Beruflich Dokumente
Kultur Dokumente
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CopyrightO 1998
All rightsreserved.The copyrightof this documentis the propertyof I
CompAirHydrovaneLimited.No part of this publicationmay be
reproduced,storedin a retrievalsystem,or transmitted,in any form or I
by any means,electronic,mechanical,photocopying, recording,or
otherwisewithoutthe priorwrittenpermissionof the Technical I
PublicationsDepartment,CompAirHydrovaneLimited.
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5 - UserHandbook
8 SeriesPUAS/PWTS
j
Introduction
i Introducingyour new CompAirHydrovanecompressor
J Your new CompAirHydrovanecompressorhas been designedand manufacturedto the exacting
standards
necessaryto ensure long-life,reliabilityand high performance.CompAir Hydrovaneare world leaders
a compressed-air
in
technologyusing the most moderntechniquesand plant avaiiableto give our customersthe
followingbenefits:
d . Compactaward-winningdesign.
A . Easyto position,installand operate.
.l . Economical
to run,inexpensive
and simpleto service.
.{ . Quiet,smoothunobtrusiveperformance.
. Provenreliabilitywith the optionof extendedwarrantyperiods.
{
. Fullsupportavailablefrom world-wideDistributornetwork.
Customerwarrantyterms
All Hydrovane compressors,which are serviced by an authorisedCompAir Hydrovane Distributor
are
guaranteedfor twelvemonthsfrom the date of commissioning
or eighteenmonthsei *orxs.
,.|
The warrantyexcludesnormalservicepartsandwearitems,dirtingress,cleaningof filtersandf luiddrain
devices
and the tighteningof electricalor other connections.Also excluOlOis the adjultmentof pressureswitches
or
the adjustmentof any othercontroldeviceshown in this handbook.
{ Note: 'Advance'Five Year Warrantymay not be availablein all markets.Please refer to your
CompAir
HydrovaneDistributorfor details.
PLEASENOTE:
tl
Your CompAirHydrovaneDistributoris ableto offera wide rangeof Hydrovanecompressors, dryers,filtersano
ancillaryair-linesystemproducts.Theirengineersare fullytrainedan-dcompetentin all aspectsofcompressor
t
and air-systemmaintenance.lf you need any specialisthelp or servicepleasecontactyour Distributorquoting
t h e M O D E LT Y P Ea n d S E R T A N
L UMBER.
Page 1
CompAirHydrovaneLimited
Introduction
ProductdeveloPment
whilst
CompAirHydrovaneadopta policyof continualproductdevelopment.The informationin this handbook,
fully up to date when issued,may be subjectto changewithoutnotice.
Qualitystandards
CompAirHydrovaneQualitYManagementSystemsare approvedto BS EN / ISO 9002.
CompAirHydrovaneLimited
ClaybrookDrive
WashfordIndustrialEstate
Redditch
TelePhone
Worcestershire : Redditch(01527\ 525522
B9BODS Fax: (01527) 521140
England.
(A SrEBECOMPANY)
Modelrange
This handbookrelatesto all 50 and 60 Hz 8 SeriesPUAS and PWTS compressors,modeltypes:
8 1 8 P U A SO B 8 1 8 P U A S1 O 818PWTS08 8 1 8 P W T S1 O
822 PUASOB 822 PUAS 1O 822PWTS08 822 PWTS 10
830 PUAS 08 B 3 OP U A S1 O 830 PWTSOB B3OPWTS 1O
837 PUAS 08 837 PUAS 1O 837 PWTSOB 837 PWTS 1O
845 PUAS 08 845 PUAS 1O 845 PWTS08 845 PWTS 1O
Terminology:-
8 = 8 Series.
1 8 , 2 2 , 3 0 ,3 7 a n d 4 5 = kw.
08,10 = Normalworkingpressure.
Page2
tt Introduction
- UserHandbook
8 SeriesPUAS/PWTS
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Ownershiprecords
We recommendthat you recordthe followingdetailsfrom eitherthe compressoror motorname plates:
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Compressor Motor
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ModelNumber: Type: Rating:
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SerialNumber: KW: hp:
Volts: Amps:
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MaximumWorkingPressureOn Load: Bar
Phase: Hz:
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MaximumWorkingPressureOff Load:
F.A.D.:
Bar
US R.P.M:
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S.V.Pressure: Bar Insulation
Class: lP:
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LocalCompAirHydrovaneDistributor
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Name:
Address:
Telephone: Fax:
ContactNames: Sales:
Service:
Parts:
Page3
CompAirHydrovaneLimited F
Introduction
i
Thispageis intentionally
leftblank.
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- UserHandbook
8 SeriesPUAS/PWTS
8 SeriesPUASand PWTS
UserHandbook
Contents
Chapter Page
Healthand SafetyPrecautions 1 . 7
Transportation
and Handling 2 .13
Installation
and Commissioning 3 .19
GeneralDescription 4 .35
OperatingInstructions 5 .41
OperatingParameters 6 .47
Adjustments 7 .49
Servicing B .57
d F a u l t F i n d i .n. g. 9 .69
Page 5
CompAirHydrovaneLimited
Contents
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Chapter1
Contents
Section Page
Noteto Users. 1.1 . 8
GeneralHealthand SafetyInformation 1.2 . B
WhenOperatingthe Compressor 1.3 o
Potential
Oil HealthHazards 1.5 .10
Warnings,Cautionsand Notes 1.6 .11
PageT
CompAirHydrovaneLimited
1 Healthand SafetyPrecautions
1.1 Noteto Users 1.2 GeneralHealthand Safety
1.1.1 The compressor warrantywillbe invalidated
Information
if unapprovedsparepartsor lubricantsare used.Using 1.2.1 Any personsoperatingor carryingout any
such items may cause the efficiencyand servicelife type of maintenancework on this compressor,must
of the compressorto be reducedand could createa use safe engineeringworkingpracticesand abideby
hazardousconditionover which CompAirHydrovane a l l l o c a l a n d G o v e r n m e n tH e a l t h a n d S a f e t v
has no control. regulations.
1.1.2 Failureto maintainthe compressor correctly, The Health and Safety at Work Act, 1974.
or modifyingit without prior approvalfrom CompAir
Hydrovane,may also create a hazardouscondition. 1.2.2 In orderto complywith your responsibilities
This will also invalidatethe warranty. underthe aboveact,it is essentialthatthe compressor
is transporled,positioned,installed,operated and
1.1.3 CompAirHydrovaneacceptno responsibility maintainedby competentpersonsin accordancewith
for damageor injurycausedby use of non-approved the instructions in thishandbook.
parts or lubricants,unauthorisedmodifications, or
failureto complywith maintenanceinstructions. 1.2.3 When transporting or loadingthis machine
only use the liftingmethodsquotedin this handbook.
1.1.4 Consequential damageof any natureis not
coveredby the warranty. 1.2.4 Ensure that the compressoris positioned,
installed,electricallyconnectedand joined to your
1.1.5 Every effort has been made both in the air-linesystem by competentand qualifiedpersons
designof the compressorand in the preparationof this only.
handbook,to protect the end user from possible
dangers. 1.2.5 This compressormust only be used in the
compressionof clean atmosphericair and positioned
1.1.6 The majorityof accidentscan be avoidedif in a fumeandvapourfreenonexplosive environment.
basicsafetyprecautionsand proceduresare adhered
to. 1.2.6 lt is the responsibility
of the localsupervisor
to ensurethat peopleoperatingor maintaining the
compressornave :-
A detailedknowledgeof the productpriorto use.
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1.3 WhenOperatingthe Compressor 1.4 BeforeWorkingon Compressor
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will
1.3.1 Whenin automaticmodethe compressor 1.4.1 Potentiallylethalvoltagesare usedto power
1 re-startwithoutwarning. this machine. Do not carry out any work until the
isolatoris lockedin the off position.Fit a safetynotice
lf an automaticre-startdevice is fitted (allowingthe to the isolatoradvisingthat work is being carriedout
{ compressorto start when power is re-applied),or and that the isolatormust not be switchedon. lf in
o p e r a t i o n i s c o n t r o l l e df r o m a r e m o t e l o c a t i o n , doubt then a qualifiedelectricianmay remove the
i additional warningswillbe required. fuses and keep them in a secureplace until work is
{ 1.3.2 Do not removeany plugsor releasepipework complete.
whenthe compressoris running. 1.4.2 Ensure the compressorhas been safely
{ isolated from the main air system and cannot be
1.3.3 Do not attemptto open the starterenclosure
whilethe compressor is operating. re-introduced untilallwork has been completed.Fit a
I safetynoticeto the isolationvalve advisingthat work
1.3.4 Bewareof hot surfacesboth the air-endand is beingcarriedout.
i e l e c t r i cm o t o r a r e d e s i g n e dt o r u n a t e l e v a t e d
1.4.3 Do not undertakeany work until the
temoeratures.
compressorand receiverif fitted,have been relieved
1.3.5 Compressedair is dangerousand can be of all pressure.
fatal if misused.Do not allow compressedair jets
{ vent down cycle is
dischargedfrom any pipe or nozzleto make contact W a i t u n t i l t h e c o m p r e s s o r s
with your body. complete.
{
1.3.6 Wear safety glasses and suitableclothing Openthe test valveto releaseany pressurecontained
whenusing,or workingin an areawherecompressed in the aftercooleror associatedpipework.
air is beingused.
Checkthatthe air-endpressuregaugereadszero.Do
I
1.3.7 Hazardousvapours/fumes can be produced not proceeduntilit does.
if compressedair is used to remove chemicals,
I Carefullyunscrewthe compressor fillerplug.lf any air
cleaningagentsand lubricantsfrom equipmentand
components.Suitable respiratoryand extraction or oil escapesbeforeplug is fully removedstop! Do
, not removethe plug untilall pressureis lost.
equipmentmay be requiredin these circumstances.
Never use compressedair for cleaningpersonal 1.4.4 Safety devices fitted to the compressoror
I
clothing. air-linesystemshouldbe checkedat regularintervals
a 1.3.8 Do not use air directlyfrom compressorsfor and replacedif faulty.They should not be tampered
breathingpurposes.lf the air is to be used for human withor modified.Non returnvalvesshouldnot be used
I consumptionthen it must be subjectedto further as isolationdevices.
treatmentto ensurethat the levelsof contaminants, 1.4.5 To ensure the compressoroperatessafely
I odourand moisturemeetthe reouirements of BS 4275 y o u m u s t c a r r y o u t t h e s p e c i f i e d m a i n t e n a n c e
1974. procedures.
i 1.3.9 We recommendthat the air supplyto hand 1.4.6 Only approvedlubricantsshouldbe usedfor
heldair guns is regulatedto a lowerpressure(referto flushingpurposes.
I
localhealthand safetyregulations).
1.4.7 Extreme caution should be taken if the
I 1.3.10 Do not insert any object or part of body compressorhas been subjectedto severeoperating
throughany openingof the compressorenclosure. temperatures or fire.Certaincomponentsmay contain
I Seriouspersonalinjuryand/ordamagemay result. fluoroelastomer materialsand undertheseconditions
1.3.11 Neverrun the compressor when any covers can leave extremely corrosiveresidues.Severeburns
i or guardsare missing,unlessadvisedto do so in this and permanent skin and tissuedamagecan be a result
handbook. of skin contact.
1.3.12 The air dischargedfrom this compressor 1.4.8 The Healthand Safetyinformation contained
containsoil vapour and is unsuitablefor breathing in this Handbookis only intendedto give general
unlessspecialisedfiltrationand regulationequipment guidelines.
I has been installed.
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CompAirHydrovaneLimited
1 Healthand SafetyPrecautions
1.5 PotentialOil HealthHazards
Note! This sectionrelatesto Fluid Force 2000 oil.
For other lubricantsrefer to the Health and Safety
Instructionsissuedwith the relevantproduct.
1.5.1 There are no significanthazardsassociated
with this product when properlyused and in the
application for whichit was designed.Frequentand/or
prolongedskin contactmay give riseto skin irritations
and it is recommended thatprotectiveglovesareworn.
The carcinogenic action of mineraloils should be
*
broughtto the attentionof all users.
Note! The oil maybe hotso takecarewhencarrying
out oil changes.
1.5.2 Do not keep oily rags in pockets or wear
c o n t a m i n a t e dc l o t h i n g . D o n o t i n h a l e f u m e s o r
vapours.Do not swallow.Avoideye contact.
1.5.3 Always wash hands after use and before
eating,drinking,smokingand usingthe toilet.
Ingestion- Do not inducevomitingbecauseof the risk
Wash mouthout withwater.Give 1/2pint
of aspiration.
milk.Seek immediatemedicalattention.
.Mildly irritating.Removeby wiping.
Skin Contact -
Wash with soap and water.Applyemollientcream.
.Mildly irritating.Flush with copious
Eye Contact -
amounts of warm water. Seek medical advice if
necessary.
Page10
8 SeriesPt AS/PWTS- UserHandbook
Healthand SafetyPrecautions 1
-{
1.6 Warnings,Cautionsand Notes
*.{
Warning
Mandatory
'WARNING' Eye ProtectionMust Be Worn
is used in the text of this handbookto
{ identifyspecific hazards which can cause injury or
d e a t h . T h i s t y p e o f h a z a r d i s i d e n t i f i e do n t h e
compressorby the symbolsshown below.
I
Caution
{ Mandatory
'CAUTION'
is used in the text of this handbookto Dust ProtectionMust Be Worn
identifyincorrectprocedureswhichcan causedamage
to the comoressor.
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Notes
{ 'NOTE'
is used in the text of this handbookto draw
Mandatory
attentionto specificpointsof importance. Readthe InstructionManual
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1.6.1 Symbols
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Warning Mandatory
t Riskof ElectricShock Do Not Operatethe Machine
Withoutthe GuardBeingFitted
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Warning
Riskof Danger I
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Warning- Do not start machinewith-
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Warning out consultinghandbook
Riskof Hot Surface
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Warning
t PressurisedVessel
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Warning
i PressurisedComponentor System
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i Warning
Unit is RemotelyControlledand
MayStartWithoutWarning
Page 11
CompAirHydrovaneLimited
1 Healthand SafetyPrecautions
Page 12
L - UserHandbook
8 SeriesPUAS/PWTS
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Transportationand Handling 2
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CompAirHydrovaneLimited
2 and Handling
Transportation
2.1 lntroduction 2.3 Liftingand transportationA
(Seefigures2.3&2.4)
! a
WARN|NG
2 . 3 . 1 T h e r e c o m m e n d e dm e t h o d o f l i f t i n g ,
LIFTINGAND TRANSPORTATIONMUSTONLY BE
transportingand positioningthe compressoris by
C A R R I E D O U T B Y A U T H O R I S E DP E R S O N S , pallet or fork lift truck. A hoist may also be used for
FULLYTRAINEDIN THE USEOFTHE EQUIPMENT l i f t i n g t h e c o m p r e s s o ru s i n g t h e l i f t i n gb r a c k e t s
EMPLOYED. provided.
2.1.1 The compressormay be suppliedboxed,or
unboxedwith a protectivecover. In eithercase they
must only be liftedor transportedto the instructions
containedwithinthis handbook.
2.1.2 Ensureall liftingequipmentand means of
transportation are securelylocatedand ratedto accept
the full load.Inspectall liftingequipmentfor signsof
wear. Do not use if wear is evident.
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and Handling 2
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Figure2.1- Dimensions
(PUAS)
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GompAirHydrovaneLimited
2 and Handling
Transportation
2.4 Weightsand dimensions;
(Seefigure2.2)
WaterCooledComPressors
J To removeoilfilter mm 40 40 40
Oil Goolerand Air AftercoolerModels
Weight kg 760
A Heightto C/L mm
B Footto foot mm 1206
c Length(overall) mm 1897
D Widthof feet mm 812
E Height(overall) mm 904
F Width (overall) mm
G To open stader mm 355
H To removeair filter mm 175
J To removeoilfilter mm
Page16
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Figure2.2- Dimensions(WaterCooledUnits)
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CompAirHydrovaneLimited
2 Transportation
and Handling
S.W.L.1000Kg
a) Hoist b) ForkliftTruck
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Installation
andCommissioning 3
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{ Chapter3
I Contents
a Section Page
.l Your Compressor
Positioning BasicRequirements 3.2 .20
Ventilation 3.3 .21
.a
Accessibility 3.4 .21
,I
Air-lineSystem,Installation
Guidelines 3.5 23
a
ElectricalConnections 3.6 .25
,a Procedure
ElectricalInstallation 3.7 .26
.a CheckingDirection
of MotorRotation 3.8 27
CircuitDiagram(50 Hz) 3.9 .28
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CompAirHydrovaneLimited
3 andGommissioning
Installation
3.1 Introduction
WARNING!
Page20
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L Installationand Commissioning 3
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3.3 Ventilation(Fig.3.1) 3.4 Accessibility(Fig3.2)
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3.3.1 Positionthe compressorin a well ventilated 3.4.1 Sufficientclearancemust be allowedon all
location. Do not restrict the air-flow around the sides of the compressorfor servicingpurposes.The
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compressor.Do not allowhot airto re-circulate
compressorintake.
intothe minimumclearancerequiredis shownon thediagram.
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3.3.2 Any cooling-air inletshouldbe positioned
low
allowingunrestrictedair{lowto the compressorintake.
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The warm-airoutletshouldbe positionedhigh, and
well away from the inlet,to ensurea positivecooling
air-flowthroughthe compressor.
3.3.3 For maximum efficiencyand reliability,the
compressorshould be operated in a cool ambient
temperature.
To achievethis,ensurethe compressoris installedin
a room of the correct size and with sufficient
ventilation.The compressormust not be operatedin
ambienttemperaturesgreaterthan 4OoC.
lf the ambienttemperaturefrequentlyfalls belowOoC
c o n s u l t y o u r C o m p A i r H y d r o v a n eD i s t r i b u t o rA
.
differentgradeof oil may be required.
N o t e1 : A m b i e n t i s u s e d t o d e s c r i b e t h e a i r
temperatureat the compressorintake.
Note 2: The oil lifeof FluidForce2000willbe reduced
whenoperatingwithbulkoiltemperatures greaterthan
95"C.
.a
3.3.4 Do not positionthe compressorin conditions
i
that may causethe bulkoil temperatureto exceedthe
permittedmaximumof gsoO.
3.3.5 An extractorfan (A) or ducting(B) may be
neededif:
a. The roomis too small.
b. Thereis insufficient
naturalventilation.
{ c. Otherplantor a heat sourceis nearby.
{
Page 21
CompAirHydrovaneLimited
3 Installation
and Commissioning
MAXIMUM
AMBIENT
40" C
Figure3.1- Ventilation
Dimension Length
A 1 . 5m
B '1.0
m
c 1 . 5m
D ' 1 . 0m
E 1 . 2m
Figure3.2- Accessibility
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3.5 Air-lineSystem,Installation (D) Air discharge pipe
Guidelines
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A flexibleair pressurehose to an approvedstandard
may be used to connectthe compressoroutletvalve
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to the air-linesystem.
(E) Non-returnvalve
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AIR.LINESYSTEMMUSTONLYBE CARRIED.OUT
BY COMPETENTAND AUTHORISEDPERSONS
A non-returnvalve(checkvalve)may be fittedintothe
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F U L L Y T R A I N E D I N C O M P R E S S O R SA N D
C O M P R E S S E DA I R S Y S T E M S .T H E Y M U S T
air-linesystem to preventback-flowof air when the
compressorhas Stopped.
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F U L L Y U N D E R S T A N DA N D A D O P T S A F E
W O R K I N G P R A C T I C E S ,A N D A B I D E B Y A N Y lf a non returnvalveis fitted,any pressuretransducers
LEGISLATION OR REGULATIONSPRESENTLYIN
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PLACE.
fittedmust be repositionedafterthe non returnvalve.
(F) Air receiver
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3.5.1 Ensurethat all equipmentand pipeworkfitted
to yourair-linesystem,are sizedcorrectlyand ratedto Recommended whenthereis a f luctuatingairdemand.
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acceptthe maximumworkingpressureand air delivery A receiveris essentialto ensure optimumoperating
of the compressor. efficiencywhen operatingin the automaticstop/start
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mode.
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downstream equipmentrequiredwilldependuponthe Theyshouldbe positionedso thatexternaland internal
application.Your CompAir Hydrovanedistributor inspectionscan easily be carried out. The receiver
specialisesin all aspectsof air-linesystemsand will ratingplateshouldbe clearlyvisible.
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be pleasedto advise.
lf the air demand is constantand an air receivernot
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3.5.3 Installationguidelines(existingsystem) i n s t a l l e dt h e n t h e m a n u a l m o d e o f o o e r a t i o ni s
(Capital letters in brackets refer to Fig 3.3) recommended.
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. Ensure that the air delivery of the compressoris
condensate containedwithinit.
sufficientto fully satisfy the maximum air demand (G)
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allowingfor pressuredrops throughthe system and
Coalescingfilters
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Opens and closes the air deliveryinto the air-line
system. Always close the valve to isolatethe
compressorfrom air-linepressurefor servicing.
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(C) Test valve
t| - =- Stronglyrecommended to ensurethatpressurecan be
releasedfromthe aftercooler and associatedpipework
before servicingthe compressor.The valve is also
L, essentialto allow test and settingproceduresto be
a: quicklyand easilycarriedout.
Page23
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Figure3.3- TYPicalInstallation
Page 24
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(H) Dryer (N) Oil-water separator
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For manyapplications clean,dry air is essentialfor the
processor is requiredto ensure longer life, greater
T h e c o n d e n s a t ed i s c h a r g e df r o m t h e v a r i o u s
componentsin the air-linesystemcontainstracesof
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e f f i c i e n c ya n d r e l i a b i l i t yo f p n e u m a t i ct o o l s a n d
equipment.
oil which must not be drained into waste water
systems.
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The dryeris normallyinstalledafterthe air receiverbut The oil - water separatoris optionaland if fittedwill
if the applicationdemandssuddenhighflow surgesof automaticallycollect and separate any oil. Any oil
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air the dryer may be locatedbeforethe receiver. collectedmustbe disposedof in an approvedmanner.
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lf a dryer is already fitted, or a new dryer is to be
installed,ensure that it is the correctsize to suit the
(O) lsolator
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' w o r k i n g p r e s s u r e a n d a i r d e l i v e r yo f t h e n e w
compressor.See TechnicalData. The dryer may be
S w i t c h e s t h e m a i n s e l e c t r i c a ls u p p l y t o y o u r
compressorON and OFF. lt shouldbe locatednearto
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' eithera refrigerantor desiccantmodel. the compressorwith clear unrestrictedaccess.The
isolatorshouldbe of a type whichcan be padlockedin
Refrigerantdryer the OFF position.
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' The Hydrovanerefrigerantdryer is compact and
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efficient,achievinga pressuredew pointof 2'C. 3.6 3.6 ElectricalGonnections
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Desiccantdryer WARNING!
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cablesare firmlysecuredto the starterterminalsand
The use of galvanisedsteel pipeworkto an approved that they are of the correctcrosssectionalarea.
s t a n d a r d i s r e c o m m e n d e df o r p i p e r u n s t o
E . applications.The pipe should be sized to avoid 3.6.2 Referto starterand circuitdiagramsbefore
excessiveoressuredroo. startingwork.Notecarefullythe instructions relatingto
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=. ,. The air main shouldslopeaway from the compressor
earthing,fuses and size of cable.
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for drainingany condensate.Normally2 degreesis 3.6.3
sufficient. used to
Fusesto BS 88 (e.9.GEC type gG) must be
protectthe compressorstarter.The fuse size
mustbe as specifiedin technicaldata.
L'
l- ,. (K) Drop-legs and
3.6.4 Circuitbreakersare not recommendedsince
t-
t- .d
(L) Condensatedrain valves
they may not fully protectthe startercontactsin an
Fit drop-legsand automaticcondensatedrain valves overloadcondition.
L'
)-., -
to all low pointsin the air-linesystem. Drainvalves 3 . 6 . 5 C i r c u i t b r e a k e r s m a y o n l y b e u s e d i n
should also be fitted close to individualequipment. conjunction
L-
l _ -
with the recommended
Condensatemay containoil and must be disposedof contactyour CompAirHydrovaneDistributor.
fuses.lf in doubt
in an appropriatemanner.An automaticcondensate
L'
t*.-
drainvalveis availablefrom your CompAirHydrovane
distributor.
L.
)-2 (M) Branch pipes
L
lt_-
Branchpipes shouldalwaysbe taken from the top of
the air-main.
L.
Ir- j
Page25
Limited
CompAirHYdrovane
3 lnstallationand Gommissioning
g.7 ElectricalInstallationProcedure
WARNING!
o o o o o o D O O
BEFORE STARTINGWORK, ENSURETHAT THE K2M KlM
FUSESHAVE BEEN REMOVEDFROM
KJM
T TAIN.UIHE
ini orsrRtBUTtoN BoARD. PREcAUTIoNS o o o o o o o o o
Page 26
- UserHandbook
8 SeriesPUAS/PWTS
Installationand Commissioning 3
3.8 GheckDirectionof MotorRotation
WARNING!
CAUTION!
WARNING!
Page 27
CompAirHydrovaneLimited
3 Installation
andCommissioning
3.9 CircuitDiagram(50 Hz)
U)
p 6-lr'i o-
c
o
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el N t r t r f . = ' - <
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Page 28
t.
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!. .-
- UserHandbook
8 SeriesPUAS/PWTS
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L. Page 29
rr
I
GompAirHydrovaneLimited
3 Installation
andCommissioning
3.11 Technical Data
ModelNumber
818 822 830 837 845
MinimumVentilationRequirements
AmbientTemoeratureRanoe sc 0to40 0to40 0to40 0to40 0to40
MinimumRoomVolume M3 35 35 60 90 90
Air lnlet/ Outletarea M2 0.5 0.5 0.6 1.0 1.0
CoolingAir Flow Rate M3/hr 3400 3400 6900 14000 14000
Pipework
Air Connection
Size Rp '1.0 '1.0 1.0 1.5 1.5
Air SupplyNon ReturnValve Rp 1.0 1.0 '1.0 '1.5 1.5
RecommendedAir ReceiverCapacity Litres 500 500 500 500 500
Dryer
Refrigerant(PressureDew Point+2 nC) HRD 220 220 270 310 390
Desiccant(PressureDew Point-40 nC) HDD 30A 35A 40A 704 70A
Filters
GeneralPurpose GP 300 300 350 400 400
Hiqh Efficiency HE 300 300 350 400 400
Dust Removal DR 300 300 350 400 400
OdourRemoval OR 300 300 350 400 400
CASEProducts
DutySelector H F P0 2 HFP 02 H F P0 2 HFP 02 HFP 02
AutomaticTime Controller H F P0 4 HFP 04 H F P0 4 HFP 04 HFP 04
RemoteStoo/StartController H F P0 5 HFP 05 H F P0 5 H F P0 5 H F P0 5
CondensateDrainValve 33958- 33958- 33958- 33958- 33958-
01 01 01 01 01
CompAirHydrovaneServiceKits
2000 Hourservicekit KM 82 KM 82 KM 83 KM 85 KM 86
6000Hourseparator
kit KS 82 KS 82 KS 83 KS 84 KS 84
Topup kit KT 82 KT 82 KT 84 KT 84 KT 84
Note: Allthree servicekitswill be requiredfor a completeoverhaul.
Page30
- UserHandbook
I SeriesPUAS/PWTS
Installationand Commissioning 3
ModelNumber
818 822 830 837 845
Minimumincomingcablesize(copperconductors)
220V50 Hz models mm2 25 25 50
220V 60 Hz models mm2 25 25 50 70 70
380V 50 Hz models mm2 10 10 to 50 50
380V 60 Hz models mm2 10 10 to 25 50
415V50 Hz models mm2 10 10 to 50 50
440V 60 Hz models mm2 10 10 to 25 50
Fusesize (for protectionof supplycables)BS88TypegG
220V 50 Hz models Amps 100 100 125
220V 60 Hz models Amps 80 100 125 160 200
3B0V50 Hz models Amps 63 63 BO 100 125
380V 60 Hz models Amps 50 63 80 100 125
415V50 Hz models Amps 63 63 BO 100 100
440V 60 Hz models Amps 50 63 BO 100 100
(Directdrive)
Drivemotorspecifications
Soeed50 Hz models rpm 1500 1500 1500 1500 1500
Speed60 Hz models rpm 1800 1800 1800 1800 1800
Power KW 18.5 22 30 37 45
hp 25 30 40 50 60
Linecurrent220V50 Hz models Amps 69 79 116
Linecurrent220V 60 Hz models Amps 68 BO 110 135 164
Linecurrent380V50 Hz models Amps 40 46 67.5 85 100
Linecurrent380V60 Hz models Amps 40 46 64 7B 95
Linecurrent415V50 Hz models Amps 36.3 42 61.5 78 91.3
Linecurrent440V60 Hz models Amps 34 43 58 68 85
protection
Enclosure (TEFV)50 Hz models lPs5 tP55 tP55 tP55 tP55
protection
Enclosure (Dripproof)50 Hz models tP23 lP23 tP23 tP23 tP23
Enclosureprotection(TEFV)60 Hz models tP55 lP55 tP55 tP55 tP55
Page 31
CompAirHydrovaneLimited
3 Installation
and Commissioning
ModelNumber
818 822 830 837 845
OperatingPressures
Nominaloperatingpressure(8 bar models) Bar 8.0 8.0 8.0 8.0 8.0
Maximumoperatingpressure(B bar models) Bar 9.0 9.0 9.0 9.0 9.0
Nominaloperatingpressure('10bar models) Bar 10.0 10.0 10.0 10.0 10.0
Maximum operatingpressure ('10barmodels) Bar 10.8 10.8 10.8 10.8 10.8
Recommendedminimumoperatingpressure Bar 6.0 6.0 6.0 6.0 6.0
Minimumpressurevalvesetting Bar 5.5 5.5 5.5 5.5 5.5
Oil chambervent down time to idle pressure Mins 2.0 2.0 2.0 2.0 2.0
(Automode)
Oil chamberventdowntime stoppedin Mins 3.0 3.0 3.0 3.0 3.0
manual"
Oil chambervent down time stoppedin auto* Mins 1.0 1.0 1.0 1.0 1.0
Air Delivery
Freeair delivered@ 8.0 Bar 50 Hz Litres/sec 49.2 59.5 78.0 94.0 114
Freeair delivered@ 8.0 Bar 60 Hz Litres/sec
Freeair delivered@ 10.0Bar 50 Hz Litres/sec
Maximumair dischargetemp aboveambient sc <10 <10 <10 <10 <10
Oil Information
Recommended
oil Type Fluidforce2000
Compressor
totaloilcapacity Litres 13.6 13.6 13.6 14.5 24.0
interval
Oil change/service Hours 2000 2000 2000 2000
2000
Normaloil operatingtemperature ec 80-90 80-90 80-90 B0-90 80-90
Maximumoil temperature ec 100 100 100 100 100
Oil Consumption
Oil carryover(By weight) ppm 5.0 max 5.0max 5.0max 5.0max 1 . 0m a x
This representsan actualconsumptionof;
Litresoer '100hours8 Bar machines Litres 0.12 0.14 0.19 0.23 0.06
Litresper500hoursB Barmachines Litres 0.59 0.70 0.95 1. 1 6 0.28
Litresper 2000 hours8 Bar machines Litres 2.37 2.79 3.80 4.64 1.12
Note: .Afterstoppingthe air-endmustbe allowedto vent down naturally.Speedingup the de-pressurisation
may causeseparatorflooding.
Page32
=-i
- UserHandbook
8 SeriesPUAS/PWTS
L.
l-,-r
L- Installation
and Commissioning 3
l--{
L-
f -.^
t-
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ModelNumber
L. 818 822 830 837 845
[' FilterInformation
l-4
20 20 20 20 20
t- Air filtersoecification
Air filterchange
Microns
Hours 2000 2000 2000 2000 2000
f' Separatorelements Quantity 2 z 3 3 +
f'
f-r
Separatorelementspecification
initialpressure
Separator drop
Microns
Bar
z
0.2
2
0.2
2
0.2
2
0.2
2
0.2
t-
l - {
maximum
Separator pressure
drop Bar '1.0 1.0 1.0 1.0 1.0
t- Separatorelementchange Hours
Microns
6000
10
6000
10
6000
10
6000
10
6000
10
f'
l-r
Oilfilter
O i l f i l t ecr h a n g e Hours 2000 2000 2000 2000 2000
t-
l-r
Recommended PressureControlSettings(8 bar)
Servovalvesetting(Off load) Bar 8.8 8.8 8.8 8.8 B.B
L -
f- -r
Cut out P. unload Bar 8.2 8.2 8.2 8.2 8.2
t-
l-^
ResetP. reload
Cut in P. load
Bar
Bar
7.7
-7A
7.7
7.0
7.7
7.0
7.7
7.0
7.7
7.0
t-
l-{
Recommended PressureControlSettings(10bar)
t-
l-.4
Servovalvesetting(Off load) Bar
Bar
10.8
10.2
10.8
10.2
10.8
10.2
10.8
10.2
10.8
10.2
Cut out P. unload
t-
l- .r ResetP. reload Bar 9.7 9.7 9.7 9.7 9.7
t-
!-.,!
Cut in P. load Bar 7.0 7.0 7.0 7.0 7 n
ControlPanelSettings(Recommended)
t-
I- .A F2l Q1F Transformercircuitbreaker Amps 6.0 6.0 6.0 6.0 o.u
L-
I- ..r
Run-ontime minimumsetting Mins 2 (May be increasedto suit)
t- T1 Transformersecondary
TighteningTorques
Volts 24 and 110 (Fixed)
f"
l_r
Oilfilter
O i l f i l l e pr l u g 75
Handtigh only - See servicing
75 75 75 75
t-
f_ -i O i l d r a i np l u g
N/M
N/M 80 80 80 80 80
1
r-!
- Electricalterminals N/M See labelinsidestarterpanel
t-
l--.-'
NoiseLevel(Measured
Noiselevel(50 Hz)
to Pneuroptest code C.A.G.l)
dBA 7 61 3 7813 80r3 8 41 3 8513
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Noiselevel(60 Hz) dBA
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I
Page33
I
CompAirHydrovaneLimited
3 and Commissioning
Installation
ModelNumber
818 822 830 837 845
SafetyDevices
(thermistor)
re protection
Over-temperatu
warning
Compressor sc 100 100 100 100 100
Compressor (stop)
over-temperature sc 110 110 110 110 110
-
(stoP) ac 160 160 160 160 160
Motorover-temperature
protection
Overpressure (fixedsetting)
Safetyvalve (oil chamber)B bar models Bar 10 10 10 10 10
Safetyvalve (oilchamber)10 bar models Bar 12 12 12 12 12
Sealedunit DONOTADJUST
.60 Hz unitsfittedwith motoroverload.
Note:
Page 34
1-
i.
f--{
- UserHandbook
8 SeriesPUAS/PWTS
t_- GeneralDescription 4
f---r
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Contents
t- Section Page
f' Compressor (PUAS)
assembly 4 . 1. . . . 3 6
f'
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Compressor (watercooled)
assembly 4.2 ...38
t-
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Controls 4 . 3. . . . 4 0
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Page 35
CompAirHydrovaneLimited
4 GeneralDescription
4.1 CompressorAssembly(PUAS)
(seefig 4.1)
The HydrovanePackage Unit comprisesa single
stage, oil sealed, rotary, sliding vane compressor
air-end driven by an electric motor mounted on a
tripod. lt is suppliedwith control panel, starter,and
c o m b i n a t i o no i l c o o l e r / a i ra f t e r c o o l e rw i t h a l l
accessoriespipedin and electricallyconnected.
The compressorair-end (A) is assembledvia bell
housing(B) to the flangeface of drive motor(C). The
rotorof the air-endis directlycoupledto the driveshaft
of the motor. The motor is mounteddirectlyto the
compressortripod (D) with the air-endsupportedby
supportbracket(E).Locatedinsidethe box securedto
the compressortripod are two pressureswitches(F)
which controlthe compressorwhen operatingin the
automaticstop/startmode.
Page 36
L,
t-
- UserHandbook
I SeriesPUASiPWTS
l---{
t- GeneralDescription 4
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Page 37
CompAirHydrovaneLimited
4 GeneralDescription
4.2 CompressorAssembly(PWTS)
Seefig 4.2)
The Hydrovane Package Unit comprises a single
stage, oil sealed, rotary, sliding vane compressor
air-end driven by an electric motor mounted on a
tripod. lt is suppliedwith controlpanel, starter,and
water cooled oil cooler.All accessoriesare piped in
and electricallyconnected.
The compressorair-end (A) is assembledvia bell
housing(B) to the flangeface of drive motor(C). The
rotorof the air-endis directlycoupledto the driveshaft
of the motor. The motor is mounteddirectlyto the
compressortripod (D) with the air-endsupportedby
supportbracket(E).Locatedinsidethe box securedto
the compressortripod are two pressureswitches(F)
which controlthe compressorwhen operatingin the
automaticstoo/startmode.
Page 38
[. - UserHandbook
8 SeriesPUAS/PWTS
L
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Page 39
1-
CompAirHydrovaneLimited
4 GeneralDescription
4.3 Controls(seefig 4.3)
A B D
(A) Mains lamp (white)
Page 40
tL - UserHandbook
8 SeriesPUASiPWTS
l*
L OperatingInstructions 5
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Introduction 5.'1 .42
l_
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Checkingprocedurebeforestarting 5.2.. .42
f-
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Compressorvent down time 5.9 .44
Faultconditions(50 Hz models) 5.10 .44
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Faultconditions 5.11 .45
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Page41
CompAirHydrovaneLimited
5 OperatingInstructions
5.1 Introduction 5.3 Selectoperatingmode
WARNING! The selectorswitchallowstwo operatingmodes:
T H E C O M P R E S S O RS H O U L D O N L Y B E 5.3.1 Position 'll' Automatic Stop/Startmode.
OPERATEDBY AUTHORISEDPERSONSFULLY
TRAINED lN:- THE STARTING,STOPPINGAND This is the normalmodeof operationgivingmaximum
EMERGENCYSTOP PROCEDURES. e f f i c i e n c ya n d e c o n o m y . R e c o m m e n d e df o r
applicationswith fluctuatingair demands.With the
BEFORESTARTINGTHE COMPRESSOR,READ auto mode selectedthe compressorwill load/unload
THE'HEALTHAND SAFETYPRECAUTIONS" a n d s t o p / s t a r ta u t o m a t i c a l l yi n r e s p o n s et o a i r
demand.
5.2 CheckingProcedureBefore lf the motor restartsmore than ten times oer hour or
Starting continuallyrestartswithin thirty secondsof stopping
then K8T run-ontimer setting may be increasedto
5.2.1 Checkoil levelis abovesightglass. reduce frequency.lf after adjustmentthe condition
5.2.2 Check filler and drain plugs are fitted persistsswitchto position'l'ContinuousRun mode.
securely. 5.3.2 Position'l'ContinuousRunmode
5.2.3 Checkfor any signsof oil or waterleaks.
Recommendedwhere excessivestop/startsoccur
5.2.4 Refitall coversand secure. and/orwhen there are rapid changesof pressurein
the air-linesystem.Whenthe continuousrun modeis
5.2.5 Checkair-outletvalve is open and test-valve selected the compressor will continue to operate
is closed. irrespective of air-linepressure.
5.2.6 Checkselectorswitchis in off '0' positionand
that emergencystop buttonis released.
5.2.7 Turn mainselectricity
supplyon.
Page 42
+
L- - UserHandbook
I SeriesPUAS/PWTS
l-,'
L- OperatingInstructions 5
l- r-
L-
I - r
5.4 StartingProcedure 5.5 StartingProcedure
Automaticmode Continuousrun mode
L-
I - r WARNING! 5.5.1 Completethe pre-startcheckingprocedure.
L-
I-r WHENIN AUTOMATICMODETHE COMPRESSOR 5.5.2 Selectswitchposition'l'. The compressoris
L-
l- r
WILL RESTARTWITHOUTWARNING. readyto be startedin the continuousrun mode.
Note: Figuresin bracketsreferto 10 bar machines. 5.5.3 Press reset push-button.Reset lamp will
L-
l \ 5.4.1 Completethe pre-startcheckingprocedure.
extinguishand motorwill start.
L-
J - r 5.4.2 Selectswitchposition'll'.The compressor
The compressorwill now runcontinuously irrespective
is of eitherthe pressurein the air-linesystemor the air
L-
J . r
readyto be startedin the automaticstop/startmode. demand.
5.4.3 Press reset push-button.Reset lamp will On initial start-up,with no pressure in the air-line
L-
l- .r
extinguishand motorwill start. system,the air-linepressurewillriseslowlyand should
On initialstad-up,with no pressurein the air-line not exceed the servo valve setting of 8.6/9.0 bar
L-
l- -r system,the air-linepressurewillriseslowlyand should ( 1 0 . 5 / 1 0 .b8a r ) .
L-
J - r
not exceed the high pressuresetting of 8.218.4bar Once the air-line
(10.2110.4bar).
system is fully chargedthe air-line
pressurewillvarywithfluctuations in air demand.lf a
L.
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Once the systemis fullychargedthe air-linepressure pressure
normally
gauge
read
is
between
fittedin
8.0
the
and
air-line
8.8
systemit should
bar (10.0and 10.8
will vary with fluctuationsin the air demand. lf a
L-
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pressuregaugeis fittedin the air-linesystemit should bar).
normallyreadbetween6.0 and 8.4 bar (6.0and 10.4
L-
l_ ..
bar).
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switch setting ol 8.218.4bar (10.2/10.4bar) the
L'
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automaticstoppingsequencebegins,the run-ontimer
KBT starts and the compressorair-end pressure
L
t-.
- beginsto vent.lf thereis no demandfor air duringthe
run-ontime(typically 2 mins)the compressor willstop.
L' J - r
The compressorwill remainstoppeduntilthere is a
d e m a n d f o r a i r w h i c h a l l o w s t h e a i r - l i n es y s t e m
L' l - r
pressure to fall to pressure switch PS2 setting,
typically6.0 bar. As soon as the pressurefallsto 6.0
L' l - j
bar the compressorrestartsand rechargesthe air-line
t- system.
Page 43
CompAirHydrovaneLimited
5 OperatingInstructions
5.6 Changeoperatingmode 5.10 FaultConditions(50Hz models)
. T o s e l e c t c o n t i n u o u sm o d e w h e n r u n n i n g i n There may be a faultwith the compressorif:
automatic: selectswitchposition'l'.
a) The compressorhas stopped.
lf running,the compressor willnotstop.However,
if the compressorhas stoppedin the auto mode, b) The emergencystop button has not been
it will immediatelyrestart. operated.
Page 44
1,,
L-
- UserHandbook
8 SeriesPUASiPWTS
L! Operatinglnstructions 5
I -r-
L-
I r -
5.11 FaultConditions(60Hz models)
These models are fitted with a motor overloadand
l_-
i-. - comoressorthermistor.LED's are not fitted to the
thermistorcontrolboard.
t
I ' r l - Theremaybe a faultwiththecompressor
if:
I
"l a) hasstopped.
Thecompressor
i
i- rt b) The emergencystop buttonhas not been
I _-- operated.
I \ 1
c) Resetlampis illuminated.
l_-
i.'-
i* ^,
:Tl:'
STOP THE COMPRESSORAND ISOLATEFROM
I rHE MAINSELEcTRTcAL
supply. LocK THE
-- ., ISOLATORIN THE OFF POSITION.FIT A SAFETY
I N o r c E To rH E rso L A T o RA D VTsTNG
THAT
; : . ,- woRK ts BETNG C A R R T EO DU TO N T H E
CoMPRESSoR. Figure5.1- ThermistorBoardLocation.
t
I -
.l
. Opencontrol
paneldoor.
L
f- I . Insoect motor overload. lf motor overload has
L
)- I
tripped,a motorfaulthas occurred.Investigate
rectifybeforeresetting.
and
L
t* J
. l f m o t o r o v e r l o a d h a s n o t t r i p p e d ,e i t h e r a
L .I
l-
compressor over-temperaturefault, or a mains
supplylailurehas occurred.Investigateand rectify
L-
l- .t
beforeresetting.
.- Close
/
paneldoorandlockin position.
control
f.
l- .' . Removesafetynotice.Referto 5.4.
L'
t- .,
L-
l * , r
L-
t. .l
L. l--.r
L_ L-- .l
L- a- ,.
t
l._,1
t-
l'-.1
L-
f;'
1r-.j
L.
tr --
E-=
III
It Page 45
rtl - !
CompAirHydrovaneLimited
5 OperatingInstructions
Page 46
I--
t
,.1
- UserHandbook
8 SeriesPUAS/PWTS
l-. - t
t OperatingParameters 6
l- - l
t
t -
t
t -
t
t- _ l
t
l -
L
t,
t
f- Chapter6
L
f- Contents
L{
f,
Section Page
L
a_ AmbientTemoerature. 6.1 .48
L
l-
Operating Temperatures 6.2 .48
L
l-
High OperatingTemperatures 6.3 .48
L
f- 5
Oil Life Of FluidForce2000 6.4 .48
t
f-
Oil Level 6.5 .48
L
f-
t
f
t
l_ .rl
t
f, .i
L .-.:
J-
t
t- . l
Page 47
CompAir Hydrovane Limited
6 OperatingParameters
6.1 AmbientTemperature 6.4 Oil Life of FluidForce2000
The compressoris designedto operate within a
temperaturerangeof 0'C and 40"C. SumpOil MaximumOil
Temperature ChangePeriod
lf the ambienttemperaturefrequentlyfalls below0'C (DegreesCentigrade) (HoursRun)
then consultyour CompAirHydrovaneDistributor.
Upto 95 2000
6.2 OperatingTemperatures 9 5- 1 0 0 1500
6 . 2 . 1 Y o u r c o m p r e s s o ri s d e s i g n e d t o g i v e 1 0 0- 1 0 5 1000
optimum performanceand trouble free service life
when the bulk oil temperatureis betweenB0'C and 105-110 500
90'c. O v e r11 0 No guaranteedservicelife
The temperaturecan be measuredby placing a
thermometerinto the thermometerpocket locatedin 6.5 Oil Level
t h eo i l f i l l ep
r lug.
Check oil level when compressorhas stopped.Oil
N o t e : T h e c o m p r e s s o r t e m p e r a t u r eg a u g e mustbe visiblein the oil-levelsight-glass.
lf oil is not
indicatesairtemperature in the separatormanifoldand visible,the compressormust be topped-up.See
shouldnot be usedas a measureof oiltemoerature. servicing.
6.2.2 Conditions whichpreventthe
or applications
compressortemperaturefrom stabilisingbetween 6.6 NoiseLevel
these parametersshouldbe avoided.
Noise emissionsare below 85 dBA. However the
lf yourcompressorf requentlyoperatesin highambient compressorshouldbe positionedwherenoisewill not
temperaturesthen the oil lifewill be reduced. be a problem.We recommendear protectionis used,
when nearthe compressorfor extendedperiods.
6.3 High OperatingTemperatures
Noise
95 - 100'C Level
818 822 830 837 845
S o m e o f t h e r e a s o n s f o r h i g h c o m p r e s s o ro i l
temperaturesare: dBA 76 7B 80 84 85
Caution !
lf compressortemperaturegauge readsgreaterthan
95oCinvestigatecause immediately.
Page 48
!-- - UserHandbook
t-
l.-,.t'
8 SeriesPUAS/PWTS
L- Adjustments 7
l- r-
t-
I .r-
L-
I . r
t-
J - r
t-
l..r
L-
l r
L- Chapter7
l-r
L_
J-r
Gontents
t-
J.- r
Section Page
t-
J- .,
lntroduction 7.1 .50
L-
l- \'
Servovalve .50
Pressure
t-
I- .t
switches
Highpressure
switchPS'1
.52
.52
t-
J-\ Lowpressure
switchPS2 . . .52
t-
l _ . i
Controltimers .54
t-
J - . t
L-
J - , r
L-
J - , r
t-
]
t-
f
t-
l-.1
t-
a , l
t-
f- rl
t-
l- rr
f-
J . q
Page 49
CompAir Hydrovane Limited
7 Adjustments
. Checkcompressorpressuregaugereading:
7.1 Introduction
WARNING! lf reading too low, turn grub-screw(E)
clockwiseto increasepressure.
READ HEALTH AND SAFETY PRECAUTIONS
BEFOREMAKING ANY ADJUSTMENTS. Note: Must not exceed9.0 bar (10.8bar).
Page 50
- UserHandbook
8 SeriesPUAS/PWTS
L-
TL-.-
Adjustments 7
L-
f-.-'
L-
f-..
L-
J*.r
L-
l--
L-
f- .e
L-
I r r
L-
J-r
L- ,/. N.i
L e , V+
L- l/i
L a l
L_
L r l
L_
1- r(
L-
I .^r
L'
1- ^{
L"
l- -l
L-
f_..{
L-
f-.(
L-
f * . (
L-
J ' t
L-
f . l
L-
l-.. 1
L_
f - {
818/822
t-
a .{
t-
l. ,(
1-
l. .t
L_
a-. r
L-
l-... r
830t837t845
L
}*.
L-
lt"_-.
L
lL--. .
Figure7.1- ServoValve
L_
> . r
Page 51
CompAir Hydrovane Limited
7 Adjustments
7.3 Pressureswitches 7.5 Low pressureswitch PS 2
(seeFig 7.2)
Introduction
switchPS2 (E) functions in automatic
The compressor is fittedwithtwo pressureswitches ^tlY,ll:,tt're
modeonly.Twoadjusting
stop/start screwsallowany
pre-setatthefactory. Therecommended ran----'-'-:-;::
requirement
individual to be satisfied'
of highpressureswitchps 1 mustnorbe ::;""t]:3
and the differentialsettingkeptto a minimum.The Operatingpressure(range)either:
rangesettingof low pressureswitchPS 2 may be
adjustedto suit individualrequirements with the a) Restartsthecompressorafterstoppinginthe
keptto a minimum.
differential automode.
Pressure sensing b) Cancelsthe stoppingsequenceif the air-line
pressurefallsto settingduringthe operating
The Package Unit is suppliedwith the pressure time of the vent down timer K7T.
sensingfeedto the pressureswitcheslocatedafterthe
minimumpressurevalve(M.P.V.).lt is recommended 7.5.1 Setting procedure
that a non-returnvalve is not fitted in the air-line
systemadjacentto the compressoroutlet.However,if Note: Before undertakingthis procedure,ensure
a non-returnvalve is required,then the pressure that:
sensingfeed must be relocatedafter the non-return (a) An accuratepressuregaugeis fittedintothe
valve. air-linesysteme.g.in the air receiver.
The switchesare locatedon the compressortripod
and (b) T h e a i r - l i n es y s t e m d o w n s t r e a mo f t h e
may be accessedby removingthe protectivecover. pressuregaugeis closed.
Page 52
!='. - UserHandbook
H
L- Adjustments
8 SeriesPUAS/PWTS
7
l_.ri
L-
I - r .
L-
l - r .
L-
l-. r-
L-
l - r
L-
I
L-
J- r
L-
f-.
L-
l - '
L-
f- ..
L-
f-.
L'
I_
L "
t- ..
L_
l- .,
Figure7.2- PressureSwitches
Page53
CompAirHydrovaneLimited
7 Adjustments
. Checkdifferential (diff)(H) is set to minimum(0.5 7.6 Controltimers(seeFig 7.3)
bar) on both switches.
rs are locatedin the starterpanel.
The controltime
. Closeair outletvalveto air-linesvstem.
Page 54
L. - UserHandbook
8 SeriesPUAS/PWTS
r-,-.
t- Adjustments 7
J-r'.
1-
r-..,
t-
l-.-.
t-
l -.'
t-
l - .
o o o o
KJ[/
o o o o o
K2t\/ K1l'/
t-
I .
o o o o o o o o o
t*
f - .
u2w2 o
t-
l .
o o o
t-.
l "
t-
f .
t-
l-. ,
t-
f l
t-
l-. r 60 Hz 8371845STARTER
t-
f-. I
t*
f-. .r
t*
J- "r
t-
f - {
t-
f- ,r
L_
l-. {
t-
l- ,.t
t-
f . {
tr - --, {
t
t- ,{
t
r_. {
L
r-i
L
]-{
L.
lr-{
50 Hz 8181822STARTER
Figure7.3- ControlTimers
Page55
CompAirHydrovaneLimited
7 Adjustments
7.6.3 Run-ontimer K8T(C)
Startstimingthe instantK7Ttimesout. DuringKBT
timingperiodthe air-endpressurewillfallto 2.0 bar
At the end of the timingperiodthe
and stabilise.
compressor willstopandtheair-endpressure willfall
IOZerO.
Factorysetting= 2 minsrecommended
minimum
Range= 0 to 10 mins
Caution !
Page 56
- UserHandbook
8 SeriesPUAS/PWTS
Servicing I
Chapter8
Contents
Section Page
Introduction .....8.1 ..58
RoutineServiceSchedule 8.2 . . ..58
CheckingOperationof the Compressor 8.3 . . . 6 0
OilTop-upProcedure 8.4 . . . .62
50 HourMeekly ServiceProcedure 8.5 . . . 6 3
2000 Hour (Yearly)ServiceProcedure 8.6 . 6 4
Page 57
CompAirHydrovaneLimited
I Servicing
8.1 Introduction
WARNING!
8.2 RoutineServiceSchedule
The work listed below must be carried-outat the
which must be regardedas a
indicatedrunning-hours
maximum.In dusty, hot or humid conditionsmore
frequentservicingmay be necessary.
( 2 ) E n s u r e t h a t a l l e l e c t r i c a lc o n n e c t i o n sa r e
tightenedto recommendedtorque settings.Pay
carefulattentionto the mainspowerconnections
includingcablesconnectedto the contactorsand
incomingterminals.
Thissectionshowsthe minimumservicerequirements
f o r y o u r c o m p r e s s o r .T o e n s u r e t h a t t h e f u l l
compressormaintenanceprogrammeis carriedout,
Hydrovane recommendthat your compressoris
r e g u l a r l ys e r v i c e d b y a n a u t h o r i s e dH y d r o v a n e
distributor.
Page 58
L
F , l
- UserHandbook
L.
I - l
8 SeriesPUAS/PWTS
L- Servicing I
I-.- |
f-
I.-- | CompressorServiceSchedule
l_"
I-.-|
Installation Every 50 1000 2000 6000
f-
- .'l
Ensure- Beforestart-up
Day Hours Hours Hours(1) Hours
L*
r "'l Suitableoosition
l_*
r .'l
Adequateventilation
Ambienttemperature
1_-
I .-l Sufficientaccess
L_
I I
Clearof airbornecontaminants
Torqueelectricalconnections(2)
L-
l l Correctoil level
l_-
l l
Correctdriverotation
Check- Changeif necessary
l-"
I . Air leaks
L-
I l
Oil leaks
Air filter
L"
l _ . Oiltemperature
L*
l _ l
Drivemedia
Contactors
L"
l - l Solenoidvalves
L*
f_ .l
oil pipes
Perishable
L-'
!_.{
Clean
Air / Oil radiatorexternal
t"
! - {
Electricmotorexternal
t*
F . {
Condensatebowl / Solenoids
Change - lf fitted
t-
E.r
Fluidforce2000oil
t'
t - {
Oilfilter
Air filter
l--- Minimumpressurevalveseals
Unloadervalveseals
Vacuumvalve seals
Seoaratorelements
Thermalmotor
Perishable
oil pipes
Test / Reset
Servo valve
Unloadervalve
Vacuumvalve
Minimumpressurevalve
Air delivery
Poweron load
Poweroff load
Page 59
CompAir Hydrovane Limited
I Servicing
8.3 CheckingOperationof the
Compressor
Note: You are remindedthat service work must
only be carried-outby competentpersons.Refer to
healthand safetyprecautionsbeforestartingwork.
8.3.1 Check the compressor operating
temperature
Poura smallamountof oilintothethermometer pocket
of the oil fillerplug.Screwa temperature gaugeinto
t h e f i l l e r p l u g o r p l a c e a t h e r m o m e t e ri n t o t h e
thermometerpocket.
Checktheair-linesystempressureby usingtheair-line
pressuregauge.
Condition 8 Bar 1 0B a r
When compressoris stopped 0 - 9.0bar 0 - 1 0 . 0b a r
Normalworkingpressure(handmode) 8 . 0- 9 . 0 b a r 1 0 . 0- 1 0 . 8b a r
Stop compressorand see fault finding if > 9.0 bar > 1 0 . 8b a r
Normalworkingpressure(automode) 6 . 0- 8 . 4 b a r 6 . 0- 1 0 . 4b a r
Page 60
- UserHandbook
I SerlesPUAS/PWTS
Servicing 8
8.3.3 Check pressure (2) compressor air-end
To checkthe air-endpressure,usethe pressuregauge
locatedin the air-end.
. t
Page 61
CompAir Hydrovane Limited
I Servicing
8.4 Oil Top-upProcedure
C D E
WARNTNG
! a a
STOP THE COMPRESSORAND ISOLATEFROM
M A I N S E L E C T R I C A LS U P P L Y . L O C K T H E
ISOLATORIN THE OFF POSITION.FIT A SAFETY
N O T I C E T O T H E I S O L A T O R A D V I S I N GT H A T
W O R K I S B E I N G C A R R I E DO U T O N T H E
COMPRESSOR.
WARNING!
DO NOT PROCEEDUNTILGAUGEREADSZERO!
. Carefullyunscrewcompressor
fillerplug(A).
WARN|NG
! a
IF ANY AIR OR OIL ESCAPESBEFOREPLUG IS
FULLY REMOVEDTHEN STOP! COMPRESSOR
AIR.ENDIS PRESSURISED!
DO NOTREMOVEPLUGUNTILALL PRESSUREIS
LOST. DO NOT ALLOW ANY COMPRESSEDAIR
JETS TO MAKE CONTACTWITH YOUR BODY.
. Removefillerplug(A). Retainbondedseal (B).
. Top-upto overflowwith an approvedoil (e.9.Fluid
Force2000).
. Examinebonded
seal,if notdamagedrefittooilfiller Figure8.1- FillerPlugLocation
plug.
. Refitsealand fillerplug,tightento 75Nm.
. Removesafetynotices.
Page 62
- UserHandbook
8 SeriesPUAS/PWTS
Servicing I
8.5 50 Hour (Weekly)Service 8.5.2 Cleancombinationoilcooler/
Procedure aftercooler
In additionto the dailychecksthe followingprocedures The combination cooleris locatedvertically. The inside
should be carried out every 50 hours or weekly face of the coolermust be cleaned and is accessed by
(whichever is the sooner). removing the cover plates fittedto the coolerduct.
. Removecoverplatesfrom coolerduct.
WARNTNG!
a a o . Carefullyblowcompressedair throughcooler,from
S T O P C O M P R E S S O RA N D I S O L A T E F R O M
M A I N S E L E C T R I C A LS U P P L Y . L O C K T H E insideto out.
ISOLATORIN THE OFF POSITION.FIT A SAFETY . Use a vacuum cleanerto removeany dust or dirt
NOTICE TO THE ISOLATOR ADVISING THAT remainingon the combination
cooler.
WORK IS BEING CARRIED OUT ON THE
COMPRESSOR. . Vacuumdust or dirt from intakeand outletgrills.
Page 63
CompAirHydrovaneLimited
I Servicing
8.6 2000Hour(Yearly)Service
Procedure
In additionto dailyand 50 hourservice,the following
proceduresshouldbe carriedout every2000 hoursor
yearly(whicheveris the sooner).
Page 64
- UserHandbook
8 SeriesPUAS/PWTS
rl
Servicing 8
' t
Page 65
CompAirHydrovaneLimited
I Servicing
8.6.5 Electricalchecks 8.6.6 Cleanand checkelectricmotors
I A
WARNING A WARNING!
Page 66
\
- UserHandbook
I SeriesPUAS/PWTS
I
Servicing I
I
8.6.7 Checkoperationof Over-temperature
a ControlUnit
WARNING
I A A
THE FOLLOWINGFAULT FINDINGPROCEDURE
SHOULDBE CARRIEDOUT BY QUALIFIEDAND
COMPETENTPERSONSONLY.
. Openthe starterpaneldoor.
CAUTION:
lf the abovesequenceis not achievedthena faultmay
have occurredwhich has damaged the OTC. The
compressormustnot be operateduntila replacement
OTC has been fitted and the above procedure
repeated.
all panels.
Reinstate
a A t
/ \ l Jt - r - - .
i i \ I tl aA)
lt
I I
nt\ytlln-=
?T-1 lL il ---
LJ ll
6r--r ' l- l h 'H l
ll n l"j!r!-o l
I
(\ _, /) fU/Ul U7 Ul 7 v t j l j l I
I I
- l - l l - l
-...=-15
td bl
j ^l t _ |
g F le.-ol
41 6 40 49 48 39 38
Figure8.3- Over-temperature
ControlUnit
Page 67
CompAirHydrovaneLimited
I Servicing
left blank.
This page is intentionally
Page 68
- UserHandbook
8 SeriesPUAS/PWTS
FaultFinding 9
Chapter9
Contents
Section Page
Introduction 9.1 .70
Faults 9.2 .71
Page 69
CompAirHydrovaneLimited
I FaultFinding
9.1 lntroduction
WARNING!
H I G HP R E S S U R E Pressurerisesuntil
safetyvalvelifts.
HIGHTEMPERATURE Oiltemperaturehigher
t h a n1 0 0 " C .
Page 70
- UserHandbook
8 SeriesPUAS/PWTS
FaultFinding I
{
9.2 Faults
:
Symptom Action
!
9.2.1 High pressure
-
.l
Pressure risesandsafetyvalveblows. Firstensurethat safetyvalve liftsat the
r- Airloilvapourdischargedfromintake.Rapid correctpressure.
pressure losson stoppingcompressor. a) lf pressurerisesquickly,check:
r' Air/oilvapourdischargedfromintakeon Servovalve setting(too high).
stopping compressor. Servovalve may be stickingclosed.
, Hightemperature andhighpowerabsorption. Servofiltermay be blocked.
Unloadervalvesmay be stuckopen.
b) lf pressurerisesslowly,check:
Possibleleak from unloadervalve seat.
Unloadervalve 'O' ring(s)may be
leaking.
Vacuumvalve adjusterseal leaking(off
load).
Vacuumvalve Airzetseal leaking(off
load).
9.2.2 Hightemperature
Compressor cutsout. Verifycompressoroil temperature.
Compressor seizing. a) Environmental check:
Lowairoutput. Insufficientventilation.
Highpowerabsorption. Excessivelydusty conditions.
Compressor temperature
displayreading Air intakenear heat source.
o v e r1 0 0 " C . b) Compressorcheck:
Low oil level.
Wrongtype/gradeof oil.
Blockedoilcooler.
Blockedoilfilter.
Thermalbypassvalvestuck in closed
position.
Incorrectstatorend clearance.
Statorend clearanceshims leaking.
Oil reliefvalve(s)stickingopen.
Internaloil passagesblocked.
9.2.3 Low air-output
Malfunction
of air-tools/equipment. Checkcompressorair outputustngtest
Rapidpressure lossin airsystem. nozzle.
Pressure
gaugereadinglessthannormal. Checkfor excessiveair demand.
Rapidpressure lossfromcompressoron Checkpressuregaugefor accuracy.
stopping. a) lf pressuregauge readingnormal:
Restriction in airlinee.g.valvesclosed.
Minimumpressurevalve stuckclosed.
b) lf pressuregauge readinglessthan
normal:
Air intakefilterblockage.
Unloadervalve may be stuckclosed.
Servovalvesetting(too low).
Servovalve may be stuckopen.
Separatorblockage.
Leakagein air line
L e a k i n g ' Or'i n g ( si)n m i n i m u m
pressurevalve.
Safetyvalvedefective.
Page71
CompAirHydrovaneLimited
9 FaultFinding
SYmPtom Action
9.2.4 Oildischarge
Heavycompressor oilconsumption. Verifythat oil dischargeexceeds
Lowairoutput. compressorspecification.
highpowerabsorPtion.
Possible a) Generalcheck:
highoiltemperature.
Possible Wrongtype/gradeof oil.
Incorrectstoppingprocedure.
Excessiveair demand.
Compressornot sited level.
b) Compressorcheck
Separatorelementf ractured.
Separatorelementincorrectlylocated.
Filterson oil returnrestrictorsblocked.
Page72