Edition: 1.12.2009 · BA 883-EN
Original Operating Instructions
C-KLR
C-KLR 80 | 140
C-Serie
C-Series
Klaue
Claw
Table of contents
Table of contents
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Zulieferdokumentation und mitgeltende Dokumente . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Areas of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Connecting pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4 Relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5 Filling with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.6 Connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Commissioning and decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.1 Checking the rotation direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Decommissioning/ storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Table of contents
7 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1 Ensuring operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2.1 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2.2 Air fi ltering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2.3 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.3 Reparatur/ Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Malfunctions: Causes and elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Foreword
1 Foreword
1.1 Principles
These operating instructions:
• are a part of the following contact free running
claw pressure/vacuum pumps, models C-KLR 80
and C-KLR 140.
• 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 Zulieferdokumentation und mitgeltende Dokumente
Document Contents No.
Operating Instructions BA 883-EN
Supplier documentation
Declaration of Conformity C 0078-EN
Declaration of harmlessness 7.7025.003.17
Spare parts‘ list Spare parts‘ document E 883
Data sheet Technical data D 883
Info sheet Storage guidelines for machines I 150
Manufacturer’s declaration
EU Directive 2002/95/EG (RoHS)
—
1.4 Abbreviations
Fig. Figure
C-KLR Pressure/vacuum pump
3
/h Flow rate Compressed air/ intake air
m
bar Excess pressure/ negative pressure
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
Terms Explanation
Machine Pump and motor combination ready to be connected
Motor Pump drive motor
Pressure/vacuum pump
In combined use the machine may produce a vacuum and excess pressure at the same time.
Claw Machine's design or active principle
Volume fl ow A pressure vacuum pump’s suction air or compressed air.
Overpressure (pressure) Difference in pressure compared with atmospheric pressure. The corre-
sponding working pressure is greater than the atmospheric pressure.
Under pressure (vacuum) Difference in pressure compared with atmospheric pressure. The corre-
sponding working pressure is lower than the atmospheric pressure.
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, storage and disposal
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, storage and disposal
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 -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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Set up and operation
4 Set up and operation
4.1 Setup
1
E
E
ZUV R Q ZBD
SS
A
B
F
P
1
F
E
F
Fig. 2 Pressure vacuum pump C-KLR 80
A Vacuum connection
NMOP
HJ
F
IK
O Rotation direction plate
Q
B Pressure connection
E Cooling air inlet
F
Cooling air outlet
H
Oil fi lling point
Oil sight glass
I
J Plug-connector
Oil discharge point
K
M Oil recommendation plate
P
P
1
R
S
S
1
Q
ZBD Pressure relief valve
ZUV Vacuum relief valve
N Data plate
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Drive motor
Motor data plate
Compressed air aftercooler
Suction fi lter ‘ suction air
Suction fi lter’ Interim charging
hot surfaces > 70°C
4.1.1 Data plate
Set up and operation
1
3
4 52
2 Year of construction
1 Type/ Size (mechanical version)
3 Motor design
4 Serial number
5 Item no.
6 Overpressure / Vacuum
Typ KTR 100 (01)
Bauj./Nr. 09
2843970
1027630137
+0,60 / -0,60 bar
100 / 120 m³/h
3~ Mot.
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. 3 Data plate (example)
4.2 Description
The ZEPHYR C-KLR is a double shaft rotary piston pressure 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 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 gearbox and the compression chamber are separated from
each other by special seals. The gearbox is sealed from the outside with piston sealing rings and O rings,
the compressor chamber with piston rings.
The ZEPHYR C-KLR is enclosed in an insulation 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. 2/E) and discharges the heated air out of the cooling air outlet (Fig. 2/F). The compressed air aftercooler
(Fig. 2/R) provides a low blowing air temperature.The ZEPHYR C-KLR is driven by standard fl anged threephase motors via a coupling (with an elastomer component).
Relief valves (Fig. 2/ZUV) and (Fig. 2/ZBD) are installed as standard to protect against overload..
4.3 Areas of application
These contact free running claw pressure vacuum pumps models C-KLR 80 and C-KLR 140 are suitable for
creating pressure and vacuum at the same time. Constant operation is permissible.
The nominal fl ow rate is 80 and 140 m
3
/h at 50 Hz. The load limits (bars) on the intake and pressure sides
are specifi ed on the data plate (Fig. 2/N). Data sheet D 883 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 (C-KLR 80) or 10 times
(C-KLR 140) per 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 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), 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
20 cm away 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 lters (Fig. 2/S, 2/S
1
).
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.
Ensure that the foundation complies with the follow-
ing conditions:
• Even and level
• 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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Installation
5.3 Connecting pipes
a) Vacuum connection at (Fig. 2/A) and pressure
connection at (Fig. 2/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 pumping capacity of the machine is reduced if the suction pipe is too narrow and/or too
long.
b) Check to ensure the intake line and pressure
connection are 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 Relief valves
As a protection against overload safety valves
(Fig. 2/ZUV) and (Fig. 2/ZBD) are installed as standard.
NOTICE
Do not operate without standard relief valves.
If the permissible fi nal compression pressure and
the permissible vacuum are exceeded (see data
plate) the machine may be damaged.
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Installation
5.5 Filling with lubricating oil
a) Fill the lubricating oil (for suitable types see
„Maintenance“) for the gear wheels and bearings
at the oil fi lling point (Fig. 2/H) up to the middle
of the sight glass (Fig. 2/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. 2/N) or on the motor data plate (Fig. 2/
). 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
(Fig. 2/J) or a motor protection switch (for safety
reasons a motor protection switch is required
and cable fi tting must be provided to provide
strain relief for the connection cable). 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
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16
The conditions at the installation location must
match the information on the motor data plate.
Without derating the following is permissible:
• ± 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) 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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17
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) 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 pressure
nozzles using adhesive foil.
g) Insert the desiccant bag into the fi lter housing.
see also Section 3.2.1, Page 11
6.3 Re-commissioning
a) Check the condition of the machine (cleanliness,
cabling etc.).
b) Remove the desiccant bag from the fi lter hous-
ing.
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18
For installation see Section 5 Page 14
For commissioning see Section 6.1 Page 17
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) 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 regulating valves and ventilation slots on the ma-
—
chine and the motor cooling ribs.
monthly Check the oil level 7.2.1
5.000 h Changing the oil
monthly/ every 6 months Clean or replace fi lter cartridge 7.2.2
at least once a year Check for coupling wear 7.2.3
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19
Maintenance and repair
7.2.1 Changing the oil
Fig. 4 Changing the oil
H
Oil fi lling point
Oil sight glass
I
Oil discharge point
K
M Oil recommendation plate
M
H
IK
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. 4/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. 4/M)).
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20
7.2.2 Air fi ltering
f
g
2
g
1
Fig. 5 Suction fi lter
e Filter cartridge for inlet air
f Filter cartridgeinterim charging
g
Filter housing cover
1
g2 Suction fi lter cover
Screws
s
1
Maintenance and repair
NOTICE
Insuffi cient maintenance on the air fi lter
The power of the machine lessens and damage may
occur to the machine.
The fi lter cartridges (Fig. 5/e) for intake air and
e
s
1
(Fig. 5/f) for interim charging must be cleaned by
blowing through from the inside out depending on
how dirty they are. In spite of cleaning the fi lter its
separation effi ciency will continue to deteriorate.
Therefore the fi lters should be replaced every six
months.
The fi lter cartridge (e) can be removed for cleaning
after removing the screws (Fig. 5/s
housing lid (Fig. 5/g
). The fi lter cartridge (f) can be
1
) and the fi lter
1
removed for cleaning after unscrewing the suction
fi lter cover (Fig. 5/g
).
2
Clean the fi lter housing chambers too.
NOTICE
Do not damage the fi lter cartridges when cleaning
them.
1
Fig. 6 Purging fi lter cartridge
1 Filter cartridge
2
Compressed air
No dirt must get into the machine when cleaning
the fi lter housing chambers.
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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21
Maintenance and repair
7.2.3 Coupling
s
4
m
Fig. 7 Coupling C-KLR 80
Coupling sprocket
k
Motor
m
Fan housing
n
2
Coupling half on the motor side
q
s4 Screws
v Fan
n
2
wear and must be checked regularly (at least once a
year).
CAUTION
The coupling sprocket (Fig. 7/k, 8/k)) is subject to
v
q
k
Defective coupling sprocket.
Defective sprockets may lead to the rotor shaft
breaking.
To check the coupling switch the motor
(Fig. 7/m, 8/m) off and ensure that it cannot be
switched on again.
C-KLR 80
Undo the screws (Fig. 7/s
) on the motor fl ange.
4
Remove the motor with the coupling half on the motor side (Fig. 7/q) from the fanhousing (Fig. 7/n2) axially and suspend using a lifting tool. If the sprocket
(Fig. 7/k) is damaged or worn, then replace it. The
fan (Fig. 7/v) should also be checked for damage
from time to time and replaced if necessary.
C-KLR 140
Undo the hexagonal nuts (Fig. 8/s6) on the motor
fl ange. Remove the motor with the coupling half
on the motor side (Fig. 8/q) from the fan housing
(Fig. 8/n2) axially and suspend using a lifting tool.
If the sprocket (Fig. 8/k) is damaged or worn, then
replace it. The fan (Fig. 8/v) should also be checked
n
2
for damage from time to time and replaced if necessary.
m
s
6
Fig. 8 Coupling C-KLR 140
k
Coupling sprocket
Motor
m
n
Fan housing
2
Coupling half on the motor side
q
Hexagonal nut
s
6
v Fan
NOTICE
v
q
k
Frequent starting up and high ambient temperature
The service life of the sprocket (Fig. 7/k, 8/k) is
reduced.
Re-assemble in reverse order.
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7.3 Reparatur/ Service
Maintenance and repair
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. 9 Clearance certifi cate 7.7025.003.17
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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23
Maintenance and repair
7.4 Spare parts
Order spare parts in accordance with the:
• Spare parts list :
E 883/1 ➝ C-KLR 80
E 883/2 ➝ C-KLR 140
• 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.
NOTICE
Fig. 10 Spare parts list (example)
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. 11 Web site
http://www.service-er.de
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24
Malfunctions: Causes and elimination
8 Malfunctions: Causes and elimination
Fault Cause Troubleshooting Important
Machine is switched
off by the motor protection switch
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 suction fi lter cartridges
are dirty
The relief valves are dirty so
that the permissible pressure
and/or vacuum values have
been exceeded.
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 fi lter
cartridges
Clean or replace the regulating valves
Section 7.2.2
Section 7.4
Section 7.2
Section 7.4
Intake or blowing
power is not suffi cient
The suction fi lter cartridges
are dirty
Lines are too long or too nar-
Clean or replace the fi lter
cartridges
Check the hose or the pipe Section 5.3
row
Machine or system leaking Check the pipework and
screw connections for leaks
and to ensure that they are
fi rmly seated.
Section 7.2.2
Section 7.4
Section 7.2
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25
Malfunctions: Causes and elimination
Fault Cause Troubleshooting Important
Excess pressure or
vacuum not achieved
Machine or system leaking Check the pipework and
screw connections for leaks
Section 7.2
and to ensure that they are
fi rmly seated.
Machine gets too hot Ambient or intake temperature
is too high
Cooling air supply is obstructed
Ensure it is being used properly
Check environmental conditions
Section 2.3
Section 5.1
Clean ventilation slots Section 7.2
The suction fi lter cartridges
are dirty
The relief valves are dirty so
that the permissible pressure
Clean or replace the fi lter
cartridges
Clean or replace the regulating valves
Section 7.2.2
Section 7.4
Section 7.2
Section 7.4
and/or vacuum values have
been exceeded.
The machine makes
an abnormal noise
Deposits on the rotary piston Clean the working space and
the rotary piston
Elmo Rietschle
Service
A relief valve is vibrating Replace the valve Section 7.4
Please contact Elmo Rietschle Service for other malfunctions or those that cannot be eliminated.
| www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH
26
Technical Data
9 Technical Data
C-KLR 80 140
Sound pressure level (max.)
EN ISO 3744
Tolerance± 3 dB(A)
dB(A)
50 Hz 83 85
60 Hz 88 88
50 Hz 94 97
Sound power level dB(A)
60 Hz 99 99
Weight * kg 120 160
Length * mm 778 1016
Width mm 387 355
Height mm 415 500
Vacuum connection G 1
Pressure connection G 11/
/
4
4
G 11/
G 11/
2
2
1
Correct amount of oil l 0,55 0,60
* The length and the weight may differ from the information listed here depending on the motor manufac-
turer.
Fig. 12 Data sheet (example)
You will fi nd more technical data on the data sheet
D 883
• Download the pdf fi le:
D 883 ➝ C-KLR 80 / C-KLR 140
• Download the pdf fi le:
http://www.gd-elmorietschle.com
➝ Downloads
➝ Product Documents
➝ C-Series ➝ Data Sheets
NOTICE
Subject to technical changes.
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27
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 pressure/vacuum pump
Series: C-KLR
Type: C-KLR 80, C-KLR 85, C-KLR 100,
C-KLR 110, C-KLR 115, C-KLR 140
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, 01.8.2010
Dr. Friedrich Justen, Director Engineering
C_0078_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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