Ingersoll-Rand GHH RAND SILU CS80 User manual

Mounting instructions
(Translation of the original instructions)
47757781 A
SILU CS80
SILU CS700 LITE
SILU CS700 STANDARD
SILU CS700 IC
www.ingersollrand.com/ghhrandtransport
EN

2 47757781 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.
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.
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.
RO IMPORTANT!
Instrucțiunile de exploatare în limba țării dvs., împreună cu instrucțiunile de montaj (versiunea în
limba engleză și germană) sunt disponibile pentru descărcare în format electronic pe site-ul web
www.ingersollrand.com/ghhrandtransport. De asemenea, la cerere vă putem trimite o versiune tipărită.
HU FONTOS!
Az üzemeltetési útmutató az Ön nyelvén a szerelési útmutatóval (angol és német nyelvű változat) együtt
elektronikusan letölthető a www.ingersollrand.com/ghhrandtransport webhelyről. Kérésére szívesen
küldünk egy kinyomtatott változatot is.
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.

47757781 A 3
SI POMEMBNO!
Navodila za uporabo so v elektronski obliki na voljo za prenos v vašem lokalnem jeziku skupaj z navodili
za montažo (angleška in nemška različica) na spletni strani www.ingersollrand.com/ghhrandtransport.
Na zahtevo vam bomo z veseljem poslali tudi tiskano različico.
LT SVARBU!
Elektroninę eksploatavimo instrukcijos Jūsų šalies kalba versiją kartu su montavimo instrukcija (anglų ir
vokiečių kalbomis) galite atsisiųsti iš interneto svetainės www.ingersollrand.com/ghhrandtransport. Jei
pateiksite užklausą, mielai atsiųsime ir išspausdintą versiją.

4 47757781 A
Introduction
Before installing and commissioning the SILU CS80 screw compressor or the SILU CS700 LITE, SILU CS700
STANDARD, SILU CS700 IC compressor units, please read through these mounting instructions carefully
(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 and the above-mentioned screw compressor units. The mounting instructions do not apply for the
installation of components/units from other companies by an external installer. If a third-party manu-
facturer designs and manufactures a compressor unit based on the CS80 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.

47757781 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 CS80 screw compressor.......................................................................................9
1.7.1 Performance data CS80 screw compressor ..............................................................................11
1.8 Technical data CS700 LITE compressor unit..............................................................................13
1.9 Technical data CS700 STANDARD compressor unit ..................................................................14
1.10 Technical data CS700 IC compressor unit .................................................................................15
1.11 Technical data compressor unit.................................................................................................16
1.12 Operating the compressor at high altitudes.............................................................................17
1.13 Maximum running time .............................................................................................................17
1.14 External oil cooler for extreme conditions................................................................................18
 ..................................................................................................................................... 
2.1 General........................................................................................................................................19
2.2 Authorised personnel, training and qualication.....................................................................19
2.3 Safety-conscious work................................................................................................................19
2.4 Safety instructions for the owner/operator ..............................................................................19
2.5 Unauthorised conversions and spare parts..............................................................................20
2.6 Incorrect operating methods.....................................................................................................20
2.7 Disposal.......................................................................................................................................20
 .................................................................................................... 
3.1 Internal transportation ..............................................................................................................21
3.1.1 Internal transportation of the screw compressor ....................................................................21
3.1.2 Internal transportation of the unit ............................................................................................22
3.2 Drive ............................................................................................................................................22
3.2.1 V-belt drive..................................................................................................................................22
3.2.2 Articulated shaft .........................................................................................................................23
3.2.3 Direct drive..................................................................................................................................23
3.3 Installation and position ............................................................................................................23
3.3.1 Permitted inclination..................................................................................................................24
3.4 Preparing installation.................................................................................................................24
3.4.1 Required space conditions for the unit .....................................................................................24
3.4.2 Checking the direction of rotation.............................................................................................24
3.4.3 Checking the direction of rotation of the unit ..........................................................................24
3.4.4 Aligning the compressor unit on the vehicle/ange parallelism.............................................24
3.4.5 Air ow CS700 IC.........................................................................................................................25
3.5 Observe the tightening torques ................................................................................................25
3.6 Completion of the screw compressor........................................................................................26
3.6.1 Installing the hose connection ange (example) .....................................................................26
3.6.2 Installing the maintenance indicator on the hose connecting ange ....................................26
3.6.3 Installing the oil pressure gauge...............................................................................................27
3.6.4 Oil cooler connection on the compressor (optional)................................................................27

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3.6.5 Installing the intake silencer and air lter ................................................................................28
3.6.6 Mounting the discharge silencer...............................................................................................29
3.6.7 Installing the safety valve ..........................................................................................................30
3.6.8 Installing the non-return valve ..................................................................................................31
3.6.9 Installing the oil dipstick ............................................................................................................31
3.6.10 Installing the screw compressor on the mounting console (third-party manufacturer) .......32
3.6.11 Installing the pressure line ........................................................................................................32
3.7 Completion of the compressor unit...........................................................................................33
3.7.1 Test mounting of the compressor unit......................................................................................33
3.7.2 Installing the compressor unit...................................................................................................35
3.7.3 Installing the articulated shaft...................................................................................................36
3.8 Connecting the external oil cooler (optional) ...........................................................................37
3.8.1 Installing the external oil cooler fan controller (optional) .......................................................37
3.9 Connecting the control unit CS700 IC .......................................................................................38
  ........................................................................................................................
4.1 Attaching the stickers to the unit (example).............................................................................40
  ...................................................................................................... 
5.1 Lubricant .....................................................................................................................................41
5.2 Filling with lubricant...................................................................................................................42
5.3 Removing the preservation........................................................................................................42
5.4 Test run........................................................................................................................................43
5.4.1 Switching on ...............................................................................................................................43
5.4.2 Checking the direction of rotation.............................................................................................43
5.4.3 Checking the drive speed...........................................................................................................44
5.4.4 Cooling fan CS700 IC .................................................................................................................44
5.4.5 Function control of external oil cooler fan (optional)...............................................................44
5.4.6 Switching o ...............................................................................................................................44
5.4.7 Checks after the test run............................................................................................................45

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
1 General
1.1 Application
GHH RAND builds and supplies the CS80 screw compressor and the CS700 compressor units
for installation 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.
·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.

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
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.
·V-belt drive ratio
·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.
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

47757781 A 9

1.7 Technical data CS80 screw compressor
All dimensions are approximate.
C Suction ange
D Pressure ange
E Feather key
F2 Oil ll nozzle with oil dipstick
G Space required to remove the oil dipstick
H Connection for oil pressure gauge
I Space required to remove the oil lter
K Oil drain
L Connection for measuring the nal pressure
M Connection for measuring the
nal temperature
N Connection for vacuum gauge
O Direction of rotation
P In the event of damage to the lead seal, any war-
ranty claims are invalid
Q Connection for external oil cooler
(pipeline to the oil cooler)
R Connection for external oil cooler
(pipeline from the oil cooler)
U When installing an oil cooler, replace the existing
locking screw with special screw
(item no.:22200000)
V Threaded hole for lifting accessories

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
 
Length (approx) mm 640 min. rpm 1000
Width (approx.) mm 392 max. rpm 2000
Height (approx) mm 345
Weight (approx) kg 146
 
max. 2.5 bar approx. 9 litres
 
max. 65 mbar min. 0.3 bar

Thread of attachment screw 4 x M16
Intake ange NW80/Ø122 - 4 x M12
Pressure ange NW65/Ø118 - 4 x M12
Drive journal Ø 40 m5/70 lg
Permitted radial force Frmax. = 6000 N
(measured 35 mm from shaft shoulder)
Feather key A12 x 8 x 60 DIN 6885
Compressor direction of rotation Clockwise (viewed looking towards the drive journal)
NOTE
More detailed information can be found in the separately available installation drawing of the screw
compressor.

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
1.7.1 Performance data CS80 screw compressor
All information for:
Feed medium: atmospheric air
Intake pressure: 1bar (abs.)
Intake temperature: 20°C
Permitted min. ambient temp.: -20°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

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
All information for:
Feed medium: atmospheric air
Intake pressure: 1bar (abs.)
Intake temperature: 20°C
Permitted min. ambient temp.: -20°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

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
1.8 Technical data CS700 LITE compressor unit
Model: R - PTO L (standard ratio) All dimensions are approximate.
Model: L - PTO R (standard ratio) All dimensions are approximate.

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
1.9 Technical data CS700 STANDARD compressor unit
DIN Flansch
Ø100 mm / 6 Loch / Ø8 mm
Model: R - PTO L (standard ratio) All dimensions are approximate.
Model: L - PTO R (standard ratio) All dimensions are approximate.

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
1.10 Technical data CS700 IC compressor unit
Model: R - PTO L (standard ratio) All dimensions are approximate.
Model: L - PTO R (standard ratio) All dimensions are approximate.

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
1.11 Technical data compressor unit
 CS700 LITE  CS700 IC
Width (approx.) mm 785 800 800
Depth (approx.) mm 715 780 830
Height (approx) mm 745 745 835
Weight (approx) kg 318 371 400


 
Compressor unit drive speed rpm 800 1200 1600
V-belt drive transmission ratio (standard) 1.25
CS80 compressor rotational speed rpm 1000 1500 2000
* Transmission ratio may vary. Several V-belt drives are available from the factory for the transmission ratio (adjustable to the auxil-
iary drive installed in the vehicle).
NOTICE

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. 9litres
 
max. 65mbar min. 0.3bar

Pressure joint R 2.5" external thread
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 compensation may be used.
NOTE
The performance data of the CS700 compressor unit correspond to screw compressor CS80 (Chapter
1.7.1 on page 11).
NOTE
More detailed information can be found in the separately available installation drawing of the
compressor unit.

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
1.12 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 11).
1.13 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.

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
1.14 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 direct-driven or
belt-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
conditions.
* 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
installation specications of the oil cooler).

47757781 A 19

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).

20 47757781 A
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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
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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 1.14 on page 18.
2.7 Disposal
Compressor components, as well as operating materials used in conjunction with the screw compressor
and compressor unit must be disposed of observing the local regulations.