Gardner Denver RFL Series User manual

PD BLOWERS & VACUUM
PUMPS
RFL SERIES |
Owner’s Manual
RFL 102
RFL 7 500
Version 03
April 11, 2018

RFL-7-500 Page 1
TABLE OF CONTENTS
1. HEALTH AND SAFETY..........................................................................................................................3
2. SAFETY RULES & NOTES ON DANGER.............................................................................................4
2.1 INTENDED USAGE ...................................................................................................................................4
2.2 ACCEPTANCE &MONITORING..................................................................................................................4
2.3 OPERATIONAL SAFETY............................................................................................................................4
2.4 ENVIRONMENTAL PROTECTION................................................................................................................4
2.5 ATTENTION.........................................................................................................................................4
2.6 INFORMATION.........................................................................................................................................4
2.7 POINTS TO NOTE ....................................................................................................................................4
3. TECHNICAL DATA.................................................................................................................................6
3.1 MACHINE DATA.......................................................................................................................................6
3.2 DIMENSIONS...........................................................................................................................................7
3.3 LUBRICATION..........................................................................................................................................8
3.4 COOLING................................................................................................................................................8
3.5 DRIVE METHODS ....................................................................................................................................8
4. TRANSPORT & STORAGE ...................................................................................................................9
4.1 TRANSPORT ...........................................................................................................................................9
4.2 STORAGE...............................................................................................................................................9
4.3 SCOPE OF DELIVERY...............................................................................................................................9
5. INSTALLATION....................................................................................................................................10
5.1 INSTALLATION LOCATION AND ATTACHMENT...........................................................................................11
5.2 PREVENTION OF SUCTION INTAKE OF DIRT AND RESIDUE........................................................................12
5.2.1 Suction Pipe..................................................................................................................................12
5.2.2 Vacuum Intake Filter.....................................................................................................................12
5.2.3 Safety Dome.................................................................................................................................12
5.2.4 Safety Tank...................................................................................................................................12
5.2.5 Combination Air Filter...................................................................................................................13
5.3 NOISE SUPPRESSION (LOW NOISE INSTALLATION)..................................................................................13
5.4 SAFETY AND MONITORING FEATURES....................................................................................................14
5.4.1 Vacuum Gauge.............................................................................................................................14
5.4.2 Vacuum Intake Filter.....................................................................................................................14
5.4.3 Ventilation Valve...........................................................................................................................14
5.4.4 Maintenance Indicator on Suction Air Filter..................................................................................15
5.4.5 Non-return Valve ..........................................................................................................................15
5.4.6 Thermometer................................................................................................................................15
5.4.7 Safety Valve..................................................................................................................................15
5.4.8 Manometer....................................................................................................................................15
5.4.9 Contact Prevention.......................................................................................................................15
5.4.10 Oil Level Monitoring...................................................................................................................16
5.4.11 Rotation Speed Monitor.............................................................................................................16
5.5 COOLING..............................................................................................................................................16
5.6 DRIVE ..................................................................................................................................................16
5.6.1 Hydraulic Motor ............................................................................................................................16
5.6.2 Flexible Coupling..........................................................................................................................17
5.6.3 Drive Shaft....................................................................................................................................17
5.6.4 V-Belt............................................................................................................................................17

RFL-7-500 Page 2
6. INITIAL OPERATION ...........................................................................................................................19
6.1 CHECKING THE SYSTEM........................................................................................................................19
6.2 LUBRICATING OIL..................................................................................................................................19
6.3 VALVES................................................................................................................................................19
6.4 ROTATING DIRECTION...........................................................................................................................19
6.5 DRIVE ..................................................................................................................................................19
6.6 CHECKING THE ROTATION SPEED,VACUUM AND PRESSURE...................................................................20
6.7 LUBRICATION OILS FOR COMPRESSOR/VACUUM PUMPS.........................................................................20
7. OPERATION.........................................................................................................................................21
7.1 START UP.............................................................................................................................................21
7.2 REGULAR CHECKS................................................................................................................................21
7.2.1 Safety Valve..................................................................................................................................21
7.2.2 Ventilation Valve...........................................................................................................................22
7.2.3 Checking Intervals........................................................................................................................22
7.3 POSSIBLE OPERATING ERRORS.............................................................................................................22
7.4 PRECAUTIONS FOR LONG STANDSTILL PERIODS.....................................................................................23
7.5 RINSING AFTER MACHINE WAS OVER-SUCKED .......................................................................................23
7.6 PROCEDURE IF FAULTS OCCUR.............................................................................................................23
8. MAINTENANCE....................................................................................................................................25
8.1 WARRANTY ..........................................................................................................................................25
8.2 MAINTENANCE PLAN.............................................................................................................................25
8.2.1 Cooling System ............................................................................................................................26
8.2.2 Compressor/Vacuum Pump .........................................................................................................26
8.2.3 Vacuum Filter................................................................................................................................26
8.2.4 V-Belts and V-Belt Tension ..........................................................................................................27
8.2.5 Cleaning the Oil Tank...................................................................................................................27
8.2.6 Non-Return Valve.........................................................................................................................28
8.2.7 Ventilation Valve...........................................................................................................................28
8.2.8 Rotor Vane Wear Measurement...................................................................................................29
9. SERVICE PARTS .................................................................................................................................30
9.1 SPARE PARTS ......................................................................................................................................30
9.2 PARTS SUBJECT TO WEAR .....................................................................................................................30
9.3 KITS FOR REBUILD...........................................................................................................................30

RFL-7-500 Page 3
1. HEALTH AND SAFETY
Read 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 orifices.
Do not place any objects, especially fingers, into the orifices since personal injury could result.
Installation
A relief valve must be fitted 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 inlet and discharge ports covered.
•Rotate the drive shaft of the machine monthly, in the direction shown by the arrows on the sides of the
machine body.
•Where the compressor is mounted on the vehicle and 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 flouroelastomer polymers which degrade if exposed to temperatures
above 300°C. If the material has been exposed to such temperatures, then it must not be handled with bare
hands.
Surface temperatures can exceed 150°C. Highly combustible materials must not come into contact with the
discharge 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
Tests carried out by Gardner Denver Drum show that the maximum noise levels for the RFL 102 should typically
not exceed 77 dB(A) in the worst case (1500rpm, 2.0 barg). Other vehicle/equipment noise levels are likely to be
greater.
IN ACCORDANCE WITH OUR POLICY OF CONTINUOUS PRODUCT IMPROVEMENT, GARDNER DENVER DRUM
RESERVE THE RIGHT TO ALTER DETAILS AND SPECIFICATIONS WITHOUT NOTICE.

RFL-7-500 Page 4
2. SAFETY RULES & NOTES ON DANGER
2.1 Intended Usage
The compressor/vacuum pump is designed exclusively for compression or suction of filtered air. Use for any other purpose
is not considered intended use.
Intended use also requires adherence to the operating data and listed maintenance as set forth in this manual.
2.2 Acceptance & Monitoring
The compressor/vacuum pump itself is not subject to any general acceptance and monitoring requirements.
The operator is responsible for meeting any special regulations that are in effect at the site of operation.
2.3 Operational Safety
This symbol indicates possible dangers for personal safety. Working safety requires exact observation of
instructions so marked. Safety instructions must be known to all personnel who use the machine!
2.4 Environmental Protection
This symbol shows that environment protection regulations must be observed.
2.5 ATTENTION
“ATTENTION” defines regulations and instructions which are designed to prevent damage to the machine.
2.6 Information
This symbol indicates information of particular interest to the operator of the machine!
2.7 Points to Note
The compressor/vacuum pump has been constructed according to the latest technological standards and safety
regulations; however, during use of the machine it is still possible that the health and life of the operator or other
personnel may be endangered, or that damage to the machine or to other property may be caused.
•Only use the machine when it is in a technically perfect condition; such use must be carried out in accordance with the
intended usage and with due regard for safety. In particular, any faults which are relevant to the safety of the machine
must be repaired immediately.
•Alterations, attachments or modifications to the compressor/vacuum pump which may affect the safety of the machine
are not acceptable without consulting the manufacturer.
•All warning notices on the machine must be observed, and care must be taken that all such notices are always in legal
condition.
•Attention must be paid to fire detection and fire-fighting features.
•Work on electrical devices must be carried out by a qualified electrician in accordance with the electrical and technical
regulations.

RFL-7-500 Page 5
All personnel who are required to work with the machine must read the operating instructions, especially the safety
instructions, before commencing such work.
•Work on the machine must only carried out when the machine is at a standstill.
•Before such work begins, measures must be taken to prevent the drive from being switched on.
•During such work, the machine must not be subjected to pressure or vacuum.
•On the vehicle side:
•Close the shut-off valve
•Bleed or vent the pressure pipe between the machine and the shut-off valve.
•Release pressure manually at the safety valve, or vent the machine at the ventilation valve.
•Pay attention to the manometer!
•The drive prevention device must only be removed when the machine is at a standstill.
•The contact prevention guards must only be removed when the machine and the pressure pipe are cool.
•Before switching on the machine, ensure that all safety devices are correctly in place.
For the sake of environmental protection, all liquids which come from the machine during maintenance work, e.g.
lubricating oil, must be collected and disposed of in a way that does not harm the environment.
ATTENTION
“MAX SURFACE TEMPERATURE 150°C!”

RFL-7-500 Page 6
3. Technical Data
3.1 Machine Data
The RFL 102 is an air-cooled, oil lubricated rotary vane compressor.
On the rating plate of each machine you will find, in addition to the machine number, the most important data.
Compressor/Vacuum Pump Units RFL 102
Max. pressure in compression operation
2)
psig 2.9
Nominal vacuum
1)
psiA 2.9
Max. permitted vacuum (up to 3 minutes per hour)
1)
psiA 2.18
Power requirement at drive shaft for 2 bar pressure hp 41.6
Min. speed rpm 1000
Max. speed rpm 1500
Nominal speed rpm 1500
Oil consumption g/h 0.26
Capacity of oil tank g 1.25
Mass moment of inertia lbft
2
5.72
Sound pressure at a distance of 7m at 2 barg operating pressure db(A) 76
Weight with non-return valve lb 397
1)
Protect with ventilation valve!
2)
Protect with safety valve!

RFL-7-500 Page 7
3.2 Dimensions
Fig 3.1 Dimensions of RFL 102
9
Fig 3.2 Hydraulic Drive Dimensions
Hydraulic Drive Details
Kit Number TEN009820
Motor Flange Type SAE ‘C’ 4-BOLT
Gearbox Details
Kit Number TEN009819
Motor Flange Type SAE

RFL-7-500 Page 8
3.3 Lubrication
Lubrication is performed by means of the integrated, fixed drive oil pump.
Lubrication oil specification: Single range oils of classes:
API: CD/SF and higher
MIL-L: 2104 C and higher
Compressor/Vacuum Pump
Units
RFL 102
Oil Tank Capacity l (gal)
4.75 (1.25)
Oil Consumption l/h (gal/min)
0.1 (0.0004)
Add Oil After Operating Hours h
40
Oil Level Checks per Day once
3.4 Cooling
Air cooling is carried out by means of two fans mounted at either end of the rotor shaft, which draw in cool air to pass over the
cooling fins on the machine body.
When the machine is installed, care must be taken to ensure that cooling air can circulate, providing sufficient cooling.
3.5 Drive Methods
From the vehicle engine:
•by auxiliary drive and drive shaft
•by V-Belt
•by Hydraulic Motor
From a diesel or electric engine:
•by flexible coupling
•by gearbox
•
For exact details, see section 5.6.

RFL-7-500 Page 9
4. Transport & Storage
Symbols on the packaging:
Top
Fragile
Protect from rain
4.1 Transport
Avoid use of force and load/unload packages with care. Attach lifting equipment only to the firmly installed eyebolts.
Remove all packaging before installation.
4.2 Storage
Store the machine in a dry and heated room until installation. Remove the covers on inlet and discharge ports only at the time of
actual installation.
Rotate the drive shaft of the machine monthly, in the direction shown by the arrows on the machine body.
The protective coating on the bare parts remains effective for approximately 1 year. If the machine is stored for a longer period, it
must be renewed.
4.3 Scope of Delivery
The contents of the consignment are described in the delivery note. Check for short delivery and transit damage on receipt. Claims for
damages can only be accepted if made promptly in writing.