Gardner Denver Reavell 5236 Installation and operation manual

www.gdhighpressure.com
INDUSTRIALS GROUP
Operating & Maintenance Manual
5236 Compressor M-V-A-M
Sales Order No. 4072412
Publication No. 98407.5877
v2.0 En

AMENDMENTS
ISSUE
No.
DESCRIPTION
DATE
SECTION
1
NEW
09/10/2019
ALL
2
UPDATE GA-VERSION B
15/04/2020
3

TABLE OF CONTENTS
Section 1 General
Section 2 Compressor
Section 3 Drawings
Section 4 Motor
Section 5 Control Panel
Section 6 Equipment Data Sheet

Section 1
General Information

General Safety Information
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General Safety Information
WARNING
The use of replacement parts or lubricating oils not supplied,
recommended or approved by Gardner Denver, or the failure to
maintain this equipment in accordance with the maintenance
instructions, may invalidate the WARRANTY, cause equipment failure,
create unsafe or hazardous conditions or result in damage to the
equipment.
Gardner Denver cannot accept responsibility for damage, injury or
failure caused by these situations.
USE ONLY GARDNER DENVER GENUINE PARTS AND
AUTHORISED SERVICE AGENTS

TABLE OF CONTENTS
1DISCLAIMER............................................................................................................................... 1
2FOREWORD............................................................................................................................... 1
3WARRANTY................................................................................................................................ 2
4MAINTENANCE WARNING........................................................................................................ 2
5STANDARDS, TESTING AND DOCUMENTATION................................................................... 2
6OWNERSHIP DATA.................................................................................................................... 3
6.1 TECHNICAL DATA .............................................................................................................. 3
6.2 GARDNER DENVER CONTACT DETAILS......................................................................... 3
7WARNINGS, CAUTIONS & NOTES........................................................................................... 4
8HEALTH AND SAFETY PRECAUTIONS.................................................................................... 5
8.1 GENERAL PRECAUTIONS................................................................................................. 5
8.2 INSTALLATION PRECAUTIONS......................................................................................... 6
8.3 OPERATIONAL PRECAUTIONS......................................................................................... 7
8.4 MAINTENANCE & REPAIR PRECAUTIONS ...................................................................... 8
8.5 PRECAUTIONS IN THE EVENT OF FIRE WITHIN THE COMPRESSOR......................... 8
9PURGING INSTRUCTIONS FOR GAS INSTALLATIONS......................................................... 9
10 DISPOSAL OF CONDENSATE AND USED PARTS ............................................................ 10

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General Safety Information
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1 DISCLAIMER
While every care was taken in the preparation of these instructions, it cannot be guaranteed that every
aspect has been covered. Gardner Denver cannot, therefore, accept liability for direct or consequential
damage that may arise resulting from non-conformity with this Manual, from repairs carried out
improperly, from using other than original spare parts, and from non- observance of good operating
and maintenance engineering practices. Should there be any doubt whatsoever, or should any further
information or explanation be required, Gardner Denver must be contacted.
This information is given in good faith, no warranty or representation is given concerning such
information, which must not be taken as establishing any contractual or other commitment binding
upon Gardner Denver.
Gardner Denver reserve the right to make changes to any information contained within this manual
without prior notice.
2 FOREWORD
The standard build of all Gardner Denver products are not intended for use in either Explosive or
Potentially Explosive Atmospheres as defined in Directive 2014/68/EU.
An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases,
vapours, hazes or dusts in which, after ignition has occurred, combination propagates to the entire
unburned mixture and may cause a hazard.
Gardner Denver compressors are designed and manufactured to give optimum performance and
safety, together with long life and reliability whilst compressing the gas for which they have been
designed. They must not be used to compress other gases without prior consultation with the Gardner
Denver factory.
This Manual will help you to obtain the best performance from your compressor. It provides the
information required for safe installation, commissioning and operation, together with a maintenance
schedule to ensure maximum service life.
Servicing facilities and the supply of genuine replacement parts are provided through a world-wide
network of Gardner Denver companies and authorised distributors, backed by the Gardner Denver
factory.
The information in this Manual was correct at the time of printing, but modifications to parts and
procedures may be made without notice which could affect the servicing requirements of the
compressor.
In any communication concerning the compressor it is necessary to quote the the MODEL, SERIAL
No. and CONTRACT reference in order that the correct information is supplied.
It is important that this Manual is retained with the compressor for reference and that it should remain
with the compressor if it is sold or transferred to another user. The new user must be made fully aware
of the need to study this Safety Section and any Warnings for safe operation given throughout the
manual.

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3 WARRANTY
The compressor(s) and ancillary equipment supplied by Gardner Denver are covered under Warranty
for the period agreed in the Supply Contract.
The equipment provided is well designed to afford many years of trouble free service. However, should
the need arise to implement a warranty claim then this can be done using warranty Claim Form
obtainable from Gardner Denver Service Department. It should be noted that consumable parts that
require replacement during normal compressor operations are not normally covered under Warranty.
Similarly, the Warranty does not cover running adjustments.
Gardner Denver are well known in the market place for the design, manufacture and supply of high-
quality air compressor equipment. These compressors are constructed from the highest quality
materials and are designed and built according to the latest manufacturing techniques. The
compressor design will give good service providing that it is operated and maintained in accordance
with the information contained within this Manual.
4 MAINTENANCE WARNING
The use of replacement parts or lubricating oils not supplied or approved by Gardner Denver may lead
to failures in service which would not be covered by warranty.
Before any servicing or maintenance work is undertaken, the user is advised to contact the local
Gardner Denver Company or authorised Distributor for revised or up-dated information.
To ensure continued trouble free operation of the compressor it is important that periodic maintenance
and servicing are carried out in accordance with the information given in the "Maintenance" section of
this Manual. If any replacement or repair is needed use genuine Gardner Denver parts.
Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance
instructions may make it unsafe. The use of replacement parts not supplied by Gardner Denver may
create hazardous conditions over which Gardner Denver has no control.
Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily
injury or result in damage to the equipment. Gardner Denver can bear no responsibility for equipment
which has unapproved replacement parts fitteded.
5 STANDARDS, TESTING AND DOCUMENTATION
Gardner Denver / Reavell compressors / booster and modules incorporate manufacturer’s
standard equipment and selected components in order to manufacture specific packages for
the compression of Air and Gases. Reavell design, manufacture, testing is based in general
on the following standards:-.
2006/42/EC Machinery Directive
BS EN292 Safety of Machinery
BS EN1012-1 Compressors –safety requirements
2014/68/EU Pressure Equipment Directive
2014/34/EU Equipment and Protective Systems Intended for Use in Potentially Explosive
Atmosphere (ATEX) Directive
Gardner Denver quality systems are accredited with ISO 9001 approval by Lloyd’s Quality Assurance.

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General Safety Information
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6 OWNERSHIP DATA
6.1 TECHNICAL DATA
It is recommended that details taken from the compressor nameplates are recorded below.
6.2 GARDNER DENVER CONTACT DETAILS
Address
Gardner Denver Ltd
Claybrook Drive
Redditch
Worcestershire
B98 0DS
UK
Telephone
[phone]
Fax
[phone]
Email
[e-mail]
Web
www.gdhighpressure.com
For any comments or queries about the contents of this manual, please write to Gardner
Denver at the above address.

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7 WARNINGS, CAUTIONS & NOTES
The following details for this Safety Section relate to ESSENTIAL SAFETY REQUIREMENTS referred
to in Machinery Directive 2006/42/EC.
Warnings call for attention to operating procedures involving specific hazards which could cause injury
or death and are identified by the following
RISK OF DANGER
RISK OF HIGH PRESSURE
RISK OF GAS EXHAUST
RISK OF ELECTRIC SHOCK
RISK OF HOT SURFACE
CONSULT MANUAL

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General Safety Information
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8 HEALTH AND SAFETY PRECAUTIONS
The following health and safety precautions must be read in conjunction with any other manufacturers
equipment supplied.
8.1 GENERAL PRECAUTIONS
This compressor is designed to compress only the gas(es) or gas mixes detailed in the LEADING
PARTICULARS. Operation with any other gas(es), concentrations or constituents than those
specified, may result in fire or explosion in the compressor, in the filters, or other ancillary equipment,
and could lead to sever injury, death, and significant property damage.
For the Heliox compressors sets with 3 inlets, suitable measures must be taken to ensure that the
compressor cannot operate on oxygen concentrations exceeding 21%. Example: an inlet oxygen
system integrated into the compressor control system.
Operation, maintenance, repair or modifications to the compressor and its associated equipment must
only be carried out by competent persons under a “PERMIT TO WORK” system.
The compressor safety relates to the document EN1012-1 Compressors and vacuum Pumps - Safety
Requirements, and the UK Pressure Systems Safety Regulations 2000.
When handling, operating or carrying out maintenance on the station, personnel must observe safe
engineering practices and all relevant local regulations.
Gardner Denver cannot anticipate every possible circumstance which might represent a potential
hazard. The WARNINGS in this manual are therefore not all inclusive. If the user employs an operating
procedure, an item of equipment or a method of working which is not specifically recommended by
Gardner Denver, then they must ensure that the unit will not be damaged or made unsafe and that
there is no risk to persons or property.
Read and understand all WARNINGS, CAUTIONS & MANDATORY LABELS on the compressor
before operating, carrying out maintenance or servicing.
When using cleaning solvents, provide good ventilation and use suitable protection such as a breathing
filter face mask, safety glasses, protective apron and gloves.
Safety shoes should be compulsory in all workshops. Safety helmets must be worn if there is a risk of
falling objects.
If using compressed air for cleaning purposes, ensure safety regulations are complied with and
appropriate clothing worn. Never use compressed air to clean loose dirt from clothing.
Never direct compressed gas onto your skin or at other people.
Before releasing compressed air or gas through a flexible hose, make sure the free end is held
securely so that it cannot whip and cause injury.

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8.2 INSTALLATION PRECAUTIONS
Installation work must only be carried out by competent personnel under a “PERMIT TO WORK”
system
A fused isolator switch must be fitted between the main power supply and the compressor. The isolator
shall be suitably sized and be in accordance with Section 7.2 of EN 60204-1:2006 & A1:2009.
If not requested with the supplied equipment, suitably sized over-current protection must be provided to
protect the power circuit. The protection shall be in accordance with Section 7.2 of EN 60204-1:2006 &
A1:2009.
Guards must be fitted to make sure that Foreign Objects cannot be drawn into cooling air intake
ducting or louvers.
Ensure that the discharge gas piping from the compressor module to the users pipework, gas storage
cylinders or gas dispensing system is free to expand and that no flammable material is within the
vicinity. If any such material is close-by take steps to preclude ignition.
A manual shut-off valve should be fitted in the discharge line to allow the compressor to be isolated.
Non return valves cannot be relied upon for isolating parts from a pressure system. A safety valve
must be installed between any compressor unit and the isolating valve.
A pressure-reliving device must be fitted to every pressure vessel, or equipment containing air or gas
above atmospheric pressure. They must be suitably sized for the pressure and flowrate of the gas
involved. For specific details, contact Gardner Denver.
To minimse the risk of Legionnaires Disease, Gardner Denver advise caution with the use of cooling
towers for water cooling the compressor. Potable water should be used, and treated where necessary
to prevent harmful bacteria from entering the compressed air. The cooling tower manufacturers
maintenance schedules should be observed to prevent the development of harmful bacteria. Closed
circuit or direct mains cooling is preferred.
Always use an appropriate shackles or hooks, properly positioned. Arrange lifting cables so that there
are no sharp bends. Use a spreader bar to ensure vertical lift and avoid side loads on hooks, eyes and
shackles and never leave a heavy load unattended.
When a load is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration
and speed within safe limits.

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General Safety Information
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8.3 OPERATIONAL PRECAUTIONS
The compressor must only be operated by competent personnel under a qualified supervisor.
If the compressor noise levels are greater than 85 dB A at one meter, ear defenders should be worn by
operators.
Ensure that all instructions concerning operation and maintenance are strictly followed and that the
complete installation with all accessories and safety devices are kept in good order.
Do not operate the compressor module, or any other parts of the equipment with any inspection cover
removed. e.g. compressor crankcase doors, valve covers,dispenser panel etc.
Do not remove or tamper with safety devices, or guards. This does not only extend to mechanical
safety devices and guards, but all devices including electrical safety devices and controls. Particular
attention should be paid to low inlet pressure sensing devices which must be operational in conjunction
with the compressor control system during compressor operation.
The maximum pressure for safety valves under fault conditions is 1.10 times the set pressure, the set
pressure being a minimum of 1.05 times the maximum operating pressure to ensure seat tightness.
Compressor sets designed for use with flammable gases are fitted with low inlet pressure switches.
These are an essential safety item. Their operation should be checked regularly. They must not be
tampered with or linked out of operation. Should the gas inlet pressure fall to a low level and the switch
has been linked out or made inoperable there is a danger the compressor will draw in air. This could
then form an explosive mixture within the compressor. In extreme conditions it could also allow air to
be drawn into the gas main.
Pipework or other parts with a surface temperature above 70°C which may be accidentally touched in
normal operation must be guarded or insulated. Other high temperature pipework should be clearly
marked.
The compressor must only be operated at the supply voltage and frequency for which it is designed.
Always isolate power before maintenance or servicing.
When mains power is ON, lethal voltages are present in the electrical circuits.
ESSENTIAL MAINTENANCE WORK ON THE ELECTRICAL SYSTEM MUST ALWAYS BE
COMPLETED BY A QUALIFIED ELECTRICIAN.
If the compressor is equipped with a Remote Control device, attach warning notices stating “THIS
UNIT CAN BE STARTED REMOTELY” in prominent locations around the equipment.
If there is any indication that the compressor is overheating it must be shut down. (A high air or gas
temperature switch is fitted as standard to guard against operating with excessive
temperature). Beware of burns from hot oil and water (if applicable) when working on a unit recently
shut-down.
Use only lubricating oils and greases approved by Gardner Denver to avoid potential hazards
especially the risk of explosion or fire and the possibility of decomposition or generation of
hazardous gases.

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8.4 MAINTENANCE & REPAIR PRECAUTIONS
Maintenance, repair and modifications must only be carried out by competent persons under a
“PERMIT TO WORK” system..
Pressure gauges, temperature switches and other protection devices should be checked at least every
12 months and thoroughly examined at least every 48 months. They must be renewed or service
exchanged if acceptable tolerances are exceeded or if they are not functioning correctly.
Before dismantling any part of the compressor close, and lock if possible, the isolating valves upstream
and downstream of the compressor system’s air, gas and water supplies as appropriate.
Check that all pressure gauges register zero and that all air or gas pressure in the system has been
released.
Before dismantling any part of the compressor, ensure that all heavy movable parts are secure.
Oil lubricated compressor will have preserving oil applied to interior surfaces. Oil free models will have
desiccant bags in valve covers and distance pieces which must be removed prior to start-up.
Protect components and exposed openings by covering with clean cloths or tape during repair or
maintenance work.
Protect all items as necessary against the ingress of moisture if steam cleaning is undertaken.
On completion of any maintenance or repair ensure that no tools, loose items or rags etc., are left on
or inside the compressor or other parts of the system.
Always clean oil spills from the compressor module before and after maintenance work.
Viton Seals
Viton ‘O’ seals under normal operating conditions are safe.
However, should there be a fire within the compressor or these seals are likely to exceed a
temperature of 300°C the material will decompose.
Degraded Viton gives off Hydrogen Fluoride fumes and if in contact with skin an
acid is formed causing severe burns.
If Viton seals appear charred or gummy do not touch with unprotected hands: wear
neoprene or PVC gloves.
When the seal has been removed, wash the area with limewater and avoid breathing any
fumes. If contamination of the skin occurs, wash with limewater and seek medical advice.
8.5 PRECAUTIONS IN THE EVENT OF FIRE WITHIN THE COMPRESSOR
Use extreme caution when handling components that have been subjected to fire or very high
temperature. Some components may contain fluoroelastomer materials which decompose under these
conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns
resulting in permanent skin and tissue damage.

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General Safety Information
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9 PURGING INSTRUCTIONS FOR GAS INSTALLATIONS
Before any attempt is made to run the compressor on process gas, the operator must be
satisfied that the compressor and its associated pipework is purged free of air and that they are
fully conversant with the operating procedures of the equipment.
If in any doubt as to efficiency of the purging, always repeat the procedure.
When the gas being compressed is flammable, or its purity is important, it must be a plant requirement
to purge the compressor to remove any air in it before letting the process gas into the system. The
compressor should be purged free of air, in accordance with purging procedures which apply to the
whole plant using the inert gas specified, after the compressor has been commissioned on air and
before the process gas is introduced into the system.
The installation should have purging valves fitted to the inlet and outlet lines of the compressor,
permitting the inert gas used for purging to be admitted and discharged before and after the equipment
being purged.
Once this has been acheived the valves should be locked and /or plugged to avoid them being left
open whilst running on gas.
Operators should also be aware that the compressor is not guaranteed leak tight whether in normal
operation or under fault conditions and It is assumed that the compressor is situated in a well ventilated
area with suitable gas leakage detection equipment to minimise possible risks.
Due to the unknown nature of the plant processes involved, Gardner Denver cannot be held
responsible for any heath risk arising from leakage of gas into the atmosphere.
The following comments may help to achieve successful purging of the compressor:-
The use of an Oxygen meter is recommended when purging prior to running on flammable gases.
Feeding the purge gas at pressure (maximum 0.5 bar g) will speed up procedure.
The crankcase will be purged more quickly if the oil filler cap is removed and the rod inside is
depressed to allow the air to escape.
The pipes from the separators to the unloader valves and from the first stage to unloaders (and water
valve if fitted) can be purged by disconnecting them at their far end, allowing the purge gas to pass
through and remove the air, before reconnecting them.
After any maintenance or repairs have been carried out which involves dismantling and opening up gas
containing parts, the system must always be re-purged.

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10 DISPOSAL OF CONDENSATE AND USED PARTS
Whilst recyclable materials are used as far as possible, please ensure when disposing of condensate,
spent oil, used filter elements and any discarded parts or waste material of any kind make sure that
there is no pollution to any natural water-course, drain system and that no burning of waste takes place
which could cause pollution of the atmosphere.
Condensate, waste oil and used consumable items should be disposed of in line with Local Authority
regulations and Section 7.1.4 of EN 626-1:1994+A1:2008.