Gardner Denver ESM 30 Original User Manual - page 35

Manual is about: Screw Air Compressor

Summary of ESM 30

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    Original user manual screw air compressor esm 30-esm 50 ● gb ● cdn ● usa id. No. Zs1064358 / 00 - january 2010

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    Deutsche basis-ba: zs1064357 / 00 3 general information these compressors are for compressing atmospheric air and are not suitable for compressing any other gas. They are designed and manufactured to give optimum performance with long life and reliability. This manual gives the user all the informat...

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    Data sheet for users 4 fig. 1 the values on the type plate are maximum values. Your gardner denver distributor name: address: ______________________________________________________________________________________ ______________________________________________________________________________________ ...

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    1. Foreword 5 1 for ew or d 1.1 notes on the compressor gardner denver screw compressors are the result of many years of research and development. These prerequisites combined with high quality standards guarantee the manufacture of screw compressors providing a long service life, high reliability a...

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    1. Foreword 6 besides the operating instructions and the binding regulations for the prevention of accidents, which are valid in the country and place of operation of the machine/unit, the generally recognized technical regulations for safe and proper working have also to be observed. Guarantee oper...

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    2. Table of contents 7 2 tab le of co nte nt s 1 foreword ...............................................................................................................................................................................5 1.1 notes on the compressor ........................................

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    2. Table of contents 8 10 annex...................................................................................................................................................................................49 10.1 technical data ......................................................................

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    3. Safety regulations 9 3 safet y r eg ula tio ns 3.1 identification of safety guidelines gardner denver is not liable for any damage or injury resulting from the non-observance of these safety instructions or negligence of the usual care and attention required during handling, operation, maintenanc...

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    3. Safety regulations 10 for the execution of maintenance work, tools and workshop equipment adapted to the task on hand are absolutely indispensable. The personnel must be made familiar with the location and operation instructions of fire extinguishers ! Observe all fire-warning and fire-fighting p...

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    3. Safety regulations 11 if a remote control is used, the system must carry a clearly visible sign with the following note: attention! This installation is operated by remote control and can start up without prior warning! As an additional safety measure, persons, who start remotely controlled syste...

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    3. Safety regulations 12 before blowing through a hose or an air pipe ensure that the open end is positively held. A free end whips and can cause injuries. Before decoupling a hose ensure that it is pressureless. Refrain from any working method which is doubtful in terms of safety. Never play around...

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    3. Safety regulations 13 maintenance/rectification of faults the employer has to inform the employee of the dangers possibly arising during the repair and maintenance of the machine/unit as well as on how to avoid them; the employee has to observe all measures for safety at work. Safety equipment fo...

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    3. Safety regulations 14 if the set-up, maintenance or repair require the demounting of safety equipment, this equipment has to be remounted and checked immediately after these activities. Ensure that consumables and replacement parts are disposed of in a safe and environmentally friendly manner. 3....

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    3. Safety regulations 15 oils, greases and other chemical substances when handling oils, greases and other chemical substances, observe the safety regulations for this product! Be careful when handling hot fuels and consumables (danger of burning or scalding)! Rooms subject to explosion hazards dang...

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    3. Safety regulations 16 3.8 symbols and explanations carefully read the operating manual before commissioning or servicing this compressor. Never breathe in compressed air from this system. Never operate the unit with open doors or loose access panels..

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    3. Safety regulations 17 warning: hot surface warning: pressurized part or system warning: this system can start up by means of a remote control or automatically after a power failure..

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    3. Safety regulations 18 warning: the system continues to run for 30 seconds after pressing the o-key warning: danger of electric shock attention: lifting point.

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    3. Safety regulations 19 attention: check and, if required, re-tighten connection terminals. For further details, see the operating instructions. Attention: opening pressure safety valve = xx bar (value "xx" see sticker on compressor).

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    4. Design and functioning 20 4 desig n a n d f un cti oni ng 4.1 design of the unit fig. 2 1 intake filter 2 intake regulator 3 electric motor 4 screw compressor 5 pressure reservoir 6 oil fine separator 7 oil filling port 8 oil drain 9 oil level indicator 10 oil filter 11 oil cooler 12 safety valve...

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    4. Design and functioning 21 4.2 schematic diagram 4.2.1 schematic diagram esm 30 fig. 3 a 1 intake filter 2 intake regulator 2.1 actuator 2.2 pressure control valve 2.3 controller block 3 electric motor 4 compressor block 5 final compression temperature sensor (r2) 6 pressure reservoir 7 fine separ...

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    4. Design and functioning 22 4.2.2 schematic diagram esm 37-esm 50 fig. 3 b 1 intake filter 2 intake regulator 2.1 actuator 2.2 pressure control valve 2.3 check valve 2.4 controller block 3 electric motor 4 compressor block 5 final compression temperature sensor (r2) 6 pressure reservoir 7 fine sepa...

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    4. Design and functioning 23 4.3 oil circuit the oil flows from the pressure reservoir (- 6 - fig. 3) into the oil thermostat (- 22 - fig. 3). With oil tempera- tures oil cooler directly into the oil filter (- 11 - fig. 3) and is then injected into the screw compressor (- 4 - fig. 3). With oil tempe...

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    4. Design and functioning 24 automatic operation (open-close operation) • when the pressure reaches the upper switching point set on the network pressure sensor (-28 - (b1)), solenoid valve (- 30 - (y1)) is deenergised. • the pressure valve (-2.2-) closes because the lower control space of the adjus...

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    4. Design and functioning 25 stopping the system • to de-energise the solenoid valves (- 19 - (y1) and - 20 - (y4)) press the off push-button on the keypad of the compressor control gd pilot mk. • the pressure control valve (- 2.2 -) in the intake regulator (- 2 -) closes and the pressure reservoir ...

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    4. Design and functioning 26 4.5.3 manner of operation of the suction regulator esm 45-esm 50 load running mode when switching over to delta connection the two solenoid valves are supplied with power (7 (y1) and 9 (y4)). The relief spool (11) is closed. At the same time compressed air flows through ...

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    5. Transport and installation 27 5 tr ans por t an d i ns tall ati on 5.1 transport fig. 6 fig. 7 1 wire pin 2 hinge pin note the wire pins (-1- fig. 7) and the doors must be removed prior to transportation. Danger the compressor must be lifted using a suitable forklift truck which complies with the...

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    5. Transport and installation 28 5.2 installation fig. 8 danger • the weight carrying capacity of the foundation has to be taken into account when installing the compressor. • provide for a solid and plane base. • the system may not be operated on the transport pallet. • the intakes are to be locate...

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    6. Preparations for commissioning 29 6 pr epar ati on s f or com m iss io nin g 6.1 cooling air volume/minimum cross fig. 9 1 cooling air intake 2 cooling air outlet 3 cooling-air inlet for optional refrigeration dryer 4 cooling-air outlet for optional refrigeration dryer the cooling air volume requ...

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    6. Preparations for commissioning 30 6.2 compressed air connection fig. 10 fig. 11 1 compressed air connection 2 thread identification compressed air connection the compressed air line system is connected at the compressed air supply of the screw compressor ( - 1 - fig. 10). For this you should use ...

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    6. Preparations for commissioning 31 to establish an electrical connection, proceed as follows: route the supply cable through the cable gland (-1 - fig. 12) on the control cabinet and tighten screws. Connect the supply line to the connecting terminals as shown in the circuit diagram. Fig. 12 checki...

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    6. Preparations for commissioning 32 recommended supply cable cross-sections and fuses compressor type supply voltage [v] installed nominal motor power [kw] fuse protection (slow-blow fuse) [agl] line cross section at 30°c [mm 2 ] 50-hz-compressors esm 30 220v 380v 400v 30 160 100 80 3x70pe35 4g35 4...

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    6. Preparations for commissioning 33 6.3.2 electrical connection (usa/canada-version only) danger the power supply to the compressor side has to be fitted for industrial equipment and fulfilling the requirements of en60204-1/iec60204-1. To avoid strong damages and fire on the power electric componen...

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    6. Preparations for commissioning 34 recommended supply cable cross-sections and fuses for multi-wire cables or three current-carrying conductors in raceway based on 86 °f ambient temperature line cross section conductor rated compressor type supply voltage installed nominal motor power fuse(s) prot...

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    6. Preparations for commissioning 35 6.4 oil level check danger only check the oil level when the screw compressor unit is out of operation and depressurized! The pressure reservoir can be under pressure and the oil hot. Warning: danger of scalding! Do not spill oil! Check for leakage! Fig. 14 1 oil...

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    7. Commissioning 36 7 com m issio ni ng 7.1 first commissioning danger make sure before commissioning that nobody is in the danger zone of the screw compressor. Only operate the screw compressor with closed access panels. Important although every gardner denver screw compressor has been subjected to...

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    7. Commissioning 37 1 fig. 15 1 drive motor‘s direction of rotation for geared compressor 1 fig. 15 b 1 drive motor‘s direction of rotation in the case of direct drive fig. 15 c 1 cooling air intake 2 cooling air outlet 3 arrow “direction of rotation for compressor“ (direction of rotation may deviat...

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    7. Commissioning 38 display of the compressor control gd pilot mk 1 5 6 7 fig. 16 1. Emergency stop pushbutton 2. Start push-button [ i ] 3. Stop push-button [ o ] 4. Acknowledgement push-button [ Θ ] 5. Final compression temperature 6. Final compression pressure 7. Network pressure the final compre...

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    8. Service and maintenance 39 8 ser vice an d m ai nte na nce 8.1 maintenance recommendations note the screw compressor unit can only operate to your complete satisfaction when the maintenance work is carefully carried out at the specified intervals. In order to facilitate this task, the scope of su...

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    8. Service and maintenance 40 8.3 maintenance schedule danger when performing control, adjusting and mainte- nance work, be careful with hot surfaces of machine parts. Checks and maintenance work may only be carried out when the following points are observed: • press the stop button on the control p...

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    8. Service and maintenance 41 8.4 oil change fig. 17 1 oil reservoir 2 oil filler cap r1" 3 oil-level indicator 4 max. Oil level 5 min. Oil level 6 oil drain r1/2" 7 drain hose danger only change the oil when the screw compressor unit is not in operation and is depressurized! Be careful when drainin...

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    8. Service and maintenance 42 8.5 change of oil filter cartridge fig. 18 1 oil filter cartridge danger only replace the oil filter cartridge when the screw compressor unit is out of operation and depressurized! Be careful with hot oil: danger of scalding! Do not spill oil! Note dispose of the oil fi...

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    8. Service and maintenance 43 if the oil fine separator is monitored (option), too high a differential pressure is indicated on the keypad of the compressor control gd pilot mk. When the corresponding warning lights up, change the oil fine separator. Fig. 19 b change the oil fine separator as follow...

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    8. Service and maintenance 44 danger only perform checks and carry out work on the screw compressor when the unit is out of operation and depressurized! Important never operate the screw compressor unit without the air filter (even a short operating time without this filter can result in considerabl...

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    8. Service and maintenance 45 8.9 connecting terminals in the switch cabinet/control transformer setting danger in the case of electric voltage: • actuate stop button at the operating panel • set the customer-fitted main power switch to "o" (off). The connecting terminals in the switch cabinet have ...

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    8. Service and maintenance 46 cleaning: clean the filter mat by brushing or washing. Important never install the filter mat in a wet or moist state! Changing times for the filter mat the operating modes and the quality of the suctioned air (e.G. Dust content) has a strong influence on the filter ser...

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    9. Trouble-shooting 47 9 tr ou ble -s ho oti ng in the case of faults or warnings that are detected by the compressor control gd pilot mk, please refer to the chapter “fault/warning table” in the operating instructions of the gd pilot mk. Malfunction possible cause remedy 1. No operating or control ...

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    9. Trouble-shooting 48 malfunction possible cause remedy unit switches off 1. Ambient temperature too high 1. Ventilate compressor room 2. Electric motor defective 2. Check electric motor and thermistor 3. Fan defective 3. Check/replace fan 4. Sensor, connections or lines defective 4. Check sensors,...

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    10. Annex 49 10 ann ex 10.1 technical data 10.1.1 europe version esm 30-esm 37 esm 30 esm 37 technical data 50hz 7.5 10 13 7.5 10 13 maximum operating pressure bar 7.5 10 13 7.5 10 13 minimum operating pressure bar 5 ambient temperature °c 1...45°c flow m 3 /min 5.75 5.11 4.36 7.1 6.17 5.3 after-coo...

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    10. Annex 50 10.1.2 europe version esm 45-esm 50 esm 45 esm 50 technical data 50hz 7.5 10 13 7.5 10 maximum operating pressure bar 7.5 10 13 7.5 10 minimum operating pressure bar 5 ambient temperature °c 1...45°c flow m 3 / min 8 7 6.11 8.67 7.55 after-cooler outlet temperature above ambient temp. °...

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    10. Annex 51 10.1.3 north america version esm 30-esm 37 technical data 60hz north america esm 30 esm 37 nominal pressure psi g 100 125 190 100 125 190 maximum working pressure psi g 110 130 190 110 130 190 minimum working pressure psi g 75 ambient temperature - min / max °f 34...113 fad at nominal p...

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    10. Annex 52 10.1.4 north america version esm 45-esm 50 technical data 60hz north america esm 45 esm 50 nominal pressure psi g 100 125 190 100 125 maximum working pressure psi g 110 130 190 110 130 minimum working pressure psi g 75 ambient temperature - min / max °f 34...113 fad at nominal pressure ...

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    10. Annex 53 10.2 layout plan fig. 23 (all dimensions in mm) a compressed air connection europe version: male screwed thread din 2999 - r 1 1/2 canada usa version: male screwed thread npt 1 1/2 - 11 ½ b condensate connection (only for dryer option or for integrated water-separator option) outer- ∅ 1...

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    10. Annex 54 fig. 24 (all dimensions in mm).

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    10. Annex 55 10.3 declaration of conformity 1. Ec declaration of conformity in accordance with the ec machinery directive 2006/42/ec, supplement ii a 2. We, hereby declare gardner denver deutschland gmbh argenthaler str.11 d-55469 simmern that the product: type: trade mark: manufacturer no.: kompres...

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    Gardner denver compressor division, 1800 gardner expressway, quincy, illinois 62305 telephone: (800) 682-9868 fax: (217) 224-7814 gardner denver deutschland gmbh argenthaler str. 11 55469 simmern deutschland tel. ++49 (0)6761 832-0 fax ++49 (0)6761 832-409.