EDIZIONE 01/12

OPERATING MANUAL
AND
SPARE PART LIST
ROTARY VANES COMPRESSORS
MODEL GC

GENERAL EUROPE VACUUM Srl

VIA DEL COMMERCIO, 9
20090 BUCCINASCO (MI) ITALY
TEL. ++39 02 48841120
FAX ++39 02 4453957
e-mail: [email protected]
http://www.gevac.com
GC compressors – Operating Manual Pag 2 di 22
 DICHIARAZIONE DI CONFORMITA’ COMPLIANCE DECLARATION
DECLARACION DE CONFORMIDAD KONFORMITAETSERKLAERUNG
DECLARATION DE CONFORMITÉ

COMPRESSORE ROTATIVO VACUUM PUMP / COMPRESSOR

POMPE A VIDE/ COMPRESSEUR VAKUUMPUMPE / KOMPRESSOREN
Modelo GC 6-12-45-100
Modello
Model
Matricula
Matricola
Serial nº. Desde/ Da/ From: 1201001 Hasta/ A/ To: 1212500
Maschinen nº.
Nº. De machine
Año de Construcción – Anno di costruzione - Baujahr
2012
Year of manufacture – Anèe de construction
LA FIRMA – LA SOTTOSCRITTA – THE UNDERSIGNED – LA SOUSSIGNEE – DIE
UNTERZEICHNENDE
GENERAL EUROPE VACUUM, S.r.l.
Via del Commercio, 9 * I-20090 BUCCINASCO (Milano) ITALY

Dichiara sotto la Declares under its Declare sous sa propre Erklaert unter eigener Declara bajo su propia
propria responsabilità own liability that the rèspon-sabilitè que la Verantwortung, dass responsabilidad, que
che il suddetto new machine machine neuve dont la die neue Maschine la maquina indicada
macchinario herebolow described description est la nachstehend arriba denominada:
denominato : as : Rotary vanes suivante: pompe beschrieben als: bomba rotativa de
compressore rotativo a vacuum pump couplèe directment à Vakuumpumpe direkt paletas, acoplada
palette, accoppiato directly coupled to un moteur electrique gekoppelt mit elektri- directamente a un
direttamente ad un electric triphase ou 1phase. Le schen Motor, dreifasig motor eléctrico,
motore elettrico trifase threephase/monophas refroidissement est oder einfasig.Die trifasico ó
o monofase con e motor with air realise directment par kuehlung erfolgt monofasico, con el
raffreddamento cooling carried out ventilateur du moteur, direkt durch den enfriamiento de la
realizzato da ventola by means of motor par une ventilateur Ventilator des Motors, misma producido por
motore; ventola fan, fan directly couplèe sur le Ventilator direkt an el ventilador del
calettata sul giunto di coupled to the manchon de trasmis- Trasmissionskupplung motor; el ventilador
trasmissione o trasmission joint or sion ou par le gekoppelt oder instalado directamente
serpentina/radiatore è by coil/radiator, fully radiateur /serpentin de Radiator kuehl- en la unión de
conforme alle seguenti complies the refroidissement, est schlange. Entspricht transmisión
direttive: 2006/42/CE, following directives conforme aux dispo- den gesetzlichen motor/bomba ó
73/23CEE, 89336CEE n° 2006/42/CE, sition: 2006/42/CE, Bestimmungen unter serpentín/radiador, es
e i loro successivi 73/23CEE, 73/23CEE, folgenden conforme a las
emendamenti. 89/336CEE and the 89/336CEE et aux Vorschriften directiva 2006/42/CE,
. following modification 2006/42/CE, 73/23CEE, 89336CEE
amendaments. successiv 73/23CEE 89/336CEE y sus sucesivas
und allen actualizaciones.
nachtraeglichen
Abaenderungen.

GC compressors – Operating Manual Pag 3 di 22

GENERAL INSTRUCTIONS

The instructions shown in the present manual are related to :

 Oil lubricated and rotary vanes compressors model GC
 Range: from 6 to 100

Drawings and data stated in this manual are not binding. G.E.V. reserves the right, firmly keeping
the performances and the operation of the described compressor to alter the design and any data
herewith given , any time that it deems appropriate, either for improving the pumps same or for any
other reasons, without being forced to immediately bring to up to date this manual.

It is absolutely mandatory that these operating instructions be read and understood

prior to the compressor installation and start up.

The GEV compressors have been manufactured according to the newest technical standards and
safety regulations as per “Machines directives 2006/42 CE” and additions.
If not properly installed or used without following the stated instructions, dangerous situations or
damage might occur.

Warning

This signal indicates the operating procedures that must be strictly observed to prevent
hazard to persons..

Warning

When working on the compressor or on the pumping system, it is important to strictly observe and
follow the “Operating instructions “.
Before starting any work disconnect the unit from power supply.
Take all the precautions for ensuring that the pump cannot suddently start
If the compressor has pumped hazardous gases, it will be absolutely necessary to determine the
nature of the hazard and take the appropriate safety precautions.
Take the appropriate precautions prior to open the intake or exhaust port.

GEV ASSISTANCE
If you send a compressor to General Europe Vacuum indicates whether it is free of substances
damaging the health or whether it is contaminated. If contaminated, indicate the nature of hazard.

Warning
The compressor must be packed in a way that will not be damaged during shipping and that no
harmful substances can escape from the package.

GC compressors – Operating Manual Pag 4 di 22

 GENERAL INDEX

DESCRIPTION PARAGRAPH

General instructions --
Technical assistance --

OPERATING INSTRUCTIONS

 DESCRIPTION A
- Operating principle A.1
- Field of application A.2
- Lubricants A.3
- Transport, lifting, manipulation and stock A.4

 INSTALLATION B
- Installation B.1
- Connection to system B.2
- suction side B.2.1
- exhaust side B.2.2
- Electric connection B.3
- start-up B.4
- running B.5
- Oil drops regulations B.6

 MAINTENANCE C
- Maintenance schedule C.1
- Oil check C.2
- Oil level C.2.1
- Oil condition C.2.2

 Suction filters D
 Troubleshooting guide E
 Exploded drawings and components list F
 Overall dimensions, technical datas G
 Safety instructions for installation in hazardous areas H

GC compressors – Operating Manual Pag 5 di 22

OPERATING INSTRUCTIONS

A. Description

A.1 Operating principle :

The GC compressors are single stage, oil-sealed rotary vanes. The compressors are driven by a
directly flanged motor by means of coupling or directly assembled without coupling.
The rotor assembled eccentrically to the stator has 6 vanes dividing the pump chamber. Each
section’ volume varies periodically during the rotor rotation as the blades, running freely inside the
rotor cavities, are pushed, thanks to centrifuge power, toward the cylinder walls. The gas, during the
expansion chamber phase, gets sucked thru the suction inlet.
The sucked gas flows thru the pumping chamber, where, during the next phase, gets compressed
and exhausted thru the oil separator together with the nebulized lubrication oil, at a changeable
pressure regulated by a valve.
The oil injected into the pumping chamber assures tightness, lubrication and pump cooling. The oil
cycle is maintained by the pressure difference exhisting between the oil and the suction.

A.2 Field of application

GC compressors have been engineered for their application in the range of pressure till 2 bar g.
They can handle gases as air, LPG, or in special esecutions as Biogas, Methan.

A.3 Lubricants

General Europe Vacuum recommends its special oil “TYPE G 880” to allow vacuum pump works
properly
If you use a non-approved oil, GEV cannot guarantee that the pumps will meet their operating
specifications ( ultimate pressure, pumping speed, operating temperature etc. ) However the
warranty is voided only if a non-approved oil adversely affects the operation and reliability of the
pump.
Use of others special grades lubricants for special applications is allowed after GEV approval.
If a synthetic oil has been selected, GEV recommends its synthetic oil “TYPE SYG 880”
Caution:don’t mix different oil into the pump.
A specific procedure has to be applied to change standard oil by a synthetic oil.
This specific procedure has to be done by GEV
For any additional information and/or explanation please refer to our office .

GENERAL EUROPE VACUUM Srl

VIA DEL COMMERCIO 9
20090 BUCCINASCO (MI) ITALY
TEL. ++39 02 48841120
FAX ++39 02 4453957
e-mail: [email protected]
http://www.gevac.com

GC compressors – Operating Manual Pag 6 di 22

A.4 Transport, lifting, manipulation and stock

Compressor is supplied complete with electric motor.

Usually the compressor is supplied without oil. Running
without it would affect compressor performances seriously.
Fill up the compressor before start up moving it always in
the upright position. The slope angle must be minimized,
otherwise the oil will pour out. Avoid any other orientation
while moving compressor.
For compressor lifting use the proper bands, balacing the
weight properly.

Warning
Check if compressor leaks oil because there is slip danger . Use proper lifting equipment and make
sure that all the safety norms have been observed.

Beware

Until the compressor is put back in to service once more, it should be stored in a dry place ,
preferably at room temperature. Before taking the compressor out of service, it should be properly
disconnected from the system, purged with dry nitrogen and the oil should be renewed too. Both
inlet and exhaust ports must be blanked off using the supplied seals .
If the compressor has been shelved for over one year, standard maintenance must be effected and
oil must be refreshed too before putting it into service again. Contact GEV again for any
information.

B. INSTALLATION

B.1 Installation

It is essential to observe the following instructions, step by step, to ensure a safe start up. Start up
shall have to be carried out by skilled and trained personell. Compressor must be installed on a flat
and horizontal surface.

GC compressors – Operating Manual Pag 7 di 22

Beware

The oil level cannot be read properly if the compressor is tilted. The environmental temperature
should be between 12°C. and 40° C. To ensure proper air cooling to the compressor it is advisable
to leave sufficient space aside being sure that the motor cooling side is free.
Moreover check to leave enough space close to the compressor allowing easy access to all the
components, like : filter, oil level indicator, oil fill up and exhaust cap.

B. 2 Connection to system

The standard compressor does not fit for being installed in explosion and hazard areas. Take contact
with GEV if you are planning to install it in such areas. Compressor must be installed by skilled and
trained personell. Take all safety precautions.

B.2.1 Suction side

Warning

-Disconnect compressor from mains when connected to suction piping.

- Use flexible hoses either in suction and at discharge so that you can easily remove for making
maintenance
- The suction piping must at least have the same diameter of the compressor connection .
A smaller piping can reduce the pumping speed.
- Both raw material and seals used for piping assembling must comply with sucked gases nature.
- If the sucked gas contains dust, it is absolutely necessary to equip a filter. In the event of steams
suction, it is advisable to contact GEV in advance.
- No solid or liquid particles shall enter the pump.

B.2.2 Exhaust side

We recommend you to connect a discharge hose fit for any type of sucked gas. This is always
necessary when the discharge gases are dangerous . The working pressure could to be regulated by
a valve installed at the outlet.

Warning

Follow all the precautions when sucting process gases. The exhaust piping section must be like the
compressor exhaust hose .

GC compressors – Operating Manual Pag 8 di 22

B. 3 ELECTRIC CONNECTIONS

Warning

Check that electric main is off before connecting the junction box or in case you have to operate on
it- The connection to main must be carried out by a skilled technician and according to the safety
norms. Refer to the scheme underneath for connection.
Connect the feeding cables to the junction box. The European standards declare to protect the
electric motor with a proper device calibrated according to the datas shown on motor lable.

Warning

If any motor or electric switch cuts the compressor out. Re-start up of the compressor can be
carried out only manualy. After having carefully checked the stopping reason.

Compressor can start up also when suction is already loaded. After connecting motor and every
time you alter the wiring, check motor rotation direction, check the arrow shown on motor lable.
During check, suction must be open. If motor rotation is wrong, oil may be flushed back from the
suction fitting. Switch on the motor for a while for checking the situation . If the motor rotates
contrarily to the correct direction, stops it immediately and inverte 2 phases of the electric
connection to wiring. A prolonged motor rotation in the wrong direction will damage the
compressor.

GC compressors – Operating Manual Pag 9 di 22

B.4 Start-up

Compressor must be filled up to the half of the oil sight glass. Always check that oil level & and
motor rotation are correct before start up it for the first time or before changing electric connections
Compressor can run to a temperature over 12° C.

B.5 Running

Warning

Compressor when running is hot and some parts could reach a surface temperature of 80°C.
Burning risk in case of touching. Read carefully the warning printed on the red lable stickered to
compressor.

B.6 Oil drippers regulation

Check during the compressor running that each driller get 3-4 drops/ minute till model 20, 5-6
drops/minute till model 80 and 6-8 drops/minute till model 300. To adjust the driller screw or
unscrew the up-side cover (sometime with a screwdriver)

C. MAINTENANCE

Warning

 Disconnect electric supply before disconnecting compressor.

 If compressor has sucked dangerous substances, check the nature risk and take the adequate
safety precautions.
 When wasting the exhaust oil , follow the environmental norms, any intervention must be
skilled personell
 Use only original spare parts
Maintenance or repairing being wrongly carried out or using unproper materials could damage
The pump
 Maintenance or repairing must be carried out by skilled technicians as an uncorrect intervention
on compressor could affect its lifetime and performances thus cancelling the warranty.
 Do not use weared gaskets, use new one.

GC compressors – Operating Manual Pag 10 di 22

C.1 Maintenance schedule
The maintenance schedule stated in the maintenance sheet underneath are approximate values for a
normal function of compressor. Difficult environmental conditions and/or aggressive gases can
increase significally the maintenance interventions.

CHECK AND MAINTENANCE FREQUENCY

Oil level check Daily

Oil conditions check Depending upon process
Replacement of vanes & gaskets Every year or whenever an oil leak occures

C.2 Oil check

C. 2.1 Oil level

The oil casing has two oil sight glasses.:
- at the bottom, where the oil must never go below
- at the top, for normal check of oil status
The oil lstatus must always be in the middle of the oil sight glass

C. 2.2 Oil condition

Under normal conditions, oil looks transparent. If it gets black, must be changed.
Final pressure is compromized, if gases or liquids are mixed into the oil

Unscrew the oil drainage tap and let the oil flow into the proper tank carefully following the safety
norms.

Close the oil draining tap.

Unscrew the oil fill-up tap again and fill-up compressor with fresh oil up to the bottom limit of the
oil-glass level, switch on the compressor shortly and then change the oil again following the above
mentioned procedure.

Do follow all the environmental instructions when wasting exhausted oil

GC compressors – Operating Manual Pag 11 di 22

D. SUCTION FILTERS

They are mainly used for avoiding foreign substances in the inlet and they are usually supplied
upon request. They can be with paper cartridge ( type GFC ) or metal ( type GFM) depending from
final application.
The oil-sump filter ( type GFOP ) is particularly used for being used in heavy dusty environments.

Type GFM- GFC Type GFOP

Type GFM - GFC GFOP

20 60 100 200 300 35 120 350 500
Capacity 20 65 110 200 300 36 120 350 600
(m3/h)
Weight (kg) 0,5 0,7 0,9 2 2,5 0,5 1,9 3,7 13
A 90 135 135 135 135 72 130 185 320
B 150 130 210 270 375 165 215 340 560
CØ ½”G 1”G 1”G 2”G 2”G ¾”G 1”G 2”G 4”G
DØ - 1”G 1”G 2”G 2”G ¾”G 1”G 2”G 4”G
EØ ½”G - - - - - - - -
F 165 - - - - 60 110 150 210
G 123 100 177 140 260 130 155 225 412
HØ 50 68 68 95 95 - - - -
IØ 26 26 26 65 65 - - - -
Oil q.ty (gr.) - - - - - 125 350 700 1300

GC compressors – Operating Manual Pag 12 di 22

E. TROUBLESHOOTING GUIDE

FAULTS CAUSES REMEDY

Compressor does Motor is not properly connected Connect motor correctly
not start or the The thermal device has not been Readjust the thermal device
thermal device properly adjuested
starts after few The Volts do not fit with the motor’s one Replace motor
Compressor is stucked Replace compressor

Compressor does The rotating sense is uncorrect Change the rotation direction
not start easily,
The oil temperature is too low, ( less Heat the environment and
vanes noise and then 12°C) the oil with a less viscousity one
higher powerOil is too viscous Use the correct oil and clean during
absorption the comp. running with gasoline
Pump has been stopped since long time Let compressor run with closed
suction untill hot
Exhaust piping is clogged Clean all the exhaust piping
Compressor does Measuring instrument is damaged or Check the measuring technique and
not reach the unsuitable the used instruments
stated Leaking from both oil and pipings Check and tighten all fittings housed
Tag pressure both on pipings and oil

Oil missing in the compressor Fill up compressor with oil

Shaft seals out of order or uncorrectly Replace the tight rings
positioned
Poor lubrication due to :
. unsuitable or contaminated oil Change the oil
. oil filter clogged Clean the oil lines
. oil pipings clogged Clean the vacuum line
Drippers are not regulated See the details B.6

GC compressors – Operating Manual Pag 13 di 22

 FAULTS CAUSES REMEDY
Compressor is Cooling air is not enough Place compressor in a more aired
too hot location
Piping or fan is dirt Clean with air or solvent
Too high temperature of the gas aspired Verify the system and the reiability of
the compressor
Insufficent oil quantity in the compressor Restore oil level
Oil recyrculation piping obstructed Verify and clean
Oil filter is dirt Replace oil filter

Compressor Fittings and oil cyrculation piping are Verify the fittings, tight them, verify
leaks oil not tight or are spoiled the pipings and eventually replace
them
Shaft seals too much used Replace the seals

Oil is dark Oil has been used for too many hours Drain oil and replace it
Oil is not the correct one Replace oil filter and oil
Oil is burned by the too high temperature Check the compressor
of the pump
Motor runs but Coupling insert is broken Verify & replace
the compressor
doesn’t

Compressor is Compressor needs oil Verify & fill up

clogged and the Vanes broken Verify & replace the vanes
motor doesn’t
run

Compressor is Oil level is down Fill up oil

noisy Vane don’t move during running Change oil and clean with gasoline
into the running

GC compressors – Operating Manual Pag 14 di 22

OIL LUBRICATED VANE COMPRESSOR GC 6-12

Component list (refer to the split draw)

POS Q.TY DESCRIPTION

1 1 ELECTRIC MOTOR
2 1 SEEGER RING
3 1 SHAFT SEAL
4 1 MOTOR FLANGE
5 4 SCREW
6 1 ROTOR
7 6 VANE
8 1 O-RING
9 1 STATOR
10 4 SCREW
11 1 O-RING
12 1 COVER
13 4 SCREW
14 1 INLET FITTING
15 1 OIL DRIPPER
16 1 OIL PIPING
17 1 OUTLET FITTING
18 1 OIL TANK
19 2 SIGHT GLASS
20 1 SIGHT GLASS
21 1 SIGHT GLASS

GC compressors – Operating Manual Pag 15 di 22

COMPRESSOR GC45 Spare list (relating to exploded drawing)
Pos. Q.ty CODE DESCRIPTION Pos. Q.ty CODE DESCRIPTION

1 1 - ENSEMBLE BY-PASS VALVE 32 1 20 00 31 FAN PROTECTION CARTER

2 1 17 00 14 COVER PROTECTION CARTER 35 8 - SCREW
3 2 - SCREW WITH FLAT WASHER 36 4 - SCREW
4 4 - ALLEN SCREW 37 1 17 00 04 CAP
5 1 17 00 02 DISCHARGE FLANGE 38 1 O-RING
6 1 20 00 16 SPRING 39 1 17 00 06 CAP PUMP
7 1 20 00 15 SUCTION PAN AND O-RING 40 1 - BEARING
8 1 20 00 20 SUCTION WASHER 41 2 - O-RING
9 1 - SEEGER 42 4 17 00 11 VANE
10 1 20 00 17 FILTER 43 1 80 05 09 ROTOR
11 1 20 00 09 COVER SUCTION 44 1 - BEARING
12 4 - SCREW 45 4 - PIN
13 1 - WEDGE 46 1 20 00 03 BODY PUMP
14 1 17 00 08 JOINT PUMP SIDE 48 1 17 00 05 COVER PUMP MOTOR SIDE
15 1 - PIN 50 1 SEAL
16 1 - SCREW ANCHOR 52 1 17 00 03 OIL DRIPPER SUPPORT
17 1 - PIN 53 1 - BRACKET OIL TANK
18 4 - SCREW MOTOR FIXING 54 1 - SEEGER
19 1 17 00 07 TURRET 55 1 - SCREW WITH FLAT WASHER FOR
BEARING LOCK
21 2 - SELF-THREADING WITH FLAT WASHER 56 1 - SCREW LOCKING CARTER
22 2 OIL DRIPPER 57 1 - NIPPLES G3/4-G3/4
23 1 17 00 01 OIL TANK 58 1 - T-CONNECTOR a T G3/4-G3/8-G3/4
24 1 MOTOR 59 1 - PIPE diameter 10
25 1 20 00 13 PUMP PROTECTION CARTER 60 1 - BY-PASS VALVE
26 1 - DISCHARGE WASHER 61 1 - T-CONNECTOR G1”-G3/8-G1”
27 1 - NO VIBRANT 62 4 - NUT WITH OGIVE
28 1 - NUT
29 1 - ENSEMBLE PUMP
30 1 20 00 65 COOLING FAN
31 1 - SCREW WITH FLAT WASHER
GC compressors – Operating Manual Pag 18 di 22
 OIL TANK Spare list (relating to exploded drawing)

POS QUANTITY DESCRIPTION

GC 45
1 6 SCREW
2 1 OUTLET COVER
3 2 OIL MIST ELIMINATOR PLATE
4 1 OUTLET GASKET
5 2 NUT
6 2 SPRING
8 1 FILL UP PLUG
10 1 OIL TANK
18 2 SIGHT GLASS
19 2 SIGHT GLASS GASKET
20 1 OIL DRAIN PLUG
21 1 O-RING PLUG
22 2 NUT
23 2 WASHER
24 2 ANTIVIBRATION FOOT
38 1 BODY OUTLET GASKET
39 1 OIL TANK COVER
40 1 OIL TANK GASKET
205 2 OIL MIST ELIMINATOR

GC compressors – Operating Manual Pag 19 di 22

GC compressors – Operating Manual Pag 20 di 22
GC compressors – Operating Manual Pag 21 di 22
H. SAFETY INSTRUCTIONS FOR INSTALLATION IN HAZARDOUS AREAS

Before to install rotary vane compressor type GC in potentially explosive areas, classified
accordingly to ATEX Directive 94 / 9 / EC please read carefully these instructions.

 Read carefully Operation and Maintenance Manual

 Verify vanes compressor is suitable to operate in the choose area, both for the external
environment and for the sucked gases and vapours.
Area classification is customer responsibility.

 Verify that electric motor, instruments and all the compressor accessories are suitable for the
area
 Verify very carefully ATEX conformity of the following equipments:
- Electric motor must be EEx and suitable for the gas group, category and
temperature class
- The same for the coupling joint

 It’s mandatory to install all instruments and accessories as specified in the risks analysis for
the ATEX category and temperature class of installation

 A thermal probe is mounted in the warmer part of the compressor. Set point calibration
must be at temperature below the temperature class of the area.

 An oil level switch is mounted on the compressor to avoid compressors running without
lubrication
 Install the compressor in a clean and dust free room. All the compressor external surfaces
will be clean periodically. Dust on hot surface must be carefully avoided.

 Verify, every 6 months, the cooling fun integrity. No clearence must be in the joint points.
Eventually change it.

 Not more than 5-6 start up cycles per hour must be performed. If the process need an high
number of start / stop cycles, install an isolation valve on the compressors suction and leave
the compressor running continuously.

 For any modification to compressor running or performance parameters please contact us

before
 Is necessary to connect to earth the compressor with a suitable cable.

THESE SAFETY INSTRUCTION MUST BE OBSERVED CAREFULLY TOGETHER WITH THE

OPERATION AND MAINTENANCE MANUAL OF ROTARY VANE COMPRESSOR TYPE GC

GC compressors – Operating Manual Pag 22 di 22