Gardner Denver TR20 Rear CW User manual

TR20 SCREW
COMPRESSOR
Models
TR20 Rear ACW
TR20 Rear CW
Installation,
Operating &
Maintenance
Manual
(Original Instructions)
November 2016
4990497003

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4990497003 Date: 11/2016 TR20 Installation, Operating & Maintenance Manual
1 Health & Safety
Health & Safety ..................................................................3
2 General
2.1 Product general description .........................................4
2.2 Drive options ......................................................................4
2.3 Available packages...........................................................5
2.4 Dimensions, performance data,
and operating environment..........................................6
3 Installation
3.1 General mounting considerations..............................7
3.2 Lifting ....................................................................................7
3.3 Mounting .............................................................................8
3.4 Lubrication...........................................................................9
3.5 PTO and prop. shaft drive alignment...................... 10
3.6 Pipe work........................................................................... 12
3.7 Commissioning lter..................................................... 12
3.8 Ancillaries.......................................................................... 13
3.9 Package 1 layout/parts................................................. 14
3.10 Package 2 layout/parts................................................. 15
4 Operating and Commissioning
4.1 Pre-commissioning check list.................................... 16
4.2 Inlet commissioning lter ........................................... 16
4.3 Monitoring probes......................................................... 16
4.4 Commissioning procedure ......................................... 17
4.5 Driver Operating Instructions.................................... 19
4.6 Driver Training................................................................. 20
Commissioning Test sheet .......................................... 21
5 Maintenance
5.1 Schedule............................................................................ 22
5.2 Change Gear Case Oil ................................................... 22
5.3 Valves.................................................................................. 23
5.4 Silencers/Pipework ........................................................ 23
5.5 Air Inlet Filter - cyclonic................................................ 24
5.6 Alternative Oils................................................................ 24
Service Maintenance sheet......................................... 25
Contents
Chapter Page

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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 since personal injury could result.
Installation.
A relief valve must be tted 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 each week, in the direction shown by the arrow on the cover.
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)
Fire.
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.
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)

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2
General
2.1 Product general description
The TR20 is a robust, high ow, oil free, contactless, low maintenance screw
compressor designed for the contaminant free discharge of a wide range of product
types including the following:
1. Granular, pellet and random particle products at 1-1.5 bar g (e.g.
sugar, plastic granules and animal feeds) with a higher pressure
availability to dislodge any blockages in conveying pipes during the
discharge.
2. Discharging more dense bulk powder products (e.g. cement, our
and lime), usually at 1.5-2.0 bar g (at the tank) pressure in 3”, dicult
or large bore conveying pipe.
The machine comprises synchronised screw rotors, combined main body/step up
gearcase assembly and inlet bearing carrier.
The compact shape and size of the compressor make it ideal for mounting inside the
chassis on most vehicles to enable low cost prop shaft driving.
CW or ACW machines are available, with mounting points on either side of the
machine to provide further exibility.
The standard compressor package consists of the following equipment:
• Basic TR20 machine and mounting kit.
• Inlet lter kit
• Commissioning lter
• Relief valve
• Check valve and ange pack.
• Discharge (outlet) silencer - absorptive or reactive
• Torque limiting coupling
2.2 Drive options
The TR20 can currently be driven using the following drive systems:
Prop shaft drive Direct from a vehicle PTO
The shape and size of the
compressor make it particularly
suitable for PTO/prop shaft
driving inside the vehicle chassis
on most applications.
NOTE

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Figure1. Standard Packages (1 & 2 )
General
2.3 Available packages - see g 1
The following packages are available as standard:
Package 1 - Loose ancillaries with absorptive discharge silencer
Standard ancillaries supplied as separate items including the absorptive type
discharge silencer and inlet lter kit
Package 2 - Loose ancillaries with reactive discharge silencer
Standard ancillaries supplied as separate items including the reactive type discharge
silencer and inlet lter kit
TR20 PACKAGE 1
Absorptive, Separate Ancillaries
TR20 PACKAGE 2
Reactive, Separate Ancillaries
A number of optional/locally
supplied items are pictured,
please refer to pages 14 & 15 for
details of package contents.
NOTE

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2.4 Dimensions, Performance data & Operating
Environment
Dimensions
The dimensions of the basic TR20 are shown in gure 2 below.
Performance
The performance details and power requirements of the compressor are shown on
the product data sheet.
For additional information, the constant running torque does not exceed:
347 Nm on the standard TR20 Speed range 900 - 1650 rpm
Operating environment
The permissible/foreseen operating environment is as follows:
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 100 mbar
Orientation See g 4 page 8
Max. outlet temperature 250°C
Figure 2. Dimensions - basic machine
General
Prop shaft drive start-up
conditions could be severe.
A Gardner Denver torque limiting
coupling is recommended to
protect the compressor and drive
system.
CAUTION
347
154
135
382
578 441
306
103101
339
284
59
129
242
454
58 180
68
137
250
292
347
3000003622
ACW Drive
3000003625
CW Drive
Shaft Details

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3
Installation
3.1 General
When selecting the machine mounting position, the following points should
be considered:
• Access to oil ll/level and drain plugs
• 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.
• Fit the relief and/or protection valve control valves as close as possible to
the TR20 discharge port.
• Venting valves must be positioned so that hot air cannot vent onto the
operator or the compressor
• Silencers should be tted as close as possible to the discharge port.
For the recommended layout of the machine and ancillaries, see gure 1.
3.2 Lifting - see g. 3
The weight of the basic compressor without ancillaries is 140 kg.
The mounting face to which the basic machine is tted should be at to
avoid distortion/stress and mounting bolts/locking nuts should be M16,
grade 8.8 or higher.
The basic compressor is supplied with an eyebolt attached for lifting.
When the machine has been installed, the eyebolt should be removed.
Any equipment used for lifting should be rated accordingly.
Figure 3. Lifting
Do not lift using other parts of
the machine.
CAUTION

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3.3 Mounting
The TR20 should be installed vertically utilising all three mounting feet on one side of
the machine. The drive direction is specic to machine and is shown on the machine
itself (arrow indicating rotation next to input shaft). Additionally, the machine has
discharge anges on both sides and above.
The input drive rotation and air path possibilities are shown below.
Installation
Figure 4. Mounting & Drive options
An incorrect drive rotation will
damage the compressor.
CAUTION
Outlet
Inlet
The basic TR20 compressor should be installed/mounted (using the M16 ttings
supplied in the machine mounting kit) as shown in g. 5.
All M16 Grade 8.8 mounting nuts/bolts should be applied at a torque setting
of 225Nm.
Loctite 270 should also be applied
to secure the M16 mounting
studs into the TR20 feet.
NOTE
The compressor has three
mounting feet on each side
of the machine and should be
mounted using all 3 feet on
one side only.
NOTE
Rear CW
Rear ACW
Inlet on
either side,
3 outlet options

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Installation
Figure 6. Oil Lubrication Components
3.4 Lubrication
The TR20 is supplied complete with oil.
When the compressor has been mounted, the oil level should be re-checked as
shown in gure 6 and topped-up with oil through, and up to, one of the ll/level plug
holes (approximately 2.5 litres total if necessary).
Key
1 - Magnetic drain plug and washer
2 - Fill plug and washer
Figure5.MountingDetails-separateancillarypackages
Alternative mounting channels
maybe neccesary due to other
vehicle ancillaries (e.g. fuel
tank). These should provide
comparative strength to the
conguration shown.
NOTE
No. Description
1. M16 stud
2. M16 Flanged Self locking nut, Grade 8
3. Mounting channels
4. Spacer (if required)
Taper washers should be
used if mounting channels
with tapered anges are to be
used.
NOTE
1
4
2
3

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Parts List
Item Qty Description
1 1 Friction Coupling, DIN (Red Flange)
2 1 Ring Adaptor, DIN
3 1 Washer
4 1 Key, Parallel Rectangular Round End 10 x 8 x 50 Long
5 1 Socket Head Cap Screw M12 x 40 Long
Figure 7b. DIN Friction Coupling
Installation
3.5 PTO and prop shaft drive alignment
Drive couplings
See the ‘Ancillaries’ (section 3.8-torque coupling) for recomendations on
couplings for PTO drives.
Before tting, the tapers on the machine shaft and drive coupling should be
clean and damage free to help ensure the ange ts correctly. Both tapers
should be smeared with a light oil to aid future separation.
The companion ange should be tted to the compressor shaft in line with
Figure 7b, for the DIN type coupling and Figure 7c for the SAE type coupling.
The cap screw and washer which is used to retain the coupling to the shaft,
should be tightened to a torque of 88Nm.
Flange/coupling removal should only be undertaken with the aid of a puller
type device and screw in the shaft end, as shown in Figure 7a, to avoid
damaging the ange or shaft end.
Figure 7a. Drive Flange Removal
Cap Screw (Item 5) should be
tightened to a torque of 88Nm.
NOTE