Gardner Denver ESM 30 Original User Manual

Text of Gardner Denver ESM 30 User Guide:

• Gardner Denver ESM 30, 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 with compressed air! Never aim compressed air at your skin or at other persons! Never use compressed air to clean your clothing. When using compressed air to clean equipment take the utmost care and always wear protective goggles. The compressed air generated by these compressors must never be

• Gardner Denver ESM 30, 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 cfm 278.7 160.8 214.5 304.7 279.7 Discharge temperature of air above ambient °F 13 11 11 13 11 Free field noise level (ISO 2151)

• 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 separator 8 Oil drain ball valve 9 Safety va

• Gardner Denver ESM 30, 6. Preparations for commissioning 29 6 Preparations for comm issioning 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 required by these screw compressors is as follows: ESM 30 65 m 3 /min ESM 37 78 m 3 /min ESM 37RS 78 m 3 /min ESM 45 87 m 3 /min ESM 50 87 m 3 /min ESM 45RS 87 m 3 /min The required cooling-air flow is increased by 33 m³/min. if a dryer is installed. Under unfavourable local

• Gardner Denver ESM 30, 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 follows: • Switch the screw compressor unit off and make sure that it is depressurised and no voltage is supplied. For this, while the system is switched off carefully open the ballcock (- 1 - Fig. 19 b) on the downstream cooler until the system has been bled, then close the

• 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 considerable damage to the machine)! As a standard, the air filter is

• Gardner Denver ESM 30, 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. 3.6 Warning of special dangers Electric energy Use only original fuses with the specified current rating. Switch off the machine/unit immediately if trouble occurs in the electric system. Work on the electrical system or equipment may only be carried out by a skilled electrician or b

• Gardner Denver ESM 30, 10. Annex 49 10 Annex 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-cooler outlet temperature above ambient temp. °C 7 6 6 7 6 6 Sound pressure level (to ISO 2151) dB(A) 67 68 Nominal motor rating kW 30 37 Full-load current max. IP55 (220V, 380V, 400V) A 130 / 75 / 71 154 / 89 / 85 Motor protection

• 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 information required to install and operate the compressors and c

• 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.

• Gardner Denver ESM 30, 9. Trouble-shooting 47 9 Trouble-shooting 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 voltage 1. Check fuses, main switch and supply line Unit cannot be started 2. Malfunction not acknowledged 2. Acknowledge fault message 3. Pressure reservoir not depressurized 3. Wait until depressurized. Screw compressor does not

• Gardner Denver ESM 30, 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 adjusting cylinder (-2.1.-) is relieved by the deenergised valve (-30-(Y1)) the upper control space is impinged with pressure via the valve (-32-). • The oil separator tank is relieved to no-load pressure (residual pressure) via the two valves (-31- and -32-). • The screw compressor is now running in the

• 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-∅ 10 for polyamide pipe PA11/12

• Gardner Denver ESM 30, 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 a flexible connection (e.g. compressed air hose, compensator). Europe-Version: DIN 2999 R 1 1/2" USA/CANADA-Version: NPT 1 1/2“ - 11-1/2 Danger When connecting the compressor on the mains side to the compressed air system available at the customer‘s end, check the operating temperatures and operating pressures required and examine the requi

• Gardner Denver ESM 30, 2. Table of contents 8 10 Annex...................................................................................................................................................................................49 10.1 Technical Data ............................................................................................................................................................49 10.1.1 EUROPE version ESM 30-ESM 37................................................................................................................49 10.1.2 EUROPE version ESM 45-ESM 50...........................................................................................................

• 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 compression temperature (-

• Gardner Denver ESM 30, 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. °C 7 6 6 7 6 Sound pressure level (to ISO 2151) dB(A) 69 67 Nominal motor rating kW 45 Full-load current max. IP55 (220V, 380V, 400V) A 188 / 109 / 102 Motor protection type - IP55, EFF1, ECA Nominal speed rpm 3000 Nominal fan moto

• Gardner Denver ESM 30, 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 to be checked and, if required, re-tightened during first commissioning and later on in line with the maintenance schedule. The setting of the control transformer must be checked according to chapter 6.3 “Electrical connection”. 8.10 Fittings The fittings of the air and oil cir

• Gardner Denver ESM 30, 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 procedures! Limit values (pressures, time settings, etc.) have to be permanently identified! Selection and qualification of personnel; basic responsibilities Work on/with the machine/unit must be carried out by reliable person

• Gardner Denver ESM 30, 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 Operate this compressor only if you have an exact knowledge of the machine taking into respect these instructions. Gardner Denver cannot be held responsible for the safe operation of the machine/unit if it is used in a manner which does not correspond to the intended use, or for other applic

• Gardner Denver ESM 30, Data sheet for users 4 Fig. 1 The values on the type plate are maximum values. Your Gardner Denver distributor Name: Address: ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Telephone: Fax: Contact: Spare Parts: Service:

• Gardner Denver ESM 30, 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 panel and wait until the screw compressor unit has come to rest and the screw compressor unit is depressurized • The pressure display does no longer indicate pressures < 0.3 bar/4.4 PSI. • Shortly after switching the screw compressor off, the system can contain a low resi

• Gardner Denver ESM 30, 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 filter cartridge in line with the regulations - special waste ! Check for leakage! For the changing intervals, see the maintenance schedule. Change the oil filter cartridge as follows: • Switch the screw compressor unit off and ensure that it is depressurized, electrical

• Gardner Denver ESM 30, 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 components, any kind of operation outside of the stated limits of EN60204-1/IEC60204-1 is inadmissible. To establish an electrical connection, proceed as follows: Route the supply cable through the cable gland (- 1 - Fig. 12) on the contro

• Gardner Denver ESM 30, 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 for the prevention or elimination of danger has to be maintained regularly and functionally checked at least once a year. Faults observed have to be immediately rectified and/or reported to the responsible person. Use only original spare parts. Only carry out maintenance and repair work when the system is not in operation and the power supply

• Gardner Denver ESM 30, 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 deviate from this representation) Note For switching the compressor off “normally”, use only the stop push-button (- 3 - Fig. 16), but not the EMERGENCY STOP push-button (- 1 - Fig. 16). After shutdown the compressor has a run on time of 30-50 seconds (soft-stop). T

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