Gardner nver UVWIROUOAR Compressors Screw compressor CT 10-16 Operation and maintenance instructions Spare parts (© 1999 Gardner Denver OyDeclaration by the manufacturer (direktive 98/37/EY, Annex II B) Manufacturer: Gardner Denver Oy Address: Etu-Hankkionkatu 9 33700 Tampere Finland herewith declares that CT 10, CT 16 is intended to be incorporated into machinery or to be assembled with other machinery to constitute machinery covered by direetive 98/37/BY as amended; does therefore not in every respect comply with the provisions of this directives does comply with the provisions of the follo- wing other EEC directives. And furthermore declares that is not allowed to put the machinery into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of Directive 98/37/EY and with national implementing legislation, i.e, as a whole, including the machinery referred to in this declaration ‘Tampere 02.02.2000 (place) ° (date) ore Use ure) Jorma Koivula, Design Manager tion in Company Gardner Denver Oy P.O.Box 516 33101 Tampere FinlandSai Siver ‘O20 3000 List of contents To the user . Safety .... General safety instruction: Installation and preparations for use . Operation. Maintenance ‘The safety sigt Technical specifications Dimensions URLRRONNE Operating prin Compressor unit. Air compressing process . Oil circulation . . Capacity control. Instrument panel. Stocking, transporting and installing Stocking the compressor . Lifting the compressor. : Moving the compressor with a forklift truck. . Installing ...... : Installing location Electric connection .. Connecting to pressuriz Operation First start of compressor. . : Normal starting and stopping of compressor. Adjust of modulating ‘Temperature gauge Maintenance Procedures before starting maintenance . Procedures after maintenance .. Service chart. Adding oil and oil change - Replacing oil filter . Replacing air filter . Replacing oil separator element. Removing drive wheel and its mounting sleeve . Removing the sheave of the air end Installing drive wheel and its mounting sleeve . Installing the sheave of the air end . Testing safety valve . Troubleshooting chart Removing from service Oil recommendationGardner Senpenvet gna 3000 To the user GARDNER DENVER wishes you welcome among the users of screw compressors! ‘This manual instructs you in the correct operation, use, and service of your screw compressor. Read these instructions carefully before taking your serew compressor into use. This ensures correct preparations and use from the very beginning. Storing the books All the instructions in this manual have been provided to guarantee long life and reliable ‘operation of your screw compressor. Keep the manual always at hand near the compressor, and make sure that the compressor is ‘operated and serviced according to the instructions. ‘Terms of guarantee Acquaint yourself with the terms of guarantee for the compressor. The guarantee becomes void if the conditions are not observed. Do not exceed the maximum pressure, rotation speed, and capacity ratings of the compressor. ‘The guarantee is not valid if other than original spare parts are used. Always use the recommended oil types only. Carefully fill in the guarantee slip accompanying the compressor, and return it as instructed to the seller. Log book ‘Any repairs of the screw compressor should be left for trained, qualified service personnel authorized by Gardner Denver or its representative. After any maintenance or repair, always fill in the service log provided with the compressor. Inquiries When making inquiries concerning your screw compressor, always quote the complete type specification and the serial number as they are given on the type plate of the compressor. Use original spare parts only. mn and manuals of the Gardner Denver reserves itself the right to change the constru compressors without prior notice.San SiTe ‘02023000 Safety This chapter contains the general safety instructions concerning this compressor. Read also the safety instructions for transport, commissioning, use, and maintenance presented separately in each section of the manual. Always read the safety instructions before starting to work. In this manual, the instructions concerning safety are marked with the symbol: In addition to these instructions, the local regulations in your country may impose additional requirements that must be observed. General safety instructions Installation and preparations for use The compressor’s noise level, measured in an open space, may rise higher if the installing location is surrounded by walls that reflect sound, Observe this when choosing the best location for the compressor. Observe the local regulations on the use of hearing protectors. ‘Make sure that the intake air for the compressor is clean and cool. Prevent the exhausted air from recirculating to the intake. Make sure that foreign objects cannot get into the compressor with the intake air. Make sure that the intake air does not contain any explosive gases. Do not exceed the compressor’s rated maximum pressure, capacity, or rotation speed (Cf. Technical Specifications). Use pneumatic hoses that are rated to withstand the working pressure. Pay special attention to the hose mountings. A whipping hose may cause unpredictable damage. Remove the pressure in the hoses before disconnecting. ‘The pressure vessels in the pressurized air network must fulfill pressure vessel regula The electrical connection shall be made by authorised, qualified persons. There might be some oil in the water condensate. Notice the regulations concerning the oil remove. ions. Operation Do not blow pressurized air against the skin. Do not use the compressor with its doors open. ‘Use recommended oil types only. Do not mix different types of oil. Compressors with remote starting should be provided with a warning sign that indicates the method of starting. Do not use the compressor in explosive environment. Maintenance ‘Maintenance work on the compressor should always be done with the compressor stopped and disconnected from the mains. The shut-off valve to the pressurized air network should also be closed, Make sure that the air/oil receiver is pressureless before you start maintenance. Do not repair the container by welding. All alterations must conform to the regulations concering pressure vessels. Starting of compressors with remote control and in multicompressor use must be prevented while maintenance work is in progress. Do not neglect the regular check-ups and maintenance of the compressor. With the exception of the repairs described in this manual, all repair work should be carried out by company authorized by Gardner Denver.So Siva ‘The safety signs used on the compressor 2023000 © Read the operator's Hearing protection instruction must be worn [> Risk of hot surface Risk of electric shock > Compr. is remotely Risk of rotating controlled and may parts start without warning > Blow downTechnical spesification Capacity and power consumption Normal working pressure Capacity at normal working pressure Shaft power at normal working pressure Maximum working pressure Minimum working pressure Idling shaft power consumption Male rotor speed Transmission Cooling (without after cooler) Allowed ambient temperature Compressed air temperature above cooling me- dium temperature Air-cooled compressor Cooling air flow Dimensions of air outlet Max. cooling air pressure drop Cooling air temperature rise Motor and electrical values Main motor: F-class, IP54 Speed of rotation SOHz Speed of rotation __ 60H. Btizovon 02.02.2000 General technical data Oil quantity Oil content Air delivery pipe Noise level (Cagi Pneurop PN8NTC2.2, +3dB) Compressor weightNivea TIO ONITHS IO «19 LF1LNO UIV GaSS3uANOD now 069) _ Ty oe | 1 7 3 =H TaNvagonve | e_s ss HOS THT a [ g pe sg van Op ce - s + ji H083A3 - o| 0833 oe a NODRIVES TO l wait uIv To3 e ObLO ss x MW (© 1990 Gardner Denver Oy02033000, Operating principles Compressor unit Main components of the compressor unit: Air end body (1), two screw rotors (2,3) mounted on bearings in air end body (1) and inlet flange (4), and bearing cover (6). ‘The drive shaft is sealed with a shaft seal (5).‘O20 3000 Air compressing process In a screw compressor, the air is compressed in the compressor unit driven by an electric motor. The meshing rotors take in air between the ridges as they pass by the intake opening. When the rotors tur, the connection to the intake opening closes, and the space between the ridges starts decreasing. At the end of the compression phase, the desired pressure has been reached, and the connection to the receiver opens. ‘The air in the compressor unit is cooled by oil that is injected into the compressor unit. In the compressor unit, the oil cools the air and the compressor unit. In addition, the oil lubricates the bearings and seals the clearances between the rotors and the rotor housing.Gardner “Denver Seen 2000 Oil circulation From the air end the mixture of compressed air and oil mist is ducted into the oil separator, where the oil is separated from the air. The oil separation process is two-phase. Most of the oil is separated in a cyclone by centrifugal force, and the rest in oil separator clement (1). From the oil separator element the oil flows back to the circuit through return pipe (2). Orifice (3) restricts the backward air flow to the air end. On its way back into the air end, the hot oil flows through cooler (7) and oil filter (4). If the oil is cold, thermostat (5) in the oil separator directs it past the cooler. This forced oil circulation is maintained by the pressure difference between oil separator and air end. In order for the oil circulation to work whenever the compressor delivers air, there is an ‘output control valve (6) to prevent the oil separator pressure from dropping below the pre-set minimum (3 bar).‘02023000 Capacity control The system is designed to regulate compressor output according to use of compressed air, and this to minimize energy consumption per cubic metre of air produced. Production is stepplessly regulated from nought to maximum compressor output. Output is governed by opening or closing the intake valve. Pilot valve (1) automatically operates the intake valve trough monitoring output pressure and keeping it within a set range. Normally this range is Ibar, i. compressor output pressure may vary by Ibar depending on air consumption. When power unit is stopped, pressure release valve (2) opens and releases pressure in air/oil container. [Component Purpose Pilot valve ‘Opens and closes intake val Pneumatic valve Empties receiver at sto)Instrument panel 1, Network pressure gauge 2. Temperature gauge The compressor stops if the output air temperature reaches 115°C (Cf. the page 17). 10‘2033000 Stoc g, transporting and Stocking the compressor If the compressor is stocked for a long time, the stock room must be dry and warm. Is reasonable to slack or loosen the V-belts for the period of stocking. Lifting the compressor Notice the center of gravity of the compressor. Cf. dimensions drawing (p.5). Don’t go under the load.Gardiner “Denver 02.03.3000 Moving the compressor with a forklift truck A Observe special caution during lifting and transporting. A forklift pallet should be used. Installing Installing location 1. The compressor must be installed on an even surface, bearing in mind the compressor’s weight (Cf. Technical specifications). Observe the need for draining (oil separating well or a separate container) for condensate water. A ‘The water contains 2. Study the dimensional drawing for the required minimum distances to walls and other machines. 3. Make sure that the compressor room is properly ventilated. The cooling air temperature must not be higher than +40°C or lower than 0°C. Prevent recirculation of cooling ait. If the compressor is provided with air ducts, observe the required air volume and the max.pressure loss of the blower. Observe also the possibility to the cleaning of the coolers (Cf. Technical specifications). Notice that almost the whole input power of the compressor moves to the cooling air of the air cooled compressor. 4. Install the temperature gauge in place (if it’s delivered loose). Connect the safety functions of the temperature gauge (temperature alarm and stopping) Cf. separate instruction p.17. 12Gardner “Denver Electric connection (models with electric motors) 2023000 ‘The electric connections must made according to the IEC standards. All local safety regulations must also be observed. Make sure that the operating volatge is correct. The voltage must be as rated, 5%. Connect the power supply cable through the main switch of the compressor. Observe the power requirement (Cf. electric diagrams and technical data). Connecting the protective earth lead correctly is especially important. A Power supply connections are only See the connecting of the temperature gauge, separate instruction p.17 . lowed to qualified electricians. Connecting to pressurized air network Install a shut-off valve between the compressor and the network for maintenance purposes. Observe the minimum size of the network main pipe (Cf. Technical specifications). Use a flexible hose to connect the compressor to the network. If a piston type compressor is connected to the network, a pressurized air container must be installed between the piston and screw compressor, unless the volume of the network between them is big enough. If the pressurized air network include after-treatment devices (as a dryer), please connect to the distributor of Gardner Denver. B: = First start of compressor If the compressor has been stocked for a long time, check the functioning of the belt tightening. 1. Top up compressor oil to the upper limit of the receiver (Cf. oil recommendation and oil changing instructions). 2. Start the compressor for a second to check the compressor unit for correct direction of rotation (marked with an arrow on the compressor unit ). Do not run the compressor longer than 2 seconds. of rotation will damage the compressor unit. Wrong dire A The compressor unit’s direction of rotation must be checked always when the compressor is reconnected to the power supply network. 3. Start the compressor. 4, Adjust the operating pressure as required (Cf. separate instructions). 14Normal starting and stopping of compressor Starting Start the compressor. Stopping Push the stopping button. Before the restart wait about 1 minute to allow the receiver to empty. 15Adjust of modulating Output pressure can be regulated by turning the adjusting screw (B) on the valve. Locking nut (A) must be loosened before adjusting = turning the screw clockwise increases pressure and turning it anticlockwise lowers pressure. Tighten the locknut after adjustments! Do not exceed the compressor's specified maximum pressure (Cf. Technical data).Santer Temperature gauge 02033000 For temperature measuring the compressor is equipped with a temperature gauge. ‘At 100°C the temperature alarm lights and at 115°C the compressor will stop. 6 | | St <2 \ 4 ‘The safety functions; the temperature alarm (S1) and stopping (S2) are located in the temperature gauge. Connect them accordingly to these wiring diagrams, which are also on the side of the temperature gauge. The safety functions must absolutely be connected before taking the compressor into use. 7apse mngz3 3000 Maintenance Procedures before starting maintenance AX cantio : 1. Stop the compressor, and make sure that the receiver is pressureless. The blow-out function empties the receiver after stopping; wait 2 minutes. Hot surfaces immediately after stopping. 2. Turn power off and make sure that the compressor cannot be accidentally started, 3. Close the shut-off valve between the network and the compressor. 4, Open the safety valve cap 4-5 tums. Procedures after maintenance 1. Close the safety valve. 2. Open the shut-off valve between the network and the compressor. 3. Start the compressor. 18A mon Service chart " Correct lubrication of motor significantly lengthens the life of the bearings. ‘Always fill in the operating log. Have other maintenance work done by service personnel authorized by Gardner Denver. vice | Check oil level 1) Change oil, Replace oil filter a Replace oil separator cartridges Clean oil return pipe screen Replace air filters Clean cooler externally Check oil leaks ‘Check operation of safety valve - Check condition of hoses Fighten connections and screws _ Clean inside compressor Replace belts (el. motor | driven) _ Replace intake valve seals | Replace discharge valve seals_ _— Check and tight contactor and motor connections Check running tempera | ture _ Check the operation of stop contact of the ther- mometer - Lubricate electric motor | Cf. Motor manual! bearings __| Service electric motor__| 1) Check oil level when the compressor is stopped (wait until air and oil are separated). 2) At least once a year. 3) First time after 100 h. 4) Running hours <2000h. Note! The service intervals must be shorter in the very severe conditions. 19Gardner a Benver Adding oil and oil change “ae Use recommended oil types only. Do not mix different oils. ‘Watch out! The oil is hot right after compressor stop. Do not remove the filler plug when the oil separator is under pressure. Dispose of old oil according to the waste oil regulations. Adding oil 1. Take the precautions listed on page 18. 2. Remove filler plug (1) and pour in new oil until the upper limit of the level indicator is reached. 3. Put filler plug (1) back in its place. 4. Close safety valve (2) and open the shut-off valve between compressor and compressed-air system. Oil change 1. Run the compressor until the oil temperature is +40...50°C. 2. Take the precautions listed on page 18, 3, Remove filler plug (1). Open drain valve (3) and let the oil flow out. 4. Close drain valve (3) and top up the oil sump with fresh oil. 5. Put filler plug (1) back in its place. 6. Close safety valve (2) and open the shut-off valve between compressor and compressed. system, 20Replacing oil filter “_ Allow the compressor to cool down before the replacement. Dispose of the old filter according to the regulations on hazardous waste. Use original Gardner Denver oil filters only. 1. Take the precautions listed on page 18. 2. Use a protective cloth as some oil will escape when the filter is being removed. 3. To remove the oil filter, turn it counter-clockwise with the help of a straining strap. Mounting 1, Lubricate the seal of the new filter with oil. 2, Mount the filter by turning it manually clockwise. 2Gardner “Denver “02033000 Replacing air filter AN Allow the compressor to cool down before maintenance work. ‘The filter element cannot be reused or cleaned. 1. See page 18 for precautions before starting the work. 2. Remove the cover (1) and remove the old filter element (2). 3. Clean the cover on the inside. 4, Install a new air filter element (2) and the cover (1). Replace the preventive filter (3) after two years or after four air filter replacement. ‘The particle remover (4) always downwards. 22Replacing oil separator element Dispose of the old element according to the regulations on hazardous waste. A Allow the compressor to cool down before the replacement. 1. Take the precautions listed on page 18. 2. Remove output control valve (1). 3. Remove oil separator element (2). Mounting 1. Clean output control valve (1) and the contact surfaces of the oil separator. 2. Clean orifices (3) in the hose ends, 3. Clean strainer (4) and, if necessary, the oil separator. 4, Lubricate the O ring of the oil separator and mount a new element (2). 5. Replace the O ring (5) between oil separator and output control valve. 6. Replace the seals of the output control valve with a new set. When assembling the valve, leave nut M6 (6) about 2 mm off the valve cover. 7. Mount the assembled valve back in its place. 8. Tighten the screws alternately to equal tightness. 23Gardner. osc Removing drive wheel and its mounting sleeve ae Unscrew the screws (2 pes), and screw one of them into the removing hole. Tighten the screw evenly until the sleeve comes loose from the hub. The loosened wheel and the sleeve can be removed from the shaft by hand without hammering or otherwise damaging. Removing the sheave of the air end 1, Take the precautions listed on page 18. 2. The thread of fastening bolt (1) is left-handed. To remove the bolt, use an Allen key. Knock the key bar sharply with a hammer, holding the sheave in place by means of Gardner Denver clamping tool ID=034 769 18 or big circlip tongs. 3. Pull sheave (2) from the rotor shaft with an extractor. Protect the threaded hole in the shaft end. 4, Sleeve (3) comes off with the sheave. 5. Always replace both sleeve and shaft seal. Remove the sleeve from the sheave by knocking it with a drift through the three holes in the sheave. 6. Pull out shaft seal (4) with an extractor. Protect the threaded hole in the shaft end. 24Sania Installing drive wheel and its mounting sleeve eee 1, Remove all protective grease from the sleeve and the wheel hub. Install the sleeve to the wheel hub and align the holes. 2. Grease the two mounting screws (1) and tighten them lightly. The positions of the ‘mounting screws are shown in the illustration. The thread for mounting is in the pulley. 3. Clean the shaft and mount the wheel and the sleeve onto it. When mounting the wheel, remember that the sleeve fastens to the shaft first and, after this, the wheel moves still a little in relation to the sleeve. Observe this when aligning the wheels. 4, Tighten the screws evenly. 5. Knock the sleeve lightly with a drift, and retighten the screws. Repeat this a few times to make sure that the sleeve really sits tight. 6. Check the tightness of the screws from time to time. 7. Fill the extracting holes with grease to protect them from dirt. Sleeve | Tightening torque Nm Note! Sleeve type is marked on the end of the 1610 20 ~+Y Sleeve. 2012 31‘02073000 Installing the sheave of the air end 1 2 a4 1. Clean the shaft end and the seal housing carefully. 2. Apply Loctite $42 on the metallic outer surface of the shaft seal. Push the seal into the housing with a drift. 3, Push the sleeve on the rotor shaft with a drift. 4, Apply Loctite 601 thinly on the part of the sheave that will be inserted in the sleeve. Press the sleeve in place, and mount the sheave with the help of the fixing bolt. Hold the sheave in place with Gardner Denver clamping tool ID=034 769 18, and tighten the bolt to 80 Nm. 26Sapeiver seen. 3000 Testing safety valve Alll adjusting and repair work on the safety valve must be left for a qualified mechanic. (Observe the local regulations.) ‘The opening pressure of the safety valve ‘must be tested in a separate pressurized air line. ‘The operation of the valve can be tested by turning the cap (1) of the valve I - 2 tums counterclockwise. 27Troubleshooting chart COMPRESSOR FAILS TO | Main motor overload check motor temperature START No power supply —check fuses and voltage Compressor stopped Detect cause of overheating: because of overheating faulty thermostat — insufficient cooling air —high ambient temperature cooler clogged wrong oil type or low oil level INSUFFICIENT AIR OUT- |_Airfilter clogged ~replace PUT Oil separator clogged replace [Intake valve broken __| —repair or replace Blow-out valve broken ~clean or replace Leaks in network ___| 0°C) — min. 7mm?/s by running temperature of oil (= 55°C over the ambient temperature) = min. 180°C (open cup) In normal circumstances these conditons are fulfilled when using ISO VG 32...46 or SAE 10W...20W/20 oils. Before taking the oil in continuous use the following facts should be checked which have ef- fect on compressor operation: — running temperature (continuous over 90°C running temperature will half the normal oil change intervall for mineral oil) = oil consumption (high running temperature increases oil consumption) — if glogged oil separators ~ if varnish formation (affects the cooling and oil separation) Varnish formation can be seen on metal levels as a brown lacquer coating. Note! Different oil qualities must never be mixed together 30SECOMA se réserve le droit de mouiter sans préavis es caractérsiques techniques de cate notice, ‘SECOMA reserves the right to change speciation and/or design at any time without notice. BAO ROCIE SANDVIK TAMROCK SECOMA S.A. 19 avenue De Lattre-de-Tassigny - ZI B.P. 46 - 69881 MEYZIEU Cedex Tel : (83) 472 45 22 00 Telefax : (33) 478 31 79 80