Gardner Denver GD150 User manual

4990616006

June 2016

GD150

ROTARY VANE

COMPRESSOR

Installation,

Operating &

Maintenance

Manual

(Original Instructions)

Page 2

4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

1 Health & Safety

Health & Safety Issues......................................................3

2 General

2.1 Product General Description.........................................4

2.2 Power Options....................................................................4

2.3 Storage/Low Use ...............................................................4

2.4 Dimensions, performance data,

and operating environment..........................................6

3 Installation

3.1 General..................................................................................7

3.2 Mounting ............................................................................7

3.3 Lifting ....................................................................................8

3.4 Mounting orientations....................................................8

3.5 Lubrication...........................................................................8

3.6 PTO and prop. shaft drive alignment.........................9

3.7 Machine and PTO alignment ..................................... 10

3.8 Pipe work........................................................................... 10

3.9 Ancillaries.......................................................................... 12

4 Operating and commissioning

4.1 Pre-operating check-list............................................... 13

4.2 Test/operating procedure ........................................... 13

4.3 Driver Training................................................................. 14

5 Maintenance

5.1 Schedule............................................................................ 15

5.2 Checking the relief valve operation ........................ 15

5.3 Inspecting the check (non-return) valve ............... 15

5.4 Silencers/Pipe work ....................................................... 15

5.5 Lubrication........................................................................ 15

5.6 Air Inlet Filter.................................................................... 16

5.7 Checking the blade wear............................................. 17

Contents

Chapter Page

Page 3

4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

Health & Safety

1READ THE WHOLE MANUAL BEFORE

COMMENCING INSTALLATION.

Static electricity.

Ensure, that where required, the compressor and ancillaries are earthed

in accordance with BS5958 Part 1 1983; ‘Control of Undesirable Static

Electricity’.

Powder-air combinations are potentially explosive.

Drive line.

It is the responsibility of the installer of the equipment to ensure all rotating

and moving parts of the installation are adequately guarded to a standard

which complies with the prevailing safety legislation.

Compressor.

The compressor has internal moving parts some of which may be accessed

through the inlet and outlet apertures. Do not place any objects especially

ngers into these apertures as personal injury could result.

Installation.

A relief valve must be tted in the appropriate machine port or in the outlet

pipe work as close to the compressor as possible. The valve must be

positioned so as not to vent air onto any personnel since the air discharged

will be hot and can cause severe burns.

Storage/Low use

Before the machine is installed or when it will not be used for long periods:

• Store in a dry, heated building.

• Handle with care and keep the suction and delivery ports

covered.

• Rotate the drive shaft of the machine each week, in the direction shown by

the arrow between the suction and delivery ports on the machine body

Where the compressor is mounted on a vehicle and located outside, itand located outside, it

should be operated for at least 15 minutes each week (twice a week In damp/

cool conditions)

Fire & Heat.

The compressor includes seals made of uoroelastomer polymers which

degrade if exposed to temperatures above 300°C. If the material has been so

exposed then it must not be handled with bare hands.

Surface temperatures can exceed 150°C. Highly combustable materials must

not come into contact with the discharge pipework or compressor body.

Relief Valve Check

This procedure should be carried out every month to clear the valve seat and

check the valve is functional. (Ear protection is recommended)

Noise

Gardner Denver Drums own tests show maximum noise levels for the

GD150 should typically not exceed 91/92 dB(A) in the worst case (1600rpm

2.5bar g).

In accordance with our policy of continuous product improvement, Gardner Denver Drum

reserve the right to alter details and specications without notice.

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4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

General

2.1 Product general description

The GD150 is a light-weight, compact rotary vane compressor designed for

the oil free discharge of bulk liquids from general purpose tankers, e.g. liquid

foodstu, solvents, acids alkalis, hot bitumen, resins and other chemicals.

The main advantage of using a compressor to discharge liquids is that the

product does not come into contact with machine. This eliminates any prob-

lems of material compatibility with the liquid enabling a much wider variety

of products to be discharged.

The machine is an oil free sliding/reciprocating vane design with the main

stainless steel rotor being supported by bearing arrangements at either end.

All the components in the main bore cavity are manufactured from corrosion

resistant materials to resist any possibility of atmospheric corrosion.

The very compact shape and size of the machine make it ideal for mounting

inside the chassis to enable direct low-cost prop. shaft driving or via other

drive methods more suitable for a particular application.

A through shaft allows CW or ACW input drive rotation and the compressor

can be installed on any face to provide the maximum mounting exibility.

The standard package consists of:

Basic GD150 machine and mounting kit

Induction kit including the GD150 inlet lter

Relief valve

Check valve

2.2 Power Options

The GD150 can be driven using any of the following drive systems.

Prop. shaft Direct from a gearbox mounted PTO

Hydraulically Several standard drives are available.

Electrically Motor drive packages on base frames/plates

Engine Drive packages on base frames/plates.

2.3 Storage/Low use

Before the machine is installed or when it will not be used for long periods:

• Store the machine in a dry, heated building.

• Handle the machine with care and keep the suction and delivery ports

covered.

• Rotate the drive shaft of the machine each week, in the direction shown by

the arrow between the suction and delivery ports on the machine body.

Where the compressor is mounted on a vehicle and located outside, it

should be operated for at least 15 minutes each week (twice a week in

damp/cool conditions).

Do not allow dirt, oil and

grease to enter the machine

ports as this could cause

severe damage.

NOTE

The shape and size of the

machine make it particularly

suitable for PTO/prop. shaft

driving inside the vehicle

chassis.

Page 5

4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

No. Description

1. Inlet lter kit - exible

2. GD150 inlet lter

3. Basic GD150 Machine

4. Relief Valve

5. Check (non-return) Valve

6. Micronic Discharge Filter

Figure1. Recommended Layout

General

180mm

"A"

Page 6

4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

2.4 Dimensions, Performance Data & Operating

Environment

Dimensions

The dimensions of the compressor are shown in gure 2 below.

Performance

The performance details and power requirements of the GD150 compressor

are shown on the product data sheet.

For additional information, the constant running torque does not exceed:

56 Nm Speed range 1000 - 1600 rpm

Operating environment

The permissible/foreseen operating environment is as follows:

Figure 2. Dimensions

General

244

40 PORT DETAIL

SHAFT DETAI

¯25

¯68

¯32

180

230

80 80

125120

40 5

¯12

174

265 195

509

120120

141 59

Ambient temperature range -40 to +50°C

Resistant to tropical rain (in operation and transit), salt and sun

Humidity level Up to 100% RH condensing

Vibration level 0 to 40 Hz; ± 40 mm amplitude tested.

Inlet depression Not to exceed 50 mbar

Orientation See g 4 page 8

Max. outlet temperature 220°C

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4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

Installation

3.1 General

For the recommended layout of the machine and ancillaries, see gure 1.

When selecting the machine mounting position, the following points should

be considered:

• Direction of input rotation to the machine must be correct and is simple to

change by swapping over the plastic cowls (see section 3.5 for how to

change the machine input rotation) and driving the shaft at the other end

of the machine.

• Install away from sources of heat, e.g. vehicle exhaust air or hot pipes that

could eect the compressor temperature in any way.

• Venting relief/control valve air must be unobstructed and direct to the

atmosphere.

• Separately mounted relief valves should be tted as close as possible to

the GD150 discharge port and before any other discharge ancillary.

• Any valves should be positioned to avoid hot air venting onto the

operator.

• A cooling fan is tted at each end of the machine and the cooling air path

into the fan must not be obstructed.

• A space of at least 25mm must be allowed around the machine for air

circulation. If mounting to a solid plate, the machine should be mounted at

least 25mm from the plate or a cooling hole should be cut into the plate.

• Any exible coupling assembly used with the machine (e.g. on hydraulic

drives) must incorporate shaft end clearance (at least 1mm) to avoid

interference through temperature expansion during operation.

3.2 Mounting

Each mounting foot is attached to the machine using two long capscrews

(Fig 3, Item 2) and washers (Fig 3, Item 3) with the spacing bushes

(Fig. 3, Item 4) tted between the brackets (Fig 3, Item 1) and the cowls.

12mm diameter holes are provided in the bottom of feet to allow 10mm

studs, screws and nuts (all grade 8.8 or higher) to be used for securing the

machine.

The feet should be xed to a at surface to avoid inducing unnecessary

stresses into the machine and mounting feet. This can be achieved using

shimming if necessary.

Operating in reverse, even

for a short period, can cause

severe damage to the machine

No. Description

1. Mounting foot

2. M10 Cap Screw

3. Spring washer

4. Spacing Bush

Figure 3. Foot mounting details

CAUTION

NOTE

Only the longer capscrews

supplied with the brackets

must be used for securing the

brackets to the machine.

All fasteners should be

tightened to 35 Nm.

Page 8

4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

Installation

3.5 Lubrication

The GD150 is supplied complete with sealed greased bearings which should

not need re-lubricating within the normal life of the machine.

3.3 Lifting

The weight of the compressor without ancillaries is 32 kg and we

recommend that the machine is lifted with a suitable sling. The machine

must be supported/lifted under the main body and not by the plastic cowls

Any equipment used for lifting the machine should be rated accordingly.

3.4 Mounting orientations

The GD150 can be installed on any of the 4 mounting faces shown below

and can be driven in both rotations by using either end of the input shaft.

Additionally, the mounting brackets can be tted facing inwards or outwards

increasing the total tting positions and hole centre positions available.

The machine has the inlet and discharge anges on the same face to simplify

connection and routing of pipe work.

Figure 4. Mounting & Drive options

Only lift/support the machine

using the main body and not

the plastic cowls.

CAUTION

Outlet

Inlet

Page 9

4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

3.6 PTO and prop. shaft drive alignment.

Changing the machine rotation

The current direction of input rotation is indicated by cast arrows on the

compressor body. Changing rotation is a simple process of swapping over

the plastic cowls, key & drive ange as shown in the diagram below.

Installation

Figure 6. Drive Flange Removal

Fitting the drive ange

Standard drive anges (and fasteners) are supplied with all new packages to

t either end of the rotor shaft.

Before tting, the shaft and ange should be clean and damage free to

ensure it ts correctly.

Both the shaft and coupling bore should be smeared with a light oil during

assembly to aid future separation.

A Hollow Set Screw (Grub Screw) should be used for retaining the drive

ange, in position on the shaft.

Apply Loctite 270 to the Grub Screw and tighten to a torque of 7.2Nm.

A puller type device will be required to remove the ange (see Fig. 6) to help

avoid damaging the shaft or ange.

Figure 5. Changing Rotation

The machine rotor must

always rotate in the same

direction, but the opposite

input drive rotation can be

achieved by driving the rotor

from the other end of the

machine.

NOTE

No. Description

1. Cap Screw

2. Spring Washer

3. Mounting Foot

4. Spacing Bush

5. Plastic Cowl - Non Drive End

6. GD150

7. Plastic Cowl - Drive End

8. Drive Flange

9. Key

Page 10

4990616006 Date: 06/16 GD150 Installation, Operating & Maintenance Manual

Installation

3.7 Machine and PTO Alignment

The drive axis on the majority of PTO’s is at 3 - 5° to the horizontal, which

reects the angle of the engine and gearbox.

The compressor should be mounted so that its drive axis is parallel to the

PTO’s drive axis (within 1 degree) - see g 7 .

The compressor should also be mounted so that the prop. shaft angle

between the PTO and GD150 in any plane (including compound angles) is

less than or equal to 12°.

Consideration should be given to the prop. shaft length when mounting the

machine and the prop. shaft should be sized so that it always has sliding

clearance.

Also check the prop shaft

manufacturers information for

the permitted installed angle.

NOTE

Equal Angle

3.8 Pipe work - Figures 1 & 8 show typical pipe work layouts

Standard inlet

A exible inlet pipe, inlet lter, machine inlet ange and gasket are all

provided in the inlet induction kit.

Fabricated pipework

Where any pipe work is to be fabricated, the following points should be

followed/noted to prevent damage to the machine:

• A stainless steel slip-on-weld anges provided with the machine

for use with 1.5”nominal bore pipe work.

• Inlet pipe work should be made in stainless steel or thick wall aluminium to

help prevent corroded particles entering the machine.

• Outlet pipe work can fabricated from any material (including mild steel) to

suit the application, although stainless steel is recommended.

• All fabricated pipe work should be carefully de-scaled/cleaned before

commissioning the compressor.

• Pipe work should be attached to the vehicle chassis using exible

mountings to prevent unnecessary vibration, expansion stress, noise

transfer and avoid distorting the machine body.

• A exible element is recommended in the discharge pipe work (and inlet

pipe work when necessary) to absorb any pipework distortion created

through chassis movement and heat expansion.

• All inlet and discharge pipe work should be as free from bends as

possible to minimise pressure drops. This allows the machine to work in

the best inlet conditions and provide the maximum discharge pressure.

Figure 7. Drive Alignment

Note: The combined angle in any plane

should not exceed 12˚

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