UT1 2M90 704708 A Operation Manual en (Aeration Blower)

Appendix
8.30 4201-M10_BA_Aeration Blower A+B_EN_00

06_Appendix_LSP_1.0.fm Revision: 00
Operation and Maintenance Manual UT1-2M90-704708

Appendix
06_Appendix_LSP_1.0.fm Revision: 00
Operation and Maintenance Manual UT1-2M90-704708

Operating instructions
Aeration Blower A+B, 480Nm³/h

LSP Complex Project - Ash Handling System
Order No. Job No. Type KKS

1980079 4201-0-M10 GM 7 L 60-C-6178A, 60-C-6178B
60-CM-AS6102A, 60-CM-AS6102B
60-BL-AS6102A, 60-BL-AS6102B
GESTRA_RueckschlagKl_DB-Spring.fm Revision: 00
© FLSmidth Hamburg GmbH

Haderslebener Strasse 7
25421 Pinneberg
Germany
Tel.: +49 4101 788-0
Fax: +49 4101 788-140
E-mail: Hamburg@flsmidth.com
Internet: www.flsmidth.com
Translation of the original manual

13.01.2020
2 Compressor Unit 1
OPERATING INSTRUCTIONS
POSITIVE DISPLACEMENT BLOWER
DELTA BLOWER
Read the instructions prior to performing any task!

Keep for future reference!
202101_10 / 1236965
Translation of the original operating instructions

Order no.: 7535/1 Vietnam
Type: GM7L
Doc content: 1.02.2020
Print content: 24.02.2020
Series: GM 3 S - GM 150 S
GB
Aerzener Maschinenfabrik GmbH
Reherweg 28
31855 Aerzen
Germany
Telephone: +49 (0) 5154 81-0
Fax: +49 (0) 5154 81-9191
Email: info@aerzener.de
Internet: www.aerzen.com
DB G5 max. Doc, 1, en_GB
This manual was created by:

Technical documentation department of Aerzener Maschinenfabrik
GmbH
Technical editing and illustration
Heiko Nickel/Angela Pedack
© Aerzener Maschinenfabrik GmbH 2020
2 202101_10 / 1236965 26.02.2020

Table of contents
Table of contents
1 General Information............................................................ 8
1.1 Information about these instructions............................. 8
1.2 Explanation of symbols................................................. 8
1.3 Copyright protection.................................................... 11
1.4 Addresses................................................................... 11
1.4.1 Manufacturer............................................................ 11
1.4.2 Customer service..................................................... 12
2 Safety................................................................................. 13
2.1 Residual risks and fundamental risks......................... 13
2.1.1 Electrical hazards.................................................... 14
2.1.2 Hazards associated with the acoustic hood............. 16
2.1.3 Hazards at the installation site and operating site... 19
2.1.4 Mechanical hazards................................................. 22
2.1.5 Thermal hazards...................................................... 23
2.1.6 Risks from pressurised components........................ 24
2.1.7 Hazards due to hazardous substances................... 25
2.1.8 Risks from flammable substances........................... 26
2.1.9 Risks from supplier components.............................. 27
2.2 Intended use............................................................... 27
2.3 Foreseeable misuse................................................... 28
2.4 Responsibility of the operator..................................... 30
2.5 Replacement parts...................................................... 32
2.6 Requirements for personnel....................................... 33
2.6.1 Qualifications........................................................... 33
2.6.2 Unauthorised personnel........................................... 35
2.6.3 Training.................................................................... 36
2.7 Personal protective equipment................................... 37
2.8 Safety devices............................................................ 38
2.8.1 EMERGENCY STOP function................................. 38
2.8.2 Motor mount without lifting device........................... 41
2.8.3 Acoustic hood.......................................................... 41
2.8.4 Safety valve............................................................. 42
2.9 Safety classification.................................................... 42
2.10 Instruction signs........................................................ 44
2.11 Hazard area and controls area and/or display area.. 45
2.12 Securing the machine against restarting.................. 45
2.13 Environmental protection.......................................... 47
3 Design and operation....................................................... 48
3.1 Overview of assemblies.............................................. 48
3.2 Operating principle...................................................... 49
3.3 Operating modes........................................................ 49
3.4 Application ranges...................................................... 50
3.4.1 Operating information for pneumatic conveyance... 50
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Table of contents
3.4.2 Operating information for air-separation systems.... 50

3.5 Description of the assemblies..................................... 50
3.5.1 Intake side............................................................... 51
3.5.2 Machine stage......................................................... 51
3.5.3 Oil system................................................................ 51
3.5.4 Drive system............................................................ 52
3.5.5 Discharge side......................................................... 52
3.6 Control elements (optional)......................................... 53
3.6.1 Factory-installed control element............................. 53
3.6.2 Customer-installed control element......................... 53
3.7 Accessories................................................................ 54
3.7.1 Drive motor.............................................................. 54
3.7.2 Instrumentation........................................................ 55
3.7.3 Frequency converter................................................ 56
3.7.4 Soft starter (optional)............................................... 58
3.7.5 Operation with a pole-changing motor..................... 59
3.7.6 Discharge pressure gauge....................................... 59
3.7.7 Maintenance indicator.............................................. 59
3.7.8 Intake silencer.......................................................... 60
3.7.9 Discharge silencer................................................... 61
3.7.10 AERZEN safety valve............................................ 61
3.7.11 Non-return flap....................................................... 62
3.7.12 Belt drive................................................................ 62
3.7.13 Acoustic hood........................................................ 63
3.7.14 Bondal sheet.......................................................... 64
3.8 Required tools............................................................. 65
4 Transport, packaging and storage.................................. 67
4.1 Transport..................................................................... 67
4.1.1 Safety instructions................................................... 67
4.1.2 Type of delivery........................................................ 71
4.1.3 Packaging................................................................ 72
4.1.4 Transport inspection................................................ 74
4.1.5 Transport of packaged units.................................... 75
4.1.6 Transport to the installation site............................... 76
4.2 Storage and preservation........................................... 78
4.2.1 Storage.................................................................... 78
4.2.2 Preservation............................................................. 79
5 Set-up and installation..................................................... 82
5.1 Safety instructions...................................................... 82
5.2 Requirements for the installation site.......................... 84
5.3 Alignment and dowelling............................................. 85
5.4 Connecting the system pipeline.................................. 88
5.5 Connecting the drive motor......................................... 89
5.5.1 Preparing the connection......................................... 89
5.5.2 Routing cables......................................................... 90
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Table of contents
5.5.3 Connecting the drive motor...................................... 90

5.6 Connecting the earthing.............................................. 91
5.7 Laying the insulation mat............................................ 91
6 First commissioning......................................................... 92
6.2 Preparation for initial commissioning.......................... 93
6.3 Performing first commissioning................................... 97
6.3.1 Filling oil, version with oil system............................. 97
6.3.2 Establishing an electrical connection....................... 98
6.3.3 Handling the hinged motor support without lifting
device.................................................................... 100
6.3.4 Carrying out a test run........................................... 102
6.4 Performing checks after first commissioning............ 105
7 Operation......................................................................... 106
7.1 Safety instructions.................................................... 106
7.2 Shut-down in case of emergency............................. 107
7.3 Switching on............................................................. 108
7.3.1 Local control mode................................................ 108
7.3.2 Remote operation.................................................. 109
7.3.3 Automatic operation............................................... 109
7.4 Displaying operating parameters.............................. 109
7.5 Switching off.............................................................. 110
7.5.1 On-site operation.................................................... 110
7.5.2 Remote-controlled operation.................................. 110
7.5.3 Automatic operation............................................... 111
7.6 Decommissioning...................................................... 111
7.7 Measures for recommissioning................................. 111
7.7.1 Commissioning after maintenance work................ 111
7.7.2 Commissioning after fault rectification.................... 111
8 Maintenance.................................................................... 112
8.1 Safety instructions..................................................... 112
8.2 Maintenance plan...................................................... 115
8.2.1 Maintenance schedule for normal operation.......... 116
8.2.2 Maintenance schedule for arduous operating condi-
tions........................................................................ 119
8.3 Maintenance work..................................................... 121
8.3.1 First filling of lube oil.............................................. 122
8.3.2 Checking the oil level............................................. 123
8.3.3 Correcting the oil level........................................... 125
8.3.4 Replacing the grease on gas-tight drive shafts...... 127
8.3.5 Changing lube oil................................................... 129
8.3.6 Replacing the intake filter...................................... 132
8.3.7 Checking the belt pulleys....................................... 132
8.3.8 Replacing belts, version without lifting device ...... 133
8.3.9 Checking the AERZEN safety valve...................... 134
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Table of contents
8.3.10 Checking that sealing plugs have been removed 135

8.3.11 Checking the non-return flap................................ 136
8.3.12 Checking the inlet and exhaust air openings of the
acoustic hood....................................................... 136
8.3.13 Checking pipelines for leaks................................ 137
8.4 Cleaning after maintenance...................................... 137
8.5 Commissioning after maintenance........................... 138
8.6 Checks after maintenance work............................... 138
9 Faults............................................................................... 139
9.2 Fault diagnosis and troubleshooting......................... 142
9.3 Supplier status and fault messages.......................... 143
9.4 Commissioning after fault rectification...................... 144
9.5 Checks after fault rectification................................... 144
10 Disassembly and disposal............................................. 145
10.1 Safety instructions.................................................. 145
10.2 Disassembly........................................................... 147
10.3 Disposal.................................................................. 147
11 Technical data................................................................. 151
11.1 Dimensions and weights......................................... 151
11.2 Dimension specifications sheet............................... 152
11.3 Operating data........................................................ 153
11.4 Technical performance data.................................... 154
11.5 Rating plate(s) and their locations ......................... 155
11.6 Noise emissions...................................................... 158
11.7 Operating materials................................................. 159
11.7.1 Lube oil specifications.......................................... 159
11.7.2 Grease specifications........................................... 162
11.7.3 Lubricant quantities.............................................. 163
11.8 Paintwork................................................................ 164
11.9 Electrical information............................................... 165
11.9.1 Voltage fluctuations.............................................. 165
11.9.2 Earthing strap cross-section ............................... 165
11.9.3 Motor overload protection.................................... 165
11.10 Supplier components............................................ 166
11.10.1 Intake filter.......................................................... 166
11.10.2 Balancing grade................................................. 166
12 Notes on the Declaration of Conformity....................... 167
13 Glossary........................................................................... 168
14 Index................................................................................. 169
Appendix.......................................................................... 172
A AERZEN Declarations .................................................... 175
A.1 Declaration of Conformity ........................................ 177
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Table of contents
A.2 Declaration of Conformity PED ............................... 181

A.3 Declaration of Conformity EAC ............................... 185
B Safety Data Sheet ........................................................... 189
C Accessories .................................................................... 225
C.1 Drive motor .............................................................. 227
C.2 Motor data sheet ..................................................... 257
C.3 Safety valve ............................................................. 263
D Drawing ........................................................................... 323
D.1 Installation drawing ................................................. 325
D.2 Diagram ................................................................... 329
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General Information
Explanation of symbols
1 General Information
1.1 Information about these instructions
These instructions allow for the safe and efficient handling of this
machine. These instructions are an integral part of the machine
and must be kept in the immediate vicinity of the machine so that
they are accessible to personnel at all times. Keep these instruc-
tions in a safe place for future reference.
Personnel must read these instructions carefully and have under-
stood them before beginning work. A fundamental requirement for
working safely is compliance with all specified safety notes and
guidelines in these instructions.
In addition, the local occupational health and general safety regula-
tions apply to the machine’s range of applications.
The diagrams in these instructions serve to provide the user with a
basic understanding and may deviate somewhat from the actual
design.
The following is a list of additional, supplementary documents to

this instruction manual:
Declaration of Conformity CE MRL 1012-...

EAC
PED Safety valve
Installation drawing 4001018551
Diagram 4001020315
Instruction manual See list in the appendix
Drive motor
Instruction manual G4-002...
AERZEN Safety Valve
Lube oil safety data sheet SDB...
Project-related documentation See list in the appendix
1.2 Explanation of symbols

Safety instructions Safety instructions in this manual are illustrated using symbols.
The safety instructions are organised into signalling words which
designate the level of danger posed.
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General Information
DANGER!
This combination of symbol and signalling word
points to an imminently dangerous situation that
could be fatal or lead to serious injury if it is not
avoided.
WARNING!
points to a potentially dangerous situation that
could be fatal or lead to serious injury if it is not
avoided.
CAUTION!
could lead to minor injuries if it is not avoided.
NOTICE!
could lead to material damage if it is not avoided.
ENVIRONMENT!
points to a potential risk for the environment.
Safety instructions as part of oper- Safety instructions may relate to certain individual operating guide-
ating guidelines lines. These safety instructions are integrated into the operating
guidelines themselves so as to simplify the task of reading while
carrying out work. The signalling words mentioned above are used.
Example:
1. Loosen screw.
2.
CAUTION!
Pinch hazard on the cover!
Close cover carefully.

3. Tighten screw.
26.02.2020 202101_10 / 1236965 9

General Information
Tips and recommendations

This symbol draws attention to useful tips and rec-
ommendations as well as information about effi-
cient and trouble-free operation.
Special safety instructions To draw attention to exceptional hazards, the following symbols are
used as part of the safety instructions:
Warning signs Type of danger

Warning – automatic start-up.
Warning – hand injuries.
Warning – high-voltage.
Warning – explosive sub-

stances.
Warning – flammable sub-

stances.
Warning – hot surface.
Warning – danger zone.
Additional designations To draw attention to operating guidelines, events, listings, refer-

ences and other elements in this manual, the following designa-
tions are used:
Designation Explanation
Step-by-step operating guidelines
1., 2., 3. ...
References to sections of this manual and
to relevant documentation
Lists without a designated sequence
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General Information
Addresses > Manufacturer
Designation Explanation
[push-button] Control elements (e.g. push-buttons,
switches), display elements (e.g. signal
lamps)
„Display“ Screen elements (e.g. buttons, allocation of
function keys)
1.3 Copyright protection

The contents of this manual is protected by copyright. The use of
this manual is permitted within the framework of machine use. Any
other use is excluded unless there is written approval by the manu-
facturer.
1.4 Addresses
1.4.1 Manufacturer
Tab. 1: Manufacturer
Address Aerzener Maschinenfabrik GmbH
Reherweg 28
31855 Aerzen
Germany
Telephone +49 (0) 51 54 81-0
Fax +49 (0) 51 54 81-9191
e-mail info@aerzener.de
Internet www.aerzen.com
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General Information
Addresses > Customer service
1.4.2 Customer service

Our customer service staff are on hand to provide you with tech-
nical information:
Tab. 2: After sales service/service contact

Reherweg 28
31855 Aerzen
Germany
Service hotline +49 171 3 51 18 34
E-mail info@aerzener.de
In addition, we are always interested in receiving information and

feedback pertaining to machine use that could be useful in helping
us improve our products.
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Safety
Residual risks and fundamental risks
2 Safety
This section gives an overview of all important safety aspects rele-
vant to the protection of persons and to safe and fault-free opera-
tion. Further task-based safety instructions are contained in the
section on the individual phases of the machine’s service life.
Non-compliance with the handling and safety instructions provided
in this instruction manual can lead to serious hazards.
The following section outlines the residual risks and hazards during
the service life of the product that may arise as a result of non-
compliance with safety instructions or disabling of safety equip-
ment.
In order to reduce health and safety risks and to avoid dangerous
situations, the safety instructions and warnings in this instruction
manual must be observed.
2.1 Residual risks and fundamental risks

The following chapter states the general residual risks that have
been established on the basis of a risk analysis.
n Compliance with these safety instructions and the safety
instructions in the main chapters reduces the risk of personal
injury, property damage and environmental harm and prevents
dangerous situations.
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Safety
Residual risks and fundamental risks > Electrical hazards
2.1.1 Electrical hazards

Electric current
DANGER!
Risk of fatal injury from electric current!
Coming into contact with live parts poses an imme-
diate and potentially fatal risk of an electric shock.
Damage to insulation or individual components can
prove fatal.
– Work on the electrical system should only be
carried out by qualified electrical personnel.
– If the power supply’s insulation is damaged,
switch off the machine immediately and have
the damage repaired.
– Before starting to work on active parts of the
electrical systems and operating equipment,
ensure that the machine is completely discon-
nected from any power source and remains so
for the for the duration of the work.
When doing this observe the following 5 safety
rules:
– Disconnect the machine completely.
– Secure the machine against restarting.
– Confirm that the machine is completely dis-
connected from any power source.
– Ground and short-circuit the unit.
– Cover or shut off adjacent live parts.
– Never bypass or deactivate fuses.
– When changing fuses, comply with the correct
specified amperage.
– Keep moisture away from live parts. Moisture
can cause the machine to short-circuit.
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Safety
Residual risks and fundamental risks > Electrical hazards
Stored charges
DANGER!
There is a risk of fatal injury from stored
charges!
Electrical charges can be stored in electronic com-
ponents and maintained even after the deactiva-
tion and disconnection of the electric power supply.
Coming into contact with these components can
lead to fatal injuries.
– Observe all applicable safety rules.
– Before performing any work on the listed com-
ponents, disconnect them completely from the
power supply.
– Observe a waiting period of 15 minutes under
all circumstances! This will allow the internal
capacitors to discharge.
– Measure to ensure there is no live voltage!
Operating faults caused by short-

circuiting WARNING!
Risk of injury from operating faults!
If the electrical system short circuits this can render
the entire system inoperable. Operating faults can
lead to serious injuries.
– Connect the machine’s earthing connections
and acoustic hood to the local equipotential
bonding rail.
– Install a fault-current circuit breaker in order to
prevent sparks and contact voltage in the event
of a fault.
– After all work on the machine has been carried
out, ensure that the earthing connection and
equipotential bonding are connected correctly.
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Safety
Residual risks and fundamental risks > Hazards associated with the acoustic hood
2.1.2 Hazards associated with the acoustic hood

Within the acoustic hood
DANGER!
Risk of injury if the acoustic hood is open
during operation!
By opening the acoustic hood while the machine is
in operation, there is a risk of direct contact with
sources of danger, e.g. hot surfaces or rotating or
moving components.
– Never open the acoustic hood while the
machine is in operation or in stand-by mode.
– Never walk on or reach into the acoustic hood
while the machine is in operation or in stand-by
mode.
– Always lock the acoustic hood with the key pro-
vided and keep it locked.
– Only allow authorised personnel access to the
key.
Falling parts
CAUTION!
Risk of injury from unsecured parts of the
acoustic hood!
Unsecured parts of the acoustic hood can lead to
injuries if they fall from the machine.
– Secure loose elements against falling.
– Always wear protective gear.
– Have a second person help you.
Air flow at the air outlet

CAUTION!
Risk of injury from the strong air flow at the air
outlet of the acoustic hood!
Strong air flows at the air outlet on the acoustic
hood can suck in dirt particles from the environ-
ment and disperse them.
– Avoid standing in the direct vicinity of the air
flow.
– Wear safety glasses and a safety mask.
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Safety
Noise
WARNING!
Risk of injury from noise!
The noise level present at the installation area can
cause hearing damage. The magnitude of the
noise level is dependent on operating data, among
other factors.
– Never undertake measures to bypass or deac-
tivate sound insulation.
– Wear hearing protection while working.
– Only stand in the high-noise-level area if it is
absolutely necessary.
Risk of falling
CAUTION!
Risk of injury from standing on the roof ele-
ments!
Standing on the roof elements of the acoustic hood
carries with it a risk of injury from the potential col-
lapse of the roof elements. Persons could fall into
the internal area of the machine.
– Never stand on the roof elements of the
acoustic hood.
– Never exert force on the roof elements of the
acoustic hood.
Spark-generating work
WARNING!
Risk of fire, injury and material damage from
spark-generating work in the immediate vicinity
of the machine!
Welding or cutting work on the machine or in the
immediate vicinity of the machine can cause fire to
break out. This can result in material damage or
personal injury.
Sparks and incandescent or flammable objects
could be sucked in through the supply air openings
on the acoustic hood or through the intake silencer.
Sparks may be fanned by the fan of the acoustic
hood. The insulation material could begin to
smoulder.
– Avoid allowing sparks to fly in the direction of
the machine.
– Never carry out work that generates sparks
while the machine is in operation.
26.02.2020 202101_10 / 1236965 17

Safety
Risk of fire and injury

WARNING!
Risk of fire from easily-flammable materials
that are sucked into the machine!
Easily-flammable material, fluids or gases can be
sucked into the machine and cause it to catch fire.
This can lead to serious or fatal injuries.
– Never allow flammable materials to be sucked
into the machine.
– In case of emergencies, have extinguishing
agents (fire blanket, fire extinguisher, fire-extin-
guishing powder for fire classes A, B and C) at
hand.
– Immediately report suspicious materials, liquids
or gases to the responsible persons.
– In the event of fire, stop your work immediately
and make an emergency call.
Use of non-original belts

WARNING!
Risk of fire and injury from using non-original
belts!
If, for a number of possible reasons, the machine
is running sluggishly or is blocked, the belts may
slip if non-original belts are being used. This
results in strong heat generation which may lead to
a fire.
– Only use original belts from the machine manu-
facturer.
– Adhere to the designated belt type, as only this
type will have the required characteristics.
– Never select and use random belts.
– Activate motor overload protection and observe
the setting values.
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Safety
Residual risks and fundamental risks > Hazards at the installation site and operating site
2.1.3 Hazards at the installation site and operating site

Fehlende Absicherung
WARNING!
Risk of fatal injury due to missing protection
for the system provided by the customer!
The safety valves used by AERZEN serve to pro-
tect the machine. It is not permissible for these
safety valves to be used to protect the system pro-
vided by the customer. Neither sufficient relief nor
the requisite functional safety is ensured.
Non-compliance can result in life-threatening per-
sonal injuries and material damage to the system.
– The operator must ensure compliance with the
maximum permissible system pressure by
means of safety valves provided by the cus-
tomer, regardless of the safety valves used by
AERZEN.
– The operator must ensure sufficient relief for
the system.
Securing the machine against

restarting DANGER!
An unauthorised or unregulated restart can
have fatal consequences.
An unauthorised or unregulated restart of the
machine can lead to serious or fatal injuries. There
may be people located in the hazard area. Acti-
vating the energy supply and starting the machine
could result in those people being fatally injured.
– Prevent the machine from restarting by:
– disconnecting the electrical power supply
– activating the EMERGENCY STOP func-
tion.
– operating the main circuit breaker and dis-
connecting the machine from the power
source.
– attaching a padlock to the main circuit
breaker.
– ensuring that the machine is completely
de-energised and disconnected from the
power source.
– displaying a sign on the machine that pro-
hibits a machine start.
– displaying a sign on the control centre that
prohibits a machine start.
– Before restarting, ensure that safety devices
are installed and functioning correctly and that
there are no potential hazards to the safety of
any persons.
26.02.2020 202101_10 / 1236965 19

Safety
Water contact with live compo-

nents DANGER!
Risk of fatal injury from water contact with live
components!
Risk of fatal injury from cleaning work using water
in the vicinity of live components.
Water spray may enter electrical and electronic
components.
– Do not use water.
– Proceed carefully when performing cleaning
work. Water must not come into contact with
live components.
– Water spray must not enter electrical and elec-
tronic components.
– Never clean voltage-carrying areas with a high-
pressure jet.
Unexpected start-up
WARNING!
Risk of injury or personal shock if the machine
starts suddenly!
For example, a superordinate control system could
send a start command to the machine so that it
starts operating.
– Shut down the machine for all work and secure
it against restarting.
– If running the machine from a control room,
take precautions to prevent a restart there as
well.
– You must be prepared for the machine to start
at any time.
Sharp edges and corners

CAUTION!
Risk of injury from sharp edges and corners!
Sharp edges and corners can cause excoriations
and cuts to the skin.
– If working in the vicinity of sharp edges and
corners, proceed with caution.
– Wear protective gloves.
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Safety
Intake components
WARNING!
Risk of injury from intake components!
Intake side silencers suck in ambient air with great
force at their inlets.
– During operation, never place body parts or
objects in front of the inlet of the silencer.
– Maintain a safe distance from intake compo-
nents.
Sudden gas emission

CAUTION!
Risk of injury from sudden gas emission!
Components such as safety valves and start
unloading devices may open suddenly during oper-
ation and emit hot compressed gas. Dust particles
may be blown around.
– Never attempt to look inside the blow-off
opening.
– Wear safety glasses when in the immediate
vicinity of these components.
– Never close the blow-off opening.
– Always keep the blow-off opening clean.
Vibrations
WARNING!
Risk of injury from vibrations!
Vibrations may, in the long term, lead to injuries
and chronic damage to personal health. The vibra-
tion source is decoupled from the surrounding
environment by means of a vibration damper.
– Do not deactivate the vibration damper.
– Avoid coming into contact with vibrating areas.
26.02.2020 202101_10 / 1236965 21

Safety
Residual risks and fundamental risks > Mechanical hazards
Build-up of fluids
CAUTION!
Risk of injury from slipping as a result of a
build-up of fluids!
Slipping on fluids that have built up on the floor
area may lead to a fall. A fall may result in injury.
– Immediately remove built-up fluids with a suit-
able medium.
– Wear non-slip safety shoes.
– Place a warning notice and mandatory sign on
or in the vicinity of any area where there could
be a build-up of fluids on the floor area.
2.1.4 Mechanical hazards

Rotating components
WARNING!
Risk of injury from rotating components!
Rotating components may cause serious injury.
– During operation never reach into or perform
work on rotating components.
– Never open covers during operation.
– Observe the run down time: before opening
covers, make sure that no components are still
moving.
– When in a hazard area, wear tight-fitting pro-
tective work clothing with low tensile strength.
Fan
WARNING!
Risk of injury from rotating components of the
fan!
Rotating components of the fan can cause serious
injuries due to their high revolution speed.
– Prior to any work, switch off the machine and
secure it against restarting.
– Observe the run down time.
– Before opening covers, check that no compo-
nents are still moving.
– Never open covers or maintenance covers and
work on the fan during operation.
– The blade wheel must not be accessible during
operation.
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Safety
Residual risks and fundamental risks > Thermal hazards
Risk of crushing and shearing inju-

ries WARNING!
Risk of crushing and shearing injuries from the
hinged motor support!
Moving or adjusting the hinged motor support can
lead to a risk of injury.
– When transporting the machine, always have
the hinged motor support fixed in place.
– Never step or reach into the swivelling range of
the hinged motor support.
2.1.5 Thermal hazards

Hot surfaces
WARNING!
Risk of injury from hot surfaces!
Component surfaces may become very hot during
operation. Skin contact with hot surfaces causes
serious burns.
– For all work performed in the vicinity of hot sur-
faces, wear protective work clothing and pro-
tective gloves.
– Make sure all surfaces have cooled down to
ambient temperature before beginning any
work.
Hot media
WARNING!
There is a risk of injury from the sudden emis-
sion of hot media from the shut-off valve, e.g. a
safety valve.
The emission of hot media may lead to scalding.
– Never stand in the immediate vicinity of the
outlet vent.
– Never attempt to look inside the outlet vent.
– Never close or cover the outlet vent.
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Safety
Residual risks and fundamental risks > Risks from pressurised components
2.1.6 Risks from pressurised components

Pressurised components
WARNING!
Risk of injury from compressed conveyed
materials!
When disassembling pressurised components, or
in the case of a fault in a pressurised component
such as pipes, containers, hoses or valves, hot
conveying material can escape with a strong gas
flow. This can result in serious injury.
– Before beginning work, fully relieve pressurised
components of pressure.
– Check that components are not pressurised.
– Replace malfunctioning components immedi-
ately.
– Only disassemble pressurised components
when they are not under pressure.
Noise during disassembly

CAUTION!
Risk of injury from noise during the disas-
sembly of pressurised gas pipes!
When disassembling pressurised components
conveying material is released, resulting in noise.
This can cause hearing damage.
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Safety
Residual risks and fundamental risks > Hazards due to hazardous substances
2.1.7 Hazards due to hazardous substances

Hazardous substances
WARNING!
Risk of poisoning from hazardous substances!
Risk of skin irritation and allergic reactions!
Substances such as lubricants and cleaning
agents contain hazardous ingredients. These may
lead to serious poisoning, irritation or allergic reac-
tions.
– Observe the safety data sheets.
– Avoid shaking these substances and avoid
mist formation.
– If inhalation occurs, bring the affected person
out into fresh air immediately. Seek medical
help.
– If a substance is swallowed, seek medical help
immediately. The mouth must be rinsed out
thoroughly with water.
– Avoid contact with the skin and eyes:
Before working with these substances, apply
suitable hand protection cream.
Wear plastic or rubber protective gloves.
– Remove any dirt from the workspace properly
and in an environmentally-friendly way.
Lubricants and cleaning agents must not enter
the sewerage system or soil.
– When working with these substances do not
eat, drink or smoke.
Hazardous dust
WARNING!
Risk of injury from rising dust!
Dust deposits may rise during machine operation.
Inhaling this dust may, in the long term, lead to
lung damage or other health problems.
– Avoid the hazardous area.
– Wear light respiratory protection for any work in
the hazard area.
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Safety
Residual risks and fundamental risks > Risks from flammable substances
2.1.8 Risks from flammable substances

Fire hazard
WARNING!
Fire hazard from spark-generating work and
ignition sources in the immediate vicinity of the
machine!
Easily-flammable substances, fluids or gases may
catch fire and cause serious or fatal injury.
– Take measures to protect against the build-up
of steam in deep-lying or closed areas.
– Take measures to protect against electrostatic
pressure charging.
– Do not smoke in the hazard area or in the
direct vicinity of the machine.
– Do not use naked lights, fire or ignition sources
of any kind.
– Immediately report suspicious materials, liquids
or gases to the responsible persons.
– Have extinguishing agents (fire-extinguishing
powder) for fire classes A, B and C at hand.
– In the event of fire, stop work immediately.
Leave the hazard area until it is safe to return
and notify the fire brigade.
Improper fire protection

WARNING!
There is a risk of injury and material damage
from limited or improper fire protection!
If, in the event of fire, the fire extinguisher is not
operational or not suited to the specific class of
fire, there is a risk of serious or fatal injury and con-
siderable material damage.
– Ensure that only suitable fire extinguishers
(fire-extinguishing powder for fire classes A, B
and C) are at hand.
– Inspect fire extinguishers every 2 years to
ensure they are functioning correctly.
– Refill fire extinguishers after each use.
– Only use extinguishing agents and replace-
ment parts that correspond to the recognised
model specified on the fire extinguisher.
– In case of use, observe the safety and oper-
ating instructions on the fire extinguisher.
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Safety
Intended use
2.1.9 Risks from supplier components
WARNING!
Risk of injury from live, rotating and hot com-
ponents!
Electric motors feature dangerous live, rotating and
hot components. The removal of covers, improper
use of the motor, incorrect operation or insufficient
maintenance, can result in death, serious physical
injury or property damage.
– Only remove protective covers in accordance
with the applicable requirements and in compli-
ance with safety regulations.
– For the purposes of cleaning, maintenance or
repairs, take the motor out of operation in the
proper manner and in compliance with safety
regulations.
– Prevent unauthorised or unregulated restarts.
– Only use the motor as intended.
– Comply with maintenance intervals.
– Use contact protection for the operation of
rotating components.
– Allow components to cool before touching
them.
Source(s): Operating manual Drive motor /, Appendix C.1
2.2 Intended use

The positive displacement blower machine is intended for con-
veying and compressing air and non-flammable gases.
Fig. 1: Correct use
The positive displacement blower machine is intended for

operation with non-flammable gases in a non-explosive atmos-
phere.
The positive displacement blower machine has been designed

and constructed solely for its “intended use” in the industrial field,
as described here.
Observe and comply with the order-related operational data and
operational limits.
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Safety
Foreseeable misuse
This intended use also includes compliance with all information in

this instruction manual.
Any use beyond the intended use or any other type of application
is considered misuse.
Operating data that deviates from the standard

must be agreed with AERZEN.
2.3 Foreseeable misuse

Serious injury
DANGER!
Danger in case of misuse! Dangerous situa-
tions could occur that may lead to fatal or
serious injury!
– Never disregard the instructions for “intended
use”.
– Never operate the machine in an operating
area other than that intended.
– Never convey gases that are not listed in the
order confirmation and the technical data.
– Never disregard the following information on
misuse.
Serious material damage

NOTICE!
tions could occur that may lead to serious
machine damage!
use”.
– Never operate the machine in an operating
area other than that intended.
– Never convey gases that are not listed in the
order confirmation and the technical data.
misuse.
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Safety
Foreseeable misuse
Misuse
The machine is not intended for:

n Conveying media in solid, liquid or powder form.
n Conveying caustic media.
Fig. 2: Prohibited use n Conveying corrosive media.
n Conveying flammable or poisonous gases, vapours or mists.
n Alteration, retrofitting or modification of the overall design or
of individual equipment parts, with the aim of altering the field
of application or scope of use.
Further examples of misuse The following application ranges or operations and uses are con-
sidered improper and must be avoided!
n Operation:
– outside the scope of intended use
– outside the scope of the intended operating data
– with gases other than those originally intended
– with the machine operating in the incorrect direction of rota-
tion
– in a potentially explosive atmosphere
– with closed flange connections
– with missing or damaged components
– without a correctly connected control system, fault trans-
mitter, EMERGENCY STOP function
– without any or with damaged protective equipment
– with contaminated intake filter or starting strainer
– without sufficient ventilation of the room
– activation while coming to a stop or when rotating back-
wards
– pole changing to a lower rotational speed before the drive
motor has come to a standstill.
– non-compliance with maintenance intervals
– exceeding the maximum oil level
– ensuring the system pressure provided by the customer by
means of AERZEN safety valves
– using AERZEN safety valves as a safety-oriented compo-
nent in the system line
n Operation without:
– intake filter
– safety valve
– intake silencer
– oil
n Applications:
– using the machine to “purge” blockages in the conveying
pipes. for exceeding the maximum permissible discharge
pressure.
– using the safety valve to adjust operating data
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Safety
Responsibility of the operator
n Installation:
– Installation on inclined, sloped or lamellar surfaces
– Installation outdoors without due consideration of particular
protective measures for avoiding the effects of weather
conditions
– Attachment of transportation equipment to the acoustic
hood
– Open flames or spark formation in the immediate vicinity of
the machine
2.4 Responsibility of the operator

Owner The owner is the person who either operates the machine them-
selves, for commercial or business purposes, or who assigns the
use of the machine to a third party. During operation, the owner
holds legal responsibility pertaining to the product, for the protec-
tion of the user, personnel and third parties.
Operator’s obligations The machine is used for commercial purposes. The operator of the
machine is thus subject to the applicable legal obligations for occu-
pational safety.
Alongside the safety instructions in this manual, the safety, occupa-
tional and environmental regulations relevant to the field of applica-
tion for the machine must also be complied with.
The operator is obligated to:
n Inform themselves about the applicable occupational protection
regulations. As part of a hazard assessment, the operator must
also establish the hazards that could result from special
working conditions at the machine location. They must imple-
ment these for the operation of the machine in the form of
operating instructions. The necessary safety data sheets can
be obtained from the relevant manufacturer.
n During the entire service life of the machine, check that the
operating instructions created by the manufacturer correspond
to the current status of the applicable regulations. If necessary,
adjust the operating instructions accordingly.
n Clearly structure and specify the responsibilities for installation,
operation, fault rectification, maintenance and cleaning.
n Ensure that all persons who come into contact with the
machine have read and understood these instructions. In addi-
tion, the operator must regularly provide personnel training and
inform personnel of the related hazards.
n Provide personnel with the necessary protective equipment
and communicate to them that wearing this protective equip-
ment is compulsory.
In addition, the operator is responsible for ensuring that the
machine is in perfect technical condition.
For this reason, the following applies:
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Safety
n The maintenance intervals described in this instruction manual

must be complied with.
n All safety devices must be regularly inspected to ensure they
are in good working order.
Additional obligations of the owner The owner must ensure that the following requirements are com-
plied with and put into practice:
n The machine is only operated in its original delivered condition.
In cases where the operator adds his own fittings or makes
modifications, the manufacturer’s declaration of conformity is
rendered void.
n Any working behaviour that jeopardises the safety of the
machine is prohibited.
n The machine must always be kept in a technically-perfect and
operationally-safe condition. Replace damaged or non-opera-
tional components immediately. If in doubt, be sure to contact
the manufacturer or the responsible contact person.
n Do not operate the machine if the protective equipment has
been disassembled or disabled.
n Observe all warnings and notices displayed on the machine
and make sure they are readable. You must replace loose or
illegible signs. Ask the manufacturer for replacements.
n Install the separately provided components listed in the scope
of delivery onto the machine and incorporate these into the
overall safety concept.
n Do not disassemble or incorrectly fit any electrical, mechanical
or hydraulic connections.
n For protection against potential damage caused by lightning,
make sure a suitable earthing system is in place.
n If the conveyed medium tends to form condensate, the conden-
sate must be bled off (e.g. using discharge tanks, residual gas
pipes or by briefly opening the lower condensation holes).
n Separate dusty material before it enters the machine. Material
that collects in the conveying chamber or on the rotors pres-
ents a particular danger for the working safety of the machine.
Operator’s obligations at the instal- The owner must ensure that the following requirements are com-
lation site plied with and put into practice:
n Machine use only in a stable three-phase power supply.
Voltage fluctuations/drops beyond the tolerance level may
cause serious damage to the drive system.
n Motor overload protection muss be active.
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Safety
Replacement parts
n For system variants without a main circuit breaker featuring an

EMERGENCY STOP function, the safety circuit of the machine
should be incorporated into the EMERGENCY STOP concept
for the overall system. Ensure the accessibility of additional
EMERGENCY STOP switches in the vicinity of the machine.
The machine must be equipped with one or more EMER-
GENCY STOP command devices for the purposes of opera-
tion.
The EMERGENCY STOP function must be available and
operational at all times, independent of the operating mode.
n It must not be possible for a powered-down machine to start
automatically.
n For the purposes of operation, the machine must be equipped
with a command device that shuts down the machine in dan-
gerous situations.
In dangerous situations, the power supply to the motor must be
cut off.
If this is not possible, the “standstill” operating condition must
be monitored and maintained.
n Avoid electrostatic charges. Connect an equipotential bonding.
n For accidents and emergencies, incorporate emergency meas-
ures for the machine into the overall operational emergency
measures. Integrate these measures into the evacuation and
rescue plan and the fire warning plan.
n The owner must ensure compliance with the maximum permis-
sible system pressure by means of safety valves provided by
the customer. This is to be done independently of the safety
valves used by AERZEN!
n In emergency situations, the owner must ensure sufficient relief
for the system.
2.5 Replacement parts

Use of incorrect replacement parts
CAUTION!
Safety risk from using incorrect replacement
parts!
Incorrect, defective or unsuitable replacement
parts or copies of original components may
endanger personal safety and lead to damage,
faults or total failure.
– Only use the manufacturer’s original replace-
ment parts or parts approved by the manufac-
turer.
– If in doubt, always contact the manufacturer.
Purchase replacement parts from an authorised dealer or directly

from the manufacturer.
For contact information, see Customer serviceÄ on page 12.
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Safety
Requirements for personnel > Qualifications
Replacement parts Replacement parts that have not been supplied by AERZEN have
not been tested or approved. They do not correspond to the orig-
inal components. The use of such products can potentially have an
effect on the default design characteristics of the systems. The
manufacturer assumes no liability for damage resulting from the
use of non-original components.
2.6 Requirements for personnel

2.6.1 Qualifications
The various tasks described in this manual are associated with a
variety of requirements in terms of the qualifications of the persons
responsible for carrying out these tasks.
Insufficient qualifications
WARNING!
Risk if persons are not sufficiently qualified!
Insufficiently qualified persons are unable to gauge
the risks presented by the use of the machine and
put themselves, and others, at risk of serious or
fatal injury.
– Only allow work to be carried out by suitably
qualified persons.
– Observe the information on qualifications in
this manual.
– Keep insufficiently qualified persons away from
the operating range of the machine.
For the purposes of all work with this machine, only allow persons
who are expected to carry out their work reliably to do so. Persons
whose reaction times have been impaired, e.g. through drug or
alcohol consumption or medication, are not be permitted to work.
The follow section of this manual states the qualification require-

ments for persons carrying out the various tasks:
Authorised electricians
Authorised electricians, on the basis of their field-specific training,
expertise, experience and knowledge of the relevant standards and
requirements, are able to carry out their work on electrical systems
safely while independently recognising and avoiding hazards.
Authorised electricians are specially trained for the environment in
which they work and are familiar with the relevant standards and
requirements.
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Safety
Authorised electricians with additional qualifications

Authorised electricians have the additional qualifications needed
for working in the field of frequency converters and EMC. Author-
ised electricians are familiar with the relevant standards and
requirements.
Written documentation acts as proof of a completed safety instruc-
tional course and evidence of the necessary additional knowledge.
Due to their additional qualifications, these authorised electricians
are able to carry out work on electrical systems with frequency
converters and can independently recognise and avoid possible
hazards. The additional skills that constitute this qualification
should be taught through regular practical application.
Manufacturer’s customer service division

Certain work may only be performed by the customer service divi-
sion of the manufacturer. On the basis of its special, field-specific
training, expertise and experience, the customer service division is
up to the task of performing highly-skilled work.
The customer service division is a competent point of contact. It is
able to perform all work with the highest efficiency.
Service personnel
Service personnel are able to carry out their work on the basis of
their field-specific training, expertise, experience and knowledge of
the relevant standards and requirements. They recognise hazards
independently and avoid risks.
Service personnel in particular possess practical experience and
extensive field-specific expertise for the following activities:
n Transport
n Assembly/installation
n Commissioning
n Maintenance
n Fault rectification
n Disassembly
Depending on the designated job, additional qualifications are
required:
n Operation and handling of compressors
n Parameterisation of compressors
n Optimisation work within the permissible operating data range
Trained persons
A trained person has been expressly instructed and, if necessary,
trained on site by the responsible management about the tasks
delegated to them and the risks that are posed by improper behav-
iour. A trained person has been instructed regarding the necessary
protective equipment and protective measures. They are in a posi-
tion to work cautiously and to recognise hazards and react accord-
ingly. The trained person may not interfere with the handling and
operation of the machine.
Depending on the designated job, the person must have the fol-
lowing expertise:
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Safety
Requirements for personnel > Unauthorised personnel
n Transport and handling of packaged units.

n Ability to perform visual inspections of the machine.
User
The machine user is trained by the system operator in terms of
operation, maintenance work and basic fault rectification. They are
informed of possible operational hazards and improper behaviour.
Tasks that go beyond those for which the machine user is trained
or instructed may only be carried out if these tasks are listed in this
instruction manual and the operator has expressly designated
these tasks to the user.
2.6.2 Unauthorised personnel

Unauthorised personnel in the
installation area WARNING!
Risk of fatal injury for unauthorised persons in
the installation area!
Unauthorised persons who do not fulfil the require-
ments described here, are not familiar with the
hazards in the installation area. Therefore, unau-
thorised persons are at risk of serious or fatal
injury.
– Keep unauthorised persons away from the
installation area.
– If in doubt, instruct such persons to leave the
installation area.
– Stop all work as long as unauthorised persons
are in the installation area.
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Safety
Requirements for personnel > Training
2.6.3 Training
The operator must regularly provide safety training for personnel.
For tracking purposes, a training report must be drafted with the
following mandatory content:
n Date of training
n Name of the training participant
n Content of the training
n Name of the training instructor
n Signatures of the participant and instructor
Date Name Type of training Training Signatures

provided by
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Safety
Personal protective equipment
2.7 Personal protective equipment

Personal protective equipment is used to protect people from
adverse effects on safety and health when at work.
Personnel, when working near or with the machine, must wear the
personal protective equipment described separately in the indi-
vidual sections of this manual.
Description of personal protective The following is a description of the personal protective equipment:
equipment
Hearing protection (7010-M003)
Hearing protection serves to protect against hearing damage from
noise.
Industrial hard hat (7010-M014)

Industrial hard hats protect the head against falling or stray objects
and loads and from collisions against stationary objects.
Light respiratory protection (7010-M016)

Light respiratory protection protects against harmful dusts.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture
hazards or more serious injuries and from contact with hot sur-
faces.
They are oil-resistant and protect hands from coming into contact
with lubricants.
Protective work clothing (7010-M010)

Protective work clothing is tight-fitting work clothing with minimal
tensile strength, tight sleeves and without protruding parts.
Safety goggles (7010-M004)

Safety goggles serve to protect the eyes against flying particles
and splashing liquids.
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Safety
Safety devices > EMERGENCY STOP function
Safety shoes (7010-M008)

Safety shoes protect feet from being crushed, from falling objects
and from slipping on slippery surfaces.
2.8 Safety devices
Function of the safety devices

WARNING!
Risk of fatal injury from non-functioning safety
devices!
Incorrectly operated, non-functioning and deacti-
vated safety devices give rise to a risk of serious or
fatal injury.
– Before beginning work, check that all safety
devices are functioning correctly and are cor-
rectly installed.
– Never deactivate or bypass safety devices.
– Ensure that all safety devices are accessible at
all times.
2.8.1 EMERGENCY STOP function
The EMERGENCY STOP function serves, in cases

where there is a hazard or when one is averting a
hazard, to bring the machine quickly to a safe stop
(standstill).
Depending on the customer’s specifications, machine variants are

available with or without a power circuit breaker system.
Depending on the model, the machine:
n may not feature a control system
n may not feature an EMERGENCY STOP function
Before operating the machine:

Check whether the EMERGENCY STOP function is in place and
installed.
It must function perfectly.
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Safety
EMERGENCY STOP command

device
An EMERGENCY STOP command device includes a special com-
mand unit which is connected to the control system.
The EMERGENCY STOP function allows for the machine to be
shut down safely and immediately in case of a potential or existing
hazard.
The power supply to all turning components is interrupted immedi-
ately when the EMERGENCY STOP function is activated.
Fig. 3: Example of an EMERGENCY
It is also possible to install additional EMERGENCY STOP com-
STOP command device
mand devices.
Without a power circuit breaker n For this variant, an EMERGENCY STOP command device is
system not installed on the machine at the factory.
n The machine is delivered without an EMERGENCY STOP
apparatus.
n The owner must provide a power circuit breaker system with
electrical overload protection, an On/Off command unit and an
EMERGENCY STOP function.
n Activate Stop Category 0.
n Detail the performance data of the electrical installation in
accordance with the operating data of the motor. Take into con-
sideration the necessary data, for example: Voltage, current,
frequency.
n The connection to the power supply is made using the installed
and delivered power cabinet.
n The lines running to the power supply are fed directly to the
electric motor and are connected inside a terminal box.
n Feed the connection lead through the cable conduit to the ter-
minal box.
n Protect the motor against overheating.
n A main circuit breaker must be installed.
With a power circuit breaker n Depending on the model, an EMERGENCY STOP command
system device is installed at the factory in the power circuit breaker
system.
– If the factory-installed power circuit breaker system does
not feature an EMERGENCY STOP command device, this
must be provided by the operator.
Activate Stop Category 0.
–If the factory-installed power circuit breaker system does
feature an EMERGENCY STOP command device, Stop
Category 0 is performed.
n A main circuit breaker must be installed if it is not part of the
power circuit breaker system.
n The power supply is connected at the power cabinet.
n Observe the wiring diagram!
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Safety
Notes on installation by the oper- The EMERGENCY STOP device must:

ator
n be installed and integrated into the safety line of the system
controller.
n be clearly recognisable, highly visible and quickly accessible.
n shut down dangerous operation quickly without causing any
additional risks.
n if necessary, trigger specific safety measures or authorise the
triggering of safety measures.
n be installed in such a way that the machine user can activate it
immediately in an emergency.
n be designed in such a way that, in cases where there is an
interruption in the power supply or the power supply is acti-
vated after an interruption, no situations can occur in which
there is a threat of personal injury or material damage.
n supplement other protective measures without acting as a sub-
stitute for them.
Requirements for installation by The EMERGENCY STOP function must be available and opera-
the operator tional at all times, independent of the operating mode.
The EMERGENCY STOP facility must not require the entire
machine to be voltage-free. In situations where a risk is detected, it
must be possible for the user to stop the machine in order to pro-
tect against a hazard. For the purposes of a controlled shut-down,
electrical voltage may be necessary. The electrical system is still
under voltage.
If several EMERGENCY STOP devices are in place, all of these
devices must be able to shut down the machine.
The EMERGENCY STOP function must, after being triggered,
remain effective until authorisation is given for a restart.
It must not be possible to attempt to block the EMERGENCY
STOP device without a “stop” command being issued.
Ensure that it is only be possible to release the EMERGENCY
STOP device by means of authorised activation.
This authorisation must not cause the machine to start operating
again automatically but rather it should make a machine restart
possible.
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Safety
Safety devices > Acoustic hood
2.8.2 Motor mount without lifting device

1 DN50
2 DN80
The motor mount serves to protect against

mechanical hazards.
n The motor mount holds the motor hinge in place during trans-
port and assembly. It prevents uncontrolled movement of the
hinged motor support.
n When operating the machine, the motor mount must be
Fig. 4: Motor mount released and positioned accordingly.
2.8.3 Acoustic hood
The acoustic hood serves to protect against

mechanical and thermal hazards.
n The acoustic hood is an essential safety component of the

product.
n The elements of the acoustic hood must be locked with the cor-
rect key during operation and in stand-by mode.
n Operation with an open acoustic hood is not permissible.
n The locking key for the acoustic hood is a component of the
overall safety concept. Access to the key must only be possible
for personnel who have been briefed in the safe operation of
the machine and the contents of the instruction manual.
Fig. 5: Front view (example)
Fig. 6: Rear view (example)
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Safety
Safety classification
2.8.4 Safety valve

AERZEN safety valve
The safety valve is set at the factory.
If the set value is exceeded, the valve opens and releases excess
conveyed material into the atmosphere.
Fig. 7: Safety valve
2.9 Safety classification

The following symbols and notices are displayed on the machine.
They relate to the immediate vicinity in which they are located.
Unreadable signage
WARNING!
There is a risk from unreadable signage!
There is a risk of injury resulting from dirty or
illegible signs. It may be impossible to recognise
hazards and to follow the necessary operating
information.
– Keep all safety, warning and operating informa-
tion in a thoroughly readable condition.
– Replace damaged signs or stickers immedi-
ately.
Safety symbols and warning signs

The layout of warning signs involves a set of stickers affixed to the
machine. This includes the warning, instruction and prohibition
signs. Furthermore, signs relating to lubricants and their handling
are only visible when the acoustic hood is closed.
Fig. 8: Layout of warning signs
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Safety
Placement of the sticker set on the acoustic hood.
Fig. 9: Position on the acoustic hood.
Warning sign on the AERZEN safety valve.
Fig. 10: Position on the AERZEN

safety valve
Access for unauthorised persons

forbidden
Only persons given authorisation by the owner may enter the
hazard area.
Electrical voltage
Only qualified electrical personnel may work in the signposted
working area.
Unauthorised persons are not permitted to enter the signposted
working area or open the signposted cabinet.
Automatic start-up
The sudden start-up of operational machines in the rest position is
possible at any time.
Take heed of the stand-by mode! A sudden start is possible.
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Safety
Instruction signs
Hot surfaces
Hot surfaces, such as hot machine parts or system parts, con-
tainers or materials - but also hot liquids - are not always notice-
able. Do not touch them without protective gloves.
Hand injuries
Keep hands away from areas that carry this warning sign.
There is a risk that hands could be crushed, trapped or injured in
some other way.
Gas emission
Risk from sudden gas emission.
The opening of the safety valve results in the emission of gas and
accompanying noise emissions. There is a risk of hearing damage,
injuries to eyes or injuries to skin.
Pressure in the piping

Pipelines may be placed under pressure.
Before carrying out disassembly work, deactivate the pressure in
the pipelines.
2.10 Instruction signs

Wear hearing protection
In areas where this symbol is displayed there is a risk of hearing
damage. Therefore, wear hearing protection when in these areas.
Information on wearing hearing protection

< 80 dB(A) Hearing protection is not prescribed as
mandatory but should be worn as a matter
of personal responsibility.
80 to 85 dB(A) Hearing protection is recommended
> 85 dB(A) Hearing protection must be worn
Observe the instruction manual

Only use the labelled machine once you have read the instruction
manual.
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Safety
Securing the machine against restarting
2.11 Hazard area and controls area and/or display area

Hazard area
Controls and/or display area
The hazard area is located in the marked zone (in the acoustic
hood interior zone). It is not permitted to open acoustic hood ele-
ments and protective covers during operation. Opening is permis-
sible only for maintenance work or for troubleshooting and pro-
vided all safety precautions are observed. The controls and/or
display area is the position marked in green (example).
Fig. 11: Hazard area and controls

and/or display area (view from above)
2.12 Securing the machine against restarting

Sudden restart
DANGER!
may be people located in the hazard area. Acti-
vating the energy supply and starting the machine
could result in those people being fatally injured.
– Prevent the machine from restarting by:
– disconnecting the electrical power supply
– activating the EMERGENCY STOP func-
tion.
– operating the main circuit breaker and dis-
connecting the machine from the power
source.
– attaching a padlock to the main circuit
breaker.
– ensuring that the machine is completely
de-energised and disconnected from the
power source.
– displaying a sign on the machine that pro-
hibits a machine start.
– displaying a sign on the control centre that
prohibits a machine start.
– Before restarting, ensure that safety devices
are installed and functioning correctly and that
there are no potential hazards to the safety of
any persons.
EMERGENCY STOP button (option)

1. Press the EMERGENCY STOP button.
ð The power supply is shut off.
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Safety
Securing the machine against restarting
2. Activate the main circuit breaker.

ð The machine is free of current.
3. Attach a padlock to the main circuit breaker.
4. Ensure that the machine is completely de-energised and dis-
connected from the power source.
5. Inform supervisory personnel of work in the hazard area.
6. Place a sign on the machine and (where applicable) control
centre that notifies persons of the work being carried out in
the hazard area and forbids activation of the machine. The
sign must contain the following information:
n Shut-down on:
n Shut-down at:
n Shut-down by:
n Important: Do not switch on!
n Important: Only switch on the machine once it has been
ensured that there is no risk to personal safety.
EMERGENCY STOP feature (oper-

ator-installed) The particular approach to preventing a restart is
dependent on the operator-installed EMERGENCY
STOP feature.
1. Secure the machine against restarting in accordance with the

operator’s instructions.
2. Follow the instructions of the responsible supervisory per-
sonnel.
3. Once all work has been completed, check that there is no
risk to personal safety.
4. All safety devices and protective equipment must be installed
and fully functional.
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Safety
Environmental protection
2.13 Environmental protection

Environmentally hazardous mate-
rials ENVIRONMENT!
Improper handling of environmentally haz-
ardous materials presents a threat to the envi-
ronment!
Incorrect handling of environmentally hazardous
materials, particularly in the case of improper dis-
posal, can cause considerable damage to the envi-
ronment.
– Always observe the information below on the
handling of environmentally hazardous mate-
rials and their disposal.
– If environmentally hazardous materials are
inadvertently released into the environment,
take appropriate action immediately. If in doubt,
inform the responsible local authority about the
damage and seek advice on taking appropriate
measures.
The following environmentally hazardous materials are used:
Insulation material Damage to insulation material can release fibres that may lead to
accumulation of dust and dust residues. Skin contact with these
fibres can lead to an itching sensation.
Disposal is performed in conjunction with the applicable provisions
and procedures in the country in which the use or disposal takes
place.
Lubricants Lubricants such as greases and oils contain poisonous sub-

stances. They must not be released into the environment. Disposal
must be carried out by a certified waste management company.
Electronics Electrical and electronic components may contain poisonous mate-

rial. These components must be collected separately and depos-
ited at local collection points or disposed of by specialist compa-
nies.
Anti-corrosion agents Anti-corrosion agents may contain poisonous substances. They

must not be released into the environment. Disposal must be car-
ried out by a certified waste management company.
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Design and operation
Overview of assemblies
3 Design and operation

3.1 Overview of assemblies
Fig. 12: Acoustic hood with oil system

1 Intake side
2 Machine stage
3 Oil system
4 Drive system
5 Discharge side
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Operating modes
3.2 Operating principle

The medium to be conveyed is connected using an elastic rubber
sleeve or the compensator of the discharge-side connection
casing.
The medium to be conveyed enters through the intake silencer.
This offers the possibility of an intake-side pipe connection. There
is a replaceable filter element located inside the intake silencer.
Dirt levels in the filter element can be displayed using a service
indicator or the control system display.
The positive displacement blower conveys and compresses the
medium to be conveyed. The medium then flows through the dis-
charge silencer, via a non-return flap, into the customer’s system.
The positive displacement blower is powered by a drive motor
using a belt drive. The belt drive derives tension automatically from
the weight of the motor. The drive motor is powered by connecting
its power lines in the terminal box.
A safety valve is installed on the base support or on the connection
housing. The working pressure can be displayed by a pressure
gauge or in the control system screen.
The acoustic hood is ventilated by a fan.
3.3 Operating modes

On-site operation Operation of the machine is carried out directly on site.
Remote operation Operation of the machine is carried out via control station.
Automatic operation Automatic operation of the machine is carried out by sensors or a

system switch.
Load operation Load operation is the operating mode in which the machine pro-
cesses the specified operating data.
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Description of the assemblies
3.4 Application ranges

3.4.1 Operating information for pneumatic conveyance
Pneumatic conveyance When the machine is being used for the purposes of pneumatic
conveyance, pressure surges must not occur when switching
between different delivery lines.
Pressure surges can be prevented by making the switching
process for the intake-side and discharge-side valves take at least
five seconds. This pre-accelerates the gas column in the pipework.
The gas can no longer accelerate suddenly. This prevents damage
to the machine.
The distance between the switchover valve and the intake-side
flange must be at least 10 x DN. DN = nominal diameter of the
pipework.
This safety note applies to both positive pressure operation and
vacuum operation.
3.4.2 Operating information for air-separation systems

Air-separation systems When the machine is being used in air-separation systems with
alternating air-separation columns, pressure surges must not occur
when switching between different delivery lines.
Pressure surges can be prevented by making the switching
process for the intake-side and discharge-side valves take at least
five seconds. This pre-accelerates the gas column in the pipework.
The gas can no longer accelerate suddenly. This prevents damage
to the machine.
The distance between the switchover valve and the intake-side
flange must be at least 10 x DN. DN = nominal diameter of the
pipework.
This safety note applies to both positive pressure operation and
vacuum operation.
3.5 Description of the assemblies
For the purposes of explaining its functionality, the machine is

divided into several assemblies. Each assembly consists of a
number of components which, combined, perform a specific
machine function. A single assembly can consist of sub-assem-
blies and additional components.
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Description of the assemblies > Oil system
3.5.1 Intake side

3,410 Intake silencer, housing
3,470 Intake silencer, filter element
The intake-side assembly comprises the components of the con-
veying system's intake side. The intake-side assembly includes all
components fitted upstream of the machine stage gas inlet. The
conveyed medium is drawn into the machine stage by these com-
ponents. An intake silencer serves to reduce noise emissions. A
filter ensures clean intake gas.
Fig. 13: Intake side
3.5.2 Machine stage

100 Machine stage
The machine stage is the core of the machine and includes all
components for gas compression. The gas compression process
takes place in the machine stage.
Fig. 14: Machine stage
3.5.3 Oil system

The oil system contains all components necessary for providing
lube oil to the machine stage.
Fig. 15: Oil system
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Description of the assemblies > Discharge side
3.5.4 Drive system

1810 Motor
2110 Belt drive
The drive system comprises the drive motor and the drive ele-
ments, e.g. the belts and belt pulleys. The drive system provides a
high revolution speed for the rotational motion of the machine
stage.
Fig. 16: Drive system
3.5.5 Discharge side

610 Base support
4420 Safety valve
2710 Flexible pipe connection
The discharge-side assembly represents the components of the
discharge-side conveying system. The discharge-side assembly
includes all components fitted downstream of the machine stage
gas outlet. All components are pressurised during operation and
have hot surfaces. A discharge silencer serves to reduce noise
emissions.
Fig. 17: Discharge side with base sup-

port
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Control elements (optional) > Customer-installed control element
3.6 Control elements (optional)

3.6.1 Factory-installed control element
Factory-installed control element
Observe the AERtronic instruction manual.
The AERtronic instruction manual is included with the product.
Fig. 18: Operator interface

1 Information menu
2 Service display
3 Local/LOCATION/START
4 Local/LOCATION/STOP
5 Pressure ranges register
6 Temperature ranges register
7 Additional operating parameters register
8 Service and setup register
9 Selection buttons of the given display menu within a register
10 Graphic representation
11 Numerical representation
12 Bar graph display
13 Measurement value display
3.6.2 Customer-installed control element

Customer-installed control element
Depending on the machine model and version -
with or without a corresponding controller - the
control elements are not part of the scope of
delivery. The installation and design of the control
elements is then the responsibility of the customer.
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Accessories > Drive motor
3.7 Accessories
The accessories are the total collection of components belonging
to the machine or to the supplementary equipment.
3.7.1 Drive motor

Motor connection requirements
The cable and lead sheathing must be resistant to
the normal wear expected due to the movement of
the hinged motor support and the effects of con-
taminants in the atmosphere.
General requirements n Fine-core cable is recommended for the connecting lead.

n The connecting hardware must be suitable for the cross-sec-
tion and type of conductor to be connected.
n Depending on the size and output of the machine, it may be
necessary to remove the intake console and the acoustic hood
roof in order to connect the motor.
n Cables, leads and connection points must not be subjected to
excessive bending and tensile forces. Install the connecting
cable via a cable bridge (not included in the delivery) to prevent
the terminal box being subjected to forces or moments.
n Install cables and leads in such a way that they cannot sustain
any external damage.
n Avoid contact with the machine, excessive friction and exces-
sive radiant heat.
n The connecting cable must be resistant to light movements,
e.g. the changes in the speed of the motor.
Requirements for the mains supply

NOTICE!
There is a risk of material damage due to
voltage fluctuations/voltage drops.
Voltage fluctuations/voltage drops beyond the tol-
erance interval may lead to serious damage to the
drive system.
Requirements for operating rotary piston machines
with electric induction motors in a three-phase AC
supply system:
– Use suitable means of protection to shut down
the motor and safeguard it against an auto-
matic restart in the event of impermissible elec-
trical operating data.
– Observe the voltage and frequency
limits.Ä Chapter 11.9.1 „Voltage fluctua-
tions“ on page 165
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Accessories > Instrumentation
Connection n Only authorised electricians may perform the connection.

n Authorised electricians must observe all applicable regulations
when connecting the drive motor.
n Observe the tightening torques of the terminal screws.
n Secure all connections against inadvertent release or loos-
ening.
n Ensure that the nominal electrical data is complied with during
operation.
Circuit types n Star-delta connection

n Pole changing
n Speed control using a frequency converter
n Direct start
Permissible starting frequency up to 160 kW 6 starts per hour

from 200 kW 3 cold starts or 2 warm starts per hour
Refer to the instruction manual provided by the drive motor man-
ufacturer for further specifications and information.
3.7.1.1 Factory installation of the drive motor

Factory installation
Observe the information on the rating plate and in
the drive motor instruction manual.
Refer to the drive motor instruction manual for
electrical operating data, maintenance intervals
and suitable lubricants.
3.7.2 Instrumentation
The instrumentation consists of several assemblies.
n Pressure and temperature sensors in conjunction with the
AERZEN AERtronic control system.
n Switches for pressure and temperature in conjunction with dis-
play instruments.
Shut-down locking n The shut-down devices are set at the factory.

n All shut-downs must be self-locking. Once the shut-down has
been given clearance, the machine must not be able to start
automatically.
n Prior to a restart, the cause of the malfunction must be deter-
mined and eliminated. Start-up must then be performed man-
ually.
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Accessories > Frequency converter
NOTICE!
The switching points of the switches/sensors are
fixed and must not be changed.
Pressure and temperature switches If intake pressure, discharge pressure or discharge temperature
switches are used to safeguard the machine, the drive motor must
be switched off when the limit switch is triggered.
Contacts open ® Drive motor off.
Pressure switch (optional) It is also possible to use an additional pressure switch. A calibrated
gauge is used to adjust the switching limit point. The scale on the
switch only serves as a guide.
3.7.3 Frequency converter

For machine use, observe the fol- n If the motor is driven by a frequency converter, the motor must
lowing be approved for use with a frequency converter.
n Note the electrical and mechanical properties of the motor.
n To prevent bearing damage due to shaft currents being too
high, the motor needs to be protected by means of current-
insulated bearings on the B-side as of a certain size.
Motors supplied by AERZEN with a nominal power of at least
90 kW are always equipped with current-insulated bearings.
Note the specifications for the motor provided by the manufac-
turer.
n AERZEN recommends the use of input filters and output filters
(dv/dt filter, motor throttle, sinusoidal filter or common mode
filter).
These are specifically designed for the frequency converter.
They reduce reactions in the power supply system and filter
dangerous harmonics from the drive current.
This prevents damage to the motor winding and to the motor
bearings. The electromagnetic compatibility of the machine is
improved.
n The maximum permissible slew rate (dv/dt) must not exceed
the value 1,350 V/µs. Similarly, the peak voltage at the connec-
tion terminals must not exceed 1,350 V.
NOTICE!
Danger of insulation damage and motor failure if
the motor throttle or motor filter coil are not used!
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Accessories > Frequency converter
NOTICE!
– Proper installation ensures improvement in
electromagnetic compatibility and prevents
failure susceptibility.
– Proper connection can only be ensured if
shielded lines are used to connect the motor.
– Apply the shielding braid of the connection line
at earth potential on both sides and over a
large area.
– A low-impedance earthing of all metallic
system parts is required.
NOTICE!
– Use EMC cable glands and EMC shield clamps
designed for the connection cable.
– Connect further connection cables (e.g. PTC)
with shielded lines as well.
These measures must be specially adapted to the

respective frequency converter in accordance with
the manufacturer’s specification and be designed
for the relevant requirements.
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Accessories > Soft starter (optional)
NOTICE!
– The maximum current limit of the motor (nom-
inal motor current) must not be exceeded.
Observe the specifications on the motor’s
rating plate.
– Set the fixed minimum frequency specified by
AERZEN. This frequency must not fall below
the fixed minimum during operation.
– The maximum frequency is to be set by taking
into account the maximum motor speed and
the maximum machine speed.
– The changeover speed for the acceleration
ramp and deceleration ramp must not exceed
1 Hz per second during normal operation.
– The frequency converter must be designed
with a constant load torque for operation with a
working machine.
– The machine must shutdown without braking.
The activation of a brake ramp or quick stop is
not permissible. Free coastdown is required.
– To prevent operational faults the function “Inter-
ception circuit” must not be parameterised in
the control of the frequency converter.
– A restart lock must be activated when shutting
down the frequency converter.
A restart should only be possible after the
machine has come to a complete standstill.
3.7.4 Soft starter (optional)

Starter
Observe the soft starter instruction manual pro-
vided by the manufacturer.
n The soft starter must be designed with a constant load torque

for operation of a machine.
The use of a 2-phase, controlled soft starter is not recom-
mended.
n It is necessary to start the machine with reduced torque.
This depends on the machine type and version. It can be done
by a relief valve on the discharge side or with a start unloading
device, for example.
n The soft starter must be designed in accordance with the
machine’s start-up curve.
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Accessories > Maintenance indicator
3.7.5 Operation with a pole-changing motor

When operating with a pole-changing motor, observe the following:
n If no control technology is used, the drive motor needs to have
reached zero speed each time the motor speed changes from
a high to a low speed.
n Changeover from a low to a high speed can take place directly
and instantaneously.
3.7.6 Discharge pressure gauge

Positive pressure mode
The gauge displays the discharge pressure of the compressed
gas.
It is a display instrument without a switching function.
The gauge is connected on the discharge side.
Fig. 19: Pressure gauge
3.7.7 Maintenance indicator

Positive pressure mode The maintenance indicator shows the dirt levels in the intake filter.
The maintenance requirements of the intake filter depend on the
dirt levels of the medium taken in.
Replace the filter element when the following display values are
reached and no later:
At -45 mbar (red display field), replace the intake filter.

After the filter has been changed, reset the pointer to its initial posi-
tion by “pressing” the reset button.
Fig. 20: Version a)
When the level of contamination increases, the red trailing pointer

will be pulled over with the black pointer and stay at the maximum
intake pressure.
Replace the filter element when the trailing pointer reaches the red
area of the scale.
Once the filter has been replaced, reposition the trailing pointer
between 0 and -10 mbar.
Fig. 21: Version b)
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Accessories > Intake silencer
The yellow indicator piston moves in 12 stages as the contamina-

tion level increases.
Replace the filter element once the yellow indicator piston has
reached the area marked red.
Reset the display by pressing the pushbutton on the maintenance
indicator.
Fig. 22: Version c)
The red indicator piston engages once the maximum contamina-

tion value has been reached.
Replace the filter element if the engaged indicator piston can be
seen in the inspection window.
Reset the display by pressing the pushbutton on the maintenance
indicator.
Fig. 23: Version d)
3.7.8 Intake silencer

Intake silencer
The intake silencer contains the intake filter. The intake filter pre-
vents harmful particulate matter entering the conveying chamber of
the machine.
The intake filter corresponds to filter class G4.
NOTICE!
Risk of machine damage! Never operate the
machine without the intake filter.
Fig. 24: Open intake silencer with filter
Machine damage caused by the

intake filter NOTICE!
There is a risk of machine damage from the use
of contaminated, damaged or non-original
intake filters!
Heavily contaminated or damaged intake filters
reduce performance. They affect functionality and
may cause machine failure. Copies and reproduc-
tions of intake filters do not have the necessary
properties.
– Inspect for damage.
– Comply with maintenance intervals.
– Only use original replacement parts.
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Accessories > AERZEN safety valve
3.7.9 Discharge silencer

Discharge silencer
The base support serves as the base for the whole bodywork of
the machine. The base support also acts as a discharge silencer.
The discharge silencer is an absorbtion-agent-free component.
The acoustic energy inside the discharge silencer is reduced by
means of air deflection.
Fig. 25: Discharge silencer
3.7.10 AERZEN safety valve

AERZEN safety valve
Note the instruction manual for the safety valves. It

is included with the product.
The safety valve is used for the conveyance of air.

The safety valve is set at the factory.
If the set value is exceeded, the safety valve opens and releases
excess conveyed material into the atmosphere.
Fig. 26: Safety valve
The safety valve is NOT a control component and is not to be used
as such.
The safety valve can be used up to a temperature of 200°C.
NOTICE!
Risk of premature wear and failure!
The safety valve is not intended for controlling the
operating data!
Disabling the safety valve, e.g. by setting a higher
opening pressure, can cause serious material
damage.
The outlet of the safety valve must not be made
narrower or closed. Keep the cross-section unob-
structed!
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Accessories > Belt drive
3.7.11 Non-return flap

Non-return flap
The non-return flap prevents the machine stage from running in
reverse and stops gas from escaping after a shut-down.
Fig. 27: Non-return flap
3.7.12 Belt drive

Belt drive
The sheaves are mostly fitted and aligned in the factory.
The sheave for the machine stage is fitted to the drive shaft. The
position and orientation of this sheave therefore affects the align-
ment of the drive motor pulley.
Check the alignment:
n Before first commissioning
n According to the maintenance plan
n After replacing the pulley(s)
Fig. 28: Belt drive The maximum permitted sheave offset is 0.5 mm.
It is extremely important that only original replace-

ment parts be used for the purposes of belt-pulley
operation!
Only use replacement and wear parts that are rec-
ommended and approved by AERZEN!
Original replacement parts

NOTICE!
Risk of material damage!
Pulleys must only come from one manufacturer
and from one production batch.
– Otherwise varying belt tensions can occur
which can result in uneven running and prema-
ture wear.
– As a result of a risk of snapping, the sheaves
must be suitable for the peripheral speed
encountered!
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Accessories > Acoustic hood
3.7.13 Acoustic hood

Acoustic hood
The acoustic hood serves to reduce noise and acts as a guard.
The acoustic hood is a component designed for product safety with
lockable door elements.
Always keep the acoustic hood closed during operation.
The key must only be accessible for authorised personnel.
An earthing strap or threaded hole is located on the outer edge of
the floor tray.
Fig. 29: Acoustic hood, version dia-

gram
Lock
Operation with an open acoustic hood is not per-
missible!
– Always lock the elements of the acoustic hood
with the key provided.
– The key must only be accessible for authorised
personnel.
Fan The acoustic hood is ventilated by a fan.

The fan is connected at the factory. The fan must be activated in
parallel with a machine start.
Intake from a pipeline The acoustic hood makes intake-side machine suction possible
from the system pipeline.
The pipeline is guided through the acoustic hood to the machine
through prefabricated openings.
The following steps must be complied with: Ä Chapter 5.3 „Align-
ment and dowelling“ on page 85
Acoustic hood heater

NOTICE!
There is a risk of material damage from low
ambient temperatures!
If there are temperatures of below –10 °C in the surrounding area,

provide an acoustic hood heater!
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Accessories > Bondal sheet
This prevents damage to the machine by heating up the housing

and preheating the lube oil and medium to be conveyed.
3.7.14 Bondal sheet

Bondal sheet
If the machine is installed on an open steel structure, a Bondal
sheet needs to be used as the base.
NOTICE!
The Bondal sheet protects the machine from
damage.
Fig. 30: Bondal sheet
Dimensions Nominal diameter Profile dimensions Weight

Discharge nozzles H x W x D (mm) (kg)
DN 50 805 x 805 x 12 51
DN 80 935 x 1,145 x 12 85
DN 100 1,255 x 1,355 x 12 134
DN 125 1,255 x 1,355 x 12 134
DN 150 1,505 x 1,805 x 12 214
DN 200 1,750 x 2,105 x 12 291
All threaded holes are M12.
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Required tools
3.8 Required tools

The following tools are required:
Auxiliary materials, tools
e.g. receptacle for oil, drain hose, cleaning cloth.
Conveyor rails
The conveyor rails must be made of steel. They act as slide-in
modules in the forklift tunnel of the acoustic hood. The cables are
pulled by the conveyor rails and joined above the machine using
the lifting beams.
Drills
Drills for making fastening holes.
Electric drill
Electric drill, e.g. for drilling fixing holes.
General measurement tools and equipment

For example a steel ruler, plumb line, folding yardstick, spirit level.
General tools
For example various screwdrivers, a combination key, socket driver
set, Allen key set, hammer.
Hinged motor support lifting equipment

This lifting equipment is a steel profile for mounting the hinged
motor support. It provides power transmission for lifting and low-
ering the hinged motor support with a hydraulic lift.
Hydraulic lift
The hydraulic lift is a lifting device for lifting the hinged motor sup-
port to enable the installation or change of a belt. Only use the
hydraulic lift on solid, level ground.
Lifting beams
Transverse truss required for crane transport for absorbing cable
force.
Lifting equipment
For lifting loads, e.g. ropes, belt anchorages, shackles, eyebolts
with nuts.
Locking key
The locking key is a component of the overall safety concept. This
must be stored safely and should only be made accessible to
trained personnel. It is intended for the proper opening and closing
of the acoustic hood elements.
Oil funnel
The oil funnel is used for the precise filling of lubricant oil.
Test pump
The test pump is used to simulate system pressure in the meas-
urement lines during commissioning. This allows for the operation
of the pressure switch or the pressure sensors to be checked.
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Required tools
Tools for authorised electricians

Basic electrical engineering equipment, e.g. multimeter, voltage
detector, insulated tools.
Transport equipment
For transporting packaged units and the machine, e.g. with lift
trucks, forklifts.
Transport securing rod

The transport securing rod serves to fix the hinged motor support
in place during transport. It also serves as lashing equipment for
the hinged motor support during lifting to relieve and, if necessary,
support the hydraulic lift. The transport securing rod must be
removed for the machine to be operated.
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Transport, packaging and storage
Transport > Safety instructions
4 Transport, packaging and storage

4.1 Transport
4.1.1 Safety instructions
Improper transport
WARNING!
Risk of injury from improper transport!
Improper transport may result in personal injury.
– Proceed with caution upon delivery, when
unloading the machine and during in-house
transport.
– Observe the symbols and information on the
packaging.
– Only use the intended anchorage points.
– Observe the centre of gravity.
– Attach lifting equipment accordingly and hang
the load so that it is balanced.
– Do not remove the packaging until just before
installation of the machine.
Improper transport
NOTICE!
Risk of damage from improper transport!
Improper transport may result in considerable
material damage.
unloading the machine and during in-house
transport.
– Only use the intended anchorage points.
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Industrial trucks
WARNING!
There is a risk of fatal injury from industrial
trucks!
Transport with industrial trucks can result in objects
and other loads falling accidentally and causing
serious or fatal injury. There is also the risk of the
driver failing to see persons and running them
over.
– Industrial trucks should only be operated by
trained drivers (e.g. forklift drivers).
– Only walk past an industrial truck if the driver
has signalled that he has recognised the
person in his path.
– Only use approved industrial trucks with suffi-
cient load carrying capacity.
– Never transport materials over persons or the
areas in which persons are located.
Suspended loads
WARNING!
Lethal danger from suspended loads!
During lifting work, loads may swing out and fall.
This can result in serious or fatal injury.
– Never walk under or into the range of a sus-
pended load.
– Move loads under supervision only.
– Observe lifting points.
– Ensure that the lifting slings are fitted securely.
– Do not hang lifting equipment on protruding
machine parts or on the lugs of attached com-
ponents.
– Only use approved hoists, load handling equip-
ment and lifting slings with sufficient load car-
rying capacity.
– Do not use damaged load handling equipment
such as chains, ropes or pulleys.
– Do not lay load handling equipment across
sharp edges or corners and do not tie or twist
them.
– Set down the load when leaving the work area.
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Disregard for the machine’s centre

of gravity WARNING!
There is a risk of the unit toppling and falling
over if there is disregard for the machine’s
centre of gravity!
If the machine’s centre of gravity is disregarded,
the packaged unit may topple and cause life-
threatening injury.
– Observe the packaging information on the
machine’s centre of gravity.
– Attach lifting equipment in such a way that it is
located above the centre of gravity.
– Raise the load carefully and ensure that it does
not topple. If necessary, change the position of
the lifting equipment.
Risk of slipping
CAUTION!
Risk of injury due to slipping on the packaging
foil!
The packaging foil features a slippery surface that
can cause persons to slip on it. Moisture, creases,
edges and tension straps on the packaging foil
entail a risk of slipping or stumbling. The pack-
aging foil is not suitable for supporting weight. A
fall may result in injury.
– Never stand on the packaging foil.
– Never lean on the packaging foil or use it for
support.
Requirements for personnel Requirements for transport:

Transport of packaged units
Personnel: n Trained persons
Transport of unpacked machines

Personnel: n Service personnel
Requirements for personnel When checking storage criteria, you require the following:
When checking and applying preservation, you require the fol-

lowing:
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Protective equipment Requirements for transport:

Protective equipment: n Protective work clothing (7010-M010)
n Safety shoes (7010-M008)
n Protective gloves
Protective equipment Preservation requires:

Protective equip- n Protective work clothing (7010-M010)
ment: n Safety shoes (7010-M008)
n Protective gloves
n Light respiratory protection (7010-M016)
Special tools Requirements for transport:
NOTICE!
Risk of damage to the machine! Chains, steel
cables and similar equipment are not suitable
lifting equipment.
Special tool: n Lifting equipment

n Transport equipment
Special tool: n Lifting beams

n Locking key
n Conveyor rails
Dimensions of the conveyor rails
Nominal diameter Profile dimensions Profile length

Discharge nozzles H x W x D (mm) (mm)
DN 50 80 x 60 x min. 4 950
DN 80 80 x 60 x min. 4 1,285
DN 100 100 x 80 x min. 4 1,870
DN 125 100 x 80 x min. 4 1,870
DN 150 120 x 80 x min. 6 2,520
DN 200 120 x 80 x min. 6 2,520
Fig. 31: Rectangular hollow profile
Material: S 235 JR
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Transport > Type of delivery
Nominal diameter Profile dimensions Profile length

Discharge nozzles H x W x D (mm) (mm)
DN 250 120 x 80 x min. 8 2,750
DN 300 120 x 80 x min. 10 3,350
Material: S 235 JR
The profile length must be at least 150 mm longer

than the dimensions of the acoustic hood.
4.1.2 Type of delivery

4.1.2.1 Delivery of the machine
The machine is shipped using a freight forwarder. In accordance
with the given requirements the machine is sealed in foil and may
be additionally packed in wood.
Transport on a truck
1. Lash the package to the truck as shown in the diagram.
2. Always use appropriate edge protection to avoid damage to
the package.
Fig. 32: Lashing down the machine
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Transport > Packaging
4.1.3 Packaging
4.1.3.1 Symbole auf der Verpackung
Symbols on the packaging
The following symbols are displayed on the packaging. Always
observe these symbols during transport.
Fig. 33: Symbols on the front/rear side
Explanations
Centre of gravity
1. Displays the centre of gravity and weight of the machine.
Observe the location of the centre of gravity for lifting work
and transport.
Fig. 34: Centre of gravity
Forklift lifting points

2. Only lift transport items at the lifting points marked with this
symbol.
Fig. 35: Forklift lifting points
Transport on a truck
3. Lash the package to the truck as shown in the diagram.
4. Always use appropriate edge protection to avoid damage to
the package.
Fig. 36: Transport on a truck
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Explanations Comply with the order (pos.1-pos.3) of the work stages.

Transport without a palette
1. Open the operating side of the acoustic hood (pos.1).
2. Open the rear side of the acoustic hood (pos.2).
3. Separate the machine from the transport pallet by removing
the fastening screws.
4. Drive the fork of the forklift under the machine (pos.3).
WARNING!
Risk of injury if the machine topples or falls!
Observe the machine’s centre of gravity.
5. Determine the machine’s centre of gravity by raising it care-

fully.
Fig. 37: Transport without a palette 6. Transport the machine so that it is balanced. The machine
must not lean to one side.
7. Remove the lifting equipment at the installation site.
4.1.3.2 Handling packaging

Handling packaging The individual packaged items are packed in accordance with the
anticipated transport conditions. In as far as it is possible, environ-
mentally-friendly materials are used for the packaging.
The packaging is intended to protect individual components from
transport damage, corrosion and other forms of damage. For this
reason, do not destroy the packaging and only remove it shortly
before assembly.
Only remove packaging for transport to the installation site if it has
been expressly permitted.
Removing packaging
Packaging material made of solid wood (e.g.
wooden pallets, wooden crates) comply with the
IPPC standard. This material is re-usable. When
disposing of the material, national and local
requirements must be complied with.
From the machine/system compo- 1.

nents CAUTION!
Risk of injury from rough packaging material
and protruding nails!
Remove packaging material.

2. Detach the packing foil and remove it.
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Transport > Transport inspection
3. Separate the machine/system component from the transport

pallet by removing the fastening screws.
4.
ENVIRONMENT!
Packaging materials are valuable raw mate-
rials. It can be used several times or pro-
cessed and then re-used. Improper disposal
of packaging material can present a risk to
the environment.
5. Sort packaging according to the material used and dispose of

it properly.Ä Chapter 10.3 „Disposal“ on page 147
4.1.4 Transport inspection
Completeness
Checking for completeness
Check the goods for completeness immediately
after delivery. Register missing parts and contact
the manufacturer.
Check the delivery for completeness on the basis of the packing

slip.
n The packing slip is provided with the product.
Transport damage
Transport damage
Inspect the package for potential damage immedi-
ately. Initiate a complaint immediately if there is
any damage.
Inspect the delivery immediately for transport damage.

In case of perceptible external damage, proceed as follows:
n Do not accept the delivery or only accept it under certain condi-
tions.
n Note the scope of the damage in the transport documents or
on the delivery docket provided by the carrier.
n Register the claim.
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Transport > Transport of packaged units
4.1.5 Transport of packaged units
4.1.5.1 Transport using industrial vehicles
1.
NOTICE!
Risk of toppling loads! Packages may only be
transported using lifting equipment that rea-
ches under the machine and fits into the
transport pallet fully.
2. Insert the equipment into the provided opening in the trans-

port pallet.
3. Take into account the centre of gravity! See the labelling on
the packaging.
4.
Fig. 38: Transporting packages DANGER!
Risk of fatal injury from toppling components!
Determine the package’s centre of gravity by raising it care-

fully.
5. Transport the machine so that it is balanced. The package
Transportation of the Bondal sheet 1.

NOTICE!
Risk of toppling loads! The transport may
only be carried out using lifting equipment
that reaches under the packaged unit and fits
into the transport pallet fully.
2. Insert the equipment into the provided opening in the trans-

port pallet.
3. Take into account the centre of gravity!
4.
DANGER!
Determine the package’s centre of gravity by raising it care-

fully.
5. Transport the Bondal sheet horizontally. The package must
not lean to one side.
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Transport > Transport to the installation site
4.1.5.2 Transport using a crane
1. Guide the conveyor rails through the openings of the trans-

port pallet.
2. Place the lifting beams onto the acoustic hood. Span width at
least 150 mm larger than the dimensions of the acoustic
hood.
3. Guide lifting equipment, such as cables or straps, through the
conveyor rails and join them above the machine using the
lifting beams.
the packaging.
5.
Fig. 39: Transport of packaged units DANGER!
Determine the packaged unit’s centre of gravity by raising it

carefully.
6. Transport the machine so that it is balanced. The packaged
unit must not lean to one side.
4.1.6 Transport to the installation site
4.1.6.1 Transport using industrial vehicles

1. Completely remove packaging material.
2. Open the operating side of the acoustic hood (pos.1).
3. Open the rear side of the acoustic hood (pos.2).
5. Drive the transport fork under the machine (pos.3).
the packaging.
7.
DANGER!
Determine the machine’s centre of gravity by raising it care-

fully.
Fig. 40: Transport with acoustic hood
8. Transport the machine so that it is balanced. The machine
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Transport > Transport to the installation site
4.1.6.2 Transport using a crane
1. Completely remove packaging material.

2. Remove the front and rear elements of the acoustic hood and
store them safely.
3. Guide the conveyor rails through the openings of the forklift
tunnel.
4. Place the lifting beams onto the acoustic hood. The span
width must be at least 150 mm greater than the dimensions
of the acoustic hood.
5. Guide lifting equipment, such as cables or straps, through the
conveyor rails and join them above the machine using the
lifting beams.
Fig. 41: Transport to the installation
site
the packaging.
8.
DANGER!
Determine the machine’s centre of gravity by raising it care-

fully.
9. Transport the machine so that it is balanced. The machine
1. Screw the eyebolts of size M12 tightly into all four bores.
2. Attach the lifting equipment to the eyebolts.
3. Fasten the lifting equipment to the crane hooks.
4. Take into account the centre of gravity!
5.
DANGER!
Fig. 42: Bondal sheet Risk of fatal injury from toppling components!
Determine the centre of gravity by raising it carefully.

6. Transport the Bondal sheet horizontally. The Bondal sheet
7. If the Bondal sheet is in the exact installation position on the
steel structure, the lifting equipment.
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Storage and preservation > Storage
4.2 Storage and preservation
4.2.1 Storage
Storage notes Store packages under the following conditions:
n Keep flange connections closed. Avoid entry of foreign sub-
stances.
n Do not store outdoors.
n Store in a dry and dust-free place.
n Do not expose it to any aggressive media.
n Protect the packaged unit from exposure to the sun.
n Avoid mechanical vibrations.
n Avoid extreme temperature fluctuations.
n Avoid adverse water effects.
n Storage temperature: -10 to +40 °C
n Relative humidity: maximum 80%
n If a vibration-free storage area is not available, move the mov-
able components by two to three rotations every six to eight
weeks.
NOTICE!
Risk of corrosion!
To avoid potential damage, an inspection of the
overall extent of supply should be undertaken by
the manufacturer every 2 years.
There may be information on the packaged unit

regarding storage that goes beyond the require-
ments listed here. Comply with this information.
Storage information for periods of Additional measures:

over 12 months
n Packaging with VPI paper
n Sealed in PVC foil

over 12 months in a tropical climate
n Drying agent (VPI power in a bag) inside the packaging
n Packaging with VPI paper
n Sealed in PVC foil
Storage in air-conditioned rooms with minimum

humidity has a positive influence on corrosion pro-
tection.
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Storage and preservation > Preservation
Packaging during storage n Inspect the general condition of the packaging regularly. Imme-
diately rectify damage to the packaging. If necessary, refresh or
replace the preservation material.Ä „Carrying out preservation
treatment“ on page 80
n After opening the packaging:
– Inspect uncoated parts for sufficient corrosion protection.
– Protect against humidity and damaging environmental influ-
ences.
– Do not remove sealing flaps from the connection openings.
n Replace the drying agent regularly in accordance with climate
conditions.
NOTICE!
Risk of corrosion! Customised packaging is
required for tropical climate zones and in the case
of special customer requirements.
Damaged packaging
NOTICE!
Risk of corrosion! As a result of damaged pack-
aging, moisture and damaging environmental influ-
ences could directly affect the product.
Measures in the case of damaged packaging:

n Immediately rectify damage to the packaging. If necessary,
refresh or replace the preservation material.
n Dry the machine, if necessary.
n Check the drying agent and replace it if necessary.
n Repair or replace the packaging.
4.2.2 Preservation
Preservation Factory preservation protects the product for a certain time period
in accordance with the relevant storage and packaging information.
Factory preservation/standard
Conveying chamber BIO-CHEM Food Biodegradable;
Tech Oil does not contami-
nate groundwater
Oil chamber Mobil SHC 626 Operating lube oil
Shelf life Up to 12 months With compliance
with storage condi-
tions
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Repeat After 12 months
Extended shelf life More than 12 Only with suitable
months long-term preserva-
(no standard) tion and packaging
Preservation from assembly to commissioning

Apply preservative More than 6 weeks Avoiding damage
to the conveying of non-use caused by corrosion
chamber and turn and non-use
the rotors two to
three turns
Preservation after breaks in operation

Preservation of con- More than 6 months Special preservation
veying chamber, oil measures are
chamber required
Carrying out preservation treat-

ment
Preservation measures:
1. Open the packaging. Check the machine for good accessi-
bility.
2.
WARNING!
Risk of poisoning from inhaling oil vapour!
Preservation treatment of the conveying chamber:

Spray suitable preservative oil over the intake nozzle at the
machine stage.
NOTICE!
Risk of filter damage!
Do not spray preservative oil into the intake
filter. Never treat filter elements with preser-
vative oil!
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3.
WARNING!
Preservation treatment of the oil chamber:

Spray suitable preservative oil into the machine stage
through the oil fill opening and oil drain opening.
ð Let excess preservative oil flow out of the oil drain
opening.
4. Seal the oil fill opening and oil drain.
5.
WARNING!
Treat the outer, uncoated surfaces with suitable preservative

oil.
6. Check the sealing flaps.
7. Check and restore the packaging.
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Set-up and installation
Safety instructions
5 Set-up and installation

5.1 Safety instructions
Improper set-up and installation

WARNING!
Risk of injury from improper set-up and instal-
lation!
Improper set-up and installation can result in
serious personal injury or material damage.
– Before beginning any work, ensure there is suf-
ficient space for installation.
– Keep the workspace tidy and clean.
– Only use commercially-available tools or, if
necessary, special tools.
Unsuitable or damaged tools may cause injury!
– Secure components against falling during
installation work.
– Install components correctly.
– Comply with the specified screw-tightening tor-
ques.
Electrical system
DANGER!
There is a risk of fatal injury from touching live
components. Live electrical components may make
uncontrolled movements and cause extremely
serious, or even fatal injury.
– Before beginning work, switch off the electric
power supply and secure it against restarting.
Electrostatic charges
WARNING!
Risk of injury from electrostatic charges!
The belt drive may generate electrostatic charges.
– Before first commissioning put in place equipo-
tential bonding.
– Only use electrically-conductive belts.
Requirements for personnel Requirements for set-up and installation:

Set-up and installation of electrical components
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Safety instructions
Personnel: n Authorised electricians
Set-up and installation of mechanical components

Protective equipment Requirements for set-up and installation:

n Protective gloves
n Safety goggles (7010-M004)
n Industrial hard hat (7010-M014)
Special tools Requirements for set-up and installation:

Special tool: n Tools for authorised electricians
n Electric drill
n Drills
n General tools
n General measurement tools and equip-
ment
Special tool: n Locking key
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Requirements for the installation site
5.2 Requirements for the installation site

Ground properties Inspect the ground properties. These should be as follows:
n stable
n level
n free of vibrations
n without any incline
n without holes
NOTICE!
Risk of deformation of the acoustic hood substruc-
ture! Do not install or mount the machine on
“hollow” or lamellar foundations.
Subsurface requirements for the cement floor.

The cement floor should have a recommended
compressive strength of 30—40 N/mm².
Flatness tolerance according to DIN 18202

Distance between measuring points in (m)
0.1 1 4 10 >15 /
Dimension 2 4 10 12 15 /
tolerance in
(mm)
Angular tolerance according to DIN 18202

Distance between measuring points in (m)
over 1 over 3 over 6 over
up to over
up to up to up to 15 up
1 30
3 6 15 to 30
Dimension ±6 ±8 ± 12 ±16 ± 20 ± 30
tolerance in
(mm)
Surroundings n Ensure there is a suitable fresh air supply.

n Avoid heat accumulation.
NOTICE!
Risk of corrosion! There must not be any excessive
levels of dust, acids, steam or explosive or flam-
mable gases at the installation site!
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Alignment and dowelling
Installation with acoustic hood The machine is suitable for indoor and outdoor installation.
Installation site
n Comply with the overall dimensions for maintenance work. Also
consult the installation drawing.
n Take the following precautionary measures:
– If possible, switch off the machine before entering the oper-
ating area.
– Otherwise wear hearing protection.
– Only trained persons must be able to access the installa-
tion site.
– Provide appropriate signage at the installation site.
Fig. 43: Installation dimensions – Choose an installation site where the duration of time per-
sons spend in the immediate vicinity of the machine is
extremely limited.
5.3 Alignment and dowelling

Models with acoustic hoods
1. Carefully align the machine.

2. Position it so that it is balanced.
Fig. 44: Spirit level alignment
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3.
NOTICE!
Risk of irreversible machine failure! Installing
a machine at an angle can lead to a total
loss, due to the undefined oil level.
Observe the evenness and angle tolerances.
If necessary, use the intended shims on the bolting surfaces.
Fig. 45: Shim alignment
4. Recommendation: drill and dowel four mounting holes and

screw the machine into these.
Fig. 46: Fastening points
Use of the Bondal sheet

1.
Note the bores of the Bondal sheet and the
machine’s fastening points!
Position the machine on the Bondal sheet.
Fig. 47: Installing the machine
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2. Put the machine in a horizontal position.
Fig. 48: Spirit level alignment
3.
NOTICE!
Risk of irreversible machine failure! Installing
a machine at an angle can lead to a total
loss, due to the undefined oil level.
Observe the evenness and angle tolerances.
If necessary, use the intended shims on the bolting surfaces.
Fig. 49: Shim alignment
4. Screw the machine and Bondal sheet together on the open

steel structure at four fastening points.
Fig. 50: Fastening points
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Connecting the system pipeline
5.4 Connecting the system pipeline

System pipeline
NOTICE!
Risk of machine damage! The connected pipeline
must not exert forces or moments that affect the
machine.
Secure and fasten the system pipeline.
Observe the labelling and dimensions on the

installation drawing.
Preparation of the model with 1. If necessary: “break” the perforated sheets on the rear side of
acoustic hoods the acoustic hood.
2. Cut an opening into the foam material. The opening should
be the size of the pipeline diameter.
3. Guide the service pipe through the opening and attach it.
4. Cover and seal the opening using shims.
1. Remove the sealing cover from the connection openings.

Bushing connection/2 clamps
2. Connect the system pipeline.
ð Make sure that the clamps are offset by 180° to one
another.
Fig. 51: 2 clamps
Bushing connection/4 clamps

ð Make sure that the clamps are offset by 180° to one
another.
Fig. 52: 4 clamps
Connection of a compensator
5. Close off the pipeline duct using a shim.
Fig. 53: Connection of a compensator
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Connecting the drive motor > Preparing the connection
5.5 Connecting the drive motor

5.5.1 Preparing the connection
Preparation of the acoustic hood
1. Note the instructions from the chapter “Set-up and function"!
Ä Chapter 3.7.1 „Drive motor“ on page 54
2.
DANGER!
Risk of fatal injury in the case of incorrect
electrical connection data!
Compare the electrical connection data of the drive motor

with those of the owner’s grid.
3. Shut down the power from the owner-side grid.
4. Observe the cable routing on the installation drawing!
Fig. 54: Position on the acoustic hood
5. Prepare the cable feedthroughs.

6.
DANGER!
Check that there is no live current in the connection cable.

7. Lay the connection cable through the cable feedthroughs.
Fig. 55: Preparation
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Connecting the drive motor > Connecting the drive motor
5.5.2 Routing cables

Laying the connection cable
1. Route the connection cable in accordance with the installa-
tion drawing.
2.
NOTICE!
Risk of damage! The minimum bending
radius must not be undershot!
Observe the bending radii.

Fig. 56: Cable laying alignment Bending radius of the connection cable = 15 x cable sheath
diameter
5.5.3 Connecting the drive motor

Connecting the drive motor
Fig. 57: Connection layout
Star-delta connection Delta connection Star connection Thermal winding shield
1. Open the motor terminal box.

2. Check the alignment of the terminal box.
ð The terminal box must be aligned with openings for the
cable feedthroughs facing in the direction of the motor
fan.
3. Attach a screwed cable gland to the terminal box.
4. Guide the motor cable through the screwed cable gland.
5. Connect the cable connections with the motor terminals cor-
rectly, in accordance with the connection layout.
6. Close the terminal box.
7. Ensure that the connection cable is not damaged by the
movement of the hinged motor support.
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Laying the insulation mat
5.6 Connecting the earthing

Connecting the earthing
1.
The exact position of these connections can
be found in the installation drawing.
Earth the machine using the connections provided.

2. Observe the cross-sections of the earthing strap! Ä Chapter
11.9.2 „Earthing strap cross-section “ on page 165.
3. Beware of uncovered metal contact surfaces.
Fig. 58: Example connection
4. Screw the contacts together tightly.
5.7 Laying the insulation mat

Laying the insulation mat
n Depending on the scope of delivery, the insulation mat is deliv-
ered separately.
n Lay the insulation mat in the exhaust duct of the acoustic hood.
Fig. 59: Laying of the insulation mat
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First commissioning
Safety instructions
6 First commissioning
Improper first commissioning

WARNING!
Risk of injury from improper first commis-
sioning!
Improper first commissioning may lead to serious
injury and considerable material damage.
– Before first commissioning, ensure that all
installation work has been carried out and com-
pleted in accordance with the information and
notes in this instruction manual.
– Before first commissioning, ensure that there
are no persons in the hazard area.
Requirements for personnel Requirements for first commissioning:

First commissioning of electrical components
First commissioning the frequency converter:

Personnel: n Authorised electricians with additional
qualifications
First commissioning of mechanical components

Protective equipment Requirements for first commissioning:

n Hearing protection (7010-M003)
n Protective gloves
Special tools Requirements for initial commissioning:
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First commissioning
Preparation for initial commissioning
Special tool: n Oil funnel

n Test pump
n General tools
ment
n Tools for authorised electricians
Special tool: n Hinged motor support lifting equipment

n Hydraulic lift
n Transport securing rod
6.2 Preparation for initial commissioning

Preparation 1. Check that the machine has been correctly installed. See
requirements at the installation site.Ä Chapter 5.2 „Require-
ments for the installation site“ on page 84
2. Check that the packaging has been fully removed.
3. If present, completely remove protective foil from acoustic
hoods made of stainless steel.
4. Check that all seals and covers on the pipe connections have
been removed.
5. Check that the pipe connections are clean. Remove any dirt,
dust or foreign matter from the intake area.
6. Ensure that the cross-sections of the inlet and exhaust air
openings on the acoustic hood are unobstructed.
Ventilating the installation site 7.
Take the ambient temperature into consider-
ation. Ä Chapter 11.4 „Technical perform-
ance data“ on page 154
Ensure adequate ventilation and air extraction at the installa-

tion site.
Taking noise protection into con- 8.
sideration Natural vibrations and sound emissions may
be induced in pipes and foundations.
Prevent natural vibrations and sound emission by using suit-

able measures, e.g. insulation.
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First commissioning
Ventilating the pressure gauge

9. Prepare the pressure gauge in line with the specific model.
n Cut off the rubber seals on the top.
n Turn the bleeder flap to “OPEN”.
Fig. 60: Ventilating the pressure

gauge
Adjusting the maintenance indi-

cator (a)
10. Carry out adjustment to zero.
n Press the front reset button and set the pointer to the
zero position.
Fig. 61: Version a)
Adjusting the maintenance indi-

cator (b)
n Remove the plugs on the front.
n Adjust the set screw using a screwdriver.
n Observe the “+” and “-” markings.
n Position the red trailing pointer between 0 and -10 mbar.
Fig. 62: Version b)
Maintenance indicator (c)

n Press the yellow reset button and set the pointer to the
zero position.
Fig. 63: Version c)
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First commissioning
Maintenance indicator (d)

n Press the bottom reset button and set the pointer to the
zero position.
Fig. 64: Version d)
Aligning the sheaves 14. Check the alignment of the sheaves.

n The maximum belt pulley offset is 0.5 mm.
Connecting the pipe 15. Connect the depressurised system pipes.
Removing the sealing plugs
16. Remove the sealing plugs from the balancing holes.
The sealing plugs may be coated in machine

paint due to the manufacturing process.
The number of sealing plugs varies
depending on the machine type.
Depending on the design, they may already
have been removed before shipping.
Fig. 65: Layout example

NOTICE!
Risk of damage if sealing plugs are not
removed!
If these sealing plugs are not removed, there
is a risk that the machine will leak oil. Lube
oil could enter the conveying chamber.
No filling of lube oil

17.
NOTICE!
Risk of damage! These holes are not to be
filled with any lube oil.
Fig. 66: Do not fill with oil These holes are solely intended to discharge leaking gases.
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First commissioning
Checking the acoustic hood fan

18. Check that the fan wheel is running smoothly and does not
come in contact with other components.
If necessary, adjust the cover plate.
Fig. 67: Fan cover
Positioning and connecting the fre- 19.

quency converter Observe the manufacturer’s instruction
manual.
Position and mount the frequency converter.

n Connect as per the specifications of the manufacturer.
n Note the description of the frequency converter
assembly.Ä Chapter 3.7.3 „Frequency con-
verter“ on page 56
Checking the EMERGENCY STOP 20. Check whether the EMERGENCY STOP function is in place
function and installed.
n Check for correct operation.
n Enter the test result in the test book.
Preparing the hinged motor sup-

port
Handling without a lifting device
Disassembling the transport safety
lock
1. Remove the safety screws for transport.
Fig. 68: Example: DN50
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First commissioning
Performing first commissioning > Filling oil, version with oil system
Disassembling the transport safety

lock
2. n 1.) Remove the split pin.
n 2.) Disassemble the safety rod for transport.
ð The safety rod later acts as an aid for supporting the
hinged motor support.
6.3 Performing first commissioning

6.3.1 Filling oil, version with oil system
1. Open the maintenance elements of the acoustic hood.
Filling with lube oil
2.
When working with operating materials such
as lube oil, always wear personal protective
equipment.
ENVIRONMENT!
Risks to the environment due to incorrect
handling of lubricants!
Fill with lube oil. Ä Chapter 8.3.1 „First filling of lube

oil“ on page 122
Fig. 70: Model with oil system
Checking the oil level on the

acoustic hood
3. Check the lube oil level on the acoustic hood’s oil level dis-
play. Correct if necessary.
Fig. 71: Acoustic hood oil level display
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First commissioning
Performing first commissioning > Establishing an electrical connection
Checking the oil level on the

machine stage
Fig. 72: Oil level display (machine

stage)
4. Check the lube oil level on the machine stage’s oil level dis-
plays (pos.2). Correct if necessary.
Fig. 73: Oil level display (pos.2)
6.3.2 Establishing an electrical connection

Establishing an electrical connec- 1.
tion DANGER!
Supply electrical components with electricity.

Ä Chapter 5.5 „Connecting the drive motor“ on page 89
2. Connect and activate motor overload protection.Ä Chapter
11.9.3 „ Motor overload protection“ on page 165
3. Observe the permissible starting frequency of the drive motor
Ä Chapter 3.7.1 „Drive motor“ on page 54.
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First commissioning
Performing first commissioning > Establishing an electrical connection
Checking direction of rotation,

models with acoustic hood
4.
WARNING!
NOTICE!
Risk of machine damage from incorrect
direction of rotation!
Check the direction of rotation without belts in place.

Fig. 74: Motor direction of rotation n If in place, remove the perforated plate cover of the drive
motor’s sheave.
n Observe the sign with direction of rotation on the
machine stage and on the drive motor.
n Start the drive motor briefly (approx. 1–2 seconds).
n Viewed towards the front of the drive shaft, the drive
motor turns anti-clockwise.
– Direction of rotation is correct = continue initial com-
missioning.
n From the viewing position, the drive motor turns right in
front of the drive shaft.
– Direction of rotation is incorrect = correct the elec-
trical connection.
n Where applicable, attach the perforated plate cover of the
drive motor.
Disconnecting the electrical power 5.
supply WARNING!
Risk of injury from an automatic start-up!
Deactivate the machine and secure it against restarting.
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First commissioning
Performing first commissioning > Handling the hinged motor support without lifting device
6.3.3 Handling the hinged motor support without lifting device

Raising the hinged motor support
1. Insert the lifting bracket in the motor’s attachment rail.
NOTICE!
Only use hydraulic lifts on solid, level ground.
Position the hydraulic lift securely.
2.
WARNING!
Risk of shearing and crushing from moving
loads!
Slowly raise the hinged motor support by pumping the

hydraulic lift.
Raising the hinged motor support 3.

of the DN50 WARNING!
Risk of injury from the hydraulic lift tipping up
or slipping!
Raise the hinged motor support in small steps. Always put

timber underneath! This prevents the sudden downward
movement of the hinged motor support if the hydraulic lift tips
up or slips.
Raising the hinged motor support 4.
of the DN80 WARNING!
or slipping!
Raise the hinged motor support in small steps. While doing

so, use the transport safety rod to brace the hinged motor
support in the recess of the base support. This prevents the
sudden downward movement of the hinged motor support if
the hydraulic lift tips up or slips.
5. Raise the hinged motor support until the belts can be fitted.
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First commissioning
Performing first commissioning > Handling the hinged motor support without lifting device
Fitting the belts

6.
CAUTION!
Risk of injury from tensioned components!
Fit the belts. Observe and comply with the permissible

Fig. 77: Permissible belt layout groove layout.
Tensioning the belts 7.

WARNING!
Risk of injury from tensioning, moving or
rotating components!
Release the hydraulic lift carefully and slowly.

ð The hinged motor support is lowered.
If released too quickly, the hinged motor support drops
suddenly.
The belts are tautened by the weight of the motor.
8. Completely remove the hydraulic lift and other auxiliary
equipment and store them safely for future maintenance pur-
poses.
9.
NOTICE!
Risk of damage to the belt drive! The hinged
motor support must not rest on the base sup-
port, the transport safety lock or similar
equipment.
Completely remove the hydraulic lift, transport safety lock

and other auxiliary equipment and store them safely for
future maintenance purposes.
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First commissioning
Performing first commissioning > Carrying out a test run
6.3.4 Carrying out a test run

Checking the oil level
Fig. 78: Oil level display
1. Check the lube oil level on the oil level displays.

The lube oil level remains steady at a point between the min.
and max. markings on the oil level display.
The oil level is OK.
Fig. 79: Oil level display The lube oil level does not remain steady at a point between
the min. and max. markings on the oil level display.
Correct the machine’s alignment. Observe the filling
quantities.
2.
CAUTION!
Risk of injury from moving components!
Carry out a test run of the belt drive and check that it is oper-
ating correctly.
Characteristics:
n quiet, smooth operation
n even load
n no excessive vibrations
n no whistling noises
n no increased wear
Closing the acoustic hood 3. Close the maintenance element of the acoustic hood.
Connecting the power supply 4.
WARNING!
Risk of injury from electric current!
Supply electrical components with electricity.
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First commissioning
Inspecting shut-downs
5. Check the correct operation of all pressure switches/pressure
sensors that can trigger a shut-down.
n Connect the test pump to the corresponding measure-
ment line.
n Simulate the tripping pressure.
n Check to see whether the shut-down process is trig-
gered.
n Remove the measurement line from the test pump.
n Fit the measurement line to the measuring point on the
machine.
Fig. 80: Test pump
Opening the system line 6. Open valves on the system side.

Checking the safety valve 7. Check the safety valve for correct operation.
Starting briefly 8.
WARNING!
WARNING!
Risk of injury from pressurised components!
Do not loosen or remove any blanking plugs
or pipe connections.
Switch on the drive motor.

n After approx. 20 seconds, switch it off.
n Make sure the machine coasts down smoothly.
Checking the frequency converter 9.
for correct operation DANGER!
Risk of fatal injury from electric current and
residual energy when performing any work
on frequency converters!
See also the assembly description for frequency con-

verters.Ä Chapter 3.7.3 „Frequency converter“ on page 56
Starting the drive motor 10.
WARNING!
As long as there are no malfunctions: Restart the drive motor.

n Check the EMERGENCY STOP function.
n Check the machine’s protective equipment.
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First commissioning
Checking after the first commis- 11.

sioning WARNING!
Risk of injury from pulling or opening pressur-
ised pipes with lubricating oil.
Perform the following checks:

Ä Chapter 6.4 „Performing checks after first commis-
sioning“ on page 105
Acoustic hood protection 12.
WARNING!
Risk of injury if protective equipment is not
present.
Correctly close the elements of the acoustic hood.

n Store the acoustic hood key safely.
n Only allow access for authorised personnel.
Operational readiness If there are no malfunctions, the machine is ready for operation.
After the first few operating hours, preservative oil

may gather in the parting faces as a result of the
machine warming up.
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First commissioning
Performing checks after first commissioning
6.4 Performing checks after first commissioning

Inspection After the first 3 op. After the first 25 op.
hrs hrs
Screw connec- check after the
tions machine has cooled
down, re-tighten if
necessary
Safety valve check for correct
operation
Oil level check, correct if nec- check, correct if nec-
essary essary
Alignment of check, correct if nec-

sheaves essary
Condition of the check, change if nec-
belts essary, establish
cause
Control system, check for correct
fault transmitter, operation
pressure and
temperature sen-
sors
Motor overload connected and active
protection
Accumulation of check, remove if nec-
preservative oil essary
op. hrs = operating hours
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Operation
Safety instructions
7 Operation
Improper operation
WARNING!
Risk of injury from improper operation!
Improper operation may lead to serious injury and
considerable material damage.
– Carry out all activities in accordance with the
information and notes in this instruction
manual.
– Before beginning work, observe the following:
– Ensure that all covers and safety devices
are installed and operating correctly.
– Ensure that there are no persons in the
hazard area.
– Never deactivate or bypass safety devices
during operation. Do not operate such devices
in a manner that deviates from the operating
data.
An open acoustic hood

WARNING!
Risk of injury from operation with an open
acoustic hood!
Open acoustic hoods may lead to dangerous situa-
tions and cause injury during machine operation.
– Always keep the acoustic hood closed during
operation.
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Operation
Shut-down in case of emergency
Risk of explosion and fire

DANGER!
Risk of explosion and fire from ignition haz-
ards!
Avoid allowing ignition hazards (open flames, flying
sparks, weld spatter) into the vicinity of the
machine. Sparks and incandescent or flammable
objects could be sucked in through the supply air
openings on the acoustic hood or through the
intake silencer. The fan may ignite the mixture,
causing an explosion or fire.
– Avoid ignition hazards.
– Never carry out work that generates sparks
while the machine is in operation.
– Ventilate the installation site properly.
Requirements for personnel Requirements for operation:

Using the machine
Personnel: n User
Adjusting valves
Personnel: n User
n Authorised electricians
Protective equipment Requirements for operation:

Special tools Adjusting the valves requires:

Special tool: n General tools
7.2 Shut-down in case of emergency

In hazardous situations, the movements of components must be
stopped as quickly as possible and the electric power supply must
be shut off.
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Operation
Switching on > Local control mode
Shut-down in case of emergency In an emergency, proceed as follows:

1. Activate the EMERGENCY STOP immediately.
2. Inform the responsible staff.
3. Switch off the main circuit breaker and secure it against
restarting.
4. Assign qualified personnel the task of rectifying the fault.
5.
WARNING!
Before commissioning, ensure that all safety devices are

installed and operational.
7.3 Switching on
Operating modes Depending on the operating mode, the machine can be switched
on in the following ways:
If possible, start up the machine without load!

Observe the control circuit types!
When starting and stopping the drive motor, observe all of the
machine's protective measures. Power take-offs must be actuated
by a potential-free contact or be actuated directly. The start-up of
the power take-offs runs in parallel to the drive motor.
7.3.1 Local control mode

On-site manual operation
DANGER!
Risk of injury if protective equipment is
missing!
Manually activate the starter switch on the machine on site.

ð The machine starts and comes on stream.
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Operation
Displaying operating parameters
7.3.2 Remote operation

Via remote station
DANGER!
Risk of fatal injury if protective equipment is
missing!
WARNING!
Risk of injury if the machine starts suddenly!
Activate the starter switch in the remote station.

ð The machine is started remotely and comes on stream.
7.3.3 Automatic operation

Automatic activation
DANGER!
Risk of fatal injury if protective equipment is
missing!
WARNING!
Risk of injury if the machine starts suddenly!
The starting command is carried out by sensors or a system

switch.
ð The machine starts automatically and comes on stream.
7.4 Displaying operating parameters

AERtronic (optional)
A detailed explanation is contained in the separate

operating manual AS-002.
Fig. 81: AERtronic display
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Operation
Switching off > Remote-controlled operation
Analogue instruments (optional) Depending on their design, analogue instruments display the given
operating data, e.g. discharge pressure, discharge temperature, oil
pressure.
Control system (optional) Depending on the customer’s control system, additional operating
parameters can be recorded and displayed.
7.5 Switching off

Operating mode Depending on the operating setup, the machine can be switched
off in the following ways:
7.5.1 On-site operation

On-site manual operation
WARNING!
Risk of injury from unbraked shut-down!
Manually activate the cut-out switch on the machine.

ð The machine is switched off and shuts down. The
machine does not stop immediately.
7.5.2 Remote-controlled operation

Via remote station
WARNING!
Activate the cut-out switch in the remote station.

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Operation
Measures for recommissioning > Commissioning after fault rectification
7.5.3 Automatic operation

Switching off automatically
WARNING!
The shut-down command is carried out by sensors or a

system switch.
7.6 Decommissioning
Decommissioning means the shut-down of a

machine for a longer period.
Measures 1. Switch off the machine properly and secure it against an

unintentional start.
2. Disconnect fuses.
3. Close the shut-off valves of the delivery lines.
4. Put the machine in a depressurised state.
5. Prevent condensate from entering the machine.
6. For a downtime of over six weeks: preserve the conveying
chamber.
Avoiding damage caused by down- For a downtime of over six weeks

time and corrosion
Preserve the conveying chamber. Ä „Preservation“
on page 79
Move the rotors every six weeks by 2-3 rotations.
7.7 Measures for recommissioning

7.7.1 Commissioning after maintenance work
After maintenance Carry out work stages Ä Chapter 8.5 „Commissioning after main-
tenance“ on page 138.
7.7.2 Commissioning after fault rectification

After fault rectification Carry out work stages Ä Chapter 9.4 „Commissioning after fault
rectification“ on page 144.
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Maintenance
Safety instructions
8 Maintenance
Improperly performed maintenance

work WARNING!
Risk of injury from improperly performed main-
tenance work!
Improperly performed maintenance may lead to
serious injury and material damage.
– Only perform maintenance work when the
machine has been switched off.
– Secure the machine against a restart.
– Allow the machine to cool down to the ambient
temperature.
– Before beginning work, ensure that there is
sufficient space for installation work.
– Only perform maintenance work with suitable
tools.
– Ensure removed components are re-installed
correctly.
– Re-install all fastening elements and observe
the screw tightening torques.
Maintenance work when the

machine is in operation WARNING!
Risk of injury from maintenance work while the
machine is currently in operation!
Performing maintenance work during operation of
the machine can lead to serious or fatal injuries.
– Always shut down the machine prior to mainte-
nance work!
Never start up the machine for maintenance
work!
– Never operate or start up the machine with dis-
assembled assemblies and accessories!
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Maintenance
Safety instructions

restarting WARNING!
may be people located in the hazard area.
– Before beginning work, switch off the energy
supply and secure it against restarting.
Electrical system
DANGER!
serious injury.
Rotating or moving components

WARNING!
Risk of injury from rotating or moving compo-
nents!
Rotating or moving components can cause serious
injuries.
– Never touch rotating or moving components.
– Never reach into the clamping area of the
belts, for example.
– Keep a safe distance from rotating or moving
components.
– Wear tight-fitting protective work clothing with
low tensile strength within the hazard area.
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Maintenance
Safety instructions
Hot operating materials

WARNING!
Risk of injury from hot operating materials!
Operating materials may reach high temperatures
during operation. Skin contact with hot operating
materials causes serious burns.
– For all work performed with hot operating
materials, always wear protective work clothing
and protective gloves.
– Before any work with operating materials,
check whether they are hot. If necessary, allow
them to cool down to ambient temperature.
Requirements for personnel The maintenance work described here may only be performed by
the designated personnel. The personnel entrusted with the
respective maintenance tasks are listed in the maintenance plan.
For the preparation of the maintenance plan, the following is nec-
essary:
n Service personnel
For cleaning after maintenance, the following is necessary:

Personnel: n User
Commissioning after maintenance requires:

n Service personnel
Protective equipment For maintenance, the following is necessary:

n Protective gloves
Special tools The following is necessary for maintenance:

Special tool: n Oil funnel
n General tools
ment
n Auxiliary materials, tools
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Maintenance
Maintenance plan

n Hydraulic lift
8.2 Maintenance plan

The following section describes the maintenance work that is
required for optimal and fault-free operation of the machine.
If regular inspections reveal an increased level of abrasion, reduce
the necessary maintenance intervals in accordance with the actual
signs of wear and tear. For questions on maintenance work and
intervals contact the manufacturer. Contact information Ä Chapter
1.4 „Addresses“ on page 11
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Maintenance
Maintenance plan > Maintenance schedule for normal operation
8.2.1 Maintenance schedule for normal operation

Interval Maintenance work Personnel
After the first 500 op. Change the lube oil. Ä Chapter 8.3.5 „Changing lube Service personnel
hrs oil“ on page 129
n All lube oils as per lube oil specification
n Except Delta Lube 06
Change the grease.Ä Chapter 8.3.4 „Replacing the grease Service personnel
on gas-tight drive shafts“ on page 127
n For gas-tight shaft seal
Weekly Check the intake filter for contamination. (display unit, max. User
permissible - 45 mbar)
Check the oil level. Ä Chapter 8.3.2 „Checking the oil User
level“ on page 123 Correct it if necessary. Ä Chapter
8.3.3 „Correcting the oil level“ on page 125
If the maximum value (- 45 mbar) is exceeded, change the Service personnel
intake filter.Ä Chapter 8.3.6 „Replacing the intake
filter“ on page 132
Observe the relubrication intervals of the drive motor! Service personnel
Observe the signage of the drive motor!
Ä More information on: Drive motor /
Observe the cleaning intervals for the drive motor! Depends Service personnel
on the contamination class.
Observe the instruction manual of the drive motor!
Clean the cooling air channels.
Check the motor bearings and the lubricant supply. Service personnel
Replace the motor bearings if necessary.
Renew the lubricant.
Relubrication intervals Observe the instruction manual and signage of the drive Service personnel
for the drive motor motor.
After every 4,000 op. Check and clean the inlet and exhaust air openings on the Service personnel
hrs or every 6 months acoustic hood. Ä Chapter 8.3.12 „Checking the inlet and
exhaust air openings of the acoustic hood“ on page 136
Check the acoustic hood fan for correct operation.Ä Chapter
8.3.12 „Checking the inlet and exhaust air openings of the
acoustic hood“ on page 136
Check the safety valve for correct operation and clean Service personnel
it.Ä Chapter 8.3.9 „Checking the AERZEN safety
valve“ on page 134
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Maintenance

After every 4,000 op. Check the condition of the belts. If necessary, replace them. Service personnel
hrs or every 6 months Ä Chapter 8.3.8 „Replacing belts, version without lifting
device “ on page 133
Check the belt pulleys for unusual wear and tear or obvious
damage. Check for correct alignment and stability. Ä Chapter
8.3.7 „Checking the belt pulleys“ on page 132
If necessary, replace the sheaves. Manufacturer’s
customer service
division
Change the lube oil. Ä Chapter 8.3.5 „Changing lube Service personnel
oil“ on page 129
n ISO VG 220
n At a discharge temperature of over 140 °C
n ISO VG 220
After every 8,000 op. Change the lube oil. Ä Chapter 8.3.5 „Changing lube Service personnel
hours or every 12 oil“ on page 129
months
n Except Delta Lube 06, note the differential pressures
oil“ on page 129
n DELTA LUBE 06
n Only for differential pressures > 800 mbar
n When using all lube oils as per lube oil specification
Replace the intake filter.Ä Chapter 8.3.6 „Replacing the Service personnel
intake filter“ on page 132
After every 16,000 op. Replace the belts. Ä Chapter 8.3.8 „Replacing belts, version Service personnel
hrs or every 2 years without lifting device “ on page 133
Check the alignment of the belt pulleys. Correct if neces-
sary.Ä Chapter 8.3.7 „Checking the belt pul-
leys“ on page 132
Check the non-return flap for wear and tightness. Replace if
necessary.Ä Chapter 8.3.11 „Checking the non-return
flap“ on page 136
Check the flexible pipe connection on the discharge and
intake side for leaks. Replace if necessary.Ä Chapter
8.3.13 „Checking pipelines for leaks“ on page 137
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Maintenance

After every 16,000 op. Change the lube oil.Ä Chapter 8.3.5 „Changing lube Service personnel
hrs or every 2 years oil“ on page 129
n Delta Lube 06
After every 20,000 op. Check the hose lines for tightness. Replace if necessary. Service personnel
hrs or every 3 years
Recommendation: Replace the hose lines every 6 years.
Recommended main inspection and maintenance. Manufacturer’s
customer service
Check and replace spare parts and wear parts. division
Inspection of the entire machine.
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Maintenance
Maintenance plan > Maintenance schedule for arduous operating conditions
8.2.2 Maintenance schedule for arduous operating conditions

For example:
n year-round ambient temperatures over 30°C
n high dust levels

After the first 500 op. Change the grease.Ä Chapter 8.3.4 „Replacing the grease Service personnel
hrs on gas-tight drive shafts“ on page 127
oil“ on page 129
n Except Delta Lube 06
Weekly Check the intake filter for contamination. (display unit, max. User
permissible -45 mbar)
Check the oil level. Ä Chapter 8.3.2 „Checking the oil User
level“ on page 123 If necessary, correct it. Ä Chapter
8.3.3 „Correcting the oil level“ on page 125
If the maximum value (-45 mbar) is exceeded, change the Service personnel
intake filter.Ä Chapter 8.3.6 „Replacing the intake
filter“ on page 132
After every 2,000 op. Check the safety valve for correct operation and clean Service personnel
hrs or every 3 months it.Ä Chapter 8.3.9 „Checking the AERZEN safety
valve“ on page 134
Replace the intake filter.Ä Chapter 8.3.6 „Replacing the Service personnel
intake filter“ on page 132
Observe the relubrication intervals of the drive motor! Service personnel
Observe the signage of the drive motor!
Observe the cleaning intervals for the drive motor! Depends Service personnel
on the contamination class.
Observe the instruction manual of the drive motor!
Clean the cooling air channels.
Check the motor bearings and the lubricant supply. Service personnel
Replace the motor bearings if necessary.
Renew the lubricant.
Drive motor relubrica- Observe the instruction manual and signage of the drive Service personnel
tion intervals motor.
After every 4,000 op. Change the lube oil. Ä Chapter 8.3.5 „Changing lube Service personnel
hrs or every 6 months oil“ on page 129
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Maintenance
Maintenance plan > Maintenance schedule for arduous operating conditions

After every 4,000 op. n ISO VG 220
hrs or every 6 months n At a discharge temperature of over 140 °C
n ISO VG 220
oil“ on page 129
oil“ on page 129
n DELTA LUBE 06
n Only for differential pressures > 800 mbar
n When using all lube oils as per lube oil specification
Check and clean the inlet and exhaust air openings of the Service personnel
acoustic hood. Ä Chapter 8.3.12 „Checking the inlet and
exhaust air openings of the acoustic hood“ on page 136
Check the acoustic hood fan for correct operation.Ä Chapter
8.3.12 „Checking the inlet and exhaust air openings of the
acoustic hood“ on page 136
Check the condition of the belts. If necessary, replace them. Service personnel
Ä Chapter 8.3.8 „Replacing belts, version without lifting
device “ on page 133
Check the belt pulleys for unusual wear and tear or obvious
damage. Check for correct alignment and stability. Ä Chapter
8.3.7 „Checking the belt pulleys“ on page 132
If necessary, replace the sheaves. Manufacturer’s
customer service
division
After every 8,000 op. Change the lube oil.Ä Chapter 8.3.5 „Changing lube Service personnel
hours or every 12 oil“ on page 129
months
n Delta Lube 06
Check non-return flap for wear and tightness. Replace if nec- Service personnel
essary.Ä Chapter 8.3.11 „Checking the non-return
flap“ on page 136
After every 16,000 op. Replace the belts. Ä Chapter 8.3.8 „Replacing belts, version Service personnel
hrs or every 2 years without lifting device “ on page 133
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Maintenance
Maintenance work

After every 16,000 op. Check the alignment of the belt pulleys. If necessary, correct
hrs or every 2 years it.Ä Chapter 8.3.7 „Checking the belt pulleys“ on page 132
Check the flexible pipe connection on the discharge and
intake side for leaks. Replace if necessary.Ä Chapter
8.3.13 „Checking pipelines for leaks“ on page 137
After every 20,000 op. Check the hose lines for tightness. Replace if necessary. Service personnel
hrs or every 3 years
Recommendation: Replace the hose lines every 6 years.
Recommended main inspection and maintenance. Manufacturer’s
customer service
Check and replace spare parts and wear parts. division
Inspection of the entire machine.
8.3 Maintenance work

Preparation 1. Agree maintenance work with the person responsible at the
operating site.
2. Switch off the machine.
3. Trigger the EMERGENCY STOP function.
4. Switch off and secure the main circuit breaker.
5. Observe the warning signs on the machine!
6.
DANGER!
Risk of injury from electric current!
Ensure there is no live electricity.

7.
DANGER!
Risk of injury during maintenance work!
Open the maintenance elements.
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Maintenance
Maintenance work > First filling of lube oil
8.3.1 First filling of lube oil

8.3.1.1 Model with oil system
1. Check the drain valve for firm seating.
2. Check that the sealing cap of the drain valve is firmly in
place.
3. Open the oil container.
4. Ensure that the ventilation pipe in the oil filling container is
unobstructed.
5.
CAUTION!
Risk of skin irritation from lube oil!
Fig. 82: Filling with lube oil

ENVIRONMENT!
Observe the oil quantity Ä Chapter 11.7.3 „Lubricant quanti-

ties“ on page 163 and specification Ä Chapter 11.7.1 „Lube
oil specifications“ on page 159.
First, fill 3/4 of the listed quantity of oil.
6. Wait 5-10 minutes. The lube oil continues to flow.
ð The oil level regulates itself in the oil system and in the oil
chambers.
7. Check the oil level.
Fig. 83: Acoustic hood sight glass
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Maintenance
Maintenance work > Checking the oil level
Fig. 84: Machine stage sight glasses
9. Fill the rest of the lube oil up to the mark on the acoustic
hood’s sight glass. Observe the run down time of the lube oil.
ð The oil level is correct when it is between min. and max.
10. Close the oil filling container.
11.
ENVIRONMENT!
Risk of environmental damage from incorrect
storage of lube oil!
Clean the workspace thoroughly.

Dispose of the lube oil residue in an environmentally friendly
way.
Clean all auxiliary equipment.
8.3.2 Checking the oil level

Model with oil system
1 Oil fill opening (oil filling container)
2 Oil level display
3 Oil drain
Fig. 86: Oil system
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Maintenance
Maintenance work > Checking the oil level
Checking the oil level

1. Check the lube oil level. Correct if necessary.
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Maintenance
Maintenance work > Correcting the oil level
8.3.3 Correcting the oil level

8.3.3.1 Oil level too high
Draining lube oil
1.
WARNING!
Risk of scalding from hot lube oil!
NOTICE!
Material damage to the drain hose from lube
oil temperatures over 60 °C!
Allow the lube oil to cool down to the ambient temperature.

Fig. 90: Draining lube oil 2.
Observe the volume of the lube oil and the
oil-resistant receptacle. Ä Chapter
11.7.3 „Lubricant quantities“ on page 163
Have a receptacle ready.

3. Open the oil opening on the oil filling container.
ð Lube oil flows out more evenly from the oil drain.
4. Feed the drain hose into the receptacle.
5.
CAUTION!
Risk of skin irritation from old lube oil!
Remove the sealing cap from the drain valve.

Twist the drain hose onto the drain valve.
ð The drain valve opens automatically.
6.
Fig. 91: Fitting the drain hose CAUTION!
Risk of slipping from lube oil spillage!
Guide the excess lube oil into the receptacle.
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Maintenance
Maintenance work > Correcting the oil level
7. Observe and check the oil level.

8. If the permissible oil level is reached, remove the drain hose.
ð The drain valve closes automatically.
9. Screw the sealing cap onto the drain valve.
10. Close the oil fill opening.
11.
ENVIRONMENT!
Risk of environmental damage from lube oil!
Fig. 92: Sight glass for oil level display
Collect old and residual lube oil properly and dispose of it in

an environmentally friendly manner.
8.3.3.2 Oil level too low


place.
3. Open the oil filling container.
unobstructed.
5.
CAUTION!

ENVIRONMENT!
Specifications Ä Chapter 11.7.1 „Lube oil specifica-

tions“ on page 159
Fill the lube oil in stages and in small quantities.
6. Observe the oil level. Wait 5‑10 minutes. The lube oil con-
tinues to flow.
chambers.
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Maintenance
Maintenance work > Replacing the grease on gas-tight drive shafts
8. Check the lube oil level on the oil level displays.

Fig. 96: Oil level display (pos.2) The lube oil level does not remain steady at a point between
Correct the oil level.
10.
ENVIRONMENT!

way.
8.3.4 Replacing the grease on gas-tight drive shafts

The replacement of grease is only required for the gas-tight version
of the drive shaft (optional).
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Maintenance
Maintenance work > Replacing the grease on gas-tight drive shafts
Press the grease a few operating hours before the

lube oil change. The used, excess grease reaches
the oil chamber of the machine stage and is dis-
charged with the lube oil change.
Pressing the grease
1.
WARNING!
Risk of burns from hot surfaces on the
housing!
Allow the surfaces of the housing to cool down to ambient

temperature.
2. Press the grease by turning the Stauffer lubricator.
Fig. 97: Stauffer lubricator CAUTION!

Risk of skin irritation from escaping grease!
Observe the grease amount and number of turns. Ä Chapter

3. After pressing the required amount of grease, turn the
Stauffer lubricator one revolution backwards. The volume of
grease can then expand when it is heated.
4. Open the Stauffer lubricators and fill them with grease.
Observe the specification of the grease. Ä Chapter
11.7.2 „Grease specifications“ on page 162
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Maintenance
Maintenance work > Changing lube oil
8.3.5 Changing lube oil

Draining lube oil
1.
WARNING!
Risk of scalding from hot lube oil!
NOTICE!
Material damage to the drain hose from lube
oil temperatures over 60 °C!
Allow the lube oil to cool down to the ambient temperature.

Fig. 98: Draining lube oil 2.
Observe the volume of the lube oil and the
oil-resistant receptacle. Ä Chapter
Have a receptacle ready.

3. Open the oil opening on the oil filling container.
ð Lube oil flows out more evenly from the oil drain.
4. Feed the drain hose into the receptacle.
5.
CAUTION!
Risk of skin irritation from old lube oil!
Remove the sealing cap from the drain valve.

Twist the drain hose onto the drain valve.
ð The drain valve opens automatically.
6.
Fig. 99: Fitting the drain hose CAUTION!
Risk of slipping from lube oil spillage!
Guide all emerging lube oil into the receptacle.

7. Remove the drain hose.
ð The drain valve closes automatically.
8. Screw the sealing cap onto the drain valve.
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Maintenance
10.
ENVIRONMENT!
Risk of environmental damage from lube oil!
Collect old and residual lube oil properly and dispose of it in

an environmentally friendly manner.

place.
3. Open the oil filling container.
unobstructed.
5.
CAUTION!

ENVIRONMENT!
Observe the oil quantity Ä Chapter 11.7.3 „Lubricant quanti-

ties“ on page 163 and specification Ä Chapter 11.7.1 „Lube
oil specifications“ on page 159.
First, fill 3/4 of the total listed quantity of lube oil.
6. Wait 5‑10 minutes. The lube oil continues to flow.
chambers.
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Maintenance
Fig. 101: Sight glass for oil level dis-

play

1 Oil fill openings, marked in red
2 Oil level displays
3 Drain valves
plays (pos.2) and adjust as necessary.
The lube oil level does not remain steady at a point between
Correct the oil level.
10.
ENVIRONMENT!

way.
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Maintenance
Maintenance work > Checking the belt pulleys
8.3.6 Replacing the intake filter

Replacing the intake filter
1.
CAUTION!
Risk of air contamination from scattered dust
particles.
Open the cap locks of the intake silencer.

2. Remove the maintenance flap.
Fig. 104: Replacing the intake filter 3. Loosen the intake filter by turning it anti-clockwise and
remove it.
4.
NOTICE!
Risk of machine damage from objects inside
the intake silencer that enter the intake
opening.
Remove residual dust inside the intake silencer.

5. Replace the intake filter.
6. Fasten the intake filter in place by turning it clockwise. Check
that it is aligned correctly.
7. Fasten the maintenance flap on the housing of the intake
silencer using the catch.
8. Reset the maintenance indicator (in accordance with the
given variation).
8.3.7 Checking the belt pulleys

For wear and damage
1. Remove the belts.

2. Check for unusual wear and tear or obvious damage.
3. Check for correct alignment and stability.
4. If necessary, replace the belt pulleys.
5. Install the sheaves.
6. Fit the belts.
Fig. 105: Belt pulleys
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Maintenance
Maintenance work > Replacing belts, version without lifting device
8.3.8 Replacing belts, version without lifting device

of the DN50
NOTICE!

2.
WARNING!
loads!

hydraulic lift.
3.
WARNING!
or slipping!
Raise the hinged motor support in small steps and always

support it with timbers! This prevents the sudden downward
movement of the hinged motor support if the hydraulic lift tips
up or slips.
of the DN80
NOTICE!

5.
Fig. 107: Example: DN80 WARNING!
loads!

hydraulic lift.
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Maintenance
Maintenance work > Checking the AERZEN safety valve
6.
WARNING!
or slipping!
Raise the hinged motor support in small steps. While doing

so, use the transport safety rod to brace the hinged motor
support in the recess of the base support. This prevents the
sudden downward movement of the hinged motor support if
the hydraulic lift tips up or slips.
7. Raise the hinged motor support until the belts can be fitted.
Fitting the belt
8.
CAUTION!
Risk of injury from tensioning components!
Fit the belt. Observe and comply with the permissible groove
Fig. 108: Permissible belt layout layout.
Tensioning the belts 9.

WARNING!
Risk of injury from tensioning, moving or
rotating components!
Release the hydraulic lift carefully and slowly.

ð The hinged motor support is lowered.
If released too quickly, the hinged motor support drops
abruptly.
The belts are tautened by the weight of the motor.
10.
NOTICE!
Risk of damage to the belt drive! The hinged
motor support must not rest on the base sup-
port, the transport securing rod or similar
equipment.
Completely remove the hydraulic lift, transport securing rod

and other auxiliary equipment and store them safely for
future maintenance purposes.
8.3.9 Checking the AERZEN safety valve

Movement test n G2", G3", DN 50, DN 80, DN 125
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Maintenance
Maintenance work > Checking that sealing plugs have been removed
1. Remove the protective caps or blanking plugs from the main-

tenance holes in the protective cylinder.
2. Guide a screwdriver into each hole.
3. Raise the valve bell with the screw drivers using leverage
force.
ð The valve’s opening function must be operational and the
valve must move.
4. Lower the valve bell.
5. Remove the screwdrivers.
Fig. 109: using a screwdriver
ð An intact valve will close.
6. Insert the protective caps or blanking plugs into the mainte-
nance holes in the protective cylinder.
Movement test n DN 150, DN 200, DN 300
1. Raise the valve bell using the stirrup.

ð The valve’s opening function must be operational and the
valve must move.
2. Release the pressure on the stirrup and lower the valve bell.
ð An intact valve will close.
Fig. 110: using the stirrup
8.3.10 Checking that sealing plugs have been removed

Checking balancing holes
Check that the (plastic) sealing plugs have been removed
from the balancing holes.
The sealing plugs are coated in machine-

colour paint as part of the manufacturing
process.
The number of sealing plugs varies
depending on the machine type!
Depending on the design, they may already
have been removed before shipping or
Fig. 111: Sealing plug layout during preparations for commissioning.
If there are no more sealing plugs in place, bring the check to

an end.
Remove the sealing plugs, bring the check to an end.
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Maintenance
Maintenance work > Checking the inlet and exhaust air openings of the acoustic hood
8.3.11 Checking the non-return flap

Checking for wear and tear and
tightness
1. Loosen the fastening screws.
Light impact on the flange cover of the non-return

flap loosens the sealing and makes disassembly
easier.
Fig. 112: Non-return flap

2. Remove the non-return flap from the housing.
3. Carry out a visual inspection.
4. If no damage and/or hardening is visible, the sealing is
acceptable.
ð Re-use the non-return flap.
5. If damage and/or hardening is visible, the sealing is not
acceptable.
ð Replace the non-return flap.
Assembling the non-return flap 1. Remove dirt, grease and used sealing agent from the flange
surface.
2. Apply sealing agent (liquid surface sealant) to the flange sur-
face of the housing.
3. Guide the non-return flap into the housing.
Remove any bleeding sealing agent with a cloth.

Observe the curing time of the sealing material!
4. Mount the flange cover with screws.
8.3.12 Checking the inlet and exhaust air openings of the acoustic hood
Checking the openings 1. Perform a visual inspection of the inlet and exhaust air open-
ings.
2. Clean the openings. Remove dirt.
Checking fan operation 1. Check the direction of flow in the operating position with a
closed acoustic hood. Observe the specifications in the
installation drawing.
2. If exhaust air is discharged from the acoustic hood, the check
is finished.
ð The acoustic hood fan is operating correctly.
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Maintenance
Cleaning after maintenance
3. If no exhaust air is discharged from the acoustic hood, the

fan is malfunctioning.
ð Replace the fan.
Replacing the fan 1. Open the maintenance door of the acoustic hood.
2.
WARNING!
Loosen the screw for fastening the fan.

3. Pull the fan from the shaft and replace it.
4. Seal the fastening screw with liquid threadlocker.
5. Screw on the fan.
6. Close the maintenance door of the acoustic hood.
7. Check the cooling air throughput during machine operation.
8.3.13 Checking pipelines for leaks

Checking for leaks on the dis- Check the pipelines for leaks (visual inspection).
charge side
Changing seals or bushings

Ensure that the pipelines have been depressur-
ised!
1. Reinforce the pipelines if necessary.

2. Disassemble leaking pipe connections.
3. Use new seals or bushing.
4. Assemble the pipe connections.
8.4 Cleaning after maintenance

Cleaning after maintenance work 1.
NOTICE!
Risk of damage! Do not used high pressure
cleaners, steam jet pumps, grease removal
agents, thinners, compressed air etc. as
cleaning methods.
2. Dust and dirt must be cleaned with suitable cloths.
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Maintenance
Checks after maintenance work
3. Clean components susceptible to scratches, display units

and touch panels of control systems, gauges etc. with a soft,
wet towel.
4. Remove all cleaning agents from the immediate vicinity of the
machine before commissioning.
5. Dispose of cloths in an environmentally-friendly way.
8.5 Commissioning after maintenance

Commissioning after maintenance 1. Inform the responsible on-site person about the result of the
work carried out and agree commissioning steps with that
person.
2. Check all previously loosened screw connections for tight-
ness.
3. Properly install all previously loosened or disassembled
assemblies or accessories.
4. Mount all protective hardware and protective covers that
were previously removed.
5. Remove all used tools, materials and other equipment from
the workspace.
6. Clean the workspace. Remove operating substances, oper-
ating materials, processing material and similar materials and
dispose of them appropriately.
7. Check that there are no persons in the hazard area.
8. Release the main circuit breaker and activate it.
9. Release the EMERGENCY STOP function.
10. Start operation in accordance with the instructions in the
“Operation” chapter.
11. Inform the responsible on-site person about the result of the
work carried out.
8.6 Checks after maintenance work

hrs hrs
operation
Oil level check and, if neces- check and, if neces-
sary, correct sary, correct
Alignment of check and, if neces-
sheaves sary, correct
Op. hrs = operating hours
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Faults
Safety instructions
9 Faults
The following chapters describe possible causes of faults and
steps to be taken to rectify them.
If faults cannot be rectified using the following instructions, contact
the manufacturer.
Improper fault rectification

WARNING!
Risk of injury from improper operation fault
rectification!
Improper fault rectification may lead to serious per-
sonal or material damage.
– Only perform fault rectification work when the
temperature.
– Only attempt to rectify faults with suitable tools.
correctly.
– Check the following before a restart:
– All safety and protective equipment is
installed and functioning correctly.
– No persons are located in the hazard area.
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Faults
Safety instructions
Fault rectification when the

machine is in operation WARNING!
Risk of injury from fault rectification while the
machine is currently in operation!
Performing fault rectification during operation of
the machine can lead to serious or fatal injuries.
– Always shut down the machine to search for a
fault and never start up the machine to detect a
fault!
– Never operate or start up the machine for fault
rectification!
– Never operate or start up the machine with dis-
assembled assemblies and accessories!
Electrical system
DANGER!
serious injury.

restarting WARNING!
may be people located in the hazard area.
– Before beginning work, switch off the energy
supply and secure it against restarting.
Requirements for personnel The fault rectification work described here may only be performed
by the designated personnel. The personnel entrusted with the
respective troubleshooting tasks are listed in the table of fault
descriptions in addition to their designated tasks.
Requirements in the event of faults and for preparations for fault
rectification work:
n Service personnel
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Faults
Safety instructions
For commissioning after rectification of a malfunction, the following

is necessary:
n Service personnel
Protective equipment For fault rectification work the following is necessary:

n Protective gloves
Special tools For troubleshooting and commissioning after a fault, the following
is necessary:
ment

n Hydraulic lift
Behaviour in the event of faults 1.

DANGER!
Risk of injury during fault rectification!
In case of a fault, activate the EMERGENCY STOP immedi-

ately.
2. Switch off the main circuit breaker and secure it against
restarting.
3. Immediately inform the responsible staff on location about
the fault.
4.
DANGER!
Ensure there is no live current.

5. Earth and short-circuit the device.
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Faults
Fault diagnosis and troubleshooting
6. Cover or shut off adjacent live parts.

7. Establish the cause of the fault.
9.2 Fault diagnosis and troubleshooting

If one of the specified causes occurs and it can only be rectified by
the manufacturer, customer service is to be contacted immedi-
ately.Ä Chapter 1.4.2 „Customer service“ on page 12
Fault description Cause Remedy Personnel

Abnormal running Belt pulleys are not Check and correct. Ä Chapter Service per-
sounds. aligned properly. 8.3.7 „Checking the belt pul- sonnel
leys“ on page 132
Bearing damage. Replace the bearings. Manufacturer’s
customer
service divi-
sion
Foreign bodies in gear Check gear wheels, rectify the damaged Manufacturer’s
wheels. areas and, if necessary, replace them. customer
service divi-
sion
Shaft deflection. Determine the shaft deflection. Replace Manufacturer’s
the component. customer
service divi-
sion
The machine gets Intake filter contami- Replace the intake filter.Ä Chapter Service per-
hot. nated (display unit, 8.3.6 „Replacing the intake sonnel
max. -45 mbar). filter“ on page 132
Ambient temperature Ensure that there is sufficient ventilation User
too high. and air extraction.
Openings of the Clean the openings. Ä Chapter User
acoustic hood for 8.3.12 „Checking the inlet and exhaust air
supply air and exhaust openings of the acoustic
air are contaminated. hood“ on page 136
The acoustic hood fan Replace the fan. Ä Chapter Service per-
is faulty. 8.3.12 „Checking the inlet and exhaust air sonnel
openings of the acoustic
hood“ on page 136
The permissible oper- Check operating data, comply with correct User
ating data has been data.
exceeded.
Lube oil in the con- Wear and tear on seals. Replace the seals. Manufacturer’s
veyed medium. customer
service divi-
sion
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Faults
Supplier status and fault messages

Lube oil in the con- Oil level too high. Correct the oil level. Ä Chapter Service per-
veyed medium. 8.3.3 „Correcting the oil sonnel
level“ on page 125
Balancing holes are Remove the sealing caps. Ä Chapter Service per-
sealed. 8.3.10 „Checking that sealing plugs have sonnel
been removed“ on page 135
Intake volume is too Intake filter contami- Replace the intake filter.Ä Chapter Service per-
low. nated (display unit, 8.3.6 „Replacing the intake sonnel
max. -45 mbar). filter“ on page 132
Intake volume is too Intake piping is leaking. Seal the intake piping. Service per-
low. sonnel
The motor requires The operating data dif- Check the operating data and comply with User
too much power. fers from the order correct data.
data.
Mechanical damage. Replace faulty components. Service per-
sonnel
Belts are vibrating. There is wear on the Replace the belts. Ä Chapter Service per-
belts. 8.3.8 „Replacing belts, version without sonnel
lifting device “ on page 133
Belt pulleys are not Check and correct. Ä Chapter Service per-
aligned properly. 8.3.7 „Checking the belt pul- sonnel
leys“ on page 132
Machine runs in Non-return flap is Replace the component.Ä Chapter Service per-
reverse after being leaking or faulty. 8.3.11 „Checking the non-return sonnel
shut down. flap“ on page 136
Medium leaking Safety valve not Replacing the safety valve Service per-
from the safety opening or closing. sonnel
valve.
The motor starts up Overload. Reduce the load. Service per-
sluggishly. sonnel
The motor vibrates. Defective motor bear- Replace the motor bearings. Service per-
ings. sonnel
9.3 Supplier status and fault messages

Suppliers
A detailed explanation of status and fault mes-
sages can be found in the separate instruction
manual
Control system fault message Depending on the customer’s control system, additional fault mes-
sages can be recorded and displayed.
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Faults
Checks after fault rectification
9.4 Commissioning after fault rectification

Commissioning after fault rectifica- 1. Check all previously loosened screw connections for tight-
tion ness.
2. Properly install all previously loosened or disassembled
assemblies or accessories.
3. Mount all protective hardware and protective covers that
were previously removed.
the workspace.
ating materials, processing material and similar materials and
dispose of them appropriately.
6. Inform the responsible on-site person about the result of trou-
bleshooting.
7. Check that there are no persons in the hazard area.
10. Confirm the removal of the fault in the control system.
11. Start operation in accordance with the instructions in the
“Operation” chapter. Ä Chapter 7.3 „Switching
on“ on page 108
work carried out
9.5 Checks after fault rectification

hrs hrs
operation
Oil level check and, if neces- check and, if neces-
sary, correct sary, correct
Alignment of Check and correct if
sheaves necessary
Op. hrs = operating hours
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Disassembly and disposal
Safety instructions
10 Disassembly and disposal

Protecting the environment and conserving resources are among
the manufacturer’s foremost priorities.
Once the machine’s service life is over, it must be disassembled
and disposed of in an environmentally-friendly way. The following
is a set of recommendations for environmentally-friendly disposal.
Improper disassembly
WARNING!
Risk of injury from improper disassembly!
Stored residual energy, sharp components, edges
and corners on or in the machine or on the neces-
sary tools can cause injury.
– Before beginning work, ensure there is suffi-
cient space.
Allow the machine to cool down to the ambient
temperature.
– Proceed with caution when working with open,
sharp-edged components.
– Keep the workspace tidy and clean. Compo-
nents and tools that are loosely stacked or
lying around can cause accidents.
– Disassemble components correctly. Pay atten-
tion to the high dead weight of some compo-
nents. If necessary, use hoists.
– Secure components, so they do not topple or
fall.
– If in doubt, contact the manufacturer.
Electric current
DANGER!
Disassembly of live components can cause serious
or fatal injury.
– Switch off the power to the operating cable.
– Check there is no live current.
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Safety instructions
Disassembling the delivery line

WARNING!
materials!
For the disassembly of pressurised components
conveying material escapes with a strong gas flow.
This can result in serious injury.
Requirements for personnel Requirements for disassembly:

Disassembly of electrical components
Personnel: n Authorised electricians with additional

qualifications
Requirements for disassembly:

Disassembly of mechanical components
Protective equipment Requirements for disassembly:

n Protective gloves
Special tools Requirements for disassembly:

n Auxiliary materials, tools
n Lifting equipment
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Disposal
10.2 Disassembly
Preparation 1. Notify the responsible staff at the site of operation about dis-
assembly.
2. Switch off the machine and secure it against restarting.
3. Shut off the pressure line and remove it.
4. Physically disconnect the entire power supply from the
machine. Discharge the stored residual energy.
5. If necessary, disconnect the machine control system from a
connected process control system.
6. Remove the operating, auxiliary and residual processing
materials, and dispose of them in an environmentally friendly
way.
Performing 1. In addition to this, clean the assemblies and components

thoroughly. Dismantle them in accordance with local regula-
tions for occupational safety and environmental protection.
2. Remove the machine’s anchor bolts.
3. During disassembly, there should be a general sorting of
parts according to disposal categories.Ä Chapter 10.3 „Dis-
posal“ on page 147
10.3 Disposal
The machine is composed primarily of steel, casting material and
various non-ferrous metals. In general, metallic materials are fully
recyclable.
Proper disposal In as far as no agreement has been made on the return or disposal
of the machine, send dismantled components for recycling:
n Scrap metals.
n Send plastics for recycling.
n Sort and dispose of other components according to material
composition.
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Disposal
Improper disposal
ENVIRONMENT!
Environmental risk from improper disposal!
Improper disposal can present a risk to the envi-
ronment.
– Have insulating material, electronic waste,
electronic components, auxiliary materials and
chemicals disposed of by a professional waste
disposal company.
– If in doubt, contact the local authorities or spe-
cialist companies for information on environ-
mentally-friendly waste disposal.
Lube oil and lubricants

ENVIRONMENT!
Environmental risks from lube oil and lubri-
cants!
The improper disposal of lube oil and lubricants
can present a risk to the environment.
– Collect lube oil carefully, store it and dispose of
it properly or recycle it.
cialist waste disposal companies for informa-
tion on environmentally-friendly waste disposal.
Battery
ENVIRONMENT!
Environmental risk from batteries!
The improper disposal of batteries, e.g. from the
control system, can present a risk to the environ-
ment.
– Collect batteries and dispose of them properly
at local collection points.
cialist waste disposal companies for informa-
tion on environmentally-friendly waste disposal.
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Disposal
Categories for sorting
Scrap iron Non-ferrous metal Insulation material Electronic waste Auxiliary mate-
(except for scrap (encoder elec- rials and chemi-
iron) tronics) cals
Scrap Aluminium Various isolators (in Electrical tools Lube and gear oils
terminal boxes)
n Scrap steel Grease
n Foundry scrap
n Scrap from non-
rusting steels
n Stainless steel
scrap
Used metal/2A Copper Voltage and current Measurement, con- Cleaning agents
materials transformers trol and regulatory and solvents
systems
n Steel beams
n Steel sheets
Machines made of Brass Power cables and Paint residue
metal leads
n Without elec-
tronics
Motor windings Instrument wiring Anti-corrosion
agents
Surge arresters Cloths (soaked in
agents or chemi-
cals)
Heat insulation Batteries from the
materials control system
(AERtronic, AER-
smart)
This does not Valve disposal This does not n Solvents,
include: include: cleaning agents
n Remove the and paint res-
n Hazardous medium before n PCB capacitors idue must not
adhesions disposal! be allowed to
n Sealed hollow Neutralise mix!
parts (due to residual
n Sort oils sepa-
danger of defla- medium in the
rately according
gration or haz- valves.
to emulsions
ardous con- and solvents.
tents)
n Agents and
chemicals must
be collected in
separate,
labelled con-
tainers.
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Disposal
Disposal of accessories Motor

n For safety reasons, disposal may only be performed by spe-
cialists for industrial waste or, alternatively, it can be returned to
the manufacturer.
n The encoder electronics are electronic waste.
Frequency converter
DANGER!
Hazard if the capacitor explodes and forms poi-
sonous gases!
n For safety reasons, disposal may only be performed by spe-

cialists for industrial waste or, alternatively, it can be returned to
the manufacturer.
n The encoder electronics are electronic waste.
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Technical data
Dimensions and weights
11 Technical data
11.1 Dimensions and weights

General information The following dimensions and weights relate to standard versions
and can vary depending on the specific model.
Exact details can be found on the installation drawing.
Information on weight can be found on the packing note and the
designation on the rating plate.
Dimensions, including packaging, are included in the forwarding
order.
Tab. 3: Dimensions and weights

Positive pressure operation
Size Width (W) Depth (D) Height (H) Nominal Weight Weight with
diameter without acoustic
mm mm mm acoustic hood,
DN hood, without without
motor and motor and
without belt without belt
drive drive
approx. kg approx. kg
GM 3 S 800 800 1,055 50 148 212
GM 4 S 925 1,135 1,280 80 207 299
GM 7 L 925 1,135 1,280 80 212 304
GM 10 S / 925 1,135 1,280 80 236 328
DN80
GM 10 S / 1,250 1,350 1,500 100 336 496
DN100
GM 15 L 1,250 1,350 1,500 100 351 511
GM 25 S 1,250 1,350 1,500 125 407 567
GM 30 L 1,500 1,800 1,900 150 690 1,020
GM 35 S 1,500 1,800 1,900 150 780 1,100
GM 50 L / 1,500 1,800 1,900 150 830 1,160
DN150
GM 50 L / 1,700 2,055 2,111 200 905 1,475
DN200
GM 60 S 1,700 2,055 2,111 200 1,035 1,605
These dimensions and weights refer to the standard model, and are approximate values. The infor-
mation may vary depending on the order.
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Technical data
Dimension specifications sheet

Size Width (W) Depth (D) Height (H) Nominal Weight Weight with
diameter without acoustic
mm mm mm acoustic hood,
DN hood, without without
motor and motor and
without belt without belt
drive drive
approx. kg approx. kg
GM 80 L 1,900 2,200 2,308 250 1,550 2,200
GM 90 S 1,900 2,200 2,308 250 1,620 2,270
GM 100 S 1,900 2,200 2,308 250 1,820 2,470
GM 130 L 2,100 2,850 2,345 300 2,436 3,410
GM 150 S 2,100 2,850 2,345 300 2,796 3,780
These dimensions and weights refer to the standard model, and are approximate values. The infor-
mation may vary depending on the order.
11.2 Dimension specifications sheet

An accompanying dimension specifications sheet/installation
drawing is provided with the product documentation.
These documents contain important dimensions for installation and
set-up.
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Technical data
Operating data
11.3 Operating data
Order no. 202101_10

Factory no.:
Serial no.: 4079331, 4079332
Item no.:
Year of manufacture 2020
Type GM7L
Nominal diameter 80
Conveyor Luft/Air
Density r 1.099 kg/m³
Conveyed quantity Q1 8.07 m³/min
Intake temperature T1 40 °C
Discharge temperature T2 83 °C
Height above NN 0 m
Absolute pressure at input p1 1.013 bar
Absolute pressure at output p2 1.413 bar
Positive pressure at output p2e 0.400 bar
Pressure difference Dp 400 mbar
Power consumption P 7.82 kW
Main piston speed n 4720 1/min
Sound pressure level 74 dB(A)
Motor rating PMOT 11.00 kW
Motor rotational speed nMOT 2950 1/min
Safety valve, set pressure p 750 mbar

Intake pressure valve, set pressure p 0 mbar
Machine weight m 435 kg
Oil quantity V 1.00 ltr
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Technical data
Technical performance data
11.4 Technical performance data

Tab. 4: Performance data and application limits
Size Differential pressure Flow rate Motor power
max. mbar max. m3/h Maximum kW
GM 3 S 900 247 7.5
GM 4 S 1,000 282 15
GM 7 L 700 493 15
GM 10 S / DN80 1,000 542 22
GM 10 S / DN100 1,000 696 30
GM 15 L 700 1,038 30
GM 25 S 1,000 1,452 55
GM 30 L 700 2,082 75
GM 35 S 1,000 2,418 90
GM 50 L / DN150 700 2,610 75
GM 50 L / DN200 700 3,306 90
GM 60 S 1,000 3,540 132
GM 80 L 700 5,034 160
GM 90 S 1,000 5,418 200
GM 100 S 1,000 6,266 250
GM 130 L 700 8,040 200
GM 150 S 1,000 9,120 355
These operating limits are maximum values. Observe the order-specific operating data.
Maximum installation elevation Data Value Unit

Maximum installation elevation above 0 m
NN*
If installed at a different elevation, observe the order-specific

design data sheets.
Environmental limits Data Value Unit

Temperature range -10 to +40 °C
Relative humidity 0 to +80 %
Chemical-free atmosphere
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Technical data
Rating plate(s) and their locations
Operating period Data Value Unit

Maximum operating period 24 h
Break until next operation - h
11.5 Rating plate(s) and their locations
Placement on the machine stage Manufacturer/rating plate on the machine stage.

Pos.1 Manufacturer plate
Pos.2 Rating plate
Fig. 113: Layout examples
Manufacturer plate - pos.1

Manufacturer plate
Fig. 114: Manufacturer plate
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Technical data
Rating plate - pos.2
Fig. 115: Rating plate

Pos.1 Machine type
Pos.2 Factory/serial number
Pos.3 Order number
Pos.4 Speed of machine
Pos.5 Power consumption
Pos.6 Year of manufacture
Pos.7 Weight
Pos.8 Speed of motor
Pos.9 Conveyed quantity
Pos.10 Pressure input (absolute) p1
Pos.11 Overpressure output p2e
Position on the acoustic hood The manufacturer and rating plate are on the operating side of the
acoustic hood.
Pos.1 / acoustic hood Manufacturer and rating plate
Fig. 116: Acoustic hood signage
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Technical data
Manufacturer and rating plate - pos.

1
Fig. 117: Manufacturer and rating plate of the acoustic hood

Pos.1 Manufacturer, including address
Pos.2 Designation
Pos.3 Machine type
Pos.4 Customer order number
Pos.5 Serial number
Pos.7 Max. intake pressure (absolute) p1
Pos.8 Max. discharge pressure (absolute) p2
Pos.9 Nominal power of motor
Pos.10 Machine weight (total)
Type designation The type designation is derived from the following table:
Tab. 5: Explanation using example: GM 90 S

Designation Explanation Details
GM Product designation Positive displacement blower
90 Maximum flow rate in m³/min
(approx.)
S Design L: Pressure differences up to 700
mbar
S: Pressure differences up to
1,000 mbar
Safety valve signage When using the AERZEN safety valve, the rating plate is on the
valve housing.
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Technical data
Noise emissions
Pos.1 Manufacturer and rating plate
Fig. 118: Signage
Safety valve rating plate
Fig. 119: Manufacturer and performance data plate

Pos.1 Manufacturer, including address
Pos.2 Material
Pos.3 Nominal diameter
Pos.5 Customer order number
Pos.6 Application temperatures
Pos.7 Valve set pressure
Pos.8 Narrowest cross-section
Pos.9 Maximum permissible pressure
Pos.10 max. flow rate
Pos.11 Medium type
11.6 Noise emissions
Information on noise emissions This information is determined in accordance with the performance
data. Ä Chapter 11.4 „Technical performance data“ on page 154
No-load operation or operation below the maximum performance
values reduces noise emissions.
Machines without an acoustic hood have considerably higher noise
emissions. Observe the measures for emission reduc-
tion.Ä Chapter 5.2 „Requirements for the installation
site“ on page 84
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Technical data
Operating materials > Lube oil specifications
Measurement conditions n applied basic standard DIN EN ISO 2151

n measured according to basic standard DIN EN ISO 3744
n with acoustic hood
n Connected, insulated pipelines
n Tolerance ± 2 dB(A)
Positive pressure Size A-weighted sound

pressure level, LpAdB(A)
GM 3 S 72
GM 4 S 72
GM 7 L 72
GM 10 S / DN 80 74
GM 10 S / DN 100 74
GM 15 L 75
GM 25 S 75
GM 30 L 77
GM 35 S 77
GM 50 L / DN 150 77
GM 50 L / DN 200 78
GM 60 S 80
GM 80 L 82
GM 90 S 83
GM 100 S 86
GM 130 L 86
GM 150 S 86
11.7 Operating materials

11.7.1 Lube oil specifications
Lube oil specifications
Choice of lubricant
When operating the machine, only use lubricants
that comply with this specification!
The quality of lube oil has a considerable effect on the service life
of the machine.
When selecting a lube oil, the application conditions and the rele-
vant additives and viscosity class are decisive.
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Technical data
Taking the operating conditions into account, only use the following
lube oils with the corresponding viscosities and additives.
* Ambient temperature = the temperature in the immediate vicinity
of the machine all year round.
Properties of lube oil

Tab. 6: General requirements for lube oil properties
Kinematic viscosity at lube oil operating temperature min. 10‑13 cSt (mm2/s)
Kinematic viscosity at -10°C min. £ 3,500 cSt (mm2/s)
Tab. 7: Minimum properties of the oil additive

EP wear-protection additives for use in rolling bearing drives
Oxidisation stability up to 110°C oil sump temperature
Foam suppressor
Detergent for dissolving deposits
Neutrality with regard to seal materials of fluoropolymer elastomer (Viton)
Neutrality with regard to one-component resin primers
Sufficient shear stability
11.7.1.1 Lube oils

Tab. 8: Standard first filling
Delta Lube 06
Intake temperature, machine stage Up to 50 °C
Discharge temperature at the discharge nozzle, Up to 140 °C
machine stage
Ambient temperature* no restriction
Delta Lube 06 is used as the first filling for standard operating conditions.
11.7.1.1.1 Alternative lube oils

Tab. 9: One or two-shift operation/intermittent operation
AERZEN special rotary piston oil
Intake temperature, machine stage Up to 50 °C
machine stage
Ambient temperature* no constraints
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Technical data
Tab. 10: Continuous operation: 24 hours a day

ISO VG 150
Fully-synthetic poly-alpha-olefin (PAO), gear or compressor oil
Intake temperature (machine stage) Up to 50 °C
machine stage
Example: MOBIL SHC 629
Tab. 11: Operation with a discharge temperature at the discharge nozzle of over 140 °C
ISO VG 220
Synthetic lube oil with a base oil of type polyglycol
Continuous oil temperature 120 °C ‑ 140 °C
Discharge temperature at the discharge nozzle, over 140 °C
machine stage
Example: ESSO Glycolube 220, ARAL Degol GS 220
11.7.1.2 Changing the lube oils

Delta Lube 06, AERZEN special rotary piston oil ‑‑> fully syn-
thetic PAO lubricants
The AERZEN lubricants (Delta Lube 06, AERZEN special rotary
piston oil) are fully compatible with fully synthetic PAO lubricants.
Measures: If you change to another lube oil, no specific measures
need be taken. However, to preserve the working properties of the
new lube oil, the lube oil that is replaced should be drained com-
pletely. After an operating time of 100 hours, the lube oil and the oil
filter (if any) must be replaced once. Only lube oil of the same type
should be used for topping up.
Delta Lube 06, AERZEN special rotary piston oil, fully syn-
thetic PAO lubricants --> polyglycol oils (PAG)
The AERZEN lubricants (Delta Lube 06, AERZEN special rotary
piston oil) as well as PAO lubricants are not compatible with poly-
glycol oils (PAG) or perfluorinated polyether oils, e.g. Fomblin.
Measures: In order to change the lube oil type, the machine must
be completely dismantled and the entire oil system thoroughly
cleaned of residue. A rinsing is recommended before initial com-
missioning. Only lube oil of the same type should be used for top-
ping up.
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Technical data
Operating materials > Grease specifications
11.7.2 Grease specifications
Only for the gas-tight version of the drive shaft!
Tab. 12: Greases for the gasket of the drive shaft

Grease KHC-2P-30
Using the lubricating oils according to AERZEN lube oil specification, excluding polyglycol oils
Filling at the factory KLÜBER PETAMO GHY 133 N
Grease MPG2K-40
Using a polyglycol oil according to AERZEN lube oil specification
Filling at the factory KLÜBER SYNTHESO PROBA 270
Information on grease
n Avoid mixing different greases.
n Relubrication is only permitted with the same grease.
n If these greases are not available, completely remove the
grease and replace it with another grease in accordance with
KHC-2P-30 or MPG2K-40.
n Observe the seal compatibility with Viton!
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Technical data
Operating materials > Lubricant quantities
11.7.3 Lubricant quantities
The following values for lubricant levels are guide-

line values. The main factor in determining the oil
fill quantity is the level shown on the relevant oil
level displays.
Tab. 13: Version with oil system

Total oil quantity
Oil level middle sight glass on the acoustic hood
Operating material Machine type Fill quantity, approx. Unit
Lube oil GM 3 S 0.55 Litres (ltr)
GM 4 S 1.00
GM 7 L 1.00
GM 10 S 1.40
GM 15 L 1.40
GM 25 S 1.75
GM 30 L 1.75
GM 35 S 3.75
GM 50 L 4.50
GM 60 S 7.50
GM 80 L 7.50
GM 90 S 12.50
GM 100 S 12.50
GM 130 L 12.50
GM 150 S 12.00
Grease filling quantity for machine

stage Only for the gas-tight model of the drive shaft!
Machine type Fill quantity,

Operating material Unit
approx.
Grease GM 3 S 5 cm3
GM 4 S 5
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Technical data
Paintwork
Machine type Fill quantity,

Operating material Unit
approx.
GM 7 L 5
GM 10 S 5
GM 15 L 5
GM 25 S 5
GM 30 L 5
GM 35 S 10
GM 50 L 10
GM 60 S 10
GM 80 L 10
GM 90 S 10
GM 100 S 10
GM 130 L 10
GM 150 S 20
Stauffer lubricators
Tab. 14: Grease quantity per Stauffer lubricator for each rotation
Stauffer lubricator size Rotation Grease amount in
cm3
3 1 0.8
5 1 2.3
Fig. 120: Stauffer lubricator
Drive motor grease quantity
Fill quantity,
Operating material Motor size Unit
approx.
Grease Observe the specifications in the motor documentation and
on the rating plate.
11.8 Paintwork
Corrosion protection The housing surfaces receive the following coatings to protect
them against corrosion.
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Technical data
Electrical information > Motor overload protection
Standard coating
Undercoat Corrosion protection on alkyd resin basis
End coating Alkyd resin surface coating
Coating for heightened corrosion protection

Undercoat Corrosion protection on 2-component
basis (epoxy resin micaceous iron oxide)
Intermediate coating
End coating Polyurethane surface coating
11.9 Electrical information

11.9.1 Voltage fluctuations
Permissible voltage fluctuations Permissible voltage fluctuations are described in the international
standard IEC 60038 subject to country-specific supply voltage tol-
erances.
Machine use only in a stable three-phase power supply. Voltage
fluctuations or drops beyond the tolerance level may cause serious
damage to the drive system.
11.9.2 Earthing strap cross-section

Earthing strap Power [kW] Cross-section [mm²]
to 55 14
to 200 70
to 315 2 x 70
11.9.3 Motor overload protection

Installation value Nominal motor current [%]
max. 110
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Technical data
Supplier components > Balancing grade
11.10 Supplier components
11.10.1 Intake filter

Technical data Intake filter Values Unit
Filter resistance in clean condition > 10 mbar
max. filter resistance 45 mbar
11.10.2 Balancing grade

Technical data
The vibration behaviour is determined not only by
the balancing grade of the drive shafts but also by
the balancing grade of the drive elements.
The drive shafts of the pistons and rotors are balanced according
to the half-key principle. Sheaves and couplings must therefore
correspond to balancing type “H”.
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Notes on the Declaration of Conformity
12 Notes on the Declaration of Conformity

This document is provided for informational pur-
poses only and gives an account of the contents of
the Declaration of Conformity. The original docu-
ment is provided with the product or is sent in a
separate document.
Declaration of Conformity
1012-1
pursuant to the EC Machinery Directive 2006/42/EC, Appendix II 1A

Translation of Original Declaration of Conformity
Manufacturer Representative pursuant to the Machinery Directive

Representative for technical documentation
Aerzener Maschinenfabrik GmbH Aerzener Maschinenfabrik GmbH
Phone: +49 5154 81-0 Phone: +49 5154 81-0
Fax: +49 5154 81-9191 Fax: +49 5154 81-9191
E-mail: info@aerzener.de E-mail: info@aerzener.de
Internet: www.aerzen.com Internet: www.aerzen.com
Reherweg 28 Reherweg 28
31855 Aerzen, Germany 31855 Aerzen, Germany
Product
Designation
Type
Serial no.
Order no.
Year of construction
We hereby declare that the aforementioned product complies with all applicable provisions of the Machinery Directive 2006/42/EC.
The aforementioned product fulfils the requirements of the following applicable directives:
► Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast) 2006/42/EC
The following harmonised standards were applied:
► DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO 12100:2010)
► DIN EN 1012-1:2011-02 Compressors and vacuum pumps - Safety requirements - Part 1: Air compressors; German version EN
1012-1:2010
14.08.2018, CE MRL 1012_, 1, en_GB
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Glossary
13 Glossary
·AERZEN safety valve Component in pneumatic systems for limiting the maximum
permissible pressure and for safeguarding the machine.
AERZEN safety valves may only be operated in conjunction
with a product that has been manufactured by AERZEN!
AERZEN safety valves fulfill the function of a pressure valve.
They are not designed to fulfill a safety function.
·Belt run The belt section between two sheaves is termed a “belt run”.
·Discharge temperature Temperature measured at the discharge sockets of the
machine stage.
·EMERGENCY STOP function A function intended to alleviate the danger of impending haz-
ards in terms of injury or damage to persons and machines
during operation, or to reduce the danger of hazards that are
already present.
A function that is activated by one single action by an indi-
vidual person.
The purposeful shut-down of the machine to avoid a dan-
gerous situation. Voltage-carrying components are still
active.
EMERGENCY STOP.
·Machine A machine is an assembly of linked parts or components, at
least one of which moves. A machine is fitted or intended to
be fitted with a drive system. The machine has a proper
intended use and is assembled for a specific purpose.
Another technical term for “machine” is “unit”.
·Machine stage A machine stage is an incomplete machine. It is an
assembly that almost constitutes a machine, but that does
not fulfil a specific function. A machine stage is only intended
to be installed in and added to other machines or other
incomplete machines.
·Oil system The oil system is used in a multitude of acoustic hoods. It
comprises a filling vessel, an additional oil level display on
the acoustic hood, and the oil pipe connection.
·Sentinel filter A sentinel filter is another filter downstream from a filter.
It fulfills an end cleaning function and a safety function.
·Stop category 0 Stop category 0.
Shut-down by means of immediate interruption of the power
supply to the machine.
Performs a shut-down by means of mechanical disconnec-
tion (uncoupling) of components that pose a danger and
their mechanical drive elements and, if necessary, performs
a braking procedure.
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Index
14 Index
A Disassembly
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Performing . . . . . . . . . . . . . . . . . . . . . . . . . 147
Performance data . . . . . . . . . . . . . . . . . . . . 166 preparation . . . . . . . . . . . . . . . . . . . . . . . . . 147
Acoustic hood . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Safety instructions . . . . . . . . . . . . . . . . . . . 145
AERtronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Discharge silencer
Alignment Base support . . . . . . . . . . . . . . . . . . . . . . . . 61
Dowelling . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Disposal
Application limits . . . . . . . . . . . . . . . . . . . . . . . 154 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Assemblies Categories for sorting . . . . . . . . . . . . . . . . . 149
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Lube oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 148
B proper disposal . . . . . . . . . . . . . . . . . . . . . . 147
Belt Safety instructions . . . . . . . . . . . . . . . . . . . 145
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Drive motor
Belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 factory installation . . . . . . . . . . . . . . . . . . . . 55
Belt pulley Pole-changing motor . . . . . . . . . . . . . . . . . . 59
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Requirements . . . . . . . . . . . . . . . . . . . . . . . . 54
Bondal sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
E
C Earthing
Cleaning Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 137 Electrical information
Commissioning Earthing strap, cross-sections . . . . . . . . . . 165
after a fault . . . . . . . . . . . . . . . . . . . . . 111, 144 Motor overload protection . . . . . . . . . . . . . . 165
After maintenance . . . . . . . . . . . . . . . . 111, 138 Voltage fluctuations . . . . . . . . . . . . . . . . . . 165
Control elements . . . . . . . . . . . . . . . . . . . . . . . . 53 Emergency
Controls area Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . 107
Hazard area . . . . . . . . . . . . . . . . . . . . . . . . . 45 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Copyright protection . . . . . . . . . . . . . . . . . . . . . 11 Environmental limits . . . . . . . . . . . . . . . . . . . . 154
Corrosion protection Environmental protection . . . . . . . . . . . . . . . . . . 47
Paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Anti-corrosion agents . . . . . . . . . . . . . . . . . . 47
Customer service . . . . . . . . . . . . . . . . . . . . . . . 12 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Insulation material . . . . . . . . . . . . . . . . . . . . 47
D
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Decommissioning . . . . . . . . . . . . . . . . . . . . . . 111
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F
Dimension specifications sheet . . . . . . . . . . . . 152 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Dimensions checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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Index
Fault diagnosis M
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 142 Maintenance
Fault displays . . . . . . . . . . . . . . . . . . . . . . . . . 109 Safety instructions . . . . . . . . . . . . . . . . . . . 112
Fault rectification Maintenance indicator . . . . . . . . . . . . . . . . . . . . 59
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Maintenance schedule
Faults arduous operating conditions . . . . . . . . . . . 119
Safety instructions . . . . . . . . . . . . . . . . . . . 139 Normal operation . . . . . . . . . . . . . . . . . . . . 116
First commissioning Maintenance work . . . . . . . . . . . . . . . . . . . . . . 121
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Safety instructions . . . . . . . . . . . . . . . . . . . . 92 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Frequency converter Misuse
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 foreseeable . . . . . . . . . . . . . . . . . . . . . . . . . 29
H N
Hazard area Noise emissions . . . . . . . . . . . . . . . . . . . . . . . 158
Controls area . . . . . . . . . . . . . . . . . . . . . . . . 45 Non-return flap . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 136
I
Initial commissioning O
Performing . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Oil level
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 93 checking with the oil system . . . . . . . . . . . . 124
Installation too high . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Safety instructions . . . . . . . . . . . . . . . . . . . . 82 too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Installation elevation . . . . . . . . . . . . . . . . . . . . 154 Openings
Instrumentation Inlet and exhaust air . . . . . . . . . . . . . . . . . . 136
Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Operating
Intake filter Safety instructions . . . . . . . . . . . . . . . . . . . 106
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Shut-down in case of emergency . . . . . . . . 107
Technical data . . . . . . . . . . . . . . . . . . . . . . 166 Operating data . . . . . . . . . . . . . . . . . . . . . . . . 153
Intake silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Operating materials
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 163
Operating period . . . . . . . . . . . . . . . . . . . . . . . 155
L
Operating principle . . . . . . . . . . . . . . . . . . . . . . 49
Lube oil
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Overview
filling with the oil system . . . . . . . . . . . . . . . 122
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Specification . . . . . . . . . . . . . . . . . . . . . . . . 159
Lubricants P
Filling quantities . . . . . . . . . . . . . . . . . . . . . 163 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Paintwork
Corrosion protection . . . . . . . . . . . . . . . . . . 164
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Index
Explosion class IIC . . . . . . . . . . . . . . . . . . . 164 Soft starter

Performance data . . . . . . . . . . . . . . . . . . . . . . 154 Soft starter . . . . . . . . . . . . . . . . . . . . . . . . . 58
Personnel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Qualifications . . . . . . . . . . . . . . . . . . . . . . . . 33 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Storage for over 12 months
Pipe connection Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 78
checking on discharge-side . . . . . . . . . . . . 137 Storage for over 12 months in a tropical climate
Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . 59 Suppliers
Protective equipment Fault messages . . . . . . . . . . . . . . . . . . . . . 143
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Status messages . . . . . . . . . . . . . . . . . . . . 143
Switches
Q
Pressure and temperature . . . . . . . . . . . . . . 56
Qualifications
Switching off
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operating mode . . . . . . . . . . . . . . . . . . . . . 110
R Switching on
Rating plates Operating mode . . . . . . . . . . . . . . . . . . . . . 108
Manufacturer plate . . . . . . . . . . . . . . . . . . . 155 Symbols
Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 in the manual . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacement parts . . . . . . . . . . . . . . . . . . . . . . 32 System pipeline
Replacing the grease . . . . . . . . . . . . . . . . . . . 128 connecting . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Requirements
T
Installation site . . . . . . . . . . . . . . . . . . . . . . . 84
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 151
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Balancing grade . . . . . . . . . . . . . . . . . . . . . 166
S Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Safety classifications . . . . . . . . . . . . . . . . . . . . . 42 Transport
Safety device . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation site . . . . . . . . . . . . . . . . . . . . . . . 76
Acoustic hood . . . . . . . . . . . . . . . . . . . . . . . 41 Packaged units . . . . . . . . . . . . . . . . . . . . . . 75
EMERGENCY STOP . . . . . . . . . . . . . . . . . . 38 Safety instructions . . . . . . . . . . . . . . . . . . . . 67
Motor mount . . . . . . . . . . . . . . . . . . . . . . . . . 41 Transport inspection
Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . 42 Completeness . . . . . . . . . . . . . . . . . . . . . . . 74
Safety valve Transport damage . . . . . . . . . . . . . . . . . . . . 74
AERZEN . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Troubleshooting
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Sealing plug Type designation . . . . . . . . . . . . . . . . . . . . . . . 157
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Securing the machine against restarting . . . . . . 45
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Appendix
Appendix
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Appendix
Table of Contents
A AERZEN Declarations .................................................... 175

A.1 Declaration of Conformity ........................................ 177
A.2 Declaration of Conformity PED ............................... 181
A.3 Declaration of Conformity EAC ............................... 185
B Safety Data Sheet ........................................................... 189
C Accessories .................................................................... 225
C.1 Drive motor .............................................................. 227
C.2 Motor data sheet ..................................................... 257
C.3 Safety valve ............................................................. 263
D Drawing ........................................................................... 323
D.1 Installation drawing ................................................. 325
D.2 Diagram ................................................................... 329
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Appendix
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AERZEN Declarations
A AERZEN Declarations
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AERZEN Declarations
176 202101_10 / 1236965 26.02.2020

AERZEN Declarations
A.1 Declaration of Conformity
Name Data
Designation Declaration of Conformity
Type /
Number /
Type of manual /
Manufacturer AERZEN
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AERZEN Declarations
178 202101_10 / 1236965 26.02.2020

DocId CE MRL 1012_1 01_2014
Declaration of conformity
pursuant to the EC Machinery Directive 2006/42/EC, Annex II 1A
Translation of Original Declaration of conformity

Manufacturer Representative pursuant to the Machinery Directive
Representative for technical documentation
Aerzener Maschinenfabrik GmbH Herr Ingo Kammeyer
Phone: +49 5154 81-0 Aerzener Maschinenfabrik GmbH
Fax: +49 5154 81-9191 Phone: +49 5154 81-0
E-Mail: info@aerzener.de Fax: +49 5154 81-9191
Internet: www.aerzen.com E-Mail: info@aerzener.de
Reherweg 28 Internet: www.aerzen.com
31855 Aerzen / Germany Reherweg 28
31855 Aerzen / Germany
Product
Designation positive displacement blower
Type GM7L
Serial no 4079331, 4079332
Order no. 202101 / 000010
Year of construction 2020
We hereby declare that the above product complies with all applicable provisions of the
Machinery Directive 2006/42/EC.
- Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on
machinery, and amending Directive 95/16/EC (recast) 2006/42/EC
- DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design - Risk
assessment and risk reduction (ISO 12100:2010) 2011-03 DIN EN ISO 12100:2011-03
- DIN EN 1012-1:2011-02 Compressors and vacuum pumps - Safety requirements - Part 1: Air
compressors; German version EN 1012-1:2010 2011-02 DIN EN 1012-1:2011-02
Information on Ingo Kammeyer Location, date of issue

signatory Manager
Signature Aerzen, 24.02.2020
EN 1 / 2
CE MRL 1012_1 01 PED
Appendix: Overview of the pressure equipment

installed
Appendix to Declaration of conformity pursuant to 2006/42/EC, Annex II, No. 1A

Pursuant to Article 1, Number 2 j) of Directive 2014/68/EU:2014-05-15 the aforementioned
device contains components which fulfil the requirements of the following applicable
directives:
Directive 2014/68/EU:2014-05-15 of the European Parliament and Council on the approximation of
the laws of the Member States relating to pressure equipment
This appendix contains a listing of the pressure equipment of Category II and upwards
contained in the the machine.
Components in accordance with "good engineering practice” and Category I are covered by the
Machine Directive and are not dealt with here.
Designation Material no. Conformity- Category

assessment
procedure
EN 2 / 2
AERZEN Declarations
A.2 Declaration of Conformity PED
Name Data
Designation Declaration of Conformity PED
Type VT...
Number /
Type of manual /
Manufacturer AERZEN
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AERZEN Declarations
182 202101_10 / 1236965 26.02.2020

CE PED DV
Declaration of conformity
Pursuant to EC Pressure Equipment Directive 2014/68/EU, Annex IV
Translation of Original Declaration of conformity

Manufacturer Representative
Aerzener Maschinenfabrik GmbH Mr Oliver Palm
Fax: +49 5154 81-9191 Phone: +49 5154 81-0
E-Mail: info@aerzener.de Fax: +49 5154 81-9191
Internet: www.aerzen.com E-Mail: info@aerzener.de
31855 Aerzen / Germany Reherweg 28
31855 Aerzen / Germany
Valve size Category as per Annex II, Module

Paragraph 2 of Directive
2014/68/EU
50 Kategorie I Modul A
Product
Designation valve
Type VT50
Serial no 4079331V1, 4079332V1
Order no. 202101 / 000010
Year of construction 2020
We hereby declare that the above product complies with all applicable provisions of the
Pressure Equipment Directive 2014/68/EU.
- Directive 2014/68/EU:2014-05-15 of the European Parliament and Council on the approximation
of the laws of the Member States relating to pressure equipment.
- DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design - Risk
assessment and risk reduction (ISO 12100:2010) 2011-03 DIN EN ISO 12100:2011-03
- PED AD 2000
Information on Oliver Palm Location, date of issue

the signatory Vize President
Technology Aerzen, 24.02.2020
i.V.
EN 1 / 1
AERZEN Declarations
A.3 Declaration of Conformity EAC
Name Data
Designation Declaration of Conformity EAC
Type /
Number TR TS 010/2011
Type of manual /
Manufacturer AERZEN
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AERZEN Declarations
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AERZEN Declarations
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AERZEN Declarations
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Safety Data Sheet
B Safety Data Sheet
Name Data
Designation Safety data sheet
Type DELTA LUBE 06
Number 178 132 000
Type of manual /
Manufacturer AERZEN
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Safety Data Sheet
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Safety Data Sheet
SAFETY DATA SHEET

DELTA LUBE 06
LUBE OIL
Pursuant to Regulation (EC) no. 1907/2006 (REACH),

Appendix II - Germany
Date of issue: 01/08/2017
GB
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Safety Data Sheet

Reherweg 28
31855 Aerzen, Germany
Germany
Telephone: +49 (0) 5154 81-0
Fax: +49 (0) 5154 81-9191
SDB Delta Lube 06, 9, en_GB
This safety data sheet was created by:

GmbH
T-SE
© 2017
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Safety Data Sheet
Table of contents
Table of contents
1 Section: Designation of the medium or mixture and
the company........................................................................ 5
1.1 Product identifier........................................................... 5
1.2 Relevant, identified uses of the medium or mixture
and uses that we advise against................................... 5
1.3 Details on the supplier providing the safety data
sheet............................................................................. 5
1.4 Emergency phone number .......................................... 6
2 Section: Potential hazards................................................. 7
2.1 Classification of medium or mixture.............................. 7
2.2 Labelling elements........................................................ 7
2.3 Other hazards............................................................... 7
3 Section: Composition / information on components...... 8
3.1 Mixtures........................................................................ 8
4 Section: First-aid measures............................................... 9
4.1 Description of first-aid measures.................................. 9
4.2 Most important acute or delayed symptoms and
effects........................................................................... 9
4.3 Instructions regarding immediate medical attention or
special treatment.......................................................... 9
5 Section: Firefighting measures....................................... 10
5.1 Extinguishing equipment............................................. 10
5.2 Particular hazards arising from the medium or mix-
ture.............................................................................. 10
5.3 Advice for firefighters.................................................. 10
6 Section: Measures in the event of unintentional
release................................................................................ 11
6.1 Personal precautions, protective equipment and
emergency procedures............................................... 11
6.2 Environmental measures............................................ 11
6.3 Methods and material for retention and cleaning........ 11
6.4 Reference to other sections........................................ 11
7 Section: Handling and storage........................................ 12
7.1 Protective measures for safe handling....................... 12
7.2 Conditions for safe storage, including any incompati-
bilities.......................................................................... 12
7.3 Specific end use(s)..................................................... 12
8 Section: Limiting and monitoring exposure / personal
protective equipment........................................................ 13
8.1 Control parameters..................................................... 13
8.2 Exposure controls....................................................... 13
9 Section: Physical and chemical properties.................... 15
9.1 Information on basic physical and chemical proper-
ties.............................................................................. 15
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Safety Data Sheet
Table of contents
9.2 Other information........................................................ 16

10 Section: Stability and reactivity....................................... 17
10.1 Reactivity.................................................................. 17
10.2 Chemical stability...................................................... 17
10.3 Potential for dangerous reactions............................. 17
10.4 Conditions to be avoided.......................................... 17
10.5 Incompatible materials.............................................. 17
10.6 Hazardous products of decay................................... 17
11 Section: Toxicological information................................. 18
11.1 Information on toxicological effects........................... 18
12 Section: Environmental information............................... 21
12.1 Toxicity...................................................................... 21
12.2 Persistence and degradability................................... 21
12.3 Bioaccumulative potential......................................... 22
12.4 Mobility in the ground................................................ 22
12.5 Results of PBT and vPvB assessments................... 22
12.6 Other adverse effects................................................ 23
13 Section: Disposal instructions........................................ 24
13.1 Waste treatment methods......................................... 24
14 Section: Information on transport................................... 25
15 Section: Statutory provisions.......................................... 27
15.1 Safety, health and environmental regulations/legis-
lation specific to the substance or mixture................ 27
15.2 Chemical safety assessment.................................... 28
16 Other information.............................................................. 29
17 Index................................................................................... 31
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Safety Data Sheet
Section: Designation of the medium or mixture ...

Details on the supplier providing the safety data sheet.
1 Section: Designation of the medium or mixture and the

company
1.1 Product identifier

Product name Delta Lube 06
Product code 050143
1.2 Relevant, identified uses of the medium or mixture and uses that we
advise against.
Use of the medium/mixture Lube oil
Recommended limitations for Only for commercial users.
use
1.3 Details on the supplier providing the safety data sheet.

Reherweg 28
D-31855 Aerzen
Telephone +49 (0) 51 54 8 10
Fax +49 (0) 51 54 8 19 191
E-mail contact for the person E-mail info@aerzener.com

responsible for this SDS:
National contact information: Address Aerzener Maschinenfabrik GmbH

Reherweg 28
D-31855 Aerzen
Telephone +49 (0) 51 54 8 10
Fax +49 (0) 51 54 8 19 191
E-mail info@aerzener.com
09.12.2019 5
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Safety Data Sheet
Section: Designation of the medium or mixture ...

Emergency phone number
1.4 Emergency phone number

Emergency phone number: Emergency phone number (and service hours)
n +49 (0) 69 305 6418 (24 hours a day)
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Safety Data Sheet
Section: Potential hazards

Other hazards
2 Section: Potential hazards
2.1 Classification of medium or mixture

Classification pursuant to Regula- n Non-hazardous substance or mixture.
tion (EC) no. 1272/2008:
2.2 Labelling elements

Labelling (REGULATION (EC) No. n Non-hazardous substance or mixture.
1272/2008):
2.3 Other hazards

This substance/mixture does not contain any components in con-
centrations of 0.1% or higher that are classified as either persis-
tent, bioaccumulative or toxic (PBT), or very persistent or very bio-
accumulative (vPvB).
09.12.2019 7
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Safety Data Sheet
Section: Composition / information on componen...

Mixtures
3 Section: Composition / information on components
3.1 Mixtures
Chemical characterisation: n Ester oil
Synthetic hydrocarbon oil
Hazardous components
Chemical name CAS No. Classification Concentration Concentration

limits (% w/w)
EC no.
M-factor remarks
INDEX no.
Registration
number
Benzenamine, N- 68411-46-1 Aquatic Chronic3; >=1–<2,5
phenyl, reaction 270-128-1 H412
products with 2,4,4-
trimethylpentene 01-2119491299-23-
XXXX
For an explanation of the abbreviations, see Section 16.
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Safety Data Sheet
Section: First-aid measures

Instructions regarding immediate medical attention or special treatment
4 Section: First-aid measures
4.1 Description of first-aid measures

Following inhalation: n Bring the affected person out into the fresh air. If symptoms
persist, seek medical attention.
Keep affected persons calm and warm.
If breathing becomes irregular or ceases, initiate artificial respi-
ration.
Following skin contact: n Remove soiled clothing.

If irritation occurs, seek medical attention.
In case of skin contact, rinse skin with water immediately.
Following eye contact: n Immediately rinse eyes with plenty of water for a period of at
least 10 minutes, and be sure to also rinse under the eyelids.
If eye irritation persists, consult a medical specialist.
Following ingestion: n Bring the affected person out into the fresh air.
DO NOT induce vomiting.
Rinse out mouth with water.
4.2 Most important acute or delayed symptoms and effects

Symptoms: n No information available.
Risks: n None known.
4.3 Instructions regarding immediate medical attention or special treatment

Treatment: n No information available.
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Safety Data Sheet
Section: Firefighting measures

Advice for firefighters
5 Section: Firefighting measures
5.1 Extinguishing equipment

Suitable extinguishing equipment: n Water spray, alcohol-resistant foam, dry extinguishing agent or
carbon dioxide.
Unsuitable extinguishing equip- n High-volume water jet

ment:
5.2 Particular hazards arising from the medium or mixture

Particular hazards for firefighting: n In case of fire, the following can be released:
Carbon oxides
Nitrogen oxides (NOx)
5.3 Advice for firefighters

Special protective equipment for n In case of fire, wear a self-contained breathing apparatus.
firefighting: Wear personal protective equipment.
The inhalation of decomposition products can prove hazardous
to health.
Further information: n Standard procedures in case of chemical fires:
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Safety Data Sheet
Section: Measures in the event of unintentiona...

Reference to other sections
6 Section: Measures in the event of unintentional release
6.1 Personal precautions, protective equipment and emergency procedures

Personal precautions: n Move persons to a safe area.
Wear personal protective equipment.
See protective measures under points 7 and 8.
6.2 Environmental measures

Environmental measures: n Take all possible measures to prevent the medium from
entering drains or watercourses.
Prevent any additional discharge or spillage, insofar as it is
safe to do so.
If it is not possible to stem the spillage of larger quantities of
the medium, notify the relevant local authorities.
6.3 Methods and material for retention and cleaning

Cleaning procedures: n Stem and absorb spillages using non-flammable, absorbent
material (e.g. sand, soil, diatomaceous earth, vermiculite). For
the purposes of disposal, and in accordance with local/national
legal requirements, transfer the medium into containers (see
Section 13).
6.4 Reference to other sections

Reference to other sections: n Personal protective equipment: See Section 8.
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Safety Data Sheet
Section: Handling and storage

Specific end use(s)
7 Section: Handling and storage
7.1 Protective measures for safe handling

Notes on safe handling: n Personal protective equipment: See Section 8.
Do not eat, drink or smoke in areas where the product is being
used.
Clean hands and face before breaks and immediately after
handling the product.
Hygiene measures n After use, thoroughly wash face, hands and all exposed areas
of skin.
7.2 Conditions for safe storage, including any incompatibilities

Requirements for storage areas n Store in original containers.
and containers: Keep containers closed when they are not being used.
Store in a cool, dry and well ventilated area.
Carefully close open containers and store them upright to pre-
vent any product from escaping.
Store the product in compliance with the special legal require-
ments of the country in question.
Store in correctly labelled containers.
Storage class (TRGS 510): n 10 – flammable liquids
7.3 Specific end use(s)

Specific use(s): n Specific instructions are not required.
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Safety Data Sheet
Section: Limiting and monitoring exposure / pe...

Exposure controls
8 Section: Limiting and monitoring exposure / personal pro-

tective equipment
8.1 Control parameters

Parameters to be monitored: n Does not contain substances with occupational exposure limit
values.
Derived no effect level (DNEL) as

per Regulation (EC) No. 1907/2006:
Substance name Application range Means of expo- Potential damage Value

sure to health
Benzenamine, N- Employee Inhalation Long-term systemic 0.6 mg/m3
phenyl, reaction effects
products with 2,4,4-
trimethylpentene
Employee Skin contact Long-term systemic 0.08 mg/kg body
effects weight/day
Predicted no effect concentration

(PNEC) as per Regulation (EC) No.
1907/2006:
Substance name Environmental compartment Value

Benzenamine, N-phenyl, reaction Fresh water 0.034 mg/l
products with 2,4,4-trimethylpen-
tene
Marine water 0.003 mg/l
Microbiological activity in waste- 10 mg/l
water treatment plants
Fresh water sediment 0.446 mg/kg
Marine water sediment 0.045 mg/kg
Soil 1.76 mg/kg
8.2 Exposure controls

Technical protective measures none
Eye protection: n Safety goggles with side shielding as per EN 166
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Safety Data Sheet
Section: Limiting and monitoring exposure / pe...

Exposure controls
Hand protection
Material: n Nitrile rubber
Protection index n Class 1
Remarks: n For longer or repeated periods of contact, use gloves.

The protective gloves used must fulfil the specifications of EC
Directive 89/686/EEC and the EN 374 Standard that is derived
from it.
The breakthrough time is dependent on, among other things,
the material, thickness and design of the glove and must there-
fore be ascertained on a case-by-case basis.
Respiratory protection: n Not required, except for aerosol formation.
Filter type: n Filter type A-P
Protective measures: n The type of protective equipment must be chosen on the basis
of the concentration and quantity of the hazardous substance
in the work area.
Choose body protection according to its type, the concentration
and quantity of the hazardous substance and in accordance
with the given workplace conditions.
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Safety Data Sheet
Section: Physical and chemical properties

Information on basic physical and chemical properties
9 Section: Physical and chemical properties
9.1 Information on basic physical and chemical properties

Appearance n liquid
Colour: n blue
Odour: n characteristic
Odour threshold: n No data available
pH value: n No data available
Melting point/melting range: n No data available
Boiling point/boiling range: n No data available
Flash point: n > 240 °C
Evaporation rate: n No data available
Flammability (solid, gas): n Not applicable
Upper explosion limit: n No data available
Lower explosion limit: n No data available
Vapour pressure: n < 0.005 hPA, 20 °C
Relative vapour density: n No data available
Density: n 0.92 g/cm3 (20 °C)
Bulk density: n No data available
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Safety Data Sheet
Section: Physical and chemical properties

Other information
Water solubility: n insoluble
Solubility in other solvents: n No data available
Partition coefficient: n-octanol/ n No data available

water:
Auto-ignition temperature: n No data available
Decomposition temperature: n No data available
Dynamic viscosity: n No data available
Kinematic viscosity: n 48 mm2/s (40 °C)
Explosive properties: n Non-explosive
Oxidising properties: n No data available
9.2 Other information

Sublimation point: n No data available
Auto-ignition: n No data available
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Safety Data Sheet
Section: Stability and reactivity

Hazardous products of decay
10 Section: Stability and reactivity
10.1 Reactivity
Reactivity: n No hazards worthy of special mention.
10.2 Chemical stability

Chemical stability: n Stable under normal conditions.
10.3 Potential for dangerous reactions

Dangerous reactions: n No dangerous reactions known where the product is handled
as intended.
10.4 Conditions to be avoided

Conditions to be avoided: n No conditions worthy of special mention.
10.5 Incompatible materials

Substances to be avoided: n No substances worthy of special mention.
10.6 Hazardous products of decay

Hazardous products of decay: n No decomposition if stored and used as intended.
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Section: Toxicological information

Information on toxicological effects
11 Section: Toxicological information
11.1 Information on toxicological effects

Acute toxicity
Product:
Acute oral toxicity: n Remarks: No information available.
Acute inhalation toxicity: n Remarks: No information available.
Components: n Benzenamine, N-phenyl, reaction products with 2,4,4-tri-

methylpentene:
Acute oral toxicity: n LD50 (rat): > 5,000 mg/kg

Method: OECD Test Guideline 401
Acute dermal toxicity: n LD50 (rat): > 2,000 mg/kg

Assessment: The substance or mixture does not have any
acute dermal toxicity
Corrosive/irritant reaction on the

skin
Product: n Remarks: No information available.

methylpentene:
Species: Rabbit
Assessment: No skin irritation
Result: No skin irritation
Serious eye damage/eye irritation
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Safety Data Sheet


methylpentene:
Species: Rabbit
Assessment: No eye irritation
Result: No eye irritation
Respiratory/skin sensitisation

methylpentene:
Species: Guinea pig
Assessment: Does not cause sensitisation in laboratory ani-
mals.
Result: Does not cause sensitisation in laboratory animals.
Germ cell mutagenicity
Product:
In vitro genotoxicity: n Remarks: No available data.
In vivo genotoxicity: n Remarks: No available data.
Carcinogenicity
Reproductive toxicity
Product:
Effect on fertility: n Remarks: No available data.
Effect on foetal development: n Remarks: No available data.
Toxicity with repeated applications
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Safety Data Sheet

Aspiration toxicity
Product: n No information available.
Further information:
Product: n Remarks: The available information is based on data derived

from the components and toxicities of similar products.
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Safety Data Sheet
Section: Environmental information

Persistence and degradability
12 Section: Environmental information
12.1 Toxicity
Product:
Toxicity as relates to fish: n Remarks: No available data.
Toxicity as relates to daphnia and n Remarks: No available data.

other invertebrate water species: No available data.
Toxicity as relates to algae: n Remarks: No available data.

No available data.
Toxicity to microorganisms: n Remarks: No available data.

methylpentene:
Toxicity as relates to fish: n LC50 (Danio rerio): > 100 mg/l

Exposure time: 96 h
Test type: static test
Toxicity as relates to daphnia and n EC50 (Daphnia magna): 51 mg/l

other invertebrate water species: Exposure time: 48 h
Toxicity as relates to algae: n EC50 (Desmodesmus subspicatus): > 100 mg/l

Exposure time: 72 h
12.2 Persistence and degradability

Product:
Biodegradability: n Remarks: No available data.
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Safety Data Sheet

Results of PBT and vPvB assessments
Physical-chemical degradation: n Remarks: No available data.

methylpentene:
Biodegradability: n Test type: aerob

Inoculum culture: Activated sludge
Result: Not easily biodegradable
Biodegradability: 1%
Exposure time: 28 d
Method: OECD Test Guideline 301 B
GLP: yes
12.3 Bioaccumulative potential

Product:
Bioaccumulation: n Remarks: This mixture does not contain any substances that
are persistent, bioaccumulative or toxic (PBT).
This mixture does not contain any substances that are very
persistent and very bioaccumulative (vPvB).

methylpentene:
Partition coefficient: n-octanol/ n log Pow: > 5

water:
12.4 Mobility in the ground

Product:
Mobility: n Remarks: No data available
Distribution between environmental n Remarks: No data available

compartments:
12.5 Results of PBT and vPvB assessments

Product:
Assessment: n This medium/mixture does not contain any components in con-

centrations of 0.1% or higher, that are either persistent, bioac-
cumulative or toxic (PBT), or very persistent or very bioaccu-
mulative (vPvB).
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Other adverse effects
12.6 Other adverse effects

Product:
Other ecological information: n No ecological information currently available.
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Safety Data Sheet
Section: Disposal instructions

Waste treatment methods
13 Section: Disposal instructions
13.1 Waste treatment methods

Product: n The product must be prevented from entering, watercourses or
soil.
The waste disposal code must be stipulated by the user on the
basis of the product’s intended use.
Contaminated packaging: n Containers that have not been emptied properly are to be dis-
posed of in the same manner as the unused product.
Dispose of waste and used containers in accordance with local
regulations.
The following waste codes are only intended to be a recom-
mendation:
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Safety Data Sheet
Section: Information on transport
14 Section: Information on transport
14.1 UN number
ADR: Not regulated as a dangerous good
IMDG: Not regulated as a dangerous good
IATA: Not regulated as a dangerous good
14.2 UN proper shipping name

14.3 Transport hazard class(es)

14.4 Packing group

IATA (freight): Not regulated as a dangerous good
IATA (passenger): Not regulated as a dangerous good
14.5 Environmental hazards

IATA (passenger): Not regulated as a dangerous good
IATA (freight): Not regulated as a dangerous good
14.6 Special precautions for the user

No special precautions required.
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Section: Information on transport
Transport in bulk according to Annex II of the MARPOL Convention and the IBC Code
Remarks: Not applicable to the product in delivery state.
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Safety Data Sheet
Section: Statutory provisions

Safety, health and environmental regulations/legislation specific to the substance or mixture
15 Section: Statutory provisions
15.1 Safety, health and environmental regulations/legislation specific to the

substance or mixture
REACH - List of Substances of Very n This product does not contain any substances of very high con-
High Concern for Authorisation cern (REACH Regulation (EC) No. 1907/2006, Article 57).
(Article 59):
REACH - List of substances subject n Not applicable.

to authorisation (Annex XIV):
Regulation (EC) No. 1005/2009 on n Not applicable.

substances that deplete the ozone
layer:
Regulation (EC) No. 850/2004 on n Not applicable.
persistent organic pollutants:
Regulation (EC) No. 649/2012 of the n Not applicable

European Parliament and the
Council concerning the export and
import of hazardous chemicals:
REACH - Restrictions on the manu- n Not applicable
facture, placing on the market and
use of certain dangerous sub-
stances, mixtures and articles
(Annex XVII):
Seveso III: Directive 2012/18/EU of n Not applicable
the European Parliament and of the
Council on the control of major
accident hazards involving dan-
gerous substances:
Hazard class for water: n WGK 1 Slightly hazardous to water
Classification as per AwSV, Annex 1 (5.2)
“TA Luft” (German air pollution n Overall dust:

control regulation): Other: 0.52%
Dust-like, inorganic substances:
Not applicable
Vapour-like or gas-like inorganic substances:
Not applicable
Organic materials:
Proportion of Class 1: < 0.01%
Other: 99.48%
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Safety Data Sheet
Section: Statutory provisions

Chemical safety assessment
Volatile organic compounds: n Directive 2010/75/EU of the European Parliament and of the
Council of 24 November 2010 on industrial emissions (inte-
grated prevention and reduction of environmental pollution)
Remarks: Not applicable
15.2 Chemical safety assessment

Chemical safety assessment: n No information available.
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Safety Data Sheet
Other information
16 Other information
Full text of H statements H412

n Harmful to aquatic life with long-lasting effects.
Full text of other abbreviations ADN - European Agreement concerning the International Carriage
of Dangerous Goods by Inland Waterways; ADR - European
Agreement concerning the International Carriage of Dangerous
Goods by Road; AICS - Australian Inventory of Chemical Sub-
stances; ASTM - American Society for Testing and Materials; CLP -
Regulation on classification, labelling and packaging of materials,
Regulation (EC) No 1272/2008; CMR - Carcinogenic, mutagenic or
reproductive toxin; DIN - Standard of the Deutsches Institut für
Normung; DSL - Canada Domestic Substance List; ECHA - Euro-
pean Chemicals Agency; EC Number - Number of the European
Community; ECx - Concentration associated with x% reaction; ELx
- Loading rate associated with x% reaction; EmS - Emergency pro-
cedures; ENCS - Japanese Existing and New Chemical Sub-
stances Inventory; ErCx - Concentration associated with x%
growth rate; GHS - Globally Harmonised System; GLP - Good Lab-
oratory Practice; IARC - International Agency for Research on
Cancer; IATA - International Air Transport Association; IBC - Inter-
national Code for the Construction and Equipment of Ships Car-
rying Dangerous Chemicals in Bulk; IC50 - Half Maximal Inhibitory
Concentration; ICAO - International Civil Aviation Organisation;
IECSC - Inventory of Existing Chemical Substances in China;
IMDG - Code – International Maritime Dangerous Goods; IMO -
International Maritime Organisation; ISHL - Japan Industrial Safety
and Health Law; ISO - International Organisation for Standardisa-
tion; KECI - Korean Existing Chemicals Inventory; LC50 - Lethal
concentration for 50% of a sample population; LD50 - Lethal dose
for 50% of a sample population (median lethal dose); MARPOL -
International Convention for the Prevention of Pollution from Ships;
n.o.s. - not otherwise stated; NO(A)EC - Concentration at which no
harmful effect can be detected; NO(A)EL - Dose at which no
harmful effect can be detected; NOELR - No Observable Effect
Loading Rate; NZIoC - New Zealand Inventory of Chemicals;
OECD - Organisation for Economic Co-operation and Develop-
ment; OPPTS - Office of Prevention, Pesticides & Toxic Sub-
stances (OSCPP); PBT - Persistent, Bioaccumulative, Toxic;
PICCS - Philippine Inventory of Chemicals and Chemical Sub-
stances; (Q)SAR - (Quantitative) Structure-Activity Relationship;
REACH - Regulation (EC) No. 1907/2006 of the European Parlia-
ment and Council concerning the Registration, Evaluation, Authori-
sation and Restriction of Chemicals (REACH); RID - Regulation
concerning the International Carriage of Dangerous Goods by Rail;
SADT - Self-Accelerating Decomposition Temperature; SDS -
Safety Data Sheet; SVHC - Substances of Very High Concern;
TCSI - Taiwan Chemical Substance Inventory; TRGS - Technical
Rules for Hazardous Substances; TSCA - US Toxic Substances
Control Act; UN - United Nations; vPvB - Very Persistent, and Very
Bioaccumulative.
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Safety Data Sheet
Other information
Date of print: n 19/04/2019
Issue date: n 01/08/2017
Created by: n Aerzener Maschinenfabrik GmbH

+49 (0) 51 54 81 0
Further information: n This safety data sheet only applies to labelled products origi-
nally packed by AERZEN. The information contained therein is
subject to copyright and may not be reproduced or changed
without the express written approval of AERZEN. The for-
warding of this document is only permitted within the legally
stipulated parameters. Any further distribution, particularly
public, of our safety data sheets (e.g. as an internet download)
is forbidden without express written approval. AERZEN pro-
vides its customers with amended safety data sheets in
accordance with legal requirements. It is the responsibility of
the customer to refer his or her own customers, employees or
other product users to the data sheets and any potential
amendments, in accordance with legal requirements. AERZEN
assumes no guarantee for the up-to-dateness of safety data
sheets that users may receive from third parties. All the infor-
mation and instructions in this safety data sheet have been
produced to the best of our knowledge and are based on the
latest technology available on the day of issue. The statements
made here are intended to describe the product with regard to
the necessary safety measures. They do not act as an assur-
ance of the product’s properties nor as a guarantee of the suit-
ability of the product in individual cases and they do not consti-
tute a contractual legal relationship.
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Safety Data Sheet
Index
17 Index
C R
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Reactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Release
D
unintentional . . . . . . . . . . . . . . . . . . . . . . . . . 11
Designation
Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 S
Medium / mixture . . . . . . . . . . . . . . . . . . . . . . 5 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Statutory provisions . . . . . . . . . . . . . . . . . . . . . . 27
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
E
Emergency phone number . . . . . . . . . . . . . . . . . 5 U
exposure Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exposure
Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F
Firefighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First-aid measures . . . . . . . . . . . . . . . . . . . . . . . 9
H
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
I
Information
environmental . . . . . . . . . . . . . . . . . . . . . . . 21
on components . . . . . . . . . . . . . . . . . . . . . . . 8
other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
toxicological . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
P
Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Potential hazards . . . . . . . . . . . . . . . . . . . . . . . . 7
Properties
chemical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Accessories
C Accessories
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C.1 Drive motor
Name Data
Designation Drive motor
Type /
Number /
Type of manual Operating manual
Manufacturer ABB
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Low voltage motors

Installation, operation, maintenance and safety manual
Installation, operation, maintenance and safety manual............................................................................................ EN 3
More languages – see web site www.abb.com/motors&generators > Motors > Document library
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Low voltage motors

Installation, operation, maintenance and safety manual
Contents Page
1. Introduction................................................................................................................................................5
1.1 Declaration of Conformity.....................................................................................................................5
1.2 Validity.................................................................................................................................................5
2. Safety considerations................................................................................................................................5
3. Handling......................................................................................................................................................6
3.1 Reception............................................................................................................................................6
3.2 Transportation and storage..................................................................................................................6
3.3 Lifting...................................................................................................................................................6
3.4 Motor weight........................................................................................................................................6
4. Installation and commissioning................................................................................................................7
4.1 General................................................................................................................................................7
4.2 Motors with other than deep groove ball bearings................................................................................7
4.3 Insulation resistance check..................................................................................................................7
4.4 Foundation...........................................................................................................................................7
4.5 Balancing and fitting coupling halves and pulleys.................................................................................8
4.6 Mounting and alignment of the motor...................................................................................................8
4.7 Radial forces and belt drives................................................................................................................8
4.8 Motors with drain plugs for condensation.............................................................................................8
4.9 Cabling and electrical connections.......................................................................................................8
4.9.1 Connections for different starting methods................................................................................9
4.9.2 Connections of auxiliaries..........................................................................................................9
4.10 Terminals and direction of rotation........................................................................................................9
5. Operation .................................................................................................................................................10
5.1 General..............................................................................................................................................10
Low voltage motors manual, 3GZF500730-85 Rev. G 07-2016 | ABB Motors and Generators 3
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6. Low voltage motors in variable speed operation ................................................................................11

6.1 Introduction........................................................................................................................................11
6.2 Winding insulation..............................................................................................................................11
6.2.1 Selection of winding insulation for ABB converters...................................................................11
6.2.2 Selection of winding insulation with all other converters ...........................................................11
6.3 Thermal protection ............................................................................................................................11
6.4 Bearing currents.................................................................................................................................11
6.4.1 Elimination of bearing currents with ABB converters.................................................................11
6.4.2 Elimination of bearing currents with all other converters............................................................12
6.5 Cabling, grounding and EMC.............................................................................................................12
6.6 Operating speed................................................................................................................................12
6.7 Motors in variable speed applications.................................................................................................12
6.7.1 General....................................................................................................................................12
6.7.2 Motor loadability with AC_8_ _ – series of converters with DTC control....................................12
6.7.3 Motor loadability with AC_5_ _ – series of converter.................................................................12
6.7.4 Motor loadability with other voltage source PWM-type converters............................................12
6.7.5 Short time overloads................................................................................................................13
6.8 Rating plates......................................................................................................................................13
6.9 Commissioning the variable speed application...................................................................................13
7. Maintenance.............................................................................................................................................14
7.1 General inspection.............................................................................................................................14
7.1.1 Standby motors ......................................................................................................................14
7.2 Lubrication.........................................................................................................................................14
7.2.1 Motors with permanently greased bearings..............................................................................14
7.2.2 Motors with regreasable bearings.............................................................................................15
7.2.3 Lubrication intervals and amounts............................................................................................15
7.2.4 Lubricants................................................................................................................................17
8. After Sales Support..................................................................................................................................18
8.1 Spare parts........................................................................................................................................18
8.2 Dismantling, re-assembly and rewinding............................................................................................18
8.3 Bearings............................................................................................................................................18
9. Environmental requirements...................................................................................................................18
10. Troubleshooting.......................................................................................................................................19
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1. Introduction 2. Safety considerations

The motor is intended for installation and use by qualified
NOTE!
personnel, familiar with health and safety requirements and
These instructions must be followed to ensure
national legislation.
safe and proper installation, operation and
maintenance of the motor. They should be brought Safety equipment necessary for the prevention of accidents
to the attention of anyone who installs, operates at the installation and operating site must be provided in
or maintains the motor or associated equipment. accordance with local regulations.
The motor is intended for installation and use by
qualified personnel, familiar with health and safety
requirements and national legislation. Ignoring these WARNING!
instructions may invalidate all applicable warranties. Emergency stop controls must be equipped with
restart lockouts. After emergency stop a new start
command can take effect only after the restart
lockout has been intentionally reset.
1.1 Declaration of Conformity
The conformity of the end product according to Directive
2006/42/EC (Machinery) has to be established by the
Points to be observed:
commissioning party when the motor is fitted to the
machinery. 1. Do not step on the motor.
2. The temperature of the outer casing of the motor
1.2 Validity may be hot to the touch during normal operation and
especially after shut-down.
These instructions are valid for the following ABB electrical 3. Some special motor applications may require additional
machine types, in both motor and generator operation: instructions (e.g. when supplied by frequency
converter).
series MT*, MXMA, 4. Observe rotating parts of the motor.
series M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
5. Do not open terminal boxes while energized.
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*,
M2V*/M3V*
in frame sizes 56 - 450.
There is a separate manual for e.g. Ex motors ‘Low voltage

motors for explosive atmospheres: Installation, operation
and maintenance and safety manual (3GZF500730-47)
Additional information is required for some machine types

due to special application and/or design considerations.
Additional manual is available for the following motors:

– roller table motors
– water cooled motors
– smoke extraction motors
– brake motors
– motors for high ambient temperatures
– motors in marine applications for mounting on open deck
of ships or offshore units
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3. Handling
3.1 Reception Lifting eyebolts must be tightened before lifting. If needed,
the position of the eyebolt can be adjusted using suitable
Immediately upon receipt, check the motor for external washers as spacers.
damage (e.g. shaft-ends, flanges and painted surfaces)
and, if found, inform the forwarding agent without delay. Ensure that proper lifting equipment is used and that the
sizes of the hooks are suitable for the lifting lugs.
Check all rating plate data, especially voltage and winding
connections (star or delta). The type of bearing is specified Care must be taken not to damage auxiliary equipment and
on the rating plate of all motors except the smallest frame cables connected to the motor.
sizes. Remove eventual transport jigs fixing the motor to the
In the case of a variable speed drive application check pallet.
the maximum loadability allowed according to frequency Specific lifting instructions are available from ABB.
stamped on the motor’s second rating plate.
3.2 Transportation and storage WARNING!

During lifting, mounting or maintenance work, all
The motor should always be stored indoors (above necessary safety considerations shall be in place
–20 °C), in dry, vibration-free and dust-free conditions. and special attention to be taken that nobody will be
During transportation, shocks, falls and humidity should be subject to lifted load.
avoided. In other conditions, please contact ABB.
Unprotected machined surfaces (shaft-ends and flanges)

should be treated against corrosion. 3.4 Motor weight
It is recommended that shafts are rotated periodically (once The total motor weight can vary within the same frame size
per quarter) by hand to prevent grease migration. (center height) depending on different output, mounting
arrangement and auxiliaries.
Anti-condensation heaters, if fitted, are recommended to
be used to avoid water condensing in the motor. The following table shows estimated maximum weights
for machines in their basic versions as a function of frame
The motor must not be subject to any external vibrations at material.
standstill so as to avoid causing damage to the bearings.
The actual weight of all ABB’s motors, except the smallest
Motors fitted with cylindrical-roller and/or angular contact frame sizes (56 and 63), is shown on the rating plate.
bearings must be fitted with locking devices during
transport. Frame size Aluminum Cast iron Add.
for brake
Weight kg Weight kg
3.3 Lifting 56 4.5 – –
63 6 – –
All ABB motors above 25 kg are equipped with lifting lugs
71 8 13 5
or eyebolts.
80 14 20 8
Only the main lifting lugs or eyebolts of the motor should be 90 20 30 10
used for lifting the motor. They must not be used to lift the 100 32 40 16
motor when it is attached to other equipment. 112 36 50 20
132 93 90 30
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 160 149 130 30
fans) or terminal boxes must not be used for lifting the 180 162 190 45
motor. Because of different output, mounting arrangements 200 245 275 55
and auxiliary equipment, motors with the same frame may 225 300 360 75
have a different center of gravity. 250 386 405 75
280 425 800 –
Damaged lifting lugs must not be used. Check that 315 – 1700 –
eyebolts or integrated lifting lugs are undamaged before 355 – 2700 –
lifting. 400 – 3500 –
450 – 4500 –
If the motor is equipped with a separate fan, contact ABB

for the weight.
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4. Installation and commissioning

Insulation resistance should be used as a trend indicator
WARNING! to determine changes in the insulation system. In new
Disconnect and lock out before working on the machines the IR is usually thousands of Mohms and thus
motor or the driven equipment. following the change of IR is important so as to know
the condition of the insulation system. Typically, the IR
should not be below 10 MΩ and in no case below 1 MΩ
4.1 General (measured with 500 or 1000 VDC and corrected to 25 °C).
The insulation resistance value is halved for each 20 °C
All rating plate values must be carefully checked to ensure increase in temperature.
that the motor protection and connection will be properly
done. Figure 1, in chapter 11, can be used for the insulation
correction to the desired temperature.
When starting the motor for the first time or after it has
been in storage more than 6 months, apply the specified
quantity of grease. WARNING!
To avoid risk of electrical shock, the motor frame
See section “7.2.2 Motors with re-greasable bearings” for must be grounded and the windings should be
more details. discharged against the frame immediately after each
measurement.
When fitted in a vertical position with the shaft pointing
downwards, the motor must have a protective cover
to prevent foreign objects and fluid from falling into the If the reference resistance value is not attained, the
ventilation openings. This task can also be achieved by winding is too damp and must be oven dried. The oven
a separate cover not fixed to the motor. In this case, the temperature should be 90 °C for 12-16 hours followed by
motor must have a warning label. 105 °C for 6-8 hours.
If fitted drain hole plugs must be removed and closing

4.2 Motors with other than deep valves must be opened during heating. After heating, make
groove ball bearings sure the plugs are refitted. Even if the drain plugs are fitted,
it is recommended to disassemble the end shields and
Remove transport locking if employed. Turn the shaft of the terminal box covers for the drying process.
motor by hand to check free rotation, if possible.
Windings drenched in seawater normally need to be
rewound.
Motors equipped with cylindrical roller bearings:
Running the motor with no radial force applied to the shaft
may damage the roller bearing due to “sliding”, 4.4 Foundation
The end user has full responsibility for preparation of the
Motors equipped with angular contact ball bearing: foundation.
Running the motor with no axial force applied in the right
direction in relation to the shaft may damage the angular Metal foundations should be painted to avoid corrosion.
contact bearing. Foundations must be even and sufficiently rigid to
withstand possible short circuit forces.
WARNING! They must be designed and dimensioned to avoid the
For motors with angular contact bearings the axial transfer of vibration to the motor and vibration caused by
force must not by any means change direction. resonance. See figure below.
The type of bearing is specified on the rating plate.

Ruler
4.3 Insulation resistance check

Measure insulation resistance (IR) before commissioning, Note! Height difference shall
after long periods of standstill or storage when winding not exceed ± 0,1mm referred
to any other motor foot
dampness may be suspected. IR shall be measured
directly on the motor terminals with the supply cables
disconnected in order to avoid them affecting the result.
Foot location
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4.5 Balancing and fitting 4.7 Radial forces and belt drives
coupling halves and pulleys Belts must be tightened according to the instructions of the
supplier of the driven equipment. However, do not exceed
As standard, balancing of the motor has been carried out the maximum belt forces (i.e. radial bearing loading) stated
using half key. in the relevant product catalogs.
Coupling halves or pulleys must be balanced after
machining the keyways. Balancing must be done in WARNING!
accordance with the balancing method specified for the Excessive belt tension will damage bearings and can
motor. cause shaft damage.
Coupling halves and pulleys must be fitted on the shaft by
using suitable equipment and tools which do not damage
the bearings and seals. 4.8 Motors with drain plugs for
Never fit a coupling half or pulley by hammering or condensation
removing it by using a lever pressed against the body of the
motor. Check that drain holes and plugs face downwards. In
vertical position mounted motors, the drain plugs may be in
horizontal position.
4.6 Mounting and alignment of
Motors with sealable plastic drain plugs are delivered in an
the motor open position. In very dusty environments, all drain holes
should be closed.
Ensure that there is enough space for free airflow around
the motor. It is recommended to have a clearance between
the fan cover and the wall etc. of at least ½ of the air 4.9 Cabling and electrical
intake of the fan cover. Additional information may be
found from the product catalog or from the dimension connections
drawings available on our web pages: www.abb.com/ The terminal box on standard single speed motors normally
motors&generators. contains six winding terminals and at least one earth
Correct alignment is essential to avoid bearing, vibration terminal.
and possible shaft failures. In addition to the main winding and earthing terminals, the
Mount the motor on the foundation using the appropriate terminal box can also contain connections for thermistors,
bolts or studs and place shim plates between the heating elements or other auxiliary devices.
foundation and the feet. Suitable cable lugs must be used for the connection of all
Align the motor using appropriate methods. main cables. Cables for auxiliaries can be connected into
their terminal blocks as such.
If applicable, drill locating holes and fix the locating pins into
position. Motors are intended for fixed installation only. Unless
otherwise specified, cable entry threads are metric. The IP
Mounting accuracy of coupling half: check that clearance class of the cable gland must be at least the same as those
b is less than 0.05 mm and that the difference a1 to a2 is of the terminal boxes.
also less than 0.05 mm. See figure 2.
Certified conduit hub or cable connector has to be used at
Re-check the alignment after final tightening of the bolts or the time of installation.
studs.
Do not exceed permissible loading values for bearings as NOTE!

stated in the product catalogs. Cables should be mechanically protected and
clamped close to the terminal box to fulfill the
Check that the motor has sufficient airflow. Ensure that no appropriate requirements of IEC/EN 60079-0 and
nearby objects or direct sunshine radiate additional heat to local installation standards.
the motor.
For flange mounted motors (e.g. B5, B35, V1), make sure Unused cable entries must be closed with blanking
that the construction allows sufficient air flow on the outer elements according to the IP class of the terminal box.
surface of the flange.
The degree of protection and diameter are specified in the
documents relating to the cable gland.
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4.9.1 Connections for different starting

WARNING! methods
Use appropriate cable glands and seals in the cable
entries according to the type and diameter of the The terminal box on standard single speed motors normally
cable. contains six winding terminals and at least one earth
terminal. This enables the use of DOL- or Y/D –starting.
Earthing must be carried out according to local regulations For two-speed and special motors, the supply connection
before the motor is connected to the supply voltage. must follow the instructions inside the terminal box or in the
motor manual.
The earth terminal on the frame has to be connected to PE
(protective earth) with a cable as shown in Table 5 of IEC/ The voltage and connection are stamped on the rating
EN 60034-1: plate.
Minimum cross-sectional area of protective Direct-on-line starting (DOL):

conductors Y or D winding connections may be used.
Cross-sectional area of phase Minimum cross-sectional area For example, 690 VY, 400 VD indicates Y-connection for
conductors of the installation, of the corresponding protective 690 V and D-connection for 400 V.
S, [mm2] conductor, S, [mm2]
4 4 Star/Delta (Wye/Delta) starting (Y/D):
6 6 The supply voltage must be equal to the rated voltage of
10 10 the motor when using a D-connection.
16 16
Remove all connection links from the terminal block.
25 25
35 25 Other starting methods and severe starting
50 25 conditions:
70 35
95 50
In cases where other starting methods e.g. converter or
120 70
soft starter will be used in the duty types of S1 and S2, it
150 70
is considered that the device is “isolated from the power
185 95
system when the electrical machine is running” as in the
240 120
standard IEC 60079-0 and thermal protection is optional.
300 150
400 185 4.9.2 Connections of auxiliaries
In addition, earthing or bonding connection facilities on If a motor is equipped with thermistors or other RTDs
the outside of electrical apparatus must provide effective (Pt100, thermal relays, etc.) and auxiliary devices, it is
connection of a conductor with a cross-sectional area of at recommended they be used and connected by appropriate
least 4 mm2. means. For certain applications, it is mandatory to use
thermal protection. More detailed information can be found
The cable connection between the network and motor
in the documents delivered with the motor. Connection
terminals must meet the requirements stated in the
diagrams for auxiliary elements and connection parts can
national standards for installation or in the standard
be found inside the terminal box.
IEC/EN 60204-1 according to the rated current indicated
on the rating plate. The maximum measuring voltage for the thermistors is
2.5 V. The maximum measuring current for Pt100 is 5 mA.
NOTE! Using a higher measuring voltage or current may cause
When the ambient temperature exceeds +50 °C, errors in readings or a damaged temperature detector.
cables having permissible operating temperature
The insulation of thermal sensors fulfills the requirements of
of +90 °C as minimum shall be used. Also all other
basic insulation.
conversion factors depending on the installation
conditions shall be taken into account while sizing
the cables. 4.10 Terminals and direction of
Ensure that the motor protection corresponds to the rotation
environment and weather conditions. For example, make The shaft rotates clockwise when viewing the shaft face at
sure that water cannot enter the motor or the terminal the motor drive end, and the line phase sequence – L1, L2,
boxes. L3 – is connected to the terminals as shown in figure 3.
The seals of terminal boxes must be placed correctly in To alter the direction of rotation, interchange any two
the slots provided to ensure the correct IP class. A leak connections on the supply cables.
could lead to penetration of dust or water, creating a risk of
flashover to live elements. If the motor has a unidirectional fan, ensure that it rotates in
the same direction as the arrow marked on the motor.
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5. Operation
5.1 General
The motors are designed for the following conditions unless
otherwise stated on the rating plate:
– Motors are to be installed in fixed installations only.

– Normal ambient temperature range is from –20 °C to
+40 °C.
– Maximum altitude is 1000 m above sea level.
– The variation of the supply voltage and frequency may
not exceed the limits mentioned in relevant standards.
Tolerance for supply voltage is ±5 %, and for frequency
±2 % according to the figure 4 (EN / IEC 60034-1,
paragraph 7.3, Zone A). Both extreme values are not
supposed to occur at the same time.
The motor can only be used in applications for which

it is intended. The rated nominal values and operation
conditions are shown on the motor rating plates. In
addition, all requirements of this manual and other related
instructions and standards must be followed.
If these limits are exceeded, motor data and construction

data must be checked. Please contact ABB for further
information.
WARNING!
Ignoring any instructions or maintenance of the
apparatus may jeopardize safety and thus prevent
the use of the motor.
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6. Low voltage motors in variable speed operation

6.1 Introduction 6.2.2 Selection of winding insulation with
all other converters
This part of the manual provides additional instructions for
motors used in frequency converter supplies. The motor The voltage stresses must be limited below accepted limits.
is intended to operate from a single frequency converter Please contact the system supplier to ensure the safety of
supply and not motors running in parallel from one the application. The influence of possible filters must be
frequency converter. Instructions given by the converter taken into account while dimensioning the motor.
manufacturer shall be followed.
Additional information may be required by ABB to decide 6.3 Thermal protection

on the suitability for some motor types used in special Most of the motors covered by this manual are equipped
applications or with special design modifications. with PTC thermistors or other type of RTD’s in the stator
windings. It is recommended to connect those to the
6.2 Winding insulation frequency converter. Read more in chapter 4.9.2.
Variable speed drives create higher voltage stresses

than the sinusoidal supply on the winding of the motor. 6.4 Bearing currents
Therefore, the winding insulation of the motor as well as Insulated bearings or bearing constructions, common
the filter at the converter output must be dimensioned mode filters and suitable cabling and grounding methods
according following instructions. must be used according to the following instructions and
using table 6.1.
6.2.1 Selection of winding insulation for
ABB converters 6.4.1 Elimination of bearing currents with
In the case of ABB e.g. AC_8_ _-series and AC_5_ _-series ABB converters
single drives with a diode supply unit (uncontrolled DC In case of ABB frequency converter e.g. AC_8_ _- and
voltage), the selection of winding insulation and filters can AC_5_ _-series with a diode supply unit, the methods
be made according to table 6.1. according to table 6.1 must be used to avoid harmful
bearing currents in motors.
PN < 100 kW PN ≥ 100 kW or PN ≥ 350 kW or

IEC315 ≤ Frame size ≤ IEC355 IEC400 ≤ Frame size ≤ IEC450
UN ≤ 500 V Standard motor Standard motor Standard motor
+ Insulated N-bearing + Insulated N-bearing
+ Common mode filter
500V > UN ≤ 600V Standard motor Standard motor Standard motor
+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
OR + Insulated N-bearing + dU/dt –filter (reactor)
Reinforced insulation OR + Common mode filter
Reinforced insulation OR
+ Insulated N-bearing Reinforced insulation
+ Insulated N-bearing
500V > UN ≤ 600V Standard motor Standard motor Standard motor
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
600V > UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation

+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
+ Insulated N-bearing + dU/dt –filter (reactor)
600V > UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
Table 6.1 Selection of winding insulation for ABB converters
Please contact ABB for more information on resistor braking and converters with controlled supply units.
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NOTE!
6.7 Motors in variable speed
Insulated bearings which have aluminum oxide applications
coated inner and/or outer bores or ceramic rolling
elements are recommended. Aluminum oxide
coatings shall also be treated with a sealant to 6.7.1 General
prevent dirt and humidity penetrating into the porous With ABB’s frequency converters, the motors can be
coating. For the exact type of bearing insulation, see dimensioned by using ABB’s DriveSize dimensioning
the motor’s rating plate. Changing the bearing type program. The tool is downloadable from the ABB website
or insulation method without ABB’s permission is (www.abb.com/motors&generators).
prohibited.
For application supplied by other converters, the motors
must be dimensioned manually. For more information,
6.4.2 Elimination of bearing currents with please contact ABB.
all other converters
The loadability curves (or load capacity curves) are based
The user is responsible for protecting the motor and driven
on nominal supply voltage. Operation in under or over
equipment from harmful bearing currents. Instructions
voltage conditions may influence on the performance of the
described in chapter 6.4.1 can be used as guideline, but
application.
their effectiveness cannot be guaranteed in all cases.
6.7.2 Motor loadability with AC_8_ _ – series

6.5 Cabling, grounding and EMC of converters with DTC control
To provide proper grounding and to ensure compliance The loadability curves presented in Figures 5a – 5d are
with any applicable EMC requirements, motors above valid for ABB AC_8_ _-series converters with uncontrolled
30 kW shall be cabled by shielded symmetrical cables and DC-voltage and DTC-control. The figures show the
EMC glands, i.e. cable glands providing 360° bonding. approximate maximum continuous output torque of the
motors as a function of supply frequency. The output
Symmetrical and shielded cables are highly recommended torque is given as a percentage of the nominal torque of
also for smaller motors. Make the 360° grounding the motor. The values are indicative and exact values are
arrangement at all the cable entries as described in the available on request.
instructions for the glands. Twist the cable shields into
bundles and connect to the nearest ground terminal/bus
bar inside the terminal box, converter cabinet, etc. NOTE!
The maximum speed of the motor and application
may not be exceeded!
NOTE!
Proper cable glands providing 360° bonding must
be used at all termination points such as motor, 6.7.3 Motor loadability with AC_5_ _ – series
converter, possible safety switch, etc.
of converter
The loadability curves presented in Figures 6a – 6d are
For motors of frame size IEC 280 and above, additional valid for AC_5_ _ -series converters. The figures show
potential equalization between the motor frame and the the approximate maximum continuous output torque of
driven equipment is needed, unless both are mounted on the motors as a function of supply frequency. The output
a common steel base. In this case, the high frequency torque is given as a percentage of the nominal torque of
conductivity of the connection provided by the steel the motor. The values are indicative and exact values are
base should be checked by, for example, measuring the available on request.
potential difference between the components.
More information about grounding and cabling of variable NOTE!

speed drives can be found in the manual “Grounding and The maximum speed of the motor and application
cabling of the drive system” (Code: 3AFY 61201998). may not be exceeded!
6.6 Operating speed

For speeds higher than the nominal speed stated on the
motor’s rating plate or in the respective product catalog,
ensure that either the highest permissible rotational speed
of the motor or the critical speed of the whole application is
not exceeded.
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6.7.4 Motor loadability with other voltage 6.9 Commissioning the variable
source PWM-type converters
For other converters, with uncontrolled DC voltage and
speed application
minimum switching frequency of 3 kHz (200…500 V), the
The commissioning of the variable speed application must
dimensioning instructions as mentioned in chapter 6.7.3
be done according to the instructions of the frequency
can be used as guidelines. However, it shall be noted that
converter and local laws and regulations. The requirements
the actual thermal loadability can also be lower. Please
and limitations set by the application must also be taken
contact the manufacturer of the converter or the system
into account.
supplier.
All parameters needed for setting the converter must be
NOTE! taken from the motor rating plates. The most often needed
The actual thermal loadability of a motor may be parameters are:
lower than shown by guideline curves.
– nominal voltage
– nominal current
6.7.5 Short time overloads – nominal frequency
ABB motors can usually be temporarily overloaded as well – nominal speed
as used in intermittent duties. The most convenient method – nominal power
to dimension such applications is to use the DriveSize tool.
6.8 Rating plates NOTE!

In case of missing or inaccurate information, do not
The usage of ABB’s motors in variable speed applications operate the motor before ensuring correct settings!
do not usually require additional rating plates. The
parameters required for commissioning the converter
can be found from the main rating plate. In some special ABB recommends using all the suitable protective features
applications, however, the motors can be equipped with provided by the converter to improve the safety of the
additional rating plates for variable speed applications. application. Converters usually provide features such as
Those include the following information: (names and availability of features depend on manufacturer
and model of the converter):
– speed range
– power range – minimum speed
– voltage and current range – maximum speed
– type of torque (constant or quadratic) – acceleration and deceleration times
– and converter type and required minimum switching – maximum current
frequency. – maximum torque
– stall protection
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7. Maintenance
2. The bearing must be greased while rotating the shaft
WARNING! every year (to be reported). If the motor has been
Voltage may be connected at standstill inside the provided with roller bearing at the driven end, the
terminal box for heating elements or direct winding transport lock must be removed before rotating the
heating. shaft. The transport locking must be remounted in case
of transportation.
3. All vibrations must be avoided to prevent a bearing from

7.1 General inspection failing. All instructions in the motor instruction manual for
commissioning and maintenance have to be followed.
1. Inspect the motor at regular intervals, at least once a The warranty will not cover the winding and bearing
year. The frequency of checks depends on, for example, damages if these instructions have not been followed.
the humidity level of the ambient air and on the local
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to. 7.2 Lubrication
2. Keep the motor clean and ensure free ventilation
airflow. If the motor is used in a dusty environment,
WARNING!
the ventilation system must be regularly checked and
Beware of all rotating parts!
cleaned.
3. Check the condition of shaft seals (e.g. V-ring or radial
seal) and replace if necessary.
WARNING!
4. Check the condition of connections and mounting and Grease can cause skin irritation and eye
assembly bolts. inflammation. Follow all safety precautions specified
5. Check the bearing condition by listening for any unusual by the manufacturer of the grease.
noise, vibration measurement, bearing temperature,
inspection of spent grease or SPM bearing monitoring.
Pay special attention to bearings when their calculated Bearing types are specified in the respective product
rated life time is coming to an end. catalogs and on the rating plate of all motors, except
smaller frame sizes.
When signs of wear are noticed, dismantle the motor,
check the parts and replace if necessary. When bearings Reliability is a vital issue for bearing lubrication intervals.
are changed, replacement bearings must be of the same ABB uses mainly the L1 -principle (i.e. that 99 % of the
type as those originally fitted. The shaft seals have to be motors are certain to make the life time) for lubrication.
replaced with seals of the same quality and characteristics
as the originals when changing bearings.
7.2.1 Motors with permanently greased
In the case of the IP 55 motor and when the motor bearings
has been delivered with a plug closed, it is advisable to Bearings are usually permanently greased bearings of 1Z,
periodically open the drain plugs in order to ensure that 2Z, 2RS or equivalent.
the way out for condensation is not blocked and allows
condensation to escape from the motor. This operation As a guide, adequate lubrication for sizes up to 250 can
must be done when the motor is at a standstill and has be achieved for the following duration, according to L1.
been made safe to work on. For duties with higher ambient temperatures, please
contact ABB. The informative formula to change the
7.1.1 Standby motors L1 values roughly to L10 values: L10 = 2.0 x L1.
If the motor is in standby for a longer period of time on

a ship or in other vibrating environment the following
measures have to be taken:
1. The shaft must be rotated regularly every 2 weeks (to

be reported) by means of starting up of the system. In
case a start-up is not possible, for any reason, at least
the shaft has to be turned by hand in order to achieve
a different position once a week. Vibrations caused by
other vessel's equipment will cause bearing pitting which
should be minimized by regular operation/hand turning.
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Duty hours for permanently greased bearings at ambient Regreasing while the motor is at a standstill
temperatures of 25 °C and 40 °C are: If it is not possible to re-grease the bearings while the
motors are running, lubrication can be carried out while the
Duty hours Duty hours motor is at a standstill.
Frame size Poles at 25 °C at 40 °C – In this case, use only half the amount of grease and then
56 2 52 000 33 000 run the motor for a few minutes at full speed.
56 4–8 65 000 41 000 – When the motor has stopped, apply the rest of the
63 2 49 000 31 000 specified amount of grease to the bearing.
63 4–8 63 000 40 000 – After 1–2 running hours, close the grease outlet plug or
71 2 67 000 42 000 closing valve, if fitted.
71 4–8 100 000 56 000 B. Automatic lubrication
80–90 2 100 000 65 000
80–90 4–8 100 000 96 000 The grease outlet plug must be removed permanently with
100–112 2 89 000 56 000 automatic lubrication or open closing valve, if fitted.
100–112 4–8 100 000 89 000
ABB recommends only the use of electromechanical
132 2 67 000 42 000
systems.
132 4–8 100 000 77 000
160 2 60 000 38 000 The amount of grease per lubrication interval stated in the
160 4–8 100 000 74 000 table should be multiplied by three if a central lubrication
180 2 55 000 34 000 system is used. When using a smaller automatic re-grease
180 4–8 100 000 70 000 unit (one or two cartridges per motor) the normal amount of
200 2 41 000 25 000 grease can be used.
200 4–8 95 000 60 000 When 2-pole motors are automatically re-greased, the note
225 2 36 000 23 000 concerning lubricant recommendations for 2-pole motors in
225 4–8 88 000 56 000 the Lubricants chapter should be followed.
250 2 31 000 20 000
250 4–8 80 000 50 000 The used grease should be suitable for automatic
lubrication. The automatic lubrication system deliverer and
Data is valid up to 60 Hz. the grease manufacturer’s recommendations should check.
7.2.2 Motors with regreasable bearings Calculation example of amount of grease for
automatic lubrication system
Lubrication information plate and general lubrication Central lubrication system: Motor IEC M3_P 315_ 4-pole in
advice 50 Hz network, re-lubrication interval according to Table is
If the motor is equipped with a lubrication information plate, 7600 h/55 g (DE) and 7600 h/40 g (NDE):
follow the given values.
(DE) RLI = 55 g/7600 h*3*24 = 0,52 g/day
Greasing intervals regarding mounting, ambient
temperature and rotational speed are defined on the (NDE) RLI = 40 g/7600 h*3*24 = 0,38 g/day
lubrication information plate.
Calculation example of amount of grease for single
During the first start or after a bearing lubrication a automation lubrication unit (cartridge)
temporary temperature rise may appear, approximately 10 (DE) RLI = 55 g/7600 h*24 = 0,17 g/day
to 20 hours.
(NDE) RLI = 40 g/7600 h*24 = 0,13 g/day
Some motors may be equipped with a collector for old
grease. Follow the special instructions given for the RLI = Re-lubrication interval, DE = Drive end,
equipment. NDE = Non drive end
A. Manual lubrication
7.2.3 Lubrication intervals and amounts
Regreasing while the motor is running
– Remove grease outlet plug or open closing valve if fitted. Lubrication intervals for vertical motors are half of the values
– Be sure that the lubrication channel is open. shown in the table below.
– Inject the specified amount of grease into the bearing.
As a guide, adequate lubrication can be achieved for the
– Let the motor run for 1-2 hours to ensure that all excess
following duration, according to L1. For duties with higher
grease is forced out of the bearing. Close the grease
ambient temperatures please contact ABB. The informative
outlet plug or closing valve, if fitted.
formula to change the L1 values roughly to L10 values is L10
= 2.0 x L1, with manual lubrication.
The lubrication intervals are based on a bearing operating

temperature of 80 °C (ambient temperature +25 °C).
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Higher speed operation, e.g. in frequency converter

NOTE!
applications, or lower speed with heavy load will require
An increase in the ambient temperature raises the
shorter lubrication intervals.
temperature of the bearings correspondingly. The
interval values should be halved for a 15 °C increase
in bearing temperature and may be doubled for a WARNING!
15 °C decrease in bearing temperature. The maximum operating temperature of the grease
and bearings, +110 °C, must not be exceeded.
The designed maximum speed of the motor must
not be exceeded.
Amount
Frame 3600 3000 1800 1500 1000 500-900
of grease kW kW kW kW
size r/min r/min r/min r/min r/min r/min
g/bearing
Ball bearings, lubrication intervals in duty hours
112 10 all 10 000 13 000 all 18 000 21 000 all 2 5 000 all 28 000
132 15 all 9 000 11 000 all 17 000 19 000 all 23 000 all 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 all 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 all 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 all 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 all 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 all 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 all 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 all 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 all 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 all 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 all 7 000
2801) 60 all 2 000 3 500 – – – – – – –
2801) 60 – – – all 8 000 10 500 all 14 000 all 17 000
280 35 all 1 900 3 200 – – – –
280 40 – – all 7 800 9 600 all 13 900 all 15 000
315 35 all 1 900 3 200 – – – –
315 55 – – all 5 900 7 600 all 11 800 all 12 900
355 35 all 1 900 3 200 – – – –
355 70 – – all 4 000 5 600 all 9 600 all 10 700
400 40 all 1 500 2 700 – – – –
400 85 – – all 3 200 4 700 all 8 600 all 9 700
450 40 all 1 500 2 700 – – – –
450 95 – – all 2 500 3 900 all 7 700 all 8 700
Roller bearings, lubrication intervals in duty hours

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 all 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 all 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 all 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 all 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 all 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 all 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 all 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 all 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 all 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 all 3 500
2801) 60 all 1 000 1 750 – – – – – – –
2801) 70 – – – all 4 000 5 250 all 7 000 all 8 500
280 35 all 900 1 600 – – – –
280 40 – – all 4 000 5 300 all 7 000 all 8 500
315 35 all 900 1 600 – – – –
315 55 – – all 2 900 3 800 all 5 900 all 6 500
355 35 all 900 1 600 – – – –
355 70 – – all 2 000 2 800 all 4 800 all 5 400
400 40 all – 1 300 – – – –
400 85 – – all 1 600 2 400 all 4 300 all 4 800
450 40 all – 1 300 – – – –
450 95 – – all 1 300 2 000 all 3 800 all 4 400
1)
M3AA
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7.2.4 Lubricants The following high performance greases can be used:

– Mobil Unirex N2 or N3 (lithium complex base)
– Mobil Mobilith SHC 100 (lithium complex base)
WARNING! – Shell Gadus S5 V 100 2 (lithium complex base)
Do not mix different types of grease. – Klüber Klüberplex BEM 41-132 (special lithium base)
Incompatible lubricants may cause bearing damage. – FAG Arcanol TEMP110 (lithium complex base)
– Lubcon Turmogrease L 802 EP PLUS
(special lithium base)
When re-greasing, use only special ball bearing grease with
– Total Multis Complex S2A (lithium complex base)
the following properties:
– good quality grease with lithium complex soap and with NOTE!
mineral- or PAO-oil Always use high speed grease for high speed 2-pole
– base oil viscosity 100-160 cST at 40 °C motors where the speed factor is higher than
– consistency NLGI grade 1.5 - 3 *) 480,000 (calculated as Dm x n where Dm = average
– temperature range –30 °C - +120 °C, continuously bearing diameter, mm; n = rotational speed, r/min).
*) A stiffer end of scale is recommended for vertical

mounted motors or in hot conditions. The following greases can be used for high speed cast iron
motors but not mixed with lithium complex greases:
The above mentioned grease specification is valid if the
ambient temperature is above –30 °C or below +55 °C, – Klüber Klüber Quiet BQH 72-102 (polyurea base)
and the bearing temperature is below 110 °C; otherwise, – Lubcon Turmogrease PU703 (polyurea base)
consult ABB regarding suitable grease.
If other lubricants are used, check with the manufacturer
Grease with the correct properties is available from all major that the qualities correspond to those of the above
lubricant manufacturers. mentioned lubricants. The lubrication intervals are based
on the listed high performance greases above. Using other
Admixtures are recommended, but a written guarantee
greases can reduce the interval.
must be obtained from the lubricant manufacturer,
especially concerning EP admixtures, that admixtures do
not damage bearings or the properties of lubricants at the
operating temperature range.
WARNING!
In general, lubricants containing EP admixtures are
not recommended. In some cases it can cause harm
in the bearing, therefore its use has to be evaluated
case by case together with lubricant suppliers.
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8. After Sales Support 9. Environmental

8.1 Spare parts requirements
Unless otherwise stated, spare parts must be original parts Most of ABB’s motors have a sound pressure level not
or approved by ABB. exceeding 82 dB (A) (± 3 dB) at 50 Hz.
When ordering spare parts, the motor serial number, full Values for specific motors can be found in the relevant
type designation and product code, as stated on the rating product catalogs. At 60 Hz sinusoidal supply, the values are
plate, must be specified. approximately 4 dB(A) higher compared to 50 Hz values
stated in the product catalogs.
8.2 Dismantling, re-assembly For sound pressure levels at frequency converter supplies,
please contact ABB.
and rewinding
When motor(s) need to be scrapped or recycled,
Rewinding should always be carried out by qualified repair appropriate means, local regulations and laws must be
shops. followed.
Smoke venting and other special motors should not be
rewound without first contacting ABB.
8.3 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by heating

or using special tools.
Bearing replacement is described in detail in a separate

instruction leaflet available from the ABB Sales Office.
Any directions placed on the motor, such as labels, must

be followed. The bearing types indicated on the rating plate
must not be changed.
NOTE!
Any repair by the end user, unless expressly
approved by the manufacturer, releases the
manufacturer from responsibility to conformity.
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10. Troubleshooting
These instructions do not cover all details or variations
in equipment nor provide information for every possible
condition to be met in connection with installation,
operation or maintenance. Should additional information be
required, please contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be
handled by qualified persons who have the proper tools
and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor rating plate
and load factor.
Improper line connections Check connections against diagram supplied with motor.
Open circuit in winding or Indicated by humming sound when switch is closed. Check for loose
control switch wiring connections and ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator Contact ABB
or
Ensure that the supply is disconnected and grounding for work done,
disconnect the cables and measure the insulation resistance.
Poor stator coil connection Indicated by blown fuses. Motor must be rewound.
Remove end shields and locate fault.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check connection.
Open circuit Fuses blown. Check overload relay, stator and push buttons.
Motor runs and Power failure Check for loose connections to line, fuses and control.
then dies down
Motor does not Not applied properly Consult equipment supplier for proper type.
accelerate up to Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce load.
nominal speed because of line drop Check connections. Check conductors for proper size.
Starting load too high Check the motor’s starts against “no load”.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as
repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
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TROUBLE CAUSE WHAT TO DO

Motor takes too Excessive load Reduce load.
long to accelerate Low voltage during start Check for high resistance. Make sure that an adequate cable size
and/or draws high is used.
current
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
direction
Motor overheats Overload Reduce load.
while running Frame or ventilation openings may be Open vent holes and check for a continuous stream of air
full of dirt and prevent proper ventilation from the motor.
of motor
Motor may have one phase open Check to make sure that all leads and cables are well connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor
Balancing weights shifted Rebalance rotor.
Contradiction between balancing of Rebalance coupling or rotor.
rotor and coupling (half key - full key)
Poly phase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft Move pulley closer to motor bearing.
shoulder
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in kerosene and
contaminated replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.
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11. Figures Key

X-axis: Winding temperature, Celsius Degrees
Y-axis: Insulation Resistance Temperature Coefficient, ktc
100 1) To correct observed insulation resistance, Ri, to 40 °C
multiply it by the temperature coefficient ktc. Ri 40 °C = Ri x
50
Passfeder
x-Achse: Wicklungstemperatur, Grad Celsius
y-Achse: Temperaturkoeffizient des Isolationswiderstandes,
ktc
10 1) Zur Korrektur des ermittelten Isolationswiderstandes,
Ri, bis 40 °C, multiplizieren Sie ihn mit dem
5
Temperaturkoeffizient ktc. Ri 40 °C = Ri x
Légende
Axe X : Température du bobinage, degrés Celsius
Axe Y : Coefficient de température de la résistance
1.0 d'isolation, ktc
1) Pour corriger la résistance d'isolation observée, Ri,
à 40 °C, la multiplier par le coefficient de température
0.5
ktc. Ri 40 °C = Ri x
Clave
Eje X: Temperatura de devanado, grados centígrados
1)
0.1 Eje Y: Coeficiente de temperatura de resistencia de
aislamiento, ktc
1) Para corregir una resistencia de aislamiento observada,
0.05
Ri, a 40 °C, multiplíquela por el coeficiente de temperatura
ktc. Ri 40 °C = Ri x
-10 0 10 20 30 40 50 60 70 80 90 100
Legenda
Figure 1. Diagram illustrating the insulation resistance Asse X: Temperatura dell'avvolgimento, in gradi Celsius
dependence from the temperature and how to correct the Asse Y: Coefficiente di temperatura della resistenza
measured insulation resistance to the temperature of 40 °C. d'isolamento, ktc
1) Per correggere la resistenza d'isolamento osservata,
Abb. 1. Diagramm, das die Abhängigkeit des Ri, per 40 °C, moltiplicarla per il coefficiente di temperatura
Isolationswiderstandes von der Temperatur anzeigt und ktc. Ri 40 °C = Ri x
angibt, wie der gemessene Isolationswiderstand für die
Temperatur von 40 °C korrigiert wird. Explicação
Eixo X: Temperatura dos enrolamentos, Graus Celsius
Figure 1. Diagramme illustrant la dépendance de la résistance Eixo Y: Coeficiente de Temperatura da Resistência de
d'isolation à la température et la façon de corriger la Isolamento, ktc
résistance d'isolation mesurée à la température de 40 °C. 1) Para corrigir a resistência de isolamento observada, Ri,
para 40 °C, deverá ser multiplicada pelo coeficiente de
Figura 1. Diagrama que ilustra la dependencia de la temperatura ktc. Ri 40 °C = Ri x
resistencia de aislamiento respecto a la temperatura y cómo
corregir la resistencia de aislamiento medida a la temperatura Nyckel
de 40 °C. X-axeln: Lindningstemperatur, grader Celsius
Y-axeln: Isolationsresistans, temperaturkoefficient, ktc
Figura 1. Diagramma che mostra la resistenza d'isolamento 1) För att korrigera observerad isolationsresistans, Ri,
in funzione della temperatura e come correggere la resistenza till 40 °C ska den multipliceras med temperaturkoefficienten
d'isolamento misurata per la temperatura di 40 °C. ktc. Ri 40 °C = Ri x
Figur 1. I schemat visas isolationsresistansens beroende av Selitys

temperaturen och hur den uppmätta isolationsresistansen X-akseli: Käämin lämpötila, celsiusastetta
korrigeras till en temperatur på 40 °C. Y-akseli: Eristysvastuksen lämpötilakerroin, ktc
1) Korjaa havaittu eristysvastus, Ri, 40 °C:n lämpötilaan
Kuva 1. Kaavio, joka kuvaa, miten eristysvastus riippuu kertomalla se lämpötilakertoimella ktc. Ri 40 °C = Ri x
lämpötilasta ja miten mitattu eristysvastus korjataan 40 °C:n
lämpötilaan Tuş
X ekseni: Sargı sıcaklığı, Santigrat Derece
Tablo 1. Yalıtım direncinin sıcaklık ile olan bağıntısını ve ölçülen Y ekseni: Yalıtım Direnci Sıcaklık Katsayısı, ktc
yalıtım direncinin 40 °C sıcaklığa göre nasıl düzeltileceğini gösteren 1) Gözlenen yalıtım direncini düzeltmek için,
diyagram. Ri, 40 °C'ye ktc sıcaklık katsayısı ile çarpın. Ri 40 °C = Ri x
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Figure 2. Mounting of half-coupling or pulley

a1 b
Abb. 2. Montage von Kupplungshälften und
Riemenscheiben
Figure 2. Montage d'un demi-accouplement

ou d'une poulie
Figura 2. Montaje de acoplamiento o polea
Figure 2. Montaggio di semigiunto o puleggia
Figura 2. Montagem dos meios-acoplamentos

ou polias
Figur 2. Montering av kopplingshalva eller remskiva
Kuva 2. Kytkinpuolikkaan tai hihnapyörän

a2 kiinnittäminen
Tablo 2. Yarım kaplin veya kasnağın montajı
Figure 3. Connection of terminals for main supply
Abb. 3. Anschlussklemmen für Hauptversorgung
Figure 3. Raccordement des bornes pour l'alimentation principale
Figura 3. Conexión de terminales de la alimentación principal
Figura 3. Collegamento dei morsetti per l'alimentazione di rete
Figura 3. Ligação de terminais para alimentação
Figur 3. Anslutning av terminaler för elnätet
Kuva 3. Verkkosyötön liitäntöjen muodostaminen
Tablo 3. Ana besleme için terminal bağlantıları
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Y Key
1.10
X axis frequency p.u.
Y axis voltage p.u.
1 zone A
2 zone B (outside zone A)
3 rating point
1.05
Passfeder
x-Achse Frequenz p.u.
1.03
1
y-Achse Spannung p.u.
1 Zone A
3
1.09
2 Zone B (außerhalb Zone A)
X 3 Bewertungspunkt
0.95 0.98 1.00 1.02
2 Légende
0.93 Axe X fréquence p.u.
Axe Y tension p.u.
1 zone A
0.95
2 zone B (hors zone A)
3 point nominal
Clave
Eje X frecuencia p.u.
0.90 Eje Y tensión p.u.
1 zona A
2 zona B (fuera de la zona A)
3 punto nominal
Figure 4. Voltage and frequency deviation
Legenda
in zones A and B
Asse X frequenza p.u.
Asse Y tensione p.u.
Abb. 4. Spannungs- und Frequenzabweichung 1 zona A
in den Zonen A und B 2 zona B (fuori dalla zona A)
3 punto nominale
Figure 4. Écart de tension et de fréquence Explicação

dans les zones A et B Eixo X frequência p.u.
Eixo Y tensão p.u.
1 zona A
Figura 4. Desviación de tensión y frecuencia
2 zona B (fora da zona A)
en zonas A y B 3 ponto de avaliação
Figura 4. Deviazione di tensione e frequenza Nyckel

X-axeln frekvens p.u.
nelle zone A e B
Y-axeln spänning p.u.
1 zon A
Figura 4. Desvio de tensão e frequência 2 zon B (utanför zon A)
nas zonas A e B 3 märkpunkt
Selitys
Figur 4. Spännings- och frekvensavvikelse X-akseli taajuus yksikköä kohti
i zoner A och B Y-akseli jännite yksikköä kohti
1 vyöhyke A
2 vyöhyke B (vyöhykkeen A ulkopuolella)
Kuva 4. Jännite- ja taajuuspoikkeama
3 arvopiste
vyöhykkeillä A ja B
Tuş
Tablo 4. Zon A ve B'de voltaj ve frekans sapması X ekseni frekans p.u.
Y ekseni voltaj p.u.
1 zon A
2 zon B (zon A dışında)
3 değerlendirme noktası
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Guideline loadability curves with converters with DTC control

Richtlinie Belastbarkeitskurven mit Frequenzumrichtern mit DTC-Regelung
Courbes de capacité de charge de référence avec convertisseurs à contrôle DTC
Curvas indicativas de capacidad de carga con convertidores dotados de control de DTC
Curve di funzionamento con alimentazione da convertitore di frequenza, controllo DTC
Curvas de capacidade de carga orientadoras com conversores com controlo DTC
Riktlinjer: lastbarhetskurvor för omriktare med DTC-styrning
Ohjeelliset kuormitettavuuskäyrät DTC-ohjatuilla taajuusmuuttajilla
DTC kontrollü konvertörler ile kılavuz yüklenebilirlik eğrileri
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat/Eğriler 5a, 5b, 5c, 5d
Conventer with DTC control, 50/60 Hz, temperature rise B/F

Convertisseur à contrôle DTC, 50/60 Hz, élévation de température B/F
Convertidor con control de DTC, 50/60 Hz, aumento de temperatura B/F
Convertitore con controllo DTC, 50/0 Hz, sovra-temperatura classe B/F
Conversor com controlo DTC, 50/60 Hz, aumento de temperatura B/F
Omriktare med DTC-styrning, 50/60 Hz, temperaturstegring B/F
DTC-ohjattu taajuusmuuttaja, 50/60 Hz, lämpötilan nousu B/F
DTC kontrollü konverter, 50/60 Hz, sıcaklık artışı B/F
Figure 5a Figure 5b
Figure 5c Figure 5d
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Guideline loadability curves with other voltage source PWM type

Belastbarkeitskurven als Richtlinie für PWM-Frequenzumrichter mit anderen Spannungsquellen
Courbes de capacité de charge de référence avec d’autres convertisseurs PWM de source de tension
Curvas indicativas de capacidad de carga con otros convertidores de fuente de tensión de tipo PWM
Curve di funzionamento con convertitori di frequenza PWM
Curvas de capacidade de carga orientadoras com outros conversores de alimentação tipo PWM
Riktlinjer: belastbarhetskurvor för annan spänningsomriktare av PWM-typ
Ohjeelliset kuormitettavuuskäyrät muilla PWM-tyyppisillä jännitelähdetaajuusmuuttajilla
Diğer voltaj kanyağı PWM tipi ile kılavuz yüklenebilirlik eğrileri
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat/Eğriler 6a, 6b, 6c, 6d
Other voltage source PWM type converter, 50/60 Hz, temperature rise B/F
PWM-Frequenzumrichter mit anderen Spannungsquellen, 50/60 Hz, Temperaturanstieg B/F
Autre convertisseur PWM de source de tension, 50/60 Hz, élévation de température B/F
Otro convertidor de fuente de tensión de tipo PWM, 50/60 Hz, aumento de temperatura B/F
Convertitore PWM, 50/60 Hz, sovra-temperatura classe B/F
Outros conversores de alimentação tipo PWM, 50/60 Hz, aumento de temperatura B/F
Annan spänningsomriktare av PWM-typ, 50/60 Hz, temperaturstegring B/F
Muu PWM-tyyppinen jännitelähde-taajuusmuuttaja, 50/60 Hz, lämpötilan nousu B/F
Diğer voltaj kaynağı PWM tipi konverter, 50 Hz, sıcaklık artışı B
Figure 6a Figure 6b
Figure 6c Figure 6d
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Contact us
3GZF500730-85 Rev G ML 07-2016

Manufacturing units: We reserve the right to make technical changes or modify
the contents of this document without prior notice. With
ABB Shanghai Motors Co. Ltd. regard to purchase orders, the agreed particulars shall
No 88. Tianning Road prevail. ABB does not accept any responsibility what so ever
Minhang
for potential errors or possible lack of information in this
Shanghai 200245
document.
China
ABB Oy, Motors and Generators We reserve all rights in this document and in the subject
Strömbergin puistotie 5 A matter and illustrations contained herein. Any reproduction,
FI-65320 Vaasa disclosure to third parties or utilization of its contents – in
Finland whole or in parts – is forbidden without prior written consent
of ABB.
ABB India Ltd.
Plot No 5&6, 2nd Stage
Peenya industrial Area © Copyright 2016 ABB.
Peenya 560058, Bangalore All rights reserved.
Karnataka, India
ABB India Limited www.abb.com/motors&generators

32, Industrial area, NIT,
Faribadad - 121001
India
ABB Sp. z o.o.

27 Placydowska Str.
95-070 Aleksandrow Lodski
Poland
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C.2 Motor data sheet
Name Data
Designation Motor data sheet
Type /
Number /
Type of manual /
Manufacturer ABB
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Classifying code or document type
ABB Oy PERFORMANCE DATA OF MOTOR

Motors & Generators
Lang. Our ref.
En 3GZF021016-266
Motor Tag No. : CM-AS6102A/B

Motor type code M3BP 160MLA 2
Motor product code 3GBP161410-ADG
Motor type Squirrel cage Motor
Mounting designation IM 1001
Protected by enclosure IP 55
Method of cooling IC 411
Insulation Class F
Standards IEC
International efficiency classification (IEC IE2
60034-30)
Ambient temperature, max. 45 °C
Altitude, max. 1000 m.a.s.l.
Duty type S1
Temp. rise Class B
Connection of stator winding Star
Rated output 11 kW
Voltage 660 V ±10 %
Frequency 50 Hz +3 / -5 %
Speed 2928 r/min
Current 11,7 A
Relat. starting current 6,8
Relat. starting torque 2,1
Relat. maximum torque 2,8
Relat. minimum torque 2,0
No load current 3,0 A
Rated torque 35,7 Nm
Noise value 69 dB(A)
Motor weight 127 kg
Rotor weight 24 kg
Load characteristics Load % Current A Efficiency % Power Factor
100 11,7 90,1 0,92
75 8,8 91,3 0,90
50 6,2 91,1 0,85
Start 0,45
- All Motor data is subject to tolerances in accordance with IEC.
Efficiency based on typical additional load losses acc. measurements based on IEC 60034-2-1:
2014.
- For motor with a rated output less than 37 kW : Starting current is according to IEC standard.
- Starting method : DOL
- Starting duty : 3 cold / 2 hot
ABB Oy
Motors & Generators Visiting Address Postal Address Telephone Telefax
Strömbergin puistotie 5 A P.O.Box 633 +358 10 222 000 +358 10 224 7372
VAASA FI-65101 VAASA
FINLAND FINLAND
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
©Copyright 2018 ABB
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Motors & Generators
Lang. Our ref.
En 3GZF021016-266

Rated output 11 kW Power Factor 0,92
Voltage 660 V ±10 % Rated torque 35,7 Nm
Frequency 50 Hz +3 / -5 % Relat. starting current 6,8
Speed 2928 r/min Relat. starting torque 2,1
Current 11,7 A Relat. maximum torque 2,8
Torque and Current as a Function of Speed

7 3.5
6 3
5 2.5
4 2
I/In T/Tn
3 1.5
2 1
1 0.5
0 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
n/ns
I, U=100% I, U=80% Load Torque

T, U=100% T, U=80% Motor moment of inertia : JMotor = 0.044 kgm²
Load moment of inertia : JLoad = 0.11 kgm²
ABB Oy
FINLAND FINLAND
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Motors & Generators
Lang. Our ref.
En 3GZF021016-266

Time - Current and Thermal Limit Curves

10 000
1 000
100
Time [s]
10
0.1
1 2 3 4 5 6
Stator current / Rated current
Running (warm) Locked (warm) Time-current, U = 100%

Running (cold) Locked (cold) Time-current, U = 80%
Starting time at U=100% : 1.0 sec
Starting time at U=80% : 2.8 sec
Locked rotor withstand time
Safe stall time(hot) : 12 sec
Safe stall time(cold) : 22 sec
ABB Oy
FINLAND FINLAND
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Motors & Generators
Lang. Our ref.
En 3GZF021016-266

Equivalent circuit between phase and neutral (equivalent star)
Running
Stator resistance R1 (95 °C) 0.99302 Ω Rotor resistance R2' (104 °C) 0.67588 Ω
Stator reactance X1 2.4445 Ω Rotor reactance X2' 3.3821 Ω
Magnetizing reactance Xm 131.62 Ω Iron loss resistance RFe 1.9 kΩ
Starting
Stator reactance X1 2.1938 Ω Rotor reactance X2' 2.4308 Ω
Ambient condition
X1 R1 X 2’ R2 ’ / s
UN RFe Xm
3
ABB Oy
FINLAND FINLAND
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C.3 Safety valve
Name Data
Designation Safety valve
Type G4-002
Number 4079331V1, 4079332V1
Type of manual Operating manual
Manufacturer AERZEN
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Tab. 15: AERZEN safety valve operating data

Valve serial no. 4079331V1,
4079332V1
Valve version G2
Order no. 202101_10
Production order 1236965
Valve material no. 167355014,
167355014
Valve set pressure: 750 mbar

Maximum permissible pressure 1,55 bar
Valve seat material EN-GJL-250
Valve bell material MS
Minimum/Maximum permissible tempera- -10 / +200 °C
ture
Minimum flow cross-section 9 cm2
Maximum flow rate Q max. 9.760 m³/min
Medium type 2 (Luft/Air)
Spring number 505
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ASSEMBLY AND OPERATING

INSTRUCTIONS
AERZEN-SAFETY VALVE
Read the instructions prior to performing any task!

Keep for future reference!
Assembly and operating instructions

G4-002 L
Material no.: 2000020836
Doc content: 04/06/2019
Series: G2", G3", DN50, DN80, DN125, DN150, DN200, DN300
GB
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Reherweg 28
Germany
Telephone: +49 (0) 5154 81-0
Fax: +49 (0) 5154 81-9191
G4-002, 5, en_GB
This manual was created by:

GmbH
Heiko Nickel / Angela Pedack
©Aerzener Maschinenfabrik GmbH 2019
2 23.07.2019
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Table of contents
Table of contents
1 General Information............................................................ 5
1.1 Information about these instructions............................. 5
1.2 Explanation of symbols................................................. 5
1.3 Copyright protection...................................................... 7
1.4 Addresses..................................................................... 7
1.4.1 Manufacturer.............................................................. 7
1.4.2 Customer service....................................................... 8
2 Safety................................................................................... 9
2.1 Residual risks and fundamental risks........................... 9
2.1.1 Mechanical hazards................................................... 9
2.1.2 Thermal hazards...................................................... 10
2.1.3 Material/substance hazard....................................... 10
2.1.4 Hazards at the installation site and operating site... 11
2.1.5 Noise hazard............................................................ 11
2.1.6 Risks associated with conveyance of nitrogen........ 12
2.2 Intended use............................................................... 12
2.3 Foreseeable misuse................................................... 13
2.4 Responsibility of the operator..................................... 14
2.5 Spare parts................................................................. 16
2.6 Requirements for personnel....................................... 17
2.6.1 Qualifications........................................................... 17
2.6.2 Unauthorised persons.............................................. 19
2.7 Personal protective equipment................................... 19
2.8 Safety devices............................................................ 20
2.9 Safety classification.................................................... 20
2.10 Danger zone and operating area.............................. 21
2.11 Environmental protection.......................................... 22
3 Design and operation....................................................... 23
3.1 Overview of assemblies.............................................. 23
3.2 Functionality................................................................ 23
3.3 Requisite tools............................................................ 24
4 Transport, packaging and storage.................................. 25
4.2 Transport..................................................................... 27
4.2.1 Delivery method....................................................... 27
4.2.2 Packaging................................................................ 27
4.2.3 Transport inspection................................................ 28
4.2.4 Transport of packaged units.................................... 28
4.2.5 AERZEN safety valve transport............................... 29
4.3 Storage and preservation........................................... 29
5 Assembly and installation................................................ 32
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5.2 Requirements for the assembly site........................... 32

5.3 Assembly.................................................................... 33
6 First commissioning......................................................... 35
6.2 Initial start-up.............................................................. 35
7 Operation........................................................................... 37
7.2 Information on operation............................................. 37
8 Maintenance...................................................................... 38
8.2 Maintenance schedule................................................ 39
8.3 Maintenance work....................................................... 40
8.4 Cleaning after maintenance........................................ 41
9 Faults................................................................................. 42
9.2 Fault diagnosis and rectification................................. 43
9.3 Commissioning after malfunction rectification............ 44
10 Disassembly and disposal............................................... 45
10.2 Disassembly............................................................. 46
10.3 Disposal.................................................................... 46
11 Technical data................................................................... 49
11.1 Dimensions and weights........................................... 49
11.2 Operating data.......................................................... 51
11.3 Type plate(s)............................................................. 52
12 Note on Declaration of Conformity................................. 53
13 Glossary............................................................................. 54
14 Index................................................................................... 55
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1 General Information
1.1 Information about these instructions
This manual allows for the safe and efficient handling of the
AERZEN safety valve. The manual is an integral part of the safety
valve and must be kept in the immediate vicinity of the safety valve
so that it is accessible to personnel at all times. Keep this manual
in a safe place for future reference.
Personnel must read these instructions carefully and have under-
stood them before beginning work. A fundamental requirement for
working safely is compliance with all specified safety instructions
and guidelines in this manual.
In addition, all the statutory occupational health and general safety
regulations for the area and application in which the AERZEN
safety valve is used apply.
The illustrations in this manual serve to provide the user with a
basic understanding and may deviate somewhat from the actual
design.
The following is a list of additional, supplementary documents for

this instruction manual:
Declaration of Conformity PED Safety valve
1.2 Explanation of symbols

Safety instructions Safety instructions in this manual are identified by symbols. The
safety instructions are introduced by signal words that express the
scale of the hazard.
DANGER!
This combination of symbol and signal word indi-
cates an imminently hazardous situation that can
lead to death or serious injury if not avoided.
WARNING!
cates a potentially hazardous situation that can
lead to death or serious injury if not avoided.
CAUTION!
lead to minor or slight injury if not avoided.
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NOTICE!
lead to material damage if not avoided.
Safety instructions in handling Safety instructions can relate to specific, individual handling
instructions instructions. Such safety instructions are embedded into the han-
dling instruction so that they do not distract the reader's attention
while carrying out an action. The signal words described above are
used.
Example:
1. Loosen screw.
2.
CAUTION!
Entrapment hazard on the cover!
Close cover with caution.

3. Tighten screw.
Tips and recommendations

This symbol emphasises useful tips and recom-
mendations, as well as information for efficient,
trouble-free operation.
Special safety instructions In order to draw attention to specific hazards, the following symbols
are used in these safety instructions:
Warning signs Type of danger

Warning – high-voltage.
Warning – hot surface.
Warning – danger zone.
Additional markings To emphasise handling instructions, results, lists, references and

other elements, the following markings are used in this manual:
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Addresses > Manufacturer
Marking Explanation
Step-by-step handling instructions
1., 2., 3. ...
ð Results of handling steps
References to sections in this manual and
to applicable documents
Listings of no particular order
[Pushbutton] Control elements (e.g. pushbuttons,
switches), display elements (e.g. indicator
lamps)
„Display“ Screen elements (e.g. pushbuttons, assign-
ment of function keys)
1.3 Copyright protection

The contents of this manual is protected by copyright. The use of
this manual is permitted within the framework of machine use. Any
other use is excluded unless there is written approval by the manu-
facturer.
1.4 Addresses
1.4.1 Manufacturer
Tab. 1: Manufacturer
Reherweg 28
31855 Aerzen
Germany
Telephone +49 (0) 51 54 81-0
Fax +49 (0) 51 54 81-9191
e-mail info@aerzener.de
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Addresses > Customer service
1.4.2 Customer service

Our customer service staff are on hand to provide you with tech-
nical information:
Tab. 2: After sales service/service contact

Reherweg 28
31855 Aerzen
Germany
Service hotline +49 171 3 51 18 34
E-mail info@aerzener.de
In addition, we are always interested in receiving information and

feedback pertaining to machine use that could be useful in helping
us improve our products.
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Residual risks and fundamental risks > Mechanical hazards
2 Safety
This section gives an overview of all important safety aspects rele-
vant to the protection of persons and to safe and fault-free opera-
tion. Further task-based safety instructions are contained in the
sections on the individual phases of the AERZEN safety valve’s
service life.
Non-compliance with the handling and safety instructions provided
in this instruction manual can lead to serious hazards.
The following section outlines the residual risks and hazards during
the service life of the product that may arise as a result of non-
compliance with safety instructions or the disabling of safety
devices.
In order to reduce health and safety risks and to avoid dangerous
situations, the safety instructions and warnings in this instruction
manual are to be observed.
2.1 Residual risks and fundamental risks

The following chapter states the general residual risks that have
been established on the basis of a risk analysis.
n To reduce the risk of personal injury, property damage and
environmental contamination and to avoid dangerous situa-
tions, it is imperative that the safety instructions described here
and the safety instructions in the chapters on machine use be
observed.
2.1.1 Mechanical hazards

Sharp edges and corners
CAUTION!
Risk of injury from sharp edges and corners!
Sharp edges and corners can cause excoriations
and cuts to the skin.
– If working in the vicinity of sharp edges and
corners, proceed with caution.
– Wear protective gloves.
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Residual risks and fundamental risks > Material/substance hazard
2.1.2 Thermal hazards

Hot surfaces
WARNING!
serious burns.
tective gloves.
work.
Sudden gas emission

CAUTION!
opening.
2.1.3 Material/substance hazard

Airborne material particles
WARNING!
Risk of injury from flying material particles!
Safety valves can open suddenly during operation,
setting material particles in violent motion.
– Report the hazardous area.
– For all work in the hazard area, wear a safety
mask.
– Avoid the accumulation of dust.
– Filter the intake air.
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Residual risks and fundamental risks > Noise hazard
2.1.4 Hazards at the installation site and operating site

Missing protection
WARNING!
Risk of fatal injury due to missing protection
for the system provided by the customer!
The safety valves used by AERZEN serve to pro-
tect the machine. It is not permissible for these
safety valves to be used to protect the system pro-
vided by the customer. Neither sufficient relief nor
the requisite functional safety is ensured.
Non-compliance can result in life-threatening per-
sonal injuries and material damage to the system.
– The operator must ensure compliance with the
maximum permissible system pressure by
means of safety valves provided by the cus-
tomer, regardless of the safety valves used by
AERZEN.
– The operator must ensure sufficient relief for
the system.
2.1.5 Noise hazard

Noise
WARNING!
Risk of injury from noise!
When the safety valve opens, the pressurised con-
veyed medium is released, thereby generating
sudden noise. The resulting noise level can cause
severe hearing damage.
– Wear hearing protection when working.
– Only stand in the high-noise-level area if it is
absolutely necessary.
– Do not remove noise dampening equipment
(e.g. acoustic hood).
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Intended use
2.1.6 Risks associated with conveyance of nitrogen

Build-up of gas
DANGER!
Risk of suffocation from build-up of nitrogen
during conveyance!
When the safety valve is opened, nitrogen is
released from the system. There may be a build-up
of gas with high concentrations of nitrogen.
Gaseous nitrogen displaces the oxygen in the
room. High concentrations of nitrogen can cause
persons to suffocate. Symptoms here include the
loss of physical mobility and loss of consciousness.
The persons affected do not notice that they are
“suffocating”.
Escaped nitrogen can accumulate in recesses,
wells, acoustic hoods etc.
The operator is to ensure that any escaping
nitrogen is detected immediately.
– Install signalling devices (visual, acoustic).
– Avoid any build-up of gas.
– Guide gases directly out of the machine.
– Guide gases directly into a collective line.
– Ventilate the installation site properly.
2.2 Intended use
AERZEN safety valves may only be operated in

conjunction with a product that has been man-
ufactured by AERZEN.
Category I, Module A and Category II, Module A1 safety valves are

not freely available for all applications, but can only be used in con-
junction with specific AERZEN equipment up to a maximum classi-
fication level of Category II.
According to the Pressure Equipment Directive, Annex II (con-
formity assessment diagrams), a piece of equipment that serves to
protect specific devices can fall into the same category as the
device that is to be protected. Therefore, the application is only
permissible if the device to be protected does not exceed the
stated category.
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Foreseeable misuse
The safety valve serves to limit pressure in pneumatics sys-

tems. The maximum permissible pressure is limited so as to
protect the machine from excessive pressure levels (overpres-
sure safety) and in order to prevent damage.
AERZEN safety valves may only be used for air applications
and neutral-gas applications and serve as protection for the
machine.
The opening pressure of the safety valve is set by the manufac-
turer at 50 mbar above the designated operating pressure.
The AERZEN safety valve has been designed and constructed

solely for its “intended use” in the industrial field, as described
here, and only in conjunction with AERZEN products.
Observe and comply with the job-specific operating data and
operational limits!
This intended use also includes compliance with all information in
this instruction manual.
Any use beyond the intended use or any other type of application
is considered misuse.
2.3 Foreseeable misuse

Serious injuries
DANGER!
Danger in the case of misuse! Dangerous situa-
tions could occur that could lead to fatal or
serious injuries.
– Never disregard the “intended use”.
– Never use operating data that deviates from
the permissible operating data.
– Never operate the equipment in an operating
area other than the one intended.
misuse.
Serious material damage

NOTICE!
tions could occur that may lead to serious
valve damage!
use”.
– Never operate the valve in an operating area
other than the one intended.
misuse.
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Misuse In specific terms, the valve is not intended for:

n the regulating of operating data.
n the safeguarding of fluids against excessive pressures.
n alteration, retrofitting or modification of the overall design or
of individual equipment parts, with the aim of altering the field
of application or scope of use.
Further examples of misuse The following operating modes/applications and uses are consid-
ered improper and must be avoided!
n Operation:
– deviation from the intended operating data
– the device to be protected exceeds the stated category
– with an altered set pressure
– with the protection cylinder removed or with a narrowed or
sealed protective cylinder
– outside the scope of intended use
– using gases other than those originally intended
– installation of additional components
– with missing or damaged components
– without any or with damaged protective equipment
– without sufficient ventilation of the room
– non-compliance with maintenance intervals
– ensuring the system pressure provided by the customer by
means of AERZEN safety valves
– use as a safety-oriented component in the system line
n Installation:
– on slanted or diagonal connections
– in a hanging position
– outdoors without due consideration of particular protective
measures for avoiding the effects of weather conditions
– Mount components/equipment at a distance of at least
approx. 20 cm from the gas pipe outlet
2.4 Responsibility of the operator

Operator The operator is the person who uses the safety valve for commer-
cial or business purposes, or who assigns the use/application of
the safety valve to a third party. During operation, the operator
holds legal responsibility pertaining to the product, for the protec-
tion of the user, personnel and third parties.
Operator’s obligations Safety valves are highly valuable safety devices and must be han-
dled carefully. Improper, rough handling will lead to functional
impairments or even to total failure/irreparable damage of the
safety valve.
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The safety valve is used for commercial purposes. The operator of

the safety valve is subject to all applicable statutory requirements
and obligations in relation to occupational safety.
Alongside the safety instructions in this manual, the safety, occupa-
tional and environmental protection regulations relevant to the area
of application of the safety valve must also be complied with.
The operator is obligated to:
n Inform him- or herself of the applicable occupational protection
regulations. As part of a hazard assessment, the operator must
also identify hazards that could result from specific working
conditions at the machine location. The operator must imple-
ment this hazard assessment for operation of the machine in
the form of operating instructions. The necessary safety data
sheets can be obtained from the relevant manufacturer.
n Throughout the entire service life of the machine, check that
the operating instructions created by the manufacturer corre-
spond to the current status of the applicable regulations. If nec-
essary, adjust the operating instructions accordingly.
n Clearly structure and specify the responsibilities for installation,
operation, fault rectification, maintenance and cleaning.
n Ensure that all persons who come into contact with the
machine have read and understood these instructions. In addi-
tion, the operator must regularly provide personnel training and
inform personnel of the related hazards.
n Provide personnel with the necessary protective equipment
and instruct them that wearing this protective equipment is
compulsory. Monitor compliance with this instruction.
In addition, the operator is responsible for ensuring that the safety
valve is in perfect technical condition.
For this reason, the following applies:
n The maintenance intervals described in this instruction manual
must be complied with.
n Check all safety equipment at regular intervals to ensure that it
is in good working order and complete.
Additional operator’s obligations The operator must ensure that the following requirements are com-
plied with and put into practice:
n Only operate the safety valve in its original delivered condition.
The manufacturer’s declaration of conformity is rendered void if
the operator makes his own addition or conversions.
n Refrain from any working behaviour that jeopardises correct
operation of the safety valve.
n The safety valve must always be kept in a technically perfect
and operationally safe condition. Replace damaged or non-
operational components immediately. Whenever in doubt,
always get in touch with AERZEN.
n Do not operate the safety valve if the protective equipment has
been disassembled or bypassed.
n Ensure that the gas outlet is not impeded.
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Spare parts
n Observe all warnings and notices attached to the safety valve

and make sure they are legible. It is imperative that loose or
illegible signs be replaced. Ask the manufacturer for replace-
ments.
n Do not disassemble or incorrectly fit any connections.
Operator’s obligations for convey- n The operator is responsible for ensuring that the installation
ance of nitrogen site is sufficiently ventilated.
n The operator is responsible for ensuring that any escaping
nitrogen can be detected by signalling devices immediately.
n The operator is responsible for ensuring that when the safety
valve opens, the nitrogen is routed into a collective line for
residual gases.
Operator’s obligations at the instal- n The operator is obligated to integrate the emergency measures
lation site for the safety valve into the operator’s own emergency meas-
ures for the event of an accident or emergency. The operator
must make particular efforts to integrate these measures into
the evacuation and rescue plan and the fire warning plan.
n The operator must ensure compliance with the maximum per-
missible system pressure by means of safety valves provided
by the customer, regardless of the safety valves used by
AERZEN.
n In all situations, the operator must ensure sufficient relief for
the system.
2.5 Spare parts

Use of incorrect spare parts
CAUTION!
Safety risk from using incorrect replacement
parts!
Incorrect, defective or unsuitable replacement
parts or copies of original components may
endanger personal safety and lead to damage,
faults or the total failure of the machine.
– Only use the manufacturer’s original replace-
ment parts or parts approved by the manufac-
turer.
– If in doubt, always contact the manufacturer.
Obtain spare parts via authorised dealers or direct from the manu-
facturer. For contact data, see Customer Service Ä Chapter
1.4.2 „Customer service“ on page 8.
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Spare parts Spare parts not supplied by AERZEN are not tested and released.
They are not equivalent to genuine components. The use of such
products can, under certain circumstances, impact the construction
properties of the systems. The manufacturer shall not be liable for
any damage caused through the use of non-genuine components.
2.6 Requirements for personnel

2.6.1 Qualifications
The various tasks described in this manual are associated with a
variety of requirements in terms of the qualifications of the persons
responsible for carrying out these tasks.
Insufficient qualifications
WARNING!
Risk if persons are not sufficiently qualified!
Insufficiently qualified persons are unable to gauge
the risks presented by the use of the machine and
put themselves, and others, at risk of serious or
fatal injury.
– Only allow work to be carried out by suitably
qualified persons.
– Observe the information on qualifications in
this manual.
– Keep insufficiently qualified persons away from
the operating range of the machine.
For the purposes of all work with this machine, only allow persons
who are expected to carry out their work reliably to do so. Persons
whose reaction times have been impaired, e.g. through drug or
alcohol consumption or medication, are not be permitted to work.
The follow section of this manual states the qualification require-

ments for persons carrying out the various tasks:
Manufacturer’s customer service division
Certain work may only be performed by the customer service divi-
sion of the manufacturer. On the basis of its special, field-specific
training, expertise and experience, the customer service division is
up to the task of performing highly-skilled work.
The customer service division is a competent point of contact for all
stages of the machine’s service life. It is able to perform all work on
the machine with the highest efficiency.
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Service personnel
Service personnel are able to carry out their work on the basis of
their field-specific training, expertise, experience and knowledge of
the relevant standards and requirements. Personnel recognise
hazards independently and avoid risks.
Service personnel in particular possess practical experience and
extensive field-specific expertise for the variety of tasks.
n Transport
n Set-up / installation
n Commissioning
n Maintenance
n Fault rectification
n Disassembly
Depending on the designated job, the person must have additional
qualifications:
n Operation and handling of compressors.
n Parameterisation of compressors.
n Optimisation work within the persmissible operating data
range.
Skilled staff for industrial waste

Skilled staff for industrial waste posses comprehensive, field-spe-
cific expertise relating to the disposal and recycling of industrial
waste. Skilled staff transports the industrial waste to the waste dis-
posal company and holds responsibility for proper sorting of waste.
The staff incorporates this sorting into the recycling and disposal
processes.
Trained person
A trained person has been demonstrably instructed in an on-site
briefing by the person responsible about the tasks assigned to
them and the potential risks posed by improper conduct. Training
was given as required. A trained person has been instructed on the
required safety equipment and safety measures. They are able to
work with foresight, recognize risks and act accordingly. A trained
person is not allowed to intervene in the control or operation of the
valve.
Depending on the work to be carried out, they must possess the
following knowledge:
n Transport and handling of packages.
n Visual inspection at the valve.
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2.6.2 Unauthorised persons

Unauthorised persons in the instal-
lation area WARNING!
Mortal danger for unauthorised persons in the
installation area!
Unauthorised persons who do not satisfy the
requirements described here are not aware of the
hazards in the installation area. Unauthorised per-
sons are therefore at risk of severe injury.
– Keep unauthorised persons away from the
installation area.
– In case of doubt, approach the persons and
direct them away from the installation area.
– Stop work for as long as unauthorised persons
are in the installation area.
2.7 Personal protective equipment

Personal protective equipment is designed to ensure that health
and safety are not compromised at the workplace.
During the various activities on and with the machine, personnel
must wear the personal protective equipment to which special ref-
erence is made in the individual sections of this manual.
Description of the personnel pro- The personal protective equipment is explained below:
tective equipment
Hearing protection (7010-M003)
Hearing protection serves to protect against hearing damage from
noise.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture
hazards or more serious injuries and from contact with hot sur-
faces.
They are oil-resistant and protect hands from coming into contact
with lubricants.
Protective work clothing (7010-M010)

Protective work clothing is tight-fitting work clothing with minimal
tensile strength, tight sleeves and without protruding parts.
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Safety shoes (7010-M008)

Safety shoes protect feet from being crushed, from falling objects
and from slipping on slippery surfaces.
2.8 Safety devices
Function of the safety devices

WARNING!
Risk of fatal injury from non-functioning safety
devices!
Incorrectly operated, non-functioning and deacti-
vated safety devices give rise to a risk of serious or
fatal injury.
– Before beginning work, check that all safety
devices are functioning correctly and are cor-
rectly installed.
– Never deactivate or bypass safety devices.
– Ensure that all safety devices are accessible at
all times.
1 Protective cylinder
n The protective cylinder serves as protection against moving
components and as a guide pipe for any conveyed medium
that escapes.
n The protective cylinder provides protection against mechanical
and pneumatic hazards.
Fig. 1: Protective cylinder
2.9 Safety classification

The following symbols and notices are displayed on the safety
valve. They relate to the immediate vicinity in which they are
located.
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Danger zone and operating area
Unreadable signage
WARNING!
There is a risk from unreadable signage!
There is a risk of injury resulting from dirty or
unreadable signs. It may be impossible to recog-
nise hazards and to follow the necessary operating
information.
– Keep all safety, warning and operating informa-
tion in a thoroughly readable condition.
– Replace damaged signs or stickers immedi-
ately.
Warning sign on the AERZEN safety valve.
Fig. 2: Safety classification
Gas emission
Risk from sudden gas emission.
The opening of the safety valve results in the emission of gas and
accompanying noise emissions. There is a risk of hearing damage
and injuries to eyes or skin.
2.10 Danger zone and operating area

Hazard area
Operating and/or display area
The hazard area is located in the marked zone at the safety valve
outlet. The operating area is the area marked green.
Fig. 3: Hazard area and operating

and/or display area
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Environmental protection
2.11 Environmental protection

Corrosion inhibitor
ENVIRONMENT!
Bare components inside the guard cylinder are
preserved with a lube oil intended for the food
processing industry.
Information on the corrosion inhibitor:
– In accordance with the Ordinance on Haz-
ardous Substances, the corrosion inhibitor is
classified as non-irritating to eyes and skin.
– No sensitising effect known.
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Functionality
3 Design and operation
3.1 Overview of assemblies
Fig. 4: Overview
1 Spring-loaded plate 5 Bell
2 Spring 6 Piston
3 Spindle 7 Seat
4 Guide bushing
Version G2", G3", DN 50 Threaded connection with seal ring

Version DN 50, DN 80, DN 125, DN 150, DN 200, Flange connection with flat gasket
DN 300
3.2 Functionality
Using a spring action, the AERZEN safety valve is set to a defined
opening pressure of 50 mbar above the working pressure.
If the pressure difference is exceeded by more than 50 mbar, the
safety valve opens and releases the conveyed medium into the
surrounding environment or a collective line.
Due to the metallic sealing elements, a very minimal air flow can
escape when the valve is closed. AERZEN safety valves are there-
fore categorised as “not leak-tight”.
Guide bushes, bells and pistons are made of rust-proof material.
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Requisite tools
3.3 Requisite tools

The following tools are required:
Auxiliary materials, aids
including collection containers for oil, drain hose, cleaning rags.
General tool kit

including various screwdrivers, combination wrenches, set of
socket spanners, set of Allen wrenches, hammers.
Lifting equipment
For lifting loads, e.g. ropes, belt anchorages, shackles, eyebolts
with nuts.
Pronged wrench for 3" safety valve

The pronged wrench is used to tighten the R3”-model AERZEN
safety valve.
Transport equipment
For transporting packaged units and the safety valve, e.g. with lift
trucks, forklifts.
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Safety instructions
4 Transport, packaging and storage

Improper transport
WARNING!
Risk of injury from improper transport!
Improper transport may result in personal injury.
unloading the safety valve and during in-house
transport.
– Transport of safety valves classified as DN 150
or greater requires the use of cranes or indus-
trial trucks.
– Only use the intended slinging points.
Industrial trucks
WARNING!
There is a risk of fatal injury from industrial
trucks!
Transport with industrial trucks can result in objects
and other loads falling accidentally and causing
serious or fatal injury. There is also the risk of the
driver failing to see persons and running them
over.
– Industrial trucks should only be operated by
trained drivers (e.g. forklift drivers).
– Only walk past an industrial truck if the driver
has signalled that he has recognised the
person in his path.
– Only use approved industrial trucks with suffi-
cient load carrying capacity.
– Never transport materials over persons or the
areas in which persons are located.
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Safety instructions
Suspended loads
WARNING!
Mortal danger from suspended loads when
transporting by crane!
Loads can swivel out and fall during lifting opera-
tions. The result can be serious injury or even
death.
– Never step under suspended loads or into the
swivel range thereof.
– Move loads only under supervision.
– Observe the sling points.
– Make sure the lifting tackle is secure.
– Use only approved hoists and lifting tackle with
adequate load-bearing capacity.
– Do not use frayed or worn hoists such as ropes
and belts.
– Do not lay hoists such as ropes and belts on
sharp edges or corners, do not knot and do not
twist.
– When vacating the workplace, deposit the load.
Disregard for the machine’s centre

of gravity WARNING!
There is a risk of the unit toppling and falling
over if there is disregard for the machine’s
centre of gravity!
If the machine’s centre of gravity is disregarded,
the packaged unit may topple and cause life-
threatening injury.
– Observe the packaging information on the
machine’s centre of gravity.
– Attach lifting equipment in such a way that it is
located above the centre of gravity.
– Raise the load carefully and ensure that it does
not topple. If necessary, change the position of
the lifting equipment.
Requirements for personnel For transport:

Transport of packages
Personnel: n Trained person
Protective equipment Requirements for transport:
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n Protective gloves
Special-purpose tools Requirements for transport:

4.2 Transport
4.2.1 Delivery method
The safety valve is either installed in the machine or delivered as a
packaged unit. The safety valve is packaged for transport in
accordance with the given requirements.
4.2.2 Packaging
4.2.2.1 Handling packaging for individual parts
Handling packaging The various packaged items are packed in accordance with the
anticipated transport conditions. In as far as it is possible, environ-
mentally-friendly materials are used for the packaging.
The packaging is intended to protect individual components from
transport damage, corrosion and other forms of damage. For this
reason, do not destroy the packaging and only remove it shortly
before assembly.
Only remove packaging for transport to the installation area if it has
been expressly permitted.
Removing the packaging

1.
CAUTION!
Risk of injury from packaging material!
Removing all packaging.
ENVIRONMENT!
Packaging materials are valuable raw mate-
rials. They can be reused or treated and
recycled. The incorrect disposal of packaging
materials can damage the environment.
2. Sort packaging by material type and dispose of prop-

erly.Ä Chapter 10.3 „Disposal“ on page 46
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Transport > Transport of packaged units
4.2.3 Transport inspection

Transport damage
Transport damage
Inspect the package for potential damage immedi-
ately. Initiate a complaint immediately if there is
any damage.
Check the delivery for transport damage.

If there is any damage, proceed as follows:
n Do not accept the delivery or only accept it under certain condi-
tions.
n Note the scope of the damage in the transport documents or
on the delivery docket provided by the carrier.
n Register the claim.
Inspect the delivery for completeness on the basis of the packing
slip.
n The packing slip is located on the packaged unit.
4.2.4 Transport of packaged units

Transport of packaged units
1.
CAUTION!
Risk of injury when raising heavy loads!
NOTICE!
Risk of damage due to using unsuitable
transport aids!
NOTICE!
Risk of damage due to large packages tip-
ping over! Packages may be transported only
with hoists that grip below the machine and
fully into the transport pallet.
Transport packages safely and with caution.

2. Observe centre of gravity!
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Storage and preservation
4.2.5 AERZEN safety valve transport

G2"/G3", DN 50 – DN 125
Safety valve sizes G2"/G3", DN 50 – DN 125 can
be transported manually.
1. Remove packaging material.

2. Transport the safety valve manually.
Fig. 5: G2"/G3", DN 50 – DN 125
DN 150, DN 200, DN 300

Safety valve sizes DN 150 and upwards must be
transported using a crane.
1. Remove packaging material.

2. Carefully insert a hook into the holding support on the protec-
tive cylinder.
3. Take the centre of gravity into account!
WARNING!
Risk of injury from falling loads!
4. Raise and transport the safety valve.
Fig. 6: DN 150, DN 200, DN 300
4.3 Storage and preservation

Storage notes Store the packaged unit under the following conditions:
n Keep flange connections clean. Avoid entry of foreign sub-
stances.
n Do not store outdoors.
n Store in a dry and dust-free place.
n Do not expose it to any aggressive media.
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n Protect the packaged unit from exposure to the sun.

n Avoid mechanical vibrations.
n Avoid extreme temperature fluctuations.
n Avoid adverse water affects.
n Storage temperature: -10 to +40 °C.
n Relative humidity: maximum 80%.
n If a vibration-free storage area is not available, move the mov-
able components by two to three rotations every six to eight
weeks.
NOTICE!
Risk of corrosion! To avoid potential damage to the
safety valve, an inspection of the overall extent of
supply should be undertaken every two years.
There may be information on the packaged unit

regarding storage that goes beyond the require-
ments listed here. Comply with this information.

over 12 months
n Packaging with VPI paper.
n Sealed in PVC foil.

over 12 months in a tropical climate
n Drying agent (VPI power in a bag) inside the packaging.
n Packaging with VPI paper.
n Sealed in PVC foil.
Storage in air-conditioned spaces with minimal

humidity has a positive influence on corrosion pro-
tection!
Packaging during storage n Inspect the general condition of the packaging regularly. Imme-
diately rectify damage to the packaging. If necessary, refresh or
replace the anti-corrosion protection
n After opening the packaging:
– Inspect uncoated parts for sufficient corrosion protection.
– Protect against humidity and damaging environmental influ-
ences.
– Sealing flaps from the connection openings must not be
removed.
n Replace the drying agent regularly in accordance with climate
conditions.
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NOTICE!
Risk of corrosion! Customised packaging is
required for tropical climate zones and in the case
of special customer requirements.
Damaged packaging
NOTICE!
Risk of corrosion! As a result of damaged pack-
aging, moisture and damaging environmental influ-
ences could directly affect the product.
Measures in the case of damaged packaging

n Immediately rectify damage to the packaging. If necessary,
refresh or replace the preservation material.
n Dry the valve, if necessary.
n Check the drying agent and replace it if necessary.
n Repair or replacement of the packaging.
Preservation Factory preservation protects the product for a certain time period
in accordance with the relevant storage and packaging information.
Valve mechanics BIO-CHEM food biodegradable, does
tech oil not contaminate
groundwater
Shelf life up to 12 months with compliance
with storage condi-
tions
Repeat after 12 months
Extended shelf-life more than 12 only with suitable
months long-term preserva-
(no standard) tion and packaging
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Assembly and installation

Requirements for the assembly site
5 Assembly and installation

WARNING!
Risk of injury from improper installation!
Improper installation may lead to serious personal
or material damage.
– Before beginning work ensure there is suffi-
cient space for installation.
– Only use proper tools and, if necessary, the
requisite special tools.
Unsuitable or damaged tools may cause injury.
– Secure components against falling or tipping
over during installation work.
– Install components correctly.
Requirements for personnel For assembly:

Assembly and installation of the mechanical components
Protective equipment Requirements for assembly and installation:

n Protective gloves
Special-purpose tools Requirements for assembly and installation:

Special tool: n General tool kit
n Pronged wrench for 3" safety valve
5.2 Requirements for the assembly site

Surroundings n Avoid accumulation of dust and dirt.
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Assembly
NOTICE!
Risk of corrosion! There must not be any excessive
levels of dust, acids, steam or explosive or flam-
mable gases at the installation site!
Assembly location n Ensure there is sufficient space for assembly and maintenance
work.
n Provide connections without the use of inclines. Never
assemble components diagonally or so that they are sus-
pended.
n Depending on the valve size, use gaskets or sealing rings for
the sealing surfaces.
Outdoor installation Installation of the safety valve outdoors without protection against
weather conditions is not permissible! Specific protective measures
must be taken in this case to avoid the effects of weather condi-
tions.
5.3 Assembly
G2” with thread
1. Manually pre-assemble the safety valve with the sealing ring.

2. Tighten with a wrench.
Fig. 7: Safety valve G2"
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Assembly
G3” with thread
1. Manually pre-assemble the safety valve with the sealing ring.

2. Tighten with a pronged wrench.
Fig. 8: Safety valve G3"
DN 50 – 300 with flange
1. Fit the safety valve on to the connection along with the

gasket.
2. Guide the fastening screws through the fastening bores.
Position the washers.
3. Pre-tighten the screws and nuts using the same torque.
4. Tighten the screws and nuts.
Fig. 9: Safety valve flange
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First commissioning
Initial start-up
6 First commissioning

Improper first commissioning
WARNING!
Risk of injury from improper first commis-
sioning!
Improper first commissioning may lead to serious
injury and considerable material damage.
– Before first commissioning, ensure that all
installation work has been carried out and com-
pleted in accordance with the information and
notes in this instruction manual.
– Before first commissioning, ensure that there
are no persons in the hazard area.
Requirements for personnel For initial start-up:

Protective equipment Requirements for commissioning:

n Protective gloves
Special-purpose tools For initial start-up:

6.2 Initial start-up

1. Check that the pipelines have been depressurised.
2. Perform a functional check.
n The safety valve operates smoothly.
– Finish the check.
n The safety valve operates sluggishly or jams.
– Check that the installation position is free of stress
and strain.
– Replace the safety valve.
3. Pressurise the system pipeline.
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First commissioning
Initial start-up
4. Check for tightness.

n The safety valve is tight.
– Finish the check.
n The safety valve is not tight.
– Replace seal.
– Replace the safety valve.
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Operation
Information on operation
7 Operation

Improper operation
WARNING!
Risk of injury from improper operation!
Improper operation may lead to serious injury and
considerable material damage.
– Carry out all activities in accordance with the
information and notes in this instruction
manual.
– Before beginning work, observe the following:
– Ensure that all covers and safety devices
are installed and operating correctly.
– Ensure that there are no persons in the
hazard area.
– Never deactivate or bypass safety devices
during operation. Do not operate such devices
in a manner that deviates from the operating
data.
7.2 Information on operation

No further measures required for operation.
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Maintenance
Safety instructions
8 Maintenance

Improperly performed maintenance
work WARNING!
Risk of injury from improperly performed main-
tenance work!
Improperly performed maintenance may lead to
serious injury and material damage.
– Only perform maintenance work when the
temperature.
– Only perform maintenance work with suitable
tools.
correctly.
Hot surfaces
WARNING!
serious burns.
tective gloves.
work.
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Maintenance
Maintenance schedule
Hot media
CAUTION!
Pressurised safety valves may open suddenly
during operation and emit hot compressed gas.
Dust particles may be blown around.
– Deactivate the pressure in the system pipe-
lines.
opening.
Requirements for personnel The described maintenance work is reserved for the stipulated per-
sonnel. The individuals responsible and the corresponding mainte-
nance activities are listed in the maintenance schedule.
For maintenance work:
Protective equipment For maintenance the following is necessary:

n Protective gloves
Special-purpose tools For maintenance:

n Auxiliary materials, aids
8.2 Maintenance schedule

The following sections describe the maintenance work that is
required for safe and fault-free operation of the valve.
If regular inspections reveal an increased level of wear, reduce the
maintenance intervals in accordance with the signs of wear and
tear. For questions on maintenance work and intervals contact the
manufacturer. See contact details Ä Chapter
1.4 „Addresses“ on page 7.
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Maintenance
Maintenance work
Maintenance schedule Depending on which arises first:

Four times a year where Check the safety valve for proper operation. Service per-
ambient air contains dust sonnel
Clean the safety valve. Service per-
sonnel
After every 1,000 op. hrs Check the safety valve for proper operation. Service per-
sonnel
sonnel
Twice a year where Check the safety valve for proper operation. Service per-
ambient air is clean sonnel
sonnel
8.3 Maintenance work

Preparations
1. Switch off the machine and secure it against an unintentional
restart.
2. Deactivate the pressure in the system pipelines.
Movement test
G2", G3", DN 50, DN 80, DN 125
1. Remove the protective caps or blanking plugs from the main-

tenance holes in the protective cylinder.
2. Guide a screwdriver into each hole.
3. Raise the valve bell with the screw drivers using leverage
force.
ð The safety valve must open and move with the proper
functionality.
4. Move the screwdrivers back to the starting position and lower
the valve bell.
Fig. 10: using a screwdriver 5. Remove the screwdrivers.
ð An intact safety valve will close properly.
6. Insert the protective caps or sealing screws into the mainte-
nance holes in the protective cylinder.
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Maintenance
Cleaning after maintenance
DN 150, DN 200, DN 300
1. Raise the valve bell using the stirrup.

ð The safety valve’s opening function must be triggered
and it must move.
2. Release the pressure on the stirrup and lower the valve bell.
ð An intact safety valve will close properly.
Fig. 11: using the stirrup
8.4 Cleaning after maintenance

Cleaning after maintenance work 1.
NOTICE!
Risk of damage! Do not use high-pressure
cleaners, power hoses, degreasers, thinners,
compressed air, etc. as the cleaning agent.
2. Clean thoroughly using absorbent rags.

3. Remove all cleaning aids from the direct vicinity of the
machine before restarting.
4. Dispose of the cleaning rags in an environmentally-respon-
sible manner.
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Faults
Safety instructions
9 Faults

Hot surfaces
WARNING!
serious burns.
faces, always wear protective work clothing
and protective gloves.
– Before beginning any work, ensure that all sur-
faces have cooled down to ambient tempera-
ture.
Hot media
CAUTION!
opening.
Requirements for personnel Rectification work is reserved for the stipulated personnel. In the
"Fault descriptions" table, the corresponding persons are listed and
assigned to the respective rectification measures.
Procedure in case of malfunctions and preparations for rectification
work:
For start-up after rectification work:

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Faults
Fault diagnosis and rectification
Protective equipment Requirements in case of a fault:

n Protective gloves
Special-purpose tools For a malfunction:

Procedure in case of malfunctions 1.

DANGER!
Risk of injury during rectification work!
2. In case of malfunction, trigger the machine's EMERGENCY

STOP function.
3. Deactivate the main circuit breaker of the machine and
secure.
4. Communicate the malfunction to the individual responsible at
the machine's location immediately.
5.
DANGER!
Mortal danger from electric current!
6. Check the machine's electrical connection is not live.

7. Earth and short-circuit.
8. Cover or cordon off adjacent live parts.
9. Establish the cause of the malfunction.
9.2 Fault diagnosis and rectification

If the following faults occur, which only the manufacturer can rec-
tify, contact customer service immediately.Ä Chapter
1.4 „Addresses“ on page 7

Safety valve jams, only Dirt, deposits Check for/remove dirt Service personnel
operates sluggishly
Safety valve does not open Safety valve is jammed Replace the safety Service personnel
tight valve
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Faults
Commissioning after malfunction rectification

Safety valve does not open Safety valve is seated Service the safety valve Manufacturer’s customer
firmly service division
Safety valve does not close Safety valve is jammed Replacing the safety Service personnel
tight valve
Safety valve does not close Safety valve is seated Service the safety valve Manufacturer’s customer
firmly service division
9.3 Commissioning after malfunction rectification

Commissioning after fault rectifica- 1. Check all previously loosened screw connections for tight-
tion ness.
2. Mount all protective hardware and covers that were previ-
ously removed.
the workspace.
ating material, processing material and similar materials and
dispose of them in the proper way.
fault that occured.
6. Ensure that there are no persons in the hazard area.
9. Acknowledge the fault in the control system.
10. The safety valve is ready for operation.
work carried out.
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Safety instructions
10 Disassembly and disposal
Protecting the environment and conserving resources are among

AERZEN’S foremost priorities.
Once the safety valve’s service life is over, it must be disassem-
bled and disposed of in an environmentally-friendly way. The fol-
lowing is a set of recommendations for environmentally-friendly
disposal.

Incorrect disassembly
WARNING!
Risk of injury from incorrect disassembly!
Stored residual energies, angular components, tips
and corners on the valve, the machine or at the
required tools can cause injury.
– Before starting work, make sure there is ade-
quate space.
– Handle sharp-edged components with care.
– Ensure order and cleanliness at the workplace!
Components and tools laid loosely together or
left lying around can cause accidents.
– Disassemble components correctly. Some
components have high dead weights. Use
hoists if necessary.
– Secure components to prevent them from
falling or overturning.
– Contact the manufacturer in case of uncer-
tainty.
Disassembling the delivery line

WARNING!
materials!
For the disassembly of pressurised components
conveying material escapes with a strong gas flow.
This can result in serious injury.
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Disposal
Requirements for personnel For a disassembly:

Disassembly of the mechanical components
Protective equipment Requirements for disassembly:

n Protective gloves
Special-purpose tools For a disassembly:

n Lifting equipment
10.2 Disassembly
Preparing for disassembly: 1. Immediately inform the responsible staff at the operation site
about the disassembly.
2. Switch off the machine and secure it against restarting.
3. Allow the machine and safety valve to cool down to ambient
temperature.
4. Seal off the pressure line and remove it.
5. Physically disconnect the entire electric power supply from
the machine. Release stored residual energy.
6. If necessary, disconnect the machine control system from a
connected process control system.
7. In addition, clean assemblies and components thoroughly.
Dismantle them in accordance with local regulations for occu-
pational safety and environmental protection.
8. During disassembly, there should be a general sorting of
parts according to disposal categories. Ä „Categories for
sorting“ on page 48
10.3 Disposal
The safety valve is composed primarily of steel, cast materials and

various non-ferrous metals. In general, metallic materials are fully
recyclable.
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Disposal
Proper disposal In as far as no agreement has been made on the return or disposal
of the machine, send dismantled components for recycling:
n Scrap metals.
n Send plastics for recycling.
n Sort and dispose of other components according to material
composition.
Improper disposal
ENVIRONMENT!
Environmental risk from improper disposal!
Improper disposal can present a risk to the envi-
ronment.
– Have insulating material, electronic waste,
electronic components, auxiliary materials and
chemicals disposed of by a professional waste
disposal company.
cialist companies for information on environ-
mentally-friendly waste disposal.
Requirements for personnel Disposal requirements:

Personnel: n Skilled staff for industrial waste
Protective equipment Disposal requirements:

n Protective gloves
Special-purpose tools Disposal requirements:

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Disposal
Categories for sorting Scrap iron Non-ferrous metal (except for

scrap iron)
Scrap Aluminium
n Scrap steel
n Foundry scrap
n Scrap from non-rusting
steels
n Stainless steel scrap
Copper
Brass
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Technical data
11 Technical data
Sizes Declaration as per* Orientation
G2" // G3" // DN 50 // DN 80 // DN Category I, Module A any
125
DN 125 Category II, Module A1 vertical
DN 150 // DN 200
DN 300 (delta p < 650 mbar) Category II, Module A1 vertical
DN 300 (delta p > 650 mbar) Category IV, Module B vertical
Possible classification of sizes into the applicable categories. The classification of a particular safety valve
is included in the declaration of conformity for the applicable contract.
Application limits
Size Maximum positive pressure in Maximum set pressure (positive

bar pressure) in bar
G2" 1.5 1.55
G3" 1.5 1.55
DN 50 1.5 1.55
DN 80 1.5 1.55
DN 125 1.5 1.55
DN 150 1.5 1.55
DN 200 1.5 1.55
DN 300 1.0 1.05
n max. temperature 200 °C

n use neutral, clean, non-corrosive gases
11.1 Dimensions and weights

General data Weight data also include the packing list and the marking on the
type plate.
Dimensions, including for packaging, are stated on the shipping
order.
Tab. 3: Dimensions and weights

Size Width (A) Depth (B) Height (C) Weight
mm mm mm approx. kg
G2" 82 82 240 2.5
G3" 190 190 315 4.5
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Technical data
Size Width (A) Depth (B) Height (C) Weight

mm mm mm approx. kg
DN 50 165 165 260 4.0
DN 80 200 200 315 4.5
DN 125 250 250 680 14.75
DN 150 285 285 800 28
DN 200 340 350 850 37.50
DN 300 445 445 1350 82
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Technical data
Operating data
11.2 Operating data
Operating data: see table of AERZEN safety valve operating data
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Technical data
Type plate(s)
11.3 Type plate(s)

Type plates and placement
Manufacturer plate - item 1
Fig. 12: Manufacturer plate
Safety valve signage For the AERZEN safety valve the type plate is on the valve
housing.
Item 1 / safety valve Manufacturer and type plate
Fig. 13: Safety valve signage
Safety valve type plate
Fig. 14: Manufacturer and performance data plate

Item 1 Manufacturer, including address
Item 2 Material
Item 3 Nominal diameter
Item 4 Year of manufacture
Item 5 Customer order no.
Item 6 Application temperatures
Item 7 Valve set pressure
Item 8 Narrowest cross-section
Item 9 Maximum permissible pressure
Item 10 Max. flow rate
Item 11 Medium type
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Note on Declaration of Conformity
12 Note on Declaration of Conformity

This document is provided for informational pur-
poses only and gives an account of the contents of
the Declaration of Conformity. The original docu-
ment is provided with the product or is sent in a
separate document.
CE PED DV
Declaration of Conformity
pursuant to the Pressure Equipment Directive 2014/68/EU, Appendix IV
Translation of Original Declaration of Conformity
Manufacturer Representative
Fax: +49 5154 81-9191 Phone: +49 5154 81-0
E-mail: info@aerzener.de Fax: +49 5154 81-9191
Internet: www.aerzen.com E-mail: info@aerzener.de
31855 Aerzen, Germany Reherweg 28
Valve size Category as per Appendix II, Module

Paragraph 2 of Directive
2014/68/EU
Category I, Module A and Category II, Module A1 safety valves are not freely available for all applications, rather
they can only be used in conjunction with specific AERZEN equipment up to a maximum classification level of
Category II.
Product
Type
Serial no.
Order no.
Year of construction
We hereby declare that the aforementioned product complies with all applicable provisions of the Pressure Equipment Directive 2014/68/EU.
23.07.2019, DocId CE PED Druckventil, 6, en_GB
► Directive 2014/68/EU:2014-05-15 of the European Parliament and Council on the approximation of the laws of the Member States relating
to pressure equipment
The following harmonised standards and regulations were applied:
► DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO 12100:2010)
2011-03 DIN EN ISO 12100:2011-03
► PED AD 2000
Information about Location, date of issue

the
Aerzen,
Signatory
Signature
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Glossary
13 Glossary
·AERZEN safety valve Component in pneumatic systems for limiting the maximum
permissible pressure and for safeguarding the machine.
AERZEN safety valves may only be operated in conjunction
with a product that has been manufactured by AERZEN.
AERZEN safety valves fulfil the function of a pressure valve.
They are not designed to fulfil a safety function.
·Pronged wrench Tool for fastening the AERZEN safety valves. Using a partic-
ular prong shape, the force for fastening the safety valve can
be transferred via the protection cylinder.
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Index
14 Index
A M
Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Maintenance schedule . . . . . . . . . . . . . . . . . . . 40
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
C
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cleaning O
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 41 Operating area
Commissioning Hazard area . . . . . . . . . . . . . . . . . . . . . . . . . 21
after a fault . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Operating data . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Copyright protection . . . . . . . . . . . . . . . . . . . . . . 7
P
Customer service . . . . . . . . . . . . . . . . . . . . . . . . 8
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
D Personnel
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . 17
Dimensions Preservation . . . . . . . . . . . . . . . . . . . . . . . . 29, 30
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Protective equipment . . . . . . . . . . . . . . . . . . . . 19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Q
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Qualifications
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categories for sorting . . . . . . . . . . . . . . . . . . 48
proper disposal . . . . . . . . . . . . . . . . . . . . . . 47 R
E Rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental protection . . . . . . . . . . . . . . . . . . 22
F S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fault diagnosis
Protective equipment . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 43
Safety classifications . . . . . . . . . . . . . . . . . . . . . 20
Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . 14
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . 20
H Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hazard area Storage
Operating area . . . . . . . . . . . . . . . . . . . . . . . 21 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Storage for over 12 months
I
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Storage for over 12 months in a tropical climate
Intended use
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
23.07.2019 55
26.02.2020 202101_10 / 1236965 319

Accessories
Index
Structure
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Symbols
in this manual . . . . . . . . . . . . . . . . . . . . . . . . . 5
T
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transport inspection . . . . . . . . . . . . . . . . . . . . . 28
Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Type plates
Manufacturer plate . . . . . . . . . . . . . . . . . . . . 52
Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
56 23.07.2019
320 202101_10 / 1236965 26.02.2020

Accessories
26.02.2020 202101_10 / 1236965 321

Accessories
322 202101_10 / 1236965 26.02.2020

Drawing
D Drawing
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Drawing
324 202101_10 / 1236965 26.02.2020

Drawing
D.1 Installation drawing
Name Data
Designation Drawing
Type /
Number /
Type of manual /
Manufacturer AERZEN
26.02.2020 202101_10 / 1236965 325

Drawing
326 202101_10 / 1236965 26.02.2020

1 2 3 4 5 6 7 8 9 10 11 12
1135
7110 3410 / 3470
6510 3450
A A
6520 Zuluft
100 air inlet
2110 4420 7210
Drehrichtung
Ölstand
Sence of rotation
Oil level 612
B 1810 B
1297
611

610
613
620 2710
B
I A
C C A(1:5)

40
259±5
300
C C
10
Abluft     Erdungsanschluss
Earthing connection
20
exhaust-air
Erdungsanschluss M8 257±5
Earthing connection M8
787
1102
1122 
Kabelzuführung 885
D
cable entry 925 D
100
C-C ( 1 : 10 ) B ( 1 : 10 )
1135
60
120
,5
32

Kabelzuführung 54 20

cable lead 2x 40
E Balkenkraft / E
beam force
714
Stutzentabelle socket list GM 7 L
817
I Druckanschluss discharge connection DN80 / Ø88.9
539 Balken 1: 2514N
Beam 1: 2514N 7210 Ventilator fan
Balken 2: 2087N 7110 Schallhaube acoustic hood
Beam 2: 2087N 6520 Manometer pressure gauge
15 6510 Wartundsanzeiger service indicator
F Schwerpunkt 4x  4420 Druckventil pressure valve F
Gesamtgewicht: 469kg 3410 Filterschalldämpfer filter silencer
center of gravity 985
2710 Elastischer Rohranschluss flexible pipe connection
total weight: 469kg 2110 Riementrieb belt drive
z = 523mm 1060
0 1810 Motor motor
620 Motorwippe hinged motor support
613 elastischer Maschinenfuß flexible machinery mounting
0
79
426
845
925
Freiraum für Wartungsarbeiten stirnseitig 612 Rückschlagklappe non-return-flap

G min. 800mm. 611 Anschlussgehäuse connection housing G
Gaskraft / Gas force free space for maintenance work at front side 610 Grundträger base frame
Gaskraft, statisch  dynamisch = 248,3N  37,2N of unit 800mm min. 100 Gebläse blower
bei einer Grundfrequenz von 472Hz Aggregatsbefestigung für Hochleistungsanker Pos. Benennung description
Allgemeintoleranzen: Maßstab: Dokumententyp:
Verbleibende dynamische Rohrleitungskraft Bohrlochdurchmesser: d = 12mm Die Fundamentoberfläche muss eben und ISO 2768-mH 1 : 10 Aggregatszeichnung
min. Bohrlochtiefe: h = 90mm horizontal sein! ISO 13920
Achtung!
auf dem Fundament = 7,4N ISO 8015 Dokumentenstatus: Labor/Büro:
The foundation surface has to be even and Fert. Freigabe
h
110
(nicht Lieferanteil AM) Schutzvermerk nach ISO 16016 Kopie muss nicht maßstäblich sein!
horizontal! Inventor - Zeichnung

Gas force, static  dynamic = 248,3N 37,2N aggregat mounting for High performance anchor
Änderung nur mittels Inventor !
Datum Name
Delta Blower
H at a fundamental frequency of 472Hz drill hole diameter: d = 12mm Alle kundenseitigen Anschlüsse sind Erstellt durch: 17.10.2019 QUAST_M
DN80 Überdruck mit SH H
Remaining residual force from the dynamic d min. drill hole depth: h = 90mm spannungs- undmomentenfrei zu montieren! Genehmigt von: 22.10.2019 HORST_A Delta Blower-G5 | GM7L
(not included in Aerzen's scope of supply) All connections provided by the customer are Version Format Sprache Blatt
piping force on the foundation= 7,4N to be mounted stress - relieved and moment - free!
Änderungs-Nr.:
Alte Dokument-Nr.: 4001018551 000 00 A2 DE 1

1 2 3 4 5 6 7 8 9 10 11 12
(2) 01.13

UT1 2M90 704708 A Operation Manual en (Aeration Blower)

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UT1 2M90 704708 A Operation Manual en (Aeration Blower)

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Appendix

8.30 4201-M10_BA_Aeration Blower A+B_EN_00

Operation and Maintenance Manual UT1-2M90-704708

Operation and Maintenance Manual UT1-2M90-704708

Aeration Blower A+B, 480Nm³/h

Order No. Job No. Type KKS

© FLSmidth Hamburg GmbH

Translation of the original manual

Read the instructions prior to performing any task!

Translation of the original operating instructions

DB G5 max. Doc, 1, en_GB

This manual was created by:

© Aerzener Maschinenfabrik GmbH 2020

2 202101_10 / 1236965 26.02.2020

26.02.2020 202101_10 / 1236965 3

3.4.2 Operating information for air-separation systems.... 50

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5.5.3 Connecting the drive motor...................................... 90

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8.3.10 Checking that sealing plugs have been removed 135

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A.2 Declaration of Conformity PED ............................... 181

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The following is a list of additional, supplementary documents to

Declaration of Conformity CE MRL 1012-...

1.2 Explanation of symbols

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Close cover carefully.

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Tips and recommendations

Warning signs Type of danger

Warning – hand injuries.

Warning – explosive sub-

Warning – flammable sub-

Warning – hot surface.

Warning – danger zone.

Additional designations To draw attention to operating guidelines, events, listings, refer-

10 202101_10 / 1236965 26.02.2020

1.3 Copyright protection

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1.4.2 Customer service

Tab. 2: After sales service/service contact

In addition, we are always interested in receiving information and

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2.1 Residual risks and fundamental risks

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2.1.1 Electrical hazards

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Operating faults caused by short-

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2.1.2 Hazards associated with the acoustic hood

Air flow at the air outlet

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Risk of fire and injury

Use of non-original belts

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2.1.3 Hazards at the installation site and operating site

Securing the machine against

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Water contact with live compo-

Sharp edges and corners

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