Elmo Rletschle R-WPB User Manual

Directions for Use

and

Service Manual

for compact units of Types from WPB 120 to WPB 8300,

and of Types from WVB 120 to WVB 8300,

and

Base units of Types from WPB 120 to WPB 8300

BE 853 2.5.2004

Gardner Denver Schopfheim GmbH

Postfach 1260 • 79642 SCHOPFHEIM / GERMANY
Phone [phone] • Fax [phone]

[e-mail]
www.gd-elmorietschle.com

TABLE OF CONTENTS

1. Introduction

1.1. Basic information

1.2. Symbols used in the manual

2. Transport, Handling and Storage

2.1. Transport and transport data

2.2. Handling

2.3. Storage conditions

3. Installation and Assembly

3.1. Assembly conditions

3.2. Space necessary for installation and operation

3.3. Requirements for anchoring the blower set or blower

3.4. Requirements for connecting the pipeline

3.5. Instruction for connecting the blower set to the power supply

3.6. Belt installation

3.7. Precautionary measures

3.8. Machine hall ventilation

4. Machine

4.1. Blower description

4.2. Blower set description

4.3. PVO combined safety and starting valves

4.3.1. Starting valve function

4.3.2. Safety valve function

4.4. Noise-damping hood

4.5. Use

4.5.1. Work media

4.5.2. Suction and discharge temperatures

4.5.3. Suction and discharge pressures

4.5.4. Lubricant specification

4.5.5. Maximum temperatures of the lubricating system

4.5.6. Maximum speeds

4.5.6.1. Pulley revolutions

4.5.6.2. Work medium speed

4.5.7. Necessary safety equipment

4.5.8.

Warning against use in explosion-hazard environments

4.5.9. Recommendations for operation at a temperature of 0

4.5.10. Application fields for blowers and blower sets

4.5.11. Electrical equipment data

4.5.12. Certificate of conformity

5. Operating the Machine

5.1. Inspection prior to first turning on the compact unit or base unit

5.2. First turning on of the compact unit or base unit

5.3. Trial Operation

5.3.1. Check intervals for trial operation

5.4. Emergency stopping controllers

5.5. Setting and adjustment instructions

5.5.1. Filling and changing the oil

5.5.2. Replacing the filter inserts of the suction filter

5.5.3. pulleys and belt tension

5.6. Running without operators

5.7. Plates and labels used on compact unit or base unit

5.8. Instructions for tracing simple failures

5.9. Routine maintenance and checks

5.10. Service checks executed by the manufacturer

5.11. Information on improper use

5.12. Information on residual risks

5.13. Places of excessively hot surfaces

5.14. Equipment for protecting operators against residual risks

5.15. Spare parts

6. Taking the machine out of operation and waste disposal

7. Noise level

8. Training operators

Rietschle Thomas GmbH + Co. KG page 2 / 23

o

C and lower

9. Pressure Device

10. Non-standard blower drive

Appendices

1. Identification of Characteristic Values, Standard compact unit Diagram, and
pressure ratios of standard blower set

2. PVO Combined Safety and Starting Valve - Assembly

3.1 Forced and natural ventilation

3.2 Forced and natural ventilation

4. Connection diagram of the acoustic enclosure fan (3 x 400V)

5. Connection diagram of the acoustic enclosure Fan (240 V)

6. Report on measurement of blower set oscillation power

Catalogue sheet (dimensional drawing) of the compact unit
Catalogue sheet (dimensional drawing) of the compact unit in the acoustic

enclosure
Quality certificate
Connection diagram of the electric motor (not included in this Manual,

submitted on request)

1. INTRODUCTION

1.1 BASIC

INFORMATION

1.2 SYMBOLS

USED IN THE

MANUAL

The Directions for use and service manual for the
SHARK compact unit and base units (hereinafter

referred to as the Manual) contain important directions to
be observed throughout the machine’s operating life,
starting on receipt of the machine. The manual has been
compiled for complete SHARK series. It also applies to
separately delivered base units. Before installing and/or
putting the machine into operation, you must familiarize
yourself with this manual in order to ensure trouble-free
and safe operation of the machine and a long operating
life. The manual mentions and quotes safety regulations to
be considered particularly during machine operation. It is
necessary that the personnel responsible for the machine
operation and maintenance have this manual at their
disposal so that operation and maintenance is done in
accordance with the instructions stated in this manual. We
recommend entrusting repairs and redesigns only to
Rietschle Thomas (RT) specialists. If under guarantee, the
machine shall be disassembled only by RT specialists or
persons authorized by RT.
The manual contains only instructions for use of standard
blowers and blower sets designed for air transport. The
instructions for use of non-standard blowers and blower
sets for transport of other gases must be consulted with the
manufacturer.

The instructions stated in the manual apply to the blower
set, the quality certificate of which is enclosed with this
manual. If any failure occurs, immediately contact the
Section for Business-technical Services (hereinafter
referred to as the RT service department). When
contacting RT about any problem, state the data from the
type plate: the type and serial number of the blower set or
blower.

Caution: Read the directions for use!

Warning: Overlooking these instructions
might cause damage to the machine
and/or slight injuries.

Warning: Danger of injury

Warning: High temperature risk

Caution: Wear ear protectors!

Oil filling

Forbidden: Do not turn on the machine!

Forbidden: Do not use a hammer!

Suspension

2. TRANSPORT, HANDLING AND STORAGE

2.1 TRANSPORT

AND TRANSPORT

DATA

2.2

H

ANDLING

Delivery

Delivered blower sets are assembled as complete units.
Delivered belts are not installed on the machine. The
pendulous motor frame is secured by bolts in the bottom
position. Delivered compensators and non-return valves of
larger SHARK types (supplied with noise-damping hoods)
are not installed on the machine. Blowers are delivered
without oil fillings. The delivery contains the accessories
specified in the purchase contract. The dimensions and
weight are stated in the dimensional drawing of the
appropriate blower set, which is enclosed with the Manual.

Transport

Compact units must be transported in protected freight
space.

Blower sets must be transported with belts re­moved! Otherwise, the shaft or bearings could be
damaged. During transport, the pendulous motor
frame must be secured by appropriate bolts in the
bottom position!

Receipt

On receipt, the delivery must be checked with the delivery
notes for completeness. Any potential damage caused
during transport must be recorded in the presence of the
carrier. The record signed by the carrier must be
immediately submitted to the supplier.

To handle the machine, use a forklift truck and/or crane as
described below.

Base unit

The picture shows the handling of a base unit. To handle
the blower, use soft binding ropes. Steel wire ropes can be
used provided they are padded in order to prevent damage
to the paint.

WARNING
On no account should the blower be lifted with
the ropes attached to the flanges!

Compact unit

To handle the compact unit, use a forklift truck and/or
crane. The following pictures show the ideal handling of
blower sets. To handle the compact unit with a crane, use
soft binding ropes. Steel wire ropes can be used provided
they are padded in order to prevent damage to the paint.
Further, you must avoid using too short binding ropes in
order to prevent deformation of the suction filter during
transport.

Rietschle Thomas GmbH + Co. KG page 3 / 23

t

t

WARNING
On no account should the compact unit be lifted
with the ropes attached to the set bases, blower
flanges, suction silencer, and/or motor!

Without a compact uni

Acoustic enclosure

Smaller types of acoustic enclosures, in which compact
units are placed, can be handled by a crane or a forklift
truck. Ropes must be placed under the bottom base as
displayed in the picture - in the direction shown by the
arrows. The forks of the forklift truck must also be placed
in the direction shown by the arrows.
Larger types of acoustic enclosures are equipped with
lifting-eye nuts. If crane handling of the hoods is
impossible, they can be handled with a forklift truck. When
handling the enclosure with a forklift truck, you must put
baulks on the truck forks (where the enclosure is placed) in
order to prevent damage to the enclosure. The enclosure
can also be disassembled into individual parts and then
reassembled at the place of installation. The following
pictures show the handling of acoustic enclosures.

With a compact uni

Motors

The handling of motors is described in the motor manual.
For handling, motors are usually equipped with eye screws.

Rietschle Thomas GmbH + Co. KG page 4 / 23

2.3 STORAGE

R

R

R

CONDITIONS

3. INSTALLATION AND ASSEMBLY

3.1 ASSEMBLY

CONDITIONS

3.2 SPACE

NECESSARY FO

INSTALLATION

AND OPERATION

3.3 REQUIREMENTS

FOR ANCHORING THE

BLOWER SET O

BLOWE

1) 2) 3)

The blower set must be stored in its original packaging in a
dry place and must be protected against dust. Compact
units in the acoustic enclosure intended for outside use can
be stored in the open air. If the blower set has been stored
for more than six months, you should (re)preserve it. For
this purpose, you can use standard preservative agents.
Storage conditions:
Temperature: -30 °C up to 40 °C
Relative humidity: up to 80%

Assembly in the Open Air

To install the blower set (the set including the enclosure) in
the open air, you must consider the local conditions (snow,
possibility of flooding, etc.)

Service passages and the space necessary for the set
assembly in the machine hall are shown in Appendix 3.
Acoustic enclosures designed for outside use also serve as
weather protection.

Assembly in the machine hall

The minimum dimensions of the machine hall are based on
the maximum dimensions of the compact unit (acoustic
enclosure) and the necessary 1-metre (better 1.2-metre)
operation space at the sides of the blowers (enclosures) and
between the blowers (enclosures). They are further based
on the 1.2-metre space between the wall of the discharge
section at the acoustic enclosure and the wall. The machine
hall height depends on the method chosen for handling the
machine(s).

When designing the machine hall, you must remember the
openings for the blower sets (the delivered sets are
normally assembled). The acoustic enclosure are
demountable. You should consider equipping the machine
hall with an overhead track for a crane crab or leaving
enough space for a forklift truck in order to handle those
blower sets to be maintained or repaired (necessity to
dismantle the blower and/or motor if a failure has
occurred).
The space necessary for installation of individual types of
SHARK blower sets can be derived from the dimensions
stated in the dimensional drawings.

The floor designed for installation must be flat and
dimensioned for the machine weight and anchor length.
With respect to the loading capacity, no special
requirements are stipulated for the floor design since both
the blowers and motors are dynamically balanced. The
mechanical oscillation power of the blowers and motors are
stated in Tables 3 and 4. The weight of the blower set is
distributed between its individual bases. The weight of the
delivered blower set is stated in its appropriate dimensional
drawing.
The blower set must be positioned horizontally by placing
plates under the machine bases. The permitted deviation is
1 mm for 1 metre.

WARNING

After being set in its position, the blower set must
be anchored to the floor. Otherwise, it could move
spontaneously and thus be damaged.

Working procedure for anchoring compact units and
acoustic enclosures.

1. Drill a hole and clean it;

2. Stick the anchor into the hole; and

3. Tighten the nut.

OD

L

OD1

Compact unit –
acoustic enclosure

Anchor OD [mm] OD1 [mm] L [mm]

WPB/WVB 120 – 430 Upat EXA M 8K 9 8 40
WPB/WVB 550 – 8300 Upat EXA 12/15 13 12 90
K 42 - K 202 Upat EXA M 8K 9 8 40
K 302 - K 802 Upat MC 12/70 13 12 65

The space and diameters of the base holes are stated in the
enclosed dimensional drawing of the compact unit. The
procedure for anchoring acoustic enclosures is the same.
You should, however, pay attention to the tightness of the
gap between the hood and the floor. After setting the hoods
in their positions, you must also level any floor unevenness
in order to prevent the sidewalls from being tight. In order
to seal the gap between the hood and the floor, you can
apply polyurethane foam, for example. The electric cable
must be laid in the floor.
If you intend to put a blower set in the hood on a half grid,
you must order a non-standard enclosure because the
bottoms of the acoustic enclosures are not soundproof.

Connecting the pipeline to the SHARK compact unit

3.4

EQUIREMENTS

R

FOR CONNECTING

THE PIPELINE

Since the entire aggregate is placed on rubber dampers, the
pipeline must be connected through flexible elements.
Otherwise, the running blower could shake the pipeline,
thus increasing the noise level. Standard compact units are
delivered with compensators for connection of the
discharge section. If a SHARK blower for vacuum is been
required or intended to be connected to the central suction,
a compensator for connection of suction is also supplied.
Delivered compensators and valves of larger blower sets
supplied with acoustic enclosures (from the K 302 type) are
not installed. These parts must be installed behind the
outlet flange of the discharge silencer or also in front of the
inlet flange of the suction silencer according to the
following pictures:

Overpressure WPB:

F

3

TOP

TOP

4

1

4

2

Overpressure WPB - central suction:

3

4

F

F Air flow

1. Non-return valve

2. O-ring

3. Compensator

4. Sealing

Rietschle Thomas GmbH + Co. KG page 5 / 23

Vacuum version WVB:

3

3

F Air flow

1. Non-return valve

2. O-ring

3. Compensator

4. Sealing

41 2 4

F

F

4

While overpressure blower sets contain discharge pressure
gauges, vacuum blower sets contain suction pressure
gauges. If either a non-standard blower set or a separate
blower is delivered, a pressure gauge must be installed on
the pipeline as near the discharge flange of an overpressure
blower set/blower or the suction flange of a vacuum blower
set/blower as possible.

Due to gas pulsation, it is necessary

to use pressure gauges resistant to cyclical fluctuations in
the pipeline pressure, for example glycerine-charge
pressure gauges. If you use an ordinary pressure gauge, an
absorber must be installed between the pipeline and the
pressure gauge. After setting the blower set in its position,
you must open the plugs of the glycerine-charge pressure
gauges in order to de-aerate them. Otherwise, they will
indicate incorrect values! If a blower set with a acoustic
enclosure is delivered, once it has been set up it is
necessary to interconnect the pressure gauges installed on
the enclosure and the measurement points on the blower set
with the supplied tubes.
For overpressure blower sets: the point on the blower’s
suction flange located below the suction filter must be
interconnected with the button connected to the pressure
gauge that is designed for measurement of filter insert
clogging. Further, the point on the discharge silencer must
be interconnected with the glycerine-charge pressure
gauge.

For vacuum blower sets: the point in front of the suction
filter must be interconnected with the pressure gauge
installed on the hood.

Connecting the Pipeline to the SHARK compact blower

You must ensure that the intake medium is free of
impurities.
Blowers could suck in outside air. Equipping the blower
with a suction filter produced by RT will suffice in order to
ensure purity of the intake air.
If a pipeline is to be used for transport of air to the suction
part, it is suitable to equip the blower with a RT suction
filter (used for vacuum blower sets) in order to connect the
pipeline. It is also necessary to install a compensator
between the suction filter and the pipeline.
If the intake air is filtered centrally for more blowers, you
must carefully clean the suction pipeline of foreign
particles. A compensator must be installed between the
blower and the suction pipeline. It is suitable to use a
suction sieve installed as near to the blower’s suction
flange as possible for the first 500 operating hours. Suitable
sieve densities can be derived from the following table,
which provides permissible sizes of impurities for
individual blower types:

It is not permissible to load the blower sockets with the
pipeline. Before being bolted together, the flanges of the
pipeline and the blower must fit closely. The maximum gap
in the gasket circumference can be 0.05 mm, as shown in
the picture.

3.5 INSTRUCTIONS

FOR CONNECTING

THE BLOWER SET TO

THE POWER SUPPLY

Blower WPB /

WVB

Permissible
impurity size [mm]

0,05

After the flanged connections have been tightened, the
blower must spin smoothly!

Rules for connecting the pipeline:

• The pipeline must be installed in the compensator axis.

• The pipeline must be placed on both fixed and sliding

points. It is not permissible to load the compensator with
the pipeline weight. The first fixed point of the pipeline
must be as near to the compensator as possible.

• The pipeline diameters should not be smaller than the
nominal inside diameters of the blower flanges.

• The recommended flow speed in the pipeline should be
below 22 m.s

-1

.

• If possible, large radii of pipe bends should be used (in
order to reduce loss).

• The closing fittings must be installed near the branches
in order to prevent impurities from accumulating in the
blind pipeline branches.

• Hot (discharge) pipelines should be insulated.

• The wall openings should be flexible and the pipeline in

them should be soundproofed (do not cement the
pipeline in the openings).

• Compensators should be installed on long and branched
pipelines.

• You should avoid the pipeline running perpendicularly
into the registers. You should check the lengths of those
registers where standing waves could occur for the
excitation frequencies of sextuple blower revolutions
(the frequency of the air pulsations).

When designing pneumatic transport, cement clarification,
and similar applications where contaminated transported air
(the volume between the non-return valve and the
technological device) could expand after the blower has
been turned off, you must consider such applications or
ensure that the pollutants are separated when the air is
flowing back (the mechanical non-return valves do not
close immediately). Contact RT in these cases.

Warning: Only authorized persons with appropriate
electrical qualifications are allowed to connect electrical
devices.

Blowers, compact units, acoustic enclosures and electric
motors are equipped with earth lugs. The protection of the
standard blower set is determined by the electric motor
protection (IP 55).
The wiring must meet the requirements for machinery in
accordance with the 98/37/ES Directive and primarily the
requirements stipulated in the EN 60204-1 Standard. Such
requirements must be ensured by the electric part supplier.
The standard deliveries of the RT blower sets contain only
the electric motor terminals. If the delivery also includes
the control system, only the power cable (if not included in
the delivery) must be installed and connected. More
detailed instructions are given in the separate manual for
the control unit.

The supply cable must not restrict the movement of the
motor and its pendulous frame!

Electric motors should be connected in accordance with

300
400

780

120

430
550
750

0.01 0.05 0.07 0.09 0.1 0.2

1000
1300

1600
2000

3000

4000
5000
6500
7000
8300

recommendations from their Manufacturers. The
connection diagram is attached to the inside of the cover of
the electric motor’s terminal block. We recommend starting

Rietschle Thomas GmbH + Co. KG page 6 / 23

3.6 BELT

INSTALLATION

the electric motors in the star-delta connection (soft-start,
etc.) even when the user could connect high-power electric
motors directly (in the delta connection). The “soft” start
saves the blower.

Electric motors with power of over 11 kW must
not be started directly (in the delta connection)
without approval from the blower’s
manufacturer.

The electric motors of the compact units with
acoustic enclosure must be connected so that they
cannot be turned on if the electric motor fans in
the acoustic enclosure are not running – the fans
must exhaust air from the enclosures. Appendices
9 and 10 show the connection diagrams.

Due to transport of blower sets, the delivered belts are not
installed and the pendulous frame with the motor is secured
by bolts in the bottom position. Belts can be put on only
when the blower set has been set in its position. You must
first remove the bolts securing the pendulous motor frame
in the transport position. In order to lift the frame, you must
use a jack with the appropriate lifting capacity. An arrow
shows the point to place the jack. For smaller blower sets
(up to the size 2000), it is sufficient to use a screw jack
with a lifting capacity of 700 kg (the type used for lifting
private cars). For larger blower sets [from the size 3300
with motors from the 280 type (axial height in
millimetres)], you must use a jack with a lifting capacity of
2,000 kg, preferably a hydraulic one. The jack must be
placed on a solid base. If the jack is placed on a smooth
surface, such as a pavement or painted surface, you must
secure it with a rubber pad, for example, in order to prevent
it from slipping. Before starting any operation, you must
prevent the lifted pendulous motor frame from falling by
using suitable supports.

On the inside of the frame sidewall below the pendulous
motor frame, you must then install a stop checking the
lower limit of the pendulous motor frame misalignment.
Before putting on the belts, you must screw the stop bolt
into its bottom position.

When putting on the belts, be very careful you do
not injure yourself by a suddenly falling
pendulous motor frame that might come loose.
You must hold the belt only at the place that will
not be in contact with the pulley when the
pendulous motor frame has been lowered. It is
also forbidden to touch the blower set at the
places between the edges of the sub frame and the
pendulous motor frame, where a cutting effect
will occur when the pendulous motor frame is
moving.

WARNING

WARNING

P

RECAUTIONARY

MEASURES

3.8 MACHINE HALL

VENTILATION

Before putting on the belts, you must remove the supports
securing the pendulous motor frame in the lifted position.
When gradually lowering the pendulous motor frame, you
must ensure that the belts remain in the pulley grooves.
Since the pendulous motor frame is secured in its working
position only by tightened belts, you must therefore prevent
it from sudden loosening (with a jack, for example) before
adjusting the stop. The stop bolt must be adjusted to a
sufficient height so that the pendulous motor frame does
not hit it when the motor is starting. When new belts are
being installed, it is better to leave a larger gap between the
stop bolt and the pendulous motor frame as the frame will
lower after the belts have been set in their positions.

3.7

• The machine owner is obligated to observe the
provisions of this manual.

• The machine owner is obligated to maintain the
minimum spaces stipulated in this manual.

• The machine owner is obligated to see to good
readability of safety labels and markings.

• The machine owner is obligated to provide operators
with the protective equipment stipulated in this manual.

Machine hall ventilation

The machine hall is warmed by the heat radiated from the
motors, blowers, discharge silencer and discharge pipeline.
In order to reduce the machine hall temperature, the heat
must be suitably dissipated (machine hall ventilation). If
the output temperature is high, it is necessary to insulate the
outlet pipeline. In most cases when blower sets suck air
directly from the machine hall, you must ensure forced
ventilation of the machine hall.

It is not permissible to direct flow of cool air
towards any part of the blower casing. Local
cooling causes thermal deformation – the blower
could thus be damaged.

Appendix 8 shows the ventilation diagram. When
designing the machine hall, you must remember sufficient
openings for both cooling air intake and warmed air
exhaust. It is assumed that the fans will be located in the
exhaust section. Cooling air intake for the blower suction
from the machine hall must be designed so that sufficient
volumes of both cooling air and air sucked by the blower
set are ensured. If the intake air is transported from outside
by a pipeline, it will suffice to dimension the inlet opening
only for the cooling air volume and fit the exhaust section
with fans of the required capacity. The air speed in the
openings should range between 5 m.s
suction and exhaust openings must be designed so that no
noise will escape from the machine hall.

WARNING

-1

and 10 m.s-1. The

Rietschle Thomas GmbH + Co. KG page 7 / 23