HV04 - HV07 Models (ACS)
Contents
1. 435A395 Fig 20 Oil Drain and Filter Location 10 10 Air Filter Replacement Fig 18 To change the air filter element twist the cap of the air filter container D anti clockwise then lift vertically to expose the element Part No 75155 inside Remove the old element and discard in a safe manner and replace with a new element before replacing the cap 10 11 Oil Separator Replacement Fig 18 a Unscrew the oil separator C in an anti clockwise direction and discard in a safe manner ST 16048 00A Hydrovane b Using a new separator smear a small amount of oil onto the seal screw in clockwise to tighten hand tight only 10 12 Clean Oil Cooler After cooler Fig 19 and 20 a The cooler matrix airflow is from the inside to outside cleaning is best achieved by reversing the airflow to dislodge any accumulation of dirt b Using a low pressure air line less than 2 bar pressure blow a jet of air over the whole area of the matrix A Dirt dislodged can be removed using a vacuum cleaner placed through the access to the bypass filter and impellor area behind the cabinet filter B Part No 74695 c Gain access to the rear of the cooling fan filter by means of removable panel E d Using a standard household vacuum cleaner remove any dislodged debris through the access hole E Note Alldiscarded items and waste oil must be disposed of in an approved manner 10 13 Panel Refi2. 23 8 8 Stopping Single Speed 0 00 0 cee te eee 24 8 9 Stopping Regulated Speed ce eee 24 ST 16048 00A 3 Hydrovane 8 10 8 11 9 9 1 9 2 9 3 10 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 10 10 10 11 10 12 10 13 10 14 10 15 10 16 Contents Emergency Stop ooococcc en 24 Compressor Vent DOWN 24 Adjustments o2 cries eh soe A ine eee 25 Standard Compressor Control Fig 16 25 Pressure Switch Fig 17 25 Pressure Control RS compressors LL 26 Servicing lil lee EET eed cae tea eas tee 27 Introduction aa siii a Pe PROTRAE i Aa 27 Routine Service Schedule eee 27 Check Compressor Operation 27 Basic Service Fig 1820019 0oococcocccccco 28 Panel REMOVAL A A A eel SM 28 Oil Draining amp Filter Replacement Fig 18 and 20 0045 28 Oil Draining Fig 20 28 Oil Filter Replacement Fig 20 29 Oil filling Top Up 2 6 RR IRRRERRIRR AR RRIR I 29 Air Filter Replacement Fig 18 oooococcccoccc eae 29 Oil Separator Replacement Fig 18 eee 29 Clean Oil Cooler After cooler Fig 19 and 20 29 Panel Renting is ain LEE oe AS A AS ia ai 29 Electrical Cheeks i scart A i ee ele sa 29 Check operation of over temperature control unit Fig 21 29 Servicing Requirements 31 ST 16048 00A 1 Introduction 1 Introduction 1 1 Introducing your new Compair UK Limited compressor Your new Hydrovane comp
3. All rights reserved The copyright of this document is the property of CompAir UK Limited No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the Technical Publications Department CompAir UK Limited E mail Telephone Fax Servicing 10 Sales CompAir co uk 01527 525522 01527 521140 ST 16048 00A
4. AN A BEFORE STARTING WORK ENSURE THAT THE MAIN LINE FUSES HAVE BEEN REMOVED FROM THE DISTRIBUTION BOARD PRECAUTIONS SHOULD BE TAKEN TO PREVENT THEM BEING REFITTED UNTIL THE INSTALLATION IS COMPLETE a The starter must be connected to the mains electrical supply via a lockable switched and suitably rated fused isolator The isolator should be positioned as near as possible to the compressor with clear unrestricted access b To access the starter remove the top panel release two quarter turn fasteners mounted horizontally at each side of the front panel Release another two fasteners mounted vertically at the rear of the top panel and lift clear of the unit c Pass the incoming cable through the entry hole on the rear left hand side of the vertical plate continue through the bulkhead to enter the rear of the starter enclosure using suitable cable glands d Alternatively and essential for RS units cable entry can be made through the base and vertically upwards into the underside of the starter enclosure e Unlock the starter door with the key provided and connect the three mains supply cables to the contactor terminals marked L1 L2 and L3 connect the earth cable to the earth pin E f Cable sizes specified are the minimum cross section Technical Data on page 9 to suit a typical installation If the compressor is located a long way from the isolator and or the ambient temperature exceeds 35 C then the cable size
5. FOR 400 415V 1 ov i at mn 2 3 380V to 415V A FOR 380V ael ilL I 6 7 FUSE POSITION NOTE 1 FOR REMOTE CONTROL REMOVE LINK BETWEEN TERMINALS X10 amp X11 CABLE REMOTE CONTACT BETWEEN TERMINALS X10 amp X11 CLOSE CONTACT TO START OPEN CONTACT TO STOP NOTE 2 OPTIONAL THERMAL OVERLOAD REFER TO AUXILLARY CONTACT POSITIONED IN CONTROL CIRCUIT 4 NOTE 3 REFER TO CIRCUIT 74893 FOR AUTO RESTART APPLICATIONS 24VOLTS CIRCUIT 4 SEE NOTE 2 gt AAA i Ly X OPTIONAL i FS VA CUSTOMER i EIZO s SEE NOTE 2 Tox dg Xu X40 MF m Pt 59344 g X8 Ts X10 Oxo 9 7 SEENOTE 1 I oxn x amp Zan Mg f ES BES emanen 0 E7 12 22 ae 7 ew NN ae ae 7 SHOWN o X14 IN AUTO O a 3 Fh do 18 i af is PAN a8 A X13 PACA or 219 13 4354423 A1F Over temp Control PCB Starter Type 34682 Cct Diag 74904 Issue C F1F Fuse 2A T 250V IEC127 M1M Main Drive Motor FSF Fuse 2A T 500V EN 60269 M3M Cooling Fan Motor F4 Thermal Overload R2F Compressor Over temp Thermistor F5 Cooling Fan Motor Thermostat R3F Motor Over temp Thermistor H1 Hours Counter S1E Start Reset Push button H2 S1E Combined Ind Lamp r Amber Start reset Push button S2A Auto
6. compressor must be flushed out with fluid force prime 10 5 Panel Removal Wait until the compressor vent down cycle is complete vent pressure from the air aftercooler and associated pipework Check that the compressor pressure gauge reads zero before carefully removing the filler plug and bonded seal 28 Servicing 10 To conduct the following routine tasks it is necessary to remove the top and front panels including the lower right hand side steel panel Remove the top panel by releasing two quarter turn fasteners mounted horizontally at each side of the front panel Release another two fasteners mounted vertically at the rear of the top panel and lift clear of the unit Remove the front panel by releasing a single fastener from the left hand side and a single screw just above the hour counter in the control area Disconnect the pipe from the rear of the pressure gauge push fitting and remove the front panel Remove two hexagon headed screws mounted vertically upwards into the bottom of the starter enclosure that secure the lower right hand side steel panel Fig 20 F Remove the two screws that retain the small cover plate on the right hand side of the unit Fig 20 E to gain access to the bypass filter and impellor area behind the intake filter for cleaning gt gt 435A394 Fig 19 Matrix Cleaning 10 6 Oil Draining amp Filter Replac
7. 10 a i LENZE X1 2 xi a E INTERNAL LENZE X12 SI CIN INTERNAL Kia Kid RELAY im OK 15 MH X15 e Y 1 sw Qi o 09 as CL E 1 i E at SIA n 40 X0 NO Ne NO NG 13 3 14 4 15 5 dina A O IRSA A clalbhcicscherejovatciate NRE CENE ENER CASING EARTH STUD 435A421a A1F Over temp Control PCB A2A Pressure selector alarm PCB B1 Pressure Transducer 4 20mA 10 36Vdc F2F Fuse 2A T IEC127 F3 Fan Over temp Switch F4 Overload Fan Motor H1 Hours counter H2 Indicator Lamp r Amber neon H3 Alarm Lamp red LED on A2A K1M Isolating Contactor K2M Fan Motor Contactor K2A Relay Module MURR 52001 24VAC 17mA M1M M2M Q1F R2F R3F S1E S2A S4E S5P T1 U1 Y10 ZIA Starter Type 34756 Cct Diag 75263 Issue B Main Drive Motor Cooling Fan Motor Circuit Breaker 2 Pole 6A Compressor Over temp Thermistor Motor Over temp Thermistors Reset Push button Switch On Off Selector Switch Emergency Stop Switch compressor Control Pressure Switch Control Transformer 24V Secondary Variable Speed Drive Lenze E82V752K4B Vent Solenoid Valve N O 3 Phase AC input Choke Optional Fig 11 Circuit Diagram 7 5kW 400V 50Hz Variable speed 18 ST 16048 00A 6 General Description 6 General Description 6 1 Compressor Assembly Fig 12 The unit comprises of a vertical single stage oil flooded rotary sliding vane compressor driven by an electric motor mounted to a base It is supplied with control
8. If the system pressure rises above the target pressure the electric motor speed will decrease conversely if the system pressure falls below the target pressure the motor speed will increase The speed will vary between minimum and maximum limits dependent upon flow requirements 20 ST 16048 00A 7 Operating Parameters 7 Operating Parameters 7 4 Ambient Temperature The compressor is designed to operate within a temperature range of 0 C and 45 C If the ambient temperature frequently falls below 0 C then consult your CompAir UK Ltd Distributor 7 2 Operating Temperatures Your compressor is designed to give optimum performance and trouble free service life when the bulk oil temperature is maintained between 65 C and 85 C Certain operating conditions sustained over a period of time may cause problems that effect the performance and reliability of this compressor Problems may occur when compressors run for short periods on low air demand where they don t reach normal operating temperatures Prolonged use under these conditions can cause condensation build up within the compressor and may eventually lead to emulsification of the oil Normal operating temperatures are reached in typically 15 20 minutes to purge condensate from the compressor a longer running period with a high air usually a minimum of 60 minutes will be required Conditions or applications which prevent the compressor temperature stabilisi
9. X30 o X8 X9 oX10 X49 MIS Y il I I be aio ci il Ui Tvi owt n Xo de bo d Td r SE d I i Z SEENOTE 1 NOTE 1 _l i XI 11 MiM FS Z M3M 11 M M aco 2 do xit 2 1 se uu i I p Orca od aul ties 0 ES i 1 i i I 2 4 1 x130 i 5 lt AUTO PHAND X14 o ca i i SHOWN i f IN AUTO 15 i 12 13 i i X13 o 3 X j i J i 1 x x E t0 NERA i 2 i le 14 OX 40 40 NOIRE NOJ NC mE 17 i 4 i 5 Lecce hac E2 E3 E4 435A422 Starter type 34687 Cct diagram 75049 Iss D A1F Over Temperature Control PCB M3M Cooling Fan Motor F1F Fuse 1A T 250V IEC127 R2F Compressor Over temp Thermistor F3F Fuse 2A T 500V EN 60269 R3F Motor Over temp Thermistors F4 Thermal Overload S1E Start reset Push button F5 Fan Thermal Switch S2A Auto manual Selector Switch H1 Hours Counter S3N Line Pressure Switch H2 S1E Combined Ind Lamp r Amber Start reset Push button S4M Emergency Stop Stop Switch K1M Main Motor Contactor T1 Control Transformer 24v secondary K2T Run On Timer Y1 Vent Solenoid Valve N O M1M Main Drive Motor Fig 9 Circuit Diagram Up to 5 5kW 400V 50Hz DOL 16 ST 16048 00A 5 Installation and Commissioning Hydrovane INCOMING SUPPLY 400 VOLTS 380 to 415v 50Hz 30 EARTH ory Sia ist U 12 13 oo FIF 3 FUSE POSITION B
10. anti clockwise INSTALLATION Air Outlet Size Rp 3A Minimum Room Volume m3 15 Air Inlet Outlet Area m 0 3 Ventilation Rate m3 h 2000 Cooling Air Flow m3 h cfm 2209 1300 Std Ambient Temp Range C 0 45 Recommended Air Receiver Capacity L 250 ELECTRICAL Starter Panel IP Rating 5 5 RS Inverter IP Rating 4 1 380 V 60 Hz Line Current Amps 12 0 16 5 Cable Size mm 2 5 Fuse Size Amps 20M32 32 Phase Current Amps 9 5 400 V 50 Hz Line Current Amps 13 0 18 Cable Size mm awg 12 4 12 4 Fuse Size Amps 20M32 25 25 Phase Current Amps 10 4 440 V 60 Hz Line Current Amps 20 5 Cable Size mm 4 Fuse Size Amps 32 Phase Current Amps 11 8 ST 16048 00A 9 10 Hydrovane Product Information 3 Model Number HV04 HVO5 HVO7 HVO7RS 460 V 60 Hz Line Current Amps 18 Cable Size awg 12 Fuse Size Amps 25 Phase Current Amps ST 16048 00A 4 Transportation and Handling Hydrovane 4 Transportation and Handling 4 1 Introduction Ensure that all means of transportation and or lifting equipment are adequate for purpose and are rated to exceed the full load of the unit A fork lift or pallet truck are the most suitable means of transportation pay particular a
11. be provided around the unit that allows easy viewing of the control panel and pressure gauge Site the compressor as far as possible from sources of dirt coarse solids abrasive particles steam liquids and gaseous impurities Ensure adequate weather protection is provided if sited outdoors Any air connection made to the compressor outlet must be flexible as the base incorporates resilient mountings 5 2 Ventilation Fig 6 Position the compressor in a well ventilated location Do not restrict the air flow around the compressor Do not allow the hot air discharge to re circulate into the compressor or cooler intake Any cooling air inlet A should be positioned low allowing unrestricted air flow to the compressor intake The warm air outlet B should be positioned high and well away from the inlet to ensure a positive cooling air flow through the compressor To achieve this ensure the compressor is installed in a room of the correct size and with sufficient ventilation The compressor must not be operated in ambient conditions other than indicated in section Technical Data on page 9 For maximum efficiency and reliability the compressor should be operated in a moderate ambient temperature If the ambient temperature frequently falls below 0 C consult your CompAir UK Ltd Distributor A different grade of oil may be required Air ducting if fitted must not cover or restrict the cooling air flow of the compressor Total r
12. delivered through the air delivery pipe P to the after cooler The oil supply to the cooler is through oil feed pipe R with the cool oil return via oil return pipe M To ensure the compressor reaches the optimum operating temperature quickly a thermal by pass valve N allows the oil supply to by pass the cooler on initial start up U E F A m G Loa Ex H 4 B OQ M b O V c st E J OBRA v o ORI JD JUN TI n z lo e NOTE ALL COVERS REMOVED FOR CLARITY 4354400 Fig ST 16048 00A 12 Compressor Assembly 19 Hydrovane General Description 6 6 2 Control Systems Compressors can be operated either in automatic Stop Start mode or in continuous run mode Automatic Stop Start Mode This is the normal mode of operation giving maximum efficiency and economy Recommended for applicatio
13. panel starter and combination oil cooler air after cooler with all accessories piped in and electrically connected The intake cover A is assembled directly to the compressor B which is fitted to the flange face C of drive motor D The rotor of the compressor is mounted on the drive shaft of the motor The motor is bolted to the vertical column supported by the base An electrically driven impellor type horizontally mounted fan S is located below the cooler matrix Q This forces cooling air through the combination oil cooler air after cooler matrix The compressor controls G are mounted on the end of the starter enclosure H and are visible through an aperture in the front panel For RS models the inverter drive L with the optional extra keypad control is mounted in the top of the vertical column underneath the top trim panel Hydrovane The compressor air intake is protected by an air intake filter U and the oil system by oil filter J An oil level sight glass assembly V is mounted on the end of the starter unit H Oil is drained from the air end and cooler by removing drain plug K and opening the drain tap The compressor pressure gauge F is visible through an aperture in the front panel The oil separator E is located on the top of the machine and ensures that the air delivered through the minimum pressure valve has an oil cleanliness of less than 2 ppm parts per million by weight The air is
14. should be increased 9 Refer to IEE Regulations for electrical equipment installed in buildings to determine the size required pay particular attention to the circuit diagrams provided h Check that the transformer fuse is positioned to suit the supply voltage of the installation 13 Hydrovane Ensure all electrical connections are tight high voltage supply to contactors and incoming terminals are critical Close the starter door replace the top panel switch the isolator on 435A386 Fig 6 Ventilation 435A387 14 Fig 7 Accessibility Installation and Commissioning 5 Table 3 Accessibility Dimension Units Distance A mm 1000 B mm 1000 C mm 1500 D mm 1000 E mm 1000 Fig 8 Starter 5 6 Check Direction of Motor Rotation WARNING AN READ HEALTH AND SAFETY PRECAUTIONS BEFORE STARTING COMPRESSOR a Ensure that the compressor is filled correctly with approved oil Fluid Force Red 2000 and that all plugs are re fitted securely With the mains isolator on select either manual continuous run mode position i or the off position o for variable speed RS machines The cooling fan in the rear of the unit can be used as a visual aid to determi
15. to the compressor servo valve pressure setting and inverter speed control unit frequency setting will be required A rotary selector switch is provided inside the starter to select the required speed and frequency settings for the inverter drive to match servo pressures that must be adjusted manually User Warning Compressor and inverter speed control adjustments should not be attempted by the user and must be carried out by a CompAir authorised service engineer Failure to comply with this requirement may invalidate the compressor warranty 26 Adjustments 9 ST 16048 00A 10 Servicing 10 Servicing 10 1 Introduction WARNING A READ HEALTH AND SAFETY PRECAUTIONS BEFORE YOU START ANY SERVICE WORK SERVICING OF THE COMPRESSOR MUST ONLY BE CARRIED OUT BY AUTHORISED PERSONS FULLY TRAINED AND COMPETENT IN THE MAINTENANCE MAINS ELECTRICAL SUPPLY AND STARTER CONTROL EQUIPMENT OF COMPAIR COMPRESSORS THEY MUST FULLY UNDERSTAND AND ADOPT CORRECT AND SAFE WORKING PRACTICES If you are unable to carry out the work safely in the required manner then your CompAir UK Ltd distributor will be pleased to help Ensure genuine CompAir UK Ltd parts and approved oils are used To ensure the use of genuine parts during routine servicing Compair UK have the following service kits available 1 KO457 2000 hr 1 yr oil change kit 2 KM 457 4000 hr 2 yr maintenance kit 3 KT 457 Top up kit Contact your local distributor for availab
16. viewable through an aperture in the front trim panel The two glass windows show the oil level for different states of operation with the level marks on the trim panel indicating as follows A This indicates the maximum oil level when the machine is stopped and the oil allowed to settle B This indicates the minimum oil level when the machine is running 7 6 Noise Level Although the sound pressure level for these units is relatively low see Technical Data on page 9 they should be positioned where noise will not be a problem The use of ear defenders is 21 Hydrovane recommended above 85dBA or when working in close proximity to compressors for extended periods 7 7 Pressure Readings The compressor pressure is displayed by the pressure gauge located in the front panel 7 8 Air Delivery Temperature The air delivery temperature after it has passed through the air aftercooler is typically 8 C above ambient 22 Operating Parameters 7 ST 16048 00A 8 Operating Instructions 8 Operating Instructions 8 1 Introduction WARNING A THE COMPRESSOR SHOULD ONLY BE OPERATED BY AUTHORISED PERSONS FULLY TRAINED IN THE STARTING STOPPING AND EMERGENCY STOP PROCEDURES BEFORE STARTING THE COMPRESSOR READ THE HEALTH AND SAFETY PRECAUTIONS 8 2 Checking Procedure Before Starting a Check lower sight glass is full Check filler and drain plugs are fitted securely b c Check for any signs o
17. will increase the frequency of start up e Adjust screw C until the MAX scale indicates 7 2 bar This pressure should not be exceeded f Adjust screw D until the DIFF scale gives required differential Note MAX pressure minus DIFF pressure equals MINIMUM cut in pressure Note The differential pressure is factory preset to 1 bar to 1 5 bar Note High cut in pressures will increase frequency of start up g Refit keyplate B and screw A ST 16048 00A Hydrovane h Re connect the pressure gauge and replace front and top panels i Switch mains electrical supply on j Start compressor and check switch settings for accuracy If further adjustments are required repeat setting procedure A 435A391 Fig 16 Pressure Switch Locations 7 5kW machine illustrated C A B D na o gt m 435A134 Fig 17 Differential Pressure Switch Adjustment 25 Hydrovane 9 3 Pressure Control RS compressors Compressors have default factory settings for inverter speed control target pressure compressor servo valve pressure and motor speed VO7RS operating pressure 8 bar servo 9 bar frequency 66 Hz maximum speed 1980 rpm minimum speed 1050 rpm The target pressure may be adjusted from the default setting in the range of 6 to 10 bar for air compressors When operating at other than factory set pressures adjustments
18. 0 24000 hrs hrs hrs hrs hrs Clean external dirt from compressor V Y Y Y Y Y Clean external dirt from motor 4 Y 4 Y P4 Y Clean air filter Clean cabinet filter air logic Y Y N Clean servo valve lt lt Clean oil return plug where able Y Clean condensate drains Clean solenoids Y Change air filter Change cabinet filter Drain and re fill with oil SISISISIS Change oil filter where applicable Change mpv seals Change unloader valve seats SINN NINI N IN S SIN NINS SISI SIS SIN NISN NININIONS Change vacuum valve seats Change pre filter disc s 955 975 N N Check oil seal Check drive media Check perishable oil pipes on top of compressor 4 Change separator element s cartridge 4 Change thermal motor A Change perishable oil pipes XNIN SINS Check starter contactors Y SIN NINISNIN Grease motor bearings if applicable Change drive media Check motor insulation resistance Replace motor bearings Change oil return plug 4 Change oil seal SININININ Change pressure gauge 32 ST 16048 00A 10 Servicing ST 16048 00A This page is intentionally left blank Hydrovane 33 Hydrovane CompAir UK Limited Claybrook Drive Washford Industrial Estate Redditch Worcestershire England B98 ODS 34 Copyright 2003
19. CONTROL PANEL DOOR UNLESS INSTRUCTED TO DO SO IN THE FOLLOWING PROCEDURE a Isolate from the main power supply for RS machines with inverters wait at least 10 minutes for capacitors to discharge before starting work o Se TS _ Open the starter door with the key provided Unscrew terminal 38 and remove the connecting wire Re instate the power supply Yellow reset lamp should be illuminated ZO Q f With the selector switch in the run position press the start button The compressor should not start the yellow reset lamp should remain illuminated but the green LED marked COMP should be extinguished 9 Isolate from the main power supply for RS machines with inverters wait at least 10 minutes for capacitors to discharge before starting work h Re connect the wire back in to terminal 38 and remove wire from terminal 48 Re instate the power supply Yellow reset lamp should be illuminated k With the selector switch in the run position press the start button The compressor should not start the yellow reset lamp should remain illuminated but the green LED marked MOTOR should be extinguished I Isolate from the main power supply for RS machines with inverters wait at least 10 minutes for capacitors to discharge before starting work m Re connect the wire back to terminal 48 CAUTION If the above sequence is not achieved then a fault may have occurred which has damaged the OTC The com
20. Divas E ee VPN D NET ER 13 5 3 Accessibility Fig T o cenar ue eed ee ee 13 5 4 Electrical Connections ooooccoccco e 13 5 5 Electrical Installation Fig 8 0 cece BIA 13 5 6 Check Direction of Motor Rotation LL 14 5 7 Regulated Speed Compressor Installation 15 5 8 RS Operation with Other Compair Vane Compressors liuius 15 5 9 Positioning of Pressure Transducer 00 eee eee eee eee 15 5 10 Wiring Diagrams a eee 16 6 General Description iii 19 6 1 Compressor Assembly Fig 12 00 00 cece cece teens 19 6 2 Control Systems Aa ssia eead tt tte hn 20 7 Operating Parameters ees 21 7 1 Ambient Temperature oococococco n eh 21 7 2 Operating Temperatures o occcocccccco eh 21 7 3 High Operating Temperatures eh 21 7 4 Oil Life of Fluid Force Red 2000 o oocccccccccoc sees 21 7 5 Oil Eevel Eig 49 sori pe neut ioter tatu dt Ce A ol Den ies 21 7 6 Noise Level 22 24 si teer te Xen de ee de ee Renee e Ye ads 21 7 7 Pressure Readings 2 0 cece eee 22 7 8 Air Delivery Temperature 22 8 Operating Instructions 00 00 eee RR Rh 23 8 1 neenon 23 8 2 Checking Procedure Before Starting 23 8 3 Operating Mode omo e PE eli eee ete ee ew ee eee Eg 23 8 4 Compressor operation Fig 14 23 8 5 Starting Continuous Mode Fig 14 0 00 cece eee 23 8 6 Starting Automatic Mode saaana aaaea 23 8 7 Starting Regulated Speed Fig 15
21. Hydrovane User Handbook HV04 HV07 Models ACS Stationary Air Compressors ST 16048 00 Iss A 04 2003 This page is intentionally left blank Contents Hydrovane Contents 1 Introduction ik i Rev aa ee it a 5 1 1 Introducing your new Compair UK Limited compressor Lese 5 1 2 Customer warranty terms 5 1 3 Product development 5 1 4 Quality standards 5 1 5 Model range ell lh hh 5 1 6 Termiriology i ise ate Ja A es er bea cee Sea ELLEN Va EA 5 2 Safety curo cul ea 7 2 1 General Health and Safety Precautions liiis 7 2 2 The Health and Safety at Work Act 1974 7 2 3 Before Working on Compressor 00 0c cece eee senes 7 2 4 When Operating the Compressor 0 7 2 5 Potential Oil Health Hazards eee 8 2 6 Warnings Cautions and Notes 8 3 Product Information 2 22 0 oxicorte RI lI RI RI run 9 3 1 Technical Data agit re ee Rr USUS A p El RUN oes 9 4 Transportation and Handling eeeen BB 11 4 1 INTOGUCTION tia m a dd Loads Ei 11 4 2 Packing Methods Fig 1 amp 2 ees 11 4 3 Lifting and Transportation Fig 3 0 0 0 eee eae 11 4 4 Weights and Dimensions Fig 4 oooccoccccoocc 12 4 5 Ait Dryer Unit iPOD isd spaces path rx aan Seg Ae dagen 12 5 Installation and Commissioning eee 13 5 1 Positioning Your Compressor Basic Requirements 13 5 2 Ventilation Fg 6 icc Lotes A LL
22. Ltd may also create a hazardous condition This will also invalidate the warranty Read and fully understand the contents contained in the user handbook Ensure that the user Handbook is not permanently removed from the compressor Check that there are no signs of damage and or oil leaks from the air end cooler and associated pipework After completing work tools and foreign matter should be removed from the compressor and its surrounding area In the unlikely event of a compressor fire dry powder or carbon dioxide fire extinguishers should be used Never use water Before Working on Compressor Potentially dangerous volt ages are used to power this machine Do not carry out any work until the isolator is locked in the off position Fit a safety notice to the isolator advising that work is being carried out and that the isolator must not be switched on If in doubt then a qualified electrician may remove the fuses and keep in a secure place until work is complete Ensure the compressor has been safely isolated from the main air system and cannot be re introduced until all work has been completed Fit a safety notice to the isolation valve advising that work is being carried out Do not undertake any work until the compressor and receiver if fitted have been relieved of all pressure Wait until the compressors vent down cycle is complete Release any pressure contained in the aftercooler or associated pipework Check t
23. Manual Selector Switch K1M Line Contactor S3N Line Pressure Switch K2M Delta Contactor S4M Emergency Stop Stop Switch K3M Star Contactor S5N Compressor Pressure Switch K1L Mechanical Interlock K2M to K3M T1 Control Transformer 24V Secondary K4T Run On Timer Y1 Vent Solenoid Valve N O K5T Star Delta Timer Y2 Rapid Vent Solenoid Valve N C Fig 10 Circuit Diagram 5 5 7 5kW 400V 50Hz S D ST 16048 00A 17 Hydrovane Installation and Commissioning 5 INCOMING SUPPLY 400 VOLTS AC 50Hz 3a EARTH or 460 VOLTS AC 60Hz 3 EARTH U 2 3 9 9 ES EO Vice 1 f3 95 __ __ KIM 11 Ut DRIVE sel AZA Pt 75292 VARIABLE SPEED TRANSFORMER T1 SHOWN CONNECTED FOR 400V NOTE 1 FOR REMOTE CONTROL REMOVE LINK AND FIT A REMOTE NOTE 2 A SUITABLY UL LISTED MAIN DISCONNECT AND UL LISTED FUSE OR Ad SEE NOTE 1 SECONDARY Tia 24V 24VAC S4E VOLT FREE CONTACT BETWEEN TERMINALS X50 amp X53 CLOSE CONTACT TO START OPEN CONTACT TO STOP CIRCUIT BREAKER MUST BE PROVIDED BY THE USER AND FITTED ON SITE TO PROVIDE ADEQUATE BRANCH CIRCUIT PROTECTION AND DISCONNECTION OF THE PANEL pe 40 ined exi 8X40 X6 xa MF i Pt 59344 i Lo xa x10 E 10 3 10
24. RS Operation with Other Compair Vane Compressors a Compair RS compressors may be operated efficiently in conjunction with other Compair vane compressors fitted with automatic stop start control b Operation in conjunction with one other Compair vane compressor is simply achieved by adjusting the RS target pressure to midway between the maximum and minimum pressure settings of the other compressor The RS compressor will automatically assume the lead compressor role c The use of the Compair SmartBox is recommended when operating with more than two Hydrovane compressors Important Note If the RS compressor is operated with other Hydrovane standard single speed compressors feeding a common pressure system the maximum target pressure of the RS compressor must be limited to the lowest maximum pressure of the single speed machine s No attempt must be made to increase the operating pressure of the single speed machine s 5 9 Positioning of Pressure Transducer a The pressure transducer sensing point is located in the Minimum Pressure Valve Housing adjacent to the outlet from the compressor this position is suitable for the majority of installations b If the pipework from the compressor to the system is restricted or prone to pressure fluctuation the pressure transducer signal may create excessive response from the speed control unit leading to rapid speed changes and or rapid stopping and starting of the motor c S
25. d Force Red 2000 First Every Every Every Every Maintenance Actions Startup Daily Weekly 1000 2000 4000 12000 24000 hrs hrs hrs hrs hrs Check sufficient access Y Check correct drive rotation Y Y Check torque electrical connections Y 4 Y V Y Check power on load Y Y Y Y Y Check power off load Y Y Y Y Y Check operation of over temperature unit 4 4 Y 4 Y Check operation of non return valve purs Check electrical motor for damage 4 4 Y Y Y Check for loose electrical connections Y Y Y Y Y Check cables and earth are sound Y Y Y Y Y Check for motor vibration Y Y Y Y Y Check for secure cable glands Y 4 Y Y Y Test unloader valve for operation 4 4 Y 4 Y Test vacuum relief valve for operation Y Y Y Y Y Test mpv for operation Y Y Y Y Y Test air delivery Y Y Y Y Y Check oil level at filler plug Check for air leaks Y Y Y Y Check for oil leaks Y Y Y Y Y Check air filter 4 Y Check servo pressure off load 4 Y Y Y Check clear of airborne contaminants Y Y Y Y Y Y Y Y Check oil temperature P4 Y Y Y Y Y Y Y Check rsu temperature ACE Y Y 4 Y 4 Y Y Y Check ambient temperature Y Y V Y 4 Y Y Y Check oil level at sight glass Y Y Y Y Y Y Clean oil cooler Y Y Y Y Y Y Clean after cooler Y Y Y Y Y Y ST 16048 00A 31 Hydrovane Servicing 10 Preventative Maintenance Schedule Fluid Force Red 2000 First Every Every Every Every Maintenance Actions Startup Daily Weekly 1000 2000 4000 1200
26. e starter enclosure while the compressor is operating Beware of hot surfaces both the air end and electric motor are designed to run at elevated temperatures Compressed air is potentially dangerous and can be fatal if misused Do not allow compressed air jets discharged from any pipe or nozzle to make contact with your body Wear safety glasses and suitable clothing when using or working in an area where compressed air is being used Hazardous vapours fumes can be produced if compressed air is used to remove chemicals cleaning agents and lubricants from equipment and components Suitable respiratory and extraction equipment may be required in these circumstances Never use compressed air for cleaning personal clothing Do not use air directly from compressors for breathing purposes If the air is to be used for human consumption then it must be subjected to further treatment to ensure that the levels of contaminants odour and moisture meet the requirements of BS 4275 1974 We recommend that the air supply to hand held air guns is regulated to a lower pressure refer to local Health and Safety regulations Do not insert any object or part of body through any opening of the compressor enclosure Serious personal injury and or damage may result Never run the compressor when any covers or guards are missing unless advised to do so in this handbook ST 16048 00A Hydrovane 2 5 Potential Oil Health Hazards This sec
27. ement Fig 18 and 20 WARNING A AVOID UNNECESSARY CONTACT WITH HOT OIL AND COMPONENTS GLOVES ARE RECOMMENDED IF DRAINING OIL WHEN THE COMPRESSOR IS HOT 10 7 Oil Draining Fig 20 a Remove the filler plug Fig 18 B and bonded seal A to allow air to enter the compressor to aid drainage ST 16048 00A 10 Servicing b Place a suitable container below the drain point and remove the drain plug from the end of the tap D turn the tap and allow the oil to drain from the compressor c When draining is complete turn the drain tap to the off position and replace the drain plug in the tap 10 8 Oil Filter Replacement Fig 20 a Unscrew the filter C in an anti clockwise direction quickly to avoid oil spillage from the canister wipe up any spillage and discard the old filter in a safe manner b Using a new filter smear a small amount of oil onto the seal screw in clockwise to tighten hand tight only 10 9 Oil filling Top up a Fill to the correct level shown for the top sight glass with approved oil use Fluid Force Red 2000 as the standard oil do not overfill b Allow the oil level to stabilise the oil filter holds about 1 litre total capacity is 3 litres drain a small amount of oil if above the maximum fill line c Refit the filler plug Fig 18 B and bonded seal Fig 18 A renew the bonded seal if damaged and tighten using a spanner do not over tighten
28. erson only Close the starter enclosure door and lock with the key provided to prevent unauthorised access Remove the safety notice and switch the mains electricity supply on Restart the compressor and verify that direction of rotation of both the compressor and cooling fan are correct Replace the cabinet filter in the rear panel with the direction arrow pointing inwards towards the cooling fan 5 7 Regulated Speed Compressor Installation The compressor should be installed generally as instructed for a standard fixed speed compressor of the same power kW rating The installation should be completed by a Compair authorised distributor and must comply with current wiring regulations Electrical supply fuse sizes are the same as for standard fixed speed compressors of the same power kW rating Alternatively a circuit breaker of suitable size and with motor starting characteristics may be used to protect the installation The maximum starting current under all starting conditions will not exceed 150 motor full load current and will generally be no more than 100 full load current The installation must be earthed in accordance with local regulations The use of RCD s is not recommended Water drain filters or dryers fitted downstream of the compressor discharge must be correctly sized to avoid excessive flow restrictions to ensure stable operation of the speed control system ST 16048 00A Hydrovane 5 8
29. esistance of the system must not exceed 5mm w g 0 2in water gauge If the resistance is expected to be greater than 5mm w g then fan assistance will be required 5 3 Accessibility Fig 7 Sufficient clearance must be allowed on all sides of the compressor for servicing purposes The minimum clearances required are shown on the diagram 5 4 Electrical Connections WARNING A A CONNECTION TO OR INSTALLATION OF AN ELECTRICAL POWER SUPPLY MUST ONLY BE CARRIED OUT BY AUTHORISED AND QUALIFIED ELECTRICIANS THEY MUST FULLY UNDERSTAND AND ADOPT CORRECT AND SAFE WORKING PRACTICES ALL ASPECTS OF ST 16048 00A THE INSTALLATION MUST MEET THE WIRING REGULATIONS PRESENTLY IN PLACE Before connecting to the mains electrical supply ensure that the System can sustain the additional electrical load To ensure reliable low resistance joints make sure that your incoming supply cables are firmly secured to the starter terminals and that they are of the correct cross sectional area Refer to starter and circuit diagrams before starting work Note carefully the instructions relating to earthing fuses and size of cable refer to technical data Fuses to BS 88 Type gG must be used to protect the compressor starter refer to the sizes specified in Technical Data on page 9 Circuit breakers are not recommended since they may not fully protect the starter contacts in an overload condition 5 5 Electrical Installation Fig 8 WARNING
30. essor is ready to run c Press the amber reset start button B and the motor will start On initial start up with no pressure in the air line system the line pressure displayed on the pressure gauge will rise quickly to the minimum pressure valve setting Once the system is fully charged the compressor gauge will vary with fluctuations in the system air demand If the system pressure rises to the compressor high pressure setting then the automatic stopping sequence will begin The run on timer starts and the compressor begins to run off load if there is no demand for air during the run on time the compressor will stop The compressor will remain stopped until there is an air demand that allows the system pressure to fall to the compressor low pressure setting For V07 models the compressor will not restart until its internal pressure has fallen to below 1 5 bar If there is a demand for air during the run on time the stopping sequence is cancelled and the compressor returns to full on load running 8 7 Starting Regulated Speed Fig 15 Complete the checking procedure before starting Press the amber reset start button B the compressor is now ready to run Turn the selector switch A from position 0 to position 1 the compressor is now in running mode and will commence rotation if the system pressure is below the target pressure 23 Hydrovane On initial start with no pressure in the system the compre
31. f Feature Unit HV04 07 Width mm 470 B Length overall mm 680 C Height overall mm 1050 W4 Weight VO4 8 VO5 kg 152 W5 Weight VO7 kg 156 W7 Weight VO7RS kg 160 Transportation and Handling 4 models can bolt onto it creating a self contained air centre retaining the footprint ensuring a supply of high quality air Consult your local dealer for details Vino 4354420 Mero 4354384 Fig 4 Dimensions 4 5 Air Dryer Unit Fig 5 Available as an optional extra is an integrated thermal mass refrigerant dryer and filter module designed so that any of the 12 Fig 5 Unit Mounted on to Air Dryer Aircentre Table 2 Aircentre Dimensions Compressor Ref Feature Unit HV04 07 A Width mm 520 B Length overall mm 800 C Height overall mm 1620 W4 Weight VO4 amp V05 kg 242 W5 Weight VO7 kg 246 W7 Weight VO7RS kg 250 ST 16048 00A 5 Installation and Commissioning Hydrovane 5 Installation and Commissioning 5 1 Positioning Your Compressor Basic Requirements Position the compressor in a room of adequate size on a firm surface level in both planes within five degrees of the horizontal Ensure the area has sufficient load bearing capacity normally it is not necessary to bolt the unit down Sufficient access for all routine service procedures should
32. f oil or water leaks d Check air outlet valve is open and test valve is closed e Check that the stop emergency stop button is released f Turn mains electricity supply on 8 3 Operating Mode The CONTROL allows two operating modes Continuous run or automatic Stop Start 8 4 Compressor operation Fig 14 For continuous run turn selector switch A to hand mode i For automatic Stop start turn selector switch A to auto ii Note The operating mode may be altered either when the compressor is running or when it has stopped Fig 14 Compressor Operation ST 16048 00A Hydrovane 8 5 Starting Continuous Mode Fig 14 Complete the checking procedure before starting Select continuous run mode section 8 4 the compressor is now ready to run Press the amber reset start button B and the motor will start The compressor will now run continuously irrespective of either the system pressure or system air demand On initial start with no pressure in the system the compressor gauge will quickly rise but will not exceed the servo valve pressure Once the system is fully charged the compressor gauge will vary with fluctuations in the system air demand 8 6 Starting Automatic Mode WARNING A A WHEN IN AUTOMATIC MODE THE COMPRESSOR WILL RESTART WITHOUT WARNING a Complete checking procedure before starting b Select automatic see section 8 4 The compr
33. hat the compressor pressure gauge reads zero Do not proceed until it does 2 4 Carefully unscrew the compressor filler plug If any air or oil escapes before the plug is fully removed stop Do not remove the plug until all pressure is lost Safety devices fitted to the compressor or air line system should be checked at regular intervals and replaced if faulty They should not be tampered with or modified Non return valves should not be used as isolation devices To ensure the compressor operates safely you must carry out the specified maintenance procedures Only approved lubricants should be used for flushing purposes Extreme caution should be taken if the compressor has been subjected to severe operating temperatures or fire Certain components may contain fluoroelastomer materials and under these conditions can leave extremely corrosive residues Severe burns and permanent skin and tissue damage can be a result of skin contact The Health and Safety information contained in this Handbook is only intended to give general guidelines When Operating the Compressor When in automatic mode the compressor may re start without warning If an automatic re start device is fitted allowing the compressor to start when power is re applied or operation is controlled from a remote location additional warnings will be required Do not remove any plugs or release pipework when the compressor is running Do not attempt to open th
34. hould this condition occur re locate the pressure transducer sensing point further downstream e g to a manifold or ring main where restriction pressure fluctuations are at a minimum d If the installation includes a receiver consideration should be given to piping the receiver pressure to the transducer 15 Hydrovane Installation and Commissioning 5 5 10 Wiring Diagrams INCOMING SUPPLY 400 VOLTS 380 to 415v 50Hz 30 EARTH NOTE 1 FOR REMOTE CONTROL REMOVE LINK BETWEEN TERMINALS X10 amp X11 Noc AC Sere CABLE REMOTE CONTACT BETWEEN TERMINALS X10 amp X11 67 f T i CLOSE CONTACT TO START OPEN CONTACT TO STOP PE ju gu ju NOTE 2 OPTIONAL MOTOR OVERLOAD MAY BE FITTED AS SHOWN WITH AUXILIARY PE A E6 CONTACT POSITIONED IN CIRCUIT 17 cHassissTuD Ff SZ grrr nnn nnn Hew 3783 WN Nee de 8 oe CART RS dec Via IX yd PT te FEATS 9 ER Bid I iii vi ryt ie se on 2 FUSE POSITION MEME B FOR 400 415V i m BET 3 aft t a 3 avos x 7 j 380V to us 2 44 db aw T ra FUSE POSITION A 97 A FOR 380V 195558 n INSERT AS i DE i 4 aU LT 4 Ol SEE NOTE 2 MEN MELDE ND So e Prop OPTIONAL CUSTOMER ISIS B o FIT SEE NOTE 2 5 8 Ned X48 e HHH f 40 ona 7 o I Ho X7 X6 X41 xao X86 X38 t 4r Fora se AF BNO Chl e EM I Se le 434 Cal ES Pt 59944 ai Od
35. ility 10 2 Routine Service Schedule The work listed in this section must be carried out at the indicated running hours which must be regarded as a maximum In dusty hot or humid conditions more frequent servicing may be necessary This section shows the minimum service requirements for your compressor To ensure that the full compressor maintenance programme is carried out we recommend that your compressor is regularly serviced by an authorised CompAir UK Ltd distributor Servicing RS Servicing intervals and procedures are the same as specified for the standard fixed speed compressor of the same power kW rating In addition the metal cover surrounding the speed control unit should be detached and any dirt or dust collected around the control unit ventilator fan grille removed The speed control unit does not require any routine servicing After very long periods it is recommended that the speed control unit capacitors and cooling fan s be replaced to ensure continued reliability of the unit Refer to CompAir Redditch Service Department for details ST 16048 00A Hydrovane 10 3 Check Compressor Operation The drive end cover of the compressor has a facility to accept a thermal probe to record the operating temperature of the unit With the need for specialised equipment we suggest that this task should be conducted by your local Distributor Assuming the compressor is serviced correctly the machine is capable of ope
36. ne the correct rotation of the compressor To view the cooling fan remove the cabinet filter from the lower half of the rear panel the cooling fan can be viewed through the mesh grill Press the illuminated amber reset start button mounted in the control panel compressor rotation is correct if the cooling fan rotates in a clockwise direction Rotation of the compressor is clockwise as viewed from the intake end this is in the opposite direction to the normal clockwise rotation when viewed from the drive end If rotation is correct the compressor pressure gauge will immediately rise for RS machines a momentary power supply will rotate the cooling fan ST 16048 00A 5 Installation and Commissioning If rotation is not correct the compressor pressure gauge will not rise for RS machines the momentary power supply will rotate the cooling fan in an anti clockwise direction CAUTION If direction of rotation is incorrect Stop the compressor immediately serious damage will occur if the motor is allowed to run in reverse WARNING A IF DIRECTION OF ROTATION IS INCORRECT STOP THE COMPRESSOR AND LOCK THE ISOLATOR IN THE OFF POSITION FIT A SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS BEING CARRIED OUT ON THE COMPRESSOR Open the starter door with the key provided to gain access to the starter terminals Change over any two of the incoming cables connected to the starter terminals L1 L2 amp L3 Qualified p
37. ng between these parameters should be avoided Consult your local distributor or CompAir UK Redditch if you have any particular concerns about operational characteristics of your compressor 7 3 High Operating Temperatures Some of the reasons for high compressor oil temperatures are Low oil level Blocked oil cooler or cooler flow restrictions Wrong type or grade of oil High ambient temperature Cooling fan stopped or operating incorrectly If the bulk oil temperature frequently reads between 90 C 100 C then Fluid Force HPO should be used Note Compressor will stop automatically if temperature rises above 110 C 7 4 Oil Life of Fluid Force Red 2000 The standard oil is Fluid Force Red 2000 other Compair oils Fluid Force Clear and Fluid Force HPO are available Consult your local Compair dealership for technical information ST 16048 00A Hydrovane Fluid Force Red 2000 Bulk Oil Temperature Degree Celsius Maximum Oil Change Period Hours Run Up to 90 2000 90 95 1500 95 100 1000 100 110 500 Over 110 No guaranteed service life 7 5 Oil Level Fig 13 The oil level should be checked by viewing the oil level in the sight glass Lo YO B A LEVEL MARKS ON FRONT COVER MU 435A397 Fig 13 Cil Level Sight Glass and Levels The sight glass assembly C is mounted on the end of the starter panel and is
38. nitially but will eventually fall the rate of decay will depend on equipment usage and the time period the system remains idle 8 10 Emergency Stop If an emergency occurs a Press the stop emergency stop button D in Fig 14 and Fig 15 b The button will lock in the depressed position and stop the compressor immediately the offload solenoid will de energise allowing the compressor pressure to fall to zero in about 2 to 5 minutes c Clear any faults which may have occurred Do not reset until it is safe to do so d Reset the stop emergency button by twisting it clockwise before re start 8 11 Compressor Vent Down After stopping the compressor must be allowed to vent down gradually speeding up the de pressurisation may cause oil carry over or separator flooding 24 Operating Instructions 8 435A425 Fig 15 Regulated Speed Control TBA ST 16048 00A 9 Adjustments 9 Adjustments 9 1 Standard Compressor Control Fig 16 The compressor is fitted with one or two pressure switches one for cut in and cut out of line pressure A the other B if fitted reads oil chamber pressure factory set do not alter which prevents pressurised restart Adjacent to the pressure switch es are one or two solenoid valves the single valve C vents down the compressor gradually within 2 to 5 minutes when stopped The solenoid valve mounted closest to the front D
39. ns with fluctuating air demands With the auto mode selected the compressor will load unload and stop start automatically in response to air demand If the motor restarts more than ten times per hour or continually restarts within thirty seconds of stopping then the run on timer may be increased to reduce frequency If after adjustment the condition persists switch to continuous run mode Continuous Run Mode Recommended where excessive stop starts occur and or when there are rapid changes of pressure in the air line system When the continuous run mode is selected the compressor will continue to operate supplying air from full to zero flow rates Regulated Speed Operation Regulated speed compressors are automatic stop start operation only If the unit is subject to excessive stop starts consult Compair for the possibility of fitting a continuous running option The Compair Regulated Speed Vane Compressor has been designed to save energy and operating cost when compared with a fixed speed compressor of similar size The saving is achieved by automatically regulating the compressor speed to precisely match the compressor output to the system flow and pressure requirements The system pressure is measured and converted into an electrical signal by an integral pressure transducer The compressor Variable Speed Drive VSD unit senses the transducer signal and adjusts the electric motor speed to maintain a constant target pressure
40. om negligence in the application of these precautions from non observation or lack of elementary supervision in respect of handling operation servicing or repair even if not expressly stated in this instruction notice ST 16048 00A 3 Product Information 3 Product Information 3 1 Technical Data Hydrovane Model Number HV04 HVO5 HVO7RS PERFORMANCE F A D litres sec cfm 7 bar 11 24 15 32 F A D litres sec 10 bar 9 20 12 25 0 20 0 42 5 Noise Level dBA 66 66 Power kW hp 4 5 5 5 5 7 5 Starter Type Automatic DOL DOL SD Starter Type Inverter N A Soft Start Drive Type Direct Operating Controls Continuous Run Automatic Stop Start Soft Start Variable Compressor Rotation Speed rev min 60 Hz 1460 1050 1980 Oil Capacity litres 3 Ambient Temperature Range C 0 to 45 Maximum Relative Humidity 85 non condensing Air Discharge Temp C above ambient 6 8 10 FACTORY SETTINGS Minimum Pressure Valve bar 5 5 to 6 0 Pressure Switch Max bar 7 5 or 10 5 Pressure Switch Differential bar 1 0 to 1 5 Pressure Switch anti re start Max bar 3 0 Pressure switch anti re start differential bar 2 0 Servo Valve bar 8 0 or 11 0 9 0 Vacuum Relief Valve Half turn
41. pressor must not be operated until a replacement OTC has been fitted and the above procedure repeated a Close the starter door and lock with key provided 30 Servicing 10 AQ 435A424 Fig 21 Over Temperature Control Unit ST 16048 00A 10 Servicing Hydrovane 10 16 Servicing Requirements Note The following preventive maintenance charts cover all Compair compressors using Compair Fluid Force Red 2000 oil The work to be carried out must be done on or before the hours shown for this action or yearly whichever is soonest Note For service schedules using Compair Fluid Force Clear and Compair Fluid Force HPO consult you local dealer or contact CompAir UK Redditch Read health and safety precautions before starting any work Service Schedule Fluid Force Red 2000 2000 hour oil change The bulk oil temperature must not exceed 90 C If the oil is working above this temperature the oil life will be reduced Note When changing to Fluid Force Clear the compressor must be flushed out with Fluid Force Prime in order to comply with USDA H1 standard Note The service life of the air filter and cabinet filter are an indication only actual life durability will be dependant on the operating conditions Preventative Maintenance Schedule Flui
42. ranty may not be available in all markets Please refer to your CompAir UK Ltd Distributor for details PLEASE NOTE Your CompAir UK Ltd Distributor is able to offer a wide range of compressors dryers filters and ancillary air line system products Their engineers are fully trained and competent in all aspects of compressor and air system maintenance If you need any Specialist help or service please contact your Distributor quoting the MODEL TYPE and SERIAL NUMBER 1 3 Product development CompAir UK Ltd adopt a policy of continual product development The information in this handbook whilst fully up to date when issued may be subject to change without notice 1 4 Quality standards CompAir UK Ltd Quality Management Systems are approved to BS EN ISO 9001 ST 16048 00A Hydrovane Note These instructions comply with the latest European Directives regarding content and are valid for machines carrying the CE mark 1 5 Model range This handbook relates to all HV04 HV07 compressors model types HV04 HV07 V04ACS07 4035D000 V04ACS010 4035D000 V05ACS07 4035D000 V05ACS10 4035D000 V07ACS07 4035S000 V07ACS10 4035S000 V07ACS07 4035V000 This publication refers to compressors with serial numbers V04 000001 V05 000001 V07 000001 1 6 Terminology Serial Number Signifies Segment V Vane 04 05 07 kW motor AC Air Centre S Standard Con
43. rating in ambient temperatures up to a maximum of 45 C At this ambient temperature the oil temperature will be typically 85 C to 90 C When the compressor is working the temperature should be Initial start up and warm up period lt 70 Optimum working temperature 80 90 C High temperature 90 100 C Stop Consult your distributor gt 100 C Check Compressor Pressure To check the compressor pressure use the pressure gauge located in the front panel Check oil level Check the oil level using the compressor oil level sight glass fitted to the end of the starter box visible through the front panel Refer to Fig 13 for a view and description of the oil level manifold and indicator marks 27 Hydrovane C 435A393 Fig 18 Oil Filler Plug Air Filter and Separator Element Location 10 4 Basic Service Fig 18 and 19 WARNING A STOP THE COMPRESSOR AND ISOLATE FROM THE MAINS ELECTRICAL SUPPLY LOCK THE ISOLATOR IN THE OFF POSITION FIT A SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS BEING CARRIED OUT ON THE COMPRESSOR CLOSE THE AIR OUTLET VALVE TO ISOLATE THE COMPRESSOR FROM THE AIRLINE SYSTEM FIT A SAFETY NOTICE TO THE VALVE ADVISING THAT IT IS NOT TO BE OPENED DO NOT PROCEED UNTIL THE AIR PRESSURE GAUGE READS ZERO CAUTION When changing recommended oil types it is advisable to flush the compressor CAUTION When changing to fluid force clear the
44. ressor has been designed and manufactured to the exacting standards necessary to ensure long life reliability and high performance Compair UK Ltd are world leaders in compressed air technology using the most modern techniques and plant available to give our customers the following benefits Compact space saving design Easy to position install and operate Economical to run inexpensive and simple to service Quiet smooth unobtrusive operation Proven reliability with the option of extended warranty periods Full support available from world wide Distributor network This user handbook should be used in conjunction with the parts service manual IMPORTANT BEFORE INITIAL START UP ENSURE THAT THE COMPRESSOR OIL CHAMBER IS FILLED TO THE CORRECT LEVEL WITH A HYDROVANE APPROVED OIL DO NOT OVERFILL 1 2 Customer warranty terms All compressors which are serviced by an authorised CompAir UK Ltd Distributor are guaranteed for twelve months from the date of commissioning or eighteen months ex works whichever is the sooner The warranty excludes normal service parts oil and wear items dirt ingress cleaning of filters and fluid drain devices and the tightening of electrical or other connections Also excluded is the adjustment of pressure switches or the adjustment of any other control device shown in this handbook Consequential damage of any nature is not covered by the warranty Advance Five Year War
45. ssor gauge will quickly rise but will not exceed the servo valve pressure The compressor speed will change automatically to suit the pressure and flow demands of the system the compressor gauge will vary with fluctuations in the system air demand If system flow demand reduces and the system pressure rises above the compressor target pressure the inverter speed control will automatically stop the compressor after a short time delay Re starting will occur automatically when the system pressure drops below the compressor target pressure During operation of the compressor the hour s counter C will record the total running hours 8 8 Stopping Single Speed To stop the compressor in either continuous run or automatic stop start press the stop emergency stop button D The button will lock in the depressed position and stop the compressor immediately the offload solenoid will de energise allowing the compressor pressure to fall to zero in about 2 to 5 minutes System pressure will remain high initially but will eventually fall the rate of decay will depend on equipment usage and the time period the system remains idle Reset the stop emergency stop button by twisting it clockwise before re start 8 9 Stopping Regulated Speed To manually stop the compressor rotate the selector switch A from position i to position ii do not use the stop emergency stop button D unnecessarily System pressure will remain high i
46. tion relates to Fluid Force oil For other lubricants refer to the Health and Safety Instructions issued with the relevant product There are no significant hazards associated with this product when properly used and in the application for which it was designed Frequent and or prolonged skin contact may give rise to skin irritations and it is recommended that protective gloves are worn The carcinogenic action of mineral oils should be brought to the attention of all users The oil may be hot so take care when carrying out oil changes Do not keep oily rags in pockets or wear contaminated clothing Do not inhale fumes or vapours Do not swallow Avoid eye contact Always wash hands after use and before eating drinking and smoking Ingestion Do not induce vomiting because of the risk of aspiration Wash mouth out with water Give 1 2 pint milk Seek immediate medical attention Skin Contact Mildly irritating Remove by wiping Wash with soap and water Apply emollient cream Eye Contact Mildly irritating Flush with copious amounts of warm water Seek medical advice if necessary Aspiration If there is any suspicion of aspiration into the lungs for example during vomiting admit to hospital immediately Inhalation Remove from exposure into fresh air If necessary give artificial respiration or oxygen Seek medical advice Pressure injection Obtain immediate medical attention even if inj
47. trol 07 10 Delivery pressure in bar 40 400 volt 3 3 phase 5 50Hz D S V Direct On Line Star Delta Variable Speed 100 European specification 50 Hz Hydrovane Introduction 1 This page is intentionally left blank 6 ST 16048 00A 2 Safety Hydrovane 2 2 1 Safety General Health and Safety Precautions Please read carefully and proceed in accordance with the following instructions before installation operation maintenance or repair of the compressor unit 2 2 2 3 The Health and Safety at Work Act 1974 In order to comply with your responsibilities under the above act it is essential that the compressor is transported positioned installed operated and maintained by competent persons in accordance with the instructions in this handbook The standard build of all Compair UK Ltd products are not intended for use in either Explosive or Potentially Explosive Atmospheres as defined in the ATEX Directive 94 9 EC A potentially Explosive atmosphere is an atmosphere which could become explosive due to local and operational conditions The compressor warranty will be invalidated if unapproved Spare parts or lubricants are used Using such items may cause the efficiency and service life of the compressor to be reduced and could create a hazardous condition over which Compair UK Ltd has no control Failure to maintain the compressor correctly or modifying it without prior approval from Compair UK
48. ttention to ensure stability to prevent the unit tilting over 4 2 Packing Methods Fig 1 amp 2 435A398 Fig 1 UK Packing ST 16048 00A Y i 4 lif LA a Fig 2 Export Packing 435A385 Fig 3 Lifting 4 3 Lifting and Transportation Fig 3 Units are supplied in recyclable packaging either remove the clear polythene sheeting or clips that retain the wooden upper sections to gain access 11 Hydrovane The specialised base pallet can be used to transport the unit to the point of installation before removal we recommend that two people should carry out this operation Remove four bolts from the underside of the base pallet slide the unit sideways just sufficiently to allow two resilient mountings to be fitted to the base members front and rear With care slide the unit gently from the pallet until the resilient mountings rest on the floor with the unit tilted slightly slide the pallet from the underside and remove While the unit is held in this position fit the other two resilient mountings to the other side of the front and rear base members Damage to the mountings may occur if you attempt to slide the unit into position lift and place the compressor in the desired location 4 4 Weights and Dimensions Fig 4 Table 1 Significant Dimensions Compressor Re
49. tting Re connect the pressure gauge and refit the panels in reverse order See Panel Removal on page 28 test run the compressor and check operation as in 10 3 10 14 Electrical checks WARNING AN WARNING ISOLATE THE COMPRESSOR FROM THE MAINS ELECTRICAL SUPPLY LOCK THE ISOLATOR IN THE OFF POSITION FIT A SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS BEING CARRIED OUT ON THE COMPRESSOR a Open the starter panel door b Remove any terminal covers fitted to contactors and incoming supply terminals c Check for any signs of overheating and ensure that all electrical connections are tightened to correct torque Settings as per label on inside face of starter Note Pay special attention to power connections and cables connected to contactors and incoming terminals d Close the starter panel door and lock with the key provided to prevent unauthorised access Clean and check electric motors WARNING AN a Remove any dust or dirt from motor bodies and motor air intake grill located under the compressor base b Reinstate all covers c Remove safety notices 10 15 Check operation of over temperature control unit Fig 21 WARNING A AN 29 Hydrovane THE FOLLOWING FAULT FINDING PROCEDURE SHOULD BE CARRIED OUT BY QUALIFIED AND COMPETENT PERSONS ONLY THIS PANEL CONTAINS POTENTIALLY LETHAL VOLTAGES UNDER NO CIRCUMSTANCES SHOULD YOU ATTEMPT TO TOUCH ANYTHING INSIDE THE PANEL OR ON THE
50. ury appears minor Spillage Soak up with absorbent clay Waste Disposal Oil condensate filter elements etc should be disposed of in accordance with local regulations Do not allow oil to contaminate water supplies See Cautionary Notice SHW 397 Effects of Mineral Oil on the Skin and MS B 5 Skin Cancer Caused by Oil published by the Health and Safety Executive Safety 2 2 6 Warnings Cautions and Notes Warnings WARNING is used in the text of this handbook to identify specific hazards which can cause injury or death This type of hazard is identified below Risk of electric shock Risk of hazard or danger Risk of hot surfaces Eye protection must be worn Dust protection must be worn Warning pressurised vessel Warning pressurised component or system Warning unit is remotely controlled and may start without warning Read the instruction manual Do not operate the machine without the guard being fitted 6oBBBOCBB D Warning do not start the machine without consulting handbook Lifting point 1 Direction of rotation Cautions CAUTION is used in the text of this handbook to identify incorrect procedures which can cause damage to the compressor Notes Note is used in the text of this handbook to draw attention to specific points of importance Compair declines all liability in the event of material damage or bodily injury resulting fr
51. will rapidly vent the compressor within 2 to 5 seconds if the reset button is pressed before gradual venting has occurred Pressure switches and solenoid valves are mounted on top of the starter enclosure this is on the right hand side under the top panel cover WARNING A ISOLATE THE COMPRESSOR FROM THE MAINS ELECTRICAL SUPPLY LOCK THE ISOLATOR IN THE OFF POSITION FIT A SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS BEING CARRIED OUT ON THE COMPRESSOR 9 2 Pressure Switch Fig 17 a To access the starter remove the top panel release two quarter turn fasteners mounted horizontally at each side of the front panel Release another two fasteners mounted vertically at the rear of the top panel and lift clear of the unit b If necessary remove the front panel release a single fastener from the left hand side and a single screw just above the hour counter in the controls area Disconnect the pipe from the rear of the pressure gauge push fitting and remove the front panel c Remove screw A and keyplate B for maximum line pressure adjust screw C until the scale indicates 7 5 or 10 5 bar this is the high or cut out pressure For differential pressure adjust screw D until the scales indicates between 1 0 and 1 5 bar factory setting this is the minimum low or cut in pressure d Note that the maximum pressure cut out minus the differential pressure equals the minimum cut in pressure high cut in pressures
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