Service Manual Part 1
Contents
1. 1 oc 8x 211 A8x7x40 DIN6885 281 94 347 94 Model SV120 H hydraulic drive All measurements are approximate specifications Flange dimensions refer to SV120 D model C23556277_EN 11 2009 Rev 0 Dimensions amp weight Rotational speed range Connection dimensions SV120 D H SV120 Length approx mm 494 546 min min rpm 1000 Width approx mm 232 232 max min rpm 1800 Height approx mm 245 245 Weight approx kg 37 39 Intake pressure flange DN40 68 2 x M10 Articulated shaft Only articulated shafts with two joints are permitted Only balanced articulated shafts with a balancing quality of G 6 3 in accordance with DIN ISO 1940 with length compensation may be used Performance data Unit SV120 Rotary valve compressor min rpm 1000 1400 1800 Working gage pressure bar g psig 1 5 15 0 Intake volume m h cfm 75 50 119 76 163 102 Coupling output kW hp 5 0 5 5 7 1 8 1 9 8 11 1 Final temperature C F 136 229 133 231 142 247 Intake temperature max C F 46 115 46 115 46 115 Working gage pressure bar g psig 2 0 25 0 Intake volume m h cfm 65 42 109 67 152 93 Coupling output kW hp 6 0 7 3 8 2 10 1 11 3 14 0 Final temperature C F2. The arrow 1 in the compressor casing indicates the required rotation direction of the drive shaft If the rotation direction of the compressor is not the same as the rotation direction of the drive the rotation direction of the compressor must be changed by switching the covers to the respective other side e Reinstall the covers on the opposite ends Apply installation paste ceramic based heat resistant up to 250 C to the hexagon socket screws 1 insert them and tighten them with the specified torque Tightening torque M10 10 9 58 Nm 42 8 Ibf ft C23556277_EN 11 2009 Rev 0 CAUTION Do not use washers on the cover for the hydrau lic drive only SV120 H Do not tighten hexagon socket screws applying more than the specified torque because the com pressor housing may otherwise be damaged The powering now takes place at the other end of the shaft of the compressor the drive rotation direction is running counter clockwise NOTE Prior to the reattachment of the footers it needs to be determined which direction the connection flanges of the compressor should point to in the installed condition because the footers can optionally be installed so that they are off set on the compressor by 90 respectively see Section 3 3 2 in conjunction with a change of the drive rotation direction it needs to be ensured that afterwards the flanges for the installation of the vacuum and the pressure lin
3. of the rotary valve compressor It is not used to prevent material rebounds for that respective features must exist on the vehicle side 14 47 4 Safety valve Non return valve Combined non return valve and safety valve in lieu of Pos 6 and 7 Micro filter optional 60 90 WARNING Adhere to the flow direction of the non return valve arrow in the casing Do not mount the safety valve facing downwards NOTE The non return valve that is installed in the com pressor kit has the purpose to prevent a longer fast reverse motion of the compressor after shut off that is due to an existing residual pressure in the air pressure lines of the pneumatic system as well as in the tank C23556277_EN 11 2009 Rev 0 NOTE To prevent an unintended material rebound an additional non return valve or a non return flap is mandatory to be intended in the pneumatic system of the silo construction 3 5 2 Safety valve To secure the compressor and the safety valve that comes with the kit must be installed between the compressor and the non return valve WARNING To ensure a proper function the safety valves must not be installed facing downwards The length of the pressure line to the safety valve may measure no more than 1 m 3 3 ft The pressure line to the safety valve should be kept as short as possible WARNING The safety valve must be
4. 164 299 157 290 166 306 Intake temperature max C F 46 115 46 115 46 115 Working gage pressure bar g psig 2 5 36 0 Intake volume m h cfm 55 32 98 58 140 83 Coupling output kW hp 7 0 9 3 9 3 12 4 12 9 17 2 Final temperature C F 192 375 181 356 190 372 Intake temperature max C F 46 115 46 115 46 115 Final temperature with max C PF 240 464 227 441 238 460 intake temperature All information for Feed medium atmospheric air Intake pressure 1 bar abs 14 504 psia Intake temperature 20 C 68 F Technical data without intake or pressure losses Maximum operating pressure 2 5 bar rel 36 psig Environmental conditions Environmental temperature 25 to 46 C 13 to 111 8 F C23556277_EN 11 2009 Rev 0 1 7 Dimensions with the utilization of the optional installation console 21 6 58 ne al O OF O o Q O 600 O Sample illustration for SV120 D model Dimensions SV120 D H with kit aD H Length approx mm 510 546 Width approx mm 250 58 Height approx mm 358 Length without hydraulic motor optional kk Measurement from bottom edge of vehicle frame with use of the optionally
5. deliverable installation console console can be short ened on the top All measurements are approximate specifications C23556277_EN 11 2009 Rev 0 1 8 Scope of delivery Scope of delivery SV120 D kit Scope of delivery SV120 H kit SV120 D compressor SV120 H compressor 2 flange seals for intake and pressure flange at 2 flange seals for intake and pressure flange at the compressor the compressor 1 articulated shaft flange DIN or SAE 1 flexible shaft connection coupling Air intake filter kit Air intake filter kit intake filter with rain cap mounting rubber pipe intake filter with rain cap mounting rubber pipe elbow 90 pipe piece aluminum 4 hose elbow 90 pipe piece aluminum 4 hose clamps service gage and hose connection fitting clamps service gage and hose connection fitting DN50 straight optional 90 ungulate and pivot DN50 straight optional 90 ungulate and pivot able able Spiral hose length approx 1 5 m Spiral hose length approx 1 5 m Drive side flange pipe connection flange weld Drive side flange pipe connection flange weld flange flange 1 check valve and 1 safety valve or 1 combined 1 non return valve and 1 safety valve or 1 com check safety valve bined non return safety valve Optional Optional Overload coupling with shear bolt usable for DIN Installation console with compressor mount and and SAE articulated shaft flange incl 2 she
6. delivery diameter at least 1 2 so that the com pressor can be started and turned off without potential back pressure 3 5 6 Pressure line The pressure line must be mounted on the vehicle with elastic fasteners to prevent tension as well as the transmission of vibrations as much as possi ble Flexible elements should be intended in the pres sure line so that the torsions of the vehicle frame as well as the thermal expansion of the pressure lines can be compensated CAUTION The pressure line will become very hot during the operation of the compressor Lay the pressure line preferably in such a way that it cannot be accidentally touched Respective safety stickers can be affixed on the pressure line see Chapter 4 Easily flammable materials may not get in contact with the pressure line CAUTION Only the non electricity conductive flange seals that come with the kit may be used on the com pressor flanges risk of corrosion 15 3 6 Mounting NOTE The installation is shown through the example of the installation console that can be delivered as an option WARNING If not indicated otherwise installation paste ceramic base heat resistant up to a min of 250 C 482 F must be applied to all fastening screws on the compressor before they are re inserted Therefore the following work steps therefore waive this notice e Specify compressor installation
7. hazards that may lead to oper ating errors injuries and material damage Explanation of the signal words DANGER Identifies an immediately impending hazardous situation which may lead to death or serious inju ries if it is not averted WARNING Identifies a potential hazardous situation which may lead to death or serious injuries if it is not averted CAUTION Identifies a potential hazardous situation which may lead to minor or moderately severe injuries if it is not averted NOTE Identifies information or company policies that relate directly or indirectly to the safety of the staff or the protection of material assets Table of Contents E e 1 1 1 Application russ 1 1 2 Manufacturer s address 1 1 3 Machine data seen 1 1 4 Information for enquiries and orders 1 1 5 Service locatiONS ccoonnonccnninnnonccnccnnnnnss 1 1 6 Technical data of the SV120 rotary valve compressor cocccccnnnnonancanoncncncnncnnnncnn 2 1 7 Dimensions with the utilization of the optional installation console 4 1 8 Scope of delivery 5 2 Ae 6 2 1 A een 6 2 2 Authorised personnel training and QUALIFICATION uuuunennnnnnnnnnnnnnnnnnnnnn 6 2 3 Safety conscious Work 6 2 4 Unauthorised conversions and spare o snes cesuchaseerievenet xenedixecietes 6 2 5 Incorrect operating methods 6 A A asna Eee
8. 3 Measuring calibration of the bearing Oat sii ccceteas desvessececectevvsent 33 6 6 4 Final work ueesesenneneeneenennnnnnnnnnnnnn 36 6 7 Required tools 37 7 Replacement parts and OPEN cis 38 1 General 1 1 Application GHH RAND builds and delivers the SV120 rotary valve compressor in the form ofthe SV120 D Direct Drive model as well as the SV120 H Hydraulic Drive model including the respective accessories as kits for the installation on tank vehicles for a unit that is connection ready Due to the oil free compression of atmospheric air and the weight to power ratio the compressor sets are used for the installation on tank vehicles forthe compression supported emptying of liquids when the utilization of feed pumps would be dif ficult or impossible due to the fact that the direct contact of liquid pump would cause problems The products built and supplied by GHH RAND are only designed for the operation at and on utility vehicles that exclusively drive on paved roads A different use requires the consultation with the manufacturing plant 1 2 Manufacturer s address GHH RAND Schraubenkompressoren GmbH Max Planck Ring 27 46049 Oberhausen C23556277_EN 11 2009 Rev 0 1 3 Machine data The machine data is located on the type plate of the rotary valve compressor NOTE The entire identification has certificate value and may not be changed or rendered illegible 1 4 Information for en
9. DHR R AND Installation and Service Instructions Translation of the Original Instructions SV120 AR Ingersoll Rand C23556277_EN 11 2009 Rev 0 Industrial Technologies Introduction Carefully read these Installation and Service Instructions prior to the installation and start of operation of the SV120 rotary valve compressor These Installation and Service Instructions de scribe the structure and the first start of operations of the rotary valve compressor compressor kits as well as the service work that needs to be car ried out for maintenance reconditioning Make sure that these Installation and Service Instructions are available to the staff and that work is performed in accordance with the instructions therein Scope of application of the Installation and Service Instructions The Installation and Service Instructions exclu sively contain information for the installation start of operation and for the maintenance service of the SV120 rotary valve compressor in connection with the SV120 D and SV120 H compressor kits respectively The Installation and Service Instructions do not apply for the installation and the service of third party components through a third party installer Target group These Installation and Service Instructions are lim ited exclusively to the utilization through trained specialists Notes and safety instructions The following notes and safety instructions serve as a warning about
10. ar mounting material bolt as backup Hydraulic motor Installation console with compressor mount and Micro filter for drive side installation mounting material Micro filter for drive side installation C23556277_EN 11 2009 Rev 0 2 Safety 2 1 General These Installation and Service Instructions include basic notes that must be followed during the assembly installation and service Therefore these Installation and Service Instructions must be read in their entirely by the responsible specialized staff prior to the start of work 2 2 Authorised personnel training and qualification WARNING Installation work on the compressor compres sor kit may only be carried out by authorized trained and qualified persons who are familiar with the applicable safety regulations Repair work or modifications may only be per formed by authorized personnel The staff is avail able at anytime at the service sites or at GHH RAND 2 3 Safety conscious work The safety related regulations that are relevant for the installation operation and maintenance of air compressors can be found in the following publi cations Standards in particular DIN EN ISO Safety of machinery 12100 DIN EN Compressors and vacuum pumps 1012 01 safety requirements In addition the following regulations and guidelines must be adhered to Product related safety data sheets especially in regard to explosion hazar
11. based on the space requirement see Chapter 1 6 and 1 7 adhere to max angle for the articulated shaft and space requirements for the installation of the hydraulic drive only SV120 H e Determine direction of the compressor position of the connecting flanges and modify footers respectively see Chapter 3 3 2 or if the com pressor is to be attached to the optional instal lation console you must detach the footers from the compressor In this respect e Loosen Fastening screws 1 4 pieces of the feet 2 e Attach fastening screws 4 with discs 5 in the other fastening points at the compressor 3 so that the two sides remain open for the installation at the installation console or the holding plate remain open Tightening torque M10x40 10 9 58 Nm 42 8 Ibf ft 16 e Position installation console 1 at the vehicle frame 2 so that the drive flanges are parallel NOTE The installation console features a flange adjust ment of 3 see Chapter 1 6 To achieve flange parallelism the installation con sole must be positioned respectively with regard to the vehicle frame in conjunction with different slopes of the power take off flange If the installation console is to be mounted at a height where it protrudes beyond the vehicle frame the installation console can be respec tively reduced at the top e Installation location and drilling holes in
12. ds handling and stor age Technical rules for hazardous materials TRHM Technical rules for operational safety TROS In this context the respectively last applicable ver sions of these regulations shall be authoritative WARNING Special legal provisions and regulations particu larly safety regulations that may apply in your company or due to local conditions must also be adhered to In case of competing regulations the more restrictive provisions shall be applied Also adhere to the national regulations that apply in the respective country in which the installation takes place 2 4 Unauthorised conversions and spare parts Modification and changes on the compressor compressor kit are prohibited Damage to the seal will void any warranty claims Original replacement parts and accessories that are authorized by the manufacturer represent safe ty factors The use of non original or unauthorized replace ment and accessory parts may void the liability for resulting consequences 2 5 Incorrect operating methods Without the approval of GHH RAND compressors compressor kits may not be operated under any other conditions than those listed in Chapter 1 6 Technical data WARNING The operation of compressors compressor kits under conditions that are not intended may lead to serious injuries and significant material dam age 2 6 Disposal NOTE Properly dispose of
13. e are located on the respectively opposite side C23556277_EN 11 2009 Rev 0 3 3 2 Installation options for the footers Orientation of the compressor con nections The attachment footers 3 can be installed so that they are offset respectively by 90 between 2 fas tening screws 4 of the covers 1 installation posi tion see Pos 5 If necessary the footers can also be installed on the compressor so that they are turned by 180 see Pos 2 to achieve a closer spacing of the mounting drill holes on the vehicle CAUTION Do not use washers at the mounting points of the footers No washers are used either for the other two mounting screws on the cover for the hydraulic drive only SV120 H NOTE If the optional installation console is used a mounting plate is installed in lieu of the footers The mounting plate is screwed to the installation console which is attached to the vehicle see Chapter 3 6 3 3 3 Installation site The approximate position of the compressor on the vehicle must be determined prior to the instal lation considering the following framework condi tions Required space conditions e Check required space on the vehicle considering the respective dimensions see Chapter 1 6 Technical data for SV120 rotary valve compres sor and Chapter 1 7 e To ensure sufficient cooling of the compressor the space between the front covers and othe
14. formation provided by the articulated shaft manufacturer in regard to the mounting flange parallelism and inclination angle of the articulated shaft must be adhered to C23556277_EN 11 2009 Rev 0 The total inclination angle a of the articulated shaft shall not exceed 12 15 are permissible in excep tional cases 11 3 4 Air intake Component overview Air filter Spiral hose Rubber pipe angle 90 Hose connection fittings straight Hose clamp Hose connection fittings 90 pivotable optional instead of Pos 7 Service gage Flange seal Goo 0090 60 000 Pipe piece Intake flange on the compressor 12 C23556277_EN 11 2009 Rev 0 The intake air must be cleaned through the air filter that is included in the kit A paper filter should be chosen as the filter material Air flow filter installation location CAUTION The air intake must not be located in the area of warm air or emitted hot exhaust fumes If neces sary the exhaust system of the vehicle or the installation location of the air filter must be moved Temperature damage may be caused to the com pressor in case of non adherence Connection line service gage The air intake line spiral hose included in the kit is connected to the air filter via a 90 elbow fitting which the intake service gage is mounted onto NOTE Consider the accessibility and readability of the service gage when determining t
15. he installation location of the air filter The connection of the air intake line at the com pressor takes place via a hose connector fitting straight or with 90 angle and pivotable C23556277_EN 11 2009 Rev 0 NOTE To prevent a loss of pressure the nominal width DN 50 of the connection line for the air intake filter may not be reduced and the length of the connection line should be kept as short as pos sible CAUTION If a fixed piping is intended in lieu of the spiral hose it needs to be ensured that only pipes made of non corroding material e g aluminum are used Otherwise there is a risk that rust germs may enter the compressor and that the rotor may start to rust Only the non electricity conductive flange seals that come with the kit may be used on the com pressor flanges risk of corrosion 13 3 5 Drive side facilities Component overview SV120 Rotary valve compressor Flange seal Pipe connection flange Weld flange Pressure line not included in the total price 00 0090 The connection of the pressure line at the com pressor takes place via the pipe connection flange that came with the kit of the welding flange option al 3 5 1 Non return valve The non return valve that is included in the kit must be installed in the pressure line to the tank as a means of protection for the compressor The non return valve is to prevent a reverse motion
16. kings on the mounting console e Fasten installation console with hexagon screws M14 10 9 with shaft with the vehicle frame Tightening torque M14 10 9 180 Nm 133 Ibf ft C23556277_EN 11 2009 Rev 0 NOTE As shown in the illustration with the double arrow the fastening plate can be attached on the instal lation console at two different heights The dashed lines respectively show the upper and lower installation position of the fittings e Attach compressor 1 with spring washers 2 as well as the screws M10x40 10 9 3 which were previously used to attach the footers onto the fastening plate 4 Tightening torque M10x40 10 9 58 Nm 42 8 Ibf ft 17
17. lied with the kit is intended for a direct actuation from a power take off via a articulated shaft The installation of a safety coupling is recommend ed for the protection of the drive gear unit An overload coupling with shear bolt can be sup plied as an option refer to Chapter 1 8 SV120 H kit H hydraulic drive The SV120 H rotary valve compressor that comes with the kit is intended for an actuation through a hydraulic motor via a flexible coupling It is possible to attach a hydraulic motor which can be supplied as an option through a flange at the cover on the drive side of the compressor the drive shafts are connected with each other via the flexible coupling 3 3 Preparing installation 3 3 1 Rotation direction control change of rotation direction CAUTION The rotary valve compressor may only be turned in the direction as indicated by the arrow 1 on the casing Even short term turning against the stipulated rotation direction can result in major damage to the compressor Exchanging of the covers e Unscrew the hexagon socket screws 1 total of 4 take footer 4 and cover 6 off the compres sor 3 e Take fitted key 5 out of the shaft and insert it into the slot at the other end of the shaft CAUTION The fitted key slot in the shaft has sharp edges Wear appropriate protective gloves e Check the rotation direction of the drive
18. n 6 3 Installation guidelines 7 3 1 Internal transportation r 7 3 2 Drive options san 7 3 3 Preparing installation uuru en 8 3 3 1 Rotation direction control change of rotation direction 8 3 3 2 Installation options for the footers Orientation of the compressor CONNECTIONS u 9 3 3 3 Installation Site eee 10 3 3 4 Selecting the articulated shaft only SV120 D kit 11 3 4 Air intake siciliano 12 3 5 Drive side facilities 14 3 5 1 Non return valve nnnn 14 3 52 Safety valentine 15 3 5 3 Non return valves and safety valve combination 15 3 5 4 Micro filter 444 nn 15 3 5 5 Ball Valeira 15 3 5 6 Pressure line ssennnnn 15 3 6 MOUNTING ici 16 4 Safety labels u uuuuuuuunnnnnnnnnnnnn 22 5 Initial commissioning ureren 24 5 1 GAMA nn nnonanos 24 5 25 NIESE PUM cta tio oie 24 5 3 Switching Compressor Off 24 6 Repair service zununnesennnnnnnnnnnnnnnnen 25 6 1 Generalista 25 6 2 Personnel and qualification 25 8 3 SOU oe aca ea cee o tats sateen eee 25 6 4 Repair time and scope n 25 6 5 Preparatory work nseeseeennennnnnneennnnnen 26 6 6 Repair work uuueenennnnennnnnnnnnnnnnnnnnnn 26 6 6 1 De installation dismantling 26 6 6 2 Assembly installation 30 6 6
19. operating materials and com ponents in an environmentally safe way C23556277_EN 11 2009 Rev 0 3 Installation guidelines NOTE In principle the installation guidelines of the man ufacturer for the respective vehicle must be adhered to in addition to the specifications of this Installation and Service Instruction 3 1 Internal transportation The rotary valve compressor and the accessories are delivered separately The rotary valve compressor sits on a pallet and is fastened with tension straps The additional parts of the kit are delivered in a separate box WARNING Use a sufficiently dimensioned lift truck or forklift for the internal transport To transport the compressor with a crane it is pos sible to screw an eye bolt 1 into the threaded drill hole between the connection flanges on the top of the compressor WARNING Use sufficiently dimensioned lifting accessories Do not lift the compressor by the plastic covers that are attached to the sides C23556277_EN 11 2009 Rev 0 3 2 Drive options CAUTION No radial forces may be transmitted to the drive shaft of the compressor actuation with a V belt drive is therefore prohibited To avoid damage to the compressor it must be ensured that the required operating speed is achieved promptly SV120 D kit D direct drive The SV120 D rotary valve compressor that is sup p
20. quiries and orders In conjunction with inquiries and orders of replace ment parts and accessories the exact type iden tification and the machine number of the compres sor for which the replacement part or accessory is intended must be indicated WARNING Original replacement parts and accessories that are authorized by the manufacturer represent safety factors The use of non original or non authorized replace ment parts and accessories may void the liability for the resulting consequences 1 5 Service locations Addresses of the service locations can be found on the last page of these installation instructions or on the Internet page http www ghhrand com 1 6 Technical data of the SV120 rotary valve compressor 243 7 je 825 g7 160 A8x7x40 DIN 6885 M10718 250 sl Model SV120 D direct drive All measurements are approximate specifications 546 a 296 250 un a 243 7 50 5 Fang ll i Poo Oe St e cans u RNS HH 825g pO OO
21. r parts should measure at least 20 cm e Consider the orientation of the compressor and the respective space requirement for the con nection of the intake and the pressure line Orientation flange parallelism E NOTE The maximum permissible inclined position of the rotary valve compressor in longitudinal direction during the operation is 10 10 For the SV120 D compressor plan if possible for an installation and orientation on the side of the power take off in a right angle to the vehicle The optional installation console already comes with a flange fitting of 3 to achieve flange paral lelism see illustration in Chapter 1 7 Measure ments in conjunction with the use of the optional installation console C23556277_EN 11 2009 Rev 0 3 3 4 Selecting the articulated shaft only SV120 D kit Consider the following items during the determi nation of the articulated shaft e Choose the appropriate length for the jointed shaft taking into consideration the fitting dimen sions and observing the maximum extension length CAUTION The maximum permissible expansion length of the articulated shaft must be looked up in the operating instructions of the articulated shaft manufacturer and must be adhered to during the installation WARNING As amatter of principal the manufacturer s struc tural guidelines for the respective vehicle and the technical in
22. the con sole For a pre drilled vehicle frame transpose the drill pattern of the vehicle frame to the backside of the installation console WARNING Fit the installation console with at least 4 drill holes 14 5 mm min screw size M14 10 9 hexagonal bolt screws with shaft The placement of the hole pattern can be differ ent based on the respective vehicle frame Use the largest hole spaces C23556277_EN 11 2009 Rev 0 e f the vehicle frame was not drilled sufficiently at the factory initially drill holes according to the vehicle manufacturer s installation guidelines and the dimensions of the mounting console on the vehicle frame Transpose the hole patterns of the vehicle frame onto the backside of the installation console WARNING Some vehicle frames must be reinforced in the area that is to receive the installation console in accordance with the construction guidelines of the manufacturer NOTE Compensate for potentially existing slopes of the frame an off set frame or auxiliary frame by using a base plate or wedges e Attach fastening plate 3 with screws M12x35 5 plates 4 wedge locking washers 2 and screw nuts 1 on the installation console 6 Tightening torque M12x35 8 8 82 Nm 60 5 Ibf ft WARNING No welding work must be carried out on the vehi cle frame e Drill holes for the fastening screws according to the mar
23. the first component in the pressure line behind the compressor The improper placement of the safety valve my lead to the total damage of the compressor as well as to personal injury The safety valve that comes with the compressor kit is only used to protect the compressor against exceeding the permissible pressure The tank pressure container must be secured separately CAUTION The release of the safety valve may lead to inju ries or damage due to emerging hot air Install the safety valve so that potentially emerg ing hot air is not directed toward operating per sonnel or sensitive machine components It is not permitted to use the safety valve as an exhaust regulation valve C23556277_EN 11 2009 Rev 0 3 5 3 Non return valves and safety valve combination As an alternative to the individual valves there is also a combined non return valve and safety valve The explanations and notes in the sections for the individual valves refer to Chapter 3 5 1 and 3 5 2 must also be adhered to 3 5 4 Micro filter In cases when the product that is to be transport ed may not come in contact with dust particles from the compressor abrasion of the separation valve a micro filter must be installed in the pres sure line behind the non return valve available as optional delivery 3 5 5 Ball valve A ball valve should be installed in the pressure line before the non return valve not part of scope of
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