(Original Instructions) - GD TransportOriginal Instructions) 4990140009 September 2013 4990140009 Date:11/11 XK1 Installation, Operating & Maintenance Manual Page 1 Health & Safety

XK SERIES SCREWCOMPRESSOR

ModelsXK12XK12HD

Installation, Operating &MaintenanceManual(Original Instructions)

4990140009September 2013

Page �4990140009 Date:11/11 XK1� Installation, Operating & Maintenance Manual

1 Health & Safety Health&SafetyIssues....................................3

2 General 2.1 Productgeneraldescription...........................42.2 Driveoptions..................................................4 2.3 Availablepackages.........................................52.4 Dimensions,performancedata, andoperatingenvironment...........................6

3 Installation3.1 Generalmountingconsiderations.................73.2 Lifting..............................................................73.3 Mounting.........................................................83.4 Lubrication......................................................93.5 PTOandprop.shaftdrivealignment...........103.6 Pipework......................................................123.7 Commissioningfilter....................................12 3.8 Ancillaries......................................................13 3.9 Package1layout/parts.................................14 3.10 Package2layout/parts.................................15

4 Operating and Commissioning4.1 Pre-commissioningchecklist......................164.2 Inletcommissioningfilter.............................164.3 Monitoringprobes........................................164.4 Commissioningprocedure...........................174.5 DriverOperatingInstructions.......................194.6 DriverTraining..............................................20 CommissioningTestsheet...........................21

5 Maintenance5.1 Schedule.......................................................225.2 ChangeGearCaseOil..................................225.3 Valves............................................................235.4 Silencers/Pipework.......................................23 5.5 AirInletFilter-cyclonic................................245.6 AlternativeOils.............................................24 ServiceMaintenancesheet..........................25

Package 5Seeappendix1(suppliedwiththispackage)

Contents

Chapter Page


Health & Safety1 READTHEWHOLEMANUALBEFORECOMMENCINGINSTALLATION.

Staticelectricity.Ensure,thatwhererequired,thecompressorandancillariesareearthedinaccordancewithBS5958Part11983;‘ControlofUndesirableStaticElectricity’.

Powder-aircombinationsarepotentiallyexplosive.

Driveline.Itistheresponsibilityoftheinstalleroftheequipmenttoensureallrotatingandmovingpartsoftheinstallationareadequatelyguardedtoastandardwhichcomplieswiththeprevailingsafetylegislation.

Compressor.Thecompressorhasinternalmovingpartssomeofwhichmaybeaccessedthroughtheinletandoutletapertures.Donotplaceanyobjectsespeciallyfingersintotheseaperturessincepersonalinjurycouldresult.

Installation.Areliefvalvemustbefittedintheoutletpipeworkasclosetothecompressoraspossible.Thevalvemustbepositionedsoasnottoventairontoanypersonnelsincetheairdischargedwillbehotandcancausesevereburns.

Storage/LowuseBeforethemachineisinstalledorwhenitwillnotbeusedforlongperiods:•Storeinadry,heatedbuilding.•Handlewithcareandkeepthesuctionanddeliveryportscovered.•Rotatethedriveshafteachweek,inthedirectionshownbythearrowonthethecover.Wherethecompressorismountedonavehicleandlocatedoutside,itshouldbeoperatedforatleast15minuteseachweek(twiceaweekIndamp/coolconditions)

Fire.Thecompressorincludessealsmadeoffluoroelastomerpolymerswhichdegradeifexposedtotemperaturesabove300°C.Ifthematerialhasbeensoexposedthenitmustnotbehandledwithbarehands.

ReliefValveCheckThisprocedureshouldbecarriedouteverymonthtoclearthevalveseatandcheckthevalveisfunctional.(Earprotectionisrecommended)

NoiseGardnerDenverDrumLtd’sowntestsshowmaximumnoiselevelsfortheXK12shouldtypicallynotexceed94dB(A)intheworstcase(1600rpm2.5barg).

Page 44990140009 Date:11/11 XK1� Installation, Operating & Maintenance Manual

2General

2.1 Product general description

TheXK12isarobust,mediumflow,oilfree,contactless,lowmaintenancescrewcompressordesignedforthecontaminantfreedischargeofdensebulkpowderproducts(e.g.cement,flourandlime),usuallyat1.5-2.5bargpressurein3”pipework.

Themachineisgenerallycomprisedofsynchronisedscrewrotors,combinedmainbody/stepupgearcaseassemblyandinletbearingcarrier.

Thecompactshapeandsizeofthecompressormakeitidealformountinginsidethechassisonmostvehiclestoenablelowcostprop.shaftdriving.

AthroughshaftallowsCWorACWinputdriverotationwithmountingpointsoneithersideofthemachinetoprovidefurtherflexibility.

Thestandardcompressorpackageconsistsofthefollowingequipment:

•BasicXK12machineandmountingkit.

•Inletfilter/kit

•Commissioningfilter

•Reliefvalve

•Checkvalveandflangepack.

•Discharge(outlet)silencer-absorptiveorreactive

•Torquelimitingcoupling

2.2 Drive options

TheXK12canbedrivenusingthefollowingdrivesystems.

Prop. shaft drive Direct from a vehicle PTO

Hydraulic drive Severaldrivescanbeoffereddependingonthe application

Electric motor Packagesonbaseframes

Engine drive Packagesonbaseframes

TheshapeandsizeofthecompressormakeitparticularlysuitableforPTO/prop.shaftdrivinginsidethevehiclechassisonmostapplications.

NOTE


Figure1. Standard Packages (1, 2 & 5)

General

2.3 Available packages -seefig1

Thefollowingpackagesareavailableasstandard:

Package 1-LooseancillarieswithabsorptivedischargesilencerStandardancillariessuppliedasseparateitemsincludingtheabsorptivetypedischargesilencerandcyclonicinletfilter/kit

Package 2-LooseancillarieswithreactivedischargesilencerStandardancillariessuppliedasseparateitemsincludingthe reactivetypedischargesilencerandcyclonicinletfilter/kit

Fully assembled package (5) Seeappendix1foradditionalinformationonpackage5

XK12PACKAGE1Absorptive,SeparateAncillaries

XK12PACKAGE2Reactive,SeparateAncillaries

XK12PACKAGE5XK12andAirCoolerPack


2.4 Dimensions, Performance data & Operating EnvironmentDimensionsThedimensionsofthebasicXK12areshowninfigure2below.

Performance Theperformancedetailsandpowerrequirementsofthecompressorareshownontheproductdatasheet.

Foradditionalinformation,theconstantrunningtorquedoesnotexceed:

270NmonthestandardXK12 Speedrange1000-1600rpm149NmonthehighspeedXK12 Speedrange1810-2896rpm

Operating environmentThepermissible/foreseenoperatingenvironmentisasfollows:

Ambienttemperaturerange -40to+50°C

Resistanttotropicalrain(inoperationandtransit),saltandsun

Humiditylevel Upto100%RHcondensing

Vibrationlevel 0to40Hz;±40mmamplitudetested.

Inletdepression Nottoexceed100mbar

Orientation Seefig4page8

Max.outlettemperature 230°C

Figure 2. Dimensions - basic machine

General

Propshaftdrivestart-upconditionscouldbesevere.ADrumtorquelimitingcouplingisrecommendedtoprotectthecompressoranddrivesystem.

CAUTION

DETAIL A

DETAIL BH ( 1 : 2 )F-F ( 1 : 2 )

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

A A

B B

C C

D D

E E

F F

G G

H H

Designed by

KRobbinsMaterial Date

Edition Sheet

/

Scale

GA XK12 COMPRESSOR300X340A

gcolley 03/08/2006

5 1 1

Gardner Denver Drum LtdPO BOX 178, SPRINGMILL ST. BRADFORDWEST YORKSHIRE, BD5 7YHTEL: +44 (0) 1274 718100FAX: +44 (0) 1274 718101

1:2 A1Checked by

FIRST ANGLEPROJECTION

IF IN DOUBT ASK DO NOT SCALE

A

B

H

FF

111

7,5

83

3654

230

190

180

296

296

250

395

326

289

QTY 2. 1/4" BSP

MAGNETIC DRAINPLUG 3/4" BSP

EACH SIDE:FILLER LEVELPLUG - 3/8" BSP

EACH SIDE: 3 MOUNTINGBOSSES Ø38 TAPPEDM16X28 DEEP

AIR DELIVERY FLANGE(DUPLICATED ONOPPOSITE SIDE)

55

55

100

103

123

OVER MOUNTING BOSSES AT GEARBOX END



GROMMET:LIFT EYE BOSSTAPPED M12X22 DEEP

4 HOLES M10 X 23 DEEPEQUI-SPACED AS SHOWNON PCD 105

DELIVERY FLANGE DETAILS

SHAFT END DETAILSAPPLICABLE AT BOTH ENDS

SECTION THROUGHSHAFT END

242

605

107

255

192

105

52

All Printed Versions Of This Drawing AreCLASSIFIED UNCONTROLLED.Issue Status Should Be Confirmed By ReferenceTo The Electronic Master Drawing.

Rev Details Date Revised Checked1 First Issue 04/08/2006 GDC WNE2 XK12/18_EC054 PICTORIAL UPDATE 13/04/2010 WNE KR3 XK12/18_EC062 PICTORIAL UPDATE 18/11/2010 WNE KR4 XK_EC082, SHAFT GUARD WAS ON INLET END 6/9/11 KR WNE5 SHAFT TAPER DIMENSIONS CORRECTED 08/11/2011 DJC KR

ON INSTALLATION: REMOVE THIS SCREW (OR EQUIVALENTON OPPOSITE SIDE OF M/C) AND DISCARD, TO PERMIT38 MOUNTING SPACER TO LOCATE CORRECTLY

38

MOUNTING SPACER

M16 HOLE

REMOVABLE CAP FOR ACCESSTO ANTI CLOCKWISE DRIVE SHAFT,CAP CAN BE USED TO COVERCLOCKWISE DRIVE SHAFT.

306

219

2°51

' 45"

50

10N

9( - 0

,036

0,00

0+

)

90°

12M9

36

40h7

( - 0,0

250,

000

+)

54

13,6

5

30

Highspeedmachineisdimensionallyidenticaltothestandardmachine.

NOTE


3Installation

3.1 General

Whenselectingthemachinemountingposition,thefollowingpointsshouldbeconsidered:

•Accesstooilfill/levelanddrainplugs

•Adequateclearancetoallowthecoolingairtocirculatearoundthe machine

• Installawayfromsourcesofheat,e.g.vehicleexhaustairorhotpipesthat couldeffectthecompressortemperatureinanyway.

•Ventingrelief/controlvalveairmustbeunobstructedanddirecttothe atmosphere.

•Fitthereliefand/orprotectionvalvecontrolvalvesascloseaspossibleto theXK12dischargeport.

•Ventingvalvesmustbepositionedsothathotaircannotventontothe operatororthecompressor

•Silencersshouldbefittedascloseaspossibletothedischargeport.

Fortherecommendedlayoutofthemachineandancillaries,seefigure1.

3.2 Lifting-seefig.3

Theweightofthebasiccompressorwithoutancillariesis120kg.

Themountingfacetowhichthebasicmachineisfittedshouldbeflattoavoiddistortion/stressandmountingbolts/lockingnutsshouldbeM16,grade8.8orhigher.

Thebasiccompressorissuppliedwithaneyeboltattachedforlifting.Whenthemachinehasbeeninstalled,theeyeboltshouldberemovedandreplacedbytheblankinggrommet(supplied)fittedtothecover.

Anyequipmentusedforliftingshouldberatedaccordingly.

Figure 3. Lifting

Donotliftusingotherpartsofthemachine.

CAUTION


3.3 Mounting

TheXK12shouldbeinstalledverticallyutilisingallthreemountingfeetononesideofthemachineandcanbedriveninbothrotationsbyusingeitherendoftheinputshaft.

Additionally,themachinehasdischargeflangesonbothsides.

Theinputdriverotationandairpathpossibilitiesareshownbelow.

Installation

Figure 4. Mounting & Drive options

Anincorrectdriverotationwilldamagethecompressor.

CAUTION

Outlet

AlternativeOutlet

Inlet

ThebasicXK12compressorshouldbeinstalled/mounted(usingtheM16fittingssuppliedinthemachinemountingkit)asshowninfig.5.

AllM16Grade8.8mountingnuts/boltsshouldbeappliedatatorquesettingof225Nm.

Loctite270shouldalsobeappliedtosecuretheM16mountingstudsintotheXK12feet.

NOTE

Thecompressorhasthreemountingfeetoneachsideofthemachineandshouldbemountedusingall3feetononesideonly.

NOTE


Installation

12

34

5

6

Figure 6. Oil Lubrication Components

3.4 Lubrication

TheXK12issuppliedcompletewithoil.

Whenthecompressorhasbeenmounted,theoillevelshouldbere-checkedasshowninfigure6andtopped-upwithoilthrough,andupto,thefill/levelplughole(approximately1.5litrestotalifnecessary).

12

3

45

Key

1 - FillPlugwasher 2 -Fill/LevelPlug 5 - MagneticDrainPlug

3 - PlugCap 4 -DrainPlugwasher

Figure 5. Mounting Details - separate ancillary packages

Alternativemountingchannelsmaybeneccesaryduetoothervehicleancillaries(e.g.fueltank).Theseshouldprovidecomparativestrengthtotheconfigurationshown.

NOTE No. Description

1. M16stud(short)2. ShortSpacer3. M16Stud(long),Grade84. LongSpacer5. Mountingchannels6. M16FlangedSelflockingnut,Grade8

Taperwashersshouldbeusedifmountingchannelswithtaperedflangesaretobeused.

NOTE

NOTE


Parts ListItem Qty Description

1 1 Friction Coupling, DIN (Red Flange)2 1 Ring Adaptor, DIN3 1 Washer4 1 Key, Parallel Rectangular Round End 10 x 8 x 50 Long5 1 Socket Head Cap Screw M12 x 40 Long

Figure 7b. DIN Friction Coupling

Installation

3.5 PTO and prop. shaft drive alignment

Shaft coverThecompressorcanbedrivenfromeitherendoftheinputshaft(seesection3.3forfurtherdetailsoftheorienationspossible).

Theclockwiseendofthecompressorinputshaftisprotectedwithashaftcover.Ifthisshaftisrequired,removethecoverandrefititovertheunusedshaftattheoppositeendofthemachine.

Drive couplingsSeethe‘Ancillaries’(section3.8-torquecoupling)forrecomendationsoncouplingsforPTOdrives.

Beforefitting,thetapersonthemachineshaftanddrivecouplingshouldbecleananddamagefreetohelpensuretheflangefitscorrectly.Bothtapersshouldbesmearedwithalightoiltoaidfutureseparation.

ThecompanionflangeshouldbefittedtothecompressorshaftinlinewithFigure7b,fortheDINtypecouplingandFigure7cfortheSAEtypecoupling.

Thecapscrewandwasherwhichisusedtoretainthecouplingtotheshaft,shouldbetightenedtoatorqueof88Nm.

Flange/couplingremovalshouldonlybeundertakenwiththeaidofapullertypedeviceandscrewintheshaftend,asshowninFigure7a,toavoiddamagingtheflangeorshaftend.

Figure 7a. Drive Flange Removal

CapScrew(Item5)shouldbetightenedtoatorqueof88Nm.

NOTE


3.5 PTO and prop. shaft drive alignment(cont.)

Drive Couplings (cont.)

Installation

Figure 7c. SAE Friction Coupling

Parts ListItem Qty Description

1 1 Friction Coupling, SAE (Blue Flange)2 1 Ring Adaptor, SAE3 1 Washer4 1 Key, Parallel Rectangular Round End 10 x 8 x 50 Long5 1 Socket Head Cap Screw M12 x 40 Long

Figure 8. Drive Alignment

Thecombinedangleinanyplaneshouldnotexceed12°

NOTE

CapScrew(Item5)shouldbetightenedtoatorqueof88Nm.

NOTE

Page 1�4990140009 Date:11/11 XK1� Installation, Operating & Maintenance Manual

Installation

3.5 PTO and prop. shaft drive alignment(cont.)

Alignment - See Figure 8

TheaxisonmajorityofPTO’sismountedatapproximately2°-5°tothehorizontal,whichreflectstheangleoftheengineandgearbox.

ThecompressorshouldbemountedsothatitsdriveaxisisparalleltothePTO’sdriveaxis.

Thecompressorshouldalsobemountedsothattheprop.shaftanglebetweenthePTOandXK12in any planeislessthanorequalto12°.

Considerationshouldbegiventotheprop.shaftlengthwhenmountingthemachine.

Theprop.shaftshouldbesizedsothatitalwayshasslidingclearance.

ItisrecommendedthatatorquelimitingdeviceshouldbeinstalledbetweenthecompressorandPTOdriveflangestoprotectthedrivelineagainstalleventualities.Torquelimitingcouplingsaresuppliedasstandard.

3.6 Pipe Work

Figures10aand10bshowabreakdownofpackages1and2.

Flexiblepipeisprovidedintheinletinductionkitwithbothpackages.

Whereanypipeworkistobefabricatedusingslip-on-weldflanges,suchasontheinletinFig9,thefollowingpointsshouldbefollowedtopreventdamagetothemachineandcontaminationofthedischargedproduct.

•Allinletpipeworkmustbestainlesssteelorthickwallaluminiumtohelppreventcorrodedparticlesenteringthemachineandreducenoiseemissions.

•Outletpipeworkcanfabricatedfromanymaterial(includingmildsteel)tosuittheapplication.

•Allfabricatedpipework,shouldbede-scaled/cleanedbefore commissioningthecompressor.

•Pipeworkshouldbeattachedtothevehiclechassisusingflexiblemountingstopreventunnecessaryvibrationandnoisetransfer.

•Aflexibleelementisrecommendedinthedischargepipework(andinletpipeworkwhennecessary)topreventdistortionoftheXK12fromthefabricatedpipeworkthroughchassismovementandheatexpansion.

3.7 Commissioning Filter

Thecompressorissuppliedwithacommissioningfilterfittedtotheinletporttopreventdebrisenteringthemachineduringtheinstallationandinitialcommissioningprocesses.

Alsocheckthepropshaftmanufacturersinformation.

NOTE

Aftertheinitial15minutecommissioningrun(at1000rpm,1810rpmhighspeed),thefiltermustbereplacedwiththestandardinletflangegasket.

Prolongedorhigherspeedoperationwiththefilterfittedwillresultinmachinefailure.

Tightenitem1fig.9toatorqueof50Nm.Seeabove.

NOTE

Figure 9. Inlet Flange

Thecompoundprop.shaftanglemustalsobelessthan12°.

NOTE

CAUTION


Installation

3.8 Ancillaries (relating to figures 10a - 10b)

Inlet Air Filter and Flexible Induction KitShouldbelocatedsothattheinletairiscoolandclean.Donotmountclosetoexhaustsorotherwarmairsources.

Relief ValveThereliefvalveisinstalledtopreventtheXK12fromencounteringpressuresbeyonditsoperatingrange.

Thereliefvalveshouldbeinstalledascloseaspossibletothedischargeportofthemachinepriortoanyotherdischargeancillaryandshouldbemountedvertically(asshowninfig10).

Itispre-set,wiredandleaded(tamperproof)andfittedtoprotecttheXK12(ratherthanthesystemwhichshouldbeprotectedbythevehicletankreliefvalve)againstpressuresofover2.5barg.AdjustmentofthemachinereliefvalvewillinvalidatetheXK12andreliefvalvewarranty.

Discharge SilencerShouldbemounted/connectedascloseaspossibletothedischargeport(afterthereliefvalve)utilisingtheslip-on-weldflangessupplied.

Silencersshouldbemounted/supportedseparatelytopreventthegenerationofloadsonthemachineanddischargeportduetoweightortemperatureexpansion.Flexibilityinthemountingorconnectingpipeworktothesilencershouldbeincorporatedwherethiscouldoccur.

Check (non-return) valveThisistopreventaback-flowofairandproduct(oftenencounteredwhenstoppingcompressorswhilstthedischargetankisstillpressurised)fromenteringanddamagingtheXK12.

Thecheckvalveshouldbethelastancillaryonthedischargepipework(butbeforeanyregulardisconnectionpoint)toprotectalltheotherancillaries.Itisoftenmounteddirectlytothedeliveryportofthedischargesilencer.

Ifthecheckvalvehastobemountedhorizontallyonthesilencerorseparately,thecheckvalvehingeshouldbepositionedatthetopinhorizontalpipeworktoencourageclosureundergravity.Ifmountedvertically,thepositionofthecheckvalvehingeisnotimportant.

Torque CouplingWerecommendandsupplyatorque-limitingdeviceforfittingtothecompressorwhendirectPTOdriving.

Thisistoprotectallthedrive-lineequipmentagainstthepossibilityofhightorqueduringoperationforanycircumstances.

Expansion JointsAnypipeworkorequipmentshouldincorporateflexibleelementswhere:

•Movementduetothermalexpansionislikely

•Pipeworkcrossesthevehiclechassis.

Ball ValveA1“-1.5”manualballvalvemustbefittedonthedischargesideofthemachinebetweenthecompressordischargeportandthecheckvalve.

Thisallowsthecompressordischargeairtoventtoatmospheretopreventthemachinebeingstartedagainstapressurisedtank.

Comissioning Filter Seesection3.7

Fig 10. Relief valve orientation


Installation

Figure 10a Absorptive, separate ancillaries.

OP

TIO

NB

OP

TIO

NA

Installation

3.9 Package 1 - Separate ancillaries with absorptive discharge silencer

Compressorsshouldneverbestartedagainstpressurised

dischargelinesortanks.

CAUTION

**-Indicateslocallysupplieditem.

*-Indicatescustomersuppliedpipework.

Ref. No. Description

1 XK-12BasicM/C(orhighspeedunit)2 10”CyclonicInletFilter3 3.75”HoseClip4 HoseAdaptor(Cuff)-Nitrile5 Ducting-2mx89mmBore6 InletFlange-XK-127 Inletgasket8 CommissioningFilterXK-12/XK-189Gasket-OutletPort10 OutletBlankingFlange


11 OutletFlange(S0W)-77mmBore12 Reliefvalve-1.25”,2.5barg13 FlangeTW1(S0W)-80mmBore14 Gasket,90mmNB,TWI15 2”AbsorptiveDischargeSilencer16 CheckValveKit(3”BSPOutlet)17 ShearCoupling(K1310/DIN100)18 FrictionCoupling(K1310/DIN100)19 StorzCoupling-3”BSP


Installation

Figure 10b Reactive, separate ancillaries.

118

109

76

3

4

5

4

3

2

1211

9

1314

8

17

17

15

16

**

3.10 Package 2 - Separate ancillaries with reactive discharge silencer

Compressorsshouldneverbestartedagainstpressurised

dischargelinesortanks.

CAUTION


1 XK-12BasicM/C-(orhighspeedunit)2 10”CyclonicInletFilter3 3.75”HoseClip4 HoseAdaptor(Cuff)-Nitrile5 Ducting-2mx89mmBore6 InletFlange-XK-127 Inletgasket8 CommissioningFilterXK-12/XK-189 Gasket-OutletPort10 OutletBlankingFlange

Ref.No. Description

11 OutletFlange(S0W)-70mmBore12 Reliefvalve-1.25”,2.5barg13 FlangeTW1(S0W)-80/90mmBore14 Gasket,90mmNB,TWI15 ManifoldGasket16 ‘Drum’ReactiveSilencerAssembly17 CheckValveKit(3”BSPOutlet)18 FrictionCoupling(K1310/DIN100)19 ShearCoupling(K1310/DIN100)20 StorzCoupling-3”BSP

**-Indicateslocallysupplieditem.

*-Indicatescustomersuppliedpipework.


4 Commissioning

4.1 Pre-commissioning check list.

Figure 11. Commissioning Tappings

4.2 Inlet commissioning filter.

ShouldhavebeeninplacethroughouttheinstallationoftheXK12anditspipework.

Thefiltershouldberemovedduringcommissioningafter15minutesoperationat1000rpm(or1810rpmforhighspeedmachine).

4.3 Monitoring probes.

Two1/4”BSPblankingplugsarefittedineachoftheinletportflangeandunusedoutletportblankingflange.

Theseshouldberemovedandreplacedwithatemperatureprobeandapressureprobeforcommissioningonly.(seeFig.11)

IfGardnerDenverDrumsuppliedflangesarenotused,theinstallermustprovide2x1/4”BSPtappingsadjacenttotheinletandoutletportsforthecommissioningtestprobes.

Failuretoremovethecomissioningfilterduringcommissioningmayleadtofailureofthecompressor.

CAUTION

Lubricationplugsfitted.

Gearboxfilledwithoil.

Pipeboresetccleanedafterfabrication.

Commissioningfilterinposition.

Allflanges,fastenersandmountingssecure.

VehiclePTOdisengaged.

Enginemanagementsystemset-upcorrectlyfortheapplication.

Commissioningtemperatureandpressureprobesfitted(seefig.12)

Blow(ball)valveopen(ifstartingagainstatankpressure).

Commissioning2.5”-3”gatevalveandsilencerfitted.

Ancillariescorrectlyfittedandsequenced.

Tickwhencompleted


4.4 Commissioning ProcedureAllproceduresandtemperaturereadingsshouldbetakenviathe4probesfittedintheXK12inletandoutletflanges.

Commissioning

Watchoutforhot-pipesandmakesureyoureplace/re-tightenanyfastenings.

NOTE

Iftheoutlettemperatureexceeds230°Corthedifferencebetweeninlettemperatureandoutlettemperatureexceeds200°C,whicheveroccursfirststopthetestimmediatelyandcontacttheGardnerDenverDrumRepresentative.

Max. Inlet Depression 100mbarunderallcircumstances.70mbarwiththecommissioningfilterremoved.

Max. Discharge Pressure2.5barg

CAUTION

Oncompletionoftheinstallationanddrivertraining,completethecommissioningchart,sign,dateandretainforfuturereference.

Wealsorecommendphotographingtheinstallationandretainingwiththecommissioningchart.

1 Checkthatthedischargegatevalveonthepipeworkis open.

2 Starttheengine,depresstheclutchandallowthevehicle gearboxpartstostoprotating(5secondsshouldbesufficient). EngagethePTOandslowlyraisetheclutch,thensettheengine speedtogiveaPTOoutputof1000rpm.

3 Whilstthecompressorisoperating,checkthepipeworkfor leaksandgentlyagitatetheinlettoreleaseanydebristhatmay bepresent.

4 After15minutes,depresstheclutch,andengagethePTO.

5 Checktheoil/filllevelanddrainplugsforleaks,andreplacethe commissioningfilterwiththeinletgasketsuppliedbeingcareful toremoveanydebristhatcouldfallintothepipebore.

6 Repeatpoint2aboveandsetthespeedto1600rpmorthe future/workingoperatingspeed.

7 Recordtheinletdepressionandcheckforinductionleaks.A maximumof70mbarispermittedonanewmachine,ifitis greaterthanthis,checktheinletpipesandfilterforpotential blockagesandthatthecomissioningfilterhasbeenremoved.

8 Raisethedischargepressuretojustbelow2.5bargbyadjusting thegatevalvesetting.Checkforsystemleaks.Ifalliswell,run thecompressorfor45minutesrecordingtemperatures andpressuresat10minuteintervals.Measuretheinletand outletpressureandtemperatureaswellastheambient temperature.Re-checkforoilleaks

9 Increasethepressurebeyondthistooperatethereliefvalve.

10 Thereliefvalveshouldcrack(begintoopen/blowoff)ata pressurenotexceeding2.5bargandthenfullyopen(full bypass)atnomorethan2.5barg.

11 Slowlyreducethepressureuntilthereliefvalvere-seats(should bebefore2.2barg)andrecordthisvalueonthe commissioningtestsheet.

12 Makesurethatallflangesareleakfreeandthatfastenings/ mountingsarestilltight.

13 DisengagethePTO,returntheenginespeedtotickoverand thenstoptheengine.

14 Removethecommissioningprobesandplugofftheholesagain.

Tickwhencompleted


7

Commissioning

Figure 12. Commissioning Tests

No. Description1 PressureManometer 2 TemperatureGauge 3 PressureTapping(Inletdepression)4 TemperatureTapping(Inlet)5 CommissioningFilter6 PressureGauge7 PressureTapping(Discharge)8 TemperatureTapping(Discharge)


4.5 Driver Operating Instructions

Theinputspeedshouldbebetween1000and1600rpm(1810and2896rpmforhighspeedmachine)andthemaximumpressureshouldnotexceed2.5bargauge.

Wheretheoperatorwillbesubjectedtoprolongedexposuretonoise,itisrecommendedthatearprotectionisprovided.

Topreventhighshafttorqueandmaterialblow-back,theXK12shouldneverbestarteddirectlyagainstapressurisedtank.Mid-deliveryre-startingshouldonlybeundertakendirecttoatmospherebyfittingavalvefromdischargeline(priortothecheckvalve).Whenthecompressorreachesoperatingspeed,thelinecanbeslowlyclosedagaintorestartdelivery.

Starting the compressor

•CheckthatthePTOisdisengagedandthenstarttheengine.

•Settheenginespeedtotickover.

•Depresstheclutchandallowaminimumof5secondsforthegearstostoprotating.

•EngagethePTO.

•SLOWLYreleasetheclutch.

•CheckthattheXK12isproducingair.

•Settheenginespeedtogiveacompressoroperatingspeed between1000rpmand1600rpmasrequired,(1810and2896rpmforhighspeedmachine).

Stopping the compressor

•Returntheenginespeedtotickover

•DisengagethePTO.

•Stoptheengine.

Commissioning

Toavoidriskofburns,donottouchpipeworkorstandclosetoventablevalvesduringdischarge.Ifthereisarisk,suitablyresistantgloves/clothingmustbeused.

CAUTION


4.6 XK12 Driver training

Drivertrainingshouldbegivenwheneverpossibleandshouldinclude:-

SafetyInstructthedriverregarding:

•Rotatingparts

•HotPipework

•Safetyvalve

•Safetycoupling

OperationInstructthedriverregarding:

•Speedrange

•Maximumoperatingpressure

•PTOengagement

•Unloadingvalve

Routine MaintenanceInstructthedriverregarding:

•Gearboxoil-topping-upandreplacement

•Airfilter-cleaning/replacing

•Pipeconnections-checking

•Reliefvalvefunction

Commissioning


CommissioningS

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Page ��4990140009 Date:11/11 XK1� Installation, Operating & Maintenance Manual

Maintenance

5.1 Schedule5

5.2 Changingthegearcaseoil-seefig6

1.Removethemagneticdrainplugandsealingwasher(canalsoremove thefill/levelplugforfasterdrainage).

2.Allowtheoiltodrainintoacanforenvironmentaldisposal.

3.Cleanandthenrefitdrainplugandre-fillthegearcasewith approximately1.5litresoiluntiltheoilreachesthefilllevellevelhole.

Thereliefvalveshouldbeoperatedevery3monthstoclearthevalveseatandcheckthatthevalveisfunctional.

(Earprotectionisrecommended)

NOTE

IftheXK12unitcannotbecompletelydrainedofoilwithouttiltingtheunit,itwillbesufficienttodrainasmuchaspossible(1.3l/min+shouldbeatleastpossible).

NOTE

500hoursisthemaximumoilchangeinterval.

NOTE

Drivesystemsmustbemaintainedinaccordancewiththemanufacturersinstructions.

Daily •CheckAirFilterblockageindicatorandcleanorreplace filterelementifrequired.

40 - 60 hours from new

•Changethegearcaseoil;seesection5.2

Weekly Wherethecompressorismountedonavehicleandlocated outside,itshouldbeoperatedforatleast15minuteseach week(twiceaweekIndamp/coolconditions).

Monthly •Checkgearboxoillevel

•CheckfunctionofReliefValve

•Removeairfilterandcleaninsidethecasing.

•Checksecurityofcompressorandpipemountings.

500 hours run time or every 12 months(whicheverissooner)

•Changethegearcaseoil;seesection5.2 •Drainplug-cleanmagnetic(plugSeeFig.6)

Annually •Examinetheinternalsofthecheckvalve

•Examinepipesandsilencersforcorrosionandreplaceas required

•ReplaceAirFilterelement

•CheckReliefValvefunction,settingandvisually.


5.3 Valves

Check ValveThecheck(non-return)valveshouldberemoved,visuallycheckedforsignsofwear.Ifinanydoubt,replacetheentirevalve.

Relief ValveThescrewedtopofthereliefvalve(liftingscrew)canbeusedtocheck/clearthereliefvalveduringoperation.Thisremovesthenecessityforusingseperateancillaries/valvesinthedischargelinemakingcheckingmucheasierandfaster.Withthecompressoroperatingatgreaterthan85%ofitspressuresetting:-

Setting 85%

2bar(g) >1.7bar(g)

2.2bar(g) >1.87bar(g)

2.5bar(g) >2.25bar(g)

Operation / Function Test

1. RotatetheliftingscrewACWuntilaclear,audible,airdischargeis produced.

2. RotatetheliftingscrewCWuntilitreachesthelimitstop.

Thevalveisnowcheckedandreadyforoperation.

Newgasketsmayberequiredwheninspectingthecheckvalve.

NOTE

5.4 Silencers / PipeworkThesilencersandpipeworkshouldbeinspectedforsignsofdamageorcorrosion.Whenpaintworkisdamaged,cleanoffanycorrosionandtreatwithrustinhibitorbeforerepainting.Usepaintsthatcanwithstandtemperaturesof180°C.

LiftingScrew

Maintenance


Figure 14a. Replacing Air Filter

No. Description

1. EndCover2. FilterElement3. Raincap4. FilterBlockageIndicator5. VacuatorValve

Maintenance

5.5 Air Inlet Filter - Cyclonic

Theblockageindicatorisdesignedtoshow/holdthemaximuminletblockageencountered.Itissettoshow100%blockagewhentheinletdepressionreaches37mbar.Thefilterelementshouldbereplaced/cleanedbeforetheindicatorenterstheredportionoftheblockagescale.

Iftheindicatorvalvehasenteredtheredportionofthescale:

1. Presstheresetbuttonandre-checkwiththecompressoroperating.

2. Iftheblockageindicatorstillreturnstored,thefiltermustbecleaned orreplacedasfollows:

Note: Stop the machine before cleaning or replacing filter elements.

Cleaning the casing1. Unscrewtheclampretainingtheendcoveroftheairfilterand removeitnotingthepositionofthevacuatorvalve.Emptyout anydustordirtandthenre-fitintheoriginalposition(vacuatorvalve downwards)

Cleaning the elementTheairfilterisfittedwithablockageindicatortoshowwhenthefilterrequirescleaning.Ifthisindicatorshowsredwhenthecompressorisoperatingthenthefiltermustbecleanedorreplacedasfollows:

1. Removetheendcoverbyreleasingtheretainingclipsandwithdraw thefilter.

2. Cleanthefilterbyblowingcompressedairthroughthefilterfromthe insideoutwards

3. Replacementoftheelement/endcoverisadirectreversaloftheabove

Filterelementsshouldreplacedevery12monthsorsoonerifrestrictionisindicatedbytheblockageindicator.

NOTE

Figure 14b. Blockage indicator - packages 1,2 & 4

1.Indicator 2.Resetbutton

2

1

5.6 Alternative OilsOIL:- The XK12 is supplied filled with GD AEON S68 synthetic oil. Other ISO 68 Poly alpha Olefin (PAO) grade oil with EP (extreme pressure) additives can theoretically be used, but may affect the long term reliability of the machine. All oils should be checked that they are mixable with both mineral and other Synthetic PAO variants used without a reduction in performance.ISO 68 EP grade oils from

different manufacturers can be mixed.

NOTE


MonthlyForthemonthlycheck,simplyinitialtheboxesasthecheckiscompleted.

Yearstartingthemonthof

AnnuallyFortheannual/500operationalhoursservice,initialtheboxaseachcheckiscompleted.

Service Maintenance Record for XK12 Compressor Serial Number

MONTH 1 2 3 4 5 6 7 8 9 10 11 12

OilLevel

Reliefvalve

AirFilter

Security

MONTH DATE DATE DATE DATE DATE

OilChange

AirFilter

CheckValve

ReliefValve

Silencers

PipeWork

MONTH 1 2 3 4 5 6 7 8 9 10 11 12

OilLevel

Reliefvalve

AirFilter

Security

MONTH 1 2 3 4 5 6 7 8 9 10 11 12

OilLevel

Reliefvalve

AirFilter

Security

MONTH 1 2 3 4 5 6 7 8 9 10 11 12

OilLevel

Reliefvalve

AirFilter

Security

MONTH 1 2 3 4 5 6 7 8 9 10 11 12

OilLevel

Reliefvalve

AirFilter

Security

For additional information, contact your local representative or

Gardner Denver LtdPO Box 178,

Springmill Street, Bradford,

West Yorkshire, UK BD5 7YH

Tel: +44 (0)1274 718100Fax: +44 (0)1274 655272

Email: [email protected] Web: www.gd-transport.com

© 2013 Gardner Denver Ltd.

BelgiumGardner Denver Belgium N.V.Luithagen 7AHaven 200B-2030 AntwerpenBelgiumPhone: +32 (0)3 5415040Fax: +32 (0)3 5416509

email: [email protected]

AmericasGardner Denver, Inc.Industrial Products Group - Americas1800 Gardner ExpresswayQuincy, IL. 62305Toll Free: 1-800-682-9868Phone: 217-222-5400Fax: 217-221-8780


NetherlandsGardner Denver Nederland BVBarwoutswaarder 3B3449 He WoerdenThe NetherlandsPhone: +31 (0)348410150Fax: +31 (0)348418079


AustraliaGardner Denver Ind. Australia Pty Ltd30 Bearing RoadSeven HillsNew South Wales2147 AustraliaPhone: +61 2 96207000Fax: +61 2 96207955


FranceGardner Denver France SADivision Compresseurs42, rue du Montmurier, BP 60438070 Saint-Quentin-Fallavier, FrancePhone: +33 (0)474941673Fax: +33 (0)474941689


UK Sales & ServiceGardner Denver UK LtdPO Box 468Cross Lane, TongBradford, West YorkshireUnited KingdomBD4 0SUPhone: +44 (0)1274 683131Fax: +44 (0)1274 651006email: [email protected]

Rest of the WorldGardner Denver LtdPO Box 178Springmill StreetBradford, West YorkshireUnited KingdomBD5 7YHPhone: +44 (0)1274 718100Fax: +44 (0)1274 655272email: [email protected]

GermanyGardner Denver Deutschland GmbHAm Dorn 1448308 SendenGermanyPhone: +49 (0)253634840Fax: +49 (0)25363484010


SpainGardner Denver Iberica S.L.Calle Primavera, 20Poligono Industrial Las Monjas28850 Torrejon de ArdozMadrid, SpainPhone: +34 (0)916560056Fax: +34 (0)916770496


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(Original Instructions) - GD TransportOriginal Instructions) 4990140009 September 2013 4990140009 Date:11/11 XK1 Installation, Operating & Maintenance Manual Page 1 Health & Safety