Elmo Rietschle G Series User manual

Edition 04.2014 · 610.44495.40.000 Original operating instructions · English
Operating Instructions G-BH2
2BH20360 | 2BH20540 | 2BH20780

Contents
610.44495.40.000 · 04.2014 2/48 © Gardner Denver Deutschland GmbH
1
A
bout this manual ........................................................................ 4
1.1 Content of this document ............................................................... 4
1.2 Target group ................................................................................... 4
1.3 Explanation of the terms and symbols ........................................... 4
1.4 Changes in comparison to the previous version ............................ 6
1.5 Other valid documents ................................................................... 6
2 Safety and responsibility ............................................................. 7
2.1 Explanation of warning signs ......................................................... 7
2.2 Correct use of the equipment ........................................................ 7
2.3 Improper operational modes .......................................................... 7
2.4 Working in a safety-conscious manner .......................................... 8
2.5 Requirements for personnel ........................................................... 9
2.5.1 Staff qualifications and training ...................................................... 9
2.5.2 Personal protective equipment ...................................................... 10
2.6 Requirements of the operator ........................................................ 11
3 Product identification ................................................................... 12
3.1 Rating plate .................................................................................... 12
3.2 Structure ......................................................................................... 13
3.3 Options ........................................................................................... 14
3.4
A
ncillaries ....................................................................................... 14
3.5 Function principle ........................................................................... 15
3.6 EU declaration of conformity .......................................................... 16
4 Transportation and storage ......................................................... 17
4.1 Unpacking and checking the condition of delivery ........................ 17
4.2 Lifting and transporting .................................................................. 17
4.3 Storage ........................................................................................... 18
5 Mounting ....................................................................................... 19
5.1 Measures after long-term storage .................................................. 19
5.2 Mounting conditions ....................................................................... 19
5.3 Reduction of oscillations and noises .............................................. 20
5.4 Set up ............................................................................................. 20
5.4.1 Horizontal set-up on the foot ......................................................... 20
5.4.2 Vertical axis mounting on the compressor cover ........................... 21
5.4.3
A
ssembly on the wall or ceiling ...................................................... 21
5.5 Fit loose silencer and accessories ................................................. 22
5.6 Connecting pipelines and hoses .................................................... 22
6 Electric power connection ........................................................... 24
6.1 General installation regulations ...................................................... 24
6.2
A
dditional installation requirements for the drive control ............... 25
6.3 Controls .......................................................................................... 25
6.4 Prepare the motor terminal box .................................................... 26
6.5 Connect the motor to the mains .................................................... 27
6.6 Connect the drive control to the mains .......................................... 27
6.6.1 Connect integrated drive control 2FC4...-1ST/PB/CB/SC ............. 27
6.6.2 Connect integrated drive control 2FC4...-1NE ............................... 27
6.6.3 Integrated drive control by third party manufacturer ..................... 28
6.6.4 Connect external drive control 2FC4...-1ST/PB/CB/SC ................ 28
6.6.5 Connect the external drive control 2FC4...-2 ................................. 28
6.6.6 Connect external drive control from third party manufacturer ....... 28
6.7 Connect auxiliary ventilator ............................................................ 29

Contents
© Gardner Denver Deutschland GmbH 3/48 04.2014 · 610.44495.40.000
6.8 Parameterising the drive control .................................................... 30
6.8.1 Parameterize integrated drive control 2FC4...-1ST/PB/CB/SC ..... 30
6.8.2 Parameterize integrated drive control 2FC4...-1NE ....................... 30
6.8.3 Parameterize external drive control 2FC4...-1ST/PB/CB/SC ......... 30
6.8.4 Parameterize the external drive control 2FC4...-2 ......................... 31
6.8.5 Parameterize external drive control from third party ...................... 31
7 Commissioning ............................................................................. 32
7.1 Measures after a long shut-down period ....................................... 32
7.2 Tests during commissioning or re-commissioning ........................ 32
7.3 Check the direction of rotation ...................................................... 32
7.4 Sensors function check .................................................................. 33
7.5 Measure the acoustic emissions .................................................... 33
7.6 Measure oscillations ....................................................................... 33
8 Operation ...................................................................................... 34
8.1 Switch on ........................................................................................ 34
8.2 Switch off ....................................................................................... 34
8.3 Switch off in emergency ................................................................. 34
9 Troubleshooting ........................................................................... 35
10 Maintenance, repairs and spare parts ....................................... 38
10.1 Maintenance ................................................................................... 38
10.2 Repairs and complaints .................................................................. 39
10.3 Ordering spare parts ...................................................................... 39
11 Decommissioning ......................................................................... 40
11.1 Decommissioning ........................................................................... 40
11.2 Disassembly ................................................................................... 40
11.3 Disposal .......................................................................................... 40
12 Technical data .............................................................................. 41
12.1 Mechanical data ............................................................................. 41
12.1.1 Weight ............................................................................................ 41
12.1.2 Connection dimensions .................................................................. 42
12.1.3 Tightening torque values ................................................................ 42
12.2 Permitted conditions for use .......................................................... 43
12.2.1 Installation height ........................................................................... 43
12.2.2 Maximum speeds ........................................................................... 43
12.2.3 Maximum temperatures ................................................................. 43
12.2.4 Permissible pressure differences between the suction and pres-
sure side in operation ..................................................................... 44
12.2.5 Pressure differences acting on the side-channel compressor ....... 44
12.2.6 Relative humidity ............................................................................ 44
12.2.7 Minimum distances for heat dissipation ......................................... 44
12.2.8 Speed of oscillation ........................................................................ 45
12.3 Electrical data ................................................................................. 45
12.3.1 Increased operating cycle frequency ............................................. 45
12.3.2 Parameter drive control 2FC4...-1ST/PB/PN/SC/CB ..................... 46
12.3.3 Parameter drive control 2FC4...-.NE .............................................. 46
12.4 Pressure differences generated by the side-channel compressor . 47
12.5
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coustic emissions ........................................................................ 47

1 About this manual
610.44495.40.000 · 04.2014 4/48 © Gardner Denver Deutschland GmbH
About this manual
Content of this document
These operating instructions:
▪is part of the side-channel compressor:
Series G-BH2
Types 2BH20360- . . . . . - . . .
2BH20540- . . . . . - . . .
2BH20780- . . . . . - . . .
▪describe the safe, proper and efficient use in all phases of its service life.
▪must always be available to personnel at the place of use.
▪Arranged in the main sections:
– About these instructions
– Safety and responsibility
– Product identification
– Transportation and storage
– Mounting
– Electric power connection
– Commissioning
– Operation
– Troubleshooting
– Maintenance, repairs and spare parts
– Decommissioning
– Technical data
The main section on safety must always be observed. The subsequent main sec-
tions can be used as a reference and can be read independently from each other.
Cross references provided must be observed.
Target group
These instructions are aimed at operating personnel, qualified personnel, electri-
cians, the operator and planner. See also Staff qualifications and training [➙9].
Explanation of the terms and symbols
In these instructions symbols and terms will be used to mean the following.
Symbol Explanation
Requirement, pre-requisite
One-step handling instructions
1 2 3 Multi-step handling instructions
Result
Cross reference with page reference
A
dditional information, tips
Direction of rotation arrow
Direction of conveyance arrow
General warning sign (warns of risk of injury)
Electrical voltage warning
1
1.1
1.2
1.3

About this manual 1
© Gardner Denver Deutschland GmbH 5/48 04.2014 · 610.44495.40.000
Symbol Explanation
Hot surface warning
Disconnect prior to maintenance or repai
r
Observe the instructions
Use foot protection
Use hand protection
Use eye protection
Use head protection
Use ear protection
Earth prior to use
Term Explanation
Plant Part provided by the user in which the side-channel compressor is installed.
Side-channel compres-
sor = G-BH2 = vacuum
pump/compressor
Ready to connect machine for the generation of a vacuum and/or overpressure.
The side-channel compressor consists of a compressor and motor, as well as
other accessories where applicable.
Moto
r
A
synchronous motor for driving the side-channel compressor.
Compresso
r
Mechanical part of side-channel compressor without motor.
Inner chamber of the
compressor
Chamber of the compressor part that conveys media.
Substructure Mounting plate, base frame or foundation on which the G-BH2 is constructed.
Flexible/rigid When the lowest eigenfrequency of the system, consisting of the G-BH2 and
substructure, lies at least 25% per measurement direction above the rotary fre-
quency of the G-BH2, the substructure is considered to be rigid. All other sub-
structures are considered to be flexible.
A
ssembly environment Space in which the side-channel compressor is set up and operated (this may
differ from the suction environment).
Suction/discha
r
ge envi-
ronment
Chamber from which the media to be conveyed is suctioned or in which the me-
dia to be conveyed is expelled (this may differ from the assembly environment).
Single-stage Compressor part with impeller.
Two-stage Compressor part with two series-switched impellers.
Generates higher pressure difference.
Three-stage Compressor part with three series-switched impellers.
Generates the highest pressure difference.
V
acuum operation Operating mode whereby the
- pressure at inlet p1 < p atm. and
- pressure at outlet p2 = p atm.
Compressor operation Operating mode whereby the
- pressure at inlet p1 = p atm. and
- pressure at outlet p2 > p atm.

1 About this manual
610.44495.40.000 · 04.2014 6/48 © Gardner Denver Deutschland GmbH
Term Explanation
Mixed operation Operating mode whereby the
- pressure at inlet p1 < p atm. and
- pressure at outlet p2 > p atm.
Integrated drive control
= 2FC4...-
1ST/PB/PN/SC/CB
Drive control that is fitted for the G-BH2 by the manufacturer.
External drive control
2FC4...-
1ST/PB/PN/SC/CB
Drive control that is supplied by the manufacturer and is not fitted on the G-BH2
(wall assembly).
External drive control
by third party manufac-
turer
A
drive control purchased by the operator that is not fitted on the G-BH2.
Changes in comparison to the previous version
Amendments in comparison to version 07.2013
▪EU declaration of conformity
▪The term frequency inverter is replaced by drive control
▪all drive control sections
▪1.3 Explanation of the terms and symbols
▪3.1 Data plate
▪3.5 Functional principle
▪5.4 Set-up
▪6.5 Connect the motor to the mains
Other valid documents
In addition to these instructions consider the following documents:
Document number Purpose
610.44495.40.310 Repair manual with spare parts list and exploded view drawing 2BH20...-1
610.44495.40.320 Repair manual with spare parts list and exploded view drawing 2BH20...-2
610.44495.40.330 Repair manual with spare parts list and exploded view drawing 2BH20...-3
610.00260.40.000 * Operating instructions integrated drive control 2FC4...-1ST/PB/PN/SC/CB OR
610.44496.40.000 * Operating instructions for integrated drive control 2FC4...-1NE OR
610.44527.21.000 * Operating instructions for external drive control 2FC....-2NE 3.0-11 kW OR
610.44526.21.000 * Operating instructions for external drive control 2FC....-2NE 15-45 kW OR
— * Operating instructions of the drive control
–
manufacturers
610.00110.02.000 * Suction filter mounting instructions
610.00112.02.000 * In-line filter mounting instructions
610.00108.02.000 *
A
dditional silencer mounting instructions
610.00116.02.000 * Installation manual for the spring elements
*according to the model option or accessories
1.4
1.5

Safety and responsibility 2
© Gardner Denver Deutschland GmbH 7/48 04.2014 · 610.44495.40.000
Safetyandresponsibility
The manufacturer is not liable for damage caused by the failure to observe these
instructions and the related documents [➙6].
Explanation of warning signs
Warning sign Explanation
Danger that failure to observe the measures could lead to
death or serious physical injuries.
Danger that failure to observe the measures could lead to
death or serious physical injuries.
Danger that failure to observe the measures could lead to
minor physical injuries.
Danger that failure to observe the measures could lead to
material damage.
Correct use of the equipment
The G-BH2 is a continuous operation machine that is optimised for the generation
of a vacuum and pressure. The G-BH2 can be used in buildings, outside and in
dusty or damp environments. The protection class is stated on the Rating plate [➙
12].
The G-BH2
▪should only be used within the limits defined in this documentation. In particu-
lar, the limits in the following section must be observed:
– Mounting conditions [➙19]
– Permitted conditions for use [➙43]
– Electrical data [➙45]
▪only operate when fully assembled and in a technically perfect condition.
▪can deliver the following conveyed media:
– air
– All non-explosive, non-combustible, non-abrasive and non-toxic gasses
and gas/air mixtures, after consultation with the manufacturer
Other operating conditions must be agreed with the manufacturer.
Improper operational modes
It is forbidden to:
▪Operation in a potentially explosive area (ATEX).
▪Connection in a potentially explosive area (ATEX).
▪The conveyance of explosive, combustible, abrasive, unstable, oxidative or
toxic media, e.g. dusts, solvents, as well as of fluids and solid matter of any
type.
▪Use in non-industrial plants, unless essential precautions and protective
measures have been taken.
▪Mobile operation.
▪Reverse operation.
▪Use in areas with ionising or non-ionising radiation.
▪Changes to the G-BH2 and the accessories, that have not been agreed with
the manufacturer.
▪Operation outside of the limits defined in these instructions.
▪Start-up and operation with overpressure or negative pressure from the plant.
2
2.1
2.2
2.3

2 Safety and responsibility
610.44495.40.000 · 04.2014 8/48 © Gardner Denver Deutschland GmbH
Working in a safety-conscious manner
Work on running or energised vacuum pumps/compressors can lead to seri-
ous injuries due to body parts being drawn in or crushed or death due to
electric shock.
Work on the G-BH2 at a standstill only and in a de-energized condition.
1. Disconnect.
2. Secure it to prevent it from being switched back on.
3. Make sure that it is de-energised.
4. Earth it and short-circuit it.
5. Cover or block off adjacent parts which are still supplied with voltage.
During operation and after decommissioning, contact with hot surfaces can
lead to burns.
On the G-BH2, temperatures during operation can reach 160Ԩ[320°F].
1. Do not touch hot surfaces during operation.
2. Keep hot surfaces clear of highly inflammable materials.
3. Allow the G-BH2 to cool after shutting it down.
Operation with exposed parts can lead to serious injuries due to body parts
being drawn in or crushed.
1. Re-attach safety and protective devices and put them back into operation
immediately after completion of work.
2. G-BH2 should only be put into operation when fully fitted.
Changes, additions and conversions may lead to unforeseeable risks and
thus to serious injuries or death.
Changes, additions and conversions to the G-BH2 that are not described any-
where in the documentation must be authorised by the manufacturer.
Only use original parts or parts/auxiliary materials (grease, sealant) approved by
the manufacturer. Using other parts and auxiliary materials can lead to unforesee-
able hazards and may exempt the manufacturer from liability for the resulting con-
sequences.
Keep all notices attached to the G-BH2 in a clearly legible condition:
▪Labelling of connections
▪rotation arrows
▪Rating plate
▪Warning signs
2.4
Work at a standstill and
de-energised
Hot surfaces
Not fully assembled
Changes, additions and
conversions

Safety and responsibility 2
© Gardner Denver Deutschland GmbH 9/48 04.2014 · 610.44495.40.000
Requirements for personnel
Staff qualifications and training
All those who will work on the G-BH2 must have read and understood these in-
structions and the related documents [➙6].
Personnel in training may only work on the G-BH2 under supervision of personnel
who have the required knowledge.
Only allow work on the G-BH2 to be carried out by personnel with the following
knowledge:
Work tas
k
Personnel Required knowledge
Transportation,
storage
Shipper, dealer, quali-
fied personnel for
transportation and stor-
age
▪Safe handling with lifting gear such as hoists and
fork lift trucks
A
ssembly,
start-up,
correcting faults,
shut down,
dismantling
Qualified personnel for
vacuum pumps and
compressors
▪Safe handling of tools
▪Laying and connecting pipes and hoses
▪Mounting mechanical components
▪Knowledge of vacuum pumps and compressors
Working on the electri-
cal system
Electrician ▪Understanding and safe implementation of circuit
diagrams
▪Lay and connect electrical lines
▪Connection of electrical machines, switches, sen-
sors, circuit breakers
▪Analysing and testing electrical systems
▪Assessing the effectiveness of electrical protection
measures
Parameterising the
drive control
Qualified personnel for
drive controls, opera-
tors, electricians
▪Knowledge of drive controls and how to set them
Operation Operation personnel,
operator ▪Instructions for occupational safety and for han-
dling vacuum pumps and compressors
Maintenance
repair
Qualified personnel for
maintenance and repair ▪Safe handling of tools and materials
▪Disassemble and mount vacuum pumps and com-
pressors
▪Assess damage to vacuum pumps and compres-
sors
Disposal Qualified personnel for
disposal ▪Decontaminating polluted materials
▪Re-use of materials and substances
▪Correct and environmentally-friendly disposal of
materials and substances
2.5
2.5.1

2 Safety and responsibility
610.44495.40.000 · 04.2014 10 /48 © Gardner Denver Deutschland GmbH
Personal protective equipment
WARNING
Danger of crushing and cutting!
Crushing and cutting of body parts due to sharp edges or falling parts on
the open G-BH2.
1. Wear protective gloves, safety footwear and safety goggles for all assembly
and disassembly, troubleshooting and maintenance work.
2. In addition, wear head protection for transportation and overhead work.
WARNING
Risk of injury!
Serious injuries due to body parts and hair being sucked or drawn in (vac-
uum) or due to projected particles (pressure).
1. Wear eye protection and tight clothes for all work when in operation.
2. Wear a hair net for long hair.
3. Remove jewellery and rings.
WARNING
Hearing damage!
Hearing damage due to time spent in the excessive noise area when there
are adverse operating conditions or noise due to suddenly ejected media at
the discharge nozzles or piping.
Wear ear protection when remaining in the excessive noise area.
2.5.2