Hydrovane HV11, HV15RS, HV15 User Handbook Manual

User Handbook

HV11 - HV15 Models (ACE)

Stationary Air Compressors

ST 16135-00 Iss A 05/2006

Contents

Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Customer Warranty Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.3 Product Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.4 Quality Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.5 Model Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.6 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.1 General Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.2 The Health and Safety at Work Act, 1974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.3 Before Working on Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.4 When Operating the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.5 Potential Oil Health Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.6 First Aid Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.7 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.1 Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.2 High Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.3 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4 Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.2 Lifting and handling (Fig.4.1 and Fig.4.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.3 Model Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

5 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

5.1 Positioning Your Compressor - Basic Requirements . . . . . . . . . . . . . . . . . . . . . . .9

5.2 Ventilation (Fig.5.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

5.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

5.4 Electrical Installation (Fig.5.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5.5 Check Direction of Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5.6 Regulated Speed Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5.7 RS Operation with other Hydrovane Compressors . . . . . . . . . . . . . . . . . . . . . . . .11

6 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6.1 Compressor/Hypac (Fig.6.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6.2 Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6.3 Compressor Assembly (Fig.6.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

7 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.1.1 Checking Procedure Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.1.2 Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.1.3 Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7.1.4 Starting - Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7.1.5 Starting - Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7.1.6 Starting - Regulated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7.1.7 Stopping – All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7.1.8 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7.1.9 Compressor Vent Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7.2 Operational Display Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

8 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

(continued)

ST 16135-00A i

Contents

Contents (continued)

8.1 Compressor Control (Fig.8.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

8.2 Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

8.3 Pressure Control – RS Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

9 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

9.2 Routine Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

9.3 Servicing (RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

9.4 Check Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

9.4.1 Check Compressor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

9.4.2 Check oil level (Fig.9.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

9.5 Basic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

9.6 Access Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

9.7 Oil Draining and Filter Replacement (Fig.9.2 and Fig.9.3) . . . . . . . . . . . . . . . . .22

9.8 Oil Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

9.9 Oil Filter Replacement (Fig.9.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

9.10 Oil filling / Top-up (Fig.9.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.11 Air Filter Replacement (Fig.9.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.12 Oil Separator Replacement (Fig.9.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.13 Clean Oil Cooler/Aftercooler (Fig. 9.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.14 Cabinet Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.15 Panel Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.16 Electrical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.16.1 Clean motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

9.17 Servicing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

9.18 Service Schedule: Fluid Force Red 2000 (2000 hour oil change) . . . . . . . . . . . . .24

10 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

10.1 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

10.2 Shutdown Trip Error (E) – Menu P03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

10.3 Alarm (A) – Menu P04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

10.4 Run Inhibit (R) – Menu P05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

10.5 Fault Display Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

10.6 Diagnostic Menu P06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

10.7 Configuration Menu P07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

10.8 Speed Regulation Menu P08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

10.9 Calibration Menu P09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

10.10 Access Level Configuration Menu P10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

ii ST 16135-00A

1 Introduction

1

1 Introduction

IMPORTANT !

BEFORE INITIAL START-UP, ENSURE THAT THE
COMPRESSOR IS FILLED WITH A HYDROVANE APPROVED
OIL. DO NOT OVERFILL.

1.1 Support

Full support is available from your Hydrovane Distributor. If you
need any specialist help or service, please contact your
Distributor quoting the MODEL TYPE and SERIAL NUMBER.

1.2 Customer Warranty Terms

All compressors, which are serviced by an authorised Hydrovane
Distributor, are guaranteed for 12 months from commissioning or
18 months from the date of shipment.

The warranty excludes normal service parts, oil and wear items,
dirt ingress, cleaning of filters and fluid drain devices and the
tightening of electrical or other connections. Also excluded is
adjustment of the Controller settings. Consequential damage of
any nature is not covered by the warranty.

An ‘Advance’ 10 year warranty is available for approved
installations, contact your Hydrovane Distributor for details.

1.3 Product Development

Hydrovane adopt a policy of continual product development. The
information in this Handbook, whilst fully up to date when issued,
may be subject to change without notice.

1.4 Quality Standards

CompAir UK Ltd Quality Management Systems are approved to
BS EN ISO 9001.

These instructions comply with the latest European Directives
regarding content and are valid for machines carrying the
CEmark.

CompAir UK Ltd
Claybrook Drive
Washford Industrial Estate
Redditch, Worcestershire
B98 0DS, England

1.5 Model Range

This Handbook relates to all ACE HV11 - HV15 vertical range
compressors and Hypac models.

HV11 - HV15 model types:

V11ACE08-4035S000 50Hz model
V11ACE10-4035S000 50Hz model
V11ACE08-2336D005 60Hz model
V11ACE10-2336D005 60Hz model
V11ACE08-5756D005 60Hz model
V11ACE10-5756D005 60Hz model

V15ACE08-4035S000 50Hz model
V15ACE10-4035S000 50Hz model
V15ACE08-2336D005 60Hz model
V15ACE10-2336D005 60Hz model
V15ACE08-5756D005 60Hz model
V15ACE10-5756D005 60Hz model
V15ACE10-4035V000 50Hz model

1.6 Terminology

The product code segments signifies:

V Vane
11, 15 kW motor
ACE Air Centre Electronic
08, 10 Delivery pressure in bars
23 230V
40 400V
57 575V
1, 3 Single phase, 3 phase
5, 6 50 Hz, 60Hz
D, S, V Direct On Line, Star/Delta, Variable

Speed
000 European Specification (50 Hz)
005 US Specification (60 Hz)

This publication refers to compressors with serial numbers from:

V11-000001-0604
V15-000001-0604

Web: www.hydrovane.co.uk

E-mail: [e-mail]

Telephone: [phone]
Fax: [phone]

[e-mail]
www.CompAir.com

ST 16135-00A 1

2 Safety
2 Safety

2.1 General Health and Safety Precautions

Please read carefully and proceed in accordance with the
following instructions before installation, operation,
maintenance or repair of the compressor unit.

2.2 The Health and Safety at Work Act, 1974

In order to comply with your responsibilities under the above act, it
is essential that the Compressor is transported, positioned,
installed, operated and maintained by competent persons in
accordance with the instructions in this Handbook.

The standard build of all Hydrovane products are designed to
compress clean, dry, atmospheric air and are not intended for use
in either Explosive or Potentially Explosive Atmospheres as
defined in the ATEX Directive 94/9/EC.

A potentially Explosive atmosphere is an atmosphere which could
become explosive due to local and operational conditions.

The Compressor warranty will be invalidated if unapproved spare
parts or oils are used. Using such items may cause the efficiency
and service life of the Compressor to be reduced, and could
create a hazardous condition over which Hydrovane has no
control.

Failure to maintain the Compressor correctly, or modifying it
without prior approval from Hydrovane, may also create a
hazardous condition. This will also invalidate the warranty.

Read and fully understand the contents contained in the User
Handbook.

Ensure that the User Handbook is not permanently removed from
the Compressor.

Check that there are no signs of damage and/or oil leaks from the
Compressor, cooler and associated pipework.

After completing work, tools and foreign matter should be
removed from the Compressor and its surrounding area.

In the unlikely event of a Compressor fire, dry powder or carbon
dioxide fire extinguishers should be used. Never use water.

2.3 Before Working on Compressor

Potentially dangerous voltages are used to power this machine.
Do not carry out any work until the isolator is locked in the off
position. Fit a safety notice to the isolator advising that work is
being carried out and that the isolator must not be switched on. If
in doubt, a qualified electrician may remove the fuses and keep
them in a secure place until work is complete.

Ensure the Compressor has been safely isolated from the main air
system and cannot be re-introduced until all work has been
completed. Fit a safety notice to the isolation valve advising that
work is being carried out.

Do not undertake any work until the Compressor and receiver, if
fitted, have been relieved of all pressure.

Wait until the Compressor’s vent down cycle is complete.

Release any pressure contained in the aftercooler or associated
pipework.

Check that the Compressor pressure gauge reads zero. Do not
proceed until it does.

Carefully unscrew the Compressor filler plug. If any air or oil
escapes before the plug is fully removed stop! Do not remove the
plug until all pressure is lost.

Safety devices fitted to the Compressor or pipework system
should be checked at regular intervals and replaced if faulty. They
should not be tampered with or modified. Non return valves
should not be used as isolation devices.

To ensure the Compressor operates safely you must carry out the
specified maintenance procedures.

Only approved oils should be used for flushing purposes.

Extreme caution should be taken if the Compressor has been
subjected to severe operating temperatures or fire. Certain
components may contain fluoroelastomer materials and under
these conditions can leave extremely corrosive residues. Severe
burns and permanent skin and tissue damage can be a result of
skin contact.

The Health and Safety information contained in this Handbook is
only intended to give general guidelines.

2.4 When Operating the Compressor

When in automatic mode the Compressor may restart without
warning.

Additional warnings will be required if the unit is configured for
remote stop/start or to restart after power failure.

Do not remove any plugs or release pipework when the
Compressor is running.

Do not attempt to open the starter enclosure while the
Compressor is operating.

Beware of hot surfaces, both the Compressor and electric motor
are designed to run at elevated temperatures.

Compressed air is potentially dangerous and can be fatal if
misused. Do not allow compressed air jets, discharged from any
pipe or nozzle, to make contact with your body.

Wear safety glasses and suitable clothing when using or working
in an area where compressed air is being used.

Hazardous vapours/fumes can be produced if compressed air is
used to remove chemicals, cleaning agents and oils from
equipment and components. Suitable respiratory and extraction
equipment may be required in these circumstances. Never use
compressed air for cleaning personal clothing.

Air discharged from Compressors is unsuitable for breathing
purposes. Air for human consumption must be subjected to further
treatment to ensure that contaminant levels for odour and
moisture content meet the requirements of BS 4275 1974.

We recommend that air supply to hand-held air guns is regulated
to a lower pressure (refer to local Health and Safety regulations).

Do not insert any object or any part of your body through any
opening of the Compressor enclosure. Serious personal injury
and/or damage may result.

ST 16135-00A 3

Safety 2

Never run the Compressor with any covers or guards missing,
unless advised to do so.

2.5 Potential Oil Health Hazards

This section relates to Hydrovane approved oil. For other oils
refer to the Health and Safety Instructions issued with the
relevant product.

There are no significant hazards associated with this product
when properly used and in the application for which it was
designed. Frequent and/or prolonged skin contact may give rise to
skin irritations and it is recommended that protective gloves are
worn. The carcinogenic action of mineral oils should be brought to
the attention of all users. *

The oil may be hot so take care when carrying out oil changes.

Do not keep oily rags in pockets or wear contaminated clothing.
Do not inhale fumes or vapours. Do not swallow. Avoid eye
contact.

Always wash hands after use and before eating, drinking and
smoking.

2.6 First Aid Measures

Inhalation - Remove from exposure into fresh air. If necessary
give artificial respiration or oxygen. Seek medical advice.

2.7 Warnings, Cautions and Notes

Definition

WARNING ! is used in the text of this Handbook to identify

specific hazards which can cause injury or death. This type of
hazard is identified below.

Risk of electric shock

Risk of hazard or danger

Risk of hot surfaces

Eye protection must be worn

Dust protection must be worn

Warning pressurised vessel

Warning pressurised component or system

Warning unit is remotely controlled and may start
withoutwarning

Skin Contact - *Mildly irritating. Remove by wiping. Wash with
soap and water. Apply emollient cream.

Eye Contact - *Mildly irritating. Flush with copious amounts of
warm water. Seek medical advice if necessary.

Ingestion - Do not induce vomiting because of the risk of
aspiration. Wash mouth out with water. Give 1/2 pint milk. Seek
immediate medical attention.

Further Medical Treatment

Aspiration - If there is any suspicion of aspiration into the lungs
(for example during vomiting) admit to hospital immediately.

Pressure injection - Obtain immediate medical attention, even if
injury appears minor.

Spillage - Soak up with absorbent clay.

Waste Disposal - Oil, condensate, filter elements etc. should be
disposed of in accordance with local regulations. Do not allow oil
to contaminate water supplies.

* See Cautionary Notice SHW 397 ‘Effects of Mineral Oil on the
Skin’ and MS(B) 5 ‘Skin Cancer Caused by Oil’ published by
the Health and Safety Executive.

Read the instruction manual

Do not operate the machine without the guard being
fitted

Warning do not start the machine without
consultingHandbook

Lifting point

Direction of rotation

CAUTION ! is used in the text to identify incorrect procedures
which can cause damage to the Compressor.

Note: is used in the text to draw attention to specific points of
importance.

Hydrovane declines all liability in the event of material damage or
bodily injury resulting from negligence in the application of these
precautions, from non-observation or lack of elementary
supervision in respect of handling, operation, servicing or repair,
even if not expressly stated in this instruction notice.

4 ST 16135-00A

3 Product Information
3 Product Information

3.1 Operating Temperatures

Your Compressor will give optimum performance and trouble-free
service life when the bulk oil temperature is maintained between
75°C and 85°C.

Certain operating conditions sustained over a period of time may
cause problems that effect the performance and reliability of this
Compressor.

Problems may occur when compressors run for short periods on
low air demand where they don’t reach normal operating
temperatures.

Prolonged use under these conditions can cause condensation
build up within the Compressor and may eventually lead to
emulsification of the oil.

Normal operating temperatures are reached in typically 10/15
minutes. To purge condensate from the Compressor, a longer
running period with a high air demand is needed, usually a
minimum of 60 minutes will be required.

Conditions or applications which prevent the Compressor
temperature stabilising between these parameters should be
avoided.

Consult your local Hydrovane Distributor if you have any particular
concerns about operational characteristics of your Compressor.

3.2 High Operating Temperatures

Some of the reasons for high compressor oil temperatures are:

• Low oil level.

• Blocked oil cooler or cooler flow restrictions.

• Wrong type or grade of oil.

• High ambient temperature.

• Cooling fan stopped or operating incorrectly.

Note: The controller display will show a warning when the
Compressor temperature reaches 107°C.

Note: The Compressor will stop automatically if the temperature
rises above 110°C.

If the bulk oil temperature frequently reads 100°C, then Fluid
Force HPO oil should be used.

3.3 Noise Level

Although the sound pressure level for these units is relatively low,
they should be positioned where noise will not be a problem.

ST 16135-00A 5

Product Information 3

3.4 Technical Data
Model Number HV11 HV15 HV15RS

PERFORMANCE

F.A.D. litres/sec (cfm) @ 8 bar 29 (61) 38 (81) 0 - 39 (0 - 83)
F.A.D. litres/sec @ 10 bar 25 (52) 33 (71) 0 - 25 (0 - 52)
Noise Level - dBA 69 70 70
Power - kW (hp) 11 (15) 15 (20) 15 (20)
Starter Type - Automatic DOL & SD
Starter Type - Inverter N/A Soft Start
Drive Type Direct
Operating Controls Continuous Run, Automatic Stop/Start,

Compressor Rotation Speed - rev/min (60 Hz) 1450 (1760) 990 - 2040
Oil Capacity - litres 6.0
Ambient Temperature Range °C 0 to 45 0 to 40
Maximum Relative Humidity % 85 non-condensing
Air Discharge Temp - °C (above ambient) <8 <10

FACTORY SETTINGS

Minimum Pressure Valve - bar 5.5 to 6.0
Minimum Air Line Pressure - bar (PL) 7.5 to 9.5 7.5
Maximum Air Line Pressure - bar (PU) 8.5 to 10.5 9.0
REVS Delay Period (secs) (Rt) 60 (8 bar) 90 (10bar)
Run-on-Time to Stop (secs) (St) 10
Pressure Display Units (PD) 0 (bar) (1 = psi, 2 = kpa)
Temperature Display Units (Td) 0 = °C (1 = °F)
Servo Valve - bar 9.0 or 11.0 8.5
Vacuum Relief Valve One turn anti-clockwise

INSTALLATION

Air Outlet Size - Rp 3/4
Minimum Room Volume - m
Air Inlet/Outlet Area - m
Ventilation Rate - m3/h
Cooling Air Flow m3/h (cfm)

Recommended Air Receiver Capacity - L 275

COMPRESSOR OIL

Approved compressor oil Fluid Force Red 2000 & HPO

ELECTRICAL

See electrical data inside the starter door. 76103, 76196 & 76289

3

2

Reduced Energy Vent System

25

0.5

3400

3702 (2180)

Soft Start/

Variable

6 ST 16135-00A

4 Transportation and Handling
4 Transportation and Handling

4.1 Introduction

Lifting and transportation must only be carried out by authorised
persons, fully trained in the use of the equipment employed.

Ensure that all means of transportation and/or lifting equipment
are adequate for purpose and are rated to exceed the full load of
the unit.

4.2 Lifting and handling (Fig.4.1 and Fig.4.2)

A fork lift or pallet truck are the most suitable means of
transportation. Pay particular attention to ensure stability to
prevent the unit tilting over.

Lift the Hypac or Compressor and place it in the desired location.

Damage to the mountings may occur if you attempt to slide the
Compressor into position.

4.3 Model Weights

Table 4.1 shows the weights for the ACE HV11-HV15
Compressors and the Hypac range.

Fig. 4.1 - ACE HV11-15 Vertical Compressor

Table 4.1 - Model Weights

Compressor HV11 HV15 HV15RS

ACE 350 363 372
ACER 487 500 509
ACED 412 425 434
AERD 552 565 574

All weights in kilos

Fig. 4.2 - ACED HV11-15 Hypac Compressor

ST 16135-00A 7

5 Installation and Commissioning
5 Installation and Commissioning

5.1 Positioning Your Compressor - Basic
Requirements

We recommend an approved installation from an authorized
Hydrovane distributor with a service agreement to maintain your
Compressor.

Position the Compressor/Hypac in a room of adequate size on a
firm surface, level in both planes within five degrees of the
horizontal.

Ensure the area has sufficient load-bearing capacity, normally it is
not necessary to bolt the unit down.

Sufficient access (1 metre) for all routine service procedures
should be provided around the unit.

Site the Compressor/Hypac as far as possible from sources of
dirt, coarse solids, abrasive particles, steam, liquids and gaseous
impurities.

This is an industrial compressor and is intended for installation in
an indoor environment.

Any air connection made to the Compressor outlet must be
flexible as the base incorporates resilient mountings.

5.2 Ventilation (Fig.5.1)

Position the Compressor/Hypac in a well ventilated location. Do
not restrict the air-flow around the Compressor; Do not allow the
hot air discharge to re-circulate into the Compressor intake.

Any cooling-air inlet (A) should be positioned low allowing
unrestricted air-flow to the Compressor intake. The warm-air
outlet (B) should be positioned high, and well away from the inlet,
to ensure a positive cooling air-flow through the Compressor.

For maximum efficiency and reliability, the Compressor should be
operated in a moderate ambient temperature. If temperatures
frequently fall below 0°C, consult your Hydrovane Distributor. A
different grade of oil may be required.

Compressor air intake and exhaust grills have captive nuts fitted
as standard to attach ducting.

Air ducting, if fitted, must not cover or restrict the cooling air flow
of the Compressor. Total resistance of the system must not
exceed 5mm w.g. (0.2in. water gauge). If resistance is expected
to be greater than 5mm w.g. then fan assistance will be required.

Fig. 5.1 - Compressor Ventilation

5.3 Electrical Connections

WARNING !

CONNECTION TO, OR INSTALLATION OF, AN
ELECTRICAL POWER SUPPLY MUST ONLY BE
CARRIED OUT BY AUTHORISED AND
QUALIFIED ELECTRICIANS. THEY MUST FULLY
UNDERSTAND AND ADOPT CORRECT AND
SAFE WORKING PRACTICES. ALL ASPECTS OF
THE INSTALLATION MUST MEET THE WIRING
REGULATIONS PRESENTLY IN PLACE.

Before connecting to the mains electrical supply, ensure that the
system can sustain the additional electrical load. To ensure
reliable low resistance joints, make sure that your incoming supply
cables are firmly secured to the starter terminals and that they are
of correct size.

Note that the starter door panel should always be secured by the
supplied key for safety reasons and to prevent unauthorized
access.

Refer to starter circuit diagrams (located inside the starter door
panel) before starting work. Note carefully the instructions given
for earthing, fuses and cable size.

Fuses to BS 88 (Type gG) must be used to protect the
Compressor starter, refer to the sizes specified on the starter
circuit diagrams.

Circuit breakers are not recommended since they may not fully
protect the starter contacts in an overload condition.

ST 16135-00A 9

Installation and Commissioning 5

5.4 Electrical Installation (Fig.5.2)

WARNING !

BEFORE STARTING WORK, ENSURE THAT THE
MAIN-LINE FUSES HAVE BEEN REMOVED FROM
THE DISTRIBUTION BOARD. PRECAUTIONS
SHOULD BE TAKEN TO PREVENT THEM BEING
REFITTED UNTIL THE INSTALLATION IS
COMPLETE.

Starter cables must be connected to the mains electrical supply
via a lockable, switched and suitably rated fused isolator. The
isolator should be positioned as near as possible to the
Compressor with clear, unrestricted access.

To access the starter terminals, unlock the starter door panel with
the key provided. Pass the incoming cables through the entry hole
in the floor and connect the three mains supply cables to the
contactor terminals marked L1, L2 and L3, and connect the earth
cable to the earth pin E. Ensure the connections are secure.

5.5 Check Direction of Motor Rotation

WARNING !

READ HEALTH AND SAFETY PRECAUTIONS
BEFORE STARTING COMPRESSOR.

Ensure that the Compressor is filled with approved oil and that all
plugs are fitted securely.

The cooling fan in the rear of the unit may be used as a visual aid
to determine the correct rotation of the Compressor.

To view the cooling fan, remove the cabinet filter from the lower
half of the rear panel, the cooling fan can be viewed through the
mesh grill.

With the mains isolator on, press the green start button mounted
in the control panel. Compressor rotation is correct if the cooling
fan rotates in a clockwise direction.

For single speed Compressors, if rotation is correct, the
Compressor pressure display will rise immediately after starting. If
rotation is not correct, the Compressor pressure display will not
rise.

Rotation for RS Compressors will always be correct due to the
inverter drive, however the cooling fan must be checked for
correct clockwise rotation.

Fig. 5.2 - Electrical Connections to Starter

Terminal

Cable sizes specified on the circuit diagram are the minimum size
to suit a typical installation. If the Compressor is located a long
way from the isolator and/or the ambient temperature exceeds
35°C, the cable size should be increased.

Refer to IEEE Regulations for electrical equipment installed in
buildings to determine the size required, pay particular attention to
the circuit diagrams provided.

Check that the transformer fuse is positioned to suit the supply
voltage of the installation.

Ensure all electrical connections are tight, high voltage supply to
contactors and incoming terminals are critical.

Close the starter door and secure with the key provided.

CAUTION !

If direction of rotation is incorrect, stop the
Compressor immediately. Serious damage will
occur if the motor is allowed to run in reverse!

WARNING !

IF DIRECTION OF COMPRESSOR OR COOLING
FAN ROTATION IS INCORRECT, STOP THE
COMPRESSOR AND LOCK THE ISOLATOR IN
THE OFF POSITION. FIT A SAFETY NOTICE TO
THE ISOLATOR ADVISING THAT WORK IS BEING
CARRIED OUT ON THE COMPRESSOR.

Open the starter door with the key provided to gain access to the
starter terminals.

Change over any two of the incoming cables connected to the
starter terminals L1, L2 and L3.

Close the starter enclosure door and lock with the key provided to
prevent unauthorised access.

Remove the safety notice and switch the mains electricity supply
on.

Restart the Compressor and verify that direction of rotation of both
the Compressor and cooling fan are correct.

Replace the cabinet filter in the rear panel with the direction arrow
pointing inwards towards the cooling fan.

Replace the main line fuses.

10 ST 16135-00A

5 Installation and Commissioning

5.6 Regulated Speed Compressor Installation

The Compressor should be installed generally as instructed for a
standard fixed speed Compressor of the same power (kW) rating.

Electrical supply fuse sizes are the same as for standard fixed
speed Compressors of the same power (kW) rating.

Alternatively, a circuit breaker (Type D) of suitable size and with
motor starting characteristics may be used to protect the
installation.

The maximum starting current under all starting conditions will not
exceed 150% motor full load current and will generally be no more
than 100% full load current.

The installation must be earthed in accordance with local
regulations. The use of RCDs is not recommended.

Water drain, filters or dryers fitted downstream of the Compressor
discharge must be correctly sited to avoid excessive flow
restrictions to ensure stable operation of the speed control
system.

5.7 RS Operation with other Hydrovane
Compressors

Hydrovane RS Compressors may be operated efficiently in
conjunction with other Hydrovane Compressors fitted with
automatic stop-start control.

Adjust the RS minimum air line pressure to midway between the
maximum and minimum air line pressure settings of the other
Compressor. The RS Compressor will automatically assume the
lead Compressor role after several cycles.

IMPORTANT NOTES: If the RS Compressor is operated with
other Hydrovane standard single speed Compressors feeding a
common pressure system, the minimum air line pressure of the
RS Compressor must be limited to the lowest maximum air line
pressure of the single speed machine(s). No attempt must be
made to increase the operating pressure of the single speed
machine(s).

The pressure transducer sensing point is located in a valve
housing adjacent to the outlet from the Compressor. If the
pipework from the Compressor to the system is restricted, or
prone to excessive pressure fluctuation, rapid speed changes
and/or frequent stopping and starting of the motor may occur.

Should this condition arise, consult a Hydrovane Distributor who
will arrange to re-site the pressure transducer location.

ST 16135-00A 11

11

6 General Description
6 General Description

6.1 Compressor/Hypac (Fig.6.1)

This User Manual covers the Hydrovane ACE HV11-HV15 vertical
range of Compressors. The Hypac range contains a Compressor
and either a Receiver or an air dryer or both, depending on which
variant is required.

The Compressor alone is used where air demand is constant and
does not exceed the output capacity of the Compressor.

An air drier is used to provide dry air (pressure dew point 3°C) for
specialised applications

A Compressor plus receiver is used where air demand fluctuates,
the receiver stores 275 litres of air. A drier can be combined with
the Compressor plus Receiver for applications requiring large
volumes of dry air.

Figure 6.1 shows general views of the range, the Compressor
assembly is detailed in Para 6.3/Fig 6.2, the air drier is supplied
with its own manual.

Fig. 6.1 - General Views

6.2 Control Systems

Compressors can be operated either in automatic Stop/Start
mode or in continuous run mode.

All units benefit from REVS (Reduced Energy Venting System) to
minimise power consumption during operation.

On start up a short delay prevents full pressure delivery to reduce
motor power consumed.

With maximum line pressure established the venting system
lowers compressor pressure to provide substantial cost savings
due to the offload power reduction.

During offload run on time at minimum pressure the compressor
will either stop with no air demand or return to onload running if
more air is required.

Automatic Stop/Start Mode

This is the normal mode of operation giving maximum efficiency
and economy. Recommended for applications with fluctuating air
demands. With the auto mode selected, the Compressor will load/
unload and stop/start automatically in response to air demand.

Motor restarts are set to 15 times per hour, the run-on time will be
increased to maintain this frequency.

Continuous Run Mode

When the continuous run mode is selected, the Compressor will
continue to supply air from full to zero flow rates. In this mode the
energy saving benefits of REVS will not be maintained.

Regulated Speed Operation

Regulated speed Compressors are automatic stop/start operation
only.

The Hydrovane Regulated Speed Vane Compressor saves
energy and operating cost when compared with a fixed speed
Compressor of similar size. The saving is achieved by
automatically regulating the Compressor speed to precisely match
the Compressor output to the system demand.

If the system pressure rises above the minimum air line pressure
the electric motor speed will decrease, conversely, if the system
pressure falls below the minimum air line pressure the motor
speed will increase. The speed will vary between minimum and
maximum limits dependent upon system demand.

ST 16135-00A 13

General Description 6

Fig. 6.2 - Compressor Assembly

6.3 Compressor Assembly (Fig.6.2)

The unit comprises of a vertical single stage, oil flooded, rotary,
sliding vane Compressor driven by an electric motor mounted to a
base. It is supplied with control panel, starter, and combination oil
cooler/air aftercooler with all accessories piped in and electrically
connected.

The intake cover (A) is assembled directly to the Compressor (B)
which is fitted to the flange face of the drive motor (C). The rotor of
the Compressor is mounted on the drive shaft of the motor. The
motor is bolted to the vertical column supported by the base.

An electrically driven, impellor type, horizontally mounted fan (D)
is located below the combination oil cooler/air aftercooler matrix
(E). This draws cooling air through the air filter (F) and forces it
through the cooler matrix.

The Compressor control panel (G) is mounted on the front frame,
controls are accessible through an aperture in the front door
panel. The controller is an electronic device with an LCD screen.
An emergency stop button (X) is located on the front control
panel.

For RS models, the inverter drive (H) is mounted in the starter
compartment, behind the starter panel door (J).

The oil separator (S) located on the top ensures air delivered
through the minimum pressure valve has an oil cleanliness of less
than 3 ppm (parts per million by weight). The air is delivered
through the air delivery pipe (T) to the after cooler.

The oil supply to the cooler is through oil feed pipe (V) with the
cool oil return via oil return pipe (W) For a quick warm up, a
thermal by-pass valve (Y) allows the oil supply to by-pass the
cooler on initial start up.

The Compressor air intake is protected by an air intake filter (K),
and the oil system is filtered by an oil filter (L). An oil level sight
glass (M) is mounted adjacent to the oil filter.

The Compressor is filled and topped up with oil via the oil filler (N).
The sight glass should be full to overflow from the level plug orifice
(O).

Oil is drained from the Compressor and cooler by removing a
drain plug (P) and opening the drain tap (Q).

The Compressor pressure gauge (R) is visible when the top panel
is removed.

14 ST 16135-00A

7 Operating Instructions
7 Operating Instructions

7.1 Operating Instructions

WARNING !

READ HEALTH AND SAFETY PRECAUTIONS
BEFORE YOU START ANY SERVICE WORK.

THE COMPRESSOR SHOULD ONLY BE
OPERATED BY AUTHORISED PERSONS FULLY
TRAINED IN THE STARTING, STOPPING AND
EMERGENCY STOP PROCEDURES.

7.1.1 Checking Procedure Before Starting

(a) Check sight glass is full.
(b) Check filler, drain/oil level plugs are fitted securely.
(c) Check for any signs of oil leaks.
(d) Check air-outlet valve is open.
(e) Check that the emergency stop button is released.
(f) Turn mains electricity supply on.

7.1.2 Operating Mode

When electricity is first switched on the electronic controller
(Fig7.2) displays all symbols and illuminates both green and red
LED indicators for three seconds (Fig.7.1)

Fig. 7.1 - Controller Display

The display then shows the software version code for a further
three seconds before showing the normal operating display

For single speed Compressors the controller allows two operating
modes, automatic stop/start or continuous run.

7.1.3 Compressor Operation

Automatic stop/start is set as default. For continuous running
select Mo – MAN, using the touch sensitive symbol buttons on the
controller panel.

Select Mo using plus up/minus down buttons, press the enter
button, AUT will flash, press plus up/minus down button to
change, press enter button to select.

The operating mode may be altered when the Compressor is
running or stopped.

Fig. 7.2 - Controller

ST 16135-00A 15

Operating Instructions 7

Press Plus Up/Minus Down buttons to scroll through available
user menu codes P00 (view only).

(a) Mo - Select Automatic or Manual Control
(b) Td – RSU* temperature (View Only)

* Temperature at discharge from compression unit
As a default value the Td – temperature appears in the

bottom of the display.
(c) PD – Delivery Pressure (View Only)
(d) H1 – Hours Run (View Only)
(e) H2 – Loaded Hours (View Only)
(f) H3 – Hours Remaining to Service (View Only)

To select and lock other menu items, scroll to the menu required,
when in view press the ENTER button, a flashing key symbol is
displayed.

To cancel the locked selection and flashing key symbol press the
ESCAPE (C) or reset button.

During operation, the controller records the total running hours,
the hours run on load and counts down to the next service
interval.

The service interval is set for 2000 hours when using Fluid Force
Red 2000 oil. This interval will be reduced if the unit operates
above the recommended temperature.

7.1.4 Starting - Automatic Mode

Press the green START button. The Compressor will start if
system pressure is below the minimum air line pressure set point.
On initial start with no pressure in the system, the pressure
display will quickly rise to the full delivery pressure. During this
period, the green LED will be continuously illuminated.

The Compressor will continue to run and pressure will vary within
the air line pressure set points to match the system demand.

If the system demand reduces and pressure rises to the maximum
pressure set point, the REVS (Reduced Energy Venting System)
sequence will begin.

If there is an air demand during the REVS run on time sequence
the Compressor returns to full load operation.

7.1.6 Starting - Regulated Speed

For variable speed models, the starting sequence is the same as
that shown for single speed automatic mode except that, instead
of the Compressor continuing to run and pressure varying within
the air line pressure set points, the Compressor will continue to
run and the speed will vary automatically to match system
demand.

With no system demand when running at minimum speed the
Compressor will stop after the REVS venting sequence.

Automatic restart will occur when system pressure falls to the
minimum air line set point.

7.1.7 Stopping – All Models

To stop the Compressor, press the red STOP button, system
pressure will remain high initially, but will fall gradually with the
rate of decay depending on system usage.

7.1.8 Emergency Stop

If an emergency occurs, press the EMERGENCY STOP button.

The button will lock in the depressed position and stop the
Compressor immediately.

The red LED on the controller will flash quickly together with
display symbols.

Clear any faults that may have occurred. Do not reset until it is
safe to do so.

Reset the emergency stop button by twisting clockwise before
restart.

Press the RESET button on the controller to cancel the red LED
and display symbols.

Operation of the emergency stop button is recorded in the
controller error log.

7.1.9 Compressor Vent Down

Venting is controlled automatically by the REVS system for either
operating mode for all models.

If there is no air demand during the REVS run on time sequence
the Compressor will stop.

Automatic restart will occur when system pressure falls to the
minimum air line pressure set point.

7.1.5 Starting - Continuous Mode

Press the green START button. The Compressor will start, and
run continuously within the air line pressure set points to match
system demand.

On initial start with no pressure in the system, the pressure
display will quickly rise to the maximum air line pressure set point.
During this period, the green LED will be continuously illuminated.

16 ST 16135-00A

7 Operating Instructions

7.2 Operational Display Symbols

Motor running Power failure auto-restart (optional

Loaded Remote load or remote pressure

Amount of time, timer Remote start/stop

Filter, differential pressure Normal operational mode:

Pressure set point indication
(upper & lower set point indicators
displayed independently)

Condensate drain active (optional
function)

function)

regulation active

Selected item locked as
temporary default display

Menu mode:

Page item locked
(adjustment inhibited)

ST 16135-00A 17

17

8 Adjustments

8 Adjustments

8.1 Compressor Control (Fig.8.1)

The Compressor controller has additional user menus, P01 for

Operation and P02 for Error Log recording. The operation menu

contains parameter settings that can be modified to suit system

requirements.

Solenoid valves are mounted on top of the starter enclosure, on

the right hand side under the top panel cover.

A normally closed solenoid valve (A) controls compressor delivery

pressure using the REVS start system to reduce power.

The normally open solenoid valve (B) vents the compressor

during the REVS sequence for offload power savings and after

stopping allows quick restart if required.

Compressor internal pressure can only be viewed from the gauge

fitted to the intake end cover.

plus up/minus down to change the value to the desired pressure
and press ENTER.

All items configured within menu P01 can be changed to suit the
operational parameters for a particular installation.

(a) Pu Maximum Air Line Pressure
(b) PL Minimum Air Line Pressure
(c) Rt REVS Delay Period
(d) St Run-on-Time to Stop
(e) PD Pressure Display Units
(f) Td Temperature display units

Press ESCAPE to initiate a display jump-back to the normal
display mode, level P00 view only.

Note that during changes, if no key activity is detected for one
minute, the display will automatically jump back to the normal
operational display.

The error log menu P02 retains the most recently recorded fault
codes and the hours when the fault occurred. The display is view
only and will automatically alternate between the two values.

An explanation of the fault codes recorded is given in Section10,
Fault Finding.

Fig. 8.1 - Solenoid Locations

8.2 Pressure Adjustments

To alter default values in menu P01, or view error codes in P02,

press the plus up/minus down buttons together on the controller,

an access entry code will be displayed.

Use plus up/minus down buttons to enter zero for the first flashing

character, then press ENTER. The next character flashes, repeat

as before and enter zero for characters two and three, but enter 9

for the final character.

With all four characters set, press either menu P01 to change

parameter settings, or P02 to view error codes.

In menu P01, press plus up/minus down buttons to scroll to either

Pu maximum air line pressure or PL minimum air line pressure.

With Pu or PL flashing, press ENTER, the value will flash, press

ST 16135-00A 19

8.3 Pressure Control – RS Compressors

WARNING !

ISOLATE THE COMPRESSOR FROM THE MAINS
ELECTRICAL SUPPLY. LOCK THE ISOLATOR IN
THE OFF POSITION. FIT A SAFETY NOTICE TO
THE ISOLATOR ADVISING THAT WORK IS BEING
CARRIED OUT ON THE COMPRESSOR.

Compressors have factory settings for minimum and maximum
line pressure, servo valve pressure, inverter/motor speed control.

V15RS default settings are in bold type:

Operating pressure 7.0 bar 8.0 9.0 10.0

Min Line pressure PL 6.5 bar 7.5 8.5 9.5

Max Line pressure Pu 8.0 bar 9.0 10.0 11.0

Servo 8.5 bar 9.5 10.5 11.5

The minimum air line pressure may be adjusted from the 8 bar
default setting in the range 7 to 10 bar.

Adjustments 8

Both parameters PL and Pu must be set together via the controller
as above together with manual servo adjustment to ensure that
the compressor functions correctly.

USER WARNING

Compressor pressure control adjustments should not be
attempted by the user and must be carried out by a Hydrovane
authorised service engineer. Failure to comply with this
requirement may invalidate the Compressor warranty.

20 ST 16135-00A

9 Servicing

9 Servicing

9.1 Introduction

WARNING !

READ HEALTH AND SAFETY PRECAUTIONS

BEFORE YOU START ANY SERVICE WORK.

SERVICING OF THE COMPRESSOR MUST ONLY

BE CARRIED-OUT BY AUTHORISED PERSONS

FULLY TRAINED AND COMPETENT IN THE

MAINTENANCE, MAINS ELECTRICAL SUPPLY

AND STARTER CONTROL EQUIPMENT OF

HYDROVANE COMPRESSORS. THEY MUST

FULLY UNDERSTAND AND ADOPT CORRECT

AND SAFE WORKING PRACTICES.

If you are unable to carry-out the work safely in the required

manner, your Hydrovane Distributor will be pleased to help.

Use genuine CompAir parts and approved oils during routine

servicing, the following service kits available:

KO1115E 2000 hour/ 1 year oil change kit

KM1115E 4000 hour/ 2 year maintenance kit

9.4 Check Compressor Operation

Assuming the Compressor is serviced correctly, the machine is
capable of operating in ambient temperatures up to a maximum of
45°C (40°C RS). At this ambient temperature the oil temperature
will be typically 85°C to 90°C.

When the Compressor is working, the temperature should be:-

Initial start-up and warm-up period. <70°C

Optimum working temperature. 80 - 90°C

High temperature. 90 -100°C

Warning ! Consult your distributor. >107°C

9.4.1 Check Compressor Pressure

To check Compressor pressure, open the front door panel, then
remove the top panel from the snap fit location pegs. Use the
pressure gauge located adjacent to the air filter.

9.4.2 Check oil level (Fig.9.1)

With the Compressor stopped check the oil level using the sight­glass fitted near the end of the oil filter.

KT1115E Top-up kit/ Full Overhaul

9.2 Routine Service Schedule

The work listed in this section must be carried-out at the indicated

running-hours, which must be regarded as a maximum. In dusty,

hot or humid conditions, more frequent servicing may be

necessary.

This section shows the minimum service requirements for your

Compressor. To ensure that the full compressor maintenance

programme is carried out, we recommend that your Compressor

is regularly serviced by an authorised Hydrovane Distributor.

9.3 Servicing (RS)

Servicing intervals and procedures are the same as specified for

the standard fixed speed Compressor of the same power (kW)

rating.

The speed control unit does not require any routine servicing.

After very long periods, it is recommended that the speed control

unit capacitors and cooling fan(s) be replaced to ensure continued

reliability of the unit. Refer to your Hydrovane Distributor for

details.

Fig. 9.1 - Oil Level Sight Glass Location

ST 16135-00A 21

9.5 Basic Service

WARNING !

STOP THE COMPRESSOR AND ISOLATE IT
FROM THE MAINS ELECTRICAL SUPPLY. LOCK
THE ISOLATOR IN THE OFF POSITION. FIT A
SAFETY NOTICE TO THE ISOLATOR ADVISING
THAT WORK IS BEING CARRIED OUT ON THE
COMPRESSOR.

CLOSE THE AIR OUTLET VALVE TO ISOLATE
THE COMPRESSOR FROM THE AIRLINE
SYSTEM. FIT A SAFETY NOTICE TO THE VALVE
ADVISING THAT IT IS NOT TO BE OPENED.

DO NOT PROCEED UNTIL THE AIR PRESSURE
GAUGE READS ZERO !

CAUTION !

(1) When changing recommended oil types, it
is advisable to flush the Compressor.

(2) When changing to Fluid Force Clear, the
Compressor must be flushed out with Fluid Force
Prime.

Servicing 9

Fig. 9.2 - Oil Filler Plug, Air Filter and Separator

Element Location

9.6 Access Panel Removal

With the Compressor stopped ensure pressure is vented from the
air aftercooler and associated pipework.

To conduct the following routine tasks, it is necessary to unlock
(key provided) and open the hinged front door panel to allow
removal of the top panel.

Remove the top panel from the snap fit location pegs and lift clear
of the Compressor.

Check that the Compressor pressure gauge reads zero.

9.7 Oil Draining and Filter Replacement

(Fig.9.2 and Fig.9.3)

WARNING !

AVOID UNNECESSARY CONTACT WITH HOT OIL
AND COMPONENTS. GLOVES ARE
RECOMMENDED IF DRAINING OIL WHEN THE
COMPRESSOR IS HOT!

9.8 Oil Draining

Remove the filler plug (Fig.9.2 (A)) and the bonded seal (B) to
allow air to enter the Compressor to aid drainage.

Place a suitable container, capable of holding in excess of 6 litres,
below the oil drain point. Remove the drain plug from the end of
the tap (Fig.9.3), turn the tap and allow the oil to drain.

Fig. 9.3 - Oil Drain and Filter Location

When draining is complete, turn the drain tap to the off position
and replace the drain plug in the tap. Clean away any oil spillages.

9.9 Oil Filter Replacement (Fig.9.3)

Unscrew the oil filter in an anti-clockwise direction, minimise oil
spillage from the canister. Clean away any spillage and discard
the old filter in a safe manner.

22 ST 16135-00A

9 Servicing

Using a new filter, smear a small amount of oil onto the seal,

screw in clockwise to tighten, hand tight only.

9.10 Oil filling / Top-up (Fig.9.3)

Remove and retain the level plug located just behind the bypass

valve.

Fill the Compressor with oil until the sight glass is full. Fluid Force

Red 2000 is recommended as the standard oil. DO NOT

OVERFILL.

When the level is correct, oil will overflow from the level plug. Stop

filling and replace the level plug. Clean away any spillage.

Refit the filler plug Fig.9.2 (A) and bonded seal (B). Renew the

bonded seal if damaged, and tighten the plug using a suitable

spanner. Do not over tighten.

9.11 Air Filter Replacement (Fig.9.2)

To change the air filter element, twist the cap of the air filter

container (D) anti-clockwise then lift vertically to expose the

element.

Remove the old element and discard in a safe manner and

replace with a new element before replacing the cap.

9.12 Oil Separator Replacement (Fig.9.2)

Unscrew the oil separator (C) in an anti-clockwise direction and

discard in a safe manner.

Using a new separator, smear a small amount of oil onto the seal,

screw clockwise to tighten, hand tight only.

9.13 Clean Oil Cooler/Aftercooler (Fig. 9.4)

Inspect the cooler matrix for signs of damage. If the matrix is

damaged, consult your local Hydrovane Distributor.

The cooler matrix airflow is from the inside to outside; cleaning is

best achieved by reversing the airflow to dislodge any

accumulation of dirt.

Using low pressure air (2 bar), blow over the whole area of the

matrix (A). To remove the rear panel it is necessary to remove two

internal cap head screws at the top of the rear frame that hold the

panel. Ease the rear panel away from the frame and lift it clear.

Vacuum or brush the area behind the cabinet filter (B).

All discarded items and waste oil must be disposed of in an

approved manner.

9.14 Cabinet Air Filter

This is a disposable item which is to be changed every

2000hours. To remove the filter, slide upwards and pull the

bottom edge clear of the retaining lip. Refitting is the reverse.

9.15 Panel Refitting

Refit the top panel (firm push fit), close and secure the front panel

door and the starter panel door (if opened). Test run the

Compressor and check operation using the Controller.

Fig. 9.4 - Matrix Cleaning

9.16 Electrical checks

WARNING !

ISOLATE THE COMPRESSOR FROM THE MAINS
ELECTRICAL SUPPLY. LOCK THE ISOLATOR IN
THE OFF POSITION. FIT A SAFETY NOTICE TO
THE ISOLATOR ADVISING THAT WORK IS BEING
CARRIED OUT ON THE COMPRESSOR.

Open the starter panel door with the key provided.

Remove any terminal covers fitted to contactors and incoming
supply terminals.

Check for any signs of overheating and ensure that all electrical
connections are tight.

Pay special attention to power connections, cables connected to
contactors and incoming terminals and ensure all earthing wiring
is present and undamaged.

Close the starter panel door and lock with the key provided to
prevent unauthorised access.

9.16.1Clean motors

Remove any dust or dirt from motor bodies and motor air intake
grill located under the Compressor base.

Remove safety notices.

If the oil filter has been replaced, run for Compressor for a short

time (30 seconds) and re-check the oil level.

ST 16135-00A 23

9.17 Servicing Requirements

The following preventive maintenance charts cover all Hydrovane
Compressors using Hydrovane Fluid Force Red 2000 (Table 9.1)
and Hydrovane Fluid Force HPO, oils (Table 9.2). The work to be
carried out must be done on or before the hours shown for this
action, or yearly, whichever is soonest.

Note: Service Tables 9.1 & 9.2 are shown in entirety, shaded
items are Hydrovane Distributor maintenance tasks only.

For service schedules using Hydrovane Fluid Force Clear, consult
your local Hydrovane Distributor.

READ HEALTH AND SAFETY PRECAUTIONS
BEFORE STARTING ANY WORK.

9.18 Service Schedule: Fluid Force Red 2000

(2000 hour oil change)

The bulk oil temperature must not exceed 100°C. If the oil is
working above this temperature, the oil life will be reduced.

When changing to Fluid Force Clear the Compressor must be
flushed out with Fluid Force Prime in order to comply with USDA
H1 standard.

Servicing 9

The service life of the air filter and cabinet filter are an indication
only, actual life durability will depend on the operating conditions.

24 ST 16135-00A

9 Servicing

Table 9.1 - Preventative Maintenance Schedule Fluid Force Red 2000.

Every

Maintenance Actions

Site-sufficient access for service X
Site–protected from weather X
Site–adequate ventilation X X X X X X
Site–ambient temperature within limit X X X X X X
Site–dust free ambient X X X X X X
Check/torque electrical connections X X X X
Check oil level filter at plug/sight glass X X X X X X
Check correct drive rotation X X
Check for air leaks X X X X X
Check for oil leaks X X X X X
Check air intake filter/clean as necessary X X
Check power on-load X X X X
Check power off-load X X X X
Check oil temperature X X X X X
Check RSU temperature X X X X X
Check servo pressure off-load X X X X
Check motor gland/cables secure X X X X
Check motor for damage X X X X
Check motor for loose connections X X X X
Check motor cables and earth are sound X X X X
Check motor for vibration X X X X
Check flexible oil pipes are undamaged X
Check oil seal for leakage X X
* Check drive media X X
Check starter contactors X X
Check motor insulation resistance X
Check combi cooler matrix X X X X
Clean any external dirt from Compressor X X X X X
Clean any external dirt from motor X X X X X
Clean combi/cooler cabinet filter X
Clean solenoids X X X
Change separator element X X
Change 2000 hour oil X X X
Change oil filter X X X
Change air intake filter X X X
Change combi/cooler cabinet filter X X X
Change unloader valve seals X X X
Change MPV seals X X X
Change vacuum valve seals X X X
* Change flexible pipes X X
Change thermal motor X X
Grease motor bearings (if applicable) X
Full air end inspection (internal) X
* Clean servo filter X
* Change drive media X
Change oil seal X
Change pressure gauge X
Change motor bearings X
Full operational test/check X X X X

Install Daily Weekly

2000

hrs

Every

6000

hrs

Every
24000

hrs

* Not applicable to this model range

ST 16135-00A 25

Table 9.2 - Preventative Maintenance Schedule Fluid Force HPO

Servicing 9

Maintenance Actions

Site-sufficient access for service X
Site–protected from weather X
Site–adequate ventilation X X X X X X
Site–ambient temperature within limit X X X X X X
Site–dust free ambient X X X X X X
Check/torque electrical connections X X X X
Check oil level filter at plug/sight glass X X X X X X
Check correct drive rotation X X
Check for air leaks X X X X X
Check for oil leaks X X X X X
Check air intake filter/clean as necessary X X
Check power on-load X X X X
Check power off-load X X X X
Check oil temperature X X X X X
Check RSU temperature X X X X X
Check servo pressure off-load X X X X
Check motor gland/cables secure X X X X
Check motor for damage X X X X
Check motor for loose connections X X X X
Check motor cables and earth are sound X X X X
Check motor for vibration X X X X
Check oil seal for leakage X X
* Check drive media X X
Check starter contactors X X
Check motor insulation resistance X
Check combi cooler matrix X X X X
Clean any external dirt from Compressor X X X X X
Clean any external dirt from motor X X X X X
Clean combi/cooler cabinet filter X
Clean solenoids X X X
Change separator element X X X
Change 4000 hour oil X X X
Change oil filter X X X
Change air intake filter X X X
Change combi/cooler cabinet filter X X X
Change unloader valve seals X X X
Change MPV seals X X X
Change vacuum valve seals X X X
* Change flexible pipes X X X
Change thermal motor X X X
Grease motor bearings (if applicable) X X
Full air end inspection (internal) X
* Clean servo filter X
* Change drive media X
Change oil seal X
Change pressure gauge X
Change motor bearings X
Full operational test/check X X X X

Install Daily Weekly

Every

2000

hrs

Every

8000

hrs

Every
24000

hrs

* Not applicable to this model range

26 ST 16135-00A

10 Fault Finding

10 Fault Finding

10.1 Fault Finding

WARNING !

The Controller sequential logic monitors and checks the

Compressor status through all stages of the operational cycle. At

each stage, the configuration and parameter limits set within the

Controller must be met for continued safe operation of the

Compressor.

If faults occur they appear on the Controller display with a specific

code, the last character, E, A or R, identifies the fault type.

10.2 Shutdown Trip Error (E) – Menu P03

A shutdown error stops the Compressor immediately or by normal

stopping sequence, preventing damage or a hazardous condition.

The error condition must be located and corrected, press reset to

cancel the error and the Compressor can restart. Immediate

shutdown error codes have a first character of 0, normal stopping

sequence records 1 as the first character.

Er 0010 E Emergency stop
Er 0020 E Fan motor overtemperature or circuit breaker

tripped
Er 0030 E Motor overload tripped (if fitted)
Er 0080 E Motor fault (fault relay contact, overload device

contact or thermistor)
Er 0115 E Delivery pressure sensor fault
Er 0119 E Delivery pressure high
Er 0125 E Delivery temperature sensor fault
Er 0129 E Delivery temperature high
Er 0135 E Compressor pressure sensor fault
Er 0821 E Low resistance, short circuit/short circuit to earth

condition, cable or sensor fault
Er 0836 E Controller internal error
Er 0846 E Delivery pressure sensor range set too low for

default pressure settings to be applied

10.4 Run Inhibit (R) – Menu P05

A run inhibit will prevent motor start until the fault is located and
corrected. With normal operational status restored, press reset to
cancel the error.

Er 3123 R RSU delivery temperature (Td) below the set

temperature run inhibit level.
Controller allows motor start when temperature

increases above the set level.
Fluid Force 2000 is set at - 5°C

Fluid Force HPO has a value of -15°C.

Er 3137 R Run inhibited until restart time reached after

power failure.

Further menus with restricted access codes are intended for
service level activities 1 and 2. These are reserved for use by fully
trained Hydrovane authorised service engineers.

We strongly advise that no attempt is made to access these
structures, continued safe operation may be impaired and/or
serious damage may occur.

10.5 Fault Display Symbols

General fault

Emergency stop

Excess pressure

Power failure

Above set temperature limit

Lubrication, oil, oil level

10.3 Alarm (A) – Menu P04

Alarms occur as a warning when normal operating conditions are
exceeded, but will not stop the Compressor from being started
and run. General alarm codes start with a first character of 2,
service alarms begin with 4.

Er 2118 A Delivery pressure high
Er 2128 A Delivery temperature high
Er 2816 A Power failure in start mode

A service timer counts down from set values until a routine service
is due at 0 that sets off an alarm. A negative value count
continues until the timer is reset by maintenance personnel after
the required service.

Er 4804 A Service hours time expired, service due (reset

service hours countdown timer)

10.6 Diagnostic Menu P06

The menu structure allows a technician to check and test all the
inputs and outputs to the Controller individually without running
the Compressor.

Dewpoint

Motor

Service due, maintenance

Filter differential, filter service

ST 16135-00A 27

10.7 Configuration Menu P07

Basic operating configuration settings are applied to the
Compressor that control starting characteristics and pressure load
and unload features with associated time delays

10.8 Speed Regulation Menu P08

This function provides P & I loop control for a variable speed drive
in order to maintain a steady target/load pressure.

10.9 Calibration Menu P09

Pressure sensors must be set to atmospheric pressure with the
Controller pressure display set to zero. Range calibration must be
accurately applied to achieve correct performance and pressure
related safety functions.

10.10Access Level Configuration Menu P10

Special functions and settings that determine Compressor specific
configuration generally set once during factory default settings
and site commissioning.

If, for any reason, you feel unsure about fault rectification, or any
service aspect relating to your Hydrovane Compressor, please
contact your nearest Hydrovane Distributor.

Fault Finding 10

28 ST 16135-00A

Copyright © 2006

All rights reserved. The copyright of this document is the property of

CompAirUKLimited. No part of this publication may be reproduced, stored in

aretrieval system, or transmitted, in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise without the prior written

permission of the Technical Publications Department, CompAir UK Limited.

CompAir UK Limited
Claybrook Drive
Washford Industrial Estate
Redditch
Worcestershire
England
B98 0DS

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E-mail:

Telephone:

Fax:

www.hydrovane.co.uk

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ST 16135-00A