Gardner Denver GD150 User manual

4990616006
June 2016
GD150
ROTARY VANE
COMPRESSOR
Installation,
Operating &
Maintenance
Manual
(Original Instructions)

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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

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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
2
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
NOTE
The shape and size of the
machine make it particularly
suitable for PTO/prop. shaft
driving inside the vehicle
chassis.

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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
5
2
6
3
180mm
1
4
"A"

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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
92
40 PORT DETAIL
SHAFT DETAI
L
8
¯25
¯68
¯32
180
230
80 80
125120
40
40 5
18
¯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
3
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.
4
1
3
2

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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

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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.
3
2
1
4
5
6
7
3
8
9
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

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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˚