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HKL
HYDRAULIC COMPRESSORS
OPERATING INSTRUCTIONS
HKL 1800 / 8 - 46 -
O - PE
DEAR CUSTOMER!
Thank you for choosing Dynaset product from Finland. We appreciate your product expertise and
are convinced, our product is efficient and profitable for you.
This product is high technology design with latest hydraulic R&D knowledge bringing high
performance in compact size, providing long lasting reliable use for customers all over the world.
TABLE OF CONTENTS
1.
2.
GENERAL NOTES
3.
CONSTRUCTION
4.
PERFORMANCE
4.1 Lubrication system of the compressor
4
5
5.
6.
7.
AIR HUMIDITY
8.
INSTALLATION
9.1 Open centre hydraulic system with variable displacement pump
9.2 Closed centre hydraulic system with variable displacement pump
9.3 Hydraulic system with constant placement pump
9.4 Hydraulic compressor without automatic speed control valve
9.5 Connection to the air supply system
7-9
8
8
9
9
9
9.
OPERATION
10.1 Off-load mode
10
11
11
11
12-14
12
12
13
13
14
14
15-16
17
18-19
20
17. PARAMETERS
21-22
23
24
20. NOTES
25
SAFETY PRECAUTIONS
The pressure in both hydraulic and compressed air circuits of HK-compressor is considerably high. There at the
technical condition of your equipment should be under constant scrutiny. Operators and maintenance personnel
must always comply with local safety regulations and precautions in order to close out the possibility of damages
and accidents.
Especially couplings, valves and hoses should be maintained tight and clean as well as kept under constant
observation avoid possible leakages of pressure and hot blowouts. Hydraulic leakages must be rectified immediately
to avoid user and bystander injuries. Follow all your local safety instructions related to the high pressure
hydraulics.
In order to exclude possible accidents, it is not allowed to clean or inspect HK-compressor and pneumatic tools
when hydraulic or/and pneumatic circuit is pressurized. Prior to any cleaning, inspection and service hydraulic
system of your carrier machine must be stopped and both hydraulic and pneumatic circuits dissipated, for
instance, by opening the blow gun.
Always wear appropriate clothing and safety equipment such as goggles, ear protection and safety shoes at all
times when operating by the compressor. When operating the compressor, beware of machinery parts warmed
by hot hydraulic oil.
EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISASSEMBLING OR REPAIR OF
HKL-COMPRESSOR AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE AND LONG-LIFE
OPERATION OF YOUR EQUIPMENT.
Hydraulic system of a carrier machine should be maintained according to the service program.
All installation and service of both hydraulic and electric equipment must be performed by qualified and
experienced personnel only.
WARNING STICKERS
Dynaset dispatch department includes one (1) warning sticker bag per one (1) main product.
Product recipient is obligated to fix determinate warning sticker to Dynaset product.
Attach sticker to visible and appropriate place or close to Dynaset product where its easily seen.
Before attaching sticker clean surface with solvent detergent.
GENERAL CAUTION.
BEWARE OF HOT SURFACE. USE EAR PROTECTOR.
BEWARE OF PRESSURE AIR.
GENERAL NOTES
DYNASET hydraulic compressors are compact and integrated all-in-one units, especially designed for mobile
installation. The only power source is a hydraulic system to provide compressor with required hydraulic fluid
flow at demanded pressure.
DYNASET hydraulic compressor transforms hydraulic power into a high quality compressed air.
Designed to meet regular compressed air demands, HK hydraulic compressors are used to power pneumatic
tools, for cleaning, flushing etc.
CONSTRUCTION
Utilizing compact rotary vane technique, DYNASET hydraulic compressor of HKL-series is mobile unit
comprised of a hydraulic motor with incorporated automatic rotation speed control valve (up to HKL 1800)
and rotary vane compressor block. Compressor block includes stator-rotor unit, cooling and lubrication
systems, oil separator as well as unloading pressure regulator, attached to the air intake.
Hydraulic motors and compressors shafts are coupled when rotor runs inside of stator eccentrically.
10
7
1.
INTAKE AIR FILTER
2.
INTAKE/SERVO VALVES
3.
OIL CHAMBER
4.
COMPRESSION CHAMBER
5.
OIL COOLER
6.
OIL FILTER
7.
AIR / OIL LABYRINTH
8.
COMPRESSED AIR
9.
ROTOR
10.
OIL SEPARATOR
11.
OIL RETURN VALVE
12.
MINIMUM PRESSURE /
-NON RETURN VALVE
12
11
9
5
PERFORMANCE
When compressors rotor is revolved by a hydraulic motor, air is taken through a filter into a compression
chamber consisting of a stator and rotor.
The rotor is provided with longitudinal slots in which vanes slide. Vanes are pushed against the stator by
centrifugal force, generated by rotation. During compressors rotation air is being compressed through the
construction in volume comprised by walls of rotor, stator and vanes.
Pressurization, cooling and lubrication are ensured by oil, injected into a compression chamber due the
pressure differential between compression chamber and oil sump. Thereat, separate oil pump is not
required.
The compressed air/oil mixture is discharged from the rotor-stator unit passing through a labyrinth, where
most of the oil is separated from the air due to the continuous changes of direction.
The remaining oil is trapped at the separators inlet and furthers on filter element condensates it by
coalescing effect. The recovered oil returns to the intake.
The oil-free compressed air leaves the compressor through a minimum pressure / non-return valve. The
valve prevents the air from leaving the compressor until the necessary internal pressure will be achieved in
order to ensure proper hermetization and cooling. The same valve also prevents the compressed air,
already contained in the system, to return into the compressor.
The fan, mounted on a motor shaft and placed inside of an oil cooler, maintains the proper temperature of
the compressor oil and compressed air.
The quantity of air, aspirated by the compressor is regulated / limited by the intake valve, hydraulically
controlled by servo valve.
... PERFORMANCE
7
16
23
16
15
21 22
18
2
P
T
S
10
13
11
17
12
14
30
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
COMPRESSOR BLOCK
OIL SUMP, PRIMARY SEPARATION
INTAKE FILTER
INTAKE VALVE
AIR / OIL SEPARATOR
MINIMUM PRESSURE / NON-RETURN VALVE
SAFETY VALVE 12 BAR
VACUUM RELIEF VALVE
OIL DRAIN VALVE
OIL RETURN VALVE
THERMOSTATIC BY-PASS VALVE
OIL COOLER
13.
14.
15.
16.
17.
18.
21.
22.
23.
30.
OIL FILTER
SERVOVALVE
THERMOSTAT
PILOT OPERATED CHECK VALVE OF
PE-CONTROL VALVE (23) (OPTIONAL)
OFF-LOAD VALVE (O)
OIL LEVEL INDICATOR
AFTERCOOLER (OPTIONAL)
CONDENSATE SEPARATOR (OPTIONAL)
PE-CONTROL VALVE FOR OFF-LOAD VALVE
(OPTIONAL)
HYDRAULIC SOLENOID VALVE
SAFETY VALVE:
Protects compressor against internal overpressure. The safety valve is adjusted to 12 bar.
SERVOVALVE:
Limits the maximum operational pressure during compressors continuous operation by closing the
intake valve according to the increase of an internal pressure. The valve operates together with the
OFF-LOAD VALVE.
THERMOSTATIC BY-PASS VALVE:
Forwards warming the oil to the operational temperature before opening the oil circulation through the
cooler.
OFF-LOAD VALVE (O, with or without a SOLENOID CONTROL VALVE ):
When activated, drops compressors load and discharges internal pressure.
AIR-TO-ELECTRIC (PE-) CONTROL VALVE FOR OFF-LOAD VALVE :
Provides operation control in accordance with pre-adjusted maximum and minimum pressure limits
in automatic mode.
PE-valve and solenoid control valve for off-load valve are recommended when compressor is to be
started under pressure (for instance, air tank in pressure line) or compressor is operated intermittently.
i.e. stopped and restarted depending on a compressed air consumption.
The devices decompress the pressure line enabling easy restart of the compressor.
LUBRICATION SYSTEM OF THE COMPRESSOR
COMPRESSOR OIL PERFOMS FOLLOWING FUNCTIONS:
1. LUBRICATION
Pressure differential (see above) makes the oil spread along grooves to the surfaces to be
lubricated. Separate oil pump not required.
2. HERMETIZATION
Oil, injected into the stator, seals rotor blades against stators wall and lubricates them.
3. COOLING
Compressor oil removes the compression heat from the stator.
4. CAPACITY CONTROL
Off-load automatics (servo valve - off-load valve) adjusts compressors flow rate according to
the air consumption hydraulically using compressor oil.
8 + 1,0135
= 8,89
1,0135
The compression ratio for unit of 12 bar is calculated in the same way.
AIR HUMIDITY
Compressor can be operated at the relative humidity up to 90%, provided that the ambient temperature is
within the above range. If air humidity exceeds 90%, please contact DYNASETs representative.
INSTALLATION
DYNASET hydraulic compressor can be placed deliberately ensuring free air intake, sufficient cooling and an
easy access to the unit. Position of a compressor should be horizontal. To protect compressor against overheating,
do not allow the warmed cooling air to be directed by cooling fan back to the compressor block. Compressors
location should be chosen as far as possible from any source of dust and heat. Protective cover against weather
and season impacts is recommended.
Intake air should not contain any smoke, toxic or flammable gas/vapor. When necessary, intake pipe can be
fitted (the pipe should be measured properly in order to avoid load loss).
DYNASET hydraulic compressor works installed into an original hydraulic system of any carrier machine.
Additionally, return line must be connected to a hydraulic oil tank directly in the shortest possible way in order
to keep return oil pressure under 5 bar. Generally DYNASETs T-line is to be connected directly to the return
line of a hydraulic system, when hydraulic fluid flows to the tank only through the return filter and cooler.
Both filtering degree and cooling capacity of a hydraulic system should be sufficient (ref. to PARAMETERS).
P
T
It is possible to use DYNASET either as a mobile compressor and connect hydraulic power
with quick couplings, or make a fixed installation on a carrier machine.
To put DYNASET compressor into operation only pressure- (P) and return (T) lines of a
hydraulic system are to be connected to the units corresponding hydraulic ports. The
proper connection ensures correct rotation direction of the compressor and, by that, an
appropriate cooling of the compressor block. Rotation in opposite direction is not allowed.
Furthermore, cross-connection of hydraulic hoses damages hydraulic motors shaft seal.
Ensure that the oil flow is sufficient to run the unit, i.e. at least the nominal flow must be available.
At the oil flow less that demanded nominal rate, compressors delivery will be below the nominal. If the oil
flow is so excessive, that the automatic speed control valve is unable to handle it, the unit could be damaged.
In the latter case the oil flow is to be reduced either by dropping down the rotation speed of hydraulic pump
or using flow limiter valve. DYNASET priority valve is recommended.
After having been connected to the hydraulic system, DYNASET hydraulic compressor is to be started by directing
the oil flow to the units pressure port by means of control valve - manual or solenoid. Even simple ball valve
or three-way valve can be used.
To ensure DYNASETs proper operation, the hydraulic pressure must be set to the level, at which at least the
nominal power output is achieved (ref. to PARAMETERS). Lower hydraulic pressure reduces compressed air
pressure. Maximum hydraulic pressure is 250 bar (ref. to PARAMETERS). If the hydraulic system main pressure
is higher, service pressure relief valve must be used.
Ensure also that your machine oil cooling is working properly when DYNASET is in operation.
... INSTALLATION
DYNASET hydraulic compressors are designed for easy integration into hydraulic system of any type.
1.
The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED
PRIORITY VALVE.
DYNASET PV SAE 3/4 - 1 1/4 -XX lpm - 12/24 V
priority valve includes following components:
1.
AUTOMATIC
Sandwich-mounted pressure
ROTATION SPEED
CONTROL VALVE
compensator with SAE-flange
specification;
T P
2.
S
Solenoid valve 12/24V;
M
3.
Flow limiter;
4.
Pressure relief valve.
PV-SAE valve
B
LS
LS
CF
HKL
T
DYNASET PRIORITY VALVE enables trouble-free operation of your DYNASET-unit simultaneously with other
hydraulic executors.
2.
AUTOMATIC
ROTATION SPEED
CONTROL VALVE
S
M
HKL
LS-valve
... INSTALLATION
3.
T
HKL 400 - 1800
When installing a compressor of given type to a hydraulic system, is to kept in mind that the allowed
nominal hydraulic flow should not be exceeded (Qhy_nom = Qhy_max).
S
M
10
OPERATION
Prior to starting the compressor check whether the unit is filled with oil. In non-operating and depressurized
compressor oil level is over the top point of sight glass. When necessary top up with the same oil as the unit
is filled with. Replace and tighten the filler plug (Ref. to the instructions below).
Open the cut-off valve in compressors pressure line. Ensure from compressors pressure gauge that the unit
is decompressed - when pressurized, compressor may start with difficulty*).
With carriers engine running HKL-compressor is started with a hydraulic control valve. Compressor starts to
produce usable compressed air when hydraulic flow achieves the functional minimum rate, which is approx.
a half of the nominal value (Ref.to the units nameplate as well as to the PARAMETRS). The nominal
discharge is achieved when the compressor is rotated by hydraulic flow adequate to the nominal rotation
speed.
ATTENTION !
The minimum allowed rotation speed of rotary vane compressor is 1200 rpm, corresponding to the
minimum hydraulic flow - refer to pages 21 and 22 of the manual.
*)
When the compressor is to be started under pressure (for instance, air reservoir in pressure line) or the unit
is used intermittently stopping and restarting it several times according to the air demand, following
accessories are recommended:
* solenoid control valve for off-load valve;
* pressure switch.
COMPRESSORS EQUIPPED WITH AN AUTOMATIC ROTATION SPEED CONTROL VALVE
HKL400 - HKL1800
Qpi,
Qpi,
nom
Qpi,
min
l/min
DISCHARGE
CONTROL RANGE*
Qmax
Qmin
Qnom
Qhy,
l/min
HYDRAULIC FLOW
Qpi,
nom
Qpi,
min
l/min
DISCGARGE
Qpi,
Q hy_nom = Q hy_max
0
OFF-LOAD MODE
Qhy,
Qmin
Qnom = Qmax
l/min
HYDRAULIC FLOW
Compressed air is consumed according to the demand, when compressors delivery levels within 0 l/min
to the maximum. If the compressed air is not used while compressor is running, off-load automatics (=
OFF-LOAD VALVE + SERVOVALVE) closes the intake valve and sets compressors internal pressure to 1 - 2
bar (to prevent compressor oil from drain into the air filter) when the output drops to 0 l/min.
When the compressed air is consumed, off-load automatic controls the intake valve according to the
current air demand.
11
... OPERATION
ATTENTION !
The compressor must be operated neither in smoky environment nor in conditions where toxic or flammable
vapors could be aspirated.
Compressors maximum pressure must not be exceeded in any circumstances.
Compressed air delivered by a HKL-compressor must not be used as the breathing air, even if purified and
filtered. HKL-compressor is designed for air only and must not be used with any other gas.
If the compressor is connected to the distribution network or consumer with a flexible hose, ensure that the
hose is of proper diameter and pressure class. Damaged or worn hose should be replaced immediately.
The sound-proof enclosure (if used) should be closed when compressor is in the operation.
Check the compressors oil fill periodically: when the unit is in operation, the oil level must be over the
midlevel of the sight glass .
NEVER REMOVE THE OIL FILLER PLUG WHEN THE COMRESSOR IS RUNNING OR PRESSURIZED !
HYDRAULIC FLUIDS
Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic equipment.
Depending on the operating temperature, following mineral hydraulic oils are recommended:
ISO VG 32S
for oils operation temperature up to 70 C;
ISO VG 46S
for oils operation temperature up to 80 C;
ISO VG 68S
for oils operation temperature up to 90 C.
Synthetic and bio-oils can be used as well if their viscosity characteristics and lubricating efficiency are
corresponding to above mineral oils. Automatic transmission fluids and even engine oils can be used,
provided that they are allowed to be used in hydraulic system of your carrier machine.
To use special hydraulic fluids a with DYNASET equipment, please be kindly requested to contact nearest
DYNASET representative for an advice.
COMPRESSOR OILS
ROTOROIL F4 compressor oil is recommended as most preferable lubricant. If ROTOROIL lubricants are not
available it is allowed to replace them with high quality rotary vane compressor oils of same viscosity class
supplied by other manufacturers, see table below. Pay attention to long-life oil exchange interval and life
span. All Dynaset compressors are equipped with thermostat for unexpected overheating and damages.
QUALITY
AMBIENT
TEMPERATURE
OIL CHANGE
MAX, HOURS
SUPPLIER
DETAILS
ROTOROIL 8000 F4
Corena S4R
Rarus SHC 1020
- 30 ... + 45C
- 10 ... + 45C
- 10 ... + 45C
2.500 or 12 months
2.500 or 12 months
2.500 or 12 months
Dynaset
Shell
Exxon Mobil
synthetic oil
synthetic oil
synthetic oil
ATTENTION !
Do not mix together lubricants neither of different specification nor of different brand!
COMPRESSOR MAINTENANCE
DYNASET hydraulic compressors are low-maintenance units. Only normally wearing parts and materials
should be replaced either when necessary or in accordance with a service program.
Refer also to the TROUBLESHOOTING section.
Prior to starting any maintenance or repair, ensure that the compressor is completely depressurised.
The pressure gauge in oil separator housing must indicate zero.
12
COMPRESSOR MAINTENANCE
DYNASET HKL-SERIES SERVICE TABLE
Neglecting recommended services may cause device malfunction and Dynaset warranty is anymore valid.
Perform given maintenance in time according to next table.
CHECK POINTS
Check oil level
Clean compressor air intake filter
Clean oil cooler and air after cooler
Clean oil return valve filters
Change air intake filter
Tighten nuts and screws fixing the
wires in the electric control panel
and in the motor terminal board
Replace oil return valve filters
Change oil filter: FG
Change oil filter: F2 or F4
Oil change: Rotoroil 8000: FG
Oil change: Rotoroil 8000: F2 or F4
After
the
first
50 h
Weekly
or
every
50 h
O
O
O
O
Monthly Every 3
months
or
or
every
100 h
500 h
I
I
I
I
I
I
I
I
I
I
13
MAINTENANCE
OIL LEVEL CHECK AND CHANGE
FACTORY-FILL OIL
Factory-fill oil must be changed after very first 200
(max.) operation hours.
Further on compressor oil is to be changed according
to the oil quality and service time (ref. to
COMPRESSOR OILS above) or at least once a year.
ENSURE THAT THE COMPRESSOR IS COMPLETELY
DEPRESSURIZED !
Unscrew filler plug (1) slowly.
Attach proper fitting to the oil drain valve (2.1) and
open the valve. Drain the oil into the suitable pan.
(Oil drain valve could be replaced with a discharge
plug 2.2).
Shut off the valve (2.1) or replace and tighten the
plug (2.2) Fill the compressor with oil. Replace and
tighten filler plug 1. DO NOT FORGET GASKETS !
2.1
2.2
ATTENTION !
OIL SHOULD BE CHANGED WHEN THE
COMPESSOR IS WARMED UP TO THE
NORMAL OPERATIONAL TEMPERATURE.
OIL FILL
l
2,5
2,0
2,0
3,5
3,5
10
10
19
14
MAINTENANCE
AIR / OIL SEPARATOR
In normal ambient conditions oil separator elements should be replaces at each 10 000 operation hours or
when pressure loss or oil consumption increases considerably.
In heavy conditions exchange interval should be shortened.
SEPARATOR ELEMENT
SEPARATOR ELEMENT
PRESSURE REGULATION
Compressors output pressure is adjusted and
tested at factory and usually does not
required resetting.
However, if re-adjustment is required, the
procedure is to be made as follows:
1.
Start the compressor.
2.
Shut off the pressure line slowly when air
pressure achieves the maximum. Note the
pressure gauges reading *).
3.
Having removed parts, shown on the sketch,
make the adjustment with the servo valve:
3.1 loosen locknut first
3.2 to increase pressure, tighten the
adjusting screw;
to decrease pressure, loosen the
adjusting screw;
3.3 lock the setting with locknut.
SERVOVALVE
SERVOVALVES SETTING
bar
bar
8
10
8,5
10,5
ATTENTION !
ONLY THE QUALIFIED PERSONNEL IS
ALLOWED TO MAKE THE SETTING !
*)
A separate pressure gauge should be connected to the pressure line when making
the adjustment.
It is recommended to use the unit comprised of ball valve and pressure gauge as
shown on the alongside sketch.
15
TROUBLESHOOTING
1.
COMPRESSOR DOES
NOT START WHILE
CARRIERS ENGINE IS
RUNNING AND
HYDRAULIC SYSTEM IS
ON.
2.
COMPRESSOR STARTS
HARDLY
3.
AIR PRESSURE DOES
NOT ACHIEVE
REQUESTED RATE.
1.1
Malfunction of compressors
hydraulic control valve.
1.2
Compressors excessive internal
pressure.
1.1
Check and repair.
1.2
Check the minimum pressure/non return valve and
repair possible blowing.
1.3
Failure in hydraulic system.
1.3.1
Check whether the hydraulic fluid flow and pressure
are sufficient. Adjust when necessary.
1.3.2
Check the hydraulic motor for possible leakage.
Replace motor if necessary.
1.4
Air pressure in delivery line
disrupts compressors start.
1.4
Let off the pressure from the delivery line prior to
staring the compressor.
It is recommended to install the solenoid control
valve for off-load valve, especially if the pneumatic
system is provided with an air reservoir.
See 1.3
See 1.4
3.1
Servo valves incorrect setting.
3.1
Check and adjust servo valve when necessary.
3.2
Safety valve opens due to the
either the failure or incorrect
setting of servo valve.
3.2.
Check and adjust servo valve.
3.3
Failure in hydraulic system.
3.3.1
Check whether the hydraulic fluid flow and pressure
are sufficient. Adjust when necessary.
3.3.2
Check the hydraulic motor for possible leakage.
Replace motor if necessary.
3.4
Air intake filter is clogged.
3.4
Check and replace.
3.5
Oil separators filter element(s)
clogged.
3.5
Check and clean / replace filter element(s).
16
... TROUBLESHOOTING
4.
COMPRESSOR DOES
NOT PRODUCE
COMPRESSED AIR =
RUNS UNLOADED
5.
EXCESSIVE OIL
CONSUMPTION
6.
COMPRESSORS
OVERHEATING.
4.1
Delivery line closed (i.e.
OPEN/CLOSE valve is damaged) or
possible malfunction in pneumatic
executor.
4.2
Servovalves failure or incorrect
setting (i.e. adjusted to the
pressure lower than setting of
minimum pressure / non return
valve).
4.3
Air intake valve does not open.
4.1
Check and repair possible failure.
5.1
Filters of the oil return valves are
clogged.
5.1
Check and clean / replace valves.
5.2
Oil separators filter element(s)
clogged.
5.2.
Check and clean / replace filter element(s).
6.1
Dirty oil cooler.
6.1
Clean the oil cooler.
6.2
High ambient temperature.
6.2
Sufficient ventilation is to be arranged.
6.3
Low oil level.
6.3
Add compressor oil to the required level.
6.4
Due to the seizure of thermostatic
by-pass valve, compressor oil does
not circulate through oil cooler.
6.4
Check and repair the valve.
6.5
Due to the insufficient cooling
capacity of a hydraulic system
hydraulic fluid warms the
compressor.
6.5
DYNASET OY offers wide range of hydraulic
components including oil coolers !
4.2.
Check and repair possible failure.
4.3
Check the valve and repair failure. Check also the
whole valve block to order to find out and repair
possible malfunctions.
ATTENTION !
HKL-compressor is equipped with a
thermostat, which is to be used for stopping
the compressor when the units temperature
achieves thermostats constant set value.
Thermostat is to be connected to the stop
valve or alarm lamp in the Customers system
by Customer themselves.
17
PLUG R 1/8
PLUG M5
ATTENTION !
In HKL 4100 and HKL 5000
the connection is placed
on the right side of the
compressor block.
A.
The offload valve (17) is to be attached into the connection (1) of R
1/8 in oil separator (on the same side with AP-connection). Tightening
glue is used to make joint hermetic. Prior to the installation remove the
plug 1/8 from the connection port.
B.
From-valve-to-compressor unload air tube (2) (6/4 teflon) is installed to
the connection M5 (3) with a swivel fitting and tightening glue as shown
on sketches above. Prior to the installation remove the plug M5 from
the connection port.
The unload air tube is laid under the oil separator between
compressors housing and air filter cover.
Installation kit includes all necessary fittings and the nylon tube.
The valve is equipped with a pre-installed fitting 1/8.
18
23
16
23.3
POS 23
PE-control valve, including following
components:
23.1
LOCKNUT OF
PILOT VALVE
23.2
needle valve to adjust filling
time interval of air chamber 23.4
IP65
HYSTERESIS
LOCK
23.2
23.3
pressure switch, pre-adjusted
at factory (3 bar)
23.4
air chamber
14 - 15 sec
HKL 2600
.....
20 sec
HKL 5000
40 - 45 sec
ATTENTION !
PILOT VALVEs (23.1) HYSTERESIS IS ADJUSTED
AT FACTORY ! DO NOT RE-ADJUST !
19
When there is no air consumption compressor being on (i.e. delivery line is closed), air pressure in
compressors reservoir achieves its maximum, opening a pilot valve (23.1) and activating the off-load
mode.
Pilot operated check valve (16) opens and sends a signal to a compressor servov alve, which closes the air
intake valve.
An air chamber (23.4) is filled up with an air discharging from compressors reservoir until the pressure in
chamber achieves the pre-adjusted value for the opening of a pressure switch (3 bar). Pressure switch 23.3
opens de-energizing the solenoid valve (30) when the unit stops.
As soon as the compressed air is requested by a pneumatic consumer, i.e. delivery line is open - pressure in
air chamber (23.4) drops less than 3 bar, when the pressure switch closes, re-energizing the solenoid valve
(30) and restarting the compressor.
23
23.4
23.3
23.2
3 BAR
TIME
23.1
PRESSURE
16
+V
(30) HYDR.
SOLENOID
If the compressed air is requested the off-load mode being on, PE-valve drops the pressure in compressors
reservoir to the pre-adjusted value (set from the pilot valve to 5 - 6,5 bar depending on the unit size)
opening the compressors intake valve, and the unit passes into the operation directly from the unloaded
mode.
20
PRODUCT DISPOSAL
Conform to waste legislation, regulations and recommendations in waste disposal and waste recycling
issued by local authorities.
1. Precondition:
Product is permanently useless or beyond repair.
Before transportation get off all used agent (oil, cooling liquid) and dirty filters.
Items requiring special handling can normally be done by authorized waste management facility,
if not:
Separating the base materials, iron, copper, steel, electronics, removing paint, polyester resin,
and insulation tape and/or plastics residues from all components.
This waste material can now be recycled.
2. Deliver the recycling material to waste management facility.
Note! Customer can send the DYNASET equipment for reuse or recycling to the Dynaset Oy or to
other location determinate by Dynaset representative.
Customer pays shipping cost.
Equipment must be adequately packed for shipment.
Shipment documents must contain purchasers name and contact information.
21
PARAMETERS
DISCHARGE CHARACTERISTICS
Flow rate at ref. conditions*,
max. l/min
Maximum pressure
bar
400
8
800
8
1300
8
1800
8
BSP 12
BSP 1/2
BSP 1/2
BSP 3/4
HYDRAULIC CONNECTIONS
Pressure line
Return line
Drain line
BSP 1/2
BSP 1/2
NO
BSP 1/2
BSP 1/2
NO
BSP 1/2
BSP 1/2
NO
BSP 1/2
BSP 1/2
NO
20
60
210
120
14
37
210
250
140
2,8
10 - 200 / optimum 25 - 35
max. 70 **
min. 25
2,2
3,2
P
T
DR
10
35
210
14
55
170
250
140
23
66
170
130
23
66
210
250
150
250
150
OVERALL DIMENSIONS
Length
Width
Height
mm
mm
mm
525
250
325
640
390
540
640
390
540
750
390
600
WEIGHT
kg
30
50
55
95
22
PARAMETERS
DISCHARGE CHARACTERISTICS
Flow rate at ref. conditions*,
max. l/min
Maximum pressure
bar
HKL 4100/8-113
2600
8
4100
8
HKL 5000/8-135
5000
8
BSP 3/4
BSP 1
BSP 1
HYDRAULIC CONNECTIONS
Pressure line
Return line
Drain line
BSP 3/4
BSP 1
NO
BSP 3/4
BSP 1
NO
BSP 3/4
BSP1
NO
74
113
200
250
145
74
135
180
250
150
P
T
DR
33
65
210
41
82
170
250
50
135
7500
8
BSP 1 1/4
BSP 1
BSP 1
T15
72 + 12
144
260
280
200
96 + 12
188
200
250
150
OVERALL DIMENSIONS
Length
Width
Height
mm
mm
mm
790
390
600
870
495
770
870
495
770
1100
850
820
1100
850
820
WEIGHT
kg
103
185
185
325
330
6,8
9,4
10 - 200 / optimum 25 - 35
max. 70 **
min. 25
11,3
23
1.
Warranty coverage
All hydraulic accessories manufactured by
DYNASET OY are subject to the terms and
conditions of this limited warranty. Products are
warranted to the original purchaser to be free from
defects in materials or workmanship. Exclusions
from warranty are explained in item 8.
2.
3.
4.
5.
Warranty period
Warranty period is twelve (12) months based on
maximum of 2000 hours usage during this time
period. In cases where the system is provided
complete with certain special components (e.g.
drive unit), those components are considered as a
subject to their manufacturers warranty.
Warranty procedures
Immediately upon identifying a problem which
purchaser believes to be a failure subject to the
products limited warranty, purchaser must contact
primary to the seller of the product. Contact must
be made as soon as possible, latest thirty (30)
days after the problem was identified. Seller
and/or manufacturer technical staff determines the
nature of the problem primarily by phone or
e-mail. Purchaser commits to give necessary
information and to perform routine diagnostic
procedures in order to determine the nature of the
problem and necessary procedures.
Warranty repairs
If the product is found to be defective during the
warranty period, DYNASET OY will, at its option,
either repair the product, author it to be repaired at
its authorized workshop or exchange the defective
product. If the product must be repaired elsewhere
than premises of DYNASET OY or authorized
workshop, all costs excluded from this warranty
(traveling and waiting hours, daily allowance,
traveling expenses and uninstallation/reinstallation
costs) will be charged from the purchaser.
If the problem is not covered by this limited
warranty, DYNASET OY has the right to charge
purchaser of troubleshooting and repairing.
6.
7.
8.
a.
Failures due to normal wear and tear,
improper installation, misuse, abuse, negligence,
purchaser selection of improper product to intended
use, accident, improper filtration of hydraulic oil or
intake water or lack of maintenance
b.
Cost of maintenance, adjustments, installation
or startup
c.
Coating, hydraulic oil, quick couplings and
interconnection hoses (internal or external to system
assemblies)
d.
Products altered or modified in a manner not
authorized by DYNASET OY in writing
e.
Products which have been repaired during
warranty period by others than DYNASET OY or its
authorized workshop
f.
Costs of any other damage or loss, whether
direct, indirect, incidental, special or consequential,
arising out of the use of, or the inability to use, the
product
g.
Telephone or other communications expense
h.
Product that is used in exceptional conditions,
considered to cause excessive wear and tear
i.
Faults caused by nature phenomenons like
flood, thunder, etc.
DYNASET OY, all rights reserved
24
EC DECLARATION OF CONFORMITY
We hereby declare that the below-reference product design, structure and our
manufacture form fulfills relevant, fundamental safety and health requirements
with the provisions in the Council Directive on mutual approximation of laws of the
Member States on the safety of machines.
PRODUCT:
HYDRAULIC COMPRESSOR
TYPE NUMBERS:
HKL400/8-24-xxx, HKL400/10-24,
HKL801/8-26-xxx,
HKL1300/8-38-xxx, HKL1300/8-46-xxx,
HKL1800/8-46-xxx,
HKL2600/8-65-xxx, HKL2600/8-82-xxx,
HKL4100/8-113-xxx,
HKL5000/8-135-xxx,
HKL7500/8-176+12-xxx (xxx + xx)
YLJRVI 26.07.2012
DYNASET Oy
Timo Nieminen
R&D Manager
25
NOTES