Ingersoll-Rand GHH RAND CG 600 EP-belt NON EU User manual

Operating Instructions
Compressor Unit with Electric Motor
CG 600 EP–belt NON EU

Foreword
Please read these operating instructions carefully before setting
up and commissioning the compressor unit with electric motor.
They provide essential information which are to be observed to
ensure trouble-free operation and a long service life.
Table of Contents
1 General………… ……………………………………………………………………………………………………………………1
1.1 Purpose……………………………………………………………………………………………………………………………………1
1.2 Manufacturer’s address……………………………………………………………………………………………1
1.3 Identification…………………………………………………………………………………………………………………1
1.4 Services contacts…………………………………………………………………………………………………………1
1.5 Technical data of compressor unit with motor…………………………………1
1.6 Technical data of motor 400 VAC / 30kW…………………………………………………2
1.7 Technical data of compressor CG 80……………………………………………………………2
1.8 Installation procedure……………………………………………………………………………………………3
1.9 Installation instructions……………………………………………………………………………………4
1.9 Installation procedure – vibration dampers………………………………………5
2 Safety…………… ……………………………………………………………………………………………………………………6
2.1 General……………………………………………………………………………………………………………………………………6
2.2 Skilled personnel…………………………………………………………………………………………………………6
2.3 Safety information………………………………………………………………………………………………………6
2.4 Impermissible applications…………………………………………………………………………………6
3 Commissioning…… ………………………………………………………………………………………………………7
3.1 Set-up………………………………………………………………………………………………………………………………………7
3.2 Circuit diagram 30 kW………………………………………………………………………………………………8
3.3 Controls…………………………………………………………………………………………………………………………………9
3.4 Start-up motor/compressor……………………………………………………………………………………9
3.5 Shut-down motor/compressor…………………………………………………………………………………9
3.6 Allowable operating time……………………………………………………………………………………10
3.7 Compressor monitoring during operation………………………………………………11

4 Maintenance/Service ……………………… ……………………………………………12
4.1 Maintenance intervals………………………………………………………………………………………………12
4.2 Safety information………………………………………………………………………………………………………12
4.3 V-belt drive………………………………………………………………………………………………………………………13
4.4 Oil change / Bearing lubrication…………………………………………………………………14
5 Malfunctions / Remedies Compressor ……………………………………………15
6 Spare Parts List………….………………………………………………………………………… 16
7Service………………………………………………………………………………………………………………17

1 General
1.1 Purpose
GHH RAND build and supply the compressor unit with motor SILU CG600
ready for operation. These units are used to handle bulk material
pneumatically owing to their ability to compress atmospheric air
free of oil. They can either be installed in a stationary unit or
mounted on silo-type trucks.
1.2 Manufacturer’s address
GHH RAND
Schraubenkompressoren GmbH
Erlenstrasse 67
D-46149 Oberhausen
Germany
1.3 Identification
The machine data can be found on the name plate.
1.4 Service contact
Please see the Internet for addresses:
www.ghhrand.com
1.5 Technical data – compressor unit with motor
Type: CG600 EP-belt
Dimensions: 165x65x75cm Weight: 500kg
Protection class: IP 55
V-belt drive ratio: i=1.067
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Machine No.:

1.6 Technical data motor
Motor: Three-phase current
Type: B3
Power: 30 kW
Motor speed: 2950 rpm
Voltage: 400 VAC/50Hz
Weight: 218 kg
1.7 Technical data compressor CG 80
Operating instructions: (see CG 80)
Operating gauge pressure: 2.0 bar (g)
Suction pressure, abs.: 1.0 bar
Suction temperature: 20 C°
Suction temperature max.: 40 C°
Suction volume flow: 470 m³/h (at 2.0 bar(g))
Maximum temperature: 190 C°
Power: 30 kW
Speed compressor: 3170 rpm
Weight: 110 kg
Oil capacity: 9 liter
Important !!
The function of the non-return valve installed in the compressor
unit is to prevent the compressor, after having been switched off,
from running in reverse at high speed for a long time as a result
of residual pressure that exists in the discharge lines of the
pneumatic system.
To avoid an unintended return blow of material into the compres-
sor, it is mandatory that at least one further non-return valve is
installed in the pneumatic system of the silo arrangement.
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1.8 Installation procedure
In addition to the general technical operating instructions per the
regulations of the local authorities, special attention is drawn to
the following guidelines:
- Use a suitable hoist which fulfills the local safety
regulations for handling of the compressor unit. Securely
fasten all loose or swinging parts prior to handling. Do not
stand in the danger area of a lifted load.
- Remove all blank flanges, plugs and caps prior to installation
of the piping. Ensure that the distribution pipes and pipe
connections are of the correct size and suitable for the
respective operating pressure.
- Install the unit in a place where the ambient air is as cool and
clean as possible. If needed, provide for a suction duct. Never
block the air inlet. The sucked-in air must not contain any
flammable vapors or gases which might cause a fire or an
explosion.
- Do not remove or modify any safety devices, protective
covering or lagging. Protect any pressure tanks or accessory
installed outside the compressor unit for storing compressed
air by means of separate safety valves.
- The electrical connections must fulfill the local
regulations. The compressor units must be grounded and
protected against short circuits by means of fuses.
- If operation by remote control is provided for, a clearly
visible sign must be attached to the unit reading the
following:
Caution !!
This unit is operated by remote control and might
start without prior warning.
Make sure that the electrical connection is interrupted when
conducting maintenance and/or repair work.
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1.9 Operation manual
The mounting area of the vibration dampers can be between
316 mm and 600 mmm from the centre line on each side.
The position of the vibration dampers must be symmetrical to
the centre line.
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1.9 Installation procedure – vibration dampers
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After defining the mounting positions of the vibration dampers
in the supporting frame, cut a hole of 60 mm diameter in each
vibration damper by means of a hole saw. (please see drawing)
Vibration damper

2 Safety
2.1 General
These operating instructions provide important information which
must be observed during operation and maintenance. The skilled
personnel / operator / user therefore is required to read these
operating instructions before commissioning. Furthermore, the
instructions must be at hand where the machine is used at all
times.
2.2 Skilled personnel
Work on the compressor unit must be conducted by authorized
personnel only according to the safety rules in force.
2.3 Safety information
The operator / user is responsible for ensuring that the
compressor unit is always in an operationally safe condition.
Damaged parts must be replaced at once. If flammable goods are
handled with the compressor, take appropriate precautions to
avoid that the spontaneous-ignition temperature of a dust-and-
air mixture that may arise is not reached.
2.4 Impermissible applications
The compressor unit may not be used under other conditions than
those specified in the chapter “Technical data“ unless with
authorization by GHH RAND Schraubenkompressoren GmbH.
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3 Commissioning
3.1 Set-up
Mount the compressor unit in horizontal position, if possible.
If the unit is not mounted horizontally, please observe the
specified limit values.
Important !!
Maximum permissible angles of tilt during operation:
forward and backward: 10°
to the right and left: 10°
Electrical connection:
The standard electrical connection is realized by means of a
junction box with feeder clamps.
As an option, the unit can be delivered with a CEE connector plug
installed.
Attention !!
Work on the heavy current unit must be conducted by specially
authorized experts only.
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3.2 Circuit diagram 30 kW
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3.3 Controls – Operating elements and monitoring gauges
List / Designation:
- Start button (I) green
- Stop button (0) red
- Phase switch – Position 1-0-2
- Operation control lamp (white)
- Phase switch lamp (red)
- Oil pressure gauge compressor
- Maintenance indicator of compressor air filter
3.4 Start
Starting the motor / compressor
- Provide for electrical power connection
- Check phase circiut / direction of ratation
- (switch to 1 or 2 until lamp goes out)
- Press start button “green“
- Check start procedure
Important !!
Start the compressor unit completely relieved of load only.
Never start it trying to overcome any backpressure that may exist.
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3.5 Stop/Shut-down
Shut-down motor / compressor
- Relieve compressor discharge pipe
- Press stop button “red”
- Wait for shut-down
- Turn rotary switch to position “0”
3.6 Allowable operating time
- Maximum running time of the compressor without oil cooler:
3 hours followed by a 1-hour cool-down time.
- Continuous duty of the compressor is only possible with oil
cooler which can be supplied as an option.
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3.7 Compressor monitoring during operation
Oil pressure gauge
The oil pressure is indicated on the oil pressure gauge.
The oil pressure must not drop below 0.3 bar.
Important !!
If the oil pressure does not build up within a short period of
time, switch off the motor / compressor. Check the oil level and
clean the oil suction strainer, if necessary (see operating
instructions of compressor, chapter Maintenance).
Maintenance indicator for air filter
Negative pressure is indicated on the maintenance indicator of
the compressor unit.
Important !!
If the 65 mbar indication is reached, the negative pressure has
dropped below the permissible limit. Clean the filter element in
the suction filter of the compressor unit or replace it if it is
heavily constricted. Reset the maintenance indicator.
(see operating instructions of compressor, chapter Maintenance)
Oil pressure gauge Maintenance indicator
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1
2
1 2

4 Maintenance / Service
4.1 Maintenance intervals of motor / compressor
Important!!
In case of compressor units with V-belt drive, retension the
V-belts and the quick-lock taper bushes of the V-belt pulleys and
retighten the fastening screws of the discharge silecner with a
torque of 65 Nm after the first two hours of operation.
Daily:
Check the oil level in the compressor, adjust oil level, if
necessary.
Weekly:
Clean the filter element in the suction filter of the compressor or
replace it in case of heavy fouling. Check the V-belt tension and
adjust it, if necessary.
Quarterly:
Motor
Check electrical connections for tightness.
Relubricate rotor bearing, if nececssary.
(see operating instructions)
Compressor
Check non-return valve and safety valve for proper function.
(see operating instructions of compressor).
4.2 Safety information
- Conduct all checks and maintenance work only with the motor /
compressor switched off and with the system being
depressurized.
- Prior to conducting any work on the compressor unit with motor,
make sure that the main power cable is unplugged and without
power.
- In case of stationary units, remove the fuses.
Important !!
- Hazard of burning due to hot machine parts.
- Wear protective gloves
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4.3 Motor / V-belt drive
Tension the V-belts using the tensioning screw and a
measuring device in line with the instructions of the
V-belt manufacturer.
In order to change or retension the V-belts, remove the
V-belt protection to be able to check the V-belt tension.
To this end, unscrew the four screws at the foot of the
V-belt protection and lift off the protection the protection
completely.
Loosen the four fixing screws at the compressor foot
afterwards and decrease the tension of the V-belts by turning
the tensioning screw to the left or increase it by turning
the tensioning screw to the right.
After tensioning, tighten the fixing screws. Install the
V-belt protection.
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Fixing screw
Tensioning screw
V
-
belt protection

4.4 Oil change / Bearing lubrication
Oil change and oil level control
(see operating instructions – compressor)
Oil drain screw
Cleaning of the oil suction strainer
(see operating instructions - compressor)
Bearing lubrication – 45g/side every 3125 hrs
(see operating instructions - motor)
Bearing lubrication – 45g/side every 3125 hrs
(see operating instructions – motor)
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4
5
1
3
2
1
2
3
4
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5 Malfunctions / Remedies Compressor
Malfunction Possible cause Remedy
Oil pressure Drive speed too low Check drive speed
below 0.3 bar at Oil strainer soiled Clean oil strainer
operating Wrong oil grade Replace oil
temperature Oil level too low Top up oil
Oil pressure Oil level too low Top up oil
varies Oil intake pipe leaking Check screwed
connection
Oil foams Wrong oil grade Top up with approved
oil grade
Water in the oil Change the oil
Oil level too high Reduce oil
Oil leakages Screwed connection Check screwed
leaking connection
Compressed air Speed too high Adjust speed
pressure too high Non-return valve Replace non-return
defective valve
Safety valve does Check safety valve
not blow off
Negative pressure Suction filter clogged Clean / replace
gauge reading filter elements
65 mbar Speed to high Adjust speed
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6 Spare parts
Please always state the machine no.:…………………………………………………………
when ordering spare parts.
Ordering spare parts Phone (++49)208-690 3843
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7 Service
GHH RAND Schraubenkompressor GmbH
Erlenstrasse 67
D-46149 Oberhausen
Germany
SILU service hotline Phone (++49)208-690 3888
Fax Fax (++49)208-690 3844
Service Phone (++49)208-690 3840
Spare parts Phone (++49)208-690 3843
Printed in Germany
05/2008
Subject to modification of technical
Details on the data and figures in the
Operating instructions
Reprinting, translation and copying in
Full or extracts not allowed without
Authorization.
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