Ingersoll-Rand GHH RAND SILU CS104 User manual

Mounting instructions
(Translation of the original instructions)
47757787 A
SILU CS104
SILU CS1200 LITE
SILU CS1200 ICL
www.ingersollrand.com/ghhrandtransport
EN

2 47757787 A
DE WICHTIG!
Die Betriebsanleitung liegt in Ihrer Landessprache zusammen mit der Montageanleitung (englische
und deutsche Ausführung) elektronisch auf der Webseite www.ingersoll.com/ghhrandtransport für den
Download bereit. Auf Anfrage senden wir Ihnen auch gerne eine gedruckte Version zu.
EN IMPORTANT!
The operating instructions can be downloaded electronically in your language, together with the mount‑
ing instructions (in English and German) from the website www.ingersollrand.com/ghhrandtransport.
On request, we will gladly send you a printed version.
CZ DŮLEŽITÉ!
Návod k provozu je k dispozici ke stažení v jazyce Vaší dané země společně s návodem pro montáž (ang‑
lická nebo německá verze) elektronicky na webové stránce www.ingersollrand.com/ghhrandtransport.
Na vyžádání vám rádi zašleme i tištěnou verzi.
DK VIGTIGT!
Denne driftsvejledning på dit lands sprog ligger elektronisk og klar til download sammen med monte‑
ringsvejledningen (engelsk og tysk version) på hjemmesiden www.ingersollrand.com/ghhrandtransport.
Efter forespørgsel sender vi dig også gerne en trykt version.
ES ¡IMPORTANTE!
El manual de instrucciones en su idioma junto a las instrucciones de montaje (en inglés y alemán) está
disponible para su descarga en formato electrónico en www.ingersollrand.com/ghhrandtransport. Si lo
desea, podemos enviarle también un ejemplar en papel.
FR IMPORTANT!
Vous pouvez télécharger la manuel d’utilisation dans la langue de votre pays avec les instructions de
montage (en anglais et en allemand) au format électronique sur le site Web www.ingersollrand.com/
ghhrandtransport. Sur demande, nous vous enverrons volontiers une version imprimée.
IT IMPORTANTE!
Le istruzioni d’esercizio sono disponibili in formato elettronico per il download sul sito www.ingersollrand.com/
ghhrandtransport in lingua italiana, insieme alle istruzioni per il montaggio (edizione in inglese e in tede‑
sco). Su richiesta saremo lieti di inviarvene anche una copia in formato cartaceo.
NL BELANGRIJK!
De gebruikshandleiding kan samen met de montagehandleiding (Engelse en Duitse versie) in uw taal
elektronisch worden gedownload van de website www.ingersollrand.com/ghhrandtransport. Op aan‑
vraag sturen we u met alle plezier ook een gedrukte versie.
PL WAŻNE!
Instrukcja obsługi dostępna jest w ojczystym języku użytkownika wraz z instrukcją montażu (w języku
angielskim i niemieckim) w elektronicznej formie do pobrania na stronie internetowej
www.ingersollrand.com/ghhrandtransport. Na życzenie chętnie prześlemy Państwu również wersję dru‑
kowaną.

47757787 A 3
SE VIKTIGT!
Bruksanvisningen går att hämta elektroniskt på landets språk tillsammans med monteringsanvisningen
(på engelska och tyska) på webbsajten www.ingersollrand.com/ghhrandtransport. På begäran skickar vi
även gärna ett tryckt exemplar.
FI TÄRKEÄÄ!
Suomenkielisen käyttöohjeen ja (englannin‑ ja saksankielisen) asennusohjeen voi ladata sähköisessä
muodossa osoitteesta www.ingersollrand.com/ghhrandtransport. Pyydettäessä lähetämme myös tulos‑
tetun version.
BY ВАЖНА!
Электронную версію кіраўніцтва па эксплуатацыі на нацыянальнай мове разам з інструкцыяй па
мантажы (на англійскай і нямецкай мовах) можна спампаваць на сайце www.ingersollrand.com/
ghhrandtransport. Па асобным запыце мы з задавальненнем дашлем вам друкаваную версію.

4 47757787 A
Introduction
Before installing and commissioning the SILU CS104 screw compressor, the SILU CS1200 LITE compres‑
sor kit or the SILU CS1200 ICL compressor unit, please read through these mounting instructions careful‑
ly (the additional designation SILU is not used in the rest of these mounting instructions).
The mounting instructions describe how to erect and commission the above‑mentioned compressors.
Make sure that these mounting instructions are available to the installation personnel and that the tasks
are carried out in accordance with the instructions contained in it.
Scope of application of the mounting instructions
The mounting instructions only contain instructions for mounting the above‑mentioned screw compres‑
sor, the above‑mentioned compressor kit and the above‑mentioned screw compressor unit. The mount‑
ing instructions do not apply for the installation of components/units from other companies by an ex‑
ternal installer. If a third‑party manufacturer designs and manufactures a compressor unit based on the
CS104 compressor stage, they are obliged to provide the end user with their own operating instructions.
Target group
The mounting instructions are restricted exclusively for use by qualied specialists.
Notes and safety instructions
The following instructions and safety notices are used in the mounting instructions to warn of dangers
which could result in operating errors, injuries and tangible damage:
DANGER
DANGER warns of an imminent danger and indicates an imminent danger. This safety note warns of
possible irreversible to fatal injuries.
WARNING
WARNING indicates a possible imminent danger. This safety note warns of serious or perilous injuries.
CAUTION
CAUTION indicates a possible imminent danger. This safety note warns of light injuries.
NOTICE
ATTENTION warns of possible tangible damage or malfunctions.
NOTE
NOTES contain instructions to prevent operating errors and other specic useful or important informa‑
tion.

47757787 A 5
Contents
 .................................................................................................................................... 
1.1 Application ....................................................................................................................................7
1.2 Manufacturer's address ...............................................................................................................7
1.3 Screw compressor type plate.......................................................................................................7
1.4 Compressor unit type plate..........................................................................................................8
1.5 Information for enquiries and orders .........................................................................................8
1.6 Service & Support .........................................................................................................................8
1.7 Technical data CS104 screw compressor.....................................................................................9
1.7.1 Performance data CS104 screw compressor ............................................................................10
1.8 Technical data CS1200 LITE compressor kit ..............................................................................12
1.9 Technical data CS1200 ICL compressor unit ............................................................................12
1.10 Technical data compressor unit.................................................................................................13
1.11 Operating the compressor at high altitudes.............................................................................14
1.12 Maximum running time .............................................................................................................14
1.13 External oil cooler for extreme conditions................................................................................15
 ..................................................................................................................................... 
2.1 General........................................................................................................................................16
2.2 Authorised personnel, training and qualication.....................................................................16
2.3 Safety‑conscious work................................................................................................................16
2.4 Safety instructions for the owner/operator ..............................................................................16
2.5 Unauthorised conversions and spare parts..............................................................................17
2.6 Incorrect operating methods.....................................................................................................17
2.7 Disposal.......................................................................................................................................17
 .................................................................................................... 
3.1 Internal transportation ..............................................................................................................18
3.1.1 Internal transportation of the screw compressor ....................................................................18
3.1.2 Internal transportation of the unit ............................................................................................19
3.2 Drive ............................................................................................................................................19
3.2.1 Hydraulic actuation ....................................................................................................................19
3.2.2 Articulated shaft .........................................................................................................................20
3.3 Installation and position ............................................................................................................20
3.3.1 Permitted inclination..................................................................................................................21
3.4 Preparing installation.................................................................................................................21
3.4.1 Required space conditions for the compressor kit and compressor unit ...............................21
3.4.2 Checking the direction of rotation.............................................................................................21
3.4.3 Aligning the compressor on the vehicle/ange parallelism ....................................................21
3.4.4 Air ow CS1200 ICL/lter installation location CS1200 LITE ....................................................22
3.4.5 Air intake oil cooler fan CS104 L1/R1 compressor....................................................................23
3.5 Observe the tightening torques ................................................................................................23
3.6 Completion of the screw compressor........................................................................................24
3.6.1 Installation of the hose connector ange.................................................................................24
3.6.2 Mounting the maintenance indicator and oil pressure gauge................................................25
3.6.3 Oil cooler connection CS104 L2/R2 compressor.......................................................................26
3.6.4 Mounting the air intake lter.....................................................................................................26
3.6.5 Mounting the discharge silencer...............................................................................................27
3.6.6 Installing the safety valve ..........................................................................................................30

6 47757787 A
3.6.7 Mounting the non-return ap....................................................................................................31
3.6.8 Installing the overload coupling................................................................................................31
3.6.9 Installing the screw compressor on the mounting console (third‑party manufacturer) .......33
3.6.10 Installing the pressure line ........................................................................................................33
3.7 Completion of the compressor unit...........................................................................................34
3.7.1 Test mounting of the CS1200 LITE compressor kit ...................................................................34
3.7.2 Test mounting of the CS1200 ICL compressor unit ..................................................................37
3.7.3 Mounting of the CS1200 LITE compressor kit...........................................................................39
3.7.4 Mounting of the CS1200 ICL compressor unit..........................................................................42
3.7.5 Installing the articulated shaft.......................................................................................44
3.8 Connecting the external oil cooler to the CS104 L2/R2 compressor .......................................44
3.8.1 Installing the external oil cooler fan controller (optional) .......................................................44
3.9 Connecting the control unit to the CS1200 ICL compressor unit ............................................45
  ........................................................................................................................
4.1 Attaching the stickers to the unit (example).............................................................................47
  ......................................................................................................
5.1 Lubricant .....................................................................................................................................48
5.2 Filling with lubricant...................................................................................................................49
5.3 Removing the preservation........................................................................................................49
5.4 Test run........................................................................................................................................50
5.4.1 Switching on ...............................................................................................................................50
5.4.2 Checking the direction of rotation.............................................................................................50
5.4.3 Checking the drive speed...........................................................................................................51
5.4.4 Cooling fan CS1200 ICL ..............................................................................................................51
5.4.5 Function control of external oil cooler fan (CS104 L2/R2 compressor)...................................51
5.4.6 Switching o ...............................................................................................................................52
5.4.7 Checks after the test run............................................................................................................52

47757787 A 7

1 General
1.1 Application
GHH RAND builds and supplies the CS104 screw compressor and the CS1200 compressor units for instal‑
lation on silo vehicles for the connection‑ready unit.
Because of their oil‑free compression of atmospheric air and their power‑to‑weight ratio for installation
on silo vehicles, the compressor unit is used to pneumatically convey bulk goods, such as our, sugar,
salt, animal feed, powdered chemicals, dry granulate, soda, cement, sand, lime, plaster, etc.
The products built and supplied by GHH RAND are only designed for the operation at and on utility vehi‑
cles that exclusively drive on paved roads.
A dierent use requires consultation with the manufacturer.
1.2 Manufacturer's address
GHH RAND
Schraubenkompressoren GmbH
Max-Planck-Ring 27
46049 Oberhausen
1.3 Screw compressor type plate
The type plate is attached to the side of the screw compressor.
It contains the following information:
·Type
·Serial no.
·Speed range
·max. volume ow
·At max. operating pressure
·max. power consumption
NOTE
The complete identication has certicate value and may not be changed or rendered illegible.

8 47757787 A

1.4 Compressor unit type plate
The type plate on the compressor unit is attached to the mounting console.
It contains the following information:
·Type
·Year of manufacture
·Compressor serial no.
·Unit serial no.
·Unit drive speed
·Intake volume
·max. operating pressure
NOTE
The type plate for the compressor kit supplied by GHH RAND must be created by the installation manu‑
facturer and attached to the fully mounted compressor unit in a clearly visible place. It should contain
the information listed above.
NOTE
The complete identication has certicate value and may not be changed or rendered illegible.
1.5 Information for enquiries and orders
If you have enquiries or orders for spare parts and accessories, please provide details of the exact type
designation and the serial number of the screw compressor or the compressor unit, for which the spare
part or accessory is intended.
CAUTION

Original replacement parts and accessories that are authorised by the manufacturer represent safety
factors. The use of non‑original or non‑authorised replacement parts and accessories may void the
liability for the resulting consequences.
‣Only use original spare parts and accessories authorised and approved by the manufacturer.
1.6 Service & Support
www.ingersollrand.com/ghhrandtransport

47757787 A 9

1.7 Technical data CS104 screw compressor
Model: CS104 L1/R1 (version with integrated oil cooler for PTO R/L operation). All dimensions are approximate.
*Dimension for model CS104 L2/R2 (not depicted separately, other dimensions are identical)
Dimensions & weight L1/R1 L2/R2 Rotational speed range
Length (approx) mm 660 535* min. rpm 1200
Width (approx.) mm 356 338* max. rpm 1800
Height (approx) mm 485 485
Weight (approx) kg 144/140 137/134
 
max. 2.5 bar approx. 3 litres
 
max. 65 mbar min. 0.3bar
NOTE
Due to the various ways of regarding the direction of
rotation of the drive, it must be ensured that the com‑
pressor stage with the following name is used:
CS1200 LITE/ICL for
PTO-Lwith CS104 
PTO-Rwith CS104 
Code key type designation
Compressor stage type
R = clockwise
L = anti‑clockwise
1 = with oil cooler
2 = without oil cooler
CS104 R 1

10 47757787 A

1.7.1 Performance data CS104 screw compressor
All information for:
Feed medium: atmospheric air
Intake pressure: 1bar (abs.)
Intake temperature: 20°C
Permitted min. ambient temp.: -25°C
Relative humidity: 60 %
Technical data without intake or pressure losses
n Drive speed
V Intake volume
t2Final temperature
P Coupling output
t1,max Permitted intake temperature
Pressure dierence:
1.0bar
1.5bar
2.0bar
2.5bar
≤ 2.0bar

47757787 A 11

All information for:
Feed medium: atmospheric air
Intake pressure: 1bar (abs.)
Intake temperature: 20°C
Permitted min. ambient temp.: -25°C
Relative humidity: 60 %
Technical data without intake or pressure losses
n Drive speed
V Intake volume
t2Final temperature
P Coupling output
t1,max Permitted intake temperature
Pressure dierence:
1.0bar
1.5bar
2.0bar
2.5bar
≤ 2.0bar

12 47757787 A

1.8 Technical data CS1200 LITE compressor kit
Model: CS1200 LITE with integrated oil cooler PTO R/L All dimensions are approximate.
1.9 Technical data CS1200 ICL compressor unit
Model: CS1200 ICL with integrated oil cooler PTO R/L All dimensions are approximate.

47757787 A 13

1.10 Technical data compressor unit
Dimensions & weight CS1200 LITE CS1200 ICL Rotational speed range
Length (approx) mm 835/705* 865 min. rpm 1200
Width (approx.) mm 405** 725 max. rpm 1800
Height (approx) mm 460*** 910
Weight (approx) kg 220 290
* L2/R2 version without integrated oil cooler
** The space requirement may be larger with the use of spacers
***Dimension up to lower edge of vehicle frame


Exceeding the permitted speed range leads to material damage.
‣Do not operate the compressor outside of its permitted speed range.
 
max. 2.5 bar approx. 3 litres
 
max. 65mbar min. 0.3bar
Connection dimensions
Pressure joint R 2.5" external thread
Suction nozzle for intake air Ø130 mm
Air intake tting, oil cooler fan Ø125 mm
Articulated shaft Only articulated shafts with two joints are permitted.
Only balanced articulated shafts with a balance quality level of
G 6.3 in accordance with DIN ISO 1940 with length compensa‑
tion may be used.
NOTE
The performance data of the CS1200 LITE compressor kit and the CS1200 ICL compressor unit corre‑
spond to the CS104 screw compressor (Chapter 1.7.1 on page 10).
NOTE
More detailed information can be found in the separately available installation drawing of the
compressor unit.

14 47757787 A

1.11 Operating the compressor at high altitudes
If operating the compressor at high altitudes, make sure that, depending on the
existing ambient pressure, the operating overpressure must be reduced in order to prevent temperature
damage to the compressor and compressor unit.
This should be carried out in accordance with the following table:
Installation height h [m] 0 1000 1500 2000 2500 3000 3500 4000 4500
Permitted operating overpressure
ppermitted [bar]
2.53 2.25 2.11 1.99 1.87 1.75 1.64 1.54 1.44
NOTICE

An ambient temperature outside the permitted range can result in damage to the compressor.
‣The existing ambient temperature and intake temperature must be in the range of ‑20°C to t1,max (for
pressure dierence 2.5 bar, refer to respective type of compressor) (Chapter 1.7.1 on page 10).
1.12 Maximum running time
The maximum permitted running time is 3 hours. Subsequently, there must be a minimum pause of 1
hour. Non‑adherence to the running time can result in damage caused by overheating.
NOTE
Due to their construction, the screw compressor and the compressor unit are designed for the inter‑
mittent operation as described above. Continuous use of the compressor leads to a reduced service
life. The use of an external oil cooler can improve the service life in the case of extended runtimes and
extreme conditions.

47757787 A 15

1.13 External oil cooler for extreme conditions
To give the compressor an optimum service life, an external oil cooler* must be operated under the
following
conditions:
a) When operating in an enclosed environment (encapsulated), e.g. customer‑owned or direct‑driven
systems with a cover/casing, or our own electrical/diesel systems
or
b) When operating in challenging/cramped environments, e.g. installations in the immediate vicinity
of other systems/installations on the vehicle frame that are subject to heat development and/or that
prevent an unimpeded supply of fresh air (e.g. vehicle exhaust systems, side plates, cladding, etc.)
or
c) For operating times that exceed the typical duration of use of standard silos (up to 5 discharges per
day; typical discharge times of up to 3 hours)
or
d) When the breaks in operation between discharges are less than 1 hour
NOTE
In order to uphold any warranty claims, maintain the highest product reliability and
service life in terms of the compressor stage and lubricant, an external oil cooler must be installed and
used in the specied cases.
It must be ensured that it is correctly dimensioned depending on the prevailing environmental condi‑
tions.
* The required heat dissipation of the oil cooler should be at least 4 kW @ 10 litres of oil/min. and 30 °C ambient temperature (T1 or
equivalent; while observing the installation specications of the oil cooler). For special applications, for e.g. in the case of ambient
temperatures above 35 °C, the oil cooler must accordingly be designed to be larger (T2 or equivalent, while observing the installa‑
tion specications of the oil cooler).

16 47757787 A

2 Safety
2.1 General
These mounting instructions contain fundamental instructions which must be adhered to when perform‑
ing assembly and installation. This mounting instruction must therefore be read in full by the responsible
specialist sta before starting work.
2.2 Authorised personnel, training and qualication
Installation and assembly work must only be carried out by persons with the appropriate authorisation,
training and qualications, who are familiar with the valid safety regulations.
Repairs or modications must only be performed by authorised personnel who is available at any time at
the service sites or at GHH RAND.
2.3 Safety-conscious work
The safety‑related regulations that are relevant for the installation, operation and maintenance of air
compressors can be found in the following publications:
Machinery Directive 2006/42/EC
Standards, in particular:
DIN EN ISO 12100‑1/2 Safety of machinery
DIN EN 1012‑1 Compressors and vacuum pumps, safety requirements
The regulations of the professional associations, in particular:
BGI 666 Sample operating instructions for operation of container vehicles for
granular or dust‑like goods (silo vehicles).
In this context, the respectively last applicable versions of these regulations shall be authoritative. Spe‑
cial legal provisions and regulations, particularly safety regulations, that may apply in your company or
due to local conditions must also be adhered to. In case of competing regulations, the more restrictive
provisions shall be applied. You must also observe any national regulations in the respective country of
use.
2.4 Safety instructions for the owner/operator
The owner/operator is responsible for ensuring that the screw compressor is in a safe operational condi‑
tion. Damaged or faulty parts must be immediately replaced. If the screw compressor is used to convey
combustible materials, make sure that the temperature remains below the spontaneous ignition tem‑
perature for any dust/air mixture which may be created. In accordance with the professional association
regulation BGI 666, for the pneumatic transport of materials subject to dust explosion, a temperature
limit of max. 120 °C must be adhered to (measurement point before contact with the materials to be
conveyed).

47757787 A 17

2.5 Unauthorised conversions and spare parts
Conversions and modications to the screw compressor and screw compressor unit are not permitted.
In the event of damage to the lead seal, any warranty claims are invalid.
Original replacement parts and accessories that are authorised by the manufacturer represent safety
factors. The use of non‑original or unauthorised replacement and accessory parts may void the liability
for resulting consequences.
2.6 Incorrect operating methods
WARNING

The operation of the compressor under incorrect conditions may lead to serious
injuries and signicant material damage.
‣The compressor must only be operated under permitted conditions.
Unless approval is obtained from GHH RAND, the compressor must only be operated under the condi‑
tions stated in Chapter 1.7 on page 9 to Chapter 1.13 on page 15.
2.7 Disposal
Compressor components, as well as operating materials used in conjunction with the compressor, com‑
pressor kit and compressor unit must be disposed of observing the local regulations.

18 47757787 A
Installation guidelines
3 Installation guidelines
NOTE
Also observe the safety instructions in Chapter 2 on page 16.
3.1 Internal transportation
3.1.1 Internal transportation of the screw compressor
The screw compressor and the accessories are delivered separately.
The screw compressor is on a pallet and secured with straps.
The accessories are delivered in a separate box.
WARNING

If using internal transport with insuciently dimensioned transportation equipment, there is a risk of
tipping over and injuries.
‣For internal transportation, use a suciently dimensioned lifting truck or fork lift.
For the transport of the screw compressor with
a crane, it is possible to screw a ring screw (1) into
the threaded hole (M12) on the top of the compres‑
sor.
WARNING


Serious injuries, including death, are possible if
the screw compressor falls when
transporting using a crane.
‣Use suciently dimensioned lifting
accessories.

47757787 A 19
Installation guidelines
3.1.2 Internal transportation of the unit
The compressor unit (1) is fastened to a euro‑pallet
(2). For transportation, use a suciently
dimensioned lifting truck/fork lift.
WARNING


If using internal transport with insuciently
dimensioned transportation equipment, there is a
risk of tipping over and injuries.
‣For transportation, use a suciently dimen‑
sioned lifting truck or fork lift.
3.2 Drive
The compressor can be driven directly using an articulated shaft or using a hydraulic drive.
To protect the drive (vehicle drive), an overload coupling is included in the scope of delivery of the
CS1200 LITE/ICL.
NOTICE

Not installing an overload coupling can lead to damage to the drive.
‣If no overload coupling is installed, other safety measures must be taken
(e.g. articulated shaft catcher).
NOTICE

If the required operating speed is not reached promptly, the compressor can overheat and this leads
to damage to the compressor.
‣During operation, the operating speed must be reached promptly.
3.2.1 Hydraulic actuation
NOTE
For more information about the hydraulic drive of the compressor, please contact GHHRAND.
When operating a tilting bulk carrier vehicle, the hydraulic pump of the tilting plunger can also be used
for the compressor drive.

20 47757787 A
Installation guidelines
3.2.2 Articulated shaft
The compressor drive is usually carried out through an articulated shaft between the power take-o of
the vehicle drive and the ange of the overload coupling.
Selection of articulated shaft
Consider the following items during the determination of the articulated shaft:
‣Determine the length of the articulated shaft considering the installation dimensions while paying
attention to the maximum permitted expansion length.
NOTICE

Incorrect installation of the articulated shaft can result in damage to the compressor drive.
‣For the maximum permitted extension length of the articulated shaft, refer to the operating manual
of the manufacturer of the articulated shaft and maintain during installation.
NOTE
The selection of the articulated shaft should only
be made after the test mounting of the compres‑
sor on the vehicle (Chapter 3.7.1 on page 34),
since this is how the precise installation location
of the compressor is determined.
The overall inclination angle α of the articulated shaft
must not exceed 12°.
In exceptional cases, where installation space is
limited, larger angles of up to 15° may be permitted
in consultation with the vehicle manufacturer using
special articulated shafts.
3.3 Installation and position
The compressor unit must be connected to the vehicle frame using a mounting console (retaining de‑
vice). If a mounting console not supplied by GHH RAND is used, the dynamic load resulting from the
weight of the compressor and attachment parts and the condition of the road must be taken into ac‑
count when designing it.
In addition, observe the regulations and instructions from the respective vehicle manufacturer.
The screw compressor has an attachment on one side. It must be installed on a level, torsion‑free base. It
must be screwed to the console at all 3 attachment points provided (Chapter 1.7 on page 9).