G-SAP G-Series Operating Instructions
Contents
1. Supplementary operating manual A Gardner Denver Product Pumping gases and gas mixtures with side channel compressors Scope of application These safety instructions apply to all SAP and SAH side channel compressors that have been ordered with the Reduced Leakage RL2 option Versions The components that carry gas are specially impregnated and sealed AN The leakage rate can be max 1 l min at final pressure with the shaft stationary Use The above mentioned machines are suitable for pumping gases with a relative humidity of up to 90 A It is not allowed to pump inflammable gas mixtures using the above mentioned machines l e in the case of mixtures of gas air and inert gas the portion of inflammable gas to be pumped must not be within the explosion limit for this inflammable gas AN Operation in potentially explosive atmospheres is not allowed To monitor the safety of people and buildings safety features as per the locally applicable regulations must be installed for system components carrying gas Commissioning With the highest possible regulation in the system the pressure differences at the compressor must not be greater than the max permissible pressure differences as per the rating plate If there is a risk of regulation beyond the limits allowed pressure limiting is to be provided in the system The relationships between the flow rate and the partial vacuum or overpressure are given on the enclosed da2. air inlet filters are not maintained correctly 1 Mesh disc on the silencing housing Cleaning of this is possible through the opening A and B 2 Additional filter optional extra The suction filter ZAF should be cleaned every 250 operating hours and changed every 3000 operating hours Changing the filter unscrew wing nut m Remove filter cover h and filter cartridge f The filter cartridge can be cleaned by knocking out by hand or by using compressed air Replace the filter cartridge if necessary Re assemble in reverse order see picture The filter cartridge f2 of the vacuum tight suction filter ZVF must be cleaned regularly again depending upon the amount of contamination Cleaning can be achieved by washing or by blowing out with compressed air Replace the filter cartridge if necessary The cartridge f2 can be removed completely by undoing the relevant retaining clips m gt see picture 3 Bearings The units have bearings that are greased for life and require no maintenance Handling of inflammable or aggressive gases and vapours is only possible with special versions if the safety instructions XE 1 are noted 3 6 Trouble Shooting 1 Blower does not reach operating speed when starting 1 1 Check that the incoming voltage and frequency corresponds with the motor data plate 1 2 Check the connections on the motor terminal block 2 Motor starter cuts out blower 2 1 Probl
3. all repairs on site an electrician must disconnect the motor so that an accidental start of the unit cannot happen All engineers are recommended to consult the original manufacturer or one of the subsidiaries agents or service agents The address of the nearest repair workshop can be obtained from the manufacturer on application After a repair or before re installation follow the instructions as shown under the headings Installation and Initial Operation Lifting and Transport To lift and transport units SAP 180 to SAP 1500 the eye bolt on the pump must be used The weight of the blowers are shown in the accompanying table Storage SAP units must be stored in dry ambient conditions with normal humidity We recommend for a relative humidity of over 80 that the pump units should be stored in a closed container with the appropriate drying agents Disposal The wearing parts as listed in the spare parts lists should be disposed of with due regard to health and safety regulations Spare parts lists E 545 1 SAP 50 gt SAP 300 SAP 380 450 530 4 kW 4 8 kW E 545 2 SAP 380 450 530 5 5 kW gt 9 kW SAP 710 SAP 1060 SAP 1500 SAP 530 93 5 99 92 99 100 108 100 108 Weight max 88 200 608 634 664 764 790 450 471 534 534 534 525 561 617 639 606 4 6 8 08 PM7 Noise level max Sound power Elmo G series Rietschle
4. and the cooling air exits F must have a minimum distance of 10 cm from any obstruction The discharged cooling air must not be re circulated SAP units can be operated in different positions SAP 01 models can be installed on a solid floor without bolting down When installing SAP 02 models i e motor vertically upwards you must secure against torque reaction on start up When fitting onto framework we recommend using anti vibration mounts For installations that are higher than 1000 m above sea level there will be a loss in capacity For further advice please contact your supplier 2 6 Installation pictures and For operating and installation follow any relevant national standards that are in operation 1 Please remove transportation lock at A and B 2 When on vacuum operation connect the suction pipe at A and when on pressure operation connect the pressure pipe at B Long and or small bore pipework should be avoided as this tends to reduce the capacity of the blower If alternate vacuum or pressure is required a changeover valve ZWS can be fitted optional extra In this case there is only one connection for vacuum or pressure operation 3 The electrical data can be found on the data plate N or the motor data plate The m
5. Elmo Rietschie A Gardner Denver Product Side channel blower G SAP G Series Operating Instructions SAP 50 SAP 90 SAP 110 SAP 150 SAP 180 SAP 220 SAP 300 SAP 380 SAP 450 SAP 530 SAP 710 SAP 1060 SAP 1500 Pump ranges These operating instructions concern the following side channel vacuum pumps and compressors SAP The performance curves showing capacity against vacuum or pressure can be seen in data sheets D 545 1 D 545 2 and D 545 3 or D 645 1 D 645 2 and D 645 3 Description All SAP models work according to the dynamic compression principle utilising a non contact rotating impellor They have a built in motor A high efficiency double flow impellor is fitted on to the motorshaft Models up to SAP 4 kW picture use the motor fan for cooling Models SAP 5 5 kW and larger picture have an additional cooling fan situated between the motor and blower housing Air inlet and outlets have built in silencers with the addition of a mesh disc on the suction silencer to protect the unit from particles larger than 5 mm Both the inlet and outlet have an inside connection thread corresponding to DIN ISO 228 Versions of the SAP have on the suction side a solenoid valve and on the pressure side different connection flanges All the parts are made from a special aluminium alloy except for the motor rotor stator and shaft Optional extras As required vacuum or pressure limiting valve non return valve suction filter motor
6. Note If these values are exceeded when the unit is running on normal operating temperature an unloading of the unit is required by utilising limitation valves ZBS ZUV or ZBD optional extra 3 A comparison of the measured current amperage with the max current amperage on the data plate N is not advisable because the current amperage depends on the voltage Potential risks for operating personnel Noise Emission The worst noise levels considering direction and intensity sound power measured according to DIN 45635 part 13 as per 3 GSGV are shown in the table at the back When working permanently in the vicinity of an operating unit we recommend wearing ear protection to avoid any damage to hearing Maintenance and Servicing AAN When maintaining these units and where a situation exists where personnel could be hurt by moving parts or by live electrical parts UA the blower must be isolated by totally disconnecting the electrical supply It is imperative that the unit cannot be re started during the maintenance operation Do not maintain a blower that is at its normal operating temperature as there is a danger from hot parts The pressure leading pipes must be ventilated before dismantling In case of capacitor failure 1 drive replace the capacitor only with one that has identical rated value These side channel vacuum pumps and compressors need no maintenance apart from filtration The capacity of the blower can be reduced if the
7. em as per 1 1 and 1 2 2 2 Incorrect setting on the motor starter 2 3 Motor starter trips too fast Solution Use a motor starter with a time delay trip version as per IEC 947 4 2 4 Blower is overloaded i e pressure difference is too high Solution Increase the inlet or outlet diameter of the application on pipework increase the diameter of the pipework avoid restrictions in the line Limit the pressure difference by limitation valves optional extra 2 5 Motor rating selected was too small Solution If available use a blower with the next motor size exchange of the motor only is not possible 3 Required pressure difference cannot be achieved 3 1 Blower or motor rating selected was too small 3 2 Filters are contaminated 3 3 Pressure loss into pipework too high Solution Use bigger pipe diameter avoid restrictions 3 4 Leaks on the system 4 Blower operates at an abnormally high temperature 4 1 Ambient or suction temperature is too hot 4 2 Pressure difference is higher than permitted 4 3 Cooling air flow is restricted 5 Exhaust noise vacuum pump or suction noise compressor are unacceptable Solution Use an additional silencer ZGD optional extra 6 Change solenoid valve or change over valve ZWS accessory does not work 6 1 Check that the incoming voltage and frequency correspond with the information on the solenoid 6 2 Change over valve is contaminated Solution Dismantle and clean Appendix Repair on Site For
8. ng This is indicated on the data plate N and is shown in the data sheet for standard voltages and frequency SAP 50 SAP 90 SAP 110 SAP 150 SAP 180 see data sheet D 545 1 or D 645 1 SAP 220 SAP 300 SAP 380 SAP 450 see data sheet D 545 2 or D 645 2 SAP 530 SAP 710 SAP 1060 SAP 1500 see data sheet D 545 3 or D 645 3 Operating above these pressure differences the motor would be overloaded As well as considering the maximum allowable pressure difference the amperage should also be checked against the data plate N The loading of each unit depends on the specific gravity of the gas handled Therefore when handling gases other than air there are other pressure difference limits to be considered Please contact the supplier for further advice If it is possible for the flow to be throttled more than the allowed limits then the use of vacuum or pressure limitation valves optional extras should be considered The maximum permissible internal pressure is 3 5 bar abs With this pressure the performance is reduced For all applications where an unplanned shut down of the blower could possibly cause harm to persons or installations the corresponding safety backup system must be installed Handling and Setting up pictures and Pumps that have reached operating temperature may have a surface temperature at position Q of more than 70 C WARNING Do Not Touch The blower especially when the units are built in the cooling air entries E
9. otors correspond to DIN VDE 0530 and have IP 55 protection and insulation class F The connection diagram can be found in the motor terminal box unless a special plug connection is fitted Check the electrical data of the motor for compatibility with your available supply voltage frequency permissible current etc 4 Connect the motor via a motor starter It is advisable to use thermal overload motor starters to protect the motor and wiring All cabling used on starters should be secured with good quality cable clamps We recommend that motor starters should be used that are fitted with a time delayed trip resulting from running beyond the amperage setting When the unit is started cold overamperage may occur for a short time When using a solenoid valve or changeover valve ZWS the solenoid X must also be connected The voltage information on the solenoid should also be checked The electrical installation may only be made by a qualified electrician under the observance of EN 60204 The main switch must be provided by the operator Initial Operation pictures and Maximum number of starts per hour 10 1 Initially switch the pump on and off for a few seconds to check the direction of rotation against the direction arrow O 2 When installed on the application and under the highest possible load conditions the pressure differences of the unit may not be higher than the max allowable pressure differences shown on the data plate N
10. s SAP 50 SAP 90 SAP 110 SAP 150 SAP 180 SAP 220 SAP 300 SAP 380 SAP 450 SAP 530 SAP 710 SAP 1060 SAP 1500 is conform to the regulations of the guideline indicated above Furthermore the designated product is conform to the regulations of the following guidelines 2006 95 EG Directive 2006 95 EC of the European Parliament and of the Council of 12 December 2006 on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits codified version The following harmonised standards have been applied EN 1012 1 1996 Compressors and vacuum pumps Safety requirements Part 1 Compressors EN 1012 2 1996 Compressors and vacuum pumps Safety requirements Part 2 Vacuum pumps Name and address of the _ Holger Krause EC person in charge for documentation P O Box 1510 D 97605 Bad Neustadt Saale Gardner Denver Deutschland GmbH Bad Neustadt Saa 2809 08 20 The machine fulfils the material requirements of both guidelines applies only to the guideline 98 37 EC applies only to the guideline 2006 42 EC 664 44497 40 000 6 6
11. starter vacuum pressure change over valve Special versions anti corrosive internal coating gas tight version 610 44497 40 000 08 2009 Gardner Denver Deutschland GmbH Postfach 1510 97605 Bad Neustadt Saale GERMANY Fon 49 7622 392 0 Fax 49 7622 392 300 e mail er de gardnerdenver com www gd elmorietschle com SAP 01 mes SAP 02 Suitability The units SAP are suitable for use in the industrial field i e the protection equipments corresponds to EN DIN 294 table 4 for people aged 14 and above SAP models can be operated as vacuum pumps or compressors They are suitable for use with air of a relative humidity up to 90 but not aggressive gases Gas tight versions are available The tightness of each unit depends on the shaft seal The shaft seal lifetime relates directly to the operating conditions Dangerous mixtures i e inflammable or explosive gases or vapours water vapour or aggressive gases must not be handled Handling of inflammable or aggressive gases and vapours is only possible with special versions if the safety instructions XE 1 are noted Operation in potentially explosive areas is not permissible The ambient and suction temperatures must be between 5 and 40 C For temperatures outside this range please contact your supplier For less aggressive media an internal protection coating can be utilised The maximum permissible pressure difference for vacuum or pressure depends upon the motor rati
12. ta sheet and apply only to air They relate to free atmospheric air at 1 bar abs and 20 C Service and maintenance The side channel vacuum pumps or compressors are maintenance free for the stated scope of application except for the shaft sealing ring between the motor and compressor section The freedom from leaks of the compressor is to be monitored by the operating organisation If an increased leakage rate is detected the shaft sealing ring is to be replaced Replace shaft sealing ring and bearing at the latest after 10 000 operating hours or after two years The unit is not allowed to be opened e g to change the shaft sealing ring and the bearing this work must be undertaken by the manufacturer s authorised service organisation After the servicing re establish and check the reduced leakage The test pressure for the leak test is 1 5 times the maximum operating pressure stated on the rating plate Gardner Denver Deutschland GmbH All rights reserved 610 44497 40 900 P O box 1510 08 2009 D 97605 Bad Neustadt Saale English Germany Phone 49 7622 392 0 Fax 49 7622 392 300 E mail er de gardnerdenver com Original operating instructions Internet www gd elmorietschle com 5 6 Gardner enver EC Declaration of Conformity 98 37 EC or 2006 42 EC Hereby the manufacturer Gardner Denver Deutschland GmbH confirms P O Box 1510 D 97605 Bad Neustadt Saale that the machine Side channel blower of the G Series G SAP Model
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