Related Manuals for Ingersoll-Rand GHH RAND SILU CS104
Summary of Contents for Ingersoll-Rand GHH RAND SILU CS104
- Page 1 www.ingersollrand.com/ghhrandtransport Mounting instructions (Translation of the original instructions) SILU CS104 SILU CS1200 LITE SILU CS1200 ICL...
- Page 2 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. 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.
- Page 3 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. TÄRKEÄÄ! Suomenkielisen käyttöohjeen ja (englannin‑ ja saksankielisen) asennusohjeen voi ladata sähköisessä muodossa osoitteesta www.ingersollrand.com/ghhrandtransport. Pyydettäessä lähetämme myös tulos‑ tetun version.
- Page 4 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.
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Page 5: Table Of Contents
Contents GENERAL ............................ 7 Application ............................7 Manufacturer's address .......................7 Screw compressor type plate .......................7 Compressor unit type plate ......................8 Information for enquiries and orders ..................8 Service & Support .........................8 Technical data CS104 screw compressor ..................9 1.7.1 Performance data CS104 screw compressor ................10 Technical data CS1200 LITE compressor kit ................12 Technical data CS1200 ICL compressor unit ................12 1.10... - Page 6 3.6.7 Mounting the non-return flap....................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 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...
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Page 7: General
General 1 General 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 flour, sugar, salt, animal feed, powdered chemicals, dry granulate, soda, cement, sand, lime, plaster, etc. -
Page 8: Compressor Unit Type Plate
General 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 ·... -
Page 9: Technical Data Cs104 Screw Compressor
General 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) 535* min. -
Page 10: Performance Data Cs104 Screw Compressor
General 1.7.1 Performance data CS104 screw compressor All information for: Pressure difference: Feed medium: atmospheric air Drive speed Intake pressure: 1 bar (abs.) Intake volume 1.0 bar Intake temperature: 20 °C Final temperature 1.5 bar Permitted min. ambient temp.: -25 °C Coupling output 2.0 bar Relative humidity: 60 % Permitted intake temperature 2.5 bar... - Page 11 General All information for: Feed medium: atmospheric air Drive speed Pressure difference: Intake pressure: 1 bar (abs.) Intake volume 1.0 bar Intake temperature: 20 °C Final temperature 1.5 bar Permitted min. ambient temp.: -25 °C Coupling output 2.0 bar Relative humidity: 60 % Permitted intake temperature 2.5 bar 1,max Technical data without intake or pressure losses...
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Page 12: Technical Data Cs1200 Lite Compressor Kit
General Technical data CS1200 LITE compressor kit Model: CS1200 LITE with integrated oil cooler PTO R/L All dimensions are approximate. Technical data CS1200 ICL compressor unit Model: CS1200 ICL with integrated oil cooler PTO R/L All dimensions are approximate. 47757787 A... -
Page 13: Technical Data Compressor Unit
General 1.10 Technical data compressor unit Dimensions & weight CS1200 LITE CS1200 ICL Rotational speed range Length (approx) 835/705* min. rpm 1200 Width (approx.) 405** max. rpm 1800 Height (approx) 460*** Weight (approx) 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 NOTICE DAMAGE TO THE COMPRESSOR! -
Page 14: Operating The Compressor At High Altitudes
General 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] 1000 1500 2000 2500 3000 3500 4000 4500... -
Page 15: External Oil Cooler For Extreme Conditions
General 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 b) When operating in challenging/cramped environments, e.g. -
Page 16: Safety
Safety 2 Safety 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 staff before starting work. Authorised personnel, training and qualification Installation and assembly work must only be carried out by persons with the appropriate authorisation, training and qualifications, who are familiar with the valid safety regulations. -
Page 17: Unauthorised Conversions And Spare Parts
Safety Unauthorised conversions and spare parts Conversions and modifications 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. -
Page 18: Installation Guidelines
Installation guidelines 3 Installation guidelines NOTE Also observe the safety instructions in Chapter 2 on page 16. 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. -
Page 19: Internal Transportation Of The Unit
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 sufficiently dimensioned lifting truck/fork lift. WARNING RISK OF TIPPING OVER IF TRANSPORTED ON THE GROUND! If using internal transport with insufficiently dimensioned transportation equipment, there is a risk of tipping over and injuries. -
Page 20: Articulated Shaft
Installation guidelines 3.2.2 Articulated shaft The compressor drive is usually carried out through an articulated shaft between the power take-off of the vehicle drive and the flange of the overload coupling. Selection of articulated shaft Consider the following items during the determination of the articulated shaft: ‣... -
Page 21: Permitted Inclination
Installation guidelines 3.3.1 Permitted inclination NOTICE INSUFFICIENT LUBRICATION! 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°... -
Page 22: Air Flow Cs1200 Icl/Filter Installation Location Cs1200 Lite
Installation guidelines NOTICE DAMAGE TO THE BEARING! Non-observance of attachment, flange parallelism and angle of inclination of the articulated shaft can result in significant bearing loads, with the result of premature damage to the bearing. ‣ Fundamentally, the structural guidelines from the manufacturer of the respective vehicle and tech‑ nical information provided by the manufacturer of the articulated shaft with regard to attachment, flange parallelism and angle of inclination of the articulated shaft must be adhered to. -
Page 23: Air Intake Oil Cooler Fan Cs104 L1/R1 Compressor
Installation guidelines 3.4.5 Air intake oil cooler fan CS104 L1/R1 compressor For compressors and units with an integrated oil cooler (compressor types CS104 L1/R1), the rain cap for the air intake of the oil cooler fan must be installed in the vehicle frame so that it is outside the spray areas and the cleanest, coldest possible air is sucked in. -
Page 24: Completion Of The Screw Compressor
Installation guidelines Completion of the screw compressor NOTICE FOREIGN OBJECTS IN THE COMPRESSOR! If foreign objects enter the screw compressor during completion, the screw compressor will be de‑ stroyed when it is started up. ‣ Make sure that no foreign objects enter the screw compressor. 3.6.1 Installation of the hose connector flange NOTE... -
Page 25: Mounting The Maintenance Indicator And Oil Pressure Gauge
Installation guidelines 3.6.2 Mounting the maintenance indicator and oil pressure gauge The screw connections for connecting the maintenance indicator and the oil pressure gauge should be attached before vehicle assembly. Maintenance indicator: ‣ Screw the hose connection fittings (8) and (7) into the hole (5) on the air intake fittings (6). -
Page 26: Oil Cooler Connection Cs104 L2/R2 Compressor
Installation guidelines NOTICE HIGH OPERATING TEMPERATURES! The oil pressure gauge and maintenance indicator could be damaged if they are exposed to ambient temperatures greater than 60 °C. ‣ Do not mount the oil pressure gauge and maintenance indicator in the immediate area of hot parts or in the exhaust area of the safety valve. -
Page 27: Mounting The Discharge Silencer
Installation guidelines NOTICE FILTER MATERIAL AND FILTER DESIGN UNSUITABLE! Unsuitable filter material, as well as an insufficiently dimensioned filter can result in destruction of the screw compressor. ‣ Only use paper filter with the specified degree of separation. ‣ The max. permitted intake negative pressure is 65 mbar. ‣... - Page 28 Installation guidelines Mounting the discharge silencer CS1200 LITE ‣ Remove protective plugs from the threaded hole (3) on the discharge silencer (2) and screw the safety valve (1) firmly into the threaded hole. ‣ Remove the protective film from the pressure flange (4) of the compressor (6). ‣...
- Page 29 Installation guidelines ‣ Fasten brackets (13) with screws M10×25 (16) and plain washers (14) on the discharge silencer (2). Tightening torque (M10 A2-70): 37 Nm Alternative mounting of the pressure joint If necessary, the pressure joint can also be mounted on the opposite side of the discharge silencer. ‣ Unscrew the cover (8) with seal (7). ‣...
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Page 30: Installing The Safety Valve
Installation guidelines CAUTION HOT SURFACES! During operation, the screw compressor and discharge silencer are very hot. There is a risk of burning. ‣ Appropriate measures to screen the hot surfaces must be taken by the installation manufacturer. 3.6.6 Installing the safety valve NOTE When installing a safety valve, observe the manufacturer instructions. -
Page 31: Mounting The Non-Return Flap
Installation guidelines The safety valve from GHH RAND must only be installed as illustrated (0° ... 90°): NOTICE INCORRECT INSTALLATION POSITION OF THE SAFETY VALVE! An incorrect installation position of the safety valve can result in destruction of the compressor. ‣ The safety valve must only be installed at an angle of 0°... - Page 32 Installation guidelines Shear bolt overload coupling ‣ Push the coupling flange (2) over the feather key (6) on the compressor drive shaft and secure with hexagon socket screw (3). ‣ Fasten the shear bolt overload coupling (1) on the coupling flange (2) with hexagon screws M8×25 (5) and split washers (4).
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Page 33: Installing The Screw Compressor On The Mounting Console (Third-Party Manufacturer)
Installation guidelines NOTE The threaded plug is provided with screw locking paste. This must not be reused after dismantling; only use a new threaded plug. NOTE The screw depth for the articulated shaft fastening screws must be max. 12 mm. 3.6.9 Installing the screw compressor on the mounting console (third-party manufac- turer) -
Page 34: Completion Of The Compressor Unit
Installation guidelines Completion of the compressor unit 3.7.1 Test mounting of the CS1200 LITE compressor kit To determine the exact installation position on the vehicle frame and the fastening bores in the assembly console, it is necessary to position the compressor on the vehicle frame with the assembly console. It must be checked in this installation position whether all attachment parts can be mounted without prob‑... - Page 35 Installation guidelines NOTE The upper edge of the mounting console should be at least at the height of the upper edge of the vehicle frame. ‣ Make sure there is sufficient floor space for a full load. If the compressor cannot be lifted high enough due to insufficient distance to the vehicle frame, it is pos‑...
- Page 36 Installation guidelines NOTICE SUFFICIENT DIMENSIONING OF THE DRILL HOLES! Fit the mounting console with at least eight drill holes Ø 14.5 mm (min. screw size: hexagon screw with shaft M14 10.9 with the corresponding washer and self-locking nut). ‣ Preferably use the screw connections recommended by the vehicle manufacturer for load-bearing frame mounts.
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Page 37: Test Mounting Of The Cs1200 Icl Compressor Unit
Installation guidelines 3.7.2 Test mounting of the CS1200 ICL compressor unit To determine the exact installation position on the vehicle frame and the fastening bores in the adapt‑ er, it is necessary to position the compressor unit with adapter on the vehicle frame with the assembly console. - Page 38 Installation guidelines Once you have determined the correct installation position, the holes for the mounting of the adapter on the vehicle frame should be determined as follows: ‣ For a pre‑drilled vehicle frame, transpose the drill pattern of the vehicle frame (3) to the backside of the adapter (4).
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Page 39: Mounting Of The Cs1200 Lite Compressor Kit
Installation guidelines NOTICE DAMAGE TO THE VEHICLE FRAME! The vehicle frame warps or is damaged. ‣ Welding work must not be performed on the vehicle frame. ‣ Holes must only be drilled on the vehicle frame in accordance with the instructions in the manufac‑ turer's installation guidelines. - Page 40 Installation guidelines ‣ Lower the pallet and remove the fork lift or lifting truck. ‣ Fasten the rain cap (1) on one point within the vehicle frame where the coldest, cleanest air is drawn in. NOTICE INCORRECT INSTALLATION POSITION OF THE AIR INTAKE OIL COOLER FAN! If the fresh air supply to the oil cooler fan is re‑ stricted, is located in the area of warm air or dirt gets into the oil cooler, temperature damage to the compressor could occur.
- Page 41 Installation guidelines ‣ Cut the pressure hose (12) to the required length and mount pipe fittings (9) on both ends. Hold the end of the hose fast with a clamping tongs and oil with spray oil. After that, screw the screw sleeve (11) onto the hose end (12) anticlockwise up to the stop (depth d=17 mm) and screw the pipe fittings (9) into the screw sleeve (11) clockwise up to the stop on the...
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Page 42: Mounting Of The Cs1200 Icl Compressor Unit
Installation guidelines ‣ Mount the hose (2) on the hose connector flange (5) of the compressor with hose clamp (4). NOTE Install the hose line so that it does not touch any turning or hot parts. To avoid kinks in the hose due to small radii, there is a 90°... - Page 43 Installation guidelines ‣ After aligning the console (5) of the compressor unit (4), screw it to the adapter (1) with eight screws (8) M14x40, strength class 10.9 with wedge locking washers (9) and nuts (10), on both the left and right. Tightening torque (M14 10.9): 193 Nm ‣...
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Page 44: Installing The Articulated Shaft
Installation guidelines 3.7.5 Installing the articulated shaft CAUTION RISK OF INJURY DUE TO ROTATING PARTS! If the rotating parts are not adequately covered, there is a risk of injury. ‣ Provide a cover for the articulated shaft in accordance with accident prevention regulations. ‣ Screw the articulated shaft (2) to the vehicle's auxiliary drive flange (1) and to the overload coupling flange (3). -
Page 45: Connecting The Control Unit To The Cs1200 Icl Compressor Unit
Installation guidelines ‣ Unscrew the cover (2) of the fan controller (1). ‣ Pre-drill holder for the housing of the fan control‑ ler according to the fastening holes (3) (dimen‑ sions: 67 × 146 mm). ‣ Fasten the housing of the fan controller to the holder with four M4 screws. -
Page 46: Safety Labels
Safety labels 4 Safety labels The safety labels must by attached by the installer of the system. Apply maintenance instructions and lubricant recommendation (use the version in the local language of the operator)! ‣ Affix safety labels, maintenance instruction and lubricant recommendation to the relevant points of the installed compressor. -
Page 47: Attaching The Stickers To The Unit (Example)
Safety labels Attaching the stickers to the unit (example) 47757787 A... -
Page 48: Initial Commissioning
Initial commissioning 5 Initial commissioning Initial commissioning is carried out by the installer of the system. It includes filling with lubricant, removing the preservation, the test run with a check of the direction of rotation and speed, as well as the function control of the fan (IC units). If in exceptional cases the first start of operation is carried out by the customer, the following work has to be carried out: Work... -
Page 49: Filling With Lubricant
Initial commissioning Filling with lubricant NOTICE DAMAGE DUE TO INCORRECT OILS! Incorrect oils can destroy the compressor. ‣ Only use specified oil. ‣ Unscrew and remove the locking screw (1) from the compressor housing. ‣ Unscrew the cap (3) and top up with new oil ac‑ cording to the lubricant recommendation (Chap- ter 5.1 on page 48): CS104/CS1200:... -
Page 50: Test Run
Initial commissioning Test run CAUTION HOT SURFACES! During operation, the compressor and discharge silencer are very hot. There is a risk of burning. ‣ Wear protective gloves. CAUTION NOISE GENERATION! An excessive acoustic pressure level can result in damage to hearing. ‣ Do not operate the compressor without the discharge silencer. -
Page 51: Checking The Drive Speed
Initial commissioning 5.4.3 Checking the drive speed NOTICE INCORRECT SPEED RANGE! An incorrect speed range can destroy the compressor. ‣ Ensure that the compressor is only operated within its permissible rotational speed range. ‣ Check the drive speed of the screw compressor. The speed must remain within the speed range for the screw compressor specified in the technical data. -
Page 52: Switching Off
Initial commissioning 5.4.6 Switching off NOTICE RISK OF BLOWBACK OF MATERIAL! If the compressor is switched off if there is counter pressure, there is the risk of damage to the non-re‑ turn valve due to blowback of material. ‣ Do not switch off the compressor if there is counter pressure! ‣... - Page 53 Initial commissioning Printed in Germany Reserves the right to amend technical details compared to the information and illustrations of the oper‑ ating manual. A replication, copying or translation, even in parts, is not permitted without written con‑ sent. As a contribution to environmental protection: This paper has been produced from 100% chlorine free bleached pulp.
- Page 54 Service & Support www.ingersollrand.com/ghhrandtransport Subject to revision without notice Printed in Fed. Rep. of Germany 12/2022 EN...
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