STENHOJ iver » Gardner @ C Original user manual EnviroAire 37 kw Oil-Free v21. Table of contents 1 2 Table of contents Foreword nn 2.1 Normal use. 2.2 Maintenance, 2.3 General information. 24 Specifications. 24.1 Specifications EUROPE version EnviroAire VS 37, 242 Specifications EUROPE version EnviroAire 37 2.8 Declaration of conformity, Safety regulations. 3:1. Identification of safely instructions 3.2 General safety regulations 3.3. Paricular dangers associated with compressed air 3.4 Pariicular dangers associated with machines. 3.8. Particular dangers associated with water-cooled units. 3.6 Dangers present when loadingimoving machines. 3.7 General workplace dangers ' 3.8 Dangers resulting from neglecting to perform maintenance 3.9 Dangers during maintenance and repairs 43.10 Dangers resulting from conversion work/madifications on the machine 3.11 Symbols and explanations Design and functioning 4.41 Design of the unit, 4.4.4 Design of the air-cooled EnviroAire VS 37 4.4.2. Design of the water-cooled EnviroAire VS 37-W 4.1.3 Design of the unit EnviroAite 37. 4.2. Schematic diagram 42.1 Schematic diagram « air-cooled and water-cooled EnviroAlre VS 37, 4.2.2 Schematic diagram - air-cooled and water-cooled EnviroAlre 37 4.3 Control. 43.4 Control EnviroAire VS 37 (Fig. 5) 43.2 Control EnviroAire 37 (Fig. 6). Transport, installation and preparations for commissioning, 5.1 Safety regulations. Operation enn 6.1. Display of the compressor control GD Pilot TS. 6.2. Commissioning, 6.3 Commissioning after malfunction 64. Shutoff. 6.5 Emergency off. Storage of compressors. 74. Shutdown Maintenance 8.1 General maintenance information 8.2. Inspection intervals for pressure vessels and electrical installations. 83 Maintenance and inspection schedule Troubleshooting 9.1 General fault rectification information 9.2 Faulls, causes and remedy 9.3 Fault messages.2. Foreword 2.4 Normal use ‘The compressors have been bull using the latest techniques in design and in accordance with recognized safety regulations. ‘The compressors intended for the production of compressed air. It's not suitable for compressing other gases. ‘Special designs for the customer's particular form of intended use can be determined in the customer's order specifications. 2.2 Maintenance Care and maintenance are all-important ifthe sorew ‘compressors to meat the demands placed upon it. ‘Compliance with the prescribed maintenance intervals and careful execution of care and maintenance work are therefore essential, especialy under dificut working conditons. Service Contact your Gardner Denver representative in the event of problems, for maintenance, servicing and your ‘spare parts requirements. Genuine spare parts from Gardner Denver ensure product conformity and high levels of availablity. Inthe ent of queries Cc Fig. Please enter the data from the identification plate for your compressor, in the spaces above, In case of {questions or orders for spare parts, please give us the ‘compressor type, compressor number and the year of construction as given on the identification plate2. Foreword 2.3 General information This operating manual is to help you to get to know the ‘compressor and to use it forts intended applications. It must always be available at the site of the compressor. The operating manual isto be read and used by all persons in charge of work with the compressor. Besides the operating instructions and the current regulations applicable in the user's country and at the sites of operation conceming accident prevention, the recognized technical rulas for safe and proper working are also to be complied with. Warranty Only use the compressor for its intended purpose and follow this operating manual. Gardner Denver assumes, no lablity in the event of changes to the declared conformity Warranty claims cannot be made in the event of deviations from this operating manual. ‘The Guarantee and Liabilly terms of Gardner Denver's, General Terms and Conditions are not extended through the above instructions Safety regulations PEics It is important that you follow the safety regulations in Chapter 3 of the operating manual. Technical modifications We reserve the right to undertake modifications without notice inthe interests of technical progress.2. Foreword 2.4 Specifications 2.4.1 Specifications EUROPE version EnviroAire VS 37 [Technical data 50 He 60 He Environire VS 37 Maximum operating pressure bar 100 Minimum aperaling pressure ar 30 [Ambient temperature © ¥21+ a0 at min, speed at max, speed Sbar_[Fow Tmin 126 687 ‘bar _|Fow min 138) 6.05 10 bar [Flow min 1.09) 528 Discharge temp, of ar above ambient temp. (at max. om) *c 8 Fiala rssre omparaie above wat onpwaire “6 8 ‘Sound pressure level (o Gagi Pneurop PNENTC2) AOOVISOHE Ea) 71 (at 70% 1096) ‘Sound pressure level (6 Gagi Pneurop PNANTC2) AB0VI60HE asia) 72 (at 70% toad) Nominal elecirc motor power kW 7 Vatage (requency) v ‘380 - 460V (50, 60H2) Max. total current consumption at S80V/400V/460V A 85/81/68 olor protection ype TPS (6-2) - IEC 60034-2-1 ECA Qual Nominal speed min max tein 7507 3400 Nominal fan motor power 00V/S50He (460W/60H2) kW 2x 1-1 [6OMz| (2x 1.6 [6OHZ); PSE Fan motor water-cooled version KW 0.12 [S0H2/ 0,15 [60HZ}. PSA Recommended cable cross-section 380V/A00V/460V i 3x95 PE 16/4625 14625 Recommended fuse size 380V/ 400 460V_ A 100/807 80 AgL Coating a flow through ventilator (WVersion) min 125 (25) Cooling a eulet temperature above ambient temp. *c 6 Max. allowable prossure drop in duct al ambient 20°C 140°C Pa 7070 Max. cooling water quantty Vein 0 Coating water inet temperature *c 45/985 Cooling water outlet temperature (max) *c +187 + 45 (85) Coating water pressure bar 2-5 Cooling water connection (nlevoutet) orien Compressor water Sling i 6 Drinking water consumption in 24h (at 8.5 bar water mains pressure) i 1 (for one water change) Drinking water mains pressure min, | max ar 22/60 (Compressed air connection EN 10226 R 1 18" (DIN 2908.8 1 1) Water connection 2x6 38" RO water drain connection ix 1 Weight [dt aircooled | water-cooled tg 995/895 Dimensions LxWxH mm TTP 920 16592. Foreword 2.4.2 Specifications EUROPE version EnviroAire 37 Technical data Enviroaire 37, Environire 37-7 Maximum operating pressure ar a 70 8 70 Minimum operating pressure ar 30 [Ambient temperature c FRA Flow mimin | _ 5.88 5.04 5.86 5.04 Discharge tomp. of ar above ambient temp, c 8 = Final air pressure temperature above water inlet temperature *c = 2 ‘Sound pressure level (o Cagi Pneurop PNENTC2) ea) 7 oi Nominal eleciie motor power KW 37 Vatage (requeney) Vv “a00V(= 10%] (SORE) "Max. toll current consumption at 400¥ a 8 Motor protection ype IPSS (E-2)-1EC 60084-2-1 ECA Qual Nominal speed min imax ‘iin 3000 Nominal fan motor power 400Vi60Hz KW 2xta 072 Recommendad cable cross-section 400V mm 3x35 PETS Recommended fuse size 4000 a TOO AGL Cooling a flow through ventilator min 125 a Coaling ar ouet temperature above ambient temp c 6 = Max. allowable prossure drop in ductal ambient 20°C 140°C Pa 7070 = Max, cooling water quantity Vin = 6 Coating water inlet temperature c = Tare Coating water outlet temperature (max) *c = 57+ 45 Coating water pressure ar = 2-5 Coating water connection (nleVoutet) = Grier Compeessor water fling i 45 Drinking water consumption in 20h (a 3.Sbar water mains pressure) |_| 14 @ water change oycle Drinking water mains pressure min. J max bar 22/60 Compressed ar connection EN 10226 R 1 14"(DIN 2088-R 1 1/4) Water connection 2x6 38" RO water drain connection Ge Weight fay] kg 360 360 Dimensions LxWxH mim F722 x 900 x 16582. Foreword 2.5 Declaration of conformity Gardner ver 1. EC Declaration of conformity inaccordance with the EC Machinery Directive 2006/42/EC, Supplement IIA 2. We, hereby declare Gardner Denver Deutschland GmbH Argenthaler Str 1D-55489 Simmem thatthe product: Kompressor type! EnviroAire 15; EnviroAire VS 15; EnviroAire 22; EnviroAlire VS 22; EnviroAlire 37; EnviroAire VS 37; EnviroAire VS 50; EnviroAire VS 75; EnviroAlire VS 110 trade mark manufacturer no. in the form as shipped by us complies withthe following relevant provisions: 2014/29/EU 2006/4216 2014/30/60 2074/35/60 ‘This machine is exempt from the Pressure Equipment Directive 2014/68/EU. Please refer to Article 4 clauses 2¢, 211, 2) for information on this exemption, 3. Ifthe machine is modified in a way not agreed upon with us, this statement will be void. 4, Harmonised standards applied, particularly EN 1012 EN ISO 12100 EN 600341 EN 61000-64 EN 29001 EN 60204-1 EN 61000-6:2 5. National engineering standards and specifications applied ‘AD-S1/2000 —_—BetrSich DIN 3230 oe 0298 8. Recording agency: CompAir Drucklufttechnik - 2weigniederlassung der Garcner Denver Deutschland GmbH simmer, Date ae3. Safety regulations 3.1 Identification of safety instructions Gardner Denver accepts no responsibilty for indicates a potentially dangerous situation any damage or injury caused by non-compliance with which, if not protected against, could result these safety measures or non-abservance of normal in death or serious (irreversible) injuries. care and caution during the handing, operation, maintenance or repair ofthis compressor, even ifnot ‘expressly staed inthis operating manual ‘Attention Places thus marked refer to possible dangers for Doug machines or parts of machines. indicates a directly dangerous situation Note] which, if not protected against, could result in death or serious (irreversible) injuries. Places thus marked give general and technical information for optimum, cost-effective machine use. 3.2__General safety regulations Danger Safety measure required Working with compressors involves Everyone working with the machine must have first read and understood the dangers that are not immediately ‘operating manual. Don't leave this until you start work ~ i's too lato, apparent. Please keep this operating manual handy at all mes on the site of the machine / installation, in the bag provided. Pay attention to all safety and danger warnings on the machine! instalation! Deploy trained staff only. The responsiblity of he personnel for operating, setting up and maintaining the machine / installation must be clearly defined, Make sure that only authorized personnel use the machine. Define who is responsible for operating the machine, and authorize him to ignore instructions from thd partes if these instructions could compromise safety. ‘Symbols on the machine indicating Ensure that all safety and danger notices on the machinelsystem stay fully dangers may become dirty. legible. Faults and modifications to the machine In case of malfunction, shut down and secure the machine /installation may jeopardise safely immediately. Have malfunctions corrected immediately. Check the machine /installation for external damage and faults at least once per shit ‘Any changes noticed (ineluding changes in operating performance) must be reported immediately to the authority or person in charge. I necessary, shut down and secure the machine immediately.3. Safety regulations 3.3 Particular dangers associated with compressed air Danger ‘Safety measure required Compressed aris very powerful Itcan Never play about with compressed alr. be used for example to break open ‘concrete but can also put lives at risk ‘Small parts propelled at high speed by When using compressed air to clean equipment, work with extreme caution ‘compressed air can penetrate the skin and always wear sultable eye protection, or destroy an eye. yan evs Never direct compressed alr onto the skin or towards another person. Never use compressed air for cleaning clothing Compressed air connections may split Only connect the compressor to the existing compressed alr system when the and put people at risk. service temperatures and service prossures are correct and the connecting ‘lange and connecting thread are in full working order. AAllconnected components must be of the correct size and be suitable for the specified operating pressure and temperature (Le. distributing pipes and pipe connections). ‘Ahose connected to an air valve must be fitted with a sataty wire for ‘operating pressures above 7 bars; its in fact recommended that this safety dovice should be used for pressures above 4 bars. The steel wire has a diameter of 8 mm and is firmly clamped to the hose at least every 500 mm. Both ends are fitied with cable lugs. Do not use chafed, damaged or poor-quality hoses. Only use the correct type and size of hose coupling and connection ‘The compressed air line connected at the air exit of the unit must not be under strain No force should be applied to the outlet thread or the outlet flange by, for ‘example, pulling on the lines or by mounting additional equipment (e.g. a water separator or a pneumatic oiler, etc.) Compressed airlines may be breached —Compressed-air lines have to be marked distinctly according to local by accident regulations. Compressed air ines get hot and Make sure that the compressed air line from the compressor to the ait ‘expand. network can expand as a result of neat. Loose hose ends may flog and result in Fix the hose in such a way that it does not lash i the connection is broken. ey Before blowing through a hose or air ine tis essential o hold the open end firmly. Before disconnecting a hose, always make sure that itis not under pressure,3. Safety regulations Danger Safety measure required Compression results in high tomperatures. The systom should be set up such that hazardous mixtures (inflammable solvent vapours etc, but also dusts and other dangerous or toxic materials) cannot be drawn in. The same applies to flying sparks. Never use the machine in environments where the possibilty cannot be ruled out that inflammable or toxic vapours may be taken in. ‘The installation is to be set up in such a way that itis adequately accessible and that the necessary cooling is ensured. Never block the admission of air Compressor units must never be operated in areas subject to explosion hazards! (Exception: Special units with the corresponding technical modifications) ‘There is strong suction at the air inet The air intake is to be designed in such a way that no loose clothing can be drawn in, ‘There isa risk of injury, e.. from getting stuck or being drawn in ‘The personnel must not have long, loose hair, or wear loose clothing or jewelery, including rings, due to risk of injury through catching, Personal protective equioment should be worn if necessary. Connected compressed air tools may start up unexpectedly when switching Before switching on the machine / installation, or starting it up, make sure that nobody can be injured by the machine installation as it starts up. Compressed air may contain ‘substances that may damage your health if inhaled ‘The compressed air produced by these compressors must not be used as. breathable air, unless it has been processed specially for such an application in accordance with the “Safety requirements for breathable alt.” When breathing apparatus with cartridges is used, make sure that the correct cartridge has been insorted and that its service fe has not expired, The safety valves in the system only ‘uarantee the pressure relief for the ‘compressor unit ‘The pressure devices/systams connected to the compressor must be secured allowing for the weakest prassurised component (safaty valve or similar). Asa rule: If several compressors are arranged in a system, manually operated valves hhave to be installed so that each machine may be shut off individually. For the purpose of shutting off pressurized systems, you should never rely on the effectiveness of return valves alone. All pressure tanks located outside the unit with an approved operating pressure higher than atmospheric pressure and fitted with two or more pressure feed lines must be equipped with an additonal safety device to ‘automatically prevent the approved operating pressure from being exceeded by more than 10%. Never operate the system at temperatures andlor pressures below or above the values indicated in the technical data sheet.3. Safety regulations 3.4 Particular dangers associated with machines Danger Safety measure required Risk of electric shock, Electrical connections must meet the local regulations, Power units must be ‘connected to earth and protected trom short-cicuils by means of fuses. Insufficient power quality could have a strong effect on health & safety and may constitute a risk to life and lim of the user or third persons. ‘Always check a correct power supply to the compressor before commissioning, ‘The voltage supply has to full the requirements of EN60204-1/IEC60204-1 for such kind of industrial equipment. Remote-controlled units may start up Unexpectedly Ia remote control is used, the system must carry a clearly vsibte 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 systems, have to take sufficient safety precautions in order to ensure that nobody is ‘checking the system or working an it. For this, a label with a corresponding ‘warning notice has to be attached to the remote control equipment. Noise, even when itis not very loud, ‘can make us nervous and irtated, and after a longer period of time our nervous system can suffer serious damage, We recommend a separate machine room in order to keep the noise of the machine away from the workshop. ‘Where necessary, wear the personal hearing protection. In order to consider all noise-relevant parameters and to adequately protect the health of the operator, the European Regulation 2003/10/EC must be satisfied ‘completely by the user. In states outside the European Community, the respective nolse protection directives must be taken into consideration. Shielding and doors must be closed during operation so that the efficiency of the sound insulating s not reduced. 103. Safety regulations 3.5 Particular dangers associated with water-cooled units Danger Safety measure required It open cooling towers are used in the The growth and spread of bacteria must be prevented by corresponding service cooling water circuit, itis possible for and water treatment methods. legionella (Legionella pneumophila) and other bacteria to grow and spread. 3.6 Dangers present when loading/moving machines Danger ‘Safety measure required Loose parts may fall off when ling. _Allloose parts must first be removed or secured: parts titted so that they can turn Ike doors ete, must be secured and made immobile Pars to be removed for transport purposes must be carefully refitted and fixed again before putting the machine / installation back into operation, The compressor may fallif mistakes are Only use liting tackle approved forthe weightin question made when iti * ‘Observe the operating manval fr the liting tackle When heavy loads are being conveyed by means of hoisting gear, tis imperative to keep well clear of the oad in order to avoid accidents. ‘The person giving the instructions must be within sight or voice contact with the operator. Safety components may be damaged if Machines may only be hoisted correctly using hoisting gear in accordance Iited incorrectly. with the information in the operating manual (iting spots for heavy facilities etc.) ‘To avoid damage to the system or external installations, the compressed air connection, cooling water connection, condensate drain and electrical connection should be isolated from extemal lines and hoses. ‘The system must be set up on a level surface with ful contact between its base frame and the supporting surface. "3. Safety regulations 3.7 General workplace dangers Danger ‘Safety measure required This manual only describes how to work Please note and pass on general statutory and other binding regulations that safely with the compressor itself. But_ may supplement the operating manual for the prevention of accidents and the ‘other dangers will aise during work. protection ofthe environment. Such obligations may be for example the handling of hazardous materials, or the provision andlor wearing of personal protective equipment, or traffic regulations. Instructions, including supervisory responsiblity and duty of notification for taking account of special in-plant factors, for example regarding work organization, sequences of operations, personnel assigned to certain tasks, are to be added to the operating manual Before starting work, make yourself familiar with the working environment at the instalation site. ‘The location and operation of fire extinguishers must be made known, Observe the instructions conceming fire alatm and fire fighting, ‘Set up the machine in such a way that no inlets, outlets or gates are blocked. When handling chemical substances observe the safety regulations applicable for the product. Caution when handling process materials (isk of buming / scalding) 3.8 Dangers resulting from neglecting to perform m Danger ‘Safety measure required Components of importance to safety Observe the setting, maintenance, and inspection work and intervals wear over time. stipulated in the operating manual, including information about the replacement of parts / partial sections. This work may only be cattied out by specialists ‘Observe the intervals stipulated or those given in the operating manual for routine chacks and inspections. Verity regulary that safety valves and other pressure-elief devices are in perfect condition and are not blocked, for example by ditt or paint Check regularly that the safely mechanisms are fully functional. Have malfunctions corrected immediately Lines perish. (Check regularly that all hoses and/or pipes within the system are in good condition, firmly fixed and do not chate. Spurting water can result in injuries. Check allies, hoses, and bolted connections regularly for leaks and visible damage. Repair damage immediately and always arrange for damaged parts tobe replaced! Risk of electric shock, Have the electrical equipment on a machinelsystem checked regularly. Have defects lke loose connections or charred cables rectified immediately, Use only original fuses with the specified current rating. in the event of faults with the electrical power supply, switch the machine/system off immediately, and secure it from being switched on again! 23. Safety regulations Danger Safety measure required Inthe event of faulty sensors, the ‘systam can be led into a dangerous slate of operation. Check the accuracy of pressure and temperature indicators at regular intervals. If the admissible tolerance limits have been exceeded, these devices have to be replaced. 3.9 Dangers during maintenance and repairs Danger ‘Safety measure required During maintenance and repairs, parts, that may be pressurised must be removed. I you maintain the compressor and have not been trained by Gardner Denver, you will put yourself and others at risk. ‘The compressor can only be maintained by specially trained technicians. Contact your Gardner Denver agent Incorrectly configured spare parts may jeopardise safety, e.g. tear when loaded. ‘Spare parts must meet the technical requirements laid down by the manufacturer. This is always guaranteed when original spare parts are used, Risk of electric shock. Work on the electrical systems of the machine / installation may only be carried out by a trained electrician in accordance with electrical regulations. ‘The system must be secured from being switched on. Seal off the main switch and remove the key and/or attach a warning siga to the main switch EnviroAire VS 87 only: Danger of electric shock from loaded condensers! Always first disconnect the system from the power supply and wait another 10 minutes before touching the electrical components, The power condensers require this time in order to discharge! Check the DC bus voltage at the system terminal strip ofthe frequency converter by measuring this between the +DC and -DC terminals (the exact position can be found in the supplied operating manual ofthe frequency converter), between the +DC terminal and the chassis as well as between the -DC terminal and the chassis. The voltage must read zero in the case of all three measurements. ‘The machine may start up unexpectedly. Only carry out maintenance and repair work when the system is nat in ‘operation and the power supply disconnected. Ensure that the power unit ‘cannot be switched on inadvertently. The system must be secured from being switched on, ‘Seal off the main switch and remove the key andlor attach a waming sign to the main switch, Risk of injury from pressurised or moving parts. Only carry out inspection, maintenance, and repair work when the screw com- pressor system is at a standstil and is not under pressure, The system must be secured from being switched on. Before removing or opening pressurized components, positively isolate any source of pressure and depressurize the entire system. 133. Safety regulations Danger During the course of maintenance and repairs, parts can be damaged which are important for safety. Safety measure required Never weld any pressure reservoir or change it in any way. It work which produces heat, flames or sparks has to be carried out on a machine, the adjacent components have to be protected by means of non inflammable material Motor, ar fiter, electrical components and regulating equipment have to protected from the ingress of humidity, e.g. when cleaning the system by means of a steam jet. Under no circumstance must the sound-proofing material be removed or modified Never use etching solvents which could attack the materials used. Before cleaning the machine with water or steam jet (high pressure cleaner) or other cleaning agents, cover/mask all openings which have to be protected from the ingress of water, steam or detergents for safety andlor functional reasons, in particular electric motors and switch cabinets. After cleaning, remove the coversimasking completely. Mosifications to the machine impair safely. ‘After completing repair work, always check to see whether any tools, loose parts or cloths have been left in or on the machine, driving engine or driving equipment After the work has been completed, replace any protective devices that have been removed. Operation without protective devices is not permissible, ‘Always re-ighten screwed connections which have been loosened for maintenance and repair work, Machines performing a rotating movement have to be cycled several times in order to ensure that there are no mechanical faults in the machine or the drive member. Before releasing the power unit for operation after maintenance or overhaul ‘check that the operating pressures, temperatures and time settings are correct and that the regulating and shut-down equipment function properly 143. Safety regulations 3.10 _ Dangers resulting from conversion work/modifications on the machine Danger Genuine parts are designed especially for the machine. Modifications may interfere with safety equipment or give rise to new dangers for which protection is not provided. ‘Safety measure required No alterations, additions, or modifications to the machine may be carried out without the approval of the manufacturer. Unauthorized modifications to the machine are prohibited for reasons of safely, Original parts are specially designed for our machines. We must explicitly point out that parts and special accessories not supplied by us are not approved by us. Installing or using such products may thus adversely affect active andior passive safely The manufacturer accepts no liability whatsoever for damage resulting from the use of non-original parts or special accessories. This also applies tothe installation and adjustment of safety devices and valves as well as to welding on bearing and pressurized parts It protective equipment is not Tunctioning, operating the system may putlives at risk, Only operate the machine when all protective devices, shutdown devices, sound-insulating equipment and extraction equipment are in place and working Safety devices, protective covers, or insulations mounted on the system must not be removed or modified in any way. 153. Safety regulations 3.41_Symbols and explanations Carefully read the operating manual before Never breathe in compressed air from this system. commissioning or servicing this compressor. NS Never operate the unit with open doors or loose access, Waming: Hot surface panels Warning: Pressurized part or system Warning: This system can start up by means of a remote control or automaticaly after a power failure, 163. Safety regulations Waming: The system continues to run for 30 seconds after pressing the O-key Waming: Danger of electric shock I a Attention: Lifting point Attention: Check and, if required, retighten connection terminals. For further details, see the operating instructions. XX bar ‘Attention: Opening pressure safety valve = xx bar (value "xx" see sticker on compressor) @ (1) Attention: Danger of electric shock from loaded condensers! Please always first disconnect the system from the power supply and wait another 10 minutos before touching the electrical components, The power condensers require this time in order to discharge! Check the OC bus voltage at the system terminal strip of the frequency converter by measuring this between the +DC and -DC terminals (the exact positon can be found in the supplied operating manual ofthe frequency converter), between the +DC terminal and the chassis, 1s well as between the -OC terminal and the chassis, The voltage must read zero in the case ofall three measurements, 74, Design and functioning 4.1 Design of the unit 4.1.1 Design of the air-cooled EnviroAire VS 37 Fig.2 41 Intake fiter 11 Cooling air ventilator 20 Water cooler 2 Suction inlet 42 Cooling air inlet fiter mat 21 Fan protection panel 3. Electric motor 13 Compressed air outlet 22 Water level indicator 4. Screw compressor 14 Base frame 23 Water level sensor 5 Pressure reservoir 418 Control keypad 24 Network pressure sensor 68 Water filter 16 EMERGENCY OFF 25 Final compression 7 RO-Unit push-button pressure sensor 8 Safety valve 17 Contral cabinat 26 Final compression temperature 9 Pressure holding valve 18 Supply cable gland sensor 40 Water connection 19 Opening for lifting gear4, Design and functioning 4.1.2 Design of the water-cooled EnviroAire VS 37-W Fig. 4 Intake filer 2 Suction inlet 3. Electric motor 4 Screw compressor 5 Pressure reservoir 6 Water filer 7 ROUnit 8 Safely valve 9. Pressure holding valve 40 Water connection 14 Cooling air ventilator 42 Cooling air inlet fiter mat 18 Compressed air outlet 14 Base frame 16 Control keypad 16 EMERGENCY OFF push-button 17 Control cabinet 18 Supply cable gland 19 Opening for lifting gear 20 Water cooler 22 Water level indicator 23 Water level sensor 24 Network pressure sensor 25 Final compression pressure sensor 26 Final compression temperature 27 Cooling water connection4, Design and functioning 4.1.3 Design of the unit EnviroAire 37 Fig. 4 4 Intake filer 2 Intake regulator 3. Electric motor 4 Screw compressor 5 Pressure reservoir 6 Water filter 7 ROUnit 8 Safely valve 9. Pressure holding valve 40 Water connection 20 11 Cooling air ventilator 12 Cooling air inlet fiter mat 18 Compressed air outlet 14 Base frame 16 Control keypad 16 EMERGENCY OFF push-button 17 Control cabinet 18 Supply cable gland 19 Opening for lifting gear 20 Water cooler 22 Water level indicator 23 Water level sensor 24 Network pressure sensor 25 Final compression pressure sensor 26 Final compression temperature4, Design and functioning 42 Schematic diagram 4.2.1. Schematic diagram - air-cooled and water-cooled EnviroAire VS 37 fe 2 a “a va Lo Fig. 5 Intake fiter Electric motor Compressor block Final compression temperature ‘sensor (R2) Pressure reservoir Pressure holding valve Satety valve Osmosis unit Water reservoir Water fiter Water cooler Throttle Inverter Blow-off line orifice 24, 25, 26, 27, Manual valve 28. Mud flap 29. Ventilator 1 (air-cooled and 30. water-cooled) Ventilator 2 (only air-cooled) 31. Non-return valve 32, Choke valve, adjustable (water-cooled only) Dirt trapwater-cooled only) 33. Blow-off valve (¥4) 34. Bypass valve (Y11) Cooling-water solenoid vave 35, (Y7) (water-cooled only) Solenoid valve (water in) (¥8) Solenoid vaive (water out) (Y9) Solenoid valve (water stop) (Y10) Network pressure sensor81) Final compression pressure sensor (82) Motor temperature (R1) Differential pressure airfiter (S7) (Option) Water level sensor (810) 2a4, Design and functioning 4.2.2 Schematic diagram - air-cooled and water-cooled EnviroAire 37 e® eG Fig.6 Intake fiter 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) Pressure reservoir Pressure holding valve Safety valve Osmosis unit 11. Water reservoir 12. Water fiter 18. Water cooler 14, Throtle 15. Blow-off valve 16. Minimum pressure valve 18. Manual valve 19. Mud fap 20, Ventilator 1 (air-cooled and water-cooled) 21 Ventilator 2 (air-cooled only) 22 Non-eturn valve 23 Choke valve, adjustable (water-cooled only) 24 Dirt trapwater-cooled only) 28 Solenoid vaive (control valve) (Y1) 26 Cooling-water solenoid valve (¥6) (water-cooled only) 27 Solenoid vave (bypass) (Y4) (water-cooled only) 28. Solenoid valve (water in) (¥8) 29. Solenoid valve (water out) (¥9) 30. Solenoid valve (water stop) (Y10) 31, Network pressure sensor81) 32. Final compression pressure sensor (62) 33. Motor temperature (Rt) 34, Differential pressure air fiter (S7) (Option) 35 Water level sensor (810) ‘A Configuring blow-off speed minimum pressure setting (min. 3,5bar)4, Design and functioning 43 Control 4.3.1 Control EnviroAire VS 37 (Fig. 5) (Please also see the operating instructions for the ‘compressor control GD Pilot TS) ‘System downtime + Solenoid valve (-25- (¥4)) is de-energised (open) \When the system is shut down, solenoid valve (26- (Y11)) is also de-energised (closed). + The pressure vessel (6-) is depressurized to almospheric pressure via the solenoid valve (25- (Y)) and the orice (-17-) + The water stop valve (30- (¥10)) is closed. Starting up the system + The drive motor (3) starts up. + The compressor draws air in via the air fiter; a certain quantity s blown off again into the intake zone via the solenoid valves (-25- (¥4)) and (26- (Y11)) and via the orifis (177). + This way, constant pressure of approx. 4 to 4.5 bar maintained in the pressure tank (-6-), as the pressure holding non-retum valve (-7-) stil remains closed at this pressure level. + The water supply of the screw compressor (-4-) is provided by the drop in pressure between the pressure tank (-6-) and the injaction site in the ‘screw compressor. + Ifpressure in the load system falls below the ‘minimum pressure programmed on the control system, the solenoid valve (-25- (¥4) is energized (closed). Pressure then continues to build up in the pressure reservoir (6-) + Ata tank pressure of ca. 4.5 bar, the pressure hholding non-return valve (-7-) opens. + The compressed air transportation into the mains hhas begun, Stopping the system: + After pressing the OFF button on the control panel ‘of the compressor contol system GD Pilot TS, the magnet valve-25- (Y4) is de-energized (opened) and the solenoid valve (-26- (Y11)) is energized (opened) when the drive motor s running, + The pressure reservoir (-6-) is depressurized to a constant pressure of 4 to 4 S-bar. + The drive motor (-3-) reduces its number of revs to the set minimum value and comes to a standstill after 30 seconds have passed. + Once the drive motor has stopped, solenoid valve (26- (Y11)) is de-energised (closed) and the remaining pressure in the reservoir is discharged via the orifice (-17-). ‘Speed control operation Speed is controlled using a software-implemented PI regulator that adapts the RPMs according to the need for compressed air. The controler attempts to maintain the mains pressure between the values set in the control for max. and min, mains pressuretarget pressure). ‘Automatic operation + Ifthe mains pressure achieves the preset maximum value, then the electric mator-3.) will have its speed lowered in order to allow for the delivery amount to ‘adapt to the actual need for compressed air. + Ifthe motor has reached minimum speed and the load-system pressure continues to rise, solenoid valve (25- (¥4)) is de-energised (opened) and solenoid valve (-26- (Y11)) continues energized (open). Reservoir pressure is reduced to approx. 4 to 4.S-bar and the pressure-maintenance valve (-7-) closes. * This way, no more compressed air willbe supplied tothe mains. + Ifthe mains pressure does not drop to the target value within the programmed follow-up time, then the system will shut down. + Ifthe target value is achieved before the expiration of the programmed motor fellow-up time, then the ‘magnet valve will again be energized (-25- (¥4)). + The system will then go into load runs. 234, Design and functioning 4.3.2. Control EnviroAire 37 (Fig. 6) (Please also see the operating instructions for the ‘compressor control GD Pilot TS) ‘Standstill ofthe system + Ifthe plant is shut down, the suction controller (-2-) I closed by a pressure spring in the adjusting cylinder. + The water stop valve (-30- (¥10))is closed. + The solenoid valve (-25- (Y1)) is de-energised. + The pressure reservoir is released via valve (16-) to atmospheric pressure. Starting the system + The motor starts up in the Y-mode. +The intake regulator is closed. + The compressor aspires a certain amount of air through a bypass valve. Pressure builds up in the + The water stop valve (-30- (¥10)) is open. The water supply ofthe screw compressor (-4-)s provided by the drop in pressure between the pressure tank (-6-) ‘and the injection site in the screw compressor. + Ifthe drive motor is switched over to A operation, the magnetic valve switches over (-25-(Y1) since it is supplied with current. + The air circulated in the system streams over the solenoid valve (-25- (Y1)) in the upper control area fof the operating cylinder (-2.1-). Valves («15-) and (16+) are closed and the lower control space of the adjusting cylinder is ventilated. + The pressure control valve (-2.2-) in the intake regulator (-2-) opens + Ata reservoir pressure of approx. 4.5-barl65- PS! the pressure holding and check valve (-7-) opens. + Compressed airis now delivered into the consumer network, +The system is now in load running mode, ‘Stopping the system + Tode-energise the solenoid valve (-25- (Y1) and press the OFF push-button on the keypad of the ‘compressor control GD Pilot TS. + The pressure valve (-2.2-) in the suction controler (-2.) closes and the tank is relieved to atmospheric pressure via the minimum pressure valve (-16-) + After 30 seconds, the drive motor (-3-) and the cooling air ventilator motor (-20,21-) are shut down. 24 ‘Automatic operation (open-close operation) When the pressure reaches the upper switching point set on the network pressure sensor (31- (B1)), solenold valve (-25- (¥1)) is de- energised. The pressure valve (-2.2-) loses because the lower control space of the adjusting cylinder (-2.1-)is relieved by the de-energised valve (-25- (Y1) the upper control space is impinged with pressure via the valve (-16-) ‘The pressure reservoirs relieved to no-load pressure (residual pressure) via the two valves (-15- and -16+) The screw compressor is now running in the offload mode. When the pressure at the network pressure sensor (31- (B1)) does not fall to the set lower switching point within the set motor run-on time (e.g. 120 seconds), the drive motor (-3-) and the cooling air Ventilator motors (-20- and -21-) are shut down and. the system is depressurised to atmospheric pressure. Tho system is naw in the “stand-by” mode and can restart at any time when the network pressure falls to the lower switching point (see section "Starting of the system"). When the network pressure falls to the proset lower ‘switching point before the set motor run-on time has elapsed, solenoid valve (-25- (Y1)) is energised again. The unit now changes over to on-load operation.5. Transport, installation and preparations for commissioning 5.1 _ Safety regulations ‘These instructions only describe safe operation of the unit. In order to guarantee safe operation, the installation, connection and commissioning of the compressor must be carried out professionally. ‘The compressor may only be commissioned by specially trained technicians. Contact your Gardner Denver agent for first commissioning and recommissioning of a decommissioned compressor. If your compressor is not professionally commissioned, you will put yourself at risk and will not be able to guarantee safe compressor operation. 256. Operation 6.1 Display of the compressor control GD Pilot TS 62 Commissioning ‘The compressor may only be commissioned by specially trained technicians. Contact your Gardner Denver agent for first ‘commissioning and recommissioning of a decommissioned compressor. Make sure before commissioning that nobody is in the danger zone of the motor/screw compressor. Only operate the screw compressor unit with closed access panels. /f{ \ 65 4 Fig.7 4. Touchscreen Display 2. Start push-button [1] 3. Stop push-button [0] 4. red LED Flashing slowly = Wamning Flashing rapidly = fault yellow LED Flashing slowly = Maintenance required {green LED Litup permanently = Unit in operation Flashing slowly = Unit in standby mode 7. Emergency stop ‘The compressor can be automatically started at any time when it Is in standby mode, Le. the green LED is flashing 26 Note For Envirosire VS 37 only: Ifthe compressor has been in storage for a substantial period of time (up to 2 years), the main switch must be switched on (ON) for at least one (1) hour prior to it being started. This ‘ensures the operabilly of the capacitors and prevents any damage from occurring. I the compressor has been in storage for onger than 2 years, ploase contact an authorised Gardner Denver dealer prior to start-up. Start the unit as follows: + Open shut-off valves between the screw ‘compressor, reservoir and pipe. + Ensure cooling water supply (only water-cooled units), + Switch on the power supply master switch. + After the power supply was switched on, all LEDs fon the compressor control GD Plot TS light up for a display test. The fault shown on the display [power supply fault] must be acknowledged in the fault ‘memory menu item prior to starting the unit, + After the acknowledgement, the message [READY TO START] appears on the display, unless another faults present, + Prose START button [1] (2- Fig. 7). Start-up protection of the electric motor The screw compressor unit will nt start up ifthe final compression pressure is more than 0.4 bar for the EnviroAire 37 and 4,0 bar for the EnviroAire VS 37 Temperature start-up protection The screw compressor unit will nt start up ifthe ambient temperature is lower than + 2°C.6. Operation 6.3 Commissioning after malfunction ‘Attention Do not switch the screw compressor on repeatedly without having rectified the matfunction, since this may cause considerable damage to the machin Re-start after an automatic shutdown due to a malfunction as follows: + Faults are shown as text in the compressor control GD Pilot TS "fault memory" display menu. + Tum master switch off and secure it from being switched on again. + Eliminate faut, + Turn master switch on, + Acknowledge the fault in the fault memory menu, ‘After the acknowledgement, the message [READY TO START] appears on the display, unless another faults present, + Press START button [1] (-2-Fig. 7) 6.4 Shutoff To switch off the compressor use the [0] button (3 Fig. 7) and nat the emergency STOP button, ‘fier shutdown the compressor has a run on time of 30 seconds (sot-stop) ‘The soft-stop is preset to protect the compressor. Note The unit may only be shut down using the emergency off button in real emergencies. When shutting down normally, please use the [0] key. 6.5 Emergency off The emergency off button is situated next the GD Pilot TS. Itis used to immediately shut down the unit. Only use the emergency off bution (-7- Fig. 7) to shut down the unit in emergencies. When shutting down normally, alvays use the [0] button 277. Storage of compressors 7.4 Shutdown ‘The compressor can only be decommissioned professionally by specially trained technicians. Contact your Gardner Denver agent. Your agent will be able to decommission the compressor for you, or train you so that you can decommission it yourself. ‘All compressors are protected against corrosion at the factory for transport and for brief storage before commissioning. Inthe compressors are to be stored for period ‘exceeding six months, additional precautions must be taken. ‘Compressors which are to be shut down for a lengthy period must also be protected from corrosion. Since corrosion occurs more quickly in damp atmospheres than in dry conditions, its not possible to specify a maximum permissible standstil time which will apply in all cases. Note Tho following aspects must be taken into account for storage of storing compressors. The compressor should be stored in a dry building which should be heated if possible. This is particularly true during the months of winter. The coolant is to be completely drained where there is a risk of frost (t< 1°C) (compressor stage, coolers, system containers, water filers, storage containers, RO unit lines, vaives). I there is a risk that the temperature wil fall or rise above the limits of -10 °C to +65 °C, the electrical controller must be removed and stored in ambient temperatures of #5 °C to +30 °C. 288. Maintenance 8.1 General maintenance information Have the compressor maintained on a regular basis. The maintenance schedule (see chapter 8.3) must be observed. Important parts wear over time. They must be checked and replaced if necessary. ‘The compressor can only be maintained by ‘specially trained technicians. Contact your Gardner Denver agent. Your agent will be able to maintain the compressor for you, or train you so that you can maintain it yourself. Ht you maintain the compressor and have not been trained by Gardner Denver, you will put yourself and safe compressor operations at risk. ‘The ‘Warning, maintenance work underway’ sign must be put up before the following work Is undertaken, Cordon off the area around the workplace as required. 8.2 Inspection intervals for pressure 1ssels and electrical installations Pressure vessels. ‘As por the requirements of the 2014/68/EU Pressure Equipment Directive, a qualified person must inspect, the pressure vessel from inside every five years, ‘As per the requirements of the 2014/68/EU Pressure Equipment Directive, an appointed body must perform a strength test on the pressure vessel after ten years. Electrical installation ‘The electrical installation must be inspected by a qualified electrician after four years anc also each time work has been performed on it. ‘Should stricter inspection intervals apply in your ‘country, these must be observed. 8.3 Maintenance and inspection schedule Intervals are valid for normal industrial environments and operating conditions, In the case of a very dirty atmosphere, the cleaning intervals have to be shortened as required. For order numbers see the spare parts list. 298. Maintenance i : Ath atest ater onthe sess sjese gles Taitnarce evry 400, ahough at leat vary & none pect the compressor sags = afc af a Tairterance evry 0, anough AST GaCR Vr ee) 5 5 Rework/replace water valves Inspection every 4 years: Inspection of the electrical installation by a qualified electrician Inspection every § years: Internal inspection of the pressure vessel by a qualified person Inspection every 10 years: ‘Strength test of the pressure vessel by the appointed body 1 These maintenance intervals must be observed! x For your own benefit, puta cross on the servicing schedule against maintenance work when performed, 308. Maintenance 00008 4 000°82 4 o00'9 4 000" woz win up 000% 4 000'02 4 000'e9 4 000'99 waor sot wo wes 400098 4 000'28 4 000°08 4 00085 wee wes wos wus 00095 4000's 4 0002s 4 000'08 we wie wee wise oojoooolooaojoo00 0008 4 000'9% 4 000% 4 000% wee wes wee wes ooo od ‘000° 4 o00'8e 4 000'9€ 4 00096 wos wis us wis ooo 000% 4 000°08 4 000'82 4 000'92 wer wisp wep wee 4 000'%2 400072 wise wee oolooooa a19. Troubleshooting 9.1 General fault rectification information ‘The compressor can only be repaired by specially trained technicians. Whenever you encounter problems for Hf you attempt to repair the compressor and have not been trained by Gardner Denver, you will put yourself and safe compressor operations at risk. which no remedy is provided in this manual, contact your Gardner Denver agent. 9.2 Faults, causes and remedy Malfunction Possible cause Remedy Unit cannotbe started No operating or control voltage ‘Switch on the main switch, check fuses and supply cables. Matfunction not acknowledged ‘Acknowledge fauit message Pressure reservoir not depressurized Wait until depressurized Screw compressor does not start up, when reservoir pressure is > 1,0 bar (for the EnviroAire VS 37) or > 0.4 bar (for the EnviroAire 37) Electric motor or compressor defective Contact service ‘Ambient temperature less than +2"C Make sure that the ambient temperature is not less than +2 °C; have an auxiliary heater installed, f required Remote controltimer has been Deactivate remote controltimer activated Mains pressure is above the lower Wait until the mains pressure has fallen below the switch set point lower switch set point Unit stops during the ‘Too frequent manual on and aff- ‘Avoid frequent manual on and off-switching, let startup phase switching electric motor cool down Other problems Contact service Unit does not reach the Excessive alr consumption Reduce consumption or cutin a further set mains pressure compressor Other problems Contact service Unit switches off ‘Ambient temperature too high \Ventllate compressor room Other problems Contact service Excessive idling ‘System not unloaded Contact service Water in the air filer Water stop valve nat closing Contact service Safaty valve opens Safety valve defective Contact service Never operate the screw compressor defective safety v: 329. Troubleshooting Malfunction Possible cause Remedy A faultwaming cannot be acknowledged Faultiwaming stil present. Contact service No display Missing operating or control voltage ‘Switch on the main switch, check fuses and supply cables ‘System not starting automatically after power failure [AUTO RESTART] function not activated Activate (see GD Pilot TS manual) ‘System constantly running off-load without automatically switching to standby [CONTINUOUS OPERATION] mode Selectes ‘Select [AUTOMATIC OPERATION] mode (see GD Pilot TS manual) No compressed-air request within the selected switching points Prossure changeover active through timer or external contact ‘Switch off [TIMER CONTROL] or [REMOTE CONTROL] mode (see GD Pilot TS manual) Ian error cannot be eliminated according to the instructions and in the case of any other errors, contact the Service department, 9.3 Fault messages Display Possible cause Remedy [FAULT EM-STOP] Emergency-off is / has been actuated Unlock [FAULT MOTOR TEMP] Motor has been started too frequently Limit number of starts hour Inadequate motor cooling Improve DWARNING HIGH TEMP] Intake temperature too high Improve | Inadequate cooling Improve System operated with open cladding Close cladding [FAULT START TEMP] Start attempted at insufficient temperature Heat compressor room [MAINTENANCE ELAPSED) Maintenance is due Cany out maintenance [FAULT MAINT PER] Maintenance shutdown activated and 100 hours stil eft in maintenance interval Cary out maintenance [FAULT COOLING] Air-cooled systems: Resistances too high Check, install auxiliary fan ifnecessary through deliveryldischarge air channels Water-cooled systems: Cooling-water temperature too high Cooling-water flow too low Improve In the case of any other fault messages, contact the Service department 33,Gardner ver @ STENHOJ 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, +449 (0)6761 832-0 Fax +#49 (0)6761 832-409