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 Intended purpose ............................................................... 1
1.2 Manufacturer’s address ............................................ 1
1.3 Type designation ................................................................ 1
1.4 Marking .......................................................................................... 1
1.5 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 Main assemblies of compressor ................. 34
3.2 Gear execution .................................................................. 35
3.3 Directly driven execution ...................................... 35
3.4 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 1.4 Marking
The type designation is to found on the
1.1 Intended purpose compressor’s nameplate.

GHH-RAND manufacture and supply the Series

CF compressor stages as built-in elements for The whole marking has
compressed air generation systems or groups. documentary value and shall not
be removed, modified or made
The compressors are exclusively intended to illegible.
compress air within the scope of the specified
technical application limits.
1.5 Information required for
In the event of differing utilization, contacting the
manufacturer will be required.
inquiries and orders
When inquiring about and ordering spare parts
and accessories, state the exact type
1.2 Manufacturer’s address designation, the machine number and the year of
construction of the compressor, the spare part or
GHH-RAND accessory is intended for.
Schraubenkompressoren GmbH
Steinbrinkstrasse 1 Original spare parts and
D-46145 Oberhausen accessories approved by the
manufacturer contribute to safety.
The use of other spare parts and
1.3 Type designation non-approved accessories may
entail the loss of any liability for
CF75GX the consequences arising
therefrom.
Variant code
1.6 Proper use
Constructional execution
G integrated gear The Series CF screw compressor is exclusively
LG extended rotor profile, intended to compress air that has no hazardous
integrated gear additions within the scope of the technical
D/R without gear application limits specified in section „Technical
LD extended rotor profile, data“.
without gear Any other use is deemed to be improper use. The
EG slide-in unit with manufacturer does not undertake any liability for
integrated gear the damages resulting therefrom; improper use is
LEG slide-in unit with exclusively at the operating company’s risk.
integrated gear and Proper use also includes the observance of the
extended rotor profile mounting, operating, maintenance and repair
ED slide-in unit, without conditions set forth by the system manufacturer.
gear
LED slide-in unit, without
gear with extended
1.7 Sale and service point
rotor profile
The address of the sale and service point is to be
Center distance of rotors in mm found on the inside of the back cover.
For rapid and low-cost execution of inspections,
Series 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 uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible

D 16 8.11 50 1,450 8,935 X

D6 16 8.11 44 1,450 7,863 X

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = 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 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

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 = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

4
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 p 2max uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible

ED 14 8.11 35.95 1,450 6,425 X

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed

6
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 uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1

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 = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

8
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 uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible

D 16 9.74 50 1,450 7,446 X

D2 16 9.74 44 1,450 6,552 X

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = 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 uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 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 = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed

12
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 p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1

G5 16 10 44 1,489 6,552 1.1667 3.0000

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

14
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 p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1

LG3 11.5 10 44 1,489 6,552 1.1667 3.0000

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

16
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 p2max uHL min uHL max nHL min nHL max
bar (abs.) m/s m/s min-1 min-1

D 16 9.31 50 975 5,235

p2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed

18
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 p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1

G 16 10 50 1,047 5,235 0.8254 2.3824

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

20
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 p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1

LG 11.5 10 50 1,047 5,235 0.8254 2.3824

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

22
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 p 2max uHL min uHL max nHL min nHL max Belt drive
bar (abs.) m/s m/s min-1 min-1 permissible

R 16 9.74 42 725 3,127 X

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed

24
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 uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1

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 = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

26
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 p 2max uHL min uHL max nHL min nHL max imin imax
bar (abs.) m/s m/s min-1 min-1

G 14.5 10 50 575 2,875 0.4605 1.9211

p 2max = max. permissible discharge pressure

uHL = Male rotor tip speed
nHL = Male rotor speed
i = Transmission ratio

28
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 CF90G/LG CF128G/LG CF180G CF246G

1) 2) 3) 4)
3,2667 3,9310 3,0000 2,3824 2,2727 1,9211
3,1290 3,7667 2,8519 2,2857 2,1765 1,8462
3,0000 3,6129 2,7143 2,1944 2,0857 1,7750
3)
2,8788 3,4688 2,5862 2,1081 2,0000 1,7073
2,7647 3,3333 2,4667 2,0263 1,9189 1,6429
1) 3)
2,6571 3,2059 2,3548 1,9487 1,8421 1,5814
2,5556 3,0857 2,2500 1,8750 1,7692 1,5227
2,4595 2,9722 2,1515 1,8049 1,7000 1,4667
2,3684 2,8649 2,0588 1,7381 1,6341 1,4130
2,2821 2,7632 1,9714 1,6744 1,5714 1,3617
2,2000 2,6667 1,8889 1,6136 1,5116 1,3125
2,1220 2,5750 1,8108 1,5556 1,4545 1,2653
2,0476 2,4878 1,7368 1,5000 1,4000 1,2200
1,9767 2,4048 1,6667 1,4468 1,3478 1,1765
1,9091 2,3256 1,6000 1,3958 1,2979 1,1346
1,8444 2,2500 1,5366 1,3469 1,2500 1,0943
1,7826 2,1778 1,4762 1,3000 1,2041 1,0556
1,7234 2,1087 1,4186 1,2549 1,1600 1,0182
1,6667 2,0426 1,3636 1,2115 1,1176 0,9821
1,6122 1,9792 1,3111 1,1698 1,0769 0,9474
1,5600 1,9184 1,2609 1,1296 1,0377 0,9138
1,5098 1,8600 1,2128 1,0909 1,0000 0,8814
1,4615 1,8039 1,1667 1,0536 0,9636 0,8500
1,4151 1,7500 1,0175 0,9286 0,8197
1,3704 1,6981 0,9828 0,8947 0,7903
1,3273 1,6481 0,9492 0,8621 0,7619
1,2857 1,6000 0,9167 0,8305 0,7344
1,2456 1,5536 0,8852 0,8000 0,7077
1,2069 1,5088 0,8548 0,7705 0,6818
1,1695 1,4655 0,8254 0,7419 0,6567
1,1333 1,4237 0,7143 0,6324
1,0984 1,3833 0,6875 0,6087
1,3443 0,6615 0,5857
1,3065 0,6364 0,5634
1,2698 0,6119 0,5417
1,2344 0,5205
1,2000 0,5000
1,1667 0,4800
1,1343 0,4605
1,1029
1,0725
1,0429
1,0141
0,9861
0,9589
0,9324
0,9067

1) CF75EG3 type is available with these gear rations only.

2) The highest ratio available for CF75EG type is 4,2424 and it is available only as CF75EG4 version.
3) CF90G/LG toothed driving shaft versions are available with these gear ratios only.
4) The highest ratio available for CF180G type is 2,4839 and it is available as CF180G2 version.
 Components, recommended fort he screw compressor airends CF Series.

CF75D CF75G/EG CF90D CF90G/LG CF128D/R CF128G/LG CF180R CF180G CF246G

Suction Regulator X X X X X X X X X
Minimum Pressure Valve X X X X X X X X X

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
2.1 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
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:
32
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 GHH-
Rand.
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:
- 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.
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 Shaft seal

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
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 CF90LG
CF128G CF128LG
CF180G
CF246G

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 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.

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 CF75ED

36
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 oil-
injected 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 35 Nonreturn valve

discharge pressure
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 *) typical response time max. 10 seconds;
reservoir
in the switch-off range, a temperature jump
11 Quick-action temperature controller for the by 10 °C must entail switching within
temperature in the oil reservoir *) 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.
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).
– Handswitch 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.
– 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.
– Toprotect 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
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:
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:
– 3/2
way valve 20 closes because of the
absence of current, and suction valve 4 closes
because of the absence of control pressure.
– Atthe 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)
– Asthe 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
– Switch-off 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,
- a temperature behind the compressor of
more than 110 °C by quick-action
temperature controller 7,
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.
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 No-
load position.
– Ifthe 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).
4.2.5 Oil system
Utilizing the pressure difference, the oil collected
in the oil reservoir/coarse separator is used to
supply the compressor with oil.
– 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).
– 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.
– 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.
– 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.
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 35 Nonreturn valve

discharge pressure
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 40 Control cylinder

reservoir
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;
12 Pressure controller for the relief pressure in the switch-off range, a temperature jump
by 10 °C must entail switching within
13 Safety valve for the discharge pressure 1 second.
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.
4.4.1 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.
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).
– Handswitch 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.
– 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.
– Toprotect 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
– Afterreaching the required control pressure,
control cylinder 40 regulates the diesel engine
to maximum speed and opens at the same time
suction valve 4.
44
– 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.
4.4.3 No-load operation
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:
–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.
– Atthe 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
– Switch-off 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,
- a temperature behind the compressor of
more than 110 °C by quick-action
temperature controller 7,
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.
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 No-
load 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.
– Ifthe 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).
4.4.5 Oil system
Utilizing the pressure difference, the oil collected
in the oil reservoir/coarse separator is used to
supply the compressor with oil.
– 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).
– 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.
– 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.
– 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.
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).

· 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
<6 bar abs.), sufficient oil supply must be
ensured by means of an external oil pump.

46
4.6 Dew point diagram
Dew point diagram for t1 = 20 °C

Dew point Conversion from t1 = 20 °C to any t1

47
4.7 Lubricant recommendation
4.7.1 Type of lubricants
Taking into account the high strain lubrication oil
suffers in screw compressors with oil injection
cooling, the use of proven appropriate non-ageing
corrosion-protecting oils with low foam formation
property is recommended.
There is no particular standard for these
lubricants.
However, oils complying with the following
standards are approved:
– Compressor oils to DIN 51506 or
– Turbine oils L-TD to DIN 51515 or
– Hydraulic oils HLP to DIN 51524, Part 2
Besides the mineral oils often used, synthetic
lubricants can also be employed.
Because of the multitude of lubricants available
on the market, we are not in a position as to
examine them for qualification, as this requires
extended time tests and as plant criterions also
exercise great influence on the working life.
This is why individual releases for the different
lubricants cannot be granted.
However, all lubricants are approved, as far as
they meet the marginal conditions set forth in this
recommendation and harmful plant influences are
avoided.
4.7.2 Choice of lubricants
The most important criterion of a lubricant for the
compressors is the viscosity. As this changes
with the temperature, the recommendations of the
following table are valid depending on the
injection temperatures:
Injection temperature °C up to 50 up to 60
ISO viscosity class VG 32 VG 46
Viscosity at 40 °C mm2/s 28.8-35.2 41.4-50.6
Flash point COC °C > 200 > 210
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
up to 70
paid to that the bypass does not open during the
VG 68 cold start, when the pressure loss raises due to
the increased viscosity.
61.2-74.8
This is particularly dangerous because the
> 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:

• Foreign matters in the suction air Air tubings

The normal properties of the lubricants can be
severely affected by high air humidity and Suction side 15.0 - 20.0 m/s
chlorine (salt) in case of installation in maritime Pressure side (air only) 20.0 - 25.0 m/s
environment, or by gas admixtures in the (air/oil mixture) 6.0 - 8.0 m/s
suction air in case of installation in chemical
environment.
No general recommendation can be given for Oil tubings *)
these cases.
Direct consultation with the mineral oil Pressure line 1.0 - 2.5 m/s
companies is therefore unconditional. Free oil drain 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: Explanations to the filter meshing to DIN ISO 4572:

Mesh width max. 0.010 mm Example 1:

Constructional sizes CF90; CF128; CF180; Particle size in µm

CF248:
β25 = 75
Mesh width max. 0.025 mm
Calculation value for the permeability
For normal operating conditions, filters with a rate referred to 25 µm particles as follows:
retention rate to DIN ISO 4572:
100 / 75 = 1.3333 %

β25 = 75 The retention degree is:

are recommended. 100 - (100 / 75) = 98.667 %

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 %

The retention degree is:

100 - (100 / 100) = 99 %

Suction air filter meshing
99 % of the 6 µm particles are filtered out of the
Mesh width max. 0.020 mm with normal industrial oil.
air

50
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.
52
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.
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 Tel. (0 49) 2 08-6 99 40 83 Fax (0 49) 2 08-6 99 40 74

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 Subject to revision without notice
Postfach 11 03 55
D - 46123 Oberhausen
Telephone: +49 (0) 208 699 41 11
Telefax: +49 (0) 208 699 40 50