Gardner Denver Elmo Rietschle C-VLR 401 VSD User manual

C
C-Serie
C-Series
Klaue
Claw
Edition: 1.0 ·10.2017 ·BA 886-70-FU-EN
Original Operating Instructions
C-VLR 401 | 501 VSD
Vacuum pump

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Table of contents
Table of contents
1 Foreword................................................................... 4
1.1 Principles ................................................................... 4
1.2 Target group ................................................................. 4
1.3 Supplier documentation and accompanying documents .............................. 4
1.4 Abbreviations ................................................................ 4
1.5 Directives, standards, laws ..................................................... 4
1.6 Symbols and meaning ......................................................... 5
1.7 Technical terms and meaning ................................................... 5
1.8 Copyright ................................................................... 5
2 Safety ..................................................................... 6
2.1 Warning instruction markings ................................................... 6
2.2 General..................................................................... 6
2.3 Designated use .............................................................. 7
2.4 Unacceptable operating modes.................................................. 7
2.5 Personal qualifications and training ............................................... 8
2.6 Safety-conscious work ........................................................ 8
2.7 Safety notes for the operator .................................................... 8
2.8 Safety instructions for installing, commissioning and maintenance ...................... 9
2.9 Guarantee conditions.......................................................... 9
3 Transport, storage and disposal................................................ 10
3.1 Transportation ............................................................... 10
3.1.1 Unpack and check the delivery condition .................................. 10
3.1.2 Lifting and transporting................................................. 10
3.2 Storage..................................................................... 11
3.2.1 Ambient conditions for storage .......................................... 11
3.3 Disposal .................................................................... 11
4 Set up and operation ......................................................... 12
4.1 Setup ...................................................................... 12
4.1.1 Data plate ........................................................... 13
4.2 Description.................................................................. 14
4.3 Areas of application ........................................................... 14
5 Installation ................................................................. 15
5.1 Preparing for installation ....................................................... 15
5.2 Installation .................................................................. 15
5.3 Connecting pipes............................................................. 16
5.4 Filling with lubricating oil ....................................................... 16
5.5 Connecting the drive .......................................................... 17
6 Commissioning and decommissioning .......................................... 18
6.1 Commissioning .............................................................. 18
6.1.1 Checking the rotation direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.2 Post-run ............................................................ 19
6.2 Decommissioning/ storing ...................................................... 20
6.3 Re-commissioning ............................................................ 20

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Table of contents
7 Maintenance and repair....................................................... 21
7.1 Ensuring operational safety ..................................................... 21
7.2 Maintenance work ............................................................ 21
7.2.1 Changing the oil ...................................................... 22
7.2.2 Air filtering........................................................... 23
7.2.3 Coupling ............................................................ 24
7.2.4 Integrated frequency converter .......................................... 25
7.3 Repair/ Service............................................................... 25
7.4 Spare parts.................................................................. 26
8 Malfunctions: Causes and elimination........................................... 27
9 Technical Data .............................................................. 28

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Foreword
1 Foreword
1.1 Principles
These operating instructions:
• are a part of the following contact free running
claw vacuum pumps C-VLR 401 and C-VLR 501
with frequency converter (Fxxx).
• describe how to use them safely and properly in
all life phases.
• must be available where the equipment is used.
1.2 Target group
The target group for these instructions is technically
trained specialists.
1.3 Supplier documentation and accompanying documents
Document Contents No.
Supplier documentation
Operating Instructions BA 886-70
Declaration of Conformity C 0080
Declaration of harmlessness 7.7025.003.17
Connection diagram
(in the cover of the frequency converter) —
Spare parts list Spare parts document E 886
Data sheet Technical data and graphs D 886-60
Info sheet Storage guidelines for lubricants I 100
Info sheet Storage guidelines for machines I 150
Manufacturer’s declaration EU Directive 2011/65/EU (RoHS II) —
Operating Instructions Operating instructions for frequency converter 610.00260.40.00
1.4 Abbreviations
Fig. Figure
C-VLR Vacuum pump
m3/h Suction capacity
mbar (abs.) Final vacuum, operating vacuum
XD Corrosion protective coating
VSD Variable Speed Drive
1.5 Directives, standards, laws
See Conformity Declaration

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Foreword
1.6 Symbols and meaning
Symbol Explanation
Condition, pre-requisite
#### Instructions, action
a), b),... Instructions in several steps
Results
[-> 14] Cross reference with page number
Information, note
Safety symbol
Warns of potential risk of injury
Obey all the safety instructions with this symbol in order to avoid injury
and death.
1.7 Technical terms and meaning
Term Explanation
Machine Pump and motor combination ready to be connected
Motor Pump drive motor
Frequency converter Frequency converter makes possible infinitely variable of the speed
Vacuum pump Machine to create a vacuum
Claw Machine‘s design or active principle
Suction capacity Vacuum pump volume flow related to the condition in the suction con-
nection
Final pressure (abs.) The maximum vacuum that a pump reaches when the suction opening is
closed. Given as absolute pressure.
Permanent vacuum The vacuum or the suction range at which the pump operates perma-
nently.
The permanent vacuum or intake pressure is ≥ than the final vacuum
and < than the atmospheric pressure.
Noise emission The noise emitted at a specific loading given as a figure, sound pressure
level dB(A) as per EN ISO 3744.
1.8 Copyright
Passing on or copying this document, using and
providing information on its contents are prohibited
unless expressly permitted. Contraventions will lead
to claims for damages.

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Safety
2 Safety
The manufacturer is not responsible for damage if
you do not follow all of this documentation.
2.1 Warning instruction markings
Warning Danger level Consequences if not obeyed
DANGER immediately imminent danger Death, severe bodily injury
WARNING possible imminent danger Death, severe bodily injury
CAUTION possible hazardous situation Slight bodily injury
NOTICE possible hazardous situation Material damage
2.2 General
These operating instructions contain basic instruc-
tions for installation, commissioning, maintenance
and inspection work which must be obeyed to en-
sure the safe operation of the machine and prevent
physical and material damage.
The safety instructions in all sections must be taken
into consideration.
The operating instructions must be read by the
responsible technical personnel/ operator before
installing and commissioning and must be fully un-
derstood. The contents of the operating instructions
must always be available on site for the technical
personnel / operator. Instructions fixed directly onto
the machine must be obeyed and must always re-
main legible. This applies for example to:
• Symbols for connections
• Data and motor data plate
• Instruction and warning plates
The operator is responsible for observing local regu-
lations.

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Safety
2.3 Designated use
The machine must only be operated in such areas
as are described in the operating instructions:
• only operate the machine in a technically perfect
condition
• do not operate the machine when it is only par-
tially assembled
• the machine must only be operated at an ambi-
ent temperature and suction temperature of
between 5 and 40°C. Please contact us for
temperatures outside this range.
• the machine may convey, compress or extract
the following media:
• Standard version:
all non-explosive, non-inflammable, non-ag-
gressive and non-poisonous dry gases and
gas air mixtures
• Version “XD”:
moist gases and gas air mixtures
• the machine must only be operated at speed
and frequency range according to the data plate
(Fig. 2/N1)
2.4 Unacceptable operating modes
• extracting, conveying and compressing explo-
sive, inflammable, aggressive or poisonous me-
dia, e.g. dust as per ATEX zone 20-22, solvents
as well as gaseous oxygen and other oxidants,
water vapour (does not apply for version “XD”),
liquids or solid materials
• must not be operated in rooms that are at risk
of explosion and in Zone 22 dusty atmospheres
that are at risk of explosion
• using the machine in non-commercial plants if
the necessary precautions and protective meas-
ures have not been taken in the plant
• installing in environments that are at risk of ex-
plosions
• using the machine in areas with ionising radia-
tion
• modifications to the machine, default settings of
the frequency converter and accessories

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Safety
2.5 Personal qualifications and training
• Ensure that people entrusted with working on
the machine have read and understood these
operating instructions before starting work,
particularly the safety instructions for installation,
commissioning, maintenance and inspection
work.
• Manage the responsibilities, competence and
monitoring of staff
• all work must only be carried out be technical
specialists:
• Installation, commissioning, maintenance
and inspection work
• Working with electricity
• personnel being trained to work on the ma-
chine must be supervised by technical special-
ists only
2.6 Safety-conscious work
The following safety regulations apply in addition
to the safety instructions and intended use listed in
these instructions:
• Accident prevention regulations, safety and op-
erating regulations
• the standards and laws in force
2.7 Safety notes for the operator
• hot parts of the machine must not be accessible
during operation or must be fitted with a guard
• People must not be endangered by the free
extraction or discharge of pumped media
• Risks arising from electrical energy must be
eliminated.
• The machine must not be in touch with inflam-
mable substances.
Danger of fire by hot surfaces, discharge of
pumped media or cooling air

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Safety
2.8 Safety instructions for installing, commissioning and maintenance
• The operator will ensure that any installation,
commissioning and maintenance work is car-
ried out by authorised, qualified specialists who
have gained sufficient information by an in-depth
study of the operating instructions.
• Only work on the machine when it is idle and
cannot be switched on again
• Ensure that you follow the procedure for decom-
missioning the machine described in the operat-
ing instructions.
• Fit or start up safety and protective devices
again immediately after finishing work.
• Conversion work or modifications to the ma-
chine are only permissible with the manufactur-
er’s consent.
• Only use original parts or parts approved by the
manufacturer. The use of other parts may invali-
date liability for any consequences arising.
• Keep unauthorised people away from the ma-
chine
2.9 Guarantee conditions
The manufacturer’s guarantee or warranty will no
longer apply in the following cases:
• Improper use
• Not complying with these instructions as well as
operating instructions for frequency converter
• Operation by insufficiently qualified staff
• Using spare parts that have not been approved
by Gardner Denver Schopfheim GmbH
• Unauthorised modifications to the machine or
the accessories supplied by Gardner Denver
Schopfheim GmbH

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Transport, storage and disposal
Fig. 1 Lifting and transporting
1Eyebolt
2Transport shackle
3Fixing screw
3 12
3 Transport, storage and disposal
3.1 Transportation
3.1.1 Unpack and check the delivery condition
a) Unpack the machine on receipt and check for
transport damage.
b) Notify the manufacturer of transport damage im-
mediately.
c) Dispose of the packaging in accordance with the
local regulations in force.
3.1.2 Lifting and transporting
WARNING
Death or limbs crushed as a result of the items
being transported falling or tipping over
Remember the centre of gravity when transport-
ing with a forklift truck or platform lift truck.
When transporting with the lifting device remem-
ber:
a) Select the lifting device suitable for the total
weight to be transported.
b) Ensure that the machine cannot tip and fall.
c) Do not stop under a suspended load.
d) Put the goods to be conveyed on a horizontal
base.
Lifting device/ Transporting with a crane
WARNING
Bodily injury resulting from improper operation
a) Loads crosswise to the ring level are not per-
mitted.
b) Avoid impact stress.
a) Tighten the eyebolt (Fig. 1/1) and fixing screw
(Fig. 1/3) on the transport shackle (Fig. 1/2)
firmly.
b) The machine must be suspended on the eye-
bolt and the transport shackle using the lifting
device.

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Transport, storage and disposal
3.2 Storage
NOTICE
Material damage caused by improper storage.
Ensure that the storage area meets the following
conditions:
a) dust free
b) vibration free
3.2.1 Ambient conditions for storage
Ambient conditions Value
Relative humidity 0 % to 80 %
Storage temperature -20 ° C to +70 °C
The machine must be stored in a dry environment
with normal air humidity. It should not be stored for
more than 6 months.
see Info „Machine storage guidelines“, Page 4
3.3 Disposal
WARNING
Danger from inflammable, corrosive or poiso-
nous substances.
Machines that come into contact with hazardous
substances must be decontaminated before
disposal.
When disposing ensure the following:
a) Collect oils and grease separately and dispose
of in accordance with the local regulations in
force.
b) Do not mix solvents, cold cleaners and paint
residues.
c) Remove components and dispose of them in
accordance with the local regulations in force.
d) Dispose of the machine in accordance with the
national and local regulations in force.
e) Parts subject to wear and tear (marked as such
in the spare parts list) are special waste and
must be disposed of in accordance with the
national and local waste laws.

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Set up and operation
E
E
N1
F
Q
M
P
A
F
B
F
O D
K I
B1
H
F
B2
NV
4 Set up and operation
4.1 Setup
A Vacuum connection
BAir outlet connection
B1Exhaust silencer
B2 Condensate drain (only with “XD”)
DNon-return valve
ECooling air inlet
F Cooling air outlet
H Oil filling point
I Oil sight glass
K Oil discharge point with magnet
MOil recommendation plate
NData plate
N1Data plate frequency converter
ODirection of rotation arrow
P Drive motor
Q hot surfaces > 70 °C
VFrequency converter
Fig. 2 Vacuum pump C-VLR 401 and C-VLR 501

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 




















 







Set up and operation
3 521
6
487 9
10 11
4.1.1 Data plate
1 Type/ Size (mechanical version)
2 Year of construction
3 Serial number
4 Data matrix barcode
5 Item no.
6 Motor output
Following information are encrypted in the barcode:
• Material number (MA)
• Production order (PR)
• Serial number (SC)
Fig. 3 Data plate machine Fig. 4 Data plate frequency converter
7 Suction capacity
8 Ultimate vacuum (abs.)
9 Frequency range
10 Speed range
11 Motor output

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Set up and operation
4.2 Description
The C-VLR 401 and C-VLR 501 model has a connection flange on the inlet side and an exhaust silencer
on the pressure side (Fig. 2/B1). The air sucked in is cleaned by a micro-filter. An non-return valve (Fig. 2/D)
prevents the evacuated system from being ventilated after the pump has stopped.
The ZEPHYR VLR 401 and C-VLR 501 is a double shaft rotary piston vacuum pump in which the claws roll
off against each other contact free and dry. The counter-rotating claw rotors are synchronised by a gear
pair in the gearbox. The synchronous gearbox gear wheels and the bearings are lubricated with oil. These
components are in a gearbox that also contains the oil supply. Oil conveying devices always ensure that the
bearings and the gear wheels are sufficiently supplied with oil at all permissible speeds.
The gearbox and the compression chamber are separated from each other by special seals. The gearbox
is sealed from the outside with shaft seals and O rings, the compressor chamber with piston rings. The
VLR 401 and VLR 501 are enclosed in an insulating hood. In order to dissipate compression heat, the
cooling air is sucked through between the machine and the hood using a drum fan that sucks in the fresh
cooling air (Fig. 2/E) and discharges the heated air out of the cooling air outlet (Fig. 2/F).
Three-phase motor with integral frequency converter (Fig. 2/V) makes possible infinitely variable control of the
speed.
A vacuum relief valve is incorporated into the machine.
4.3 Areas of application
This contact free running claw vacuum pump, the C-VLR 401 and C-VLR 501, can be operated constantly
at any pressure between 700 mbars (abs.) and an inlet pressure of 200 mbars (abs.).
When evacuating closed systems the volume to be evacuated must be no more than 2% of the nominal
suction capacity of the vacuum pump.
The suction capacity with unrestricted suction is 380 m3/h and 495 m3/h at 50 Hz. Data sheet D 886-60
shows the dependency of the suction capacity on the intake pressure.
Version “XD”: The vacuum pump is provided with a corrosion-resistant coating and is suitable for conveying
water-moist gases (water vapor).
If the unit is switched on more frequently (at regular intervals of about 10 times an hour) or at
higher ambient temperatures and intake temperatures, the excess temperature limit of the motor
winding and the bearings may be exceeded.Please contact the manufacturer should the unit be
used under such conditions.
If it is installed in the open air the unit must be protected from environmental influences, (e.g. by
a protective roof).

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Installation
5 Installation
5.1 Preparing for installation
Check the following points:
• Machine freely accessible from all sides
• Do not close ventilation grids and holes
• Sufficient room for installing and removing pipes
and for maintenance work, particularly for install-
ing and dismantling the machine
• No external vibration effects
• Do not suck any hot exhaust air from other ma-
chines into the cooling system.
The oil filling point (Fig. 2/H), oil sight glass (Fig. 2/I) and the oil outlets (Fig. 2/K) must be easily
accessible. The cooling air inlets (Fig. 2/E) and the cooling air outlets (Fig. 2/F) must be at least
30 cm away from adjacent walls. Cooling air coming out must not be sucked in again.
5.2 Installation
NOTICE
The machine may only be operated when it is
set up horizontally.
Material damage resulting from the machine
tipping over and falling.
When installed at more than 1000 m above sea
level a reduction in power is noticeable. In this
case we would ask you to contact us.
Contamination in the intake air
To protect the machine the operator should install
appropriate filters on the suction side.
The C-VLR 501 must not be operated without
covering plates.
Ensure that the foundation complies with the
following conditions:
• Level and straight
• The bearing surface must be designed to be
able to take the weight of the machine.
It is possible to install the machine on a firm base without anchoring. When installing on a sub-
structure we recommend fixing with flexible buffers.

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Installation
5.3 Connecting pipes
a) Vacuum connection at (Fig. 2/A).
b) Connect the vacuum line.
NOTICE
Material damage resulting from the forces and
torques of the pipes on the unit being too high.
Only screw pipes in by hand.
The suction capacity of the vacuum pump is
reduced if the suction pipe is too narrow and/
or too long.
c) The extracted air can be discharged through the
exhaust silencer (Fig. 2/B) or conducted away
via a pipe.
NOTICE
Exhaust air must not be restricted
No blocking systems must be built into the
exhaust air pipe (max. pressure difference 50
mbars). When the exhaust air pipe is connected it
must be checked regularly for impurities.
5.4 Filling with lubricating oil
a) Fill the lubricating oil (for suitable types see
“Maintenance”) for the gear wheels and oil fill-
ing point (Fig. 2/H) up to the middle of the sight
glasses (Fig. 2/I).
b) Close the oil filling point.

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Installation
5.5 Connecting the drive
DANGER
Danger of death if the electrical installation has
not been done professionally.
The electrical installation must only be done by
a qualified electrician observing EN 60204. The
operating company has to provide the main switch.
For operation on the frequency converter, observe
the manufacturer‘s operating instructions for the
frequency converter.
a) The drive consisting of the components motor
and frequency converter. The mechanical and
electric connection between motor and frequen-
cy converter is already assembled on delivery.
The frequency converter is parameterised with
the basic adjustment settings.
b) Connect the frequency converter (Fig. 2/V)
according to the operating instructions
610.00260.40.000 or with the attached con-
nection diagram. For the observance with the
protection class IP 65 shall be provided suitable
cable glands resp. shutters. The electric network
connection values are to be taken from the type
label of the frequency converter.
NOTICE
Power supply
The electric supply of the frequency converter must
to be in accordance with the following values:
• Input voltage 3 AC 400 V -15 %
bis 480V + 10 %
• Input frequency 47 bis 63 Hz ±0%
• Suitable network configurations TN / TT

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Commissioning and decommissioning
6 Commissioning and decommissioning
6.1 Commissioning
WARNING
Improper use
May lead to severe or fatal injuries. Therefore be
sure to obey the safety instructions.
CAUTION
Hot surfaces
When the machine is at operating temperature the
surface temperatures on the components (Fig. 2/
Q) may go above 70°C.
You must avoid touching the hot surfaces (mar-
ked with warning plates).
CAUTION
Noise emission
The highest noise pressure levels measured as
per EN ISO 3744 are given in Section 9.
When spending a long time in the vicinity of the
running machine use ear protectors to avoid
permanent damage to your hearing.
NOTICE
Wait until the machine stops
The machine must only be switched on again
after it stops.

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Commissioning and decommissioning
6.1.1 Checking the rotation direction
The intended direction of rotation of the drive
shaft is shown by the rotary direction arrow
(Fig. 2/O).
a) Start the motor briefly (max. two seconds) to
check the direction of rotation. When looking at
the motor fan, it must rotate anti-clockwise.
NOTICE
Incorrect direction of rotation
Operating in the wrong direction of rotation leads
to damage to the machine.
Use a phase sequence indicator to check the direc-
tion of rotation (clockwise rotating field).
6.1.2 Post-run
For removing accrued dampness and impurities out
of the pump we recommend, let the vacuum pump
post-run with 700 mbar (abs.) approximately 15 to
30 minutes.
CAUTION
Condensate formation and impurities
By heightened condensate formation and impurities
after shutdown of the machine deposits can adhere
to rotors as well as compressor housing and prevent
an starting when restart.
Version “XD”:
Drain the condensate periodically and depending
on the application from the silencer (Fig. 2/B2).
Do not perform at operating temperature!

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Commissioning and decommissioning
6.2 Decommissioning/ storing
Stop the machine
a) Switch the machine off.
b) If available close the cut off device in the suction
and pressure pipe.
c) Disconnect the machine from the electricity
source.
d) Depressurise the machine:
Open the pipes slowly.
The pressure reduces slowly.
e) Remove the pipes and hoses.
f) Drain condensate from the silencer
(version “XD”).
g) Seal the connections for suction and discharge
nozzles with adhesive foil.
see also Section 3.2.1, Page 11
6.3 Re-commissioning
a) Check the condition of the machine (cleanliness,
cabling etc.).
For installation see Section 5 Page 14
For commissioning see Section 6.1 Page 17