Edition: 2.12.2009 · BA 881-EN
Original Operating Instructions
C-DLR
C-DLR 60 | 100 | 120 | 150 | 250 | 300 | 400 | 500
C-Serie
C-Series
Klaue
Claw
Inhaltsverzeichnis
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 qualifi cations 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Areas of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Connecting pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 Filling with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.6 Connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Commissioning and decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.1 Checking the rotation direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2 Decommissioning/ storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Inhaltsverzeichnis
7 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1 Ensuring operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2.1 Changing the oil and lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.2.2 Air fi ltering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.2.3 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3 Repair/ Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 Malfunctions: Causes and elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Foreword
1 Foreword
1.1 Principles
These operating instructions:
• are a part of the following contact free running claw compressors, models C-DLR 60,
C-DLR 100, C-DLR 120, C-DLR 150, C-DLR 250,
C-DLR 300, C-DLR 400 and C-DLR 500.
• 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.
Operating Instructions BA 881-EN
Supplier documentation
Declaration of Conformity C 0079-EN
Declaration of harmlessness 7.7025.003.17
Spare parts' list Spare parts document E 881
Data sheet Technical data and graphs D 881
Info sheet Storage guidelines for machines I 150
Manufacturer’s declaration
EU Directive 2002/95/EG (RoHS)
—
1.4 Abbreviations
Fig. Figure
C-DLR Compressor
3
/h Capacity, volume fl ow
m
bar Overpressure
1.5 Directives, standards, laws
See Conformity Declaration
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1.6 Symbols and meaning
Symbol Explanation
Condition, pre-requisite
#### Instructions, action
a), b),... Instructions in several steps
Results
Foreword
[-> 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 Compressor and motor combination ready to be connected
Motor Compressor drive motor
Compressor Machine to produce excess pressure
Claw Machine‘s design or active principle
Volume fl ow
The volume fl ow specifi es how much air or gas volume per time unit is
fed in by a compressor or fl ows through a pipe.
Final compression pressure Maximum excess pressure that a compressor can produce given as ex-
cess pressure in bars
Noise emission
The noise emitted at a specifi c loading given as a fi gure, 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
WARNING
CAUTION
NOTICE
2.2 General
immediately imminent danger Death, severe bodily injury
possible imminent danger Death, severe bodily injury
possible hazardous situation Slight bodily injury
possible hazardous situation Material damage
These operating instructions contain basic instructions for installation, commissioning, maintenance
and inspection work which must be obeyed to ensure 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 understood. The contents of the operating instructions
must always be available on site for the technical
personnel / operator. Instructions fi xed directly onto
the machine must be obeyed and must always remain 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 regulations.
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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 partially assembled
• the machine must only be operated at an ambient 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:
• all non-explosive, non-infl ammable, non-ag-
gressive and non-poisonous dry gases and
gas air mixtures
2.4 Unacceptable operating modes
• extracting, conveying and compressing explosive, infl ammable, aggressive or poisonous media, e.g. dust as per ATEX zone 20-22, solvents
as well as gaseous oxygen and other oxidants,
water vapour, liquids or solid materials
• using the machine in non-commercial plants if
the necessary precautions and protective measures have not been taken in the plant
• installing in environments that are at risk of explosions
• using the machine in areas with ionising radiation
• modifi cations to the machine and accessories
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Safety
2.5 Personal qualifi cations 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 specialists 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 operating 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 fi tted 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.
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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 carried out by authorised, qualifi ed specialists who
have gained suffi cient 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 decommissioning the machine described in the operating instructions.
• Fit or start up safety and protective devices
again immediately after fi nishing work.
• Conversion work or modifi cations to the machine are only permissible with the manufacturer’s consent.
• Only use original parts or parts approved by the
manufacturer. The use of other parts may invalidate liability for any consequences arising.
• Keep unauthorised people away from the machine
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
• Operation by insuffi ciently qualifi ed staff
• Using spare parts that have not been approved
by Gardner Denver Schopfheim GmbH
• Unauthorised modifi cations to the machine or
the accessories supplied by Gardner Denver
Schopfheim GmbH
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Transport, Lagerung und Entsorgung
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
a) Select the lifting device suitable for the total
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
Lifting device/ Transporting with a crane
1
a) Tighten the eyebolts (Fig. 1/1) fi rmly.
b) The machine must be suspended on the eyebolt
WARNING
Death or limbs crushed as a result of the items
being transported falling or tipping over.
When transporting with the lifting device remem-
ber:
weight to be transported.
base.
WARNING
Bodily injury resulting from improper operation
a) Loads crosswise to the ring level are not per-
mitted.
b) Avoid impact stress.
using the lifting device for lifting and transporting.
Fig. 1 Lifting and transporting
1 Eyebolt
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3.2 Storage
Transport, Lagerung und Entsorgung
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%
Lagertemperatur -10°C to +60°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 infl ammable, corrosive or poisonous 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, limescale removers 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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Transport, storage and disposal
4 Set up and operation
4.1 Setup
O D
H
S
A
F
E
B
E
E
F
P
1
IK Q
MN
P
Fig. 2 C-DLR 60 compressor
A Suction
B Pressure connection
D Safety valve
E Cooling air inlet
Cooling air outlet
F
Oil fi lling point
H
Oil sight glass
I
Oil discharge point
K
F
IK
M Oil recommendation plate
N Data plate
O Rotation direction plate
P
Drive motor
P
Motor data plate
1
hot surfaces > 70°C
Q
S Suction fi lter/ silencer
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Transport, storage and disposal
P
1
DP
H
F
E
E
F
F
IK
B
E
Q
A
Z
N P
M
1
Fig. 3 C-DLR 150 compressor
A Suction
B Pressure connection
D Safety valve
E Cooling air inlet
Cooling air outlet
F
Oil fi lling point
H
Oil sight glass
I
Oil discharge point
K
O
I
K
M Oil recommendation plate
N Data plate
O Rotation direction plate
P
Drive motor
P
Motor data plate
1
hot surfaces > 70°C
Q
Intake silencer
Z
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Transport, storage and disposal
O
P
Z
E
E
MNH
F
B
E
A
1
QDP
Fig. 4 C-DLR 300 compressor
A Suction
B Pressure connection
D Safety valve
E Cooling air inlet
Cooling air outlet
F
Oil fi lling point
H
4.1.1 Data plate
1
Bauj./Nr. 09
Typ DTR 100 (01)
2843973
1027620113
+ 0,5 bar
100 / 120 m³/h
3
4 52
3~ Mot.
I K
I
Oil sight glass
Oil discharge point
K
P
Drive motor
Motor data plate
P
1
hot surfaces > 70°C
Q
Intake silencer
Z
1 Type/ Size (mechanical version)
2 Year of construction
3 Motor design
4 Serial number
5 Item no.
6 Excess pressure
7 Pumping capacity 50 Hz /60 Hz
EN 60034
S1 5,50/ 6,50 kW
1460 / 1745 min
-1
8 Speed 50 Hz/60 Hz
9 Motor output 50 Hz /60 Hz
6
78910
10 Operating mode
Fig. 5 Data plate (example)
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Transport, storage and disposal
4.2 Description
The C-DLR range has a connecting thread on the pressure side and an intake silencer on the suction side.
With the C-DLR 60 the incoming air is cleaned by a fi lter cartridge. The C-DLR 100-500 have a micro fi lter on
the suction side.
The ZEPHYR C-DLR is a double shaft rotary piston compressor 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 bearing on the motor side 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 suffi ciently supplied with oil at all permissible speeds. The feed chamber has
no sealants or lubricants. The C-DLR 400 and 500 sizes have grease lubricated bearings on the B side.
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. Between
them there is also another atmospherically ventilated area which can be loaded with sealing gas (special version).
The C-DLR 100-500 are encapsulated by an insulating hood. In order to dissipate compression heat, the
cooling air is sucked through between the machine and the hood using drum fan that sucks in the fresh
cooling air (Fig. 3/E) and discharges the heated air out of the cooling air outlet (Fig. 3/F). The ZEPHYR DLR is
driven by standard fl anged three phase motors via a coupling (with an elastomer component).
To protect against overload a safety valve (Fig. 2/D... 4/D) is fi tted as standard.
4.3 Areas of application
These contact free running claw compressors, C-DLR are suitable for creating excess pressure between 0
and the maximum limit (in bars) given on the data plate Fig. 2/N). Constant operation is permissible.
The compressors have a fl ow rate of 60, 100, 120, 150, 235, 300, 385 and 500 m
3
/h at 50 Hz. The load limits
(bars) on the pressure side are given on the data plate (N). Data sheet D 881 shows the dependency of the
fl ow rate on the excess pressures.
If the unit is switched on more frequently (at regular intervals of about 12 times an hour (C-DLR 60
- 150)) 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 infl uences, (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
• Suffi cient room for installing and removing pipes
and for maintenance work, particularly for installing and dismantling the machine
• No external vibration effects
• Do not suck any hot exhaust air from other machines into the cooling system.
The oil fi lling point (Fig. 2/H... 4/H), oil sight glasses (Fig. 2/I... 4/I) and oil outlets (Fig. 2/K... 4/K)
must be easily accessible.
The cooling air inlets (Fig. 2/E... 4/E) and cooling air outlets (Fig. 2/F... 4/F) must be at least 30 cm
from adjacent walls. Cooling air coming out must not be sucked in again.
For maintenance work there must be a minimum of 40 cm in front of the inlet fi lter (Fig. 2/S) and
the inlet silencer (Fig. 3/Z, 4/Z) .
5.2 Installation
• Level and straight
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 fi lters on the suction side.
Ensure that the foundation complies with the following conditions:
• 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 fi rm base without anchoring. When installing on a substructure we recommend fi xing with fl exible buffers.
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16
Installation
5.3 Connecting pipes
a) Pressure connection at (Fig. 2/B... 4/B).
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 compressor volume fl ow is reduced if the
pressure pipe is too narrow and/or too long.
b) Check to ensure the pressure line is connected
correctly.
NOTICE
Length of the connection pipes
With connection pipes that have the same pipe
cross section as the machine connection and are
more than 3m long, a non-return valve especially
for the purpose must be installed in order to avoid
reverse operation when the machine has stopped.
5.4 Safety valve
As a protection against overload a safety valve
(Fig. 2/D... 4/D) is installed as standard.
NOTICE
Do not operate without the standard safety
valve
If the permissible fi nal compression pressure is
exceeded (see data plate) the machine may be
damaged.
The safety valve is a part that is subject to
wear and must be replaced after 10,000 hours
or after no more than 2 years
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17
Installation
5.5 Filling with lubricating oil
a) Fill the lubricating oil (for suitable types see
“Maintenance”) for the gear wheels and oil fi lling point (Fig. 3/H) up to the middle of the sight
glasses (Fig. 3/I).
b) Close the oil fi lling point.
5.6 Connecting the motor
DANGER
Danger of death if the electrical installation has
not been done professionally.
The electrical installation must only be done by a
qualifi ed electrician observing EN 60204. The
operating company has to provide the main
switch.
a) The motor‘s electrical data is given on the data
plate (Fig. 3/N) or on the motor data plate (Fig. 3/
). The motors comply with DIN EN 60034
P
1
and are in protection class IP 55 and insulation
class F. The appropriate connection diagram is
located in the motor‘s terminal box (not for the
plug connection version). The motor data must
be compared with the data of the existing mains
network (current type, voltage, network frequency, permitted current value).
b) Connect the motor via the plug connection or
the motor protection switch (for safety reasons,
a motor protection switch is required and the
connecting cable must be installed via a cable
fi tting to provide strain relief).
We recommend using motor protection switches
with delayed switch off, depending on possible
excess current. Temporary excess current may
occur when the machine is started cold.
NOTICE
Power supply
The conditions at the installation location must match
the information on the motor data plate.
Without derating the following is permissible:
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18
• ± 5% Voltage deviation
• ± 2% Frequency deviation
6 Commissioning and decommissioning
6.1 Commissioning
Commissioning and decommissioning
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... 4/Q) may go above 70°C.
You must avoid touching the hot surfaces (marked 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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19
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... 4/O) on the motor fl ange.
a) Start the motor briefl y (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
Running in reverse for a long time may damage the
machine.
Use a phase sequence indicator to check the direction of rotation (clockwise rotating fi eld).
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) 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.).
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20
For installation see Section 5 Page 16
For commissioning see Section 6.1 Page 19
7 Maintenance and repair
Maintenance and repair
DANGER
Danger of death from touching live parts.
Before maintenance work disconnect the machine
by pressing the main switch or unplugging it and
ensure that it cannot be turned on again.
WARNING
Hot surfaces
During maintenance work there is the danger of
getting burnt on hot components (Fig. 2/Q... 4/Q)
of the machine.
Wait for the machine to cool down.
7.1 Ensuring operational safety
Regular maintenance work must be carried out in order to ensure operational safety.
Maintenance intervals also depend on the operational demands on the machine.
With any work observe the safety instructions described in Section 2.8 “Safety notes for installation, com-
missioning and maintenance”.
The whole unit should always be kept in a clean condition.
7.2 Maintenance work
Interval Maintenance to be carried out Section
monthly Check the pipes and screws for leaks and to ensure they are
—
seated properly and if necessary seal again or tighten up.
monthly Check the terminal box and cable inlet holes for leaks and if
—
necessary re-seal.
monthly Clean the safety valve and ventilation slots on the machine
—
and the motor cooling ribs.
10.000 h Replace the safety valve —
monthly Check the oil level 7.2.1
5.000 h Changing the oil
5.000 h C-DLR 400 / 500: Lubricate the bearing on the side facing
away from the motor
monthly/ every 6 months C-DLR 60, 100 / 120 (09): Clean or replace fi lter cartridge 7.2.2
depending on how dirty the
C-DLR 100 - 500: Clean the micro fi lter
discharged medium is
at least once a year C-DLR 100 / 120/ 150: Check for coupling wear 7.2.3
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21
Maintenance and repair
7.2.1 Changing the oil and lubricating
I
Fig. 6 Changing the oil
H
Oil fi lling point
Oil sight glass
I
Oil discharge point
K
M Oil recommendation plate
H
M
K
Changing the oil:
NOTICE
Always change the oil when the machine is at
operating temperature and in an atmospherically
ventilated area.
If it is not completely emptied the amount that can
be refi lled is reduced.
The waste oil must be disposed of in compliance with
the local environmental protection regulations.
If you change the type of oil, empty the oil tank
completely.
The oil level in the sight glasses (Fig. 6/I) must be
checked every month.
The machine must be switched off and vented to atmospheric pressure to top up the oil.With clean operations the oil must be changed after every 5,000
operating hours.
The oil viscosity must comply with ISO VG 150 as
per DIN 51519.
Designation as per DIN 51502: CLP HC 150.
We recommend the following oil brand: GEARLUBE 150 or equivalent oils by other manufacturers
(also see oil recommendation plate (Fig. 6/M)).
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22
Maintenance and repair
Fig. 7 Lubrication
H
Oil fi lling point
Oil sight glass
I
Oil discharge point
K
L
Grease nipple
Lubrication plate
M
1
HKI
LLM
1
Lubrication:
The bearings on the C-DLR 400 / 500 must be lubricated with 30 g of grease every 5,000 operating
hours or after no more than 2 years 30 g Fett (see
the two grease nipples (Fig. 7/L)).
We recommend Klüber PETAMO GY 193 or other
similar greases (see lubrication plate (Fig. 7/M
)).
1
NOTICE
This lubrication interval applies when operating the
machine at an ambient temperature of 20° C. At
40°C this interval is halved.
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23
Maintenance and repair
7.2.2 Air fi ltering
g
2
Fig. 8 Suction fi lter/ silencer
f
Filter cartridge
2
g2 Suction fi lter cover
f
2
NOTICE
Insuffi cient maintenance on the air fi lter
The power of the machine lessens and damage may
occur to the machine.
Suction fi lter
(C-DLR 60, 100 / 120 (09)
The fi lter cartridge (Fig. 8/f
) for the suction fi lter
2
(Fig. 2/s) must be cleaned monthly or more often
depending on the level of contamination by purging
from the inside outwards. In spite of cleaning the
fi lter its separation effi ciency will continue to deteriorate. Therefore the fi lter should be replaced every six
months.
The fi lter cartridge (Fig. 8/f2) can be removed for
cleaning after removing the suction fi lter cover
(Fig. 8/g2):
NOTICE
Do not damage the fi lter cartridges when cleaning
them.
1
Fig. 9 Purging fi lter cartridge
1 Filter cartridge
2
Compressed air
Micro fi lters (C-DLR 100 - 500)
The micro fi lter inbuilt in the intake silencer (Fig. 3/
S
, 4/S1) must be cleaned or replaced more or less
1
often depending on how dirty the medium in it is by
washing or blowing through.
WARNING
Danger of injury when dealing with compressed air.
When blowing through with compressed air, solid
particles may be carried along or powder dust swirling around may cause injury to the eyes.
Therefore, when cleaning with compressed air always
wear goggles and a dust mask.
2
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24
7.2.3 Coupling
q
m
Fig. 10 Coupling C-DLR 60
Coupling sprocket
k
Motor
m
n
Housing
1
Coupling half on the motor side
q
Screws
s
4
Maintenance and repair
The coupling sprocket (Fig. 10/k, 11/k)) is subject to
wear and must be checked regularly (at least once a
k
s
4
n
1
year).
CAUTION
Defective coupling sprocket.
Defective sprockets may lead to the rotor shaft
breaking.
To check the coupling switch the motor
(Fig. 10/m, 11/m) off and ensure that it cannot be
switched on again.
C-DLR 60
Undo the screws (Fig. 10/s
) on the housing fl ange
4
(Fig. 10/n1) . Remove the motor axially with the
half of the coupling on the motor side (Fig. 10/q)
and suspend with the lifting device. If the sprocket
(Fig. 10/k) is damaged or worn, then replace it.
C-DLR 100 / 120/ 150
Undo the hexagonal nuts (Fig. 11/s6) on the motor
fl ange. Remove the motor with the coupling half
on the motor side (Fig. 11/q) from the fanhousing (Fig. 11/n2) axially and suspend using a lifting
tool. If the sprocket (Fig. 11/k) is damaged or worn,
then replace it. The fan (Fig. 11/v) should also be
checked for damage from time to time and replaced
if necessary.
m
s
6
Fig. 11 Coupling C-DLR 100 - 150
k
Coupling sprocket
m Motor
Fan housing
n
2
Coupling half on the motor side
q
Hexagonal nut
s
6
v Fan
n
2
NOTICE
Frequent starting up and high ambient temperature
The service life of the sprocket (Fig. 10/k, 11/k) is
v
reduced. is reduced.
q
k
Re-assemble in reverse order.
C-DLR 250 / 3 00 / 400 / 5 00
The coupling needs no maintenance.
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25
Maintenance and repair
7.3 Repair/ Service
a) For on site repair work the motor must be
disconnected from the mains by a qualifi ed
electrician so that it cannot be started up again
accidentally. For repairs use the manufacturer,
its branch offi ces or authorised dealers. Please
contact the manufacturer for the address of the
service centre responsible for you (see Manufacturer‘s address).
NOTICE
For each machine that is sent to an Elmo Rietschle
Service centre for inspection, maintenance or repair, a
fully completed, signed declaration of harmlessness
must be enclosed.
The declaration of harmlessness is part of the
supplier‘s documentation.
Fig. 12 Clearance certifi cate 7.7025.003.177
b) After a repair or re-commissioning, the actions
listed under „Installation“ and „Commissioning“
must be carried out as for initial commissioning.
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26
7.4 Spare parts
Maintenance and repair
Order spare parts in accordance with the:
• Spare parts list
E 881/1 ➝ C-DLR 100 / 250 / 300
E 881/2 ➝ C-DLR 400 / 500
E 881/3 ➝ C-DLR 60
E 881/4 ➝ C-DLR 150
• Download the PDF fi le:
http://www.gd-elmorietschle.com
➝ Downloads
➝ Product Documents
➝ C-Series ➝ Spare Parts
• Parts subject to wear and gaskets are indi-
cated separately on the list
• Web site:
http://www.service-er.de
• Select the type, size and design.
Fig. 13 Spare parts list (example)
NOTICE
Only use original spare parts or parts approved by
the manufacturer. The use of other parts may lead to
malfunctions and invalidate liability or the guarantee
for any consequences arising.
Fig. 14 Web site
http://www.service-er.de
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27
Malfunctions: Causes and elimination
8 Malfunctions: Causes and elimination
Fault Cause Troubleshooting Important
Machine is switched
off by the motor protection switch
Blowing capacity is
insuffi cient
Mains voltage/ Frequency
does not correspond with the
motor data
Connection to motor terminal
board is not correct
Motor protection switch is not
set correctly
Motor protection switch is
triggered too quickly
The safety valve is dirty so
that the permissible pressure
is exceeded.
The suction fi lter is dirty Clean or replace the suction
The pressure line is too long
or too narrow
Check by qualifi ed electrician Section 5.5
Use a motor protection switch
with an overload-dependent
delayed switch off that takes
into consideration the short
term excess current at start
up (version with short circuit
and overload trigger as per
VDE 0660 Part 2 orIEC 947-4)
Clean or replace the safety
valve
fi lter
Check the hose or the pipe Section 5.3
Section
7.2Section 7.4
Section 7.2.2
Section 7.4
Machine or system leaking Check the pipework and
screw connections for leaks
and to ensure that they are
fi rmly seated.
Section 7.2
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28
Malfunctions: Causes and elimination
Fault Cause Troubleshooting Important
Final pressure (max.
excess pressure) has
not been reached
Machine or system leaking Check the pipework and
screw connections for leaks
and to ensure that they are
Section 7.2
fi rmly seated.
Driving power selection too
low
Machine gets too hot Ambient or intake temperature
is too high
Cooling air supply is obstructed
Use next largest motor output Data sheet D
361
Ensure it is being used prop-
Section 2.3
erly
Check environmental condi-
Section 5.1
tions
Clean ventilation slots Section 7.2
The safety valve is dirty so
that the permissible pressure
Clean or replace the safety
valve
Section 7.2
Section 7.4
is exceeded.
The machine makes
a abnormal noise
Deposits on the rotary piston Clean the working space and
the rotary piston
Elmo Rietschle
Service
The safety valve is vibrating Replace the valve Section 7.4
Please contact Elmo Rietschle Service for other malfunctions or those that cannot be eliminated.
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29
Technical Data
9 Technical Data
C-DLR 60 100 120 150
Sound pressure level (max.)
EN ISO 3744
Tolerance± 3 dB(A)
dB(A)
50 Hz 81 81 83 83
60 Hz 82 85 86 84
50 Hz 93 94 95 96
Sound power level dB(A)
60 Hz 93 97 97 96
Weight * kg 57 130 128 151
Length * mm 697 817 817 921
Width mm 348 540 540 541
Height mm 382 375 375 467
Suction connection G 1 G 1
Pressure connection G 1 G 11/
/
2
2
G 11/
G 11/
2
2
G 11/
G 11/
1
Correct amount of oil l 0,4 0,55 0,55 0,6
C-DLR
Sound pressure level (max.)
EN ISO 3744
Tolerance± 3 dB(A)
50 Hz
dB(A)
60 Hz 87 89 89 89
250 300 400 500
84 85 86 86
2
2
50 Hz 96 97 99 99
Sound power level dB(A)
60 Hz 100 101 102 102
Weight * kg 293 301 442 510
Length * mm 1033 1033 1264 1374
Width mm 722 722 744 764
Height mm 535 535 535 555
Suction connection G 2 G 2 G 3 G 3
Pressure connection G 2 G 2 G 3 G 3
Correct amount of oil l 0,75 0,75 0,75 0,75
* The length and the weight may differ from the information listed here depending on the motor manufac-
turer.
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30
Technical Data
You will fi nd more technical data on the data sheet
D 881
• Download the PDF fi le:
D 881 ➝ C-DLR 60 - C-DLR 500
• Download the PDF fi le:
http://www.gd-elmorietschle.com
➝ Downloads
➝ Product Documents
➝ C-Series ➝ Data Sheets
NOTICE
Subject to technical changes.
Fig. 15 Data sheet (example)
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31
Elmo Rietschle is a brand of
Gardner Denver‘s Industrial Products
Division and part of Blower Operations.
www.gd-elmorietschle.com
er.de@gardnerdenver.com
Gardner Denver
Schopfheim GmbH
Roggenbachstraße 58
79650 Schopfheim · Deutschland
Tel. +49 7622 392-0
Fax +49 7622 392-300
Hereby the manufacturer
confirms:
EC - declaration of conformity 2006/42/EC
Gardner Denver Schopfheim GmbH
Postfach 1260
D-79642 Schopfheim
that the machine:
of the:
Claw compressor
Series: C-DLR
Type: C-DLR 60, C-DLR 100, C-DLR 120,
C-DLR 150, C-DLR 250, C-DLR 300,
C-DLR 400, C-DLR 500
is conform to the regulations of the guideline indicated above.
The following harmonized and national standards and specifications are applied:
EN 1012-1:2010
EN 1012-2:1996+A1:2009 Compressors and vacuum pumps — Safety requirements — Part 2:
Compressors and vacuum pumps — Safety requirements — Part 1:
Compressors
Vacuum pumps
These declarations of conformity are invalid when the machine has been modified without prior approval by us and the approval has been documented in writing.
Name and address of the EC person in
charge for documentation
Gardner Denver Schopfheim GmbH
Postfach 1260
D-79642 Schopfheim
Gardner Denver Schopfheim GmbH
Schopfheim, 01.8.2011
Dr. Friedrich Justen, Director Engineering
C_0079_EN
Safety declaration form
s
.
s
/
A
.
3
S
for vacuum pumps and component
7.7025.003.17
Page 1 of 1
Gardner Denver Schopfheim GmbH
Roggenbachstr. 58, 79650 Schopfheim Phone: +49/(0)7622/392-0 Fax: +49/(0)7622/392-300
Repairs and/or maintenance of vacuum pumps and components will only be carried out if a declaration has been
filled in correctly and completely
.
If not, the repair work cannot be started and delays will result.
This declaration must only be filled in and signed by authorised qualified staff
2. Reason for the submission1. Type of vacuum pumps/ components
Type description:
Machine number
Order number:
Delivery date:
3. Condition of vacuum pumps/ component
4. Contamination of the vacuum pumps
Was this being operated? YES NO components when in use
Which lubrication was used? Toxic YES NO
Corrosive YES NO
Was the pump/ component emptied? Microbiological*) YES NO
(Product/Consumables) YES NO Explosive*) YES NO
Has the pump/ component been cleaned and decontaminaRadioactive*) YES NO
other YES NO
YES
Cleaning agent:
Cleaning method:
*) Microbiological, explosive or radioactively contaminated vacuum pumps/ components will only be accepted
with proof that they have been cleaned properly.
Type of toxic substance or process-related, dangerous reaction products with which the vacuum pumps/
components came into contact:
Trade name, manufacturer's Chemical Hazard
product name name class substances are released accidents
1
2
3
4
Personal protection measures:
ction to be taken if toxic First aid in the event of
Hazardous decomposition products when subjected to thermal load
YES NO
Which?
5. Legally binding declaration
We swear that the information in this declaration is accurate and complete and that I, the undersigned, am in a
position to judge this. We are aware that we are liable to the contractor for damage caused by incomplete and
inaccurate information. We undertake to release the contractor from any damage claims from third parties arising
from incomplete or incorrect information. We are aware that, regardless of this declaration, we are directly liable
to third parties including in particular the contractor's staff entrusted with handling or repairing the product
Company:
Street: Post code/ Town:
Phone: Fax:
Name (in capitals) Position:
Date:
Legally binding signature:
TOS no. / Index: 7.7025.003.17 / 0
Office responsible: G
Company stamp:
File management: ..\7702500317.xl
Gardner Denver Schopfheim GmbH Postfach 1260 D-79642 Schopfheim
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