Gas-Ring Vacuum Pumps/ -Compressors Operating Instructions G
Contents
1. Quantity Value Unit Voltage range 14 28 V DC Nominal voltage 24 V DC Max input current 4 5 Nominal speed 9500 min Motor rating 90 W Speed control range 1000 9500 min Internal resistance at desired speed 70 Permissible ambient temperature 10 40 C Relative humidity max 95 Type 2BH10 02 _AB22 Quantitiy Value Unit Voltage range 14 28 V DC Nominal voltage 24 V DC Max input current 5 2 Nominal speed 11500 min Motor rating 115 W Speed control range 1000 12000 min Internal resistance at desired speed Permissible ambient temperature 10 40 C Relative humidity max 95 G_100 with external electronics Drivecontrol VT D 2BH10 02 _AA53 Quantity Value Unit Voltage range 38 52 V DC Nominal voltage 48 V DC Max input current TIA Nominal speed 15000 min Motor rating 300 W Speed control range 1000 15000 min Internal resistance at desired speed 70 Q Permissible ambient temperature 10 40 C Relative humidity max 95 Due to the PWM control of the electronics the power supply unit is loaded with short high current pulses For this reason the supply voltage must be blocked or filtered by means of a capacitor low ESR type suitable type for high frequencies high current switching gt 1000 for noise suppression Usually this2. Gardner Denver Deutschland GmbH 10 31 610 44431 40 000 Technical Data Fig 3 Permissible total differential pressure conversion factor 1 01 gt a Conversion factor BR 0 93 0 92 0 91 20 0 10 20 30 40 50 Gas intake and ambient temperature t C For the permissible total differential pressure at an intake and ambient temperature of 15 C see the table in section 4 1 Nominal and Limiting Values Pump p 7 In order to calculate the permissible total differential pressure for other intake and ambient temperatures proceed as follows Find out your system dependent gas intake and ambient temperature Establish the conversion factor valid for these conditions by means of the above diagram In order to do so mark your intake and ambient air temperature on the temperature axis Draw a vertical line from this value to the point of intersection with the curve Now draw a vertical line from the point of intersection to the conversion factor axis where you can read the conversion factor then Multiply the established conversion factor with the max permissible total differential pressure at 15 C as given in the table in section 4 1 Nominal and Limiting Values Pump p 7 The result will be a pressure value This is the max permiss
3. Gardner Denver Deutschland GmbH 21 31 610 44431 40 000 Installation Commissionin 6 2 2 Pipe hose connections pump Fig 9 General view G_100 On delivery the suction and delivery branches of the G_100 are sealed up in order to prevent foreign bodies from entering the pump Do not remove the seals until right before connecting the pipes hoses IMPORTANT The G_100 must not be operated with the suction or delivery branches sealed up or jammed For the arrangement of the branches see Fig 9 General view The operating direction of the G_100 is indicated by means of arrows The direction of rotation is indicated by an arrow on the pump casing The delivery direction is indicated by arrows on the suction and delivery branches IMPORTANT The main or operating direction of rotation of the G_100 is the counter clockwise rotation given by the arrow indicating the direction of rotation on the pump lid see Fig 9 5 Only with the counter clockwise rotation the nominal values will be achieved Clockwise rotation is only permissible in special cases In this instance the G_ 100 will not achieve its full output Gardner Denver Deutschland GmbH General view G_100 pump side 6 Suction branch 7 Delivery branch 8 Electrical connecting cable 9 Arrows indicating delivery direction 10 Fixing lugs for fastening to a mounting surface The pump
4. At least two power supply Check fuses terminals and Electrician no motor noise leads interrupted supply leads and close circuit where interrupted No signal at control signal Apply control signals Electrician inputs A and B see section 6 2 1 Electrical Connection Motor given No speed reference value Set speed reference value Electrician see section 6 2 1 Electrical Connection Motor Motor does not start Impeller jammed humming noise Impeller damaged Motor bearing damaged Open pump lid remove dirt Qualified personnel and foreign bodies as described in section 8 1 1 Cleaning Replace impeller After sales service Replace complete casing After sales service i e the unit consisting of casing stator and two ball bearings connecting leads Wrong connection of motor Check and if necessary Electrician correct the connection of the motor phases and hall signals to the drive electronics see section 6 2 1 Electrical Connection Motor Gardner Denver Deutschland GmbH 28 31 610 44431 40 000 Servicing Fault Cause Remedy Carried out by Power consumption too high Winding short circuit Have winding checked Electrician Motor overload Reduce operating pressure If necessary clean filter silencers and pipes Qualified personnel Impeller jammed See Motor does not sta
5. The following states are possible Level A Level B Mode of operation 0 0 Output stage disabled no current 0 1 Counter clockwise rotation according to the arrow indicating the direction of rotation on the pump lid see 12 Fig 4 5 Main operating direction of rotation of the G_100 1 0 Clockwise rotation opposed to the arrow indicating the direction of rotation on the pump lid see 12 Fig 4 5 1 1 Breaking Please take also note of the following data Wire cross section of the connecting cable 0 5 mm Control current on the supply voltage control signal connection side 9 Motor connection side The connector for motor connection connector X4 is shown in Fig 7 On the motor connection side the assignment is as follows Symbol Description Lead colour Pin L1 Motor phase 1 Terminals of the motor windings brown Pin 6 L2 Motor phase 2 Operating voltage 0 9 Uvv violett Pin 5 L3 Motor phase 3 max winding peak current 13 A yellow Pin 1 max winding temperature 115 C RPD1 Hall signal 1 Rotor position detectors green Pin 4 RPD2 Hall signal 2 Hall ICs with open collector output white Pin 3 RPD3 Hall signal 3 They must be wired to an external pull up grey Pin 8 resistor V Hall supply Feeder line of the hall ICs red Pin 2 Gnduai Hall supply black Pin 7 Gardner Denver Deutschla
6. after the impeller has come toa complete standstill Consider impeller run out Gardner Denver Deutschland GmbH 4 31 Operation of the G_100 only with the pipes hoses connected to the suction and delivery branches WARNING In case of operation with open suction or delivery branches drawing in of gases from or discharge of gases into the surroundings a piece of pipe or hose with a length of at least 120 mm must by all means be connected to the branch in question in order to prevent the impeller from being reached by fingers Disassembly of the pipes hoses connected to the suction and delivery branches only after the impeller has come to a complete standstill Consider impeller run out gt Do not reach into the G_100 through open suction or delivery branches Do not insert any objects into the G_100 through the openings Operation of the G_100 only with the motor cap assembled Disassembly of the motor cap is prohibited For protection against the running rotor provide a guard in front of the motor Operation of the G_100 only with the guard in front of the motor assembled Disassembly of the guard in front of the motor only after the rotor has come to a complete standstill Consider rotor run out Work on electrical installations may be carried out by trained and authorised electricians only gt gt The electrical connections must be surrounded by a housin
7. and the surroundings has been exceeded Make sure that the differential pressure is not exceeded Qualified personnel Current feed to the mains Caused by switching off or rapidly reducing the speed of the compressor Insert a diode Schottky diode size 6A respectively10A in the 24V respectively 48V supply lead V cc Electrician Gardner Denver Deutschland GmbH 29 31 610 44431 40 000 Shutting Down and Measures for Prolonged Standstill 9 Shutting Down and Measures for Prolonged Standstill Storage conditions Ambient temperature 20 C 70 C IMPORTANT Relative humidity 10 95 If the storage period exceeds one Atmospheric pressure 500 hPa year 1 100 hPa the life expectancy of the Vibrations see section 4 bearings might be reduced Technical Data Measures before recommissioning after Measures after shutdown before storage storage Seal up the suction and delivery branches Make sure that there is no oxide layer on the Provide loose lead ends with an ESD contacts If necessary remove oxide layer prevention bag Make sure that the insulation of the electrical Ensure the correct storage conditions see connecting cable has not become porous below Gardner Denver Deutschland GmbH 30 31 610 44431 40 000 Manufacturer s Declaration Declaration of Conformity 10 Manufacturer s Declaration Declarati
8. min A Control signals A and B are digital Low 0 lt 0 5 VDC white white B inputs High 1 gt 4 V DC grey Broad voltage range input compatible with TTL PLC signals In all four possible combinations AB Function 0 0 Motor disabled no current 01 CCW rotation 1 0 CW rotation 1 1 Motor disabled not connected brown not connected red In order to meet the requirements bearing on electromagnetic compatibility an EMI filter from Messrs CORCOM Type 6ETI F7003 6A must be connected in series with the integrated electronics type G_100 The connecting cable between the EMI filter and the G_100 must have a length of at maximum 0 5 m IMPORTANT The main or operating direction of rotation of the G_100 is the counter clockwise rotation given by the arrow indicating the direction of rotation on the pump lid see p 12 Fig 4 5 Only with the counter clockwise rotation the nominal values will be achieved Clockwise rotation is only permissible in special cases In this instance the 100 will not achieve its full output IMPORTANT The connecting cable between the G_100 and the external electronics must have a length of at maximum 0 5 m IMPORTANT When switching off the G_100 or rapidly reducing its speed a current feed into the mains might occur This can be prevented by inserting a diode Schottky diode size 6A in the 24 V supply lead
9. 0 44431 40 000 Safety and Residual Risks 2 Safety and Residual Risks A Before beginning to work on the G_100 or the system carry out the following steps for both the G_100 and the entire system switch off electricity lock against restart ensure absence of electricity ground and short circuit installation cover or bar adjacent live parts depressurise both pipes and pump Do not wear long loose hair Use a hair net Never wear wide loose clothes Transport and handling as well as assembly and disassembly may be carried out by trained and responsible personnel only Operation of the G_100 only with the gases as indicated in section 3 Intended Use with the values as indicated in section 4 Technical Data Check pipes hoses and vessels for sufficient strength Check pipe hose connections for tightness Operation of the G_100 only when completely assembled and securely fastened to the mounting surface Check fasteners for secure fixing at regular intervals gt PPP After loosening clampings fastening elements some parts and components are only held in place by their centrings or seatings or are no longer held in place at all so that they might fall down Take the necessary care during disassembly and assembly gt Operation of the G_100 only with the pump lid assembled Disassembly of the pump lid only
10. 4 V a speed reference value of 10 V and left handed rotation of the G_100 The indicated temperature refers to the gas intake temperature It is assumed that the gas intake temperature equals the ambient temperature of the G_100 IMPORTANT For the max permissible total differential pressure at temperatures other than 15 C see Fig 3 Permissible total differential pressure conversion factor p 11 In case of increased throttling inside the suction or delivery pipe a pressure relief valve must be provided In case of reduced speeds by means of a lower speed reference value the max permissible total differential pressures change as well 4 Vacuum pump operation extraction of air 5 Compressor operation having the indicated temperature at the suction branch and a pressure of 1013 mbar at the delivery branch compression of air having the indicated temperature at the suction branch and a pressure of 1013 mbar at the suction branch 6 Max permissible speed due to the mechanical components and the design of the unit 7 For Gardner Denver Deutschland GmbH operation within the permissible operating range the max permissible dynamic load due to vibrations from outside and fastening by means of rubber metal elements available as accessories 7 31 610 44431 40 000 4 2 Nominal and Limiting Values Motor and Electronics G_100 with integrated electronics Technical Data Type 2BH10 02 _AB32
11. Elmo Rietschle A Gardner Denver Product Gas Ring Vacuum Pumps Compressors Operating Instructions G Series Types 2BH10 02 2BH10 02 2BH10 02 _AB32 _AB22 _AA53 Gardner Denver Deutschland GmbH All rights reserved 610 44431 40 000 P O box 1510 Edition 01 2007 D 97605 Bad Neustadt Saale English Germany Phone 49 7622 392 0 Fax 49 7622 392 300 E mail info de gardnerdenver com Translation of the Internet www gd elmorietschle com original operating instructions Gardner Denver Deutschland GmbH 2007 Replication distribution and or editing of this document and the use and distribution of its content is prohibited unless explicitly permitted Violation obligates compensation for damages All rights reserved in case of the issue of a patent utility patent or design patent Gardner enver Table of Contents 1 Table of Contents 1 Table of COMO 3 2 Safety and Residual 2 4 3 Intended tady 6 4 Technical Data a ee te nn en 7 4 1 Nominal and Limiting Values 7 4 2 Nominal and Limiting Values Motor and Electronics 8 5 Transport and Handling eresse nnna R EA A EE A AR 12 6
12. Installation amp 12 6 1 MOU E 12 6 2 E 14 6 2 1 Electrical Connection 14 6 2 1 1 G_100 for external electronics cc 15 6 2 1 2 G_100 with integrated electronics 20 6 2 2 Pipe hose connections pump EEEE A 22 6 3 COMMISSIONING tev ere De a ain Me A 24 7 tent da 25 8 SERVICING ede 26 8 1 2 2 ea 27 8 1 1 CHG AMIN Gs 27 8 1 2 28 8 1 3 LUDIGAUON 2 lesa eerste die eee 28 8 2 Repair Troubleshoot Gs kis aka de ae 28 9 Shutting Down and Measures for Prolonged 30 10 Manufacturer s Declaration Declaration of 31 Gardner Denver Deutschland GmbH 3 31 61
13. _100 e must be trained and authorised for the work to be carried out e Work on electrical installations may be carried out by trained and authorised electricians only The G_100 e are single stage gas ring vacuum pumps compressors e are machines used to generate vacuum or overpressure e are used to extract to deliver and to compress the following pumped gases air other gases which are not explosive flammable aggressive or toxic The pumped gases must not contain any solid bodies or impurities those must be separated before entering the unit by means of a filter e exist in four fundamental designs 2BH10 02 0AB32 hose connection with enclosed motor and integrated electronics 2BH10 02 0AB22 hose connection with enclosed motor and integrated electronics 2BH10 02 0AA53 hose connection with enclosed motor external electronics 2BH1002 1 flange connection 1 In order to determine the design of your G_100 refer to the type number MLFB on the rating plate Gardner Denver Deutschland GmbH 6 31 Intended Use e are intended for industrial applications e are designed for continuous operation in case of increased turn on frequency or increased intake and ambient temperature the limiting overtemperature of the winding and the bearings must not be exceeded operation only according to Fig 3 Permissible total differential pressure conversion factor p 11 When operating the G
14. _100 it is imperative to observe the limiting values given in section 4 Technical Data Foreseeable Misuse It is prohibited e to use the 100 in applications other than industrial applications e to use the 100 in areas where explosive atmosphere might occur e to extract to deliver and to compress explosive flammable aggressive or toxic fluids e to operate the 100 with values other than those given in section 4 Technical Data Any unauthorised modifications of the G_100 are prohibited for safety reasons Maintenance work is only allowed to the extent described in these operating instructions Any further maintenance work as well as repair work may only be carried out by companies authorised by the manufacturer please contact your sales engineer IMPORTANT The G_100 is a component intended to be incorporated in a machine or system It is delivered for this purpose to manufacturers of such machinery or systems OEMs only IMPORTANT The installation of the G_100 in your machine or system must be carried out in keeping with the requirements on electromagnetic compatibility according to the EMC Directive 610 44431 40 000 4 Technical Data Technical Data 4 1 Nominal and Limiting Values Pump Type MLFB 2BH10 02 _AB32 2BH10 02 _AB22 2BH10 02 _AA53 with enclosed motor with enclosed motor with enclosed motor integrated e
15. and delivery branches In case of operation with open suction or delivery branches drawing in of gases from or discharge of gases into the surroundings a piece of pipe or hose with a length of at least 120 mm must by all means be connected to the branch in question e Use a hair net Gardner Denver Deutschland GmbH 5 31 Danger zone The vicinity of the unit during operation with open suction or delivery branches drawing in of gases from or discharge of gases into the surroundings Hazard e Injuries due to contact with pressurised fluids or due to sudden acceleration of parts e Injuries due to parts thrown out of the unit Protective measures e Ensure that fluids discharged into the surroundings are not expelled close to people e g work stations on machines e During work on or near the unit wear personal protective equipment 610 44431 40 000 3 Intended Use These operating instructions e must be completely read and understood by all operating and servicing personnel before beginning to work with or on the G_100 e must be strictly observed e must be available at the site of operation of the G_100 e applies to Gas Ring Vacuum Pumps Compressors type G_100 e contains instructions bearing on transport and handling installation commissioning operation servicing shut down and storage of the G_100 The operating and servicing personnel working with or on the G
16. ans for depressurisation in both the suction and the delivery pipes QPP Gardner Denver Deutschland GmbH 23 31 610 44431 40 000 Installation Commissionin 6 3 Commissioning WARNING Operation of the G_100 only with the pump lid assembled with the pipes hoses connected to the suction and delivery branches or incase of operation with open suction or delivery branches drawing in of gases from or discharge of gases into the surroundings with a piece of pipe or hose having a length of at least 120 mm connected to the branch in question with bearing end housing WARNING Do not reach into the G_100 through open suction or delivery branches Do not insert any objects into the G_100 through the openings IMPORTANT The G_100 must not be operated with the suction or delivery branches sealed up or jammed WARNING Before start up check pipes hoses and vessels for sufficient strength check pipe hose connections for tightness check fasteners for secure fixing Proceed as follows Make sure e thatthe suction and delivery pipes are correctly connected e that case of operation with open suction or delivery branches drawing in of gases from or discharge of gases into the surroundings a piece of pipe or hose having a length of at least 120 mm is connected to the branch in question in order to prevent the impeller from being reached by fingers e that
17. capacitor is part of the power supply unit Switch mode power supplies however are often provided with a capacitor of only very small capacitance at the output so that this kind of pulses result in interference In this case an additional capacitor must be connected as close to the motor as possible Gardner Denver Deutschland GmbH 610 44431 40 000 Fig 1 Dimensions of the 2BH1002 0 hose connection Technical Data Fig 2 Dimensions of the 2BH1002 1 flange connection Gardner Denver Deutschland GmbH cd Ae 7 29 9 31 bax M4x6 610 44431 40 000 Technical Data Hose connection B D d E F GIG OR 2BH1002 0AB32 145 133 121 95 72 20 19 53 72 11 1 450 4 2 2BH1002 0AB22 145 133 121 95 72 20 19 53 72 11 1 450 4 2 2BH1002 0AA53 145 133 121 95 72 20 19 53 92 11 1 450 4 2 Flange connection 2BH1002 1AB32 145 133 121 95 60 20 19 53 72 11 1 450 4 2 2BH1002 1AB22 145 133 121 95 60 20 19 53 72 11 1 450 4 2 2BH1002 1AA53 145 133 121 95 60 20 19 53 92 11 1 450 4 2
18. detector i RLG1 RLG2 RLG3 Internal MF 1 signal processing i 1 1 1 Supply voltage control signal Motor connection X4 connection X3 External electronics ee 222 external electronics Block diagram of the control principle BSR Colours of the connecting leads of the motor L1 brown RLG1 green black L2 violet RLG2 white L3 yellow RLG3 grey Gardner Denver Deutschland GmbH 16 31 610 44431 40 000 Installation and Commissioning Supply voltage control signal connection side The connector for supply voltage control signal connection connector X3 is shown in Fig 7 On the supply voltage control signal connection side the assignment is as follows Symbol Description Lead colour Pin A Mode of operation States white Pin 1 1 High 5 30 V 0 Low lt 0 5 V Operating voltage 38 52 V red Pin 2 Not used violet Pin 3 Ngo S Speed reference value Control voltage 0 10 green Pin 4 Reference value of the desired speed of the G_100 B Mode of operatione States grey Pin 5 1 High 5 max 30 V 0 Low lt 0 5 V IST Actual speed optional Open Collector output yellow Pin 6 Here the rotor speed can be read Gnd Betriebsspannung OV black Pin 7 5 Ground Set Value input 0 V brown Pin 8 Via the digital control inputs A and B the direction mode of operation is determined
19. ed gases vapours are taken in via the suction branch and are expelled via the delivery branch The suction branch Fig 9 1 is indicated by an arrow pointing into the pump Connect the suction pipe to this branch The delivery branch Fig 9 2 is indicated by an arrow pointing out of the pump Connect the delivery pipe to this branch IMPORTANT These instructions apply to the counter clockwise rotation In case of clockwise rotation the suction and delivery branches are exchanged Make sure to connect the pipes hoses so that the G_100 will not be subject to any stress or strain WARNING A Rotating impeller hazard of severing limbs In case of operation with open suction or delivery branches drawing in of gases from or discharge of gases into the surroundings a piece of pipe or hose with a length of at least 120 mm must by all means be connected to the branch in question in order to prevent the impeller from being reached by fingers 22 31 610 44431 40 000 Installation Commissionin IMPORTANT The pipes hoses must be attached in a secure and tight fashion They must be locked against unintentional loosening e g due to vibrations thermal expansion etc WARNING Check pipes hoses and vessels for sufficient strength WARNING Check pipe hose connections for tightness IMPORTANT Provide a shut off device and or a me
20. es 2004 06 01 EN 60204 1 Safety of machinery Electrical equipment of machines 1997 12 01 Part 1 General requirements IEC 204 1 1992 modified EN 61000 6 2 Electromagnetic compatibility EMC 2005 08 01 Part 6 2 Generic emission standard Immunity Industrial environment EN 61000 6 3 Electromagnetic compatibility EMC 2001 10 01 Part 6 3 Generic standards Emission standard for residential commercial and light EN 61000 63 11 2004 07 01 industrial environments IEC 61000 6 3 1996 modified Electromagnetic compatibility EMC Part 6 3 Generic standards Emission standard for residential commercial and light industrial environments Any modifications of the machine that have not beforehand been agreed upon and permitted by us in writing invalidate this Declaration of Conformity Gardner Denver Deutschland GmbH Bad Neustadt Saale 2007 01 30 Wolfgang A Kriesten Director Sales Gardner Denver Deutschland GmbH 31 31 Dr Uwe Seidel Director Operations and Director Engineering amp Development 664 44431 40 000 610 44431 40 000
21. g which is proof against foreign bodies humidity etc Consider the life expectancy of the seals and gaskets Ensure that no foreign bodies humidity etc enter the motor interior 610 44431 40 000 Safety and Residual Risks For heat dissipation and cooling provide a minimum distance of 15 mm on each side except for the pump lid side on which a smaller distance of at least 2 mm is permissible Burning and scalding hazard due to hot surfaces of the G_ 100 Do not touch during operation Let the unit cool after shut down Provide a guard against accidental contact The motor of the G_100 including its connecting leads must be protected against electrostatic discharge ESD Do not remove the ESD prevention bag surrounding the lead ends until right before carrying out the electrical connection attaching the connector connecting to a terminal strip or the like Carry out the electrical connection using the appropriate ESD prevention equipment Residual Risks Danger zone Hot surface Hazard Burning scalding hazard Protective measures Attach warning sign Warning of hot surface A Danger zone Impeller of the pump can be reached through open suction or delivery branches Hazard e Severing of limbs e Drawing in and entanglement of hair Protective measures e Operation only with the pipes hoses connected to the suction
22. ible total differential pressure valid for your G_100 at your system dependent intake and ambient temperature Gardner Denver Deutschland GmbH 11 31 610 44431 40 000 ransport and Handling Installation Commissionin 5 Transport and Handling Packaging On delivery the G_100 is packed up in a cardboard box When there is no connector attached to the electrical connecting cable the lead ends are surrounded by an ESD prevention bag 6 Installation and Commissioning 6 1 Mounting Fig 4 General view G_100 General view G_100 pump side Suction branch Delivery branch Electrical connecting cable surface Gardner Denver Deutschland GmbH Arrows indicating delivery direction Fixing lugs for fastening to a mounting IMPORTANT The motor of the G_100 including its connecting leads must be protected against electrostatic discharge ESD Do not remove the ESD prevention bag surrounding the lead ends until right before carrying out the electrical connection attaching the connector connecting to a terminal strip or the like For the arrangement of the G_100 and its components see Fig 4 General view G_100 For the space required and the arrangement of the mounting holes required for fastening the G_100 to the mounting surface please refer to Fig 1 Dimensions of the p 9 10 The G_100 must be mounted as follows the shaft being in any po
23. lectronics integrated electronics external electronics Weight 1 2 kg 1 2 kg 1 5 kg Dimensions see Fig 1 amp 2 9 10 see Fig amp 2 9 10 see Fig amp 2 9 10 Sound level 48 dB A 51 dB A 55 dB A max permissible total differential pressure at 15 C e vacuum pump 100 mbar 105 mbar 185 mbar operation compressor 105 mbar 105 mbar 190 mbar operation max permissible 0 15 bar 0 11 bar 0 15 bar differential pressure between pump interior and surroundings max permissible 40 C 40 C 40 C intake and ambient temperature max permissible speed 9 500 min 12 000 min 15 000 min bearing life L107 20 000 h 20 000 h 20 000 h electrical data see section 4 2 Nominal and Limiting Values Motor and Electronics 8 and section 6 2 1 Electrical Connection Motor p 14 Max permissible dynamic load of the G_100 due to vibrations from outside Vibration frequency Vibration value lt 6 3 Hz Vibration displacement s lt 0 16 mm 6 3 2 63 Hz Vibration velocity Vims lt 4 5 mm s gt 63 Hz Vibration acceleration a lt 2 55 m s Surface sound pressure level DIN 45 635 Part 13 measured at a distance of 1 m at an operating point of approx of the permissible total differential pressure with the pipes hoses connected and without vacuum or pressure limiting valve 3 Permitted only with unobstructed cooling an operating voltage of 2
24. mble pump lid 1 In order to do so carefully set the lid to the pump so that the pin 3 is inserted in the hole and thus the lid is aligned Carefully place the lid on the pump in axial direction see arrow so that the pin is not bent Screw in the bolts 2 securing them using Loctite 243 Fastening torque of the bolts T 2Nm 0 2 1 Pump lid 2 Bolts 3 Impeller Gardner Denver Deutschland GmbH 610 44431 40 000 8 1 2 Inspection Carry out the following tasks on the G_100 at regular intervals 8 2 Fastening to the mounting surface Tighten fixing bolts Fastening torque according to property class 8 8 of the bolts or nuts used as given in ISO 898 Cable entry Tighten screwed cable glands Fastening torques e on casing side 3 2 Nm 0 2 cable side T 1 5 Nm 0 2 Suction and delivery branches Check pipe hose connections for secure fixing and tightness Check pipes hoses for tightness Consider material fatigue Replace worn parts Repair Troubleshooting Servicin 8 1 3 Lubrication IMPORTANT The bearings of the G_100 are provided with a lifetime lubrication and assembled in the pump by adhesive bonding In case the bearing is damaged or grease renewal is due the complete casing i e the unit consisting of casing stator and two ball bearings must be replaced Fault Cause Remedy Carried out by Motor does not start
25. nd GmbH 17 31 610 44431 40 000 Installation Commissionin Fig 6 External electronics 92 g 3 D 6 5 5 8 Eo N cs q 3 5 38 ag 28 te ad 85 L Control signal Motor connector connector X3 4 Fig 7 Connector pin assignment and mating connector Control signal connections Motor connections X3 X4 lug Mating connector type Mating connector type MOLEX 39 01 2085 MOLEX 39 01 2085 Slot for lug Slot for lug 5 6 7 8 RLG3 Gnd L1 L2 Gnd IST 1 2 3 4 8 7 5 5 8 br 6 5 Mating connector m m m m connected to motor cable 2 4 3 2 1 E AN Not RLG1 RLG2 Upn L3 5 Ub Gardner Denver Deutschland GmbH 18 31 610 44431 40 000 Installation Commissionin If there is no connector mating connector to the external electronics connected to the motor cable of the G_100 the loose lead ends are surrounded by an ESD prevention bag In this case the socket connector must first be connected to the motor cable IMPORTANT The motor of the G_100 including its connecting leads must be protected against electros
26. no longer held in place at all so that they might fall down WARNING Before recommissioning completely re assemble the G_100 check if all fasteners have been re assembled and tightened check pipes hoses and vessels for sufficient strength check pipe hose connections for tightness WARNING Work on electrical installations may be carried out by trained and authorised electricians only P P P Gardner Denver Deutschland GmbH 26 31 610 44431 40 000 Servicin 8 1 Maintenance 8 1 1 Cleaning Exterior In case of lint or dust on the pump Clean the entire surface of the G_100 wiping it with a wet cloth Interior See also Fig 10 Disassembly assembly of the pump lid Disassemble pump lid 1 In order to do so loosen the four bolts 2 and carefully pull off the lid in axial direction see arrow so that the pin 3 is not bent Remove lint using e g a pair of tweezers IMPORTANT Do not use compressed air in order to clean the pump interior since this might result in dirt entering the motor interior IMPORTANT Don not detach the impeller nut 4 Do not disassemble the impeller 5 Otherwise inside the motor the rotor would be displaced by a spring resulting in the G_100 having to be completely disassembled and re assembled Fig 10 Disassembly assembly of the pump lid axial direction Re asse
27. o these surfaces A CAUTION Burning and scalding hazard due to hot surfaces of the G_100 during operation Provide a guard against accidental contact Place the rubber metal elements rubber pads between the fixing lugs Fig 4 6 and the mounting surface Fasten the G_100 to the mounting surface via the fixing lugs using four suitable bolts or nuts Property class of the bolts or nuts 8 8 according to ISO 898 Secure the four fixing bolts against unintentional loosening due to vibrations 610 44431 40 000 Installation Commissionin 6 2 Connection 6 2 1 Electrical Connection Motor WARNING Work on electrical installations may be carried out by trained and authorised electricians only A WARNING Before beginning any electrical work on the G_100 or the system carry out the following steps for both the G_100 and the entire system switch off electricity lock against restart ensure absence of electricity ground and short circuit installation cover or bar adjacent live parts WARNING The connecting terminals must be installed such that they cannot be touched during operation must be surrounded by a housing which is proof against foreign bodies humidity etc Consider the life expectancy of the seals and gaskets must be separated by sufficient distances mind protruding wire ends WARNING Ensure that no foreign bodies humidity etc ente
28. on of Conformity Gardner enver EC Declaration of Conformity Gardner Denver Deutschland GmbH Postfach 1510 D 97605 Bad Neustadt Saale Manufacturer Product designation Gas Ring Vacuum Pumps Compressors of the 2BH10 series models 2BH10 02 AB32 2BH10 02 AB22 2BH10 02 _AA53 The designated product complies with the provisions of the following European Directives 98 37 EC Directive 98 37 EC of the European Parliament and of the Council of 22 June 1998 on the approximation of the laws of the Member States relating to machinery 89 336 EEC Council Directive 89 336 EEC of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility The following harmonised and national standards and specifications have been applied Harmonised standards EN ISO 12100 1 Safety of machinery Basic concepts general principles for design 2003 11 01 Part 1 Basic terminology methodology EN ISO 12100 2 Safety of machinery Basic concepts general principles for design 2003 11 01 Part 2 Technical principles EN 563 Safety of machinery Temperatures of touchable surfaces 1994 06 01 Ergonomics data to establish temperature limit values for hot surfaces EN 1012 2 Compressors and vacuum pumps Safety requirements 1996 04 01 Part 2 Vacuum pumps EN ISO 3744 Acoustics Determination of sound power levels of noise sources using sound pressure 1995 09 01 EN 60034 1 Rotating electrical machin
29. onnection is to be carried out according to the applicable national and local laws and prescriptions according to the applicable system dependent prescriptions and requirements according to the applicable prescriptions of the utility company Via the motor connecting cable the supply voltage as well as the different control signals are applied to the integrated electronics For the assignment of the leads or strands please refer to Fig 8 as well as the following table Fig 8 Connection of the integrated electronics type Lead colour Assignment Cable Cable old version new version pink red yellow black Gnd green green Ndes white white grey grey B blue blue Nact brown not connected red not connected Gardner Denver Deutschland GmbH 20 31 610 44431 40 000 Installation and Commissioning Symbol Description Level Lead colour Cable Cable old version new version Vcc DC operating voltage 24 V max 28 V pink red Gnd DC operating voltage OV yellow black reference potential for all signals Ndes Speed reference value 0 10 V DC green green Reference value of the desired speed of the ELMO G 2BH10 Nact Frequency output representing the Open collector blue blue actual speed max 24 V 10 mA open collector signal which must be wired to an external pull up resistor Output frequency motor speed ratio 1 Hz 10
30. pipe hose connections for tightness check fasteners for secure fixing Speed control During operation the speed of the G_100 can be modified This allows to adapt the operating point of the G_100 to changes in the operating point of the system In order to do so adjust the control voltage applied to Naes within a range of 0 to 10 V Gardner Denver Deutschland GmbH 25 31 610 44431 40 000 Servicin 8 Servicing N WARNING Before beginning to work on the G_100 or the system carry out the following steps for both the G_100 and the entire system switch off electricity lock against restart ensure absence of electricity ground and short circuit installation cover or bar adjacent live parts depressurise both pipes and pump WARNING Disassembly of the pump lid the pipe hose connections the guard in front of the motor only after the impeller and the rotor have come to a complete standstill Consider run out gt Disassembly of the bearing end housing is prohibited CAUTION Burning and scalding hazard due to hot surfaces of the G_100 Let the unit cool after shut down WARNING Do not reach into the G_100 through open suction or delivery branches Do not insert any objects into the G_100 through the openings CAUTION After loosening clampings and fastening elements some parts and components are only held in place by their centrings or seatings or are
31. r the motor interior The _100 is operated using an electronics for speed and direction of rotation control Depending on where this electronics is located inside or outside the G_100 two types of the G_100 are distinguished e for external electronics see section 6 2 1 1 2BH10 02 0AA53 e with integrated electronics see section 6 2 1 2 2BH10 00 0AB32 2 10 02 0AB22 In order to determine the type of your G_100 refer to the type number MLFB on the rating plate Gardner Denver Deutschland GmbH 14 31 610 44431 40 000 Installation Commissionin IMPORTANT The motor of the G_100 including its connecting leads must be protected against electrostatic discharge ESD Do not remove the ESD prevention bag surrounding the lead ends until right before carrying out the electrical connection attaching the connector connecting to a terminal strip or the like Carry out the electrical connection using the appropriate ESD prevention equipment 6 2 1 1 100 for external electronics With this type the electronics is located outside the G_100 It is connected via the electrical connecting cable IMPORTANT The main or operating direction of rotation of the G_100 is the counter clockwise rotation given by the arrow indicating the direction of rotation on the pump lid see p 12 Fig 4 5 Only with the counter clockwise rotation the nominal values will be achieved Clock
32. rt humming noise Qualified personnel No vacuum pressure or too little vacuum pressure generated Leak in the system Seal leak in the system Qualified personnel Wrong direction of rotation Reverse direction of rotation by applying the correct signals to the control signal inputs and see section 6 2 1 Electrical Connection Motor Electrician Speed reference value representing the desired speed Naes too low Adjust speed reference value Naes within a range of 0 10 V Qualified personnel Temperature of the electronics too high Provide sufficient heat dissipation and cooling Qualified personnel Compressor too small Use bigger compressor Operator qualified personnel Density of the pumped gas unequal 1 23 g m density of air at 15 C and 1013 mbar Use bigger compressor Operator qualified personnel Impeller dirty Clean impeller if worn have impeller replaced Qualified personnel after sales service Abnormal screeching noise Flow rate too high Increase pipe cross section clean pipe Qualified personnel Ball bearing damaged Replace complete casing i e the unit consisting of casing stator and two ball bearings After sales service Impeller leak Relative pressure between compressor and surroundings too high The permissible differential pressure between the pump interior
33. sition such as not to exceed the vibration values given in section 4 Technical Data for heat dissipation and cooling provide a minimum distance of 15 mm on each side except for the pump lid side on which a smaller distance of at least 2 mm is permissible in case of mounting using rubber metal elements see p 13 CAUTION Choose the place of installation the mounting surface of the G_100 so that there is no hazard of tripping or bumping IMPORTANT Do not install the G_100 close to heating surfaces No direct insolation 12 31 610 44431 40 000 CAUTION Lay the electrical connecting cable so that it might not be damaged by outer influences and is free from tensile stress Sound and vibration attenuation In order to reduce sound emission fasten the G_100 only to parts or components that do not conduct or emit sound easily e g thin walls plates Provide sound absorbing shims termed rubber metal elements available as accessories These are rubber pads placed between the four fixing lugs and the mounting surface and used to absorb Gardner Denver Deutschland GmbH 13 31 Installation and Commissionin IMPORTANT During operation the surface of the G_100 might have high temperatures of more than 100 C Temperature sensitive parts or components e g electrical wires or cables or electronic components must not be in contact with or fastened t
34. tatic discharge ESD Do not remove the ESD prevention bag surrounding the lead ends until right before carrying out the electrical connection attaching the connector connecting to a terminal strip or the like Carry out the electrical connection using the appropriate ESD prevention equipment The scope of supply of the external electronics Drivecontrol VT D includes a connnector with a 300 mm wiring harness to connect the Drivecontrol to the supply voltage and control voltage In order to meet the requirements bearing on electromagnetic compatibility a suitable EMI filter e g CORCOM Type 6ET1 10 must be connected in series with the external electronics The connecting cable between the EMI filter and the G_100 must have a length of at maximum 0 3 m Gardner Denver Deutschland GmbH 19 31 610 44431 40 000 Installation Commissionin 6 2 1 2 100 with integrated electronics With this type the electronics is located inside the motor IMPORTANT With the integrated electronics type G_100 the electronics is particularly sensitive to overheating It is imperative to ensure sufficient heat dissipation and cooling On delivery the integrated electronics type G_100 is not equipped with a connector at the connecting cable In this instance the operator can according to the requirements of the system connect a connector at his option connect the terminals to a terminal strip etc The electrical c
35. the suction and delivery pipes are not jammed e that all fasteners are properly tightened e that the correct voltage and current are applied Set the control voltage serving as speed reference and applied to Naes to 0 V at first Turn on the indicated operating voltage Now increase the control voltage serving as speed reference and applied to nges 0 to 10 V to your desired value or the value given on the data sheet By means of this speed control the operating point of the G_100 is adapted to the operating point of the system Check the connections for tightness ensure that there is no fluid leakage Gardner Denver Deutschland GmbH 24 31 610 44431 40 000 7 Operation WARNING Operation of the G_100 only with the pump lid assembled with the pipes hoses connected to the suction and delivery branches or incase of operation with open suction or delivery branches drawing in of gases from or discharge of gases into the surroundings with a piece of pipe or hose having a length of at least 120 mm connected to the branch in question with the bearing end housing IMPORTANT The G_100 must not be operated with the suction or delivery branches sealed up or jammed CAUTION Burning and scalding hazard due to hot surfaces of the G_100 Do not touch during operation WARNING Before start up and at regular intervals check pipes hoses and vessels for sufficient strength check
36. wise rotation is only permissible in special cases In this instance the 100 will not achieve its full output IMPORTANT The connecting cable between the G_100 and the external electronics must have a length of at maximum 0 5 m IMPORTANT When switching off the G_100 or rapidly reducing its speed a current feed into the mains might occur This can be prevented by inserting a diode Schottky diode size 10 A in the 48 V supply lead Ooo IMPORTANT Provide good cooling of the surroundings of the motor and the external electronics e g mounting on a good thermal conductor sufficient ventilation In case of temperatures of gt 50 C measured at the surface of the external electronics Drivecontrol the output power of the pump might be reduced Gardner Denver Deutschland GmbH 15 31 610 44431 40 000 Installation and Commissioning Purchasing the external electronics Drivecontrol along with the G_100 For the order no of this option please refer to our catalogue The design of the external electronics Drivecontrol is as follows Fig 5 External electronics block diagram of the control principle Mode of operation Output stage Speed controller generation Nees 1 1 1 PWM 1 1 1 1 Commutation logic 1 A Current measurement i Speed evaluation Gnd Rotor position
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