Original Operating Instructions V-KTA
Contents
1. Data Sheets NOTICE Subject to technical changes Fig 13 Data sheet example 28 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Ricischle A Gardner Denver Product Elmo Rietschle A Gardner Denver Product Gardner enver Elmo Rietschle is a brand of Gardner Denver s Industrial Products Division and part of Blower Operations Gardner enver EC declaration of conformity 2006 42 EC Hereby the manufacturer Gardner Denver Schopfheim GmbH D 79642 Schopfheim that the machine Dry running pressure vacuum pump of the Series V KTA Type V KTA 40 1 V KTA 50 1 V KTA 60 1 V KTA 80 1 V KTA 100 1 V KTA 140 1 V KTA 40 2 V KTA 50 2 V KTA 60 2 V KTA 80 2 V KTA 100 2 V KTA 140 2 V KTA 60 3 V KTA 80 3 V KTA 100 3 V KTA 140 3 V KTA 40 4 V KTA 50 4 V KTA 60 4 V KTA 80 4 V KTA 100 4 V KTA 140 4 V KTA 80 5 is conform to the regulations of the guideline indicated above The following harmonized and national standards and specifications are applied EN 1012 1 2010 Compressors and vacuum pumps Safety requirements Part 1 Compressors EN 1012 2 1996 A1 2009 Compressors and vacuum pumps Safety requirements Part 2 Vacuum pumps These declarati2. 1 B lleger tee 20 7 2 2 Blades ssa a ER en Een S RR WE nein 20 7 2 3 Air filtering 4 4 0 2 4 4005 84 00000 RA e ER 22 7 2 4 reel EET 23 Repa Service iii om ipei ba dara EON dex a Rete E X RC Ge CR EO o RED 24 PANG PANS A SE Ee M P ds 25 Malfunctions Causes and elimination leeren 26 Technical Data ue dE 4 44 x n RR ER ENNEN cea a a a en 28 EI 25 Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 3 A Gardner Denver Product Foreword 1 Foreword 1 1 Principles 1 2 Target group These operating instructions are a part of the following dry running rotary vane pressure vacuum pumps models V KTA 60 1 to V KTA 140 3 and V KTA 80 5 describe how to use them safely and properly in all life phases must be available where the equipment is used The target group for these instructions is technically trained specialists 1 8 Supplier documentation and accompanying documents Document Contents No Supplier documentation Operating Instructions BA 450 EN Declaration of Conformit C 0074 EN Declaration of harmlessness 7 7025 003 17 Spare parts list Spare parts document E 450 E 456 E 459 Data sheet Technical data and graphs D 452 D 453 Info sheet Storage guidelines for machines 1 150 Manufacturer s declaration 1 4 Abbreviations EU Directive 2002 95 EG RoHS
3. 9 n Pull off the motor together with the motor side coupling half Fig 9 q If the coupling rubbers k are damaged remove the circlips Fig 9 1 from the coupling bolt Fig 9 r and exchange the coupling rubbers k Leave the spacer p in place Check the coupling bolts Fig 9 r for any wear and replace if necessary To replace remove the circlip Fig 9 1 pull off the coupling and fan Fig 9 v complete from the pumpshaft remove the nut Fig 9 w with washer Fig 9 u and exchange the coupling bolts NOTICE Frequent starting up and high ambient tem perature The service life of the coupling rubbers Fig 9 k is reduced Re assemble in reverse order www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 23 Maintenance and repair 7 3 Repair Service a For on site repair work the motor must be disconnected from the mains by a qualified electrician so that it cannot be started up again accidentally For repairs use the manufacturer its branch offices or authorised dealers Please contact the manufacturer for the address of the service centre responsible for you see Manufac turer s address NOTICE For each machine that is sent to an Elmo Rietschle Service centre for inspection maintenance or repair a fully completed signed declaration of harmless ness must be enclosed L The declaration of harmlessness is part of the sup A plier s documentat
4. Fig Figure V KTA Pressure vacuum pump m h Volume flow compressed suction air bar Overpressure vacuum 1 5 Directives standards laws See Conformity Declaration 4 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle Foreword 1 6 Symbols and meaning Explanation gt Condition pre requisite THHHE Instructions action a b Instructions in several steps gt Results gt 14 Cross reference with page number re N Information note eo Safety symbol Warns of potential risk of injury Obey all the safety instructions with this symbol in order to avoid injury and death 1 7 Technical terms and meaning Term Explanation Machine Pump and motor combination ready to be connected Motor Pump drive motor In combined use the machine may produce a vacuum and excess pres Pressure vacuum pum pump sure at the same time Rotary vane Machine s design or active principle Volume flow A pressure vacuum pump s suction air or compressed air Overpressure pressure Difference in pressure compared with atmospheric pressure The corre sponding working pressure is greater than the atmospheric pressure Under pressure vacuum Difference in pressure compared with atmospheric pressure The corre sponding working pressure is lower than the atmospheric pressure The noise emitted at a specific loading given as a
5. e 5 voltage deviation e 2 frequency deviation Elmo 25 Rietschle A Gardner Denver Product 6 Commissioning and decommissioning 6 1 Commissioning A Elmo LB Rietschie ene bo Ped Commissioning and decommissioning Improper use May lead to severe or fatal injuries Therefore be sure to obey the safety instructions Hot surfaces When the machine is at operating temperature the surface temperatures on the components Fig 2 Q may go above 70 C You must avoid touching the hot surfaces marked with warning plates Noise emission The highest noise pressure levels measured as per EN ISO 3744 are given in Section 9 When spending a long time in the vicinity of the running machine use ear protectors to avoid permanent damage to your hearing NOTICE Trockenbeutel The desiccant bags in the filter housing Fig 2 S must be removed before initial start up Wait until the machine stops The machine must only be switched on again after it stops www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 17 Commissioning and decommissioning 6 1 1 Checking the rotation direction The drive shaft direction of rotation is shown by the rotation direction arrow Fig 2 O on the mo tor flange Start the motor briefly max two seconds to check the direction of rotation When looking at the motor fan it must rotate clockwise A NOTICE Incorrect direction of rotation Runnin
6. ex traction or discharge of pumped media Risks arising from electrical energy must be eliminated Elmo LB Rietschie Ar Do Pete Safety 2 8 Safety instructions for installing commissioning and maintenance 2 9 Guarantee conditions Elmo 25 Rietschle A Gardner Denver Product The operator will ensure that any installation commissioning and maintenance work is car ried out by authorised qualified specialists who have gained sufficient information by an in depth study of the operating instructions Only work on the machine when it is idle and cannot be switched on again Ensure that you follow the procedure for decom missioning the machine described in the operat ing instructions Fit or start up safety and protective devices again immediately after finishing work Vor Wie derinbetriebnahme die aufgef hrten Punkte f r die Inbetriebnahme beachten Conversion work or modifications to the ma chine are only permissible with the manufactur er s consent Only use original parts or parts approved by the manufacturer The use of other parts may invali date liability for any consequences arising Keep unauthorised people away from the ma chine The manufacturer s guarantee or warranty will no longer apply in the following cases Improper use Not complying with these instructions Operation by insufficiently qualified staff Using spare parts that have not been approved by Gardner Denver Schopfheim GmbH U
7. in environments that are at risk of ex plosions using the machine in areas with ionising radia tion back pressures on the outlet side of more than 0 1bars modifications to the machine and accessories www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 7 Safety 2 5 Personal qualifications and training 2 6 Safety conscious work 2 7 8 Ensure that people entrusted with working on the machine have read and understood these operating instructions before starting work particularly the safety instructions for installation commissioning maintenance and inspection work Manage the responsibilities competence and monitoring of staff all work must only be carried out be technical specialists e Installation commissioning maintenance and inspection work e Working with electricity personnel being trained to work on the ma chine must be supervised by technical special ists only The following safety regulations apply in addition to the safety instructions and intended use listed in these instructions Safety notes for the operator www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH Accident prevention regulations safety and op erating regulations the standards and laws in force hot parts of the machine must not be accessible during operation or must be fitted with a guard eople must not be endangered by the free
8. values have been exceeded Clean or replace the regulat ing valve Section 7 2 Section 7 4 The machine makes a abnormal noise The coupling rubbers are worn Replace coupling rubbers Section 7 2 4 Section 7 4 The compressor housing is worn chatter marks Repair by manufacturer or authorised workshop Elmo Rietschle Service A regulating valve is vibrating Replace the valve Section 7 4 Discs are damaged Replace discs Section 7 2 2 Section 7 4 Please contact Elmo Rietschle Service for other malfunctions or those that cannot be eliminated Elmo Rietschle A Gardner Denver Product www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 27 Technical Data 9 Technical Data V KTA Sound pressure level max EN ISO 3744 Tolerance 3 dB A Sound power level Weight Length Width Hight Vacuum connection Pressure connections The length and the weight may differ from the information listed here depending on the motor manufac turer You will find more technical data on the data sheets I Elmo D 452 and D 453 onte Daten Wusan wampe Feet onpaper VVC e Download the PDF file D452 V KTA 60 1 V KTA 80 3 D453 V KTA 100 1 V KTA 140 3 e Download the PDF file ttp www gd elmorietschle com Downloads Product Documents gt V Series
9. 01 V KTA 31 Fig 2 Pressure vacuum pump V KTR 100 V KTR 140 Vacuum connection Plug connector Pressure connection Greasing plate Vacuum regulating valve Data plate Pressure regulating valve Rotation direction plate Drive motor hot surfaces gt 70 C Cooling air inlet Cooling air outlet o mm Do u gt nO VO 22 Ce Inlet grating Filter housing 12 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH I Rietechie A Gardner Denver Product Set up and operation 4 1 1 Data plate 1 Type Size mechanical version 1 2 345 2 Year of construction Gardner Ce Bauj Nr 09 3 Mot 3 Motor design A Denver enver un 4 Serial number Typ KTR 100 01 1027630137 0 60 0 60 bar 5 Item no 100180 BEN 6 Overpressure Vacuum 7 Pumping capacity 50 Hz 60 Hz en 8 Speed 50 Hz 60 Hz S1 5 50 6 50 kW 1460 1745 min d 9 Motor output 50 Hz 60 Hz 10 9 8 7 6 10 Operating mode Fig 3 Data plate example 4 2 Description The V KTA range has a connecting thread on the pressure side and on the suction side The aspirated air is cleaned by an inbuilt fine micro filter The carbon dust caused by the scoring of the discs can also be separated by an integral filter if necessary A fan between the compressor housing and the motor provides intensive air cooling The compressor housing is located in a s
10. Edition 1 12 2009 BA 450 EN Original Operating Instructions 2 Elmo un Rietschle V KTA 60 1 140 1 60 2 140 2 A Gardner Denver Product V KTA 60 3 140 3 80 5 V Serie V Series Drehschieber Rotary Vane Table of contents 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 1 3 2 3 3 4 2 4 3 5 1 5 2 5 3 5 4 5 5 6 1 6 2 6 3 Table of contents FOreWord a suis ma pru ani id a a en are 4 Pririclples iii A AR RA pes uh A A AS 4 Target Groupes s eee 022 ike IA p a ee A A A e 4 Supplier documentation and accompanying documents 4 Abbreviations 2 0 4 NEE e A e ea ee NEEN ee ee ER 4 Directives standards laws 0 0 ee ee eee eee ee eens 4 Symbols and meaning i c eem sn Ce Se ee cd DEN 5 Technical terms and meaning 0 00 cece eee eee 5 Greed T PPP eg BAG Hee REA ae has Cech Raed edges wwe 5 Sadfely ee aa reece A A AA AAA 6 Warning instruction markings 6 Generals i 2 errek Be RA A A A A A EENE 6 DD sigriated Se zu tet dose iue ad ee a etus eM 7 Unacceptable operating mode 7 Personal qualifications and training 0 ee een en 8 Salety CONSCIOUS WOIK face Bea s beet ae a EP X ure Pew ee EE 8 Safety notes for the operator 0 2 ee eee 8 Safety instructions for installing commissioning and maintenance 0 0000 9 Guarantee Conditions cess mun a ea ee A e EE 9 Transport storage and disposal 000 c eee
11. always re main legible This applies for example to e Symbols for connections e Data and motor data plate e Instruction and warning plates The operator is responsible for observing local regu lations El 6 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle Ganar Der Product 2 3 Designated use Safety The machine must only be operated in such areas as are described in the operating instructions 2 4 Unacceptable operating modes Elmo L Rietschie ene bee Ped only operate the machine in a technically perfect condition do not operate the machine when it is only par tially assembled the machine must only be operated at an ambi ent temperature and suction temperature of between 5 and 40 C Please contact us for temperatures outside this range the machine may convey compress or extract the following media e convey air with a relative humidity of 30 90 e all non explosive non inflammable non ag gressive and non poisonous dry gases and gas air mixtures extracting conveying and compressing explo sive inflammable aggressive or poisonous me dia e g dust as per ATEX zone 20 22 solvents as well as gaseous oxygen and other oxidants extremely damp air water vapour traces of oil oil vapour and grease using the machine in non commercial plants if the necessary precautions and protective meas ures have not been taken in the plant installing
12. and GmbH 15 A Gardner Denver Product Installation 5 5 16 Connecting the motor www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH A M Danger of death if the electrical installation has not been done professionally The electrical installation may only be done by aspe cialist electrician observing EN 60204 The operating company has to provide the main switch a The motor s electrical data is given on the data plate Fig 2 N or on the motor data plate The motors comply with DIN EN 60034 and are in protection class IP 55 and insulation class F The appropriate connection diagram is located in the motor s terminal box not for the plug connec tion version Compare the motor data with the data of the existing mains network current type voltage network frequency permitted current value Connect the motor via plug connector Fig 2 J if fitted or via the motor protection switch for safety reasons a motor protection switch is required and the connecting cable must be in stalled via a cable fitting to provide strain relief We recommend using motor protection switches with delayed switch off depending on possible excess current Temporary excess current can occur when the machine is started cold NOTICE Power supply The conditions at the installation location must match the information on the motor data plate Without derating the following is permissible
13. catalog without using e password no ordering possible Bitte w hlen Sie Ihre Sprache Please choose your language a i fw A a mm error MS Geet S E FLA m z PSA lt lt US 2 Tet ros g d KB m Ya E en E mem are em IMAMGERSTET MT LEPE Em m Ge ouma tx E M me B cg cz lt a Creme Fig 12 Web site http www service er de I Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 A Gardner Deve Product Malfunctions Causes and elimination 8 Malfunctions Causes and elimination Fault Cause Troubleshooting Important Machine is switched off by the motor pro tection switch Mains voltage Frequency does not correspond with the motor data Connection to motor terminal board is not correct Motor protection switch is not set correctly Check by qualified electrician Motor protection switch is triggered too quickly Use a motor protection switch with an overload dependent delayed switch off that takes into consideration the short term excess current at start up version with short circuit and overload trigger as per VDE 0660 Part 2 orlEC 947 4 Section 5 5 The blow out filter cartridge accessory is dirty Clean or replace the filter cartridges Section 7 2 3 Section 7 4 The regulating valves are dirty so that the permissible vacu um value is exceeded Clean or replace the regulat in
14. ch would result in the blades becoming stuck in the rotor slots When re fitting the end cover tighten the bolts even ly so that the end cover fits correctly onto the fixing pins As soon as the cover is almost touching the housing we recommend during further tightening of the bolts the fan is moved in both directions This can be achieved by taking the grill at the cooling air exit F away This then ensures that the blades are sitting correctly in their slots and avoids any edge damage Refit the suction grid Fig 4 G NOTICE Care should be taken that the bearing does not become contaminated www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 21 Maintenance and repair 7 2 3 Air filtering Fig 7 Air filtering e Filter cartridge suction air f Filter cartridge exhaust air g Filter housing cover h Filter screw in knobs Fig 8 Purging filter cartridge 1 Filter cartridge 2 Compressed air NOTICE Insufficient maintenance on the air filter The power of the machine lessens and damage may occur to the machine The filter cartridges Fig 7 e and Fig 7 f must be cleaned by blowing through from the inside out once a month or more often depending on the level of contamination In spite of cleaning the filters their separation efficiency will continue to deteriorate Therefore the filters should be replaced every six months The filter ca
15. e machine to cool down 7 1 Ensuring operational safety Regular maintenance work must be carried out in order to ensure operational safety Maintenance intervals also depend on the operational demands on the machine With any work observe the safety instructions described in Section 2 8 Safety notes for installation com missioning and maintenance The whole unit should always be kept in a clean condition 7 2 Maintenance work Interval Maintenance to be carried out Section monthly Check the pipes and screws for leaks and to ensure they are seated properly and if necessary seal again or tighten up monthly Check the terminal box and cable inlet holes for leaks and if necessary re seal monthly Clean the regulating valves and ventilation slots on the ma chine and the motor cooling ribs If there is a great deal of dust in the spaces on the cooling ribs and cooling pipes after removing the inlet grating Fig 2 G and the protective cover Fig 5 G1 clean by blowing through 4 000 h 10 000 h Lubricate the bearing on the side facing away from the motor 4 000 h 1 000 h Check blades Replace blades monthly every 6 months Clean or replace filter cartridges at least once a year Check for coupling wear EI 25 Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 1 9 A Gardner Denver Product Maintenance and repair 7 2 1 Lubr
16. ed All blades on the machine must have a minimum height Fig 6 X of more than 38 mm The blades must only be changed as a set EI www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle Aare ene rout Fig 5 Lubrication Blades G Protective cover Bolt Housing lid Bearing cover Blade Screws o0 a2 Oo O Fig 6 Blades O Direction of rotation X Minimum heigh Y Slanting side of the blade Z Drilled holes in the housing Elmo 25 Rietschle A Gardner Denver Product Maintenance and repair Changing blades If the minimum height has already been reached or if the blades have fallen below this level the whole blade set must be changed NOTICE Do not undo the slotted nuts Fig 4 w on the housing lid Fig 5 b Only the screws Fig 4 s need to be removed to change the blades Before refitting the blades clean out the housing and the rotor slots with compressed air Place the blades with the radius outwards Fig 6 Y such that the bevel is in the direction of rotation Fig 6 0 and corresponds with the radius of the housing Fig 6 Z Before refitting the end cover Fig 5 b redistribute the grease from the bearing cover Fig 5 c on to the appropriate bearing It is important that the shaft end is completely clean so that no grease can enter the housing this could mix together with carbon dust and give a viscous paste whi
17. eee 10 Transportation ge er un leans O Feb AC Pubs Ros athe oat ee Rae pe 10 3 1 1 Unpack and check the delivery condition 10 3 1 2 Lifting and transporting 22 eee ete e A ee 10 Siret ME Ur CTS 11 3 2 1 Ambient conditions for storage 11 Disposal c te eem eR RULES E Su EET RC RE PUE ORES DE QUEE EIE 11 Setup and Operation oc Au ee ERE dE ERR ee eee NIE NN Ron RR LU 12 SUD errar are er RA aia 12 4 1 1 Data plate sih nira nenna e en E lc REUS seed 13 Description ENEE a NEE eee a ADAE US A A EE EEN EN 13 AICS OF ele er ern ito as o o E oe 13 Installation iii oia eo A A A nein 14 Preparing for installation 14 Installation mL 14 Connecting PIPES aen iaa eo a bebe wo ee eae Rh kee PSS DOR EA 15 Controland relief valves siz Re 22 000 ex RR a Seen a Ree ne Ee aia 15 Connecting the Motor Ree ius daa a ee ee esse 16 Commissioning and decommissioning seeeeeeeee een 17 COMMISSIONING 2 20040 dara via Dk RE M Ru he a Pete o RA gue we 17 6 1 1 Checking the rotation direction 0 00 cee tee 18 Decommissioning stong 18 RE COMMISSIONING ENEE 18 EI www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle Ganar Denver Product 7 1 7 2 7 3 7 4 Table of contents Maintenance and repair oooocooconnco nun eee 19 Ensuring operational safety 0 cee een 19 Maintenance work 2 222044 bakes beet dens en pre ba a dee eee Rob e oe e eds 19 7 2
18. ent Cleaning method Microbiological explosive or radioactively contaminated vacuum pumps components will only be accepted with proof that they have been cleaned properly Type of toxic substance or process related dangerous reaction products with which the vacuum pumps components came into contact Trade name manufacturer s Chemical Hazard Action to be taken if toxic First aid in the event of product name name class substances are released accidents Personal protection measures Hazardous decomposition products when subjected to thermal load YES NO DO Which 5 Legally binding declaration We swear that the information in this declaration is accurate and complete and that the undersigned am ina position to judge this We are aware that we are liable to the contractor for damage caused by incomplete and inaccurate information We undertake to release the contractor from any damage claims from third parties arising from incomplete or incorrect information We are aware that regardless of this declaration we are directly liable to third parties including in particular the contractor s staff entrusted with handling or repairing the product Company Street Post code Town Phone Fax Name in capitals Position Date Company stamp Legally binding signature TOS no Index 7 7025 003 17 0 Office responsible GS File management 7702500317 xl Gardner Denver Schopfheim GmbH Postfach 1260 D 9642 Schopfhei
19. figure sound pressure Noise emission level dB A as per EN ISO 3744 1 8 Copyright Passing on or copying this document using and providing information on its contents are prohibited unless expressly permitted EI 25 Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 5 A Gardner Denver Product Safety 2 Safety 2 1 Warning instruction markings Danger level The manufacturer is not responsible for damage if you do not follow all of this documentation Consequences if not obeyed immediately imminent danger Death severe bodily injury possible imminent danger Death severe bodily injury possible hazardous situation Slight bodily injury NOTICE 2 2 General possible hazardous situation Material damage These operating instructions contain basic instruc tions for installation commissioning maintenance and inspection work which must be obeyed to en sure the safe operation of the machine and prevent physical and material damage The safety instructions in all sections must be taken into consideration The operating instructions must be read by the responsible technical personnel operator before installing and commissioning and must be fully un derstood The contents of the operating instructions must always be available on site for the technical personnel operator Instructions fixed directly onto the machine must be obeyed and must
20. g the machine in reverse for a long time may cause damage to the blades which may lead to the blades breaking Use a phase sequence indicator to check the direction of rotation anti clockwise rotating field 6 2 Decommissioning storing Stop the machine 8 b 6 3 Re commissioning Switch the machine off If available close the cut off device in the suction and pressure pipe Disconnect the machine from the electricity source Depressurise the machine Open the pipes slowly c The pressure reduces slowly Remove the pipes and hoses Seal the connections for suction and pressure nozzles using adhesive foil Insert the desiccant bag into the filter housing see also Section 3 2 1 Page 11 Check the condition of the machine cleanliness cabling etc Remove the desiccant bag from the filter hous ing For installation see Section 5 Page 14 For commissioning see Section 6 1 Page 17 EI 1 8 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle A Gardner Denver Product Maintenance and repair T Maintenance and repair A ME Danger of death from touching live parts Before maintenance work disconnect the machine by pressing the main switch or unplugging it and ensure that it cannot be turned on again A heey as Hot surfaces During maintenance work there is the danger of getting burnt on hot components Fig 2 Q of the machine Wait for th
21. g valves Section 7 2 Section 7 4 Blowing capacity is insufficient Intake filter and or blow out filter are dirty Clean or replace the intake filter Section 7 2 3 Section 7 4 The pressure line is too long or too narrow Check the hose or the pipe Section 5 3 Machine or system leaking Check the pipework and screw connections for leaks and to ensure that they are firmly seated Section 7 2 Discs are damaged Replace discs 26 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH Section 7 2 2 Section 7 4 Elmo Rietschle A Gardner Denver Product Fault Cause Malfunctions Causes and elimination Troubleshooting Important Overpressure or vac uum not achieved Machine or system leaking Check the pipework and screw connections for leaks and to ensure that they are firmly seated Section 7 2 Discs are worn or damaged Replace discs Section 7 2 2 Section 7 4 Machine gets too hot Ambient or intake temperature is too high Ensure it is being used prop erly Section 2 3 Cooling air supply is ob structed Check environmental condi tions Section 5 1 Clean ventilation slots Section 7 2 The blow out filter cartridge is dirty Clean or replace the filter cartridges Section 7 2 3 Section 7 4 The regulating valves are dirty so that the permissible pres sure and or vacuum
22. ication Fig 4 Lubrication Blades G Inlet grating L Grease nipple M Grease recommendation plate s Screws w Slotted nut 7 2 2 Blades 20 The bearings must be greased at the 2 greasing points Fig 4 L with 6 g per point after the follow ing recommended operating hours or at the latest one year operation 50 Hz V KTA 60 100 10 000 h and V KTA 140 6 000 h 60 Hz V KTA 60 80 10 000 h V KTA 100 8 000 h and V KTA 140 gt 4 000 h NOTICE These greasing instructions are valid for operation at 20 C ambient temperature At 40 C these should be reduced by 50 To lubricate the inlet grating Fig 4 G must be un screwed We recommend the following brands of grease Kl berPetamoGY193 or other equivalent greases see also grease recommendation plate Fig 4 M Blade check All V KTA models have 6 carbon blades except the V KTA 5 which has 8 carbon blades that gradually wear out during operation First check after 4 000 operating hours and then every 1 000 operationg hours or depending on the height Fig 5 X earlier Remove inlet grating Fig 4 G To remove the end cover Fig 5 b from the housing the bolt Fig 5 a located in the centre of the bearing cover Fig 5 c should be removed To achieve this one of the fix ing bolts Fig 5 s from the housing cover should be screwed into the thread in the centre of the bearing cover Remove the blades Fig 5 d to be check
23. ietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 1 3 A Gardner Denver Product Installation 5 Installation 5 1 Preparing for installation Check the following points e Machine freely accessible from all sides e Do not close ventilation grids and holes e Sufficient room for installing and removing pipes and for maintenance work particularly for install ing and dismantling the machine e No external vibration effects e Do not suck any hot exhaust air from other ma chines into the cooling system The cooling air inlets Fig 2 E and the cooling air outlets Fig 2 F must be at least 30 cm away from adjacent walls Cooling air coming out must not be sucked in again or maintenance work there must be a minimum of 40 cm in front of the filter housing Fig 2 S and the inlet grating Fig 2 G O The filter housing Fig 2 S should be easily accessible 5 2 Installation NOTICE The machine may only be operated when it is set up horizontally Material damage resulting from the machine tipping over and falling When installed at more than 1000 m above sea level a reduction in power is noticeable In this case we would ask you to contact us Ensure that the foundation complies with the follow ing conditions e Level and straight e The bearing surface must be able to bear the weight of the machine 4 It is possible to install the machine on a firm base with
24. ion in Pasame Snes Toten es Pr nae U tera gessenegjieme or schaute i q a I E b After a repair or re commissioning the actions listed under Installation and Commissioning must be carried out as for initial commissioning Fig 10 Clearance certificate 7 7025 003 17 El 24 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH I Rietschle A Gardner Denver Product 7 4 Spare parts d rn Fig 11 Spare parts list example Maintenance and repair Order spare parts in accordance with the Spare parts list E450 V KTA 60 1 140 3 01 E456 V KTA 60 1 140 3 31 E459 V KTA 80 5 36 e Download the PDF file tp www gd elmorietschle com Downloads Product Documents gt V Series Spare Parts e Parts subject to wear and gaskets are indi cated separately on the list Web site http www service er de e Select the type size and design NOTICE Only use original spare parts or parts approved by the manufacturer The use of other parts may lead to malfunctions and invalidate liability or the guarantee for any consequences arising Klicken Sie hier wenn Sie den Katalog ohne Zugangskennung benutzen m chten keine Bestellmoglichkeit Click here if you wart to acess the
25. l 3 2 Storage NOTICE Material damage caused by improper storage gt Ensure that the storage area meets the following conditions a dust free b vibration free 3 2 1 Ambient conditions for storage Ambient conditions Value Relative humidity 0 to 80 Lagertemperatur 10 C to 60 C The machine must be stored in a dry environment with normal air humidity It should not be stored for more than 6 months see Info Machine storage guidelines Page 4 Danger from inflammable corrosive or poison ous substances Machines that come into contact with hazard ous substances must be decontaminated before disposal 3 3 Disposal gt When disposing ensure the following a Collect oils and grease separately and dispose of in accordance with the local regulations in force b Do not mix solvents limescale removers and paint residues c Remove components and dispose of them in accordance with the local regulations in force d Dispose of the machine in accordance with the national and local regulations in force e Parts subject to wear and tear marked as such in the spare parts list are special waste and must be disposed of in accordance with the national and local waste laws EI 25 Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 11 A Gardner Denver Product Set up and operation 4 Setup and operation 4 1 Setup P O Q N V KTA
26. m
27. nauthorised modifications to the machine or the accessories supplied by Gardner Denver Schopfheim GmbH www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 9 Transport storage and disposal 3 Transport storage and disposal 3 1 Transportation 3 1 1 Unpack and check the delivery condition 3 1 2 Lifting and transporting Unpack the machine on receipt and check for transport damage Notify the manufacturer of transport damage im mediately Dispose of the packaging in accordance with the local regulations in force Death or limbs crushed as a result of the items being transported falling or tipping over When transporting with the lifting device remem ber Select the lifting device suitable for the total weight to be transported Ensure that the machine cannot tip and fall Do not stop under a suspended load Put the goods to be conveyed on a horizontal base Lifting device Transporting with a crane Bodily injury resulting from improper operation a Loads crosswise to the ring level are not per mitted b Avoid impact stress a Tighten the eyebolts Fig 1 1 firmly b The machine must be suspended on the eyebolt using the lifting device for lifting and transport ing Fig 1 Lifting and transporting 1 Eyebolt 10 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH I Rietschle Transport storage and disposa
28. ons of conformity are invalid when the machine has been modified without prior ap proval by us and the approval has been documented in writing Name and address of the EC person in Gardner Denver Schopfheim GmbH charge for documentation Postfach 1260 D 79642 Schopfheim Gardner Denver Schopfheim GmbH Schopfheim 1 8 2011 1 t Dr Friedrich Justen Director Engineering C_0074_EN Safety declaration form 7 7025 003 17 for vacuum pumps and components Page 1 of 1 Gardner Denver Schopfheim GmbH Roggenbachstr 58 79650 Schopfheim Phone 49 0 7622 392 0 Fax 49 0 7622 392 300 Repairs and or maintenance of vacuum pumps and components will only be carried out if a declaration has been filled in correctly and completely If not the repair work cannot be started and delays will result This declaration must only be filled in and signed by authorised qualified staff 1 Type of vacuum pumps components 2 Reason for the submission Type description Machine number Order number Delivery date 3 Condition of vacuum pumps components 4 Contamination of the vacuum pumps Was this being operated YES O NO QO components when in use Which lubrication was used Toxic YES NO Corrosive YES NO Was the pump component emptied Microbiological YES NO Product Consumables YES NO U Explosive YES NO Has the pump component been cleaned and decontamingRadioactive YES NO other YES NO OOOOOO YES OU Cleaning ag
29. ound cover The compressed air is cooled by a cooling segment The machines are driven by standard flanged three phase motors using a coupling Pressure and vacuum can be adjusted to the required levels however they are limited to a maximum point Versions 01 to 30 have cooling exits from two sides whilst versions 31 to 60 have cooling exits on one side only 4 3 Areas of application These dry running rotary vane pressure vacuum pumps models V KTA60 1 to V KTA 140 3 and V KTA 80 5 are suitable for creating pressure and vacuum at the same time Constant operation is permissible All models have nominal capacities of 60 80 100 and 140 m hr operating at 50 cycles The pressure and vacuum limits bar are indicated on the data plate Fig 2 N The tables showing capacity against pressure and vacuum can be seen in data sheets D 452 and D 453 These dry running machines are suitable for conveying air with a relative humidity of 30 9096 bh If the unit is switched on more frequently at regular intervals of about 12 times V KTA 60 80 resp 10 times V KTA 100 140 an hour or at higher ambient temperatures and intake tempera e tures the excess temperature limit of the motor winding and the bearings may be exceeded Please contact the manufacturer should the unit be used under such conditions ER If it is installed in the open air the unit must be protected from environmental influences e g by a y protective roof El 25 R
30. out anchoring When installing on a substruc v Ly ture we recommend fixing with flexible buffers EI 14 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH 25 Rietschle A Gardner Denver Product Installation 5 3 Connecting pipes a Vacuum connection at Fig 2 A and pressure connection at Fig 2 B NOTICE Material damage resulting from the forces and torques of the pipes on the unit being too high Only screw pipes in by hand Long and or small bore pipework should be avoided as this tends to reduce the capacity of the machine b Check to ensure the intake line and pressure line are connected correctly NOTICE Length of the connection pipes With connection pipes that have the same pipe cross section as the machine connection and are more than 3 m long a non return valve especially for the purpose must be installed in order to avoid reverse operation when the machine has stopped 5 4 Control and relief valves The required pressure and vacuum ranges can be set with the pressure regulating valve Fig 2 D and the vacuum regulating valve Fig 2 C as shown on the symbol plate attached to the rotary knob NOTICE Do not operate without the standard control and relief valves If the permissible final compression pressure is exceeded see data plate the machine may be damaged 2 Rietschle www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschl
31. rtridges Fig 7 e and Fig 7 f can be removed for cleaning after undoing the filter screw knobs Fig 7 h and the filter housing cover Fig 7 9 Clean the filter housing chambers too NOTICE Do not damage the filter cartridges when clean ing them No dirt must get into the machine when cleaning the filter housing chambers Danger of injury when dealing with com pressed air When blowing through with compressed air solid particles may be carried along or powder dust swirl ing around may cause injury to the eyes Therefore when cleaning with compressed air always wear goggles and a dust mask EI 22 www gd elmorietschle com Gardner Denver Schopfheim GmbH Gardner Denver Deutschland GmbH I Rietschle A Gardner Denver Product 7 2 4 Coupling Abb 9 Coupling Coupling rubber Circlip Circlip Motor Motor flange Spacer Motor side coupling half Coupling bolt Screws Washer Fan Nut Elmo 25 Rietschle A Gardner Denver Product Maintenance and repair The coupling rubbers bb 9 k are wearing parts and should be checked regularly When the coupling rubbers are worn this can be detected by a knock ing sound when the pump is started Defected coupling rubbers Defected coupling rubbers can cause extensive damage and even in some extreme cases break the rotor shaft To check the coupling stop the motor Fig 9 m and isolate Remove the screws Fig 9 ss on the motor flange Fig
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