Ingersoll-Rand GHH RAND SV205 User manual

244
92
40 PORT DETAIL
SHAFT DETAIL
8
Ø68
Ø32
180
230
80 80
125120
40
40 5
18
Ø12
174
265 195
509
120120
141 59
Ø25
Installation, Operating
&Maintenance Manual
(Original Instructions)
www.ingersollrand.com/ghhrandtransport
SV205
Rotary Vane
Compressor
May 2023
47815111 A
EN

2
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
WICHTIG!
Elektronische Versionen der Installations-, Betriebs- und Wartungshandbücher der SV150 und SV205
sowie der Serviceanleitungen können von der Website www.ingersollrand.com/ghhrandtransport heruntergeladen
werden.
IMPORTANT!
Electronic versions of the SV150 & SV205 Installation, Operating & Maintenance Manual’s plus Service
Instruction Manual’s can be downloaded from Website www.ingersollrand.com/ghhrandtransport.
IMPORTANT !
Les versions électroniques des manuels d'installation, d'utilisation et d'entretien du SV150 et du SV205,
ainsi que des manuels d'instructions de service, peuvent être téléchargées à partir du site Web www.
ingersollrand.com/ghhrandtransport.
FR
DE
EN

3
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
Contents
Chapter Page
1 Health & Safety
Health & Safety Issues 4
2 General
  
  
2.3 Storage/Low Use 
  
3 
3.1 General 
  
  
  
  
  
3.7 Machine and PTO alignment 
3.8 Pipe work 
3.9 Ancillaries 
4 
  
  
4.3 Driver Training 
5 Maintenance
5.1 Schedule 
  
  
5.4 Silencers/Pipe work 
  
5.6 Air Inlet Filter 
5.7 Checking the blade wear 

4
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
1Health & Safety
Read the whole manual before commencing installation.
Static electricity
Ensure, that where required, the compressor and ancillaries are earthed in accordance with
BS5958 Part 1 1983; ‘Control of Undesirable Static Electricity’.
Powder-air combinations are potentially explosive.
Drive line
It is the responsibility of the installer of the equipment to ensure all rotating and moving parts
of the installation are adequately guarded to a standard which complies with the prevailing
safety legislation.
Compressor
The compressor has internal moving parts some of which may be accessed through the inlet
and outlet apertures. During operation cooling fans rotate beneath the cowls at each end of the
machine and these can be accessed through the discharge aperture. Do not place any objects
especially fingers into these apertures as personal injury could result.
Installation
A relief valve must be fitted in the outlet pipe work as close to the compressor as possible.
The valve must be positioned so as not to vent air onto any personnel since the air discharged
will be hot and can cause severe burns.
Storage/Low use
Before the machine is installed or when it will not be used for long periods:
• Store in a dry, heated building.
• Handle with care and keep the suction and delivery ports covered.
• Rotate the drive shaft of the machine each week, in the direction shown by the arrow
between the suction and delivery ports on the machine body.
Where the compressor is mounted on a vehicle and located outside, it should be operated

Fire & Heat
The compressor includes seals made of fluoroelastomer polymers which degrade if exposed
to temperatures above 300°C. If the material has been so exposed then it must not be handled
with bare hands.
Surface temperatures can exceed 200°C. Highly combustable materials must not come into
contact with the discharge pipework or compressor body.
Relief Valve Check
This procedure should be carried out every month to clear the valve seat and check the valve

Noise
Tests show maximum

In accordance with our policy of continuous product improvement, GHH Rand reserve the right to alter
details and specifications without notice.

5
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
2General
2.1 Product general description
The SV205 is a light-weight, compact rotary vane compressor designed for the oil free
discharge of bulk liquids from general purpose tankers, e.g. liquid foodstuff, solvents, acids
alkalis, hot bitumen, resins and other chemicals.
The main advantage of using a compressor to discharge liquids is that the product does not
come into contact with machine. This eliminates any problems of material compatibility with
the liquid enabling a much wider variety of products to be discharged.
The machine is an oil free sliding vane design with the main stainless steel rotor being
supported by bearing arrangements at either end.
All the components in the main bore cavity are manufactured from corrosion resistant
materials to resist any possibility of atmospheric corrosion.
The very compact shape and size of the machine make it ideal for mounting inside the chassis
to enable direct low-cost prop. shaft driving or via other drive methods more suitable for
a particular application.
A through shaft allows CW or ACW input drive rotation and the compressor can be installed
on any face to provide the maximum mounting flexibility.
The standard package consists of:
SV205 cw basic machine
• Air Inlet Filter 5” Cyclonic
• Air Inlet Hose Kit

• Port Gaskets

• Non Return Valve - 1.5” BSP


2.2 Power Options
The SV205 can be driven using any of the following drive systems.
Prop. shaft Direct from a gearbox mounted PTO.
Hydraulically Several standard drives are available.
Electrically Motor drive packages on base frames/plates.
Engine Drive packages on base frames/plates.
2.3 Storage/Low use
Before the machine is installed or when it will not be used for long periods:
• Store the machine in a dry, heated building.
• Handle the machine with care and keep the suction and delivery ports covered.
• Rotate the drive shaft of the machine each week, in the direction shown by the arrow
between the suction and delivery ports on the machine body. Where the compressor is
mounted on a vehicle and located outside, it should be operated for at least 15 minutes

Note
The shape and size of
the machine make it
particularly suitable
for PTO/prop.
shaft driving inside
the vehicle chassis.
Note
Do not allow dirt, oil
and grease to enter
the machine ports
as this could cause
severe damage.

6
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
General
Figure 1. Recommended Layout
No. Description
1. Inlet filter kit - flexible
2. SV205 inlet filter
3. Basic SV205 Machine
4. Relief Valve
5. Isolating Valve
 
7. Micronic Discharge Filter
8. Alternative For hard piping
For Element
Removal
Dimension "A"
to be a Max.
of 1 metre
2

7
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
2General
2.4 Dimensions, Performance Data & Operating Environment
Dimensions
The dimensions of the compressor are shown in figure 2 below.
Performance
The performance details and power requirements of the SV205 compressor are shown
on the product data sheet.
For additional information, the constant running torque does not exceed:
78 Nm Speed range 1000 - 1600 rpm
Product Data can be found on the machine nameplate which is mounted on the side of the
compressor as shown in figure 2a below.
Operating environment
The permissible/foreseen operating environment is as follows:
Ambient temperature range -40 to +50°C

Humidity level Up to 100% RH condensing
 0 to 40 Hz; ± 40 mm amplitude tested
Inlet depression Not to exceed 50mbar
 
Max. outlet temperature 270°C
PORT DETAIL
SHAFT DETAIL
840 6
Ø 30
80 80
230
120125
180
246
120
120
256196
501
139139
145145
Ø12
40 40
18
?
50
Ø70
Figure 2a. Machine Nameplate
Figure 2. Dimensions
Figure 2a. Machine Nameplate
PORT DETAIL
SHAFT DETAIL
840 6
Ø 30
80 80
230
120125
180
246
120
120
256196
501
139139
145145
Ø12
40 40
18
?
50
Ø70
Figure 2a. Machine Nameplate

8
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
3Installation
3.1 General
For the recommended layout of the machine and ancillaries, see figure 1.
When selecting the machine mounting position, the following points should be considered:
• Direction of input rotation to the machine must be correct and is simple to change by


• Install away from sources of heat, e.g. vehicle exhaust air or hot pipes that could effect the
compressor temperature in any way.
• Venting relief/control valve air must be unobstructed and direct to the atmosphere.
• The relief valve should be fitted as close as possible to the SV205 discharge port and before

• Any valves should be positioned to avoid hot air venting onto the operator.
• A cooling fan is fitted at each end of the machine and the cooling air path into the fan must
not be obstructed.
• A space of at least 25mm must be allowed around the machine for air circulation. If mounting
to a solid plate, the machine should be mounted at least 25mm from the plate or a cooling
hole should be cut into the plate.


expansion during operation.
3.2 Mounting





thermal expansion during operation.
12mm diameter holes are provided in the bottom of feet to allow 10mm studs, screws and nuts

The feet should be fixed to a flat surface to avoid inducing unnecessary stresses into the machine
and mounting feet. This can be achieved using shimming if necessary. Check the feet are parallel
to the mounting bush and the clearance for the waved washer is equal all round.
Caution
Operating in reverse,
even for a short
period, can cause
severe damage
to the machine.
Note
Only the longer
capscrews supplied
with the feet must be
used for securing the
feet to the machine.
All fasteners
should be tightened
to 35 Nm.
Figure 3. Foot mounting details
No. Description
1. Mounting foot
2. Cap Screw, M10
3. Washer, M10
4. Location Bush
5. Waved Washer
6. Mounting Bush

9
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
3Installation
3.3 Lifting
The weight of the compressor without ancillaries is 42 kg and we recommend that the machine
is lifted with the eyebolt supplied. Alternatively the machine must be supported/lifted under
the main body and not by the plastic cowls
Any equipment used for lifting the machine should be rated accordingly.
3.4 Mounting orientations
The SV205 can be installed on any of the 4 mounting faces shown below and can be driven
in both rotations by using either end of the input shaft.
The machine has the inlet and discharge flanges on the same face to simplify connection
and routing of pipe work.
3.5 Lubrication
The SV205 is supplied complete with sealed greased bearings. Bearing re-lubrication should be
conducted in combination with the vane replacement procedure. See service instructions for
further details.
Figure 4. Mounting & Drive options
Caution
Only lift/support the
machine using the
main body and not
the plastic cowls.

10
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
3Installation
3.6 PTO and prop. shaft drive alignment
Changing the machine rotation
The current direction of input rotation is indicated by cast arrows on the compressor body.
Changing rotation is a simple process of swapping over the plastic cowls, key & drive flange
as shown in the diagram below.
Fitting the drive flange

of the rotor shaft.
It is important to use an OEM supplied flange to ensure the correct shaft fit & prevent damage
to the machine during installation.
Before fitting, the shaft and flange should be clean and damage free to ensure it fits correctly.
Both the shaft and coupling bore should be smeared with a light oil during assembly to aid
future separation.

on the shaft.
Apply Loctite 270 to the Grub Screw and tighten to a torque of 7.2Nm.

the shaft or flange.
Figure 5. Changing Rotation
Figure 6.
Drive Flange Removal
No. Description
1. Cap Screw, M10
2. Washer, M10
3. Mounting Foot
4. Location Bush
5. Waved Washer
6. Mounting Bush
7. Plastic Cowl - NDE
8. SV205
9. Plastic Cowl - DE
10. Drive Flange
11. Key
Note
The machine
rotor must always
rotate in the same
direction, but the
opposite input
drive rotation can
be achieved by
driving the rotor
from the other end
of the machine.

11
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
3Installation
3.7 Machine and PTO Alignment
The drive axis on the majority of PTO’s is at 3 - 5° to the horizontal, which reflects the angle
of the engine and gearbox.
The compressor should be mounted so that its drive axis is parallel to the PTO’s drive axis

The compressor should also be mounted so that the prop. shaft angle between the PTO

Consideration should be given to the prop. shaft length when mounting the machine
and the prop. shaft should be sized so that it always has sliding clearance.
3.8 Pipe work - Figures 1 & 8 show typical pipe work layouts
Standard inlet
A flexible inlet pipe, inlet filter, machine inlet flange and gasket are all provided in the inlet
induction kit.
Fabricated pipework
Where any pipe work is to be fabricated, the following points should be followed/noted
to prevent damage to the machine:

nominal bore pipe work.
• Inlet pipe work should be made in stainless steel or thick wall aluminium to help prevent
corroded particles entering the machine.

application, although stainless steel is recommended.
• All fabricated pipe work should be carefully de-scaled/cleaned before commissioning
the compressor.
• Pipe work should be attached to the vehicle chassis using flexible mountings to prevent
unnecessary vibration, expansion stress, noise transfer and avoid distorting the
machine body.


heat expansion.
• All inlet and discharge pipe work should be as free from bends as possible to minimise
pressure drops. This allows the machine to work in the best inlet conditions and provide
the maximum discharge pressure.
Equal Angle
Note: The combined angle in any plane
should not exceed 12˚
PLAN VIEW
CAUTION
SIDE VIEW
4O
4O
12O
Less than or
equal to 12O
Fit sha cover to
exposed sha.
Figure 7. Drive Alignment
Note
Also check the prop
shaft manufacturers
information for
the permitted
installed angle.

12
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
3Installation
Figure 8. General Arrangement
Note! - Anti-Clockwise drive shown
Ref. Qty Descripon
1 1 SV205 CW BASIC MACHINE
2 2 OVAL GASKET
3 1 DISCHARGE OVAL FLANGE,
WELD IN STAINLESS STEEL
4 4 * STUD
5 4 * WASHER
6 4 * NUT
71INLET FILTER AND KIT
Consisting of:
7.1 1 
7.1.a 1 RAINCAP
7.1.b 1 MOUNTING BAND
7.1.c 1 INDICATOR
7.2 1 
7.d 1 DUCT & MOULDED CUFF
7.e 1 SCREW ON CUFF
7.f 1 HOSE CLIP 60/80
7.g 1 HOSE CLAMP 50/7
8 1 INLET FLANGE
9 1 NON RETURN VALVE - 1.5"
BSP FEMALE BUSHED
10 1 RELIEF VALVE 1/2" BSP 2.5

11 1 WASHER JOINT 1/2"
12 1 * COMPANION FLANGE
12.1 1 * COMPANION FLANGE
FIXING SCREW
13 1 MOUNTING FEET
*N/A NOT INCLUDED WITHIN STD
PACKAGE 1
CUSTOMER / INSTALLER OWN SUPPLY
A DISCHARGE LINE
B PRESSURE GAUGE
C BALL VALVE
D ALTERNATIVE HARD INLET
E FLEXIBLE CONNECTOR

13
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
3Installation
3.9 Ancillaries
Air Inlet Filter and Flexible Induction Kit. (Fig 8, items 7)
The inlet filter is necessary to clean the air entering the machine to prevent problems
through large particle ingress and long term problems by small particles eroding main
bore components.
The filter should be located so that the inlet air is cool, dry and as clean as possible to maximise
filter and machine life.
The inlet filter should be supported using the mounting band supplied rather than mounting
directly to the suction port.
High temperature silicone sealant is recommended to be applied between the flexible inlet
hose and cuff inlet during hose fixing.
Relief Valve. (Fig 8, Item 10)

and should not be adjusted in any way. As such, adjustment of the relief valve will invalidate the
SV205 and relief valve warranty.
The relief valve required to protect the machine is a custom component set to GHH Rand
specifications. This valve is only available from GHH Rand and use of any other valve may
invalidate warranty.


The ideal mounting orientation is vertical, although the valve will function in any orientation.
Discharge Silencer (not shown)
If one is fitted, it should be located as close to the machine discharge port as possible, after the
relief valve.
Check (non-return) Valve (Fig 8, Item 9)


the compressor. It should be mounted as the last ancillary in the discharge line.
Expansion Joints (not shown)
Any pipe work or equipment should incorporate flexible elements where:
• Movement due to thermal expansion is likely.
• Pipe work crosses the vehicle chassis.
Discharge Filter (Fig 1, Item 7)
For food or other highly sensitive products, we recommend that a fine gauge discharge filter


Ball Valve(Fig 8, Item C)
A 1“ manual ball valve should be fitted on the discharge side of the machine, before the check
valve, to prevent starting the compressor against a pressurised tank/line. This allows venting
of the compressor discharge air to atmosphere during start-up.
Note
Do not mount the
machine close to
exhausts or other
warm air sources
and locate in a
position clear from
vehicle road spray.
Note
Note
Failure to fit a Ball
Valve could cause
failure due to high
shaft torque or
product blow-back.
Note
The relief valve
must be the first
ancillary in the
discharge line and
must be fitted as
close as possible,
but must vent away
from the machine
& operator.
Caution
Any excess silicone
sealant should
be removed.
Silicone entering the
machine can cause
damage or failure.

14
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
4Operating and Commissioning
4.1 Pre-operating check list
4.2 Test and operating procedure
Tick when completed


Vehicle PTO disengaged.





Tick when completed
1Check that the gate valve on the discharge pipework is open.
2
compressor.
3


1600 rpm.
4

5

6



7
30 minutes. Re-check for air leaks.
8
the relief valve.


the set pressure.

set pressure.
9

10 
11 
the engine.
12 
Caution
Tests show noise
levels fall between

1 metre and ear
protection is
recommended
for long periods
of exposure.
Caution
Never start the
compressor against
a pressurised tank
or discharge line.
Caution
Pipework will
become HOT during
test/running.
Max. Inlet Depression
50mbar under
all circumstances.
Max. Discharge
Pressure


15
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
4Operating and Commissioning
4.3 SV205 Driver training
Driver training should be given whenever possible and should include:-
Safety
Instruct the driver regarding:
• Rotating parts
• Hot Pipework
• Pressure Relief valve
• Safety couplings
Operation
Instruct the driver regarding:
• Speed range
• Maximum operating pressure
• PTO engagement
• Unloading valve
Routine Maintenance
Instruct the driver regarding:
• Air filter - cleaning
• Pipe connections - checking
• Mounting fasteners - checking
• Relief valve function
• Check valve function

16
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
5Maintenance
5.1 Schedule
Daily 
Weekly
• Clean the fans, fan covers and body ribs.

Where the compressor is mounted on a vehicle and located outside,


Monthly 
• Check inlet and discharge pipe work for leaks.
3 Monthly

replace if necessary.


6 Monthly • Check blade wear.
Annually
• Replace Air Filter Element
• Examine the internals of the check valve.

as required.
Tamperproof lead seals have been fitted into the cap screw heads on each sideplate.
Removal of these seals during the warranty period will invalidate the warranty.
5.2 Checking the relief valve operation
Check the relief valve operation as detailed in section 4 and visually check for any sign
of obvious defects.
5.3 Inspecting the check (non-return) valve

If in any doubt, replace the entire valve.
5.4 Silencers/Pipe work

When paintwork is damaged, clean off any corrosion and treat with rust inhibitor
before repainting. Use paints that can withstand temperatures of 240°C.
5.5 Lubrication
The bearings are packed with grease on assembly and need no regular attention.
See separate service instructions for machine overhaul & Regreasing.
Note
The compressor can
be carefully cleaned
with steam or water
jets, but only when
the machine is cold
as serious damage
could result.
Note
If the maximum
pressure reading is
higher than the set
pressure by more
than 0.2 bar, stop
the test and replace
the relief valve
before running the
compressor again.
Note
New gaskets may
be required when
inspecting the
check valve.
Note
The relief valve
should be operated
every month to
clear the valve seat
and check the valve
is functional.



17
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
5Maintenance
5.6 Air inlet filter
The blockage indicator is designed to show/hold the maximum inlet blockage encountered.



following processes:
Remove accumulated filter debris (machine not running)
1. Pull back the clips retaining the air inlet filter end cap and remove the end cap.
2. Empty out any dust or dirt and clean out the main filter cavity. Replace the end cap the
correct way up and re-clip in position.
Clean the filter element


2. Withdraw the filter from the filter body.
3. Clean the filter by blowing compressed air through the inside of the element.
4. Element replacement is a direct reversal of the above.
Filter elements should be replaced every 12 months or sooner if cleaning does not return
the blockage indicator to the unblocked condition.
Figure 9. Replacing Air Filter
Figure 10.
Blockage Indicator
8
9
4
5
7
6
3
1
2
No. Description
1. Filter Body
2. End Cover
3. Filter Element
4. Raincap
5. Filter Blockage

6. Vacuator Valve
7. Retaining Clips
8. Hose Clamp
9. Inlet Hose & Cuff

18
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
5Maintenance
5.7 Checking the blade wear

1. Remove the pipework from the suction port.
2. Turn the rotor, in the direction of rotation, until one of the blade slots can be seen
through the port.
3. Push the blade down to the bottom of the slot and measure, parallel to the slot, the distance

caliper or other suitable device.
4. The performance of the machine will begin to deteriorate when this measurement reaches

5. Once the measurement has reached 100mm the blades must be replaced.
Refer to separate service instruction manual for further details on blade replacement.
Replace Blades When
“A” = 100mm.
Measuring Device
“A”
Note
Failure to replace
the blades in line
with the
recommendations
will eventually
result in machine
failure. Late blade
change can
permanently
damage the
machine so that
future blade
life is reduced.
Note
When carrying out
the measurement
ensure that the
measuring device
is parallel with the
vane slot when
resting on the edge
of the suction port.
This will ensure
that the dimension
taken is as accurate
as possible.
Figure 11. Checking Blade Wear

19
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual
Notes

20
47815111 A
Date: 05/23 SV205 Installation, Operating & Maintenance Manual