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1
1.8.01 Technical data CF75D
Weight: 58 kg
Variant p 2max uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible
2
All specifications with:
3
1.8.02 Technical data CF75G
Weight: CF75G 70 kg
CF75G1 90 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
4
All specifications with:
5
1.8.03 Technical data CF75ED
Weight: 70 kg
Variant p 2max uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible
6
All specifications with:
7
1.8.04 Technical data CF75EG
Weight: EG 76 kg
EG1 92 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
8
All specifications with:
9
1.8.05 Technical data CF90D
Weight: 85 kg
Variant p 2max uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible
10
All specifications with:
11
1.8.06 Technical data CF90LD
Weight: 100 kg
Variant p 2max uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible
12
All specifications with:
13
1.8.07 Technical data CF90G
Weight: 115 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
14
All specifications with:
15
1.8.08 Technical data CF90LG
Weight: 130 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
16
All specifications with:
17
1.8.09 Technical data CF128D
Weight: 250 kg
Variant p2max uHL min uHL max nHL min nHL max
bar (abs.) m/s m/s min-1 min-1
18
All specifications with:
19
1.8.10 Technical data CF128G
Weight: 280 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
20
All specifications with:
21
1.8.11 Technical data CF128LG
Weight: 330 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
22
All specifications with:
23
1.8.12 Technical data CF180R
Weight: 725 kg
Variant p 2max uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible
24
All specifications with:
25
1.8.13 Technical data CF180G
Weight: 770 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
26
All specifications with:
27
1.8.14 Technical data CF246G
Weight: 1,600 kg
Variant p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1
28
All specifications with:
29
1.9. Available gear ratios for gear driven versions
Separator Block X X X X X X X X X
Thermostatic Valve X X X X X X
Combi-blocks X X X X
Proportional Controller X X X X X X
Venting valve X X X
For more detailed information please see the specialized components manuals.
2 Safety 2.3 Qualification and training of
personnel
2.1 General Work on the compressor like operation and
maintenance shall only be carried out by
This installation manual contains basic authorized, instructed and qualified personnel
instructions to be observed during installation, who are familiar with the safety regulations in
operation and maintenance. force.
Prior to utilization and putting into operation, the The operating company shall precisely define the
personnel shall read these instructions and those scope of responsibilities, the compentence and
in the operating manual of the machine/system the supervision of the personnel. If the personnel
into which the compressor stage is fitted. The do not have the necessary knowledge, they shall
operating manual must always be accessible to be trained and instructed accordingly.
the personnel. Moreover, the operating company shall ensure
Not only should the general safety instructions that the personnel do fully understand the
under this main section „Safety“ be followed, but contents of the operating manual.
also those particular safety instructions added to
the other main sections. Repairs or conversions shall only be carried out
Disregarding the safety instructions can cause by authorized personnel who are at any time
personal hazard, but can also endanger the available at the service points or from GHH-
environment and the machine. Disregarding the Rand.
safety instructions can entail the loss of any right
to claims for damages. 2.4 Safety awareness at work
- Standards, in particular:
· DIN EN 292 Safety of machines
In case of safety instructions likely to endanger · DIN EN 1012-1 Compressors and
the machine and its function if not observed, the vacuum pumps,
word safety requirements;
Part 1: Compressors
· ISO 5388 Stationary air compressors
- safety rules and code of
practice
32
Any particular rules and regulations, in particular 2.7 Unauthorized conversion and
safety regulations, valid in your plant or because
manufacturing of spare parts
of the local conditions shall also be followed.
In the event of concurrent regulations, always the
Conversions or modifications of the compressor
more severe shall apply.
are not allowed.
Original spare parts and accessories approved
2.5 Safety instructions for the by the manufacturer contribute to safety. The use
operating company/operator of other spare parts and non-approved
accessories may entail loss of liability for any
The operating company is responsible that the consequences arising therefrom.
compressor is always in safe operating condition.
Damaged or non-operative parts shall be 2.8 Unauthorized operation
replaced without delay. modes
Any manner of work affecting the safety of the Without previous approval of GHH-RAND, the
compressor shall be abstained from. compressor shall not be operated under other
conditions than those described in section
The operator shall immediately report any change „Technical data“.
occurring to the compressor and likely to affect
the safety.
33
3 Description of product and accessories
3.1 Main assemblies of compressor
34
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.
CF75G
CF90G CF90LG
CF128G CF128LG
CF180G
CF246G
CF75D
CF90D CF90LD
CF128D CF128R
CF180R
35
3.4 Slide-in unit with gear
The slide-in units have been developed to
manufacture compressed air generators of
extremely compact design.
36
3.6 Mode of operation of the screw compressor
The screw compressor is a two-shaft rotary piston The previously described processes: Suction,
compressor that works following the positive compression and discharge are repeated five times
displacement principle. during one male rotor revolution and thus practically
Both rotors, male rotor (1) and female rotor (2), feature ensure a continuous low-pulsation conveyance, in
screw-shaped teeth running with very small play to contrast to a reciprocating piston compressor.
each other and to the casing (3) that encloses the During operation, oil is injected into the compression
rotors. space of the CF compressors. This process allows for
high overpressures (up to 15 bar) in single-stage
The asymmetric profile shapes of the five teeth of the operation. The oil takes up the greater part of the
male rotor (1) and of the six teeth of the female rotor generated compression heat and carries it off together
(2) match best the pressure conditions of the oil- with the air. Besides, it is used to seal the gap between
injected air compressors. the individual different pressure level tooth spaces and
Intake and outlet of the air take place through the casing, and to minimize by lubrication the
particularly shaped apertures in the casing (3) of the mechanical friction losses and wear during the torque
compressor block. transmission from rotor to rotor.
When the rotors turn, a V-shaped working space that The oil carried off with the air flow must be separated
continuously enlarges forms next to the intake aperture from the air in a succeeding separator and be fed back
of the casing between two teeth of the male and female into the oil reservoir that is under discharge pressure.
rotors. As the space filled with intake air reaches its
maximum, the teeth profiles close the intake aperture The screw compresor features no pulsating parts like
(III). pistons, bars or valves. This allows for a largely
The air is conveyed to the still closed outlet and vibrationless operation and a dynamically low load onto
compressed by permanently reducing the working bearings and couplings.
space.
As the rotors continue turning, the working space The relatively low number of mechanical parts, in
finally opens by means of the control edges of the particular of wear parts, means low maintenance cost.
discharge-sided outlet (IV). The position of these The revision intervals depend mainly on the service life
control edges determines the size of the inner of the rolling bearings and of the shaft seal.
compression. When discharging the compressed air,
the working space is decreased against zero, thus
providing a compression process with least lost space.
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.
38
List of equipment
26 Dirt catcher
27 Oil filter
28 Oil cooler
29 Thermostatic valve
39
4.2 Explanations to the 4.2.2 Operation under load
electromotor drive tubing plan – Suction
valve 4 opens after the required control
pressure has been reached.
The pressures stated are – Minimum pressure valve 17 opens only after a
absolute pressures. pressure of approx. 4.5 bar has built-up in the
compressor system. This pressure ensures a
4.2.1 Start-up sufficient oil supply of the compressor.
The compressor conveys into the mains as
– Suction valve 4 is closed as no control soon as the system pressure ahead of
pressure is applied yet. nonreturn valve 18 exceeds the pressure of the
To allow for intake of a small amount of air for mains.
pressure build-up, the throttle valve 5 is set as
to provide for a pressure of approx. 0.1 bar 4.2.3 No-load operation
ahead of the compressor.
No-load operation is possible:
Throttle valve 5 is required only if
suction valve 4 does not have an 1. Automatically in case of a mains pressure
adjusting possibility for a directed that is higher than the upper switchpoint of
leakage (e.g. provision of bores in pressure controller 19.
a throttle).
2. Upon actuation of hand switch 23.
– Handswitch 23 is closed. (No-load position: Power supply for relief
Load position: Electric circuit for relief valve valve 16 and 2/3 way valve 20 is
16 and 2/3 way valve 20 is interrupted)
closed.
The course is identical:
– 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, and suction valve 4 closes
– Minimum pressure valve 17 is closed, thus because of the absence of control pressure.
separating the compressor system from the
mains. – Atthe same time, the absence of current opens
This prevents in particular in case of a large relief valve 16, the pressure in the compressor
mains oil losses occurring due to bad oil system drops.
separation as a consequence of high flow
speeds. – Nonreturn valve 18 separates the compressor
system from the mains.
– Toprotect motor 2 and coupling, starting the (In addition, minimum pressure valve 17 closes
motor should only be possible if there is a at a pressure of approx. 4.5 bar)
pressure of maximum 3 bar behind the
compressor. – Asthe mains pressure drops and reaches the
The case being, pressure controller 12 impedes lower switchpoint, pressure controller 19 again
starting the motor. 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“.
40
4.2.4 Switch-off 4.2.5 Oil system
– Switch-off takes place intentionally upon Utilizing the pressure difference, the oil collected
actuation of the motor circuit breaker or by in the oil reservoir/coarse separator is used to
means of safety cut-out in the event of: supply the compressor with oil.
- a pressure behind the compressor of more – By means of adjustable throttle valve 31, the oil
than p2 + 0,3 bar by contact manometer 6, injection amount into the compression chamber
(connection A) is adjusted in a way as to
- a temperature behind the compressor of provide for the desired discharge temperature
more than 110 °C by quick-action (between dew point temperature and 110 °C).
temperature controller 7,
– By means of thermostatic valve 29, the oil
Switch-off must be initiated at a intake temperature for the compressor stage is
temperature of not more than kept approximately constant depending on
120 °C. operating condition and dew point.
- a temperature in oil reservoir 9 of more than – Connection F is used to return the oil collected
110 °C by quick-action temperature controller in fine separator 14 into the compression
11. chamber of the compressor.
With minimum discharge pressure, adjust
Switch-off must be initiated at a throttle valve 34 in a way that (visible on sight
temperature of not more than glass 33) only a small amount of air is returned
120 °C. with the oil.
– To protect motor and coupling, the motor should – Nonreturm valve 35 prevents that, during relief,
be switched-off whenever possible from No- oil from the compression chamber is blown into
load position. the open through the fine separator and relief
valve 16.
– Ifthe motor comes to standstill before the
system is completely relieved, nonreturn valve – Nonreturn valve 25 prevents that oil flows back
8 prevents reverse motion caused by backward from compressor and oil system into the oil
pressure drop. reservoir if, when switching from No-load to
Load, a pressure has already built-up in the
– Oil stop valve 30 is generally open. It, when compressor whilst oil reservoir 9 is still relieved.
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).
41
4.3 Diesel engine drive tubing
plan
42
List of equipment
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
27 Oil filter
28 Oil cooler
29 Thermostatic valve
43
4.4 Explanations to the diesel – Minimum pressure valve 17 opens only after a
pressure of approx. 4.5 bar has built-up in the
engine drive tubing plan compressor system. This pressure ensures a
sufficient oil supply of the compressor.
The compressor conveys into the mains as
The pressures stated are soon as the system pressure ahead of
absolute pressures. 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. No-load operation is possible:
To allow for intake of a small amount of air for
pressure build-up, the throttle valve 5 is set as 1. Automatically in case of a mains pressure
to provide for a pressure of approx. 0.1 bar that is higher than the upper switchpoint of
ahead of the compressor. pressure controller 19.
– Toprotect motor 2 and coupling, starting the –As the mains pressure drops and reaches the
motor should only be possible if there is a lower switchpoint, pressure controller 19 again
pressure of maximum 3 bar behind the closes the electric circuit.
compressor. This makes relief valve 16 close and 3/2 way
The case being, pressure controller 12 impedes valve 20 open.
starting the motor. The control pressure that is still present in the
mains immediately regulates through nonreturn
valve 22 and control cylinder 40 the diesel
4.4.2 Operation under load engine to maximum speed and opens at the
same time suction valve 4.
– Afterreaching the required control pressure, Further course as described under „Operation
control cylinder 40 regulates the diesel engine under load“.
to maximum speed and opens at the same time
suction valve 4.
44
4.4.4 Switch-off 4.4.5 Oil system
– Switch-off takes place intentionally upon Utilizing the pressure difference, the oil collected
actuation of the motor circuit breaker or by in the oil reservoir/coarse separator is used to
means of safety cut-out in the event of: supply the compressor with oil.
- a pressure behind the compressor of more – By means of adjustable throttle valve 31, the oil
than p2 + 0,3 bar by contact manometer 6, injection amount into the compression chamber
(connection A) is adjusted in a way as to
- a temperature behind the compressor of provide for the desired discharge temperature
more than 110 °C by quick-action (between dew point temperature and 110 °C).
temperature controller 7,
– By means of thermostatic valve 29, the oil
Switch-off must be initiated at a intake temperature for the compressor stage is
temperature of not more than kept approximately constant depending on
120 °C. operating condition and dew point.
- a temperature in oil reservoir 9 of more than – Connection F is used to return of the oil
110 °C by quick-action temperature controller collected in fine separator 14 into the
11. compression chamber of the compressor.
With minimum discharge pressure, adjust
Switch-off must be initiated at a throttle valve 34 in a way that (visible on sight
temperature of not more than glass 33) only a small amount of air is returned
120 °C. with the oil.
– To protect motor and coupling, the motor should – Nonreturm valve 35 prevents that, during relief,
be switched-off whenever possible from No- oil from the compression chamber is blown into
load position: the open through the fine separator and relief
Due to the absence of current, 3/2 way valve 20 valve 16.
closes and releief valve 16 opens.
The absence of control pressure in control – Nonreturn valve 25 prevents that oil flows back
cylinder 40 regulates the diesel engine to from compressor and oil system into the oil
minimum speed and closes at the same time reservoir if, when switching from No-load to
suction valve 4. Load, a pressure has already built-up in the
Subsequently, the diesel engine can be compressor whilst oil reservoir 9 is still relieved.
switched off.
45
4.5 Recommendations for plant · The size of the oil reservoir/coarse separator is
decisive for the degree of preliminary separation
protection
of the oil from the compressed air. A large
reservoir means a low flow speed and thus a
The pressures stated are
good oil separation.
absolute pressures.
To build up the required lubrication oil pressure
as rapidly as possible at start-up, a minimum
pressure valve should be fitted behind the
· Maximum permissible discharge temperature:
separator ahead of the mains.
110 °C
Temperature monitoring is prescribed
· At every stage of run-up, the starting torque of
the motor must be higher than the starting
· Minimum permissible discharge pressure: 6 bar
torque of the compressor.
(with opened suction valve)
The run-up time of the motor should not be less
than 2.5 seconds.
· Maximum permissible discharge pressure see
technical data sheet (Section 1.8.01 - 1.8.14).
46
4.6 Dew point diagram
Dew point diagram for t1 = 20 °C
47
4.7 Lubricant recommendation The pour point should be at least 5 °C below the
lowest ambient temperature.
4.7.1 Type of lubricants
In case of machines operated permanently at
very low speeds (male rotor tip speeds of less
Taking into account the high strain lubrication oil
than 15 m/s), the next higher viscosity class shall
suffers in screw compressors with oil injection
be used in departure from the table.
cooling, the use of proven appropriate non-ageing
corrosion-protecting oils with low foam formation
To avoid as far as possible the wear of roller
property is recommended.
bearings and drive gears, only oils containing
wear-reducing additives and ensuring the
There is no particular standard for these
damage force rating 9 of „Forschungsstelle fuer
lubricants.
Zahnraeder und Getriebe FZG“ (research centre
However, oils complying with the following
for gearwheels and gears) are approved.
standards are approved:
4.7.3 Admixtures, impurities
– Compressor oils to DIN 51506 or
– Turbine oils L-TD to DIN 51515 or
• Water
– Hydraulic oils HLP to DIN 51524, Part 2
Water in the oil can lead to discontinuance of
the lubricating film and thus to severe bearing
Besides the mineral oils often used, synthetic
damages. The discharge temperatures should
lubricants can also be employed.
therefore always be higher than the dew point to
ensure that no water precipitates in the oil
Because of the multitude of lubricants available
circuit.
on the market, we are not in a position as to
examine them for qualification, as this requires
It will then also be insignificant for the
extended time tests and as plant criterions also
compressor whether the oil emulsifies easily or
exercise great influence on the working life.
has a good demulsifying power. A good
This is why individual releases for the different
demulsifying power should however always be
lubricants cannot be granted.
ensured if steam traps on air aftercoolers and
water separation devices are topped.
However, all lubricants are approved, as far as
they meet the marginal conditions set forth in this
• Dirt
recommendation and harmful plant influences are
Abrasive impurities e.g. by grinding or blasting
avoided.
residues lead as a rule to severe bearing
damages.
4.7.2 Choice of lubricants
Best possible filtration of the lubricant must
therefore be ensured (recommended filter
The most important criterion of a lubricant for the
meshing β25 = 75 to DIN ISO 4572).
compressors is the viscosity. As this changes
with the temperature, the recommendations of the
If oil filters with inner bypass, like those
following table are valid depending on the
mentioned in the practice instructions of the
injection temperatures:
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
Injection temperature °C up to 50 up to 60 up to 70
paid to that the bypass does not open during the
ISO viscosity class VG 32 VG 46 VG 68 cold start, when the pressure loss raises due to
the increased viscosity.
Viscosity at 40 °C mm2/s 28.8-35.2 41.4-50.6 61.2-74.8
This is particularly dangerous because the
Flash point COC °C > 200 > 210 > 220 previously filtered residues would in this case
be conveyed in strong concentration with the oil
flow into the bearings.
48
As fresh oil often already contains a great 4.8 Permissible flow rates
amount of dirt, it is recommended to filter the oil
when filling the oil reservoir (recommended filter The following values are recommended as
meshing β6 = 100 to DIN ISO 4572). maximum flow rates in the tubings:
49
4.9 Filter meshing
Oil filter meshing
Constructional sizes CF50; CF75: Explanations to the filter meshing to DIN ISO 4572:
As fresh oil often already contains a great amount 98.667 % of the 25 µm particles are filtered out of
of dirt, it is recommended to filter the oil when the oil.
filling the oil reservoir.
In this connection, a retention rate to Example 2:
DIN ISO 4572: β6 = 100 is recommended.
β6 = 100
The same applies for preservation oils and
rinsing oils to clean the lubrication system. 100 / 100 = 1 %
50
4.10 Fitting instructions
4.10.1 Coupling
51
5 Preparations for putting into 6 Maintenance
operation
Checking the operating conditions at regular
The equipment shall be set up on level ground intervals and servicing all elements of the
and as far as possible from sources of heat and compressor system correctly on time are the
dust. prerequisites for troublefree operation and a long
service life of the machine.
If an inclined position of mobile equipment cannot
be avoided, care must be taken that the oil supply As a matter of principle, the maintenance of the
is ensured and, in case of geared machines, that compressor system is within the responsability of
the gearwheels of the compressor do not run in the operating company who shall determine the
the oil. time intervals for maintenance work taking into
account the stipulations of the system
Topping up oil manufacturer and the particular operating
conditions prevailing on location (air properties,
When topping up oil, it must absolutely be cooling water properties, ambient temperature).
ensured that the whole oil system, inclusive of oil
cooler, is filled. The following information shall be used as
reference:
The oil level in the oil reservoir must be checked.
–The oil level shall be checked at regular
The oil must have the intervals.
prescribed level. If possible, use the same oil grade when topping
up.
Prior to initial start-up and after longer periods of
standstill (about 3 months), the compressor shall –The first oil change shall be made after
be topped up with oil through the intake tube. approximately 500 hours of operation.
(Observe the regulations of the oil manufacturer)
CF75/CF90 ~0.5 l
–The following oil changes shall be made every
CF128/CF180 ~1 l 3,000 - 5,000 hours of operation, however at
latest after one year.
CF246 ~2 l In case of unfavourable operating conditions
(e.g. high intake temperature, severely
Checking the sense of rotation contaminated air, dustloaden air containing
abrasive elements etc.), the oil change shall be
carried out at shorter intervals.
The sense of rotation of the driving motor must
(Observe the regulations of the oil manufacturer)
correspond with the rotation sense arrow on the
compressor.
–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).
52
Sale and service point
GHH-RAND Schraubenkompressoren GmbH, Steinbrinkstraße 1, D-46145 Oberhausen