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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.

THIS HANDBOOK CONTAINS IMPORTANTSAFETY INFORMATION.PLEASE READ IT CAREFULLY


BEFOREYOU ATTEMPTTO POSITION,INSTALL,OPERATEOR SERVICETHE COMPRESSOR.
IMPORTANT!

BEFOREINITIALSTAHT.UPENSURETHAT THE COMPRESSOROIL CHAMBERIS FILLEDTO


THE
! CORRECTLEVELWITH A COMPAIRHYDROVANEAPPROVEDOIL.
To ensure long term satisfactionwith your CompAirHydrovanecompressorit is essentialthat you follow
the
instructions
givenin this handbook.The handbooktellsyou:-
' How to position,installand operateyour compressorso that it workssafelyand economically.
' How to carry-outbasicserviceproceduresusingCompAirHydrovaneapprovedpartsand oil.
' How to checkthat the compressoris workingwithinthe recommendedoperatingparameters.

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.

PUAS = Packageunit completewith Aftercoolerand starter'

PWTS = tripodand starter.


Packageunit completewith watercooler,

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

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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

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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

BeforeWorkingon the Compressor 1.4 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.

Read and fully understandthe contentscontainedin


the userhandbook.
Been madeawareof the locationof inherentdangers,
such as intakefans and electricalsupplies.
1 . 2 . 7 E n s u r e t h a t t h e u s e r H a n d b o o ki s n o t
permanentlyremovedfrom the compressor.
1.2.8 Check that there are no signs of damage
and/oroil leaksf romthe air-end,coolerand associated
pipework.
1.2.9 After completingwork, tools and foreign
mattershouldbe removedfrom the compressorand
its surrounding
area.
1.2.1O Inthe unlikelyeventof a compressorfire,dry
powderor carbondioxidefire extinguishers
shouldbe
used.Neveruse water.

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L - Healthand SafetyPrecautions 1
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1.3 WhenOperatingthe Compressor 1.4 BeforeWorkingon Compressor
I
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.

Aspiration - lf thereis any suspicionof aspirationinto


the lungs (for example during vomiting)admit to
hospitalimmediately.

Inhalation - Removefrom exposureinto fresh air. lf


necessarygive artificialrespirationor oxygen.Seek
medicaladvice.
Pressure injection - Obtain immediate medical
attention,even if injuryappearsminor.
* See Cautionary Notice SHW 397 'Effects of
MineralOil on the Skin'and MS(B)5'Skin Cancer
Caused by Oil' published by the Healthand Safety
Executive.

Spillage - Soak up with absorbentclay.

Waste Disposal - Oil,condensate, filterelementsetc.


should be disoosed of in accordancewith local
regulations.Do not allow oil to contaminatewater
supplies.

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.
t
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
I

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

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CompAirHydrovaneLimited

1 Healthand SafetyPrecautions

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Introduction 2.1 . . . 1 4

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Weightsand dimensions(PUAS). . . 2.2 . . 1 4

Liftingand transportation 2.3 . . 1 4


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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.

2.2 Weightsand dimensions;


(Seefigure2.1)
PUASCompressors
Ref. Feature Unit 818 822 830 837 845
Weight Kg 489 500 564 635 686
A Heightto C/L mm 560 560 560 619 619
11 3 5 't185 11 8 5
B Foot to foot mm 985 985
c Length(overall) mm 1790 1790 1940 1960 1995
D Footto discharge mm 548 548 540 485 524
E Width of feet mm 735 735 754 812 812
F Height(overall) mm 845 845 840 998 998
G Width (overall) mm 850 850 867 940 940
H To openstarter mm 400 400 400 400 400
J
I
To removeair filter mm 175 175 175 175 175
K To removeoilfilter mm 40 40 40
L Min.clearancefor mm 1000 1000 1000 1000 1000
cooler

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and Handling 2
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Figure2.1- Dimensions
(PUAS)

Page15
GompAirHydrovaneLimited

2 and Handling
Transportation
2.4 Weightsand dimensions;
(Seefigure2.2)
WaterCooledComPressors

Ref. Feature Unit 818 822 830 837 | 845


O i l C o oer Models
Weight kg
A Heightto C/L mm 560 560 578
B Foot to foot mm 984 984 11 3 5 11 8 4
'1360 1360 1485 1830
c Length(overall) mm
D Widthof feet mm 728 728 748
E Height(overall) mm 842 842 924

F Width (overall) mm 941 941 953


G To ooenstarter mm 354 354 400 354
H To removeair filter mm 175 175 175 175

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

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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

Figure2.3- Liftingand Transportation

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andCommissioning 3
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{ Chapter3
I Contents
a Section Page

! lntroduction .....3.1 .20

.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
.a

CircuitDiagram(60 Hz) . . . 3.10 .29


,{
TechnicalData . 3.11 .30
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CompAirHydrovaneLimited

3 andGommissioning
Installation
3.1 Introduction
WARNING!

BEFOREINSTALLINGTHE COMPRESSOR MAKE


SURE THAT ALL PERSONSCONCERNED HAVE
'THE HEALTH AND
READ AND UNDERSTAND
SAFETY PRECAUTIONS"IN CHAPTER1 OF THIS
HANDBOOK.

3.1.1 The compressoris designedfor use over a


wide range of applications'To ensure long life,
reliabilityand maximumefficiencyit is essentialthat
your compressoris installedto these guidelines.
g.1.2 The compressor must only be used for
compressingcleandry air drawn in from atmosphere'
Do not use for compressingany othergas.
3.1.3 ContactyourCompAirHydrovaneDistributor
for advice on the range of CompressedAir System
Equipment(CASE)productsavailable.
3.1.4 To ensure that your compressoroperates
correctly,the installer must check that pressure
switchesare set to suityour air systemrequirements'

3.2 PositioningYour ComPressor


BasicRequirements
g.2.'l Positionthe compressoron a firm level
surfaceof sufficientload-bearingcapacity'Normally,
it is not necessaryto boltthe unit down.
3.2.2 The compressor must be level, in both
planes,withinfive degreesof horizontal.

3.2.3 Positionthe compressorallowingsufficient


accessfor all routineserviceproceduresand for easy
viewing of the oil level sight glass, pressureand
temperaturegauges.
3.2.4 Positionthe compressorin a dry, dust{ree
n o n - e x p l o s i v el o c a t i o n ,w i t h a d e q u a t e w e a t h e r
protection.
3.2.5 The compressorair intakemustbe free from
dirt, coarse solids,abrasiveparticles,steam, liquids
and gaseoustmPurities.
3.2.6 Precautionsshould be taken to prevent
adverseweather conditionssuch as ice, interfering
with the operationof the compressor.Pay particular
attentionto pressurereliefdevices,intakefiltersand
condensatedrainvalves.

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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
l_ t
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compressor.Do not allowhot airto re-circulate
compressorintake.
intothe minimumclearancerequiredis shownon thediagram.

La
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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.

4 d. The weatheris abnormally


hot.
e. The roomis wellinsulated.

3.3.6 lf air ducting is fitted it must not cover or


restrictin any way the warm air outlet of the
compressor.The total resistanceof the comolete
system must not exceed 5mm w.g. (0.2in.water
gauge). lf the resistanceis expectedor found to be
greaterthan Smmw.g. thena fan willbe required.

{
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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

Page22
f.
f'
l-{
- UserHandbook
8 SeriesPUASiPWTS

L. Installationand Commissioning 3
f-J

t-
l-1
3.5 Air-lineSystem,Installation (D) Air discharge pipe
Guidelines
t-
l-- 4 WARNING!
A flexibleair pressurehose to an approvedstandard
may be used to connectthe compressoroutletvalve
L.
f-{ CONNECTION TO, OR INSTALLATION OF, AN
to the air-linesystem.
(E) Non-returnvalve
L.
l- -l
AIR.LINESYSTEMMUSTONLYBE CARRIED.OUT
BY COMPETENTAND AUTHORISEDPERSONS
A non-returnvalve(checkvalve)may be fittedintothe
L-
l - 4
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.
t-
l--.,1
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
L'
l * l
PLACE.
fittedmust be repositionedafterthe non returnvalve.
(F) Air receiver
t-
f - {
3.5.1 Ensurethat all equipmentand pipeworkfitted
to yourair-linesystem,are sizedcorrectlyand ratedto Recommended whenthereis a f luctuatingairdemand.
t-
l-r
acceptthe maximumworkingpressureand air delivery A receiveris essentialto ensure optimumoperating
of the compressor. efficiencywhen operatingin the automaticstop/start
t-
f-{ 3 . 5 . 2 E a c h a p p l i c a t i o ni s u n i q u e a n d t h e
mode.

t-
l_r
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.
L-
l _ l
be pleasedto advise.
lf the air demand is constantand an air receivernot
t-
l_ -r
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.
t-
]_ .t (A) Hydrovane compressor The air receivershouldbe draineddailyto removeany
L
f_r
. Ensure that the air delivery of the compressoris
condensate containedwithinit.
sufficientto fully satisfy the maximum air demand (G)
L '
J- ,r
allowingfor pressuredrops throughthe system and
Coalescingfilters

futureexpansion.The compressormustbe positioned May be necessaryif dryer is positionedbeforethe air


L
)_/
- as statedin Section3.2. receiveror if a desiccantdryeris used.Primarilyused
to removeand dischargeliquids.The filterswill also
L'
l- .1
The compressor'saftercoolerwill condenseand allow trapand collectsolids.
the removalof most of the watervapourpresentdue
L-
l- -i
t o t h e h u m i d i t yo f t h e a i r e n t e r i n gt h r o u g h t h e
compressorintake.Thiscondensatemustbe removed
t-
fl- -/
before the air is passed into the air-linesystem. lf
installedwith an air receiver,water vapour again
tr - -- condenses and must be removed. This may be
adequatefor many industrialapplications.However,
t-
t'-r
whereclean,dry air is essentiala dryerwillneedto be
installed.
t-
l-- {
(B) Air outlet valve

t-
l-_)
Opens and closes the air deliveryinto the air-line
system. Always close the valve to isolatethe
compressorfrom air-linepressurefor servicing.
E .
L'
!=:
(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
!-
Limited
CompAirHYdrovane
L
3 lnstallationand Commissioning

Figure3.3- TYPicalInstallation

Page 24
L
f_'
L---r
- UserHandbook
8 SeriesPUAS/PWTS

L' Installation
and Commissioning 3
f--J

L'
f-- J
(H) Dryer (N) Oil-water separator

L'
l-. J
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
L'
)_, J
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.
L-
) _ J
The dryeris normallyinstalledafterthe air receiverbut The oil - water separatoris optionaland if fittedwill
if the applicationdemandssuddenhighflow surgesof automaticallycollect and separate any oil. Any oil
L-
L .
air the dryer may be locatedbeforethe receiver. collectedmustbe disposedof in an approvedmanner.

L'
l- ./
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

L
L_r
' 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
L
]_ ,/
' eithera refrigerantor desiccantmodel. the compressorwith clear unrestrictedaccess.The
isolatorshouldbe of a type whichcan be padlockedin
Refrigerantdryer the OFF position.
L
)_)
' The Hydrovanerefrigerantdryer is compact and
L -
l.- .r
efficient,achievinga pressuredew pointof 2'C. 3.6 3.6 ElectricalGonnections

L'
lL .i
Desiccantdryer WARNING!

For specialapplicationswhere a pressuredew point CONNECTIONTO, OR INSTALLATIONOF, AN


L
)--;
. of -40"C is needed. ELECTRICALPOWER SUPPLY MUST ONLY BE
CARRIEDOUT BY AUTHORISEDAND QUALIFIED
L
)__ ,
. T o a l l o w f o r s e r v i c i f l g ,a b y - p a s s r o u t e i s
recommended.
ELECTRICIANS. THEY MUST FULLY
UNDERSTAND AND ADOPTCORRECTAND SAFE
L'
Il-. r (l) Solid pafticle filter
WORKING PRACTICES. ALL ASPECTS OF THE
INSTALLATIONMUST MEET THE WIRING
L.
f_. -
May be necessaryin specialapplicationsto remove REGULATIONSPRESENTLYIN PLACE.
and collecttracesof dust or dirt.
L
|_. /
' 3.5.4 Installing a new pipework system
3.6.1
s u p p l y e
Before connectingto the mains electrical
n s u r e t h a t t h e s y s t e m c a n s u s t a i nt h e
L-
J-. .r (J) Pipework
additionalelectricalload. To ensure reliablelow
resistance joints,makesurethatyourincomingsupply

L'
l a
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
L'
=. ,. The air main shouldslopeaway from the compressor
earthing,fuses and size of cable.

L.
t- .i
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

SHOULD BE TAKEN TO PREVENTTHEM BEING u2\t2 o


nEFTTTTOUNTIL THE INSTALLATION IS
o o o
UlV] W]
COMPLETE.

3.7.1 The startermust be connectedto the mains


electricalsupply via a lockable,switchedand fused
isolator.
g.7.2 The isolatorshouldbe positionednearto the
compressorwith clearunrestrictedaccess'
3.7.3 Firmly secure cable lugs to the supply and
earthcables.
3.7.4 Pass the main cable (A) throughthe base
ptateentry hole (B) and securewith a suitablecable
supplycablesto the
ttanO.Connecttire three mains
Iuppty terminals (C) marked L1,L2 and L3' Connect
the earth cable to the earth bar (D)'

Note: Cable sizes specifiedare minimumsize to


suit typicalinstallation.lf the compressoris locateda
long'way away from the isolat-oror the ambient
t"ri"t"tur" normallyexceeds9so C,1[e1 cablesize c
may need to be increased.Referto IEE Regulations D
for LlectricalEquipmentin Buildingsto determinesize
reouired. B
g.7.5 Check transformerfuse is positionedto suit A
the suPPlYvoltage.
3.7.6 Ensure that ALL electricalconnectionsare
tight. High voltage connectionsto contactorsand Figure3.4- ElectricalConnections
incomingterminalsare critical'
! a
WARN|NG
TO ELIMINATERISK OF ACCIDENTALCONTACT
WITH LIVE TERMINALSMAKE SURE THAT ALL
i l e c r n t c A l c o v E R S A N D P A N E L SA R E
SCCUNEIYFITTEDAND LOCKEDBEFOREYOU
SWITCHON THE ELECTRICALSUPPLY.

3.7.7 Makesurethat any fusesfittedto the isolator


are the correctsize. See TechnicalData' Refit main
linefusesto distributionboard.
3.7.8 SwitchisolatorON.
! a
WARNTNG a
IF AN AUTOMATICRE-STARTDEVICEIS FITTED'
ADDITIONALWARNINGSWILL BE REQUIRED.

Page 26
- UserHandbook
8 SeriesPUAS/PWTS

Installationand Commissioning 3
3.8 GheckDirectionof MotorRotation
WARNING!

READ HEALTH AND SAFETY PRECAUTIONS


BEFORESTARTINGCOMPRESSOR.

3.8.1 Ensurethat the compressorair-endis filled


correctlywith an approvedoil and that all plugs are
fittedsecurely.
3.8.2 Switch mains electricalsupply ON. Ensure
that mains and reset lamps are illuminated.Select
continuous run mode.
3.8.3 Pressresetbuttonto startcomoressor.

3.8.4 Check directionof rotationof compressor


drive motor. The correct direction of rotation is
clockwisewhen viewedfrom the drive end (i.e. Rear
of motor).
lf correct, the pressure displayed on the air-end
pressuregaugewillimmediately riseto 5.5 bar.

lf not correct, pressurewill not rise and the pressure


gaugewillreadzero.

CAUTION!

Stop the compressorimmediately: seriousdamageto


the air-endwill resultif the motoris allowedto run in
reverse!

WARNING!

IF INCORRECTSTOP THE COMPRESSORAND


LOCK THE ISOLATORIN THE OFF POSITION.FIT
A SAFETY NOTICETO THE ISOLATORADVISING
THAT WORK IS BEING CARRIEDOUT ON THE
COMPRESSOR.

3.8.5 Changeover any two of the incomingcables


c o n n e c t e dt o t h e s t a r t e r t e r m i n a l sL 1 , L 2 & L 3
(Qualifiedperson only).
3.8.6 Ensurethatallcoversand panelshavebeen
securelyreinstated.
3.8.7 Switchthe mainselectrical
supplyon.

3.8.8 Restartcompressorand verifythat direction


of rotationis correct.

Page 27
CompAirHydrovaneLimited

3 Installation
andCommissioning
3.9 CircuitDiagram(50 Hz)

U)
p 6-lr'i o-
c
o

o
3
o-{r,
'-4' ;44
o . =
o ( !
- a r i
(J
2 P Z

o l {
6 N . =
h > @ 3
E p ( L o
E e € 3
E
( ! o
o = 9
! o : 9 *
=y . = = ;= - F=
F o ii E
O < f L F

iD
o ^
F > z c )
J
9 -
c
o -
o g
b r E
'OE r . :E k- 6m L l - o
o : 9 o
- . t s s E > 9 u 5
9 5 < h . = u - 6
F o o - E d - - 9
el N t r t r f . = ' - <
=l---- t k E o o - ' i E
5 : j : o = l - i 0 )
t ^ Y '
; j O g E d r d r

:: =' i d si td ; dFd E6 E 9
<l

o
!r \l -- -c : r Et L< L. l) , NL $l . r Lo- c ' )
a
6-NIN-4e-444,-
n k 99-b- f
o ' F c
o = =
'io r l o
ro u)
6 cic;
c o e E F
' I - r D c o
E 5 6 n o
9 - 4 = @ @
6 q q e ; -
t l b o v J : c
E E , S F E E P
E E 5 + € H A e
5 C - e l :
p : 9 ' 6 + g g E
A F J =
() c4 a

Ee a a Ep 0
X = ii; o

o - ! 3 ' x > s o -
E ! P U E = ^ }
3: fi # f i'_e
- < r r O - < v i o c f )
E E A @ A O _ O -

6
o
o
to ti
- o
r O
o , ^ =
. ' F : - - E
- 6 , c b < . r
P € E E E E ;
i E i . l r o l E
; x x o = o
g! 6 : 6 o n j E o
n r . l l - t a i -
o ' i o a @ 0 > ( r
I
(o
\t
F-
6l - C V C O $ @ N @
N ) < Y Y Y Y Y Y

Page 28
t.
a-
!. .-
- UserHandbook
8 SeriesPUAS/PWTS
I-{

l-- Installationand Gommissioning 3


l--a
l--
I-{,
3.10 CircuitDiagram(60 Hz)
l_-
I-A
= r
O
o
c
u
c
O
)

l_-
I_A
;
c
(t)
(\,1
N
)
F
=
tt
O

l_-
r-"\
3
= o

a-
b( / .) (c !
v o
v - o
f- .\ z E 3
l--
n r i {
|' Y€--l--
oi
q) ; r =
f-{
A
h E s E
L-
f-r \
l1l
f, E P <
x
Y
o @
7
>
,
l
t ) q )

?
+
-

O
o

f-
I- .t
urs
r
E
o
F
o

o
E
i
l
i
s
C
E
*

1-
I- "rr
-1-
t_!.1
ufs
6 )5
( < ( L
E Fb

t_-
I- .r l*zl F >
o
z c )

t_-
j

l = ' 9 . =
c

a-
I-r

. =A-
(
o
'o E ; i : - hH m
h F
o :L : l o - o o )
J 9

f' 'r
les*
i € E > O u r 5
g 5 < k . = u - 6
tN rt r; t ;r :Ef .B= !c< = E
a-
I-

I_r
r>zl
I ia===;
i F E F O ; O E
c r
9 e E s E ; ; i
- r v = : A o

|--
a
s z Eu ^
sl
r vgu Eu F
O s E ,

f=
l- .r
;
R = t f 5 f f i l
a
. ' O . ' r -

IE , r f
o-
z" F '.-

t- .
U
b
)
g
q
o
u
t
c
o
o
)

E:
c o 6 E
, 9 ds ) c o
E = f i s o
S o - + . = c d < t
= o i . - r

f-
E 6 c - 6 5 . E
5 E ; ;aai -x _
' = != >
E + €
v bo vt , = a

l' I
d i = 1 6 ; 5 6 p 0 )
. = : c ! : - o o 5 \
o v o - g + e q g
f' I
-1
E F q . i < q e
o_ '6
5 g E E E . - e ' :
f'
I-..i
0 ( ) F : U J / / ) : I : I :

l L
- r
E E @ u ) a a a
U r
EN LC ut <
s l
a a

I
]_ t- oq)
t- r -''
t u a
6 ^
v o )
o

I
I L O

P o ?
E - E
- 6 - c b c v

t"
II.
*6 I€} 6F- F
^ x x o = o
r
E E ;
a c E

6 : U o n i o d
a . U
'F i ; o ( ag ( ( r ! oo - ) >k t =r
L t o =

f"
-
E:
J
.-
r
Y
C
Y
! (
Y
f )
Y
$ (
Y
O N
Y
O
Y
at
E--,i
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-
f-r
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
L
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Noiselevel(60 Hz) dBA

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L'
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ts;
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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f'
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Contents
t- Section Page
f' Compressor (PUAS)
assembly 4 . 1. . . . 3 6

f'
l-r
Compressor (watercooled)
assembly 4.2 ...38

t-
J- -r
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.

A fan (G) is assembledto the end of the motorshaft


to force a coolingairflowthroughthe combinationoil
cooler/airaftercooler(H).The compressorcontrols(L)
are locatedin the door of the starterpanel(K).
The compressorair intake is protectedby air intake
filter(M) and the oil systemby oilfilter(N).

The oil is drainedfrom the compressorair-endby


removingthe oil drainplug (P).

Figure4.1 also showsthe locationof the compressor


air-endpressuregauge(R),and oilfillerplug(S).
The separator (T) is located at the rear of the
compressor and ensuresthatthe airdelivered
through
the minimumpressurevalve(U)has an oilcleanliness
standard of less than 5 ppm (parts per million by
weight).The air is deliveredthroughthe air delivery
pipe (V) to the aftercooler.

The oil supplyto the cooleris throughoilfeedpipe(W)


withthe cooloil returnvia oil returnpipe(X).To ensure
t h e c o m p r e s s o rr e a c h e s t h e o p t i m u m o p e r a t i n g
temperaturequicklya thermalby-passvalve(Y)allows
the oil supplyto by-passthe cooleron initialstartup.
T h e v e n t d o w n s o l e n o i d( Z ) a l l o w s t h e a i r - e n d
pressureto fall to 2.0 bar duringthe run-ontime and
to zero wheneverthe compressorstops.

Page 36
L,
t-
- UserHandbook
I SeriesPUASiPWTS
l---{

t- GeneralDescription 4
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Figure4.1- CompressorAssembly(PUAS)

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.

The compressorcontrols(L) are locatedin the door of


the starterpanel(K).
The compressorair intake is protectedby air intake
filter(M) and the oil systemby oilfilter(N).

The oil is drained from the comoressorair-end bv


removingthe oildrainplug (P).

Figure4.2 alsoshowsthe locationof the compressor


air-endpressuregauge(R),and oilfillerplug (S).
The separator (T) is located at the rear of the
compressorand ensurgsthatthe airdeliveredthrough
the minimumpressurevalve(U) hasan oil cleanliness
standard of less than 5 ppm (parts per million by
weight).The air is deliveredthroughthe air delivery
point(V).

Referto figure4.1 for items(T, W, X and Y).

The oil supplyto the cooleris throughoilfeedpipe(W)


withthe cooloil returnvia oil returnpipe(X).To ensure
t h e c o m p r e s s o rr e a c h e s t h e o p t i m u m o p e r a t i n g
temperaturequicklya thermalby-passvalve(Y) allows
the oil supplyto by-passthe cooleron initialstartup.
T h e v e n t d o w n s o l e n o i d( Z ) a l l o w s t h e a i r - e n d
pressureto fall to 2.0 bar duringthe run-ontime and
to zero wheneverthe compressorstops.

Connectwaterinletto oilcooler(Al ) and airaftercooler


(B1)to the bottom.Connectwateroutletfrom coolers
to the top.The air dischargepointis shownby (C1).
Note: A f lowcontrolvalveis fittedto the wateroutlet
of oil coolers.The valve remainscloseduntiloil has
reachednormaloperatingtemperature.

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)

Indicatesthat mainselectricalsupplyis switchedON.


Will alwaysbe illuminatedwhen power is suppliedto
the starter.
(B) Reset push-button / Lamp (yellow)
Indicatesthat compressor is ready to be started.
Whenbuttonis pressedlampwillextinguish. lf selector
switchis set to positionI or ll compressorwill start.
(C) Selector switch
A three positionswitchto:
'0'
S t o p s t h e c o m p r e s s o rw h e n r u n n i n g
normally.
'll'
Selectsthe automaticstop/start(auto)mode
of operation.
't'
Selectsthe continuous
run (manual)modeof
operation.
(D) Emergency stop button

Use for emergencystop only. Not recommendedfor


routinestopping.
(E) Hours counter
Indicatesthe totalhoursrun. Use in coniunction
with
serviceschedule. Figure4.3- Controls

Page 40
tL - UserHandbook
8 SeriesPUASiPWTS
l*

L OperatingInstructions 5
t- J

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Chapter5
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Contents
l_
f-
Section Page

l_
t-
Introduction 5.'1 .42

l_
f-
Checkingprocedurebeforestarting 5.2.. .42

Selectoperatingmode 5.3 .42


I)-
Startingprocedureautomaticmode 5.4 .43
L
=- Startingprocedurecontinuousrun mode 5.5 .43
L
!-
Changeoperatingmode 5.6 .44

f-
L Stoppingprocedure 5.7 .44

t]-, Emergencystop 5.8 .44

L
t-
Compressorvent down time 5.9 .44
Faultconditions(50 Hz models) 5.10 .44
t
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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.

5.2.8 Check that mains lamo and reset


push-button
lampilluminate.
CAUTION:
lf compressorstarts immediatelyand/or the reset
p u s h - b u t t o n l a m p f a i l s t o i l l u m i n a t e ,t h e
over-temperature protectionunit (F3) is inoperative.
Do not use compressoruntil the fault has been
rectified.lf in doubtcontactyour CompairHydrovane
distributor.

Page 42
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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.
J - r
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-
J_\
pressuregaugeis fittedin the air-linesystemit should bar).
normallyreadbetween6.0 and 8.4 bar (6.0and 10.4
L-
l_ ..
bar).

L
t_.
- lf the pressureof the air-linesystemrisesto pressure
switch setting ol 8.218.4bar (10.2/10.4bar) the
L'
l - .
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.

lf thereis a demandfor air duringthe run-ontimeand


the air-linepressurefalls to PS 2 settingthen the
stoppingsequenceis cancelledand the compressor
returnsto full "On Load"runningand does not stop.

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.

. To seldctautomaticwhen runningin continuous: c) Resetlampis illuminated.


'll'.
selectswitchposition To determineif the over-temperature fault is on the
T h e c o m p r e s s o rw i l l n o t s t o p . H o w e v e r , i f air-endor the motor.You must look at the thermistor
pressureis greaterthan 8.4 bar, the automatic board insidethe starter.
stoppingsequencewillbegin. Do not operatethe emergencystop buttonor turn the
mains isolatoroff at this stage.This would resetthe
5.7 Stoppingprocedure faultcondition.
. To stopthe compressor
in eithercontinuousrun or Followfaultfindingprocedurebelow.
'0'.
automaticmode:selectswitchposition
WARNING!
T h e c o m p r e s s o rw i l l s t o p i m m e d i a t e l y .T h e
compressorair-endwill begin to vent to atmosphere T H E F O L L O W I N GV I S U A L F A U L T F I N D I N G
and the air-end pressurewill fall to zero. However, P R O C E D U R ES H O U L D B E C A R R I E DO U T B Y
pressurein the air-enddeliverypipe and aftercooler QUALIFIEDAND COMPETENTPERSONSONLY.
will be equalto the pressureremainingin the air-line
THIS PANEL CONTAINS POTENTIALLYLETHAL
syslem. V O L T A G E S .U N D E R N O C I R C U M S T A N C E S
SHOULD YOU ATTEMPT TO TOUCH ANYTHING
5.8 Emergencystop I N S I D ET H E C O N T R O L P A N E L , O R O N T H E
CONTROLPANEL DOOR.
lf an emergencyoccurs, hit the emergency-stop
button.The buttonwill lock in the depressedposition . Switchthe compressoroff usingselectorswitch.
and stopthe compressorimmediately. Clearanyfaults
. Do not restartthe compressor.
which may have occurred.Do not resetuntilit is safe
to do so. . Carefullyunlockand open the controlpaneldoor.
The emergencystop buttoncan be resetby twistingit /\ /\
anticlockwise.
WARNTNG! /A l\
VISUALINSPECTION ONLY.
CAUTION:
. Look at the thermistorcontrol board to identify
The emergency-stopshould be used for emergency Seefigure
whichof the two lampsareextinguished.
purposesonly.The stopswitchshouldalwaysbe used
5 . 1( A ) .
undernormaloperatingconditions.
lf the motor LED is extinguished, a motor
5.9 CompressorVentDownTime over-temperature fault has occurred.

After stoppingthe air-end must be allowedto vent l f t h e c o m p L E D i s e x t i n g u i s h e da,


down naturally.Speedingup the de-pressurisation c o m p r e s s o ro v e r - t e m p e r a t u r fea u l t h a s
may causeseparatorflooding. occurred.
lf both LED's are extinguished,there may
havebeena mainssupplyfailure.
. Closestarterpaneldoor and lock in position.

. lsolate compressorand rectifyany faults before


resetting.Referto 5.4.

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.
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III

It Page 45

rtl - !
CompAirHydrovaneLimited

5 OperatingInstructions

This page is intentionally


left blank.

Page 46
I--

t
,.1
- UserHandbook
8 SeriesPUAS/PWTS
l-. - t

t OperatingParameters 6
l- - l

t
t -

t
t -

t
t- _ l

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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

Noise Level 6.6 .48


L
f- PressureReadings 6.7 .48
t
l- Air DeliveryTemperature 6.8 .48
t
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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

a) Low oil level.


When measuredto the testcode PneuropC.A.G.l.
b) Blockedoil cooleror coolerflow restrictions.

c) Wrong type or gradeof oil. 6.7 PressureReadings


d) Highambienttemperature. The compressorair-endpressureis displayedby the
pressuregaugelocatedin the oilchamber.
N o t e : C o m p r e s s o rw i l l s t o p a u t o m a t i c a l l yi f
temperature risesabove110'C.
/\ 6.8 Air DeliveryTemperature
WARNING ! ,/U\
The air deliverytemperatureafter it has passed
BEWAREOF HOT SURFACES!THE OIL COOLER throughthe air aftercooleris typically30/34'C.
FUNCTIONS AT A RELATIVELY HIGH i.e. 10'C aboveambienl'
T E M P E R A T U R EA N D M A Y B E T O O H O T T O
TOUCH.

Caution !
lf compressortemperaturegauge readsgreaterthan
95oCinvestigatecause immediately.

Page 48
!-- - UserHandbook
t-
l.-,.t'
8 SeriesPUAS/PWTS

L- Adjustments 7
l- r-

t-
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L-
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L- Chapter7
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Gontents
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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).

Adjustmentproceduresshown must only be carried lf reading too high or a lower operating


out by authorisedpersonsfullytrainedand competent pressure is required, turn grub-screw(E)
i n t h e m a i n t e n a n c eo f C o m p a i r H y d r o v a n e counter-clockwiseto decreasepressure.
compressors. . Open and close the test valve and check that
lf you are not able to carry out the work safely,contact pressurestabilisesat requiredsetting.
your CompairHydrovanedistributor. . Securelock-nut(D).
'10.0
Note: Figuresin bracketsreferto bar models. .
Refititems(A and B) and secure.

7.2 Servovalve(seeFig 7.1)


The servo valve controlspressureat a pre-setfactory
settingwhen there is no demandfor air.The specified
settingis a maximum and must not be exceeded.

Factorysetting8 bar models:- 8.5 /9.0 bar

Factorysetting10 bar models:- 10.5/10.8bar


lf the servo needs minor adjustmentsor a lower
pressure is required then carry out the following
procedure:
. Closeair outletvalveto air-linesystem.
. Fit silencer.Open test valve.
. Selectmanualmode and startcompressor.

. Adjusttest valve so that the pressuregauge reads


a p p r o x i m a t e l y8 . 0 b a r ( 1 0 . 0 b a r ) a n d a l l o w
compressorto warm up.
. Afterapproximately10 minutes,closethe testvalve
and stop the compressor.
. Removeair filtercover (A), air filter(B).
. Slackenservo lock-nut(D) throughhole in support
housing.
. Checktest valve and air outletvalve are closed.

. Select manual mode, start compressorand allow


pressureto stabilise.

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.

(c) The pipe work system incorporatingthe


7.4 High pressureswitchPS 1 pressuregauge can be vented safely and
(seeFig 7.2) quietlye.g. test valve (fitsilencer).
Pressureswitch PS 1 (B) functionsin automatic . Releasefourfastenersand removeoressureswitch
stop/startmode only.Two adjustingscrewsallowany cover (A).
individualreouirementto be satisfied.
WARNING!
Operating pressure (range)
DO NOT REMOVEPLASTIC PRESSURESWITCH
Initiatesthe stoppingsequenceif thereis no demand COVERS.110 VOLTSAT TERMINALS.
for air when operatingin the automode.
. ldentifyhigh pressureswitchPS 1 (B).
Operatingrange8.0 bar models= 8.2 I 8.4 bar
(factorysetting) . Removekey plate(C).

Operatingrange 10.0bar models= 10.2I 10.4bar . Set operatingpressure(range)to approximately


(factorysetting) screw(D) clockwise.
10.0bar by turningadjusting
Note: These are maximumsettingsand must not . ldentifylow pressureswitchPS 2 (E).
be exceeded.lf an air-linesystem pressureof less
. Removekey plate (F).
than 8.2 bar (10.2 bar) is requiredthe operating
pressure(range)settingmay be reduced. . Set operatingpressure(range)to approximately
Recommended =
minimumsetting 7.0 bar. 4 . 0 b a r b y t u r n i n g a d j u s t i n gs c r e w ( G )
counter-clockwise.
Differential(diff)

Cancelsthe stoppingsequenceif the air-linepressure


drops by the differential(diff) setting during the
operatingtime of the pressureswitchtimer K6T.
(diff)= 0.5 bar (factorysetting)
Differential

Air-linesystempressure= 7.7 I 7.9 bar (9.7/ 9.9 bar)

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.

. Open tesl valveto atmosphere.


WARNING! A
STOP THE COMPRESSORAND ISOLATE FROM
WARNING! A THE MAINS ELECTRICALSUPPLY. LOCK THE
ISOLATORIN THE OFF POSITION.FIT A SAFETY
FIT SILENCER.
NOTICE TO THE ISOLATOR ADVISING THAT
. Select auto mode. switch oosition 'll' and start 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
comoressor. COMPRESSOR.
. Slowlyclose test valve and allow pressureto rise 7.6.1 Pressureswitch timer K6T (A)
untilcompressor is running{ullyoff load.
Operatesin automaticmodeonly and is activatedthe
. Verify that compressorair-end pressure gauge instant pressureswitch PS 1 reaches high setting.
Duringits timingperiodthe vent down solenoidwill
r e a d s8 . 5 - 9 . 0 b a r ( 1 0 . 5- 1 0 . 8b a r ) .
remainenergisedand the air path throughit closed.
. Turn PS 1 (range)adjustingscrew (D) clockwise The timer is usedto reducethe numberof operations
untilpressureswitchcontacts(J) operate. of the solenoidvalve.
. Wait for 15 seconds,then check that vent down Factorysetting= 15 secs
solenoid has de-energisedand that compressor
air-endpressureis falling. Range= 0 to 60 secs
. Allowcompressorto operatefor the durationof the It is recommendedthat this timer is not adjusted.
run-ontimer.The compressorwillthenstop.
7.6.2 Vent down timer K7T (B)
. Slowly open test valve and allow pressurein
pipework system to fall until requiredsetting is Startstimingthe instantK6T times out. At the same
displayedon the systempressuregauge. time the vent down solenoidis de-energisedallowing
the air-endpressureto fall.lf the air-linepressurefalls
. Closetest valvethe instantthe pressurefallsto the by the differentialsettingof PS 1 during K7T timing
requiredre-startoperatingpressure. period the stoppingsequenceis cancelledand the
compressorrechargesthe air-linesystem.
. Raise the operatingpressureof PS 2 by turning
( r a n g e ) s c r e w ( G ) c l o c k w i s eu n t i l i n s t a n t Factorysetting= 15 secs
comoressorre-starts.
Range= 0 to 60 secs
. Set the test valve partiallyopen and allow the
c o m p r e s s o rt o c y c l e b e t w e e n h i g h a n d l o w Timer may be set between 0 and 60 secs to suit
pressuresetting. exceptionaloperatingconditionsby turningthe dial
knobto the durationrequired.
. Checksystempressuregaugereadingsand make
any fine adjustmentsnecessary.
. Closetest valveand stop the compressor.

. Refitkey plates(C) and (F) and cover(A).

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

Timer may be resetbetween2 and 10 minutesto suit


individualair system and/or operatingconditionsby
'
turningthe dialknobto the durationrequired.

Caution !

To avoid restartingagainstload KBT must not be set


to lessthan2 minutes.

7.6.4 Star delta timer K4T (D)


The star delta timer K4T is pre-setand sealedat 0.9
secondsand must not be adiusted.

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!

READ HEALTH AND SAFETY PRECAUTIONS


BEFOREYOU STARTANY SERVICEWORK.

SERVICINGOF THE COMPRESSORMUSTONLY


BE CARRIED.OUTBY AUTHORISEDPERSONS
F U L L Y T R A I N E D A N D C O M P E T E N TI N T H E
MAINTENANCE OF HYDROVANE
COMPRESSORS. T H E Y M U ST FULLY
UNDERSTAND AND ADOPT CORRECT AND SAFE
WORKINGPRACTICES.

lf you are unableto carry-outthe work safely in the


r e q u i r e dm a n n e r t h e n y o u r C o m p A i r H y d r o v a n e
distributorwill be pleasedto help.

Only routineservicingproceduresare detailedin this


handbook.Do not attemptmorecomplexworkwithout
referenceto the servicemanual.

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.

Notes for routine service schedule


(1) Every2000runninghours,or oneyear,whichever
occursfirst.Appliesfor FluidForce2000 oil only,
if standard approved oils are used period is
reducedto 500 hours.

( 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.

Assumingthe compressoris servicedcorrectlythe


m a c h i n e i s c a p a b l e o f o p e r a t i n gi n a m b i e n t
temperaturesup to a maximum of 40"C. At this
ambientthe bulkoiltemoerature measuredat the filler
plugshouldbe 90"C.

Check oil temperature.When the compressoris


workingthe temperatureshouldbe:-

Initialstart-upand warm-upperiod. <70"c


Optimum workingtemperature. 80 -90'c
Hightemperature. 9 5- 1 0 0 ' C
Stop ! See faultfindingsection. > 100'c
8.3.2 Check pressure (1) air-line systems

Checktheair-linesystempressureby usingtheair-line
pressuregauge.

lf the correctsizeof comoressorhas beeninstalledthe


gaugeshouldread:

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.

lf the correctsizeof compressorhas beeninstalledthe


gaugeshouldread:

Condition 8 Bar 10Bar


Pressure
whenstopped Aftervent down air-endpressuregauge
shouldread 0 bar.
Initialstart
up (3 seconds
approximately) 0 - 5.5bar 0 - 5.5bar
Whenchargingthe air-line 5.5 - 8.0 bar 5 . 5- 1 0 . 0b a r
Normalworkingpressure(hand mode) 8.0 - 9.0 bar 1 0 . 0- 1 0 . 8b a r
" l

Stop compressorand see fault finding il > 9.0 bar > 1 0 . 8b a r


Duringvent down time (automode) 8.4 - 2.0 bar 10.4- 2.0bar
Stoppedin auto mode 2.0- 0 bar 2.0- 0 bar

I 8.3.4 Check oil level


Check oil level using the compressoroil-levelsight
glass.The sight-glassis locatedin the intakeend face
of the oil chamber.When the compressoris running,
oil shouldbe visiblein the sight-glass.Whenstopped
the sight-glassshouldbe full.lf not top up.

. 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.

CLOSETHE AIR OUTLETVALVETO ISOLATETHE


COMPRESSOR FROMTHE AIR-LINESYSTEM.FIT
A SAFETY NOTICE TO THE VALVE ADVISING
THAT IT IS NOT TO BE OPENED.
. Wait untilair-endvent down cycleis complete.

. Open test valve to vent pressure from the air


aftercoolerand associatedpipework.
. Checkthat the air-endpressuregaugereadszero.

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.

CLOSETHEAIR OUTLETVALVETO ISOLATETHE . Refitand securecoverolates.


COMPRESSOR FROMTHE AIR.LINESYSTEM.FIT
A SAFETY NOTICE TO THE VALVE ADVISING
THAT IT IS NOT TO BE OPENED.

IF COMPRESSEDAIR IS USED FOR CLEANING,


THEN EYE PROTECTIONMUST BE WORN AND
C O M P R E S S E DA I R S A F E T Y P R E C A U T I O N S
OBSERVED.

8.5.1 Check compressor air filter


The air filter is located on the intake end of the
compressor.
. Unscrewretainingnut (C) and removethe filter
cover(D) and seal.
. Removefilterelement(E).
. Vacuumcleanor blow dust out of filterusinglow
pressure,cleandry air. Renewthe filterif it cannot
be cleanedsatis{actorily.
. Wipe clean the area insidethe filter cover and its
suppon.
. Refitair filterelement(E).
. Reinstatethe air filter,sealingwasherand cover.
Securethe assemblv..

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).

Note: You are remindedthat servicework must


only be carried-outby competentpersons.Refer to
healthand safetyprecautionsbeforestafiingwork.
WARNING
AI A A
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
ISOLATORIN THE OFF POSITION.FIT A SAFETY
NOTICE TO THE ISOLATOR ADVISING THAT
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.

CLOSETHE AIR OUTLETVALVETO ISOLATETHE


COMPRESSOR FROMTHE AIR.LINESYSTEM.FIT
A SAFETY NOTICE TO THE VALVE ADVISING
THAT IT IS NOT TO BE OPENED.

AVOID UNNECESSARYCONTACTWITH HOT OIL


AND COMPONENTS. GLOVES ARE
RECOMMENDED IF DRAININGOIL WHEN THE
COMPRESSOR IS HOT!

8.6.1 Compressor air intake filter replacement

The air intakefilteris locatedon the intakeend of the


compressor.
. Unscrewretainingnut and removethe filtercover
and seal.
. Removethe filterelementand discard.
. Wipe clean the area insidethe filtercover and its
support.
. Fit a new air filterelement.
. Reinstatethe air filter,sealingwasherand cover.
Securethe assembly.
Note: The air filter may containoil and must be
disposedof in an approvedmanner.
Figure8.2- Filterand DrainPlugLocation

Page 64
- UserHandbook
8 SeriesPUAS/PWTS
rl
Servicing 8
' t

8.6.2 Oildrainingprocedure 8.6.4 Oilfillingprocedure


{
. Wait untilair-endvent down cycle is complete. Refitdrain plug using new bondedseal.Tightento
- d
. Opentestvalveto ventpressurefromairaftercooler B0Nm.
and associatedpipework. Filltooverflowwithan approvedoil (e.9.FluidForce
. Check that compressorair-end pressure gauge 2000).
readszero. Refitfillerplug using new bondedseal.Tightento
75Nm.
WARNING!
Close test valve and check that air outletvalve is
DO NOT PROCEEDUNTILGAUGEREADSZERO! closed.
. Carefully
unSCTEWcompressor
fillerplug(A). Reinstate
allcoversand securein place.
WARNING
! A Removesafetynotices.
-: IF ANY AIR OR OIL ESCAPESBEFOREPLUG IS
Startthe compressorin manualmode and run for
FULLY REMOVED,THEN STOP! COMPRESSOR
-J 30 secondsonly,then stop.Top up oil levelas per
IS PRESSURISED. DO NOT REMOVEPLUGUNTIL oiltop up procedure8.4.
ALL PRESSUREIS LOST. DO NOT ALLOW ANY
Reinstateall panelsand covers.
WITH YOUR BODY.
u Test run the compressorand check pressure,
. Removeplug(A),discardbondedseal (B). temperature.Inspectfor oil leaks.
. belowtheoildrain . Ensurepanelsare fittedand secured,and that air
Placea shallow25 litrecontainer
,i Plu9' outletvalve is open beforeleaving.
' Carefullyremovethe oil drain plug (D) and collect Note: Any waste oil collectedmust be disposedof
alloildrained
fromthecompressor. Discardbonded in an approvedmanner.
seal.
8.6.3 Oilfilter change procedure
Thecartridgetypeoilfilteris locatedin the bellhousing
of the compressor
air-end.
. Unscrewoil filter(C) usingstrapwrench. Discard
filterand seal.
Note: The filtercontainsoil and must be disoosed
of in an approvedmanner.Filterand seal must not be
reuseo.
. Cleanthe oilfiltermanifold.

. Apply a lightsmear of approvedoil to the new oil


filterseal and screwthread.
. Screw on filter until the seal makes contactwith
manifoldjointface.
. Handtightenfilterby a further113lo112turnonly.

Note: Oil filter is fitted with a pressure by-pass


valve. Use genuine Hydrovanereplacementfilter
onry.

Page 65
CompAirHydrovaneLimited

I Servicing
8.6.5 Electricalchecks 8.6.6 Cleanand checkelectricmotors
I A
WARNING A WARNING!

E L E C T R I C A LC H E C K S S H O U L D O N L Y B E IF THE MOTORIS HOT. ALLOW TO COOL UNTIL


C A R R T E DO U T B Y C O M P E T E N TP E R S O N S , SAFE TO TOUCH.
FULLYTRAINEDIN MAINSELECTRICAL SUPPLY
. Removeany dust or dirt from motor bodies and
AND STARTER CONTROL EQUIPMENT.READ
HEALTH AND SAFETY PRECAUTIONSBEFORE motorair intakegrills.
STARTINGWORK! . Lubricatemotor bearings as per manufacturers
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 instructions.
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 . Reinstateall covers.
ISOLATORTO THE OFF POSITION.FIT A SAFETY
NOTICE TO THE ISOLATOR ADVISING THAT . Removesafetynotices.
WORK tS BEING CARRIEDOUT ON THE
COMPRESSOR.
. Openthe starterpaneldoor.

. Remove any terminalcovers fitted to contactors


and incomingsupplyterminals.
. Checkfor any signsof overheatingand ensurethat
all electricalconnectionsare tightenedto correct
torque settings, as per label on inside face of
starter.

Note: Pay specialattentionto power connections


and cablesconnectedto contactorsand incoming
terminals.
WARNING!

ENSURE THAT ANY TERMINAL COVERS


R E M O V E D A R E R E F I T T E DT O P R E V E N T
ACCIDENTAL FINGER CONTACT WITH POWER
SUPPLY!
. Lockstarterpaneldoor and removekey to prevent
unauthorisedaccess.

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.

THIS PANEL CONTAINS POTENTIALLYLETHAL


V O L T A G E S .U N D E R N O C I R C U M S T A N C E S
SHOULD YOU ATTEMPT TO TOUCH ANYTHING
I N S I D ET H E C O N T R O L P A N E L , O R O N T H E
CONTROLPANEL DOOR UNLESSINSTRUCTED
TO DO SO IN THE FOLLOWINGPROCEDURE.
. Startcomoressor.

. Openthe starterpaneldoor.

. Unscrewterminal38 and removethe connecting


wire (refto fig 8.3).
. T h e c o m p r e s s o rd r i v e m o t o r m u s t s t o p
immediately.
. Withoutre-settingthe starteror disconnecting the
mains supply to the starter re-connectthe circuit
(terminal
38).
. Reinstatethe electricalcontrolbox coverand front
paner.

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!

READ HEALTH AND SAFETY PRECAUTIONS


BEFOREYOU STARTANY SERVICEWORK.

SERVICINGOF THE COMPRESSORMUSTONLY


BE CARRIED.OUTBY AUTHORISEDPERSONS
F U L L Y T R A I N E D A N D C O M P E T E N TI N T H E
M A I N T E N A N C EO F C O M P A I R H Y D R O V A N E
COMPRESSORS. THEY MUST FULLY
UNDERSTAND AND ADOPTCORRECTAND SAFE
WORKINGPRACTICES.

lf you are unableto carry-outthe work safelyin the


r e q u i r e dm a n n e r t h e n y o u r C o m p a i r H y d r o v a n e
distributorwill be pleasedto help.
The rangeof minorfaultswhich may occur with your
Hydrovanecompressorcan be grouped under the
followingfour categories:

H I G HP R E S S U R E Pressurerisesuntil
safetyvalvelifts.
HIGHTEMPERATURE Oiltemperaturehigher
t h a n1 0 0 " C .

LOW AIR OUTPUT Lackof air at pointof


usage.

OIL DISCHARGE intoair


Oildischarged
system

The symptomsand actionsfor thesefaultsaredetailed


on the followingpages.

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

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