Manual GHH Rand CE and CF Series [PDF]

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Introduction The purpose of this installation manual is to provide assistance when fitting the Series CF compressor elements into compressor systems or groups. All information and data relating to safety contained in this manual shall be taken over into the operating company’s operation manual.



Table of contents 1 General ..................................................................................................... 1 1.1 1.2 1.3 1.4 1.5



Intended purpose ............................................................... 1 Manufacturer’s address ............................................ 1 Type designation ................................................................ 1 Marking .......................................................................................... 1 Information required for inquiries and orders ............................................................................................... 1 1.6 Proper use ................................................................................. 1 1.7 Sale and service point ................................................. 1 1.8.01 Technical data CF75D ............................................ 2 1.8.02 Technical data CF75G ........................................... 4 1.8.03 Technical data CF75ED ....................................... 6 1.8.04 Technical data CF75EG ....................................... 8 1.8.05 Technical data CF90D ......................................... 10 1.8.06 Technical data CF90LD ..................................... 12 1.8.07 Technical data CF90G ........................................ 14 1.8.08 Technical data CF90LG .................................... 16 1.8.09 Technical data CF128D ..................................... 18 1.8.10 Technical data CF128G .................................... 20 1.8.11 Technical data CF128LG ................................. 22 1.8.12 Technical data CF180R ..................................... 24 1.8.13 Technical data CF180G .................................... 26 1.8.14 Technical data CF246G .................................... 28



2 Safety ....................................................................................................... 32 2.1 General ....................................................................................... 32 2.2 Marking of instructions in the installation manual .......................................................................................... 32 2.3 Qualification and training of personnel . 30 2.4 Safety awareness at work .................................. 30 2.5 Safety instructions for the operating company/operator ......................................................... 33 2.6 Safety instructions for maintenance, inspection and mounting work ....................... 33 2.7 Unauthorized conversion and manufacturing of spare parts ........................... 33 2.8 Unauthorized operation modes ..................... 33



3 Description of product and accessories ................................................................... 34 3.1 3.2 3.3 3.4



Main assemblies of compressor ................. 34 Gear execution .................................................................. 35 Directly driven execution ...................................... 35 Slide-in unit with gear ................................................ 36



3.5 Slide-in unit in directly driven execution .................................................................................. 36 3.6 Mode of operation of the compressor ... 37



4 Recommendations for plant construction ................................................................................ 38 4.1 Electromotor drive tubing plan ....................... 38 4.2 Explanations to the electromotor drive tubing plan ................................................................................ 40 4.2.1 Start-up ........................................................................... 40 4.2.2 Operation under load ..................................... 40 4.2.3 No-load operation ............................................... 40 4.2.4 Switch-off ...................................................................... 41 4.2.5 Oil system ................................................................... 41 4.3 Diesel engine drive tubing plan ..................... 42 4.4 Explanations to the diesel engine drive tubing plan ............................................................................... 44 4.4.1 Start-up ........................................................................... 44 4.4.2 Operation under load ..................................... 44 4.4.3 No-load operation ............................................... 44 4.4.4 Switch-off ...................................................................... 45 4.4.5 Oil system ................................................................... 45 4.5 Recommendations for plant protection .................................................................................. 46 4.6 Dew point diagram ........................................................ 47 4.7 Lubricant recommendation ................................. 48 4.7.1 Type of lubricants ............................................... 48 4.7.2 Choice of lubricants ........................................ 48 4.7.3 Admixtures, impurities .................................. 48 4.8 Permissible flow rates .............................................. 49 4.9 Filter meshing ...................................................................... 50 4.10 Fitting instructions ......................................................... 51 4.10.1 Coupling ......................................................................... 51 4.10.2 Belt drive ....................................................................... 51



5 Preparations for putting into operation ........................................................................................... 52 6 Maintenance ................................................................................ 52



1



General



1.1 Intended purpose GHH-RAND manufacture and supply the Series CF compressor stages as built-in elements for compressed air generation systems or groups. The compressors are exclusively intended to compress air within the scope of the specified technical application limits. In the event of differing utilization, contacting the manufacturer will be required.



1.2 Manufacturer’s address GHH-RAND Schraubenkompressoren GmbH Steinbrinkstrasse 1 D-46145 Oberhausen



1.3 Type designation CF75GX



1.4 Marking The type designation is to found on the compressor’s nameplate.



The whole marking has documentary value and shall not be removed, modified or made illegible.



1.5 Information required for inquiries and orders When inquiring about and ordering spare parts and accessories, state the exact type designation, the machine number and the year of construction of the compressor, the spare part or accessory is intended for. Original spare parts and accessories approved by the manufacturer contribute to safety. The use of other spare parts and non-approved accessories may entail the loss of any liability for the consequences arising therefrom.



Variant code Constructional execution G integrated gear LG extended rotor profile, integrated gear D/R without gear LD extended rotor profile, without gear EG slide-in unit with integrated gear LEG slide-in unit with integrated gear and extended rotor profile ED slide-in unit, without gear LED slide-in unit, without gear with extended rotor profile Center distance of rotors in mm Series



1.6 Proper use The Series CF screw compressor is exclusively intended to compress air that has no hazardous additions within the scope of the technical application limits specified in section „Technical data“. Any other use is deemed to be improper use. The manufacturer does not undertake any liability for the damages resulting therefrom; improper use is exclusively at the operating company’s risk. Proper use also includes the observance of the mounting, operating, maintenance and repair conditions set forth by the system manufacturer.



1.7 Sale and service point The address of the sale and service point is to be found on the inside of the back cover. For rapid and low-cost execution of inspections, repairs and overhauling of our series compressors, repair kits and complete exchange compressors are at disposal in our works. 1



1.8.01



Technical data CF75D



Weight:



58 kg



Variant



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



Belt drive permissible



D



16



8.11



50



1,450



8,935



X



D6



16



8.11



44



1,450



7,863



X



p 2max = uHL = nHL =



max. permissible discharge pressure Male rotor tip speed Male rotor speed



This unit is available as foot mounted as well as face mounted versions.



2



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



3



1.8.02



Technical data CF75G



Weight:



CF75G CF75G1



Variant



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



G



16



10



50



1,787



8,935



1.0984



3.2667



G1



16



10



50



1,787



8,935



2.0339



4.9667



p2max uHL nHL i



4



70 kg 90 kg



= = = =



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



5



1.8.03



Technical data CF75ED



Weight:



70 kg



Variant



ED p 2max = uHL = nHL =



6



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



Belt drive permissible



14



8.11



35.95



1,450



6,425



X



max. permissible discharge pressure Male rotor tip speed Male rotor speed



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



7



1.8.04



Technical data CF75EG



Weight:



EG 76 kg EG1 92 kg



Variant



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



EG



14



10



35.95



1,787



6,425



0.8033



2.4375



EG1



14



10



35.95



1,787



6,425



1.0141



3.9310



p 2max uHL nHL i



8



= = = =



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



9



1.8.05



Technical data CF90D



Weight:



85 kg



Variant



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



Belt drive permissible



D



16



9.74



50



1,450



7,446



X



D2



16



9.74



44



1,450



6,552



X



p 2max = uHL = nHL =



max. permissible discharge pressure Male rotor tip speed Male rotor speed



This unit is available as foot mounted as well as face mounted version.



10



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



11



1.8.06



Technical data CF90LD



Weight:



100 kg



Variant



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



Belt drive permissible



LD



11.5



9.74



50



1,450



7,446



X



LD1



11.5



9.74



44



1,450



6,552



X



p 2max = uHL = nHL =



12



max. permissible discharge pressure Male rotor tip speed Male rotor speed



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



13



1.8.07



Technical data CF90G



Weight:



115 kg



Variant



G5 p 2max uHL nHL i



14



= = = =



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



16



10



44



1,489



6,552



1.1667



3.0000



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



15



1.8.08



Technical data CF90LG



Weight:



130 kg



Variant



LG3 p 2max uHL nHL i



16



= = = =



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



11.5



10



44



1,489



6,552



1.1667



3.0000



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



17



1.8.09



Technical data CF128D



Weight:



250 kg



Variant



D p2max = uHL = nHL =



18



p2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



16



9.31



50



975



5,235



max. permissible discharge pressure Male rotor tip speed Male rotor speed



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



19



1.8.10



Technical data CF128G



Weight:



280 kg



Variant



G p 2max uHL nHL i



20



= = = =



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



16



10



50



1,047



5,235



0.8254



2.3824



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



21



1.8.11



Technical data CF128LG



Weight:



330 kg



Variant



LG p 2max uHL nHL i



22



= = = =



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



11.5



10



50



1,047



5,235



0.8254



2.3824



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



23



1.8.12



Technical data CF180R



Weight:



725 kg



Variant



R p 2max = uHL = nHL =



24



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



Belt drive permissible



16



9.74



42



725



3,127



X



max. permissible discharge pressure Male rotor tip speed Male rotor speed



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



25



1.8.13



Technical data CF180G



Weight:



770 kg



Variant



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



G



16



10



50



745



3,723



0.6119



2.2727



G1



16



10



48



745



3,574



0.6119



2.2727



G2



16



10



42



745



3,127



0.6119



2.2727



p 2max uHL nHL i



26



= = = =



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



27



1.8.14



Technical data CF246G



Weight:



1,600 kg



Variant



G p 2max uHL nHL i



28



= = = =



p 2max bar (abs.)



uHL min m/s



uHL max m/s



nHL min min-1



nHL max min-1



imin



imax



14.5



10



50



575



2,875



0.4605



1.9211



max. permissible discharge pressure Male rotor tip speed Male rotor speed Transmission ratio



All specifications with: Medium conveyed: Atmospheric air rel. humidity: 70 % Intake pressure (abs.): 1 bar Intake temperature: 20 °C



29



1.9. Available gear ratios for gear driven versions CF75G



CF75EG



3,2667 3,1290 3,0000 2,8788 2,7647 2,6571 2,5556 2,4595 2,3684 2,2821 2,2000 2,1220 2,0476 1,9767 1,9091 1,8444 1,7826 1,7234 1,6667 1,6122 1,5600 1,5098 1,4615 1,4151 1,3704 1,3273 1,2857 1,2456 1,2069 1,1695 1,1333 1,0984



3,9310 3,7667 3,6129 3,4688 3,3333 1) 3,2059 3,0857 2,9722 2,8649 2,7632 2,6667 2,5750 2,4878 2,4048 2,3256 2,2500 2,1778 2,1087 2,0426 1,9792 1,9184 1,8600 1,8039 1,7500 1,6981 1,6481 1,6000 1,5536 1,5088 1,4655 1,4237 1,3833 1,3443 1,3065 1,2698 1,2344 1,2000 1,1667 1,1343 1,1029 1,0725 1,0429 1,0141 0,9861 0,9589 0,9324 0,9067



1) 2) 3) 4)



1) 2)



CF90G/LG 3)



3,0000 2,8519 2,7143 3) 2,5862 2,4667 3) 2,3548 2,2500 2,1515 2,0588 1,9714 1,8889 1,8108 1,7368 1,6667 1,6000 1,5366 1,4762 1,4186 1,3636 1,3111 1,2609 1,2128 1,1667



CF128G/LG



CF180G



2,3824 2,2857 2,1944 2,1081 2,0263 1,9487 1,8750 1,8049 1,7381 1,6744 1,6136 1,5556 1,5000 1,4468 1,3958 1,3469 1,3000 1,2549 1,2115 1,1698 1,1296 1,0909 1,0536 1,0175 0,9828 0,9492 0,9167 0,8852 0,8548 0,8254



2,2727 2,1765 2,0857 2,0000 1,9189 1,8421 1,7692 1,7000 1,6341 1,5714 1,5116 1,4545 1,4000 1,3478 1,2979 1,2500 1,2041 1,1600 1,1176 1,0769 1,0377 1,0000 0,9636 0,9286 0,8947 0,8621 0,8305 0,8000 0,7705 0,7419 0,7143 0,6875 0,6615 0,6364 0,6119



4)



CF246G 1,9211 1,8462 1,7750 1,7073 1,6429 1,5814 1,5227 1,4667 1,4130 1,3617 1,3125 1,2653 1,2200 1,1765 1,1346 1,0943 1,0556 1,0182 0,9821 0,9474 0,9138 0,8814 0,8500 0,8197 0,7903 0,7619 0,7344 0,7077 0,6818 0,6567 0,6324 0,6087 0,5857 0,5634 0,5417 0,5205 0,5000 0,4800 0,4605



CF75EG3 type is available with these gear rations only. The highest ratio available for CF75EG type is 4,2424 and it is available only as CF75EG4 version. CF90G/LG toothed driving shaft versions are available with these gear ratios only. The highest ratio available for CF180G type is 2,4839 and it is available as CF180G2 version.



X



X



X



X



X



Minimum Pressure Valve



Separator Block



Thermostatic Valve



Combi-blocks



Proportional Controller X



X



X



X



X



X



X



CF75G/EG



X



X



X



X



X



X



CF90D



X



X



X



X



X



X



X



CF90G/LG



X



X



X



X



X



CF128D/R



For more detailed information please see the specialized components manuals.



Venting valve



X



Suction Regulator



CF75D



Components, recommended fort he screw compressor airends CF Series.



X



X



X



X



X



X



CF128G/LG



X



X



X



CF180R



X



X



X



CF180G



X



X



X



CF246G



2



Safety



2.1 General This installation manual contains basic instructions to be observed during installation, operation and maintenance. Prior to utilization and putting into operation, the personnel shall read these instructions and those in the operating manual of the machine/system into which the compressor stage is fitted. The operating manual must always be accessible to the personnel. Not only should the general safety instructions under this main section „Safety“ be followed, but also those particular safety instructions added to the other main sections. Disregarding the safety instructions can cause personal hazard, but can also endanger the environment and the machine. Disregarding the safety instructions can entail the loss of any right to claims for damages.



2.2 Marking of instructions in the installation manual The safety instructions contained in this installation manual and likely to cause personal hazard if not observed, have been highlighted by the general danger sign



2.3 Qualification and training of personnel Work on the compressor like operation and maintenance shall only be carried out by authorized, instructed and qualified personnel who are familiar with the safety regulations in force. The operating company shall precisely define the scope of responsibilities, the compentence and the supervision of the personnel. If the personnel do not have the necessary knowledge, they shall be trained and instructed accordingly. Moreover, the operating company shall ensure that the personnel do fully understand the contents of the operating manual. Repairs or conversions shall only be carried out by authorized personnel who are at any time available at the service points or from GHHRand.



2.4 Safety awareness at work The essential technical safety provisions applicable to the installation, operation and maintenance of air compressors are contained in the following publications:



· · ·



In case of safety instructions likely to endanger the machine and its function if not observed, the word



· ·



·



has been inserted. Notices are highlighted as follows:



·



Provisions issued by the craft association (BGV), in particular: BGV A1 General provisions BGV A2 Electric systems and working stock VBG 16 Compressors Standards, in particular: DIN EN 292 Safety of machines DIN EN 1012-1 Compressors and vacuum pumps, safety requirements; Part 1: Compressors ISO 5388 Stationary air compressors - safety rules and code of practice Regulations, in particular: Pressure vessel regulation, Regulation on pressure vessels, pressure gas vessels and filling systems



Always the last revision of these provisions shall be applicable.



32



Any particular rules and regulations, in particular safety regulations, valid in your plant or because of the local conditions shall also be followed. In the event of concurrent regulations, always the more severe shall apply.



2.5 Safety instructions for the operating company/operator The operating company is responsible that the compressor is always in safe operating condition. Damaged or non-operative parts shall be replaced without delay. Any manner of work affecting the safety of the compressor shall be abstained from. The operator shall immediately report any change occurring to the compressor and likely to affect the safety.



2.7 Unauthorized conversion and manufacturing of spare parts Conversions or modifications of the compressor are not allowed. Original spare parts and accessories approved by the manufacturer contribute to safety. The use of other spare parts and non-approved accessories may entail loss of liability for any consequences arising therefrom.



2.8 Unauthorized operation modes Without previous approval of GHH-RAND, the compressor shall not be operated under other conditions than those described in section „Technical data“.



2.6 Safety instructions for maintenance, inspection and mounting work The operating company shall ensure that all maintenance, inspection and mounting work is carried out by duly authorised and qualified personnel who are adequately informed by carefully studying the operating manual. It is common pratice that the machine/system should only be worked on whilst shut down. Following the machine/system shutdown procedure described in the operating manual is imperative. Dispose of oils and greases correctly. After completion of work, immediately reinstall and reset into operation all safety and protection devices. Before resuming operation, the points mentioned in section „Putting into operation“ shall be observed.



33



3



Description of product and accessories



3.1 Main assemblies of compressor



Casings:



Rotors:



Seals:



1



Rotor casing



6



Male rotor



12



2



Gear casing



7



Female rotor



3



Gear case cover



8



Drive shaft



4



Bearing casing



9



Driving wheel and pinion



5



Cover



10



Rotor bearing



11



Drive shaft bearing



34



Shaft seal



3.2 Gear execution Driving takes place by means of an integrated gear that multiplicates or demultiplicates the motor speed to the required operating speed of the compressor. The compressor can either be directly flanged by flange connection to the driving motor using a coupling casing, or be installed or fastened using foot cams with threaded bores on the underside of the compressor. The larger compressors require an additional support in the foot area. Available constructional sizes: CF75G CF90G CF128G CF180G CF246G



CF90LG CF128LG



3.3 Directly driven execution By means of a coupling, the compressor can be directly driven by the motor on the suction-sided shaft of the male rotor, the operating speed of the compressor is equal to the motor speed. Adapting the motor speed to the required operating speed of the compressor is possible by means of an intermediate belt drive (except for constructional size CF128D). Installing and fastening is made using foot cams with threaded bores on the underside of the compressor. Available constructional sizes: CF75D CF90D CF128D CF180R



CF90LD CF128R



35



3.4 Slide-in unit with gear The slide-in units have been developed to manufacture compressed air generators of extremely compact design. The compressor is built into the pressure vessel that is at the same time oil reservoir and coarse separator. The suction-sided bearing casing of the machine is used as cover for the reservoir. The generated compressed air is directly conveyed into the oil reservoir/separator. Driving takes place by means of an integrated gear that multiplicates or demultiplicates the motor speed to the required operating speed of the compressor. The driving motor can be directly flanged by flange connection to the compressor using a coupling casing. Available constructional sizes



CF75EG



3.5 Slide-in unit in directly driven execution The slide-in units have been developed to manufacture compressed air generators of extremely compact design. The compressor is built into the pressure vessel that is at the same time oil reservoir and coarse separator. The suction-sided bearing casing of the machine is used as cover for the reservoir. The generated compressed air is directly conveyed into the oil reservoir/separator. By means of a coupling, the compressor can be directly driven by the motor on the suction-sided shaft of the male rotor, the operating speed of the compressor is equal to the motor speed. Adapting the motor speed to the required operating speed of the compressor is possible by means of an intermediate belt drive. Available constructional sizes



36



CF75ED



3.6 Mode of operation of the screw compressor



The screw compressor is a two-shaft rotary piston compressor that works following the positive displacement principle. Both rotors, male rotor (1) and female rotor (2), feature screw-shaped teeth running with very small play to each other and to the casing (3) that encloses the rotors. The asymmetric profile shapes of the five teeth of the male rotor (1) and of the six teeth of the female rotor (2) match best the pressure conditions of the oilinjected air compressors. Intake and outlet of the air take place through particularly shaped apertures in the casing (3) of the compressor block. When the rotors turn, a V-shaped working space that continuously enlarges forms next to the intake aperture of the casing between two teeth of the male and female rotors. As the space filled with intake air reaches its maximum, the teeth profiles close the intake aperture (III). The air is conveyed to the still closed outlet and compressed by permanently reducing the working space. As the rotors continue turning, the working space finally opens by means of the control edges of the discharge-sided outlet (IV). The position of these control edges determines the size of the inner compression. When discharging the compressed air, the working space is decreased against zero, thus providing a compression process with least lost space.



The previously described processes: Suction, compression and discharge are repeated five times during one male rotor revolution and thus practically ensure a continuous low-pulsation conveyance, in contrast to a reciprocating piston compressor. During operation, oil is injected into the compression space of the CF compressors. This process allows for high overpressures (up to 15 bar) in single-stage operation. The oil takes up the greater part of the generated compression heat and carries it off together with the air. Besides, it is used to seal the gap between the individual different pressure level tooth spaces and the casing, and to minimize by lubrication the mechanical friction losses and wear during the torque transmission from rotor to rotor. The oil carried off with the air flow must be separated from the air in a succeeding separator and be fed back into the oil reservoir that is under discharge pressure. The screw compresor features no pulsating parts like pistons, bars or valves. This allows for a largely vibrationless operation and a dynamically low load onto bearings and couplings. The relatively low number of mechanical parts, in particular of wear parts, means low maintenance cost. The revision intervals depend mainly on the service life of the rolling bearings and of the shaft seal.



37



4



Recommendation for plant construction The following tubing plans and descriptions are non-committal examples and provide information on possible forms of execution. They do not dispense from the liability to consider the actual operating conditions. Existing safety regulations (see also section 2 „Safety“) shall be observed. We do not assume any liability or warranty for the represented circuits, descriptions and other information. Subject to technical alteration without notice.



4.1 Electromotor drive tubing plan



38



List of equipment 1



Screw compressor



30



Oil stop valve



2



Drive motor with coupling



31



Adjustable throttle valve



3



Suction filter



32



Thermometer for the oil temperature



4



Suction valve



33



Sight glass



5



Adjustable throttle valve



34



Adjustable throttle valve



6



Contact manometer for compressor discharge pressure



35



Nonreturn valve



36



Oil level indicator Oil reservoir



7



Quick-action temperature controller for the discharge temperature *)



37



Oil filler Oil reservoir



8



Nonreturn valve



38



Oil drain Oil reservoir



9



Oil reservoir and coarse separator



39



Condensate drain Oil reservoir



10



Manometer for the pressure in the oil reservoir



*)



11



Quick-action temperature controller for the temperature in the oil reservoir *)



typical response time max. 10 seconds; in the switch-off range, a temperature jump by 10 °C must entail switching within 1 second.



12



Pressure controller for the relief pressure



13



Safety valve for the discharge pressure



14



Fine separator



15



Difference pressure controller for the fine separator



16



Relief valve



17



Minimum pressure valve



18



Nonreturn valve



19



Pressure controller for the mains pressure



20



Electromagnetic 3/2 way valve



21



Nonreturn valve



22



Nonreturn valve



23



Hand switch Load / No-load



24



Manometer for the mains pressure



25



Nonreturn valve



26



Dirt catcher



27



Oil filter



28



Oil cooler



29



Thermostatic valve



39



4.2 Explanations to the electromotor drive tubing plan The pressures stated are absolute pressures. 4.2.1 Start-up – Suction



valve 4 is closed as no control pressure is applied yet. To allow for intake of a small amount of air for pressure build-up, the throttle valve 5 is set as to provide for a pressure of approx. 0.1 bar ahead of the compressor.



4.2.2 Operation under load – Suction



valve 4 opens after the required control pressure has been reached.



– Minimum



pressure valve 17 opens only after a pressure of approx. 4.5 bar has built-up in the compressor system. This pressure ensures a sufficient oil supply of the compressor. The compressor conveys into the mains as soon as the system pressure ahead of nonreturn valve 18 exceeds the pressure of the mains.



4.2.3 No-load operation No-load operation is possible:



Throttle valve 5 is required only if suction valve 4 does not have an adjusting possibility for a directed leakage (e.g. provision of bores in a throttle). – Hand



switch 23 is closed. Load position: Electric circuit for relief valve 16 and 2/3 way valve 20 is closed.



1. Automatically in case of a mains pressure that is higher than the upper switchpoint of pressure controller 19. 2. Upon actuation of hand switch 23. (No-load position: Power supply for relief valve 16 and 2/3 way valve 20 is interrupted) The course is identical:



– At



the start of the motor, relief valve 16 closes (idle: open), the 3/2 way valve 20 opens.



– Minimum



pressure valve 17 is closed, thus separating the compressor system from the mains. This prevents in particular in case of a large mains oil losses occurring due to bad oil separation as a consequence of high flow speeds.



– To



protect motor 2 and coupling, starting the motor should only be possible if there is a pressure of maximum 3 bar behind the compressor. The case being, pressure controller 12 impedes starting the motor.



40



– 3/2



way valve 20 closes because of the absence of current, and suction valve 4 closes because of the absence of control pressure.



– At



the same time, the absence of current opens relief valve 16, the pressure in the compressor system drops.



– Nonreturn



valve 18 separates the compressor system from the mains. (In addition, minimum pressure valve 17 closes at a pressure of approx. 4.5 bar)



– As



the mains pressure drops and reaches the lower switchpoint, pressure controller 19 again closes the electric circuit. This makes relief valve 16 close and 3/2 way valve 20 open. The control pressure from the mains opens immediately suction valve 4 by means of nonreturn valve 22. Further course as described under „Operation under load“.



4.2.4 Switch-off



4.2.5 Oil system



– Switch-off



Utilizing the pressure difference, the oil collected in the oil reservoir/coarse separator is used to supply the compressor with oil.



takes place intentionally upon actuation of the motor circuit breaker or by means of safety cut-out in the event of: - a pressure behind the compressor of more than p2 + 0,3 bar by contact manometer 6,



– By



means of adjustable throttle valve 31, the oil injection amount into the compression chamber (connection A) is adjusted in a way as to provide for the desired discharge temperature (between dew point temperature and 110 °C).



- a temperature behind the compressor of more than 110 °C by quick-action temperature controller 7,



– By



means of thermostatic valve 29, the oil intake temperature for the compressor stage is kept approximately constant depending on operating condition and dew point.



Switch-off must be initiated at a temperature of not more than 120 °C. - a temperature in oil reservoir 9 of more than 110 °C by quick-action temperature controller 11.



– Connection



F is used to return the oil collected in fine separator 14 into the compression chamber of the compressor. With minimum discharge pressure, adjust throttle valve 34 in a way that (visible on sight glass 33) only a small amount of air is returned with the oil.



Switch-off must be initiated at a temperature of not more than 120 °C. – To



protect motor and coupling, the motor should be switched-off whenever possible from Noload position. the motor comes to standstill before the system is completely relieved, nonreturn valve 8 prevents reverse motion caused by backward pressure drop.



– Nonreturm



valve 35 prevents that, during relief, oil from the compression chamber is blown into the open through the fine separator and relief valve 16.



– If



– Oil



stop valve 30 is generally open. It, when switching-off, the motor comes to standstill before the system has been relieved, a pressure difference occurs between the pressure side of the compressor and the oil line of oil stop valve 30 and closes oil stop valve 30. This ensures that the compressor cannot be filled with oil from the oil system due to the pressure drop (risk of a liquid hammer when starting-up again).



–



Nonreturn valve 25 prevents that oil flows back from compressor and oil system into the oil reservoir if, when switching from No-load to Load, a pressure has already built-up in the compressor whilst oil reservoir 9 is still relieved.



41



4.3 Diesel engine drive tubing plan



42



List of equipment 1



Screw compressor



30



Oil stop valve



2



Drive motor with coupling



31



Adjustable throttle valve



3



Suction filter



32



Thermometer for the oil temperature



4



Suction valve



33



Sight glass



5



Adjustable throttle valve



34



Adjustable throttle valve



6



Contact manometer for compressor discharge pressure



35



Nonreturn valve



36



Oil level indicator Oil reservoir



7



Quick-action temperature controller for the discharge temperature *)



37



Oil filler Oil reservoir



8



Nonreturn valve



38



Oil drain Oil reservoir



9



Oil reservoir and coarse separator



39



Condensate drain Oil reservoir



10



Manometer for the pressure in the oil reservoir



40



Control cylinder



41



Speed rod assembly of diesel engine



11



Quick-action temperature controller for the temperature in the oil reservoir *)



*)



typical response time max. 10 seconds; in the switch-off range, a temperature jump by 10 °C must entail switching within 1 second.



12



Pressure controller for the relief pressure



13



Safety valve for the discharge pressure



14



Fine separator



15



Difference pressure controller for the fine separator



16



Relief valve



17



Minimum pressure valve



18



Nonreturn valve



19



Pressure controller for the mains pressure



20



Electromagnetic 3/2 way valve



21



Nonreturn valve



22



Nonreturn valve



23



Hand switch Load / No-load



24



Manometer for the mains pressure



25



Nonreturn valve



26



Dirt catcher



27



Oil filter



28



Oil cooler



29



Thermostatic valve



43



4.4 Explanations to the diesel engine drive tubing plan The pressures stated are absolute pressures.



– Minimum



pressure valve 17 opens only after a pressure of approx. 4.5 bar has built-up in the compressor system. This pressure ensures a sufficient oil supply of the compressor. The compressor conveys into the mains as soon as the system pressure ahead of nonreturn valve 18 exceeds the pressure of the mains.



4.4.1 Start-up 4.4.3 No-load operation – Suction



valve 4 is closed as no control pressure is applied yet. To allow for intake of a small amount of air for pressure build-up, the throttle valve 5 is set as to provide for a pressure of approx. 0.1 bar ahead of the compressor. Throttle valve 5 is required only if suction valve 4 does not have an adjusting possibility for a directed leakage (e.g. provision of bores in a throttle).



No-load operation is possible: 1. Automatically in case of a mains pressure that is higher than the upper switchpoint of pressure controller 19. 2. Upon actuation of hand switch 23. (No-load position: Power supply for relief valve 16 and 2/3 way valve 20 is interrupted) The course is identical:



– Hand



switch 23 is closed. Load position: Electric circuit for relief valve 16 and 2/3 way valve 20 is closed.



– At



the start of the motor, relief valve 16 closes (idle: open), the 3/2 way valve 20 opens.



–3/2 way valve 20 closes because of the absence of current. The absence of control pressure regulates through control cylinder 40 the diesel engine to minimum speed and closes at the same time suction valve 4. – At



– Minimum



pressure valve 17 is closed, thus separating the compressor system from the mains. This prevents in particular in case of a large mains oil losses occurring due to bad oil separation as a consequence of high flow speeds.



– To



protect motor 2 and coupling, starting the motor should only be possible if there is a pressure of maximum 3 bar behind the compressor. The case being, pressure controller 12 impedes starting the motor.



4.4.2 Operation under load – After



reaching the required control pressure, control cylinder 40 regulates the diesel engine to maximum speed and opens at the same time suction valve 4.



44



the same time, the absence of current opens relief valve 16, the pressure in the compressor system drops.



– Nonreturn



valve 18 separates the compressor system from the mains. (In addition, minimum pressure valve 17 closes at a pressure of approx. 4.5 bar)



–As the mains pressure drops and reaches the lower switchpoint, pressure controller 19 again closes the electric circuit. This makes relief valve 16 close and 3/2 way valve 20 open. The control pressure that is still present in the mains immediately regulates through nonreturn valve 22 and control cylinder 40 the diesel engine to maximum speed and opens at the same time suction valve 4. Further course as described under „Operation under load“.



4.4.4 Switch-off



4.4.5 Oil system



– Switch-off



Utilizing the pressure difference, the oil collected in the oil reservoir/coarse separator is used to supply the compressor with oil.



takes place intentionally upon actuation of the motor circuit breaker or by means of safety cut-out in the event of: - a pressure behind the compressor of more than p2 + 0,3 bar by contact manometer 6,



– By



means of adjustable throttle valve 31, the oil injection amount into the compression chamber (connection A) is adjusted in a way as to provide for the desired discharge temperature (between dew point temperature and 110 °C).



- a temperature behind the compressor of more than 110 °C by quick-action temperature controller 7,



– By



means of thermostatic valve 29, the oil intake temperature for the compressor stage is kept approximately constant depending on operating condition and dew point.



Switch-off must be initiated at a temperature of not more than 120 °C. - a temperature in oil reservoir 9 of more than 110 °C by quick-action temperature controller 11.



– Connection



F is used to return of the oil collected in fine separator 14 into the compression chamber of the compressor. With minimum discharge pressure, adjust throttle valve 34 in a way that (visible on sight glass 33) only a small amount of air is returned with the oil.



Switch-off must be initiated at a temperature of not more than 120 °C. – To



protect motor and coupling, the motor should be switched-off whenever possible from Noload position: Due to the absence of current, 3/2 way valve 20 closes and releief valve 16 opens. The absence of control pressure in control cylinder 40 regulates the diesel engine to minimum speed and closes at the same time suction valve 4. Subsequently, the diesel engine can be switched off.



– Nonreturm



valve 35 prevents that, during relief, oil from the compression chamber is blown into the open through the fine separator and relief valve 16.



–



Nonreturn valve 25 prevents that oil flows back from compressor and oil system into the oil reservoir if, when switching from No-load to Load, a pressure has already built-up in the compressor whilst oil reservoir 9 is still relieved.



– If



the motor comes to standstill before the system is completely relieved, nonreturn valve 8 prevents reverse motion caused by backward pressure drop.



– Oil



stop valve 30 is generally open. It, when switching-off, the motor comes to standstill before the system has been relieved, a pressure difference occurs between the pressure side of the compressor and the oil line of oil stop valve 30 and closes oil stop valve 30. This ensures that the compressor cannot be filled with oil from the oil system due to the pressure drop (risk of a liquid hammer when starting-up again).



45



4.5 Recommendations for plant protection The pressures stated are absolute pressures.



· Maximum permissible discharge temperature: 110 °C Temperature monitoring is prescribed · Minimum permissible discharge pressure: 6 bar (with opened suction valve) · Maximum permissible discharge pressure see technical data sheet (Section 1.8.01 - 1.8.14). · The minimum discharge temperature should be above the dew point temperature. If this is not the case, the water vapour contained in the air condenses. The water accumulating in the oil affects the lubricity and may lead to bearing damages. · Existing adjustment possibility for the oil injection amount to influence on the discharge temperature. · The system must be designed so that, when the motor is at standstill, any still existing pressure cannot relieve backward through the compressor unit (reverse motion of motor) or through the oil system (compressor fills with oil; risk of a liquid hammer when starting-up again). · Generally, the unit does not require an oil pump. It is sufficiently supplied with oil due to the pressure differences between the oil reservoir that is under discharge pressure, and the individual connection points. For particular operating conditions (e.g. extremely low temperatures or pressures 210



> 220



Viscosity at 40 °C



mm2/s 28.8-35.2



Flash point COC



°C



48



> 200



The pour point should be at least 5 °C below the lowest ambient temperature. In case of machines operated permanently at very low speeds (male rotor tip speeds of less than 15 m/s), the next higher viscosity class shall be used in departure from the table. To avoid as far as possible the wear of roller bearings and drive gears, only oils containing wear-reducing additives and ensuring the damage force rating 9 of „Forschungsstelle fuer Zahnraeder und Getriebe FZG“ (research centre for gearwheels and gears) are approved. 4.7.3 Admixtures, impurities • Water Water in the oil can lead to discontinuance of the lubricating film and thus to severe bearing damages. The discharge temperatures should therefore always be higher than the dew point to ensure that no water precipitates in the oil circuit. It will then also be insignificant for the compressor whether the oil emulsifies easily or has a good demulsifying power. A good demulsifying power should however always be ensured if steam traps on air aftercoolers and water separation devices are topped. • Dirt Abrasive impurities e.g. by grinding or blasting residues lead as a rule to severe bearing damages. Best possible filtration of the lubricant must therefore be ensured (recommended filter meshing β25 = 75 to DIN ISO 4572). If oil filters with inner bypass, like those mentioned in the practice instructions of the German rules for prevention of accidents as an example to prevent excessive temperatures, are employed, it must be ensured that this bypass never becomes activated. In this connection, particular attention must be paid to that the bypass does not open during the cold start, when the pressure loss raises due to the increased viscosity. This is particularly dangerous because the previously filtered residues would in this case be conveyed in strong concentration with the oil flow into the bearings.



As fresh oil often already contains a great amount of dirt, it is recommended to filter the oil when filling the oil reservoir (recommended filter meshing β6 = 100 to DIN ISO 4572). • Foreign matters in the suction air The normal properties of the lubricants can be severely affected by high air humidity and chlorine (salt) in case of installation in maritime environment, or by gas admixtures in the suction air in case of installation in chemical environment. No general recommendation can be given for these cases. Direct consultation with the mineral oil companies is therefore unconditional.



4.8 Permissible flow rates The following values are recommended as maximum flow rates in the tubings: Air tubings Suction side Pressure side (air only) (air/oil mixture)



15.0 - 20.0 m/s 20.0 - 25.0 m/s 6.0 - 8.0 m/s



Oil tubings *) Pressure line Free oil drain



1.0 - 2.5 m/s 0.1 - 0.2 m/s



*) The stated flow rates are valid for the usual viscosities of 32 - 68 cSt in the normal temperature range between 40 and 80 °C.



49



4.9 Filter meshing Oil filter meshing Constructional sizes CF50; CF75: Mesh width max. 0.010 mm Constructional sizes CF90; CF128; CF180; CF248:



Explanations to the filter meshing to DIN ISO 4572: Example 1: Particle size in µm β25 = 75



Mesh width max. 0.025 mm Calculation value for the permeability rate referred to 25 µm particles as follows:



For normal operating conditions, filters with a retention rate to DIN ISO 4572:



100 / 75 = 1.3333 % β25 = 75



The retention degree is:



are recommended. As fresh oil often already contains a great amount of dirt, it is recommended to filter the oil when filling the oil reservoir. In this connection, a retention rate to DIN ISO 4572: β6 = 100 is recommended. The same applies for preservation oils and rinsing oils to clean the lubrication system.



100 - (100 / 75) = 98.667 % 98.667 % of the 25 µm particles are filtered out of the oil. Example 2: β6 = 100 100 / 100 = 1 % The retention degree is: 100 - (100 / 100) = 99 %



Suction air filter meshing Mesh width max. 0.020 mm with normal industrial air



50



99 % of the 6 µm particles are filtered out of the oil.



4.10 Fitting instructions 4.10.1 Coupling The connecting element between compressor and driving motor shall be a well aligned flexible coupling that should be balanced dynamically, but at least statically. We recommend the use of couplings with a balancing grade of G 6.3 to DIN ISO 1940 respectively Q 6.3 to VDI 2060, balanced according to the „half feather key method“ to DIN ISO 8821. According to this, a half feather key corresponding to the contour of the inside diameter is inserted in the groove when balancing. The length of the coupling hub should correspond to the length of the driving journal (see section „Technical data“). In case of a shorter coupling hub (1), a spacer ring (2) shall be fitted between coupling hub (1) and bearing ring (3), to axially fix the bearing ring (3) and to avoid unbalance of the protruding feather key.



4.10.2 Belt drive We recommend the use of V-belt pulleys with a balancing grade of G 6.3 to DIN ISO 1940 respectively Q 6.3 to VDI 2060, balanced according to the „half feather key method“ to DIN ISO 8821. According to this, a half feather key corresponding to the contour of the inside diameter is inserted in the groove when balancing. The belt drive should be within the values represented in the graph, to achieve the longest bearing service life for the compressor. The length of the pulley hub should correspond to the length of the driving journal (see section „Technical data“). In case of a shorter pulley hub, a spacer ring shall be fitted between pulley hub and bearing ring, to axially fix the bearing ring (see graph „Coupling“). For detailed technical assistance in the execution of the belt drive, please contact our „Technology“ department.



51



5



Preparations for putting into operation



The equipment shall be set up on level ground and as far as possible from sources of heat and dust. If an inclined position of mobile equipment cannot be avoided, care must be taken that the oil supply is ensured and, in case of geared machines, that the gearwheels of the compressor do not run in the oil. Topping up oil When topping up oil, it must absolutely be ensured that the whole oil system, inclusive of oil cooler, is filled. The oil level in the oil reservoir must be checked. The oil must have the prescribed level. Prior to initial start-up and after longer periods of standstill (about 3 months), the compressor shall be topped up with oil through the intake tube. CF75/CF90



~0.5 l



CF128/CF180



~1 l



CF246



~2 l



Checking the sense of rotation The sense of rotation of the driving motor must correspond with the rotation sense arrow on the compressor.



6



Maintenance



Checking the operating conditions at regular intervals and servicing all elements of the compressor system correctly on time are the prerequisites for troublefree operation and a long service life of the machine. As a matter of principle, the maintenance of the compressor system is within the responsability of the operating company who shall determine the time intervals for maintenance work taking into account the stipulations of the system manufacturer and the particular operating conditions prevailing on location (air properties, cooling water properties, ambient temperature). The following information shall be used as reference: –The oil level shall be checked at regular intervals. If possible, use the same oil grade when topping up. –The first oil change shall be made after approximately 500 hours of operation. (Observe the regulations of the oil manufacturer) –The following oil changes shall be made every 3,000 - 5,000 hours of operation, however at latest after one year. In case of unfavourable operating conditions (e.g. high intake temperature, severely contaminated air, dustloaden air containing abrasive elements etc.), the oil change shall be carried out at shorter intervals. (Observe the regulations of the oil manufacturer) –When changing the oil, it must absolutely be taken care that the whole oil system (inclusive of the oil cooler) is drained. Thereupon, take care that the oil system is completely filled again (inclusive of the oil cooler). –Elements from other manufacturers and additional units fitted to the compressor system shall be serviced according to the instructions of the respective equipment manufacturer.



52



Sale and service point GHH-RAND Schraubenkompressoren GmbH, Steinbrinkstraße 1, D-46145 Oberhausen Sales



Tel. (0 49) 2 08-6 99 41 11



Fax



(0 49) 2 08-6 99 40 50



Customer service Tel. (0 49) 2 08-6 99 40 69



Fax



(0 49) 2 08-6 99 40 74



Spare parts



Fax



(0 49) 2 08-6 99 40 74



Tel. (0 49) 2 08-6 99 40 83



Subject to alteration without notice of technical details as against the descriptions and illustrations contained in the installation manual. Reprint, translation and reproduction, in full or in extracts, are prohibited without previous written consent.



GHH-RAND Schraubenkompressoren GmbH Postfach 11 03 55 D - 46123 Oberhausen Telephone: +49 (0) 208 699 41 11 Telefax: +49 (0) 208 699 40 50



Subject to revision without notice