Edition: 1.12.

2009 · BA 458-En

Original Operating Instructions

V-KTA /4

V
V-KTA 60/4 | 80/4 | 100/4 | 140/4

V-Serie
V-Series
Drehschieber
Rotary Vane
Table of contents

Table of contents

1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Supplier documentation and accompanying documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Directives, standards, laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Symbols and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 Technical terms and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Warning instruction markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Unacceptable operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Personal qualifications 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 Control and relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.5 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 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2.2 Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2.3 Air filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.2.4 Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3 Repair/ Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.4 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8 Malfunctions: Causes and elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Foreword

1 Foreword
1.1 Principles

These operating instructions:

• are a part of the following dry running rotary
vane pressure vacuum pumps models V-
KTA 60/1 to V-KTA 140/3 and V-KTA 80/5.
• describe how to use them safely and properly in
all life phases.
• must be available where the equipment is used.

1.2 Target group

The target group for these instructions is technically

trained specialists.

1.3 Supplier documentation and accompanying documents

Document Contents No.

Operating Instructions BA 458-EN
Supplier documentation Declaration of Conformit C 0074-EN
Declaration of harmlessness 7.7025.003.17
Spare parts’ list Spare parts’ document E 457, E 458
Data sheet Technical data and graphs D 457
Info sheet Storage guidelines for machines I 150
Manufacturer’s declaration EU Directive 2002/95/EG (RoHS) —

1.4 Abbreviations

Fig. Figure
V-KTA Pressure vacuum pump
m3/h Volume flow compressed/ suction air
bar Overpressure/ vacuum

1.5 Directives, standards, laws

See Conformity Declaration

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 Foreword

1.6 Symbols and meaning

Symbol Explanation
Condition, pre-requisite
#### Instructions, action
a), b),... Instructions in several steps
Results
[-> 14] Cross reference with page number
Information, note

Safety symbol
Warns of potential risk of injury
Obey all the safety instructions with this symbol in order to avoid injury
and death.

1.7 Technical terms and meaning

Term Explanation
Machine Pump and motor combination ready to be connected
Motor Pump drive motor
In combined use the machine may produce a vacuum and excess pres-
Pressure vacuum pump
sure at the same time.
Rotary vane Machine’s design or active principle
Volume flow 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.
The noise emitted at a specific loading given as a figure, sound pressure
Noise emission
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.

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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 immediately imminent danger Death, severe bodily injury

WARNING possible imminent danger Death, severe bodily injury

CAUTION possible hazardous situation Slight bodily injury

NOTICE possible hazardous situation Material damage

2.2 General

These operating instructions contain basic instruc-

tions for installation, commissioning, maintenance
and inspection work which must be obeyed to en-
sure 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 un-
derstood. The contents of the operating instructions
must always be available on site for the technical
personnel / operator. Instructions fixed directly onto
the machine must be obeyed and must always re-
main 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 regu-
lations.

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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 par-
tially assembled
• the machine must only be operated at an ambi-
ent 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:
• convey air with a relative humidity of 30 -
90%
• all non-explosive, non-inflammable, non-ag-
gressive and non-poisonous dry gases and
gas air mixtures

2.4 Unacceptable operating modes

• extracting, conveying and compressing explo-

sive, inflammable, aggressive or poisonous me-
dia, e.g. dust as per ATEX zone 20-22, solvents
as well as gaseous oxygen and other oxidants,
extremely damp air, water vapour, traces of oil,
oil vapour and grease
• using the machine in non-commercial plants if
the necessary precautions and protective meas-
ures have not been taken in the plant
• installing in environments that are at risk of ex-
plosions
• using the machine in areas with ionising radia-
tion
• back pressures on the outlet side of more than
+0,1bars
• modifications to the machine and accessories

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Safety

2.5 Personal qualifications 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 special-
ists 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 op-
erating 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 fitted with a guard
• eople must not be endangered by the free ex-
traction 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 car-
ried out by authorised, qualified specialists who
have gained sufficient 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 decom-
missioning the machine described in the operat-
ing instructions.
• Fit or start up safety and protective devices
again immediately after finishing work. Vor Wie-
derinbetriebnahme die aufgeführten Punkte für
die Inbetriebnahme beachten
• Conversion work or modifications to the ma-
chine are only permissible with the manufactur-
er’s consent.
• Only use original parts or parts approved by the
manufacturer. The use of other parts may invali-
date liability for any consequences arising.
• Keep unauthorised people away from the ma-
chine

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 insufficiently qualified staff
• Using spare parts that have not been approved
by Gardner Denver Schopfheim GmbH
• Unauthorised modifications 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

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:
a) Select the lifting device suitable for the total
weight to be transported.
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
base.
Lifting device/ Transporting with a crane

WARNING

Bodily injury resulting from improper operation

a) Loads crosswise to the ring level are not per-
mitted.
b) Avoid impact stress.

a) Tighten the eyebolts (Fig. 1/1) firmly.

b) The machine must be suspended on the eyebolt
using the lifting device for lifting and transport-
ing.

Fig. 1 Lifting and transporting

1 Eyebolt

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 Transport, storage and disposal

3.2 Storage

NOTICE

Material damage caused by improper storage.

Ensure that the storage area meets the following

conditions:
a) dust free
b) vibration free

3.2.1 Ambient conditions for storage

Ambient conditions Value

Relative humidity 0% to 80%
Lagertemperatur -10°C to +60°C

The machine must be stored in a dry environment

with normal air humidity. It should not be stored for
more than 6 months.
see Info “Machine storage guidelines”, Page 4

3.3 Disposal

WARNING

Danger from inflammable, corrosive or poison-

ous substances.
Machines that come into contact with hazard-
ous 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

P O Q N V-KTA /4 (04)
F
F
E

E A1 A2 B

F
F

C1 C2 S D M

F V-KTA /4 (34)

F A1 A2 E
B

F O J

F E

Fig. 2 Pressure vacuum pump V-KTA /4

A1, A2 Vacuum connection J Plug-connector
B Pressure connection M Greasing plate
C1, C2 Vacuum regulating valve N Data plate
D Pressure regulating valve O Rotation direction plate
E Cooling air inlet P Drive motor
F Cooling air outlet Q hot surfaces > 70°C
G Inlet grating S Filter housing

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 Set up and operation

4.1.1 Data plate

1 Type/ Size (mechanical version)

1 2 3 4 5
2 Year of construction
Bauj./Nr. 09 3~ Mot. 3 Motor design
2862775
4 Serial number
Typ KTA 140 (34) 1022593431
+0,6 I -0,60 II -0,3 bar 5 Item no
140 m³/h
6 Overpressure / Vacuum (Vacuum I + II)
7 Pumping capacity 50 Hz/60 Hz
EN 60034
8 Speed 50 Hz/60 Hz
S1 7,5 kW 1450 min-1
9 Motor output 50 Hz/60 Hz
10 9 8 7 6 10 Operating mode

Fig. 3 Data plate

4.2 Description

The V-KTA /4 range has two connecting threads on the suction side and one on the pressure side. The
aspirated air is cleaned by an inbuilt fine micro filter. The carbon dust caused by the scoring of the discs can
also be separated by an integral filter if necessary. A fan between the compressor housing and the motor
provides intensive air cooling. The compressor housing is located in a sound cover. The compressed air is
cooled by a cooling segment.
The machines are driven by standard flanged three-phase motors using a coupling.
Pressure and vacuum can be adjusted to the required levels, however, they are limited to a maximum point.
Versions (01) to (30) have cooling exits from two sides whilst versions (31) to (60) have cooling exits on one
side only.

4.3 Areas of application

These dry running rotary vane pressure vacuum pumps models V-KTA 60/4 to V-KTA 140/4 are suitable for
creating pressure and two different vacuum levels at the same time. Constant operation is permissible.
All models have nominal capacities of 60, 80, 100 and 140 m3/hr operating at 50 cycles. The pressure and
vacuum limits (bar) are indicated on the data plate (Fig. 2/N).
These dry running machines are suitable for conveying air with a relative humidity of 30 - 90%.
If the unit is switched on more frequently (at regular intervals of about 12 times (V-KTA 60 / 80)
resp. 10 times (V-KTA 100 / 140) an hour) or at higher ambient temperatures and intake tempera-
tures, 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 influences, (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
• Sufficient room for installing and removing pipes
and for maintenance work, particularly for install-
ing and dismantling the machine
• No external vibration effects
• Do not suck any hot exhaust air from other ma-
chines into the cooling system.

The filter housing (Fig. 2/S) should be easily accessible.

The cooling air inlets (Fig. 2/E) and the cooling air outlets (Fig. 2/F) must be at least 30 cm away
from adjacent walls. Cooling air coming out must not be sucked in again..
or maintenance work there must be a minimum of 40 cm in front of the filter housing (Fig. 2/S) and
the inlet grating (Fig. 2/G).

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:
• Level and straight
• The bearing surface must be able to bear the
weight of the machine

It is possible to install the machine on a firm base without anchoring. When installing on a substruc-
ture we recommend fixing with flexible buffers

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 Installation

5.3 Connecting pipes

a) Vacuum connections at (Fig. 2/A1) ➝ higher

vacuum and at (Fig. 2/A2) ➝ lower vacuum (se-
cond vacuum) as well as 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.

Long and/or small bore pipework should be

avoided as this tends to reduce the capacity of
the machine.

b) Check to ensure the intake line and pressure line

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 3 m 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 Control and relief valve

The required pressure and vacuum ranges can be

set with the pressure regulating valve (Fig. 2/D) and
the vacuum regulating valves (Fig. 2/C1, 2/C2) as
shown on the symbol plate attached to the rotary
knob.

NOTICE

Do not operate without the standard control

and relief valves.
If the permissible final compression pressure is
exceeded (see data plate) the machine may be
damaged.

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Installation

5.5 Connecting the motor

DANGER

Danger of death if the electrical installation has

not been done professionally.
The electrical installation may only be done by a spe-
cialist 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. The
motors comply with DIN EN 60034 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 connec-
tion version). Compare the motor data with the
data of the existing mains network (current type,
voltage, network frequency, permitted current
value).
b) Connect the motor via plug-connector (Fig. 2/J)
if fitted or via the motor protection switch (for
safety reasons, a motor protection switch is
required and the connecting cable must be in-
stalled via a cable fitting to provide strain relief).
We recommend using motor protection switches
with delayed switch off, depending on possible
excess current. Temporary excess current can
occur when the machine is started cold.

NOTICE

Power supply
The conditions at the installation location must match
the information on the motor data plate. Without
derating the following is permissible:
• ± 5% voltage deviation
• ± 2% frequency deviation

16 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Commissioning and decommissioning

6 Commissioning and decommissioning

6.1 Commissioning

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

Trockenbeutel
The desiccant bags in the filter housing (Fig. 2/S)
must be removed before initial start-up.

Wait until the machine stops.

The machine must only be switched on again
after it stops.

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Commissioning and decommissioning

6.1.1 Checking the rotation direction

The drive shaft direction of rotation is shown by

the rotation direction arrow (Fig. 2/O) on the mo-
tor flange.
a) Start the motor briefly (max. two seconds) to
check the direction of rotation. When looking at
the motor fan, it must rotate clockwise.

NOTICE

Incorrect direction of rotation

Running the machine in reverse for a long time may
cause damage to the blades which may lead to the
blades breaking. Use a phase sequence indicator
to check the direction of rotation (anti-clockwise
rotating field).

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 filter 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 filter hous-
ing.
For installation see Section 5 Page 14
For commissioning see Section 6.1 Page 17

18 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Maintenance and repair

7 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.
If there is a great deal of dust in the spaces on the cooling
ribs and cooling pipes after removing the inlet grating (Fig. 2/
G) and the protective cover (Fig. 5/G1) clean by blowing
through.
4.000 h - 10.000 h Lubricate the bearing on the side facing away from the motor. 7.2.1
4.000 h - 1.000 h Check blades Replace blades 7.2.2
monthly / every 6 months Clean or replace filter cartridges 7.2.3
at least once a year Check for coupling wear 7.2.4

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Maintenance and repair

7.2.1 Lubrication
The bearings must be greased at the 2 greasing
M points (Fig. 4/L) with 6 g per point, after the follow-
w1 ing recommended operating hours or at the latest
one year operation:
s 50 Hz: V-KTA 60 - 100 ➝ 10.000 h and V-KTA 140 ➝
6.000 h
L
60 Hz: V-KTA 60 / 80 ➝ 10.000 h, V-KTA 100 ➝
8.000 h and V-KTA 140 ➝ 4.000 h
s
NOTICE
L
w1
G These greasing instructions are valid for operation
at 20°C ambient temperature. At 40°C these should
be reduced by 50 %.

To lubricate the inlet grating (Fig. 4/G) must be un-

screwed.
Fig. 4 Lubrication/ Blades We recommend the following brands of grease:
KlüberPetamoGY193 or other equivalent greases
G Inlet grating (see also grease recommendation plate (Fig. 4/M)).
L Grease nipple
M Grease recommendation plate
s Screws
w1 Slotted nut

7.2.2 Blades
Blade check:
All V-KTA /4 models have 6 carbon blades that
gradually wear out during operation.
First check after 4,000 operating hours and then
every 1,000 operationg hours or, depending on the
height (Fig. 5/X) earlier.
Remove inlet grating (Fig. 4/G). To remove the end
cover (Fig. 5/b) from the housing, the bolt (Fig. 5/a)
located in the centre of the bearing cover (Fig. 5/c)
should be removed. To achieve this one of the fix-
ing bolts (Fig. 5/s) from the housing cover should be
screwed into the thread in the centre of the bearing
cover. Remove the blades (Fig. 5/d) to be checked.
All blades on the machine must have a minimum
height (Fig. 6/X) of more than 38 mm.
The blades must only be changed as a set.

20 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Maintenance and repair

Changing blades:
If the minimum height has already been reached or
if the blades have fallen below this level the whole
blade set must be changed.

NOTICE
a c
Do not undo the slotted nuts (Fig. 4/w1) on the
housing lid (Fig. 5/b). Only the screws (Fig. 4/s) need
to be removed to change the blades.

b G1

Before refitting the blades clean out the housing

and the rotor slots with compressed air. Place the
d blades, with the radius outwards (Fig. 6/Y), such that
the bevel is in the direction of rotation (Fig. 6/O1) and
s corresponds with the radius of the housing (Fig. 6/
Z).
Fig. 5 Lubrication/ Blades Before refitting the end cover (Fig. 5/b) redistribute
the grease from the bearing cover (Fig. 5/c) on to
G1 Protective cover the appropriate bearing. It is important that the shaft
end is completely clean so that no grease can enter
a Bolt
the housing, this could mix together with carbon
b Housing lid dust and give a viscous paste which would result in
the blades becoming stuck in the rotor slots.
c Bearing cover
When re-fitting the end cover tighten the bolts even-
d Blade ly so that the end cover fits correctly onto the fixing
s Screws pins. As soon as the cover is almost touching the
housing, we recommend during further tightening of
the bolts, the fan is moved in both directions. This
can be achieved by taking the grill at the cooling air
exit (F) away. This then ensures that the blades are
sitting correctly in their slots and avoids any edge
damage. Refit the suction grid (Fig. 4/G).

NOTICE
Z Y
Care should be taken that the bearing does not
become contaminated.
X

O1

Fig. 6 Blades

O1 Direction of rotation
X Minimum heigh
Y Slanting side of the blade
Z Drilled holes in the housing

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Maintenance and repair

7.2.3 Air filtering

NOTICE
Insufficient maintenance on the air filter
The power of the machine lessens and damage may
occur to the machine.

The filter cartridges (Fig. 7/e) and (Fig. 7/f) must be

e cleaned by blowing through from the inside out once
a month or more often depending on the level of
contamination. In spite of cleaning the filters their
f
separation efficiency will continue to deteriorate.
Therefore the filters should be replaced every six
g months.
The filter cartridges (Fig. 7/e) and (Fig. 7/f) can be
h removed for cleaning after undoing the filter screw
Fig. 7 Air filtering knobs (Fig. 7/h) and the filter housing cover (Fig. 7/
g).
e Filter cartridge (suction air) Clean the filter housing chambers too.
f Filter cartridge (exhaust air) NOTICE
g Filter housing cover
Do not damage the filter cartridges when clean-
h Filter screw-in knobs ing them.

No dirt must get into the machine when cleaning

the filter housing chambers.

WARNING

Danger of injury when dealing with com-

1 pressed air.
When blowing through with compressed air, solid
particles may be carried along or powder dust swirl-
ing around may cause injury to the eyes. Therefore,
when cleaning with compressed air always wear
goggles and a dust mask.

Fig. 8 Purging filter cartridge

1 Filter cartridge
2 Compressed air

22 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Maintenance and repair

7.2.4 Coupling

m The coupling rubbers (bb. 9/k) are wearing parts

and should be checked regularly. When the coupling
l k p r rubbers are worn this can be detected by a knock-
ing sound when the pump is started.

CAUTION

Defected coupling rubbers

Defected coupling rubbers can cause extensive
damage and even in some extreme cases break
the rotor shaft.
s5
To check the coupling, stop the motor (Fig. 9/m) and
isolate. Remove the screws (Fig. 9/s5) on the motor
n q l1 flange (Fig. 9/n). Pull off the motor together with the
v u w motor side coupling half (Fig. 9/q). If the coupling
rubbers (k) are damaged remove the circlips (Fig. 9/l)
Abb. 9 Coupling from the coupling bolt (Fig. 9/r) and exchange the
coupling rubbers (k). Leave the spacer (p) in place.
k Coupling rubber Check the coupling bolts (Fig. 9/r) for any wear and
replace if necessary. To replace, remove the circlip
l Circlip
(Fig. 9/l1), pull off the coupling and fan (Fig. 9/v)
l1 Circlip complete from the pumpshaft, remove the nut
(Fig. 9/w) with washer (Fig. 9/u) and exchange the
m Motor
coupling bolts.
n Motor flange
NOTICE
p Spacer
q Motor side coupling half Frequent starting up and high ambient tem-
perature
r Coupling bolt The service life of the coupling rubbers (Fig. 9/k)
s5 Screws is reduced.
u Washer
v Fan Re-assemble in reverse order.
w Nut

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Maintenance and repair

7.3 Repair/ Service

a) For on site repair work the motor must be
disconnected from the mains by a qualified
electrician so that it cannot be started up again
accidentally. For repairs use the manufacturer,
its branch offices or authorised dealers. Please
contact the manufacturer for the address of the
service centre responsible for you (see Manufac-
turer'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 harmless-
ness must be enclosed.
The declaration of harmlessness is part of the sup-
plier’s documentation.

b) After a repair or re-commissioning, the actions

listed under “Installation” and “Commissioning”
must be carried out as for initial commissioning.

Fig. 10 Clearance certificate

7.7025.003.17

24 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Maintenance and repair

7.4 Spare parts

Order spare parts in accordance with the:

• Spare parts list:

E 457 ➝ V-KTA 60/4 - 140/4 (04)
E 458 ➝ V-KTA 60/4 - 140/4 (34)
• Download the PDF file:
tp://www.gd-elmorietschle.com
➝ Downloads
➝ Product Documents
➝ V-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

Only use original spare parts or parts approved by

Fig. 11 Spare parts list (example) the manufacturer. The use of other parts may lead to
malfunctions and invalidate liability or the guarantee
for any consequences arising.

Fig. 12 Web site

http://www.service-er.de

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Malfunctions: Causes and elimination

8 Malfunctions: Causes and elimination

Fault Cause Troubleshooting Important

Machine is switched Mains voltage/ Frequency Check by qualified electrician Section 5.5
off by the motor pro- does not correspond with the
tection switch motor data
Connection to motor terminal
board is not correct
Motor protection switch is not
set correctly
Motor protection switch is Use a motor protection switch
triggered too quickly 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)
The blow out filter cartridge Clean or replace the filter Section 7.2.3
(accessory) is dirty. cartridges Section 7.4
The regulating valves are dirty Clean or replace the regulat- Section 7.2
so that the permissible vacu- ing valves Section 7.4
um value is exceeded.
Blowing capacity is Intake filter and/or blow out Clean or replace the intake Section 7.2.3
insufficient filter are dirty filter Section 7.4
The pressure line is too long Check the hose or the pipe Section 5.3
or too narrow
Machine or system leaking Check the pipework and Section 7.2
screw connections for leaks
and to ensure that they are
firmly seated.
Discs are damaged Replace discs Section 7.2.2
Section 7.4

26 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 Malfunctions: Causes and elimination

Fault Cause Troubleshooting Important

Overpressure or vac- Machine or system leaking Check the pipework and Section 7.2
uum not achieved screw connections for leaks
and to ensure that they are
firmly seated.
Discs are worn or damaged Replace discs Section 7.2.2
Section 7.4
Machine gets too hot Ambient or intake temperature Ensure it is being used prop- Section 2.3
is too high erly
Cooling air supply is ob- Check environmental condi- Section 5.1
structed tions
Clean ventilation slots Section 7.2
The blow out filter cartridge is Clean or replace the filter Section 7.2.3
dirty. cartridges Section 7.4
The regulating valves are dirty Clean or replace the regulat- Section 7.2
so that the permissible pres- ing valve Section 7.4
sure and/or vacuum values
have been exceeded.
The machine makes The coupling rubbers are Replace coupling rubbers Section 7.2.4
a abnormal noise worn Section 7.4
The compressor housing is Repair by manufacturer or Elmo Rietschle
worn (chatter marks) authorised workshop Service
A regulating valve is vibrating Replace the valve Section 7.4

Discs are damaged Replace discs Section 7.2.2

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 | 27

Technical Data

9 Technical Data

V-KTA /4 60 80 100 140

Sound pressure level (max.) 50 Hz 76 78 79 81

EN ISO 3744 dB(A)
Tolerance ± 3 dB(A) 60 Hz 78 80 81 83

50 Hz - - - 90
Sound power level dB(A)
60 Hz - 90 91 92

Weight* kg 92 101 127 160

Length* mm 771 788 975 975

Width mm 405 405 425 425

(04) 320 320 320 320

Hight mm
(34) 366 366 366 366

Vacuum connection G1 G1 G 11/4 G 11/4

Pressure connections G1 G1 G 11/4 G 11/4

* The length and the weight may differ from the information listed here depending on the motor manufac-
turer.

You will find more technical data on the data sheet

D 457

• Download the PDF file:

D 457 ➝ V-KTA 60/4 - V-KTA 140/4
• Download the PDF file
ttp://www.gd-elmorietschle.com
➝ Downloads
➝ Product Documents
➝ V-Series ➝ Data Sheets

NOTICE

Subject to technical changes.

Fig. 13 Data sheet (example)

28 | www.gd-elmorietschle.com © Gardner Denver Schopfheim GmbH, Gardner Denver Deutschland GmbH

 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

Elmo Rietschle is a brand of

Gardner Denver‘s Industrial Products
Division and part of Blower Operations.
 EC - declaration of conformity 2006/42/EC
Hereby the manufacturer Gardner Denver Schopfheim GmbH
confirms: Postfach 1260
D-79642 Schopfheim
that the machine: Dry running pressure/vacuum pump
of the: Series: V-KTA
Type: V-KTA 40/1, V-KTA 50/1, V-KTA 60/1,
V-KTA 80/1, V-KTA 100/1, V-KTA 140/1
V-KTA 40/2, V-KTA 50/2, V-KTA 60/2,
V-KTA 80/2, V-KTA 100/2, V-KTA 140/2
V-KTA 60/3, V-KTA 80/3, V-KTA 100/3,
V-KTA 140/3
V-KTA 40/4, V-KTA 50/4, V-KTA 60/4,
V-KTA 80/4, V-KTA 100/4, V-KTA 140/4
V-KTA 80/5
is conform to the regulations of the guideline indicated above.

The following harmonized and national standards and specifications are applied:
EN 1012-1:2010 Compressors and vacuum pumps — Safety requirements — Part 1:
Compressors
EN 1012-2:1996+A1:2009 Compressors and vacuum pumps — Safety requirements — Part 2:
Vacuum pumps

These declarations of conformity are invalid when the machine has been modified without prior ap-
proval by us and the approval has been documented in writing.

Name and address of the EC person in Gardner Denver Schopfheim GmbH

charge for documentation Postfach 1260
D-79642 Schopfheim

Gardner Denver Schopfheim GmbH

Schopfheim, 1.8.2011

Dr. Friedrich Justen, Director Engineering

C_0074_EN
 Safety declaration form 7.7025.003.17
for vacuum pumps and components
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.

1. Type of vacuum pumps/ components 2. Reason for the submission

Type description:
Machine number
Order number:
Delivery date:

3. Condition of vacuum pumps/ components 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 Action to be taken if toxic First aid in the event of
product name name class substances are released accidents
1
2
3
4
Personal protection measures:

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: Company stamp:

Legally binding signature:
TOS no. / Index: 7.7025.003.17 / 03 Office responsible: GS File management: ..\7702500317.xl
Gardner Denver Schopfheim GmbH Postfach 1260 D-79642 Schopfheim