharge air temperatures should not exceed 250 F 121 C If tempera ture is excessive consult factory Failure to do so could void the ma chine warranty NOTICE A NOTE ON NOISE Every effort has been made to keep the noise level of operating equipment below 85 dBA the current acceptable limit mandated by OSHA Although hearing protection is not required by law the manufacturer suggests the use of hearing protection when operating this equipment If your Gardner Denver centrifugal blower is being used in a hot application such as steam application recompression or similar where inlet temperatures exceed 200 F 93 C the machine must be preheated slowly to 180 F 82 C minimum prior to introduction of hot process aif 5 or vapor Sudden introduction of above without preheating can cause serious damage to the machine and will void the factory warranty C Control Systems Tests Surge Control Function Test if surge control devices supplied Bring the machine up to operating speed Set trip point slightly above surge point on meter Different types of meters require different set up procedures Consult factory for specifications With machine operating normally slowly close throttle valve and observe amp reading When amperage falls to surge set point motor should drop out If not check to see th
36. ep foreign material from entering the machine Abrasive wet or bulky material will damage the machine s internal parts and could cause catastrophic failure Servicing frequency of filter elements is not predictable A differential pressure indicator with a continuous gauge reading or one with a maximum indicator should be installed across the inlet filter It will tell how much of the service life of the filter element has been used t will also eliminate both premature filter servicing and premature blower failure due to a plugged filter when the filter pressure drop is used to establish maintenance points In all cases refer to the manufacturer s service instruc tions Due to the many types of filters it is not practical to give specific instructions covering all models In general it is recom mended to clean or replace filters when the pressure drop across the filter reaches 10 we It is extremely important to keep inlet filters clean Dirty or plugged filters will cause a low flow or surge condition which will result in substantial damage to the machine Units damaged from running in surge are NOT covered under warranty CF 0996001 7 6 Drivers For electric drivers read and comply with motor manufacturer s installation and operating instructions that are attached to the motor Make certain that motor data plate requirements agree with the nameplate with available power supply at the job site All
37. eri lati part al ions of physical h and are approximate indications on thout Purc dance specifi ny costs expenses and or obligations under haser first reac ng products accordingly Purc n reasonably necessary to enable Seller to i eva nected pipe work and mac ng qua ion tes connected machi c and implied co chemical a he same a n right and other intellectua ques or know how a rd parties or use for its own purposes an hirty 30 days from date o state having laws which ransfer or irrevocable Letter of C including reasonable a for Products by cash in ectto progress paymen roval of Seller s Credit Department If Purchaser fai resented or resolution passed for the winding up or bankrup hipment or at its option cancel the unshipped balance Seller reserves the right previous to ma ity for performance of Purchaser s obligation No failure of Seller to exercise any right accruing from any default of Purchase shall impair adm hipment or atits option cancel the unshipped balance Seller reserves the right previous to ma nd or to property in y confide invoice Del 50 require orneys fees 5 DITIONS GOVERN ALL material ll be payable tax levied or charged by any g Governme design and construction o or Equipment damaged or damaged Equipment compliance with this dispu provide at a minimu ing and use of tl with the P roduct lite ne
38. g the highest reading When the reading is brought to a value of less than 0 003 inches 0 076 re check the foot that was checked first to ascertain that a new soft foot condition has not been created An acceptable reading before alignment is less than 0 003 inches 0 076 mm Page 10 NOTE THE BEST METHOD OF ALIGNMENT IS WITH A LASER ALIGNMENT DEVICE GARDNER DENVER OFFERS FACTORY TRAINED TECHNICIANS AND LASER ALIGNMENT SERVICES CONSULT GARDNER DENVER SERVICE GROUP FOR INFORMATION Methods of Shaft Alignment It is Gardner Denver s recommendation that the alignment methods used are with a laser device or with a dial indicator The dial indicator method can be done by an experienced millwright or rotating equipment technician The laser alignment procedure can also be accomplished by persons experienced using this equipment Gardner Denver offers laser alignment field services Consult factory for details Laser Alignment Preferred See instructions supplied with laser equipment Dial Indicator 1 Clamp dial indicator on driving hub 2 Locate indicator probe on O D of driven hub 3 Rotate shafts simultaneously and take readings at 90 revolutions 4 Misalignment of coupling is half of total run out Straightedge Not recommended CF 0996001 Coupling Types Blowers may be supplied with various coupling types best suited for the application such as gear type elastomer flexible element or dis
39. it will support the dead weight of the unit Avoid mezzanines catwalks and hollow floors Foundations must be clean and level within 1 16 per foot slope or a maximum of 1 8 over the length and width of the base D Positioning Each blower is shipped with a quantity of resilient mounting pads Location of pads is shown on blower base skid As a reference FIGURE 4 d If anchor bolts are present do NOT bolt down Hand tighten ONLY see Figure 4 Use shims equal to or larger in size than the base pads under the mounting pads as required to level the unit Do not use shims between the base and pads Level in the lateral plane is especially important for oil lubricated machines Locating studs may be used to position the machine but should not be used to anchor the unit Anchoring the unit or worse grouting the base in concrete greatly increases the support stiffness and may result in increased levels of vibration measured at the bearings It is unnecessary costly and may degrade mechanical performance The locating studs should not make contact with the base There must be clearance all around the studs Gardner Denver strongly discourages grouting of the unit Use of grouting may void warranty CF 0996001 Page3 Gardner Denver recommends the use of vibration pads under multistage centrifugal base skids Foundation studs are used to locate Gardner Denver multistage centrifugal blowers Tightening
40. ke filters Faulty or inoperable valves Incorrect valve settings Piping restrictions pipes too small Improperly sized blow off Downstream pressure or resistance in excess of blower s maximum pressure capability Reduction in speed causing lower flows Upstream restrictions in piping or process CF 0996001 Page 29 APPENDIX A WARRANTY REPAIR amp TECHNICAL FIELD SERVICES POLICY The services of a technician or engineer from Gardner Denver Engineered Products Division to inspect or repair a machine in the field whether under warranty or not are subject to a service charge A firm commitment in the form of a hard copy purchase order will be required before the technician or engineer leaves from any of our US offices For Domestic and International technical field services contact Gardner Denver 770 632 5000 for current rates and expense charges A Purchase order or a signed letter of intent must be faxed to the Service Department at 770 631 0765 before any service can be performed If the machine in question is under warranty and inspection by the Gardner Denver technician or engineer reveals a defect or deficiency for which the factory is accountable the service charge will be rescinded However if in the judgment of the technician or engineer the factory is not accountable for whatever defect or deficiency exists then the service charge will apply Gardner Denver terms and conditions will apply to all field service work
41. ly recommended If they must be used do not bolt up hard on both flanges because thermal movement will be restricted causing increased vibration levels Where a flexible connection is not practical the weight of the rigid connection must be separately supported and provision must be made for thermal growth Flange loads must not exceed the limits shown in Table 1 All system piping must be cleaned internally before connection to the blower Debris left in piping will damage the blower NOTICE Flexible isolation sleeves or expansion joints must be used to isolate blower from piping Force Ib kg F2 F1 FIGURE 5 CF 0996001 system Moments ft Ib Nm F2 F1 FIGURE 6 Page 4 TABLE 1 Maximum Allowable Flange Forces and Moments On page 4 refer to Figure 5 for Force and Figure 6 for Moments INLET FLANGE F1 F2 F3 M1 M2 M3 PARALLEL TO HORIZONTAL 90 TO VERTICAL TO HORIZONTAL 90 Ib N Ib N Ib N ft Ib N m ft Ib N m ft Ib N m 310 30 133 90 400 60 267 100 136 50 68 50 68 400 40 178 120 534 80 356 200 271 100 136 100 136 510 40 178 120 534 80 356 200 271 100 136 100 136 725 60 267 150 667 120 534 300 407 150 203 150 203 550 50 222 150 667 100 445 300 407 150 203 150 203 42 60 267 150 667 120 534 300 407 150 203 150 203 732 60 267 150 667 120 534 300 407 150 203 150 203 850 60 267 180 801 120 534 400 542 200 271 200 271 741 80 356 200 890 160 712 400 542 200 271 200
42. ly include instructions Drive require ments can vary by application Contact CF 0996001 Minimize distance FIGURE 10 factory for specific belt tension requirements or follow belt manufacturer s instructions NOTICE When belts are tensioned properly a short duration squeal on start may be heard Over tightening belts leads to heavy bearing loads and premature failure FIGURE 11 Checking Belt Tension Page 12 Hot Alignment Shimming Offset Guidelines Calculations can be performed as follows Assumptions e The only growth above ambient to take place is at discharge end of blower e Inlet end is ambient and therefore considered stationary no growth e Any thermal growth in motor is considered negligible and will not be used in these calculations Necessary Terms for Calculating Thermal Offset A Height of shaft the distance between the center line of the shaft and the bottom of the blower feet B Distance between the blower feet centerline of the hold down bolts C Distance from the drive end blower feet to the drive end motor feet D Distance between the motor feet COE Coefficient of expansion for cast iron is 000006 per inch F T At The temperature change from inlet casing to outlet casing If the running temperature is not known estimate 15 degrees per blower stage For example an 8 stage machine x 15 degrees would have a At of 120 degrees E Therm
43. may add to the amount past inquent accounts shall bea B International Unless o U S Bank se in writing in it s ls to fulfill the terms of payment or if at any of Purchaser or in the event of the appoi jme before payment in full is made whether ntment of a receiver or administrator of ing any shipments to require from inistrator of ing any shipments to require from CF 0996001 Page 31 Purchaser satisfactory security for performance of Purchaser s obligation No failure of Seller to exercise any right accruing from any default of Purchase shall impair Seller s right in case of any shipment default of Purchaser 4 All sales are ex works unless otherwise expressly stipulated Seller may in its discretion select the carrier unless specified in advance by Purchaser 5 Seller s responsibility for damages in transit ceases upon delivery of goods to destination specified in the Order and Purchaser then assumes responsibility for damage determination and collection from carrier 6 While expected dates of delivery of goods are given in good faith the same are not of the essence of or in any way terms of the contract
44. nd offset RPM Angular Offset 3600 0 005 1 0 002 1800 0 007 1 0 004 1200 0 010 1 0 006 900 0 015 1 0 008 Industry Standard Alignment Specs Shimming Guidelines HOT ALIGNMENT SHIMMING OFFSET GUIDELINES INLET T MOTOR im DR RUNE His NO SHIMS OUTLET j pe e BLOWER DO NOT ADD SHIMS UNDER BLOWER FEET ADD SHIMS UNDER MOTOR FEET AS SHOWN CF 0996001 Other Factors Related to Alignment The following conditions can be a factor in trying to achieve good alignment a Base and foundation must be level and smooth b Piping must be isolated using flexible sleeves or expansion joints c Pay particular care to outlet driven machines with horizontal discharge heads as thermal expansion can be multi directional d Machine structural base should be mounted on resilient vibration pads as supplied and should not be hard grouted Do not bolt down hard e Check for soft foot All driver motor support feet must be in the same plane When one or more feet are higher than the others a soft foot condition table leg effect exists that must be corrected to allow for a more exact alignment To check for soft foot With all motor hold down bolts tight set dial indicator at top surface of foot and zero it Loosen that foot noting the indicator movement Retighten that foot Perform the same procedure on the adjacent foot Add shims to the foot showin
45. nd the blower the stationary component The motor will therefore be shimmed to achieve proper alignment with the blower remaining fixed The alignment procedure outlined in this section is fora standard two element constant speed blower motor configuration Multi element and custom configurations such as a blower that is driven through a gearbox or a turbine driven blower will be accompanied by customized alignment procedures validated by design engineers and supercede this procedure Proper alignment means that the driver and driven shafts rotate as closely as possible on a common axis Each blower and motor combination is cold aligned to design conditions at the factory This means the hot design condition is already built into the alignment After 1 2 hours of initial operation this alignment may require an adjustment if vibration and bearing temperature are not within specified limits see Section 111 Operation It is further recommended that a hot alignment be performed Centrifugal blowers experience thermal growth as they operate This thermal growth results in the movement of the blower drive shaft in the vertical direction at the discharge end of the blower A hot alignment compensates for this vertical movement so that when the blower is operating the shafts come back into alignment It is difficult to predict the amount of thermal growth in any particular blower because the temperature generated b
46. ng changes seal changes coupling service and some other external type repairs Failure to notify Gardner Denver prior to working on your centrifugal blower for any reason within the warranty period will void the factory warranty NOTICE Gardner Denver has Bearing Kits and Seal Kits available in stock for immediate shipment These kits contain all the items and instructions required for complete bearing and seal changes on both ends of the machine To place an order please call Customer Service at 770 632 5000 Major repairs usually require dismantling of the machine This should only be performed by a Factory Service Technician In all cases you should contact Gardner Denver Service in Peachtree City Georgia 770 632 5000 CF 0996001 Page 25 SECTION VII Troubleshooting Guide PROBLEM Low Air Flow or Loss of Pressure 1 Incorrect machine rotation e Check arrow on inlet 2 Restricted inlet piping e Valve not fully open e Dirty filters e Shipping covers not removed 3 Partially blocked outlet piping e Open all outlet valves e Check valve installed properly e Clogged diffusers 4 Instrumentation not reading accurately 5 Verify motor wiring e Incorrect voltage e Incorrect phasing 6 Increased inlet temperature 7 Increased inlet pressure 8 Improper design or assembly of the piping system 9 Foreign material in machine PROBLEM Excessive Vibration 1 Baseplate must never be bolted down or
47. ny representation or warranty other than the above warranty statements CONFLICTING LAW Some jurisdictions provide rights in addition to those listed above or do not allow the exclusion or limitation of implied warranties or liability for incidental or consequential damages If any provision or part of a provision of these terms is found to be illegal invalid or unenforceable under any applicable law such provision or part of a provision shall insofar as it is severable whether or not payment is yet due a petition is presented or resolution passed for the winding up or bankruptcy of Purchaser or in the event of the appointment of a receiver or administrator of Purchaser s business Seller may defer further shipment or at its option cancel the unshipped balance Seller reserves the right previous to making any shipments to require from P urchaser satisfactory security for performance of P urchaser s obligation No failure of Seller to exercise any right accruing from any default of P urchase shall impair Seller s right in case of any shipment default of Purchaser from the remaining terms be deemed omitted from these terms and shall in no way affect the legality validity or enforceability of the remaining terms SPECIAL PROMSIONS The Equipment or p to use them in such request arts sold hereunder are an instal not designed ation or activity Seller s Terms for Nuc or manufactured for use lear Sales shal
48. of bearing housing Apply grease into this port forcing old grease from bearing Wipe excess from bearing and install small Greasing Procedure amount into cap 1 With the machine fully stopped remove 4 Reinstall plugs and bearing cover and bearing cover and plugs start unit Gardner Denver AEON Centrifugal Lubricating Grease NLGI grade Thickener type Penetration Worked 25 C ASTM D217 Dropping point ASTM D2265 4 Ball Weld ASTM D 2596 Load kg Viscosity of oil ASTM D445 100 cSt 40 C Temperature range 58 F to 350 F 50 C to 177 C Part No Available in Case of 12 5 ounce tubes 304RGA786 Case of 12 14 ounce cartridges 305RGA786 Series Full Replacement Periodic Addition 310 400 1 6 oz 45 g 1 oz 28 g 510 550 42 3 1 87 g 2 56 g 5 5 oz 154 g 3 oz 84 g 7 0 oz 196 g 4 oz 112 g 850 732 741 742 870 1260 1270 CF 0996001 Page 23 Operating Conditions and Grease Lubrication Intervals Operating Conditions Standard Up to 24 hours per day a clean environment Normal or light loading 24 hours per day ina dirty or dusty environment Extreme Same conditions as Severe but with heavy dust or vibration SECTION V Maintenance Gardner Denver offers a full range of factory D technician maintenance programs at very competitive prices Consult Gardner Denver Service for details and warranty extension E programs Simple
49. onductor shielded 18 AWG Belden 9318 or equal 100 Ohm Platinum RTD Sensors 3 conductor shielded 18 AWG Belden 9553 or equal Current transformer 0 5A output 12 AWG THHN There is a distance restriction between the current transformer and control panel Please consult the control panel drawing for specific distance restrictions 8 Initial start up checklist Have you Cleared with Operations personnel No downstream maintenance being performed Shaft spins freely by hand coupling guards and safety devices in place Diffuser valves open if applicable Outlet butterfly valve to open intet butterfly valve minimum stop or closed All instrumentation properly wired and terminated to control panel if applicable LJ Piping system ready for flow of air or gas O Atmospheric bypass valves open if present LJ Energize control panel E Momentarily bump motor to verify proper rotation as indicated by arrow cast into inlet head O Verify proper lubrication of blower driver and where applicable Gardner Denver supplied butterfly valves and couplings that require lubrication CF 0996001 Page 17 B Operation Press start button Unit should reach full motor RPM in approximately 10 seconds If not de energize control panel and investigate e When full motor RPM is reached and amperage draw decreases slowly open inlet butterfly valve to achieve desired airflow or amps This should be done
50. or representations of fact All shipping dates given are approximate and while effort is made to maintain schedules Seller will not be liable for damages on account of delay In case of delay by Purchaser in furnishing complete Schedules or information delivery dates may be extended for a reasonable time depending on factory conditions The Seller shall not be responsible for reasonable or excusable delays nor shall the Purchaser refuse to accept delivery because of any such delays Excusable delays include without limitation delays resulting from accidents fires floods severe weather or other acts of God strike lockout or other labor difficulties embargoes government controls or other forms of intervention inability to obtain labor materials or services and other causes beyond Seller s control If there is a scarcity in any of its products or goods Seller will allocate its available supply in its sole discretion 7 All Equipment or parts furnished by Seller shall remain the property of Seller until paid for in full Pending payment of the full purchase price of the Equipment or parts furnished by Seller Purchaser shall at all times keep the Equipment or parts comprehensively insured against loss or damage by accident fire theft and other risks usually covered by insurance in the type of business carried on by Purchaser in an amount at least equal to the balance of the price for the same from time to time remaining outstanding 8 Between deliver
51. over greasing A special high speed grease Gardner Denver AEON Centrifugal Blower Lubricating Grease is required in Gardner Denver grease lubricated CF 0996001 Page 22 Oil Lubrication Frequency Standard Conditions 6 months 4000 Hrs Severe Conditions 3 months 2000 Hrs Extreme Conditions 1 month 1000 Hrs machines Use of any other type of grease without explicit approval of Gardner Denver Service Department will automatically void the machine warranty Gardner Denver AEON Centrifugal Blower Lubricating Grease may be purchased from the supplier of the blower exhauster or directly from Gardner Denver Cus tomer Service at 770 632 5000 AEON Lubricating Grease is formulated using a polyalphaolefin synthetic base fluid with a high quality lithium complex thickener to provide outstanding protection against wear rust corrosion and high temperature degradation Since different types of grease may not be compatible it is important not to mix various products Use of different types of grease may lead to early bearing failure Prior to shipment blower exhauster bearings are adequately lubricated If three months or more have elapsed since shipment from the Gardner Denver factory remove bearing housing covers and inspect for moisture due to condensation Remove all old grease from face of bearings housing and cover using a clean rag It is not necessary to remove bearings Remove plug on back side
52. peration Verify that no water condensation has collected in the bearing housing by removing the housing cover and inspecting for moisture inside If water is present Gardner Denver recommends replacing the bearings to insure CF 0996001 Page 16 g6 o7 warranty coverage in the event of bearing failure Consult factory Do not attempt to repair machine during the warranty period Bearings of oil lubricated machines require addition of recommended oil to the bearing reservoirs New machines have sight glasses and are shipped with oil Note export units are shipped dry Oil must be added to the proper level which is to the middle of the bull s eye Safety guards Couplings or belt on belt drive and motor fan guards should always be in place and tightened securely during operation Do not operate machine with motor junction box open or any other electrical safeguard not in place Make sure all starters or motor control centers are locked out when working on blower or motor Electrical connections Motor must be wired per data plate and the control panel connected per electrical drawing All accessories such as valves actuators tempera ture sensors etc must be correctly wired per manufacturer s instruction Unless otherwise noted in the manufacturer s instructions Gardner Denver recommends the following field wiring 120VAC 14 AWG THHN 24VDC 14 AWG THHN Vibration Sensors 4 20 mA output 2 c
53. r or maintenance personnel overfilling reservoir e Improper oil level adjustment Page 26 10 Wrong type of oil use recommended oils ONLY Breather vent clogged or vent hose clogged or pinched Labyrinth or carbon ring seal leaking excessively Incorrect bearing assembly e Oil slinger bent or not positioned properly e Housing gasket loosened or damaged e Gasket blocking oil return hole e Brass labyrinth seal oil drain holes not at bottom e Labyrinth loose in bearing housing Oil reservoir glass cracked Loose connections to oiler Oilers located on wrong side of machine Oil return holes plugged Machine not level PROBLEM Overheating 1 Overheating Machine e Surge e Inadequate air flow e Clogged intake air filters e Incorrect use of discharge valve to control flow Overheating Bearings Damaged bearings Excessive lubrication or wrong type Incorrect class of bearings Improper assembly procedure High ambient temperatures Worn housing Worn retainer Overheating Motor e High ambient temperatures Incorrect voltage Unbalanced voltage supply Restricted air flow for cooling Motor overloaded motor too small for system CF 0996001 e Improperly tensioned belts on v belt drive systems e Bearing failure e Too frequent starting e Motor fan rotation incorrect PROBLEM Repeated Bearing Failures 1 Not using Gardner Denver bearings 2 Not using Gardner Denver recommended lubricant
54. rchaser LIABILITY Seller s total liability for any and all claims damages losses and injuries arising out of or relating to Sellers performance or breach of any term herein shall not exceed the purchase price of the Equipment IN NO EVENT WHETHER IN CONTRACT TORT OR OTHERWISE SHALL SELLER BE LIABLE FOR LIQUIDATED INDIRECT EXEMPLARY INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES EXPENSES OR COSTS INCLUDING BUT NOT LIMITED TO 1 LOSS OF PROFITS BUSINESS OR GOODWILL 2 LOSS OF USE OF EQUIPMENT OR FACILITIES OR 3 LOSS RESULTING FROM UNUSABLE MACHINERY OR FACILITY DOWNTIME HOWSOEVER CAUSED AND EVEN IF THE POTENTIAL FOR SUCH DAMAGES WAS DISCLOSED AND OR KNOWN DISCLAIMER OF WARRANTY SELLER DOES NOT WARRANT THE MERCHANTABILITY OF ITS PRODUCTS AND DOES NOT WARRANT THE FITNESS OF THE PRODUCTS FOR A PARTICULAR PURPOSE SELLER DOES NOT MAKE AND HEREBY DISCLAIMS AND EXLUDES ANY WARRANTY EXPRESS OR IMPLIED OTHER THAN THE WARRANTY CONTAINED HEREIN THERE ARE NO WARRANTIES EXPRESS OR IMPLIED BEYOND THAT WHICH IS DESCRIBED BELOW WARRANTY OF GOODS MANUFACTURED BY SELLER 1 Except to the extent Seller specifies another warranty period in writing Seller warrants products and parts manufactured by it and sold hereunder to be free from material defect in material and workmanship for a period of twelve 12 months from date of startup or eighteen 18 months from date of shipment whichever occurs sooner the Warranty Period provided however that
55. ry servi losses nd elec correct errors a ecting the Products made or gained in ntial information o redit confirmed by a major advance or by money down with scheduled progress payments and unless Seller agrees otherwi UR CONTRACTS TO THE EXCLUS D ANY ORDER PLACED BY YOU CH ORDER ON OF OTHER TERMS AND CONDITIONS OUR WILL ONLY BE ACCEPTED BY OUR WRITTEN OF SU mercial Code of the State of Illinois ation is addressed And Equipment or be co means to sha herein strued under and governed by the Uniform Com he person firm or corporation to whom this quo d herein ice before an order is acknowledged by Sel ed by any verbal agreement If this proposal is deemed to constitute an offer i ions If this proposal constitutes an acceptance of an offer such acceptance is expressly hese Terms and Conditions An acceptance of any part of the Equipment or services covered nd conditions proposed by Purchaser and or any attempt by Purchaser to vary any of these ected out advance no variation asi oven n effective until may be accepted er This proposal shall not become reserves the right to adjust the nce the date of the quotation or if ce All sales are subject to nt necessitated by Seller s ice at any time prior to order acknowledgment Seller in Seller s costs beyond Seller s reasonable control si the price set out therein were the original contract pri nmental agency and are
56. services it is suggested you consider having Gardner Denver supervise the installation and start up Typical start up services include laser alignment lubrication of Gardner Denver supplied equipment and operator training In addition complete laser alignment vibration and bearing temperature baseline results will be provided to document that the start up was properly completed CF0996001 i MAINTAIN BLOWER RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER INC PARTS AND SUPPORT SERVICES Genuine Gardner Denver factory parts engineered to original tolerances are designed for optimum dependability and performance specifically for your blower Design and material innovations result from years of experience with hundreds of different blower applications When you specify genuine factory parts you are assured of receiving parts that incorporate the most current design advancements manufactured in our state of the art centrifugal blower factory under exacting ISO 9001 2000 quality standards Gardner Denver Authorized Certified Repair Centers offer all the back up you require Factory trained service technicians provide the finest product support in the blower industry on a worldwide basis Contact Information Gardner Denver Engineered Products Division 100 Gardner Park Peachtree City GA 30269 Phone 770 632 5000 Toll Free 800 982 3009 FAX 770 486 5530 parts FAX 770 631 0765 service INSTRUCTIONS FOR ORDERING REPA
57. standard product g but not limited to costs of purchased materials engineering costs and an amount to cover is greater Order Entry 1096 of purchase order value Completion of Engineering 2596 of 10096 of purchase order value hing a equipi ncludin haser undertakes uate the requirements for performing and ii perform the Contract and that hinery and inputs that it is required to provide for the design engineering installation testing and e Products erature and ce or repair or use t tions and obligations on it suffers by reason of a n he P roducts in any manner as may render the Products dangerous and the part of Seller relating to the quality of the P roducts ny breach of these undertakings ndi Tonic properties and indications of inlet pressure or vacuum pressure output and power y and are not binding in detail unless P urchaser has specified in writing a particular indication upon nd omissions provided the P roducts remain in substantial conformity with the contractual hem shall as between the parties be the property of Seller and Purchaser is not entitled to make any use he course of performing this Contract shall belong to S eller absolutely trade secrets of the other party r interest at 18 per annum thereafter until paid Said interest rate shall be herwise agreed to by the Seller s Manager of Credit and Collection n addition to such late payment charges Seller
58. subject to any price adjustme jons now or hereafter established erial equal to or superior to that origi n any orities laws and regula ductorto substitute ma pri pro nally specified without it mus herthan c ortheya cause of in 0 rs he rans he carrier All claims by Purchaser against Seller for gainst the carrier must be made in writing to Seller withi t be made against aims to be made a re waived action has accrued Only variations or modifications to the contract which e its rights under this contract will not be deemed a waiver of such rights h negotiations by knowledgeable responsible representatives of each party who are fully ve such dispute binding arbitration held in Chicago Illinois by a single arbitrator pursuant to the I bear its own costs of these procedures the parties shall equally split the fees of the arbitration and mporary restraining order or an injunction related to the purposes of this Contract to compel e resolution process ract without Seller s pri n ten 10 urs fi are made 3i his con or written consent and any attempt to do so shall be null and void and n agreement in writing with Seller covering all Sellers damages For standard Equipment m a cancellation charge of at least 15 of the purchase price of the goods covered by the ment manufactured per Purchaser s requirements and not stocked as a
59. t this simply means that the sealing member has not assumed its set and in no way should be interpreted as a failure of the valve to close easily or to seat tightly This condition if it exists will be rectified by a few cycles in service All check valve assemblies are treated with a locking solution during assembly No loose fasteners should be found When valves are installed in the horizontal position they should be bolted in place with the stationary support the hinge post in the vertical position i e in such a manner that the bolts protruding through the valve body are at the top and bottom of the installed valve perpendicular to the flow In the downward or upward positions no special attention need be given to the hinge post position The valve flanges are parallel and therefore the mating flanges of the connecting piping must be parallel to ensure a good joint and prevent undue strains on the valve body and flanges Standard gaskets and sealing compounds are recommended 4 Isolation Sleeve Expansion Joint Must be installed both in the inlet piping system and discharge piping system to ensure isolation of piping systems from unit flanges Isolation sleeves or expansion joints must be positioned upstream of the butterfly valve on the unit inlet The piping must be aligned to or 4 offset maximum Flange bolt holes must be matched to 77 tolerance 5 Inlet Filter blowers Inlet filters are required to ke
60. the bearings and machine to fail In some cases where heavy surge is experienced a centrifugal machine can fail within a matter of minutes See page 28 for more on surge Overload Protection Test On units with motor overload protection a high AMPS trip point is also on the meter This adjustment varies with the type of meter used Consult factory for details With machine in full operation adjust the meter decreasing the set point until it is less than the meter reading The over load alarm will sound and or shutdown will occur Be sure all horns lights etc respond properly to the overload condition Bearing Temperature Monitors Most Gardner Denver thermal protection systems are calibrated and preset at the factory to alarm at 220 F and trip at 230 F 110 C This high limit bearing temperature set point is sufficient for all Gardner Denver equipment and must not be adjusted Vibration Monitor System Vibration sensors must be installed securely to the blower with all wires shielded and secured according to manufacturer s recommendations Verify the alarm and trip set points are set in accordance with manufacturer s recommendations Gardner Denver recommends maximum settings of 0 4 IPS for alarm and 0 75 IPS for shut down Test of vibration protection system varies with each manufacturer Therefore consult manufacturer s installation manual for correct procedure of verifying proper operation Controls
61. to reach the design operating condition It is also used to increase the flow to move away from surge Surge is defined as the unstable flow of air through a machine that occurs when airflow through the dynamic compressor is reduced As the flow is reduced the pressure rises FIGURE 7 PREFERRED VALVE OPENING AND LOCATION LENGTH TO BE A MINIMUM OF 2 TIMES THE PIPE DIAMETER BUTTERFLY VALVE until the maximum pressure point is reached As flow is further reduced the pressure will drop below this peak point and the downstream pressure will cause flow back into the blower This creates a pulsation inside the machine and a very unstable condition see Section VIII 2 Butterfly Valve In most cases a butterfly valve is used as a throttle valve Butterfly valves are also used as discharge blow off valves which can control flow although less efficiently as the air is already compressed when it is blown off In other words the work is invested in the air before it is released Butterfly valves also see service as isolation valves that allow the blower package to be worked on without being affected by the downstream pressure Carefully remove shipping flange covers prior to assembling accessories Make sure no foreign materials enter the unit When mounting the butterfly valve on the inlet the valve should be positioned such that the valve shaft is at a right angle to the blower shaft and opens away from th
62. y and payment in full the risk in the Equipment furnished by Seller shall be with Purchaser who shall keep the same in good condition and repair properly stored and labeled as being Seller s property 9 In the event of Cancellation in accordance with the provisions hereof or in the event of non payment in full or in part for the Equipment by the due date Purchaser hereby irrevocably licenses Seller insofar as itis able to enter upon any premises to repossess the Equipment INDEMNITY Purchaser will indemnify defend and hold Seller its affiliated companies and their respective directors officers employees and agents harmless from any loss claim cost expense or damage including payment of reasonable attorneys fees suffered or incurred by any of them and or for which any of them may be liable to any third party due to arising from or in connection with directly or indirectly i any violation of law negligence omission or intentional misconduct on the part of the Purchaser its servants agents or employees ii Purchaser s instructions or lack of instructions or Purchaser s failure or delay in taking delivery iii the breach of any provision of this Agreement by Purchaser or iv any infringement or alleged infringement of patents trademarks copyright design right or other intellectual property right occasioned by the importation manufacture or sale of the Equipment if made to the specification or special requirement of Pu
63. y the machine is subject to many variables such as ambient temperature pressure output efficiency etc NOTICE The blower may have thermal growth data on the nameplate Due to seasonal variations in operating conditions blower alignment should be checked semi annually Coupling Alignment Scenarios Perfect Alignment Faces of coupling hubs parallel centerlines of shafts concentric Parallel Misalignment Faces of coupling hubs parallel centerlines of shafts offset Angular Misalignment Faces of coupling hubs not parallel centerlines of shafts not concentric NOTE FINAL COUPLING ALIGNMENT IS THE RESPONSIBILITY OF THE OWNER OR INSTALLER FAILURE TO PERFORM FINAL ALIGNMENT CAN RESULT IN WARRANTY DENIAL SHOULD VIBRATION OR OTHER PROBLEMS DEVELOP COUPLING ALIGNMENT IS NOT THE RESPONSIBILITY OF THE START UP TECHNICIAN UNLESS PREVIOUSLY APPROVED BY THE FACTORY 0996001 9 NOTICE It is important that adequate clearance between coupling halves be maintained to allow for axial shaft growth See coupling manufacturer s instructions attached to the unit for specific clearance dimensions Final corrections must be made with the blower at operating temperature Units are NOT final aligned at factory Operate unit 1 2 hours to get hot Check vibration 0 28 IPS Max Shut unit down Make final Hot adjustments to Gardner Denver specification 0 002 angularity a
64. zero in the cold position add Outlet drive motor front feet F C B B x E Outlet drive motor rear feet G B C D B x E F and G are measured in thousandths of an inch This is the amount to add to the feet of the motor once the alignment is zeroed under cold conditions CF 0996001 Page 15 SECTION Operation A 11 12 13 14 15 Pre Start up Checks Visible damage see Section 1 Check for any evidence of shipping and or installation damages such as cracked castings scrapes bent tie rods etc Verify proper installation see Section 1 Vibration pads installed sufficient foundation no grout not bolted down piping correctly installed and isolated from unit inlet filters installed all piping blind flanges removed Be sure all motor and machine hold down bolts have been tightened securely Coupling alignment see Section Il Alignment of the motor machine must always be checked prior to initial start up Alignment is the respon sibility of the installer or owner Belt alignment see Section 11 Always re align sheaves and re tension belts prior to initial start up Be sure belts are clean and dry Re check belt tension after the first couple of hours of operation Lubrication see Section IV Lubricate motor bearings per manu facturers recommendations Blower bearings on grease lubricated machines have been sufficiently lubricated for approximately 1500 hours of normal o

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