Ingersoll-Rand GHH RAND SILU CS104 User manual

EN
Operating manual
(Translation of the original instructions)
47757786 A
SILU CS104
SILU CS1200 LITE
SILU CS1200 ICL
www.ingersollrand.com/ghhrandtransport

2 47757786 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.

47757786 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.

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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 operating instructions careful‑
ly (the additional designation SILU is not used in the rest of these operating instructions).
The operating manual contains important instructions which must be strictly followed if trouble‑free
operation and a long service life are to be ensured.
Scope of application of the operating manual
These operating instructions only contain instructions for the above‑mentioned screw compressor, the
above‑mentioned compressor kit and the above‑mentioned screw compressor unit. These operating
instructions are not valid for operation of a compressor unit completed by an external installer.
Target group
The operating manual is intended for use by qualied specialist sta only.
Notes and safety instructions
The following instructions and safety instructions are used in the operating manual to warn of dangers
which could lead to 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
NOTICE warns of possible tangible damage or malfunctions.
NOTE
NOTES contain instructions to prevent operating errors and other specic useful or important informa‑
tion.

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Contents
 .................................................................................................................................... 
1.1 Application ....................................................................................................................................7
1.2 Manufacturer's address ...............................................................................................................7
1.3 Identication.................................................................................................................................7
1.4 Information for enquiries and orders .........................................................................................7
1.5 Service & Support .........................................................................................................................7
1.6 Technical data CS104 screw compressor.....................................................................................8
1.7 Technical data CS1200 compressor units....................................................................................9
1.8 Operating the compressor at high altitudes.............................................................................10
1.9 Lubricant .....................................................................................................................................10
1.10 Screw compressor type plate.....................................................................................................11
1.11 Compressor unit type plate........................................................................................................11
 ..................................................................................................................................... 
2.1 General........................................................................................................................................12
2.2 Authorized personnel, training and qualication.....................................................................12
2.3 Safety‑conscious work................................................................................................................12
2.4 Safety instructions for the owner/operator ..............................................................................12
2.5 Unauthorised conversions and spare parts..............................................................................13
2.6 Incorrect operating methods.....................................................................................................13
2.7 Disposal.......................................................................................................................................13
  ............................................................................................................................. 
3.1 Safety during operation .............................................................................................................14
3.2 Initial commissioning.................................................................................................................14
3.3 Installation ..................................................................................................................................15
3.4 Switching on ...............................................................................................................................15
3.5 Monitoring operation.................................................................................................................16
3.5.1 CS104/external installation........................................................................................................16
3.5.2 CS1200 LITE.................................................................................................................................16
3.6 CS1200 ICL ..................................................................................................................................18
3.7 External oil cooler for compressor (optional) ...........................................................................19
3.7.1 Function control of external oil cooler fan................................................................................19
3.8 Switching o ...............................................................................................................................20
3.9 Preservation................................................................................................................................20
 ........................................................................................................... 
4.1 Safety...........................................................................................................................................21
4.2 Observe the tightening torques ................................................................................................21
4.3 Maintenance Intervals................................................................................................................22
4.4 Maintenance work......................................................................................................................22
4.4.1 Retightening the fastening screws on the discharge silencer.................................................22
4.4.2 Checking the oil lines and compressor for leaks......................................................................23
4.4.3 Cleaning and replacing the intake lter element.....................................................................24
4.4.4 Checking the oil level..................................................................................................................25
4.4.5 Check the safety valve ................................................................................................................26
4.4.6 Check the non-return ap..........................................................................................................27
4.4.7 Testing and cleaning the air cooler ...........................................................................................29
4.4.8 Check and clean the oil cooler, cooling fan and intake hose ...................................................30

6 47757786 A
4.4.9 Oil change and cleaning the oil intake strainer........................................................................30
4.4.10 Replacing the overload coupling shear bolts............................................................................31
  .............................................. 

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
1 General
1.1 Application
GHH RAND builds and delivers the CS104 screw compressor, the CS1200 LITE screw compressor kit and
the CS1200 ICL screw compressor 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 the consultation with the manufacturing plant.
1.2 Manufacturer's address
GHH RAND
Schraubenkompressoren GmbH
Max-Planck-Ring 27
46049 Oberhausen
1.3 Identication
For the machine data, refer to the accompanying documents and the rating plate.
In order to always have the data on hand, we recommend that you enter it into the following blank
space.
Compressor serial no.:
Unit serial no.:
1.4 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 authorized by the manufacturer represent safety
factors. The use of non‑original or non‑authorized replacement parts and accessories may void the
liability for the resulting consequences.
‣Only use original spare parts and accessories authorized and approved by the manufacturer.
1.5 Service & Support
www.ingersollrand.com/ghhrandtransport

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
1.6 Technical data CS104 screw compressor
   
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
  CS104
Rotary valve compressor rpm 1200 1500 1800
  1.5
Intake volume m³/h 731 944 1141
Coupling output kW 32.4 42.0 52.4
Final temperature °C 141 142 146
Intake temperature max. °C 50 50 50
Intake temperature min. °C ‑20 ‑20 ‑20
  2.0
Intake volume m³/h 714 928 1126
Coupling output kW 39.3 50.3 61.9
Final temperature °C 173 170 172
Intake temperature max. °C 50 50 50
Intake temperature min. °C ‑20 ‑20 ‑20
  2.5
Intake volume m³/h 697 911 1110
Coupling output kW 46.5 58.8 71.8
Final temperature °C 207 200 201
Intake temperature max. °C 45 47 47
Intake temperature min. °C ‑20 ‑20 ‑20

Feed medium: atmospheric air
Intake pressure: 1 bar (abs.)
Intake temperature: 20 °C
Technical data without intake or pressure losses

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
Code key type designation
Compressor stage type
R = clockwise
L = anti‑clockwise
1 = with oil cooler
2 = without oil cooler
CS104 R 1
1.7 Technical data CS1200 compressor units
 CS1200 LITE*CS1200 ICL 
Width (approx.) mm 835 / 705** 865 min. rpm 1200
Depth (approx.) mm 405 725 max. rpm 1800
Height (approx.) mm 460*** 910
Weight (approx.) kg 220 290
*) in mounted condition
**) L2/R2 version without integrated oil cooler
***) 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
NOTE
The performance data of the CS1200 compressor unit correspond to screw compressor CS104 (Chapter
1.6 on page 8).

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1.8 Operating the compressor at high altitudes
If operating the compressor at high altitudes, make sure that, depending on the existing ambient pres‑
sure, the operating overpressure must be reduced in order to prevent temperature damage to the com‑
pressor.
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 over-
pressure ppermitted [bar]
2.53 2.25 2.11 1.99 1.87 1.75 1.64 1.54 1.44


An ambient temperature outside the permitted range can result in damage to the compressor.
‣The existing ambient temperature or intake temperature must be in the range -20 °C to +45°C.
1.9 Lubricant
We recommend using our fully synthetic high‑perfor‑
mance lubricant, Silol.
If you use exclusively Silol or Silol FG (foodgrade)
the interval for an oil change  to a max. 12
. The period of the manufacturer's warranty
for new compressor units  to .
NOTE
For recognition of the guarantee extension, proof
of the maintenance interval using Silol or Silol FG
is required.
Depending on the operating conditions, brand‑name
motor oils with API classication SJ/CF as per SAE
J183 can also be used.
The respective viscosity class (SAE class) can be taken
from the following diagram.
Application range ambient temperature [°C]

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
1.10 Screw compressor type plate
The type plate is attached to the side of the screw compressor. It contains the following information:
·Type
·Serial number
·Rotational 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.
1.11 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 complete identication has certicate value and may not be changed or rendered illegible.

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
2 Safety
2.1 General
This operating manual contains basic instructions to be followed during operation and maintenance/repair.
Therefore, this operating manual must be read by the responsible technical sta/operator prior to com‑
missioning and it must always be available at the place of use for the screw compressor.
2.2 Authorized personnel, training and qualication
Work carried out on the compressor, such as operation and maintenance/repair, 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 authorized personnel who is available at any time at
the service sites or at GHH RAND.
2.3 Safety-conscious work
The essential safety‑related regulations for installation, operation and maintenance/repair of air com‑
pressors are contained 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).

47757786 A 13

2.5 Unauthorised conversions and spare parts
Conversions and modications to the screw compressor and screw compressor unit are not permitted.
Damage to the seal will void any warranty claims. Original replacement parts and accessories that are
authorized by the manufacturer represent safety factors. The use of non‑original or unauthorised re‑
placement 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 1.6 on page 8 to Chapter 1.8 on page 10.
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.

14 47757786 A

3 Operation
3.1 Safety during operation
NOTE
Also observe the safety instructions in Chapter 2 on page 12.
DANGER

For the conveyance of combustible, dust‑like materials, the temperature of the compressed air at the
measurement point directly before contact with the material to be conveyed may not exceed the maxi‑
mum value of 120 °C.
‣If the maximum temperature is exceeded, switch o the compressor immediately.
CAUTION

A greater acoustic pressure level can result in damage to hearing.
‣Wear hearing protection.
CAUTION

During operation, the compressor is very hot. There is a risk of burning on hot machine parts.
‣Wear protective gloves.


Exceeding the max. running time results in tangible damage due to overheating.
‣Adhere to the max. running time: 3 hours running time and a subsequent 1 hour pause.


Exceeding the max. operating pressure results in tangible damage due to overheating.
‣Do not operate the compressor at an operating pressure of more than 2.5bar.
‣In the event of operating at high altitudes, adapt the operating pressure.
‣If exceeded, switch o the compressor.
3.2 Initial commissioning
Initial commissioning of the compressor is usually carried out on the premises of the system manu
facturer.
It includes removing the preservation, lling the oil tank and checking the direction of rotation.

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
3.3 Installation
‣Park the vehicle in as level a position as possible.
‣Observe the permitted inclination.
Permitted inclination


Excessive inclination results in irregular level of
lubricant in the housing.
‣Observe the maximum permitted inclination of
the screw compressor during operation:
·To the front and to the rear: 10°
·To the right and left: 10°
3.4 Switching on


If the compressor is started if there is counter pressure, there is the risk of damage to the non‑return
ap due to blowback of material.
‣Only start the compressor when completely depressurised.
‣Never go into operation against a potentially existing counter pressure.
NOTICE

For vehicles with side cladding installed, the side
cladding must be folded down or removed before
switching on the compressor unit in order to pre‑
vent temperature damage to the compressor.
‣Ensure sucient fresh air supply.
‣Switch on power take-o.

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3.5 Monitoring operation
3.5.1 CS104/external installation
The manufacturer installs a gauge (measurement position in the following pipeline) pneumatic system
to monitor the compression pressure. The system manufacturer or external installer must also install
displays that monitor the intake negative pressure and the oil pressure of the compressor stage. For the
operation and control of the operating displays, only the instructions from the manufacturer are applica‑
ble. The permitted operating conditions and limit values can be found in Chapter 1.6 on page 8 to
Chapter 1.8 on page 10.
NOTE
With external installations, displays from diverse manufacturers can be installed. Also observe the
instructions from the manufacturer.
3.5.2 CS1200 LITE
Oil pressure gauge
The oil pressure is displayed on the oil pressure
gauge (1).
The oil pressure may not drop below 0.3 bar.


If the oil pressure is insucient, signicant tangi‑
ble damage can occur.
‣Do not fall below the minimum permitted oil
pressure.
‣If, after a short time of operation, no oil pres‑
sure is built up, switch o the compressor and
check the oil level, as necessary clean the oil
intake strainer.
Maintenance indicator variant 1
The negative pressure in the compressor is displayed
on the maintenance indicator (1).
The negative pressure must not exceed 65 mbar (red
area on the maintenance indicator).


Excessive negative pressure (> 65 mbar) can result
in overheating and damage to the compressor.
‣Clean the intake lter elements of the compres‑
sor or, in the event of excessive clogging, re‑
place the lter (Chapter 4.4.4 on page 25).
1

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Resetting the maintenance indicator
If the negative pressure has dropped to below the permitted limit (65 mbar, red area on the maintenance
indicator), the maintenance indicator must be reset after rectication of the malfunction.
‣Push the button (2) on the front of the maintenance indicator (1).
Maintenance indicator variant 2
The negative pressure in the compressor is displayed
on the maintenance indicator (2).
The negative pressure must not exceed 65mbar. The
service display (1) is then red.


Excessive negative pressure (> 65 mbar) can result
in overheating and damage to the compressor.
‣Clean the intake lter elements of the compres‑
sor or, in the event of excessive clogging, re‑
place the lter (Chapter 4.4.4 on page 25).
Resetting the maintenance indicator
If the negative pressure has exceeded the permitted limit (service display (1) is red), the maintenance
indicator must be reset after rectication of the malfunction.
‣Push the button (3) on the top of the maintenance indicator (2).

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3.6 CS1200 ICL
Oil pressure gauge
The oil pressure is displayed on the oil pressure gauge (1).
The oil pressure may not drop below 0.3 bar.


If the oil pressure is insucient, signicant tangi‑
ble damage can occur.
‣Do not fall below the minimum permitted oil
pressure.
‣If, after a short time of operation, no oil pres‑
sure is built up, switch o the compressor and
check the oil level, as necessary clean the oil
intake strainer.
Negative pressure maintenance indicator
The negative pressure in the compressor is displayed
on the negative pressure maintenance indicator (2).
The negative pressure must not exceed 65 mbar (red
area on the maintenance indicator).


Excessive negative pressure (> 65 mbar) can
result in overheating and damage to the
compressor.
‣Clean the intake lter elements of the compres‑
sor or, in the event of excessive clogging, re‑
place the lter (Chapter 4.4.3 on page 24).
Resetting the maintenance indicator
If the negative pressure has exceeded the permitted limit, the maintenance indicator must be reset after
rectication of the malfunction. This is done accordingly for “Maintenance display variant 2” in Chapter
3.5.2 on page 16.
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
Cooling fan speed selector switch
The fan speed can be set with the selector switch (3):
·Left pos.  “HOT” fan is switched of
·Right pos.  “COOL” fan (automatic with
temperature control) is
switched on
3.7 External oil cooler for compressor (optional)
To ensure that the compressor has an optimum service life even under extreme conditions, an external
oil cooler can be connected as an option.
3.7.1 Function control of external oil cooler fan
A sheet of paper held in front of the radiator of a running fan must be sucked towards it.


The compressor can be damaged if the fan is defective.
‣Check that the fan works.
·The paper is sucked in by the fan.

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3.8 Switching o


If the compressor is switched o if there is counter pressure, there is the risk of damage to the non -
return ap due to blowback of material.
‣Do not turn compressor o if there is counter pressure!
‣If there is counter pressure, take appropriate measures to reduce pressure before switching o the
compressor.
NOTE
The non-return ap installed in the compressor unit prevents the compressor from running backwards
rapidly and for a long time (as a result of residual pressure in the compressed air lines of the pneumatic
system) after being shut down.
‣Switch o power take-o.
NOTE
Before switching o, do not manually reduce the compressor speed using the speed control.


The compressed air line ruptures if it is not disconnected from the compressor unit before starting the
journey. Internal components of the compressor unit can also be damaged.
‣Disconnect the compressed air line from the compressor unit before starting journey.
NOTE
After switching o the IC compressor unit, the fan of the air cooler continues to run until the air tem‑
perature in the IC unit is below 50 °C.
3.9 Preservation
If the compressor is shut down for an extended period of time, the compressor must be protected from
corrosion damage using a preservative. Please consult the manufacturer for a recommendation of a
suitable preservative.