User Handbook

V01-V04 Models (PUAS, PURS, PUTS)

Stationary Air Compressors

ST15948-00A 08/2011

Contents

hydrovane

1.0 Introduction
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 Product Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2.0 Safety
2.1 General Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 The Health and Safety at Work Act . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Before Working on the 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
3.0 Product Information
3.1 Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 High Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Technical Data V01-V04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.0 Transportation and Handling
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Lifting and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Weights and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.0 Installation and Commissioning
5.1 Positioning Your Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Check Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.0 General Description
6.1 Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Membrane Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 HFP06 Short Run Auto Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.0 Operating Instructions
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2 Checking Procedure Before Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3 Starting V01-V04 Receiver/PURS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.4 Starting V01-V04 Tripod/PUTS/PUAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.5 Auto/Manual V04 Tripod/PUAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.6 Stop/Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.7 Compressor Vent Down Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ST15948-00A

hydrovane

Contents

8.0 Adjustments
8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.2 Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.3 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.4 Check Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.5 Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.6 Run on Timer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.0 Servicing
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.2 Routine Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.3 Check Compressor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.4 Basic Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9.5 Servicing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.6 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.7 Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10.0 Fault Finding
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.2 High Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.3 High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.4 Low Air Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.5 Compressor Stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.6 Excessive Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.7 Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

ST15948-00A

1.0 Introduction

IMPORTANT !

hydrovane

1.5 Model Range

BEFORE INITIAL START-UP ENSURE THAT THE COMPRESSOR This handbook relates to all V01-V04 50/60Hz compressors, model
OIL CHAMBER IS FILLED TO THE CORRECT LEVEL WITH A types PUAS/PURS/PUTS.
HYDROVANE APPROVED OIL.
501PURS10-2216D305, 501PURS10-2235D300
1.1 Support
501PURS10-3836D305, 501PURS10-4035D300
Your hydrovane distributor is able to offer a wide range of compressors, dryers, filters and ancillary air-line system products. Their engineers are fully trained and competent in all aspects of compressor
and air-system maintenance. If you need any specialist help or service please contact your hydrovane distributor quoting the MODEL,
TYPE and SERIAL NUMBER.

1.2 Customer Warranty Terms

All hydrovane compressors, which are serviced by an authorised
hydrovane distributor are guaranteed for twelve months from the
date of commissioning or eighteen months ex works, whichever is
the sooner.
The warranty excludes normal service parts, oil and wear items, dirt
ingress, cleaning of filters and fluid drain devices and the tightening
of electrical or other connections. Adjustment of pressure switches
or any other control device are not covered by the warranty.
Consequential damage of any nature is not covered by the warranty.

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.

501PURS10-2415D400, 501PURS10-4035D400
501PUTS10-2216D305, 501PUTS10-2415D300
501PUTS10-4035D300
501PUTS10-2415D400, 501PUTS10-4035D400
502PURS10-2415D300, 502PURS10-2415D300
502PURS10-2235D300, 502PURS10-4035D300
502PURS10-2415D400, 502PURS10-4035D400
502PUTS10-2415D300, 502PUTS10-4035D300
502PUTS10-2415D400, 502PUTS10-4035D400
504PUAS07-3835S110, 504PUAS10-3835S110
504PUAS10-4135S110
504PUAS10-2235D110, 504PUAS07-4035D110
504PUAS10-4035D110
504PUAS07-4035D210, 504PUAS10-4035D210
504PURS10-4035D100, 504PURS10-4035D110
504PURS10-4035D200, 504PURS10-4035D210
504PRDS10-4035D200

The last three digits of the product code represent mark number
changes, you may receive a unit with numbers higher than those
Hydrovane Quality Management Systems are approved to BS EN shown above
ISO 9001.

1.4 Quality Standards

1.6 Product Terminology

These instructions comply with the stipulation of European

Directive 2006/42/EC concerning machine safety and are valid for
machines carrying the CE label.
Gardner Denver Ltd
Claybrook Drive
Washford Industrial Estate
Redditch
Worcestershire B98 0DS
United Kingdom
Tel
Fax

+44 (0)1527 525522

+44 (0)1527 521140

Web

www.hydrovane.co.uk
[email protected]
www.compair.com

E-mail

ST15948-00A

[email protected]

5, V
01,02,04
PUAS
PURS
PUTS
07, 10
22, 40
1, 3
5, 6
D, S
200, 400

Series, Vane
kW Motor
Package Unit Aftercooler Starter
Package Unit Receiver Starter
Package Unit Tripod Starter
Delivery pressure in bars
Voltage
Single/Three phase
50/60Hz
Direct on Line, Star/Delta
Revision number

This publication refers to compressors with serial numbers from:

501-017883-0810 (400 builds/MK5)
502-023294-0810 (400 builds/MK5)
504-009513-0809 (200 builds/MK3)

Page 1

hydrovane

Page 2

1.0 Introduction

ST15948-00A

2.0 Safety

hydrovane

2.1 General Health & Safety Precautions

The Health and Safety information contained in this Handbook is

only intended to give general guidelines.

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

2.4 When Operating the Compressor

2.2 The Health & 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.

When in automatic mode the compressor will re-start without

warning.
If an automatic re-start device is fitted (allowing the compressor to
start when power is re-applied), or operation is controlled from a remote location, additional warnings will be required.
Do not remove any plugs or release pipework when the compressor
is running.

The compressor warranty will be invalidated if unapproved spare

parts or lubricants are used. Using such items may cause the effi- Do not attempt to open the starter enclosure while the compressor is
ciency and service life of the compressor to be reduced and could operating.
create a hazardous condition over which hydrovane has no control.
Beware of hot surfaces both the air-end and electric motor are deFailure to maintain the compressor correctly, or modifying it without signed to run at elevated temperatures.
prior approval from hydrovane may also create a hazardous condiCompressed air is dangerous and can be fatal if misused. Do not altion. This will also invalidate the warranty.
low compressed air jets discharged from any pipe or nozzle to make
Read and fully understand the contents contained in the user hand- contact with your body.
book.
Wear safety glasses and suitable clothing when using, or working in
Ensure that the user Handbook is not permanently removed from the an area where compressed air is being used.
compressor.
Hazardous vapours/fumes can be produced if compressed air is
Check that there are no signs of damage and/or oil leaks from the used to remove chemicals, cleaning agents and lubricants from
air-end, cooler and associated pipework.
equipment and components. Suitable respiratory and extraction
equipment may be required in these circumstances. Never use comAfter completing work, tools and foreign matter should be removed
pressed air for cleaning personal clothing.
from the compressor and its surrounding area.
Do not use air directly from compressors for breathing purposes. If
In the unlikely event of a compressor fire, dry powder or carbon
the air is to be used for human consumption then it must be
dioxide fire extinguishers should be used. Never use water.
subjected to further treatment to ensure that the levels of
contaminants, odour and moisture meet the requirements of BSEN
2.3 Before Working on Compressor
529 2005.
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 then a qualified electrician may remove the fuses and keep them in a secure
place until work is complete.

We recommend that the air supply to hand held air guns is regulated
to a lower pressure (refer to local health and safety regulations).
Do not insert any object or part of body through any opening of the
compressor enclosure. Serious personal injury and/or damage may
result.

Ensure the compressor has been safely isolated from the main air Never run the compressor when any covers or guards are missing,
system and cannot be re-introduced until all work has been com- unless advised to do so in this handbook.
pleted. Fit a safety notice to the isolation valve advising that work is
being carried out.
Do not undertake any work until the compressor and receiver if fitted,
have been relieved of all pressure.
Wait until the compressors vent down cycle is complete.
Open the outlet valve to release any pressure contained in the
aftercooler or associated pipework.
Check that the air-end 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 air-line system should be
checked at regular intervals and replaced if faulty. They should not be
tampered with or modified. Non return valves should not be used as
isolation devices.
To ensure the compressor operates safely you must carry out the
specified maintenance procedures.
Only approved lubricants should be used for flushing purposes.
Extreme caution should be taken if the compressor has been subjected to severe operating temperatures or fire. Certain components
may contain fluoroelastomer materials and under these conditions
can leave extremely corrosive residues. Severe burns and permanent skin and tissue damage can be a result of skin contact.

ST15948-00A

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2.5 Potential Oil Health Hazards

2.0 Safety

2.7 Warnings, Cautions and Notes

This section relates to Fluid Force Oil. For other lubricants refer WARNING is used in the text of this handbook to identify specific
to the Health and Safety Instructions issued with the relevant hazards which can cause injury or death. This type of hazard is identified below.
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. *

Risk of electric shock

Risk of danger

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.

Risk of hot surfaces

Always wash hands after use and before eating, drinking or smoking.
Eye protection must be worn

2.6 First Aid Measures

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

Dust protection must be worn

Skin Contact - *Mildly irritating. Remove by wiping. Wash with soap

and water. Apply emollient cream.

Warning pressurised vessel

Eye Contact - *Mildly irritating. Flush with copious amounts of warm

water. Seek medical advice if necessary.
Aspiration - If there is any suspicion of aspiration into the lungs (for
example during vomiting) admit to hospital immediately.
Inhalation - Remove from exposure into fresh air. If necessary give
artificial respiration or oxygen. Seek medical advice.
Pressure injection - Obtain immediate medical attention, even if injury appears minor.

Warning pressurised component or system

Warning unit is remotely controlled and may start without

warning

Read the instruction manual

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.

Do not operate the machine without the guard being fitted

Warning do not start the machine without

consulting handbook

Lifting point

Direction of rotation

CAUTION is used in the text of this handbook to identify incorrect

procedures which can cause damage to the compressor.
NOTE is used in the text of this handbook 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.

Page 4

ST15948-00A

3.0 Product Information

hydrovane

3.1 Operating Temperatures

Your compressor is designed to give optimum performance and
trouble free service life when the bulk oil temperature is between 7585C (167-185F).
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 com pressor 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 high air demand, usually 60 minutes, will be required.
In European ambient temperature and humidity conditions, the bulk
oil tem per a ture should be main tained be tween 75-85C
(167-185F) to avoid condensation forming within the compressor.
For PURS models a short run auto timer (HFP06) is available to extend and automate the full load running period, other models should
adopt the running period as recommended above.
Conditions or applications which prevent the compressor temperature from stabilising between these parameters should be avoided.
Consult your local distributor or hydrovane if you have any particular
concerns about operational characteristics of your compressor.

3.2 High Operating Temperatures

If your compressor frequently operates in high ambient temperatures the oil life will be reduced.
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.
Note:
Compressors will stop automatically if the temperature
rises above 110C (230F).

3.3 Noise Level

The compressor should be positioned where noise will not be a
problem. We recommend ear protection is used, when near the
compressor for extended periods.

ST15948-00A

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3.0 Product Information

3.4 Technical Data V01-V04

Model Number

V01

V02

V04

Performance
Free air delivered @ 7.0 bar (102 psi)

Litre/sec (cfm)

2.65 (5.6)

4.95 (10.5)

11.6 (24.6)

Free air delivered @ 10.0 bar (145 psi)

Litre/sec (cfm)

2.03 (4.3)

3.78 (8.0)

9.47 (20.1)

dB(A)

62

69

72

Drive motor power

kW (hp)

1.1 (1.5)

2.2 (3.0)

4.0 (5.5)

Starter Type

DOL/SD

Noise level

Direct on Line, Star/Delta

Drive Type

Direct

Operating Controls

Continuous Run, Automatic Stop/Start

Rotational Speed 50Hz

rev/min

Ambient Temperature Range

C (F)

0-40 (32-104)

Maximum Relative Humidity

1450

2900

1450

85 non-condensing

Maximum air discharge temp above ambient, without aftercooler

C (F)

50 (122)

Maximum air discharge temp above ambient, with aftercooler

C (F)

<10 (50)

Minimum Pressure Valve (MPV)

bar (psi)

5.5 (80)

Nominal Pressure

bar (psi)

7.0 (102) or 10.0 (145)

Maximum Pressure

bar (psi)

7.8 (113) or 10.8 (157)

Pressure Control Valve (PCV)

bar (psi)

7.3-7.8 (106-113) or 10.3-10.8 (149-157)

Pressure Switch Cut-in

bar (psi)

5.5 (80 psi) or 6.0 to 6.8 (87 to 99)

Pressure Switch Cut-out

bar (psi)

7.2-7.4 (104-107) or 10.2-10.4 (148-151)

Factory Settings

Installation
Air Connection Size

Rp

Minimum Room Volume

Room Air Inlet / Outlet area

Cooling Air Flow Rate
Recommended Air Receiver Capacity

3/8

10

12

m
m/hr (cfm)
Litre (gallon)

0.3
1500 (883)

1800 (1060)

75 (19.8)

200 (52.8)

Compressor Oil
Approved Compressor Oil
Oil Capacity

FF Red 2000 (Mineral) & HPO (Synthetic)

Litre (gallon)

1.0 (.26)

1.8 (.48)

Electrical
Starter/Circuit Reference 220V 1PH 50Hz (PUTS)

300/MK4

35145/77391

35139/77388

Starter/Circuit Reference 220V 3PH 50Hz (PUTS)

300/MK4

35144/77673

35147/77673

Starter Reference 220V 1PH 50Hz (PUTS)

400/MK5

35208-01

35208-02

Circuit Diagram 220V 1PH 50Hz (PUTS)

400/MK5

Starter/Circuit Reference 400V 3PH 50Hz (PUTS)

300/MK4

35143/77673

35146/77673

Starter Reference 400V 3PH 50Hz (PUTS)

400/MK5

35208-03

35208-04

Circuit Diagram 400V 3PH 50Hz (PUTS)

400/MK5

Starter Reference 220V 1PH 50Hz (PURS)

400/MK5

Circuit Diagram 220V 1PH 50Hz (PURS)

400/MK5

Starter Reference 400V 3PH 50Hz (PURS)

400/MK5

Circuit Diagram 400V 3PH 50Hz (PURS)

400/MK5

Starter/Circuit Reference 220V 3PH 50Hz (PUAS)

110/MK2

35153/77396

Starter/Circuit Reference 400V 3PH 50Hz (PUAS)

110/MK2

35149/77389

Starter Reference 400V 3PH 50Hz (PUAS)

210/MK3

CC1050865

Pressure Switch Control Unit (PUAS)

210/MK3

CZ35150

Circuit Diagram 400V 3PH 50Hz (PUAS)

210/MK3

CZ77910

Page 6

77693

77693
35209-01

35209-02
77693

35209-03

35209-04

35209-05

77693

ST15948-00A

4.0 Transportation and Handling

hydrovane

4.1 Introduction
Ensure all lifting equipment and means of transportation are securely located and rated to accept the full load. Inspect all lifting
equipment for signs of wear. Do not use if wear is evident.

4.2 Lifting and Handling (Fig 4.1, 4.2, 4.3)

Before transporting, secure the compressor to a suitable pallet. Use
a Fork Lift or Pallet Truck to transport the compressor.

Fig 4.3 - V04 PURS Sling

Fig 4.1 - V01-V02 PURS Pallet

A suitable lifting platform will be required when positioning the compressor. For normal lifting a hoist may be used.
Lift the compressor and place it in the desired location.

Fig 4.2 - V04 PUAS Hoist

ST15948-00A

Page 7

hydrovane

4.0 Transportation and Handling

4.3 Weights and Dimensions (Fig 4.4, 4.5)

Table 4.1 shows weights/dimensions for the PUAS/PURS/PUTS
V01-V04 compressors.

Table 4.1 Weights and Dimensions

Ref.

Unit

V01-V02

V04

Tripod Mounted (PUAS)

-

Weight

41 (90)

90 (198)

Length

700 (27.56)

1100 (41.31)

Width

270 (10.63)

536 21.10)

Height

470 (18.50)

562 (22.13)

Receiver Mounted (PURS)

-

Weight

77 (170)

145 (320)

Length

1120 (44.09)

1410 (55.51)

Width

300 (11.81)

455 (17.91)

Height

730 (28.74)

990 (38.98)

Receiver Mounted with Dryer (PURDS)

Fig 4.4 - PURS Dimensions

Weight

93 (205)

156 (344)

Length

1153 (45.39)

1420 (55.91)

Width

320 (12.60)

459 (18.07)

Height

730 (28.74)

990 (38.98)

Weights kg (lbs), Dimensions mm (inch)

Fig 4.5 - PUTS Dimensions

Page 8

ST15948-00A

5.0 Installation and Commissioning

hydrovane

5.1 Positioning Your Compressor

5.3 Electrical Connections

We recommend an approved installation from an authorised

hydrovane distributor with a service agreement to maintain your
compressor.

WARNING !

Position the compressor in a room of adequate size on a firm surface, level in both planes within five degrees of the horizontal.
Ensure the area has sufficient load-bearing capacity, normally it is
not necessary to bolt the unit down.
Sufficient access (1 metre/3.3 ft) for all routine service procedures
should be provided all around and above the unit.
Site the compressor away 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.

5.2 Ventilation (Fig. 5.1)

Position the compressor in a well ventilated location. Do not restrict
the air-flow around the compressor or 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 0C (32F), consult your hydrovane distributor. A
different grade of oil may be required.
Air ducting, if fitted, must not cover or restrict the cooling air flow of
the compressor. Total 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.

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 AS P E C T S 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 the correct
cross sectional area.
Refer to starter and circuit diagrams before starting work. Note carefully the instructions relating to earthing, fuses and size of cable.
Fuses to BS88 (type gG) must be used to protect the starter, refer to
sizes specified on the circuit diagrams.
Circuit breakers are not recommended since they may not fully protect the starter contacts in an overload condition

5.4 Electrical Installation (Fig 5.2, 5.3, 5.4)

WARNING!
Remove starter cover (Fig 5.2).
Single phase Compressors must be connected to the mains electrical supply via a lockable, switched and fused isolator positioned
near to the compressor with clear unrestricted access.
The mains cable of all models are colour coded as follows:
BROWN
BUE
GREEN/YELLOW

LIVE, terminal 3/L2

NEUTRAL, terminal 5/L3
EARTH, terminal E

Pass the mains cable through entry hole (A). Connect the two mains
supply cables to the contactor terminals (C) marked 3/L2 (Brown)
and (D) 5/L3 (Blue). Connect the earth cable to the earth pin marked
E.
Connect a link wire from the overload terminal (B1) marked
A2/96NC (Brown) to the contactor terminal (B2) marked 1/L1.
Three phase Machines must be connected to the mains electrical
supply via a lockable, switched and fused isolator positioned near to
the compressor with clear unrestricted access.
Pass the mains cable through entry hole (A). Connect the three
mains supply cables to the contactor terminals (B) marked 1/L1
(Brown), (C) marked 3/L2 (Black) and (D) marked 5/L3 (Grey). Connect the earth cable to the earth pin marked E.
Note:
Cable sizes specified are the minimum size to suit typical
installation. If the compressor is located a long way away from the
isolator or the ambient temperature normally exceeds 35oC (95oF),
then cable size may need to be increased. Refer to IEE Regulations
for Electrical Equipment in Buildings to determine the size required.
Check transformer fuse is positioned to suit the supply voltage.

Fig 5.1 - Ventilation

Ensure that ALL electrical connections are tight, high voltage connections to contactors and incoming terminals are critical.
Switch the mains supply and/or isolator ON.

ST15948-00A

Page 9

hydrovane

5.0 Installation and Commissioning

5.5 Check Motor Rotation

WARNING !
READ HEALTH AND SAFETY PRECAUTIONS BEFORE
STATING COMPRESSOR.
Ensure that the compressor air-end is filled correctly with FLUID
FORCE RED 2000 or an APPROVED OIL and that all plugs are fitted securely.
Close air-outlet valve to air-line system and switch mains electrical
supply on.
Start compressor. Motor will now start and should rotate clockwise
when viewed from the drive-end.
If correct, the pressure displayed on the air-end pressure gauge will
immediately rise to 5.5 bar (80 psi).

Fig 5.2 Starter Cover

If not correct, pressure will not rise and the pressure gauge will read
zero.

CAUTION !
STOP THE COMPRESSOR IMMEDIATELY: SERIOUS DAMAGE
TO THE AIR-END WILL RESULT IF THE MOTOR IS ALLOWED
TO RUN IN REVERSE!

WARNING!
IF 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.
Single phase models.
Change over any two of the incoming cables connected to the starter
terminals 3/L2 and 5/L3.
Three phase models
Change over any two of the incoming cables connected to the starter
terminals 1/L1, 3/L2 and 5/L3.
Note: Qualified person only.
Ensure that all covers and panels have been securely reinstated.

Fig 5.3 V02 230V 1PH PUTS

Fig 5.4 V04 400V 3PH PURS

Page 10

ST15948-00A

6.0 General Description

hydrovane

6.1 Compressor Assembly (Fig. 6.1, 6.2)

6.2 Membrane Dryer (Fig 6.3)

The compressor assembly comprises of an air-end (A), complete

with oil cooler (B), driven by an electric motor (C). This assembly is
mounted to either an air receiver (D) or tripod (E) together with the
pressure switch (F) and starter box (R).

The compressor can be supplied with a dryer kit. This comprises of

an air-end, complete with cooler, driven by an electric motor. This
assembly is mounted to an air receiver together with the pressure
switch and starter box.

The air enters the compressor through an air filter (G). The air is
compressed with the air-end pressure displayed by pressure gauge
(H). It is then discharged through the air outlet pipe (J) and the
non-return valve (K) into the air receiver (D).

The air leaving the after cooler is feed into a water drain (Q) and two
filters (P), were solids and oil are removed. The air then enters the
membrane dryer (S), where it is passed down hollow microfibre
membranes. As air travels along the individual fibres, water vapour
contained within the air diffuses through the walls of the fibres and
collects on the outside. The air entering the receiver is now ultra dry.

Fitted into the air receiver is a safety valve (L), drain valve (M), pressure switch (F) starter (R) and pressure gauge (N) which displays
the pressure in the receiver and air-discharge tap (Z).
The oil sight glass (J) allows you to check the oil level, when the
compressor has stopped. The oil filler plug (K) incorporates a thermometer pocket which allows you to monitor the oil temperature.
When you fill or top-up the compressor the correct oil level is fill to
overflow.
To drain the compressor oil remove drain plug (L), to drain the receiver release drain valve (M).

Fig 6.3 Receiver Mounted with Dryer

Fig 6.1 Receiver Mounted

Fig 6.2 Tripod Mounted

ST15948-00A

Page 11

hydrovane

6.0 General Description

6.3 HFP06 Short Run Auto Timer (Fig 6.4)

The hydrovane HFP06 short run auto timer is designed to prevent
condensation build up in compressors that are used in applications
where they only run for a short time.
If the compressor only runs for a short time, over cooling can occur
and this means condensation build up in the compressor. The auto
timer starts up the compressor at an off duty period and lets it run on
load for a period at optimum working temperature, to boil off any
excess moisture.

Fig 6.4 HFP06 Short Run Auto Timer

Page 12

ST15948-00A

7.0 Operating Instructions

hydrovane

7.1 Introduction

7.4 Starting V01-V04 Tripod/PUTS/PUAS (Fig 7.2)

WARNING !

Complete checking procedure.

THE COMPRESSOR SHOULD ONLY BE OPERATED BY

AUTHORISED PERSONS FULLY TRAINED IN:- THE STARTING
AND STOPPING PROCEDURES.
BEFORE STARTING THE COMPRESSOR, READ THE HEALTH
AND SAFETY PRECAUTIONS.

7.2 Checking Procedure Before Starting

Check oil level.
Check filler and drain plugs are fitted securely.

Push the green start button (A).

The compressor will start immediately and run continuously irrespective of either the pressure in the air-line system or the air
demand.
On initial start-up the air-end pressure will immediately rise and the
air-end pressure gauge will read 4-6 bar (58-87 psi). The air-line
pressure will rise slowly and fluctuate with air demand.
If there is no demand for air the air-line pressure will rise until the
pressure control valve lifts and the pressure stabilises.

Check for any signs of oil or water leaks.

Refit all covers and secure.
Check compressor pressure gauge reads zero.
Check air-outlet valve is open.
Turn mains electricity supply on.

7.3 Starting V01-V04 Receiver/PURS (Fig 7.1)

Complete checking procedure.
Push the green start button (A).
The compressor will start immediately and will automatically stop
and restart according to air demand. On initial start-up the air-end
pressure will immediately rise and the air-end pressure gauge will
read 4-6 bar (58-87 psi). The air-line pressure will rise slowly and
fluctuate with air demand.
If there is no demand for air the air-line pressure will rise until the
high setting of the pressure switch is activated. The compressor will
stop immediately and will remain stopped until there is an air demand. When the pressure falls to the differential setting of the pressure switch the compressor will immediately restart.

Fig 7.2 V01-V04 Tripod/PUTS/PUAS

Fig 7.1 V01-V04 Receiver/PURS

ST15948-00A

Page 13

hydrovane

7.0 Operating Instructions

7.5 Auto/Manual V04 Tripod/PUAS (Fig 7.3)

Select AUTO (LH) for automatic stop/start and restart according to air
demand.
Select MANUAL (RH) for continuous run irrespective of either the
pressure in the air line system or the air demand.

Fig 7.3 V04 Tripod/PUAS

7.6 Stop/Emergency Stop (Fig 7.1, 7.2)
Close air-outlet valve.
Press the stop/emergency stop button (B).
If an emergency occurs, hit the stop/emergency stop button (B). The
button will lock in the depressed position and stop the compressor
immediately.
Clear ant faults which may have occurred, do not re-start until safe to
do so.
Reset the stop/emergency stop button by twisting it clockwise before
restart.

7.7 Compressor Vent Down Time

After stopping the air-end must be allowed to vent down naturally.
Speeding up the de-pressurisation may cause separator flooding.

Page 14

ST15948-00A

8.0 Adjustments

hydrovane

8.1 Introduction

Carefully open air-outlet valve (A), allow pressure to fall slowly until
compressor cuts-in (re-starts).

WARNING !

Check and record cut-in pressure shown on pressure gauge (B).

READ HEALTH AND SAFETY PRECAUTIONS BEFORE

MAKING ANY ADJUSTMENTS.

Stop compressor.

Adjustment procedures shown must only be carried out by

authorised persons fully trained and competent in the maintenance
of hydrovane compressors.
If you are not able to carry out the work safely, contact your
hydrovane distributor.

8.2 Pressure Control Valve (PUAS)

Pressure control valves are pre-set and cannot be adjusted, if faulty
they must be replaced.
Factory settings

07 bar models 7.3-7.8 (106-113 psi)

10 bar models 10.3-10.8 (149-157 psi)

8.3 Pressure Switch (Fig. 8.1)

8.5 Pressure Switch Adjustment (Fig. 8.2, 8.3)

Close air-outlet valve (A).
Start compressor, allow pressure to rise until compressor cuts-out
(stops).

WARNING !
ISOLATE THE COMPRESSOR FROM 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.

Condor Pressure Switch (Fig 8.2)

Remove pressure-switch cover.

The pressure switch (C) is located in the air receiver and is pre-set at
the factory. The recommended cut-out pressure (high pressure
switch setting) is a maximum and must not be exceeded. The cut-in
pressure (re-start pressure switch setting) may be adjusted to suit
your application.

To adjust the cut-out higher (stop) pressure; turn the screw marked
(P1) towards:-

Factory setting 10 bar (145 psi) machines:-

plus (+) to increase cut-out pressure; compressor stops at a higher

pressure.

Cut-out = 10.2-10.4 bar (148-151 psi) (max) Cut-in = 6.0 - 6.8 bar
(87-99 psi)

minus (-) to reduce cut-out pressure; compressor stops at a lower

pressure.

Note: Cut-out, higher (stop) pressure must not be set above

10.4 bar (151 psi).

Note:
Do not adjust unless pressure switch is under pressure
and the compressor has been safely isolated from the mains
electrical supply.

To adjust the lower cut-in (start) pressure; turn screw marked (P2)
towards:-

Pressure sensing

minus (-) to reduce differential and restart the compressor at a

higher pressure.

Since the pressure switch is located into the air receiver we recommend that you do not fit a non-return valve in your air-line system.
If a non-return valve is essential for your application then the
air-supply to the switch must be relocated after the non-return valve.

plus (+) to increase differential and restart the compressor at a lower

pressure.
Re-fit pressure-switch cover, switch mains electrical supply on.
Start compressor and carry-out check settings procedure.

MAX

Fig 8.1 - Pressure Switch Location

DIFF

8.4 Check Setting Procedures

Cut-out (stop) pressure:Close air-outlet valve (A).

Fig 8.2 - Condor Pressure Switch

Start compressor, allow pressure to rise until compressor cuts-out

(stops).
Check and record cut-out pressure shown on pressure gauge (B).
Cut-in (re-start) pressure:-

ST15948-00A

Page 15

hydrovane

8.0 Adjustments

Danfoss Pressure Switch (Fig 8.3)

8.6 Run on Timer Adjustment (Fig 8.4)

The maximum and differential pressures are factory pre-set, the

maximum pressure will not normally need adjustment. The differential pressure can be re-set to give the correct cut-in pressure required by the air system. Before adjustment is attempted ensure
that there are no leaks in the pipework system.

Stop the compressor

Remove the pressure switch control unit cover to expose the pressure switch (A).
Remove grommet (B), keyplate retaining screw (C), remove
keyplate (D).
Maximum Pressure Adjustment
Adjust screw (E) until the MAX scale indicates 7.2 bar (104 psi) on 7
bar compressors or 10.2 bar (148 psi) on 10 bar compressors, these
pressures should not be exceeded.
Differential Pressure Adjustment

WARNING !
ISOLATE THE COMPRESSOR FROM 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.
Remove the pressure switch control unit cover to expose the run-on
timer (A).
Adjust timer K2T to the required run on time (1-10 minutes). The
timer is pre-set at the factory for 2 minutes. Do not set the timer to
less than 30 seconds
Re-fit pressure switch cover, switch mains electrical supply on.
Start compressor and verify that setting is correct.

Adjust screw (F) until the DIFF scale gives the required differential
MAX pressure minus DIFF pressure equals MINIMUM (cut-in)
pressure.
The differential pressure is factory pre-set to between 1 (14.5 psi) or
2 bar (29 psi) depending on the compressor.
High cut-in pressures will increase the frequency of start-up.
Re-fit keyplate (D) and retaining screw (C), re-fit grommet (B).
Re-fit pressure switch cover, switch mains electrical supply on.
Start compressor and carry-out check settings procedure.

Fig 8.4 - Run on Timer

Fig 8.3 - Danfoss Pressure Switch

Page 16

ST15948-00A

9.0 Servicing

hydrovane

9.1 Introduction

Draining Air Receiver (Fig 9.1)

WARNING !

Wait for air-end vent down cycle to finish.

SERVICING OF THE COMPRESSOR MUST ONLY BE

CARRIED-OUT BY AUTHORISED PERSONS FULLY TRAINED
AND C O M P E TE N T I N THE MAINTENANCE , M AI N S
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
then your hydrovane distributor will be pleased to help.
Use gen u ine parts and FLUID FORCE RED 2000 or an
APPROVED OILS during routine servicing, the following service
kits are available.

Position suitable container beneath condensate drain valve (B).

WARNING !
THE AIR RECEIVER IS PRESSURISED, TAKE GREAT CARE
WHEN CARRYING OUT THE NEXT OPERATION.
Carefully open drain valve and allow pressure to fall slowly to zero.
Collect all condensate drained from receiver.
Note:
Condensate may contain traces of oil and must be
disposed of in an approved manner.
Close drain valve (B) and open air outlet valve (A).

Maintenance kit, 2000 hour/12 months, use KM51 (V01-V02) or

KM52 (V04).
Full overhaul/top-up kit, 24000 hour/10 year, use KT52 (V01-V02)
or KT53 (V04)

9.2 Routine Service Schedule

The work listed below 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, hydrovane recommend that your compressor is regularly serviced by an authorised hydrovane distributor.

9.3 Check Compressor Operation

Wait until air-end vent down cycle is complete.
Check that the air-end pressure gauge reads zero.

Fig 9.1 - Outlet Drain Valve Location

Pour a small amount of oil into the thermometer pocket of the oil filler
plug. Screw a temperature gauge or thermometer into the thermometer pocket.
Assuming the compressor is serviced correctly the machine is capable of operating in ambient temperatures up to a maximum of
40C (104F). At this ambient the bulk oil temperature measured at
the filler plug should be 70-90C (158-194F) .
Check oil temperature. When the compressor is working the temperature should be:Initial start-up and warm-up period. < 70C (158F)
Optimum working temperature.

75-85C (167-185F)

High temperature.

90-100C (194-212F)

Stop ! See fault finding section.

>100C (212F)

Check Air Line Pressure

Check the air-line system pressure by using the receiver mounted
pressure gauge.

Check Air-End Pressure

To check the air-end pressure, use the pressure gauge located in
the air-end.

Check Oil Level

Check that the air-end pressure gauge reads zero.
Remove filler plug and check inside oil chamber.
Oil should be filled to overflow if not top up (see oil top-up
procedure).

ST15948-00A

Page 17

hydrovane
9.4 Basic Service Procedures
WARNING !
STOP THE COMPRESSOR AND ISOLATE FROM MAINS
ELECTRICAL SUPPLY. LOCK THE ISOLATOR IN THE OFF
POSITION. FIT A SAFETY NOTICE TO THE ISOLATOR
ADVISING THAT WORK IS BEING CARRIED OUT ON THE
COMPRESSOR.

9.0 Servicing
Remove air filter (D), and filter support (E) from clip (F) if fitted.
Clean separator casing and inside of filter cover.
Vacuum clean or blow dust out of filter using low pressure, clean dry
air. Renew the filter if it cannot be cleaned satisfactorily.
Refit filter support (E), air filter (D), secure in clip (F) if fitted, refit filter
cover (A), reconnect pipe (B).

CLOSE THE AIR OUTLET VALVE TO ISOLATE THE

COMPRESSOR FROM THE AIR-LINE SYSTEM. FIT A SAFETY
NOTICE TO THE VALVE ADVISING THAT IT IS NOT TO BE
OPENED.
DO NOT PROCEED UNTIL GAUGE READS ZERO!

Oil Top-Up Procedure (Fig 9.2)

Wait until the air-end vent down cycle is complete, check that the
air-end pressure gauge reads zero.
Note:
If pressure gauge does not fall to zero then non-return
valve (D) may be faulty.
Drain air receiver following procedure above. Do not reopen air-outlet valve (A).
Carefully unscrew oil filler plug (B), remove filler plug (B), retain
bonded seal (C).
Fill compressor to overflow with FLUID FORCE RED 2000 or an
APPROVED OIL, do not overfill
Note:

Oils must not be mixed

Examine bonded seal, if not damaged refit to filler plug.

Refit seal and filler plug, tighten to 25 Nm.

Fig 9.3 - V01-V02 Intake Filter

Air Intake Filter Replacement (Fig 9.3, 9.4)

The air filter (D) is located beneath the filter cover (A). Disconnect
pipe (B), remove screws (C) if fitted.
Firmly pull filter cover (A) to remove from separator casing.
Remove air filter (D), and filter support (E) from clip (F) if fitted, clean
separator casing and inside of filter cover.
Note:
Air filter may contain traces of oil and must be disposed of
in an approved manner.
Refit filter support (E), a new air filter (D), secure in clip (F) if fitted,
refit filter cover (A) and reconnect pipe (B).

Fig 9.2 - Outlet and Filler Plug Location

Check Air Intake Filter (Fig 9.3, 9.4)

WARNING !
The air filter (D) is located beneath the filter cover (A). Filter cover
will slide over adapter and pipe (B).
Wait until air-end vent down cycle is complete,.open outlet valve to
vent pressure from the receiver and associated pipework.

Fig 9.4 - V04 Intake Filter

Check that air-end pressure gauge reads zero.

Disconnect pipe (B), remove screws (C) if fitted.
Firmly pull filter cover (A) to remove from separator casing.

Page 18

ST15948-00A

9.0 Servicing

hydrovane

Clean Cooler and Motor (Fig 9.5)

Oil Change Procedure (Fig 9.7)

WARNING!

Remove filler plug (A), discard bonded seal (B), place container beneath oil drain plug (D).

Carefully vacuum clean the oil cooler matrix (A), aftercooler if fitted
and guard rings (B).
Vacuum clean or blow dust from motor (C) and motor grill, using low
pressure, clean dry air.

Carefully remove drain plug (D) and discard bonded seal (C). Collect
all the oil that drains from the compressor.
Note:
Any waste oil collected must be disposed of in an
approved manner.
Refit drain plug (D) using a new bonded seal. Tighten to 20 Nm.
Fill to overflow with FLUID FORCE RED 2000 or an APPROVED
OIL, do not overfill.
Refit filler plug (A) using a new bonded seal. Tighten to 25 Nm.

Fig 9.5 - Cooler and Motor Location

Replace Oil Separator Element (Fig 9.6)
Remove cap head screws (A), gently tap the end cover (B) until it is
clear of the separator casing.
Unscrew the oil separator element (C) and discard.
Note:
Oil separator element contains oil and must be disposed
of in an approved manner.
Fit a new separator element. Ensure that the `O` ring (E) is in place.
Do not over tighten.
Refit end cover (B). Ensure cover is positioned correctly and bolt
holes are in line. Be careful not to damage `O` ring (D) when refitting.
Refit cap head screws (A). Tighten to 6 Nm.

Fig 9.7 - Oil Change Procedure

Electrical Checks
WARNING !
Remove the starter panel and pressure switch covers.
Check for any signs of overheating and ensure that all electrical connections are tightened to correct torque settings.
Note:
Pay special attention to power connections and cables
connected to contactors and incoming terminals.

Check Electric Motors

WARNING !
Remove any dust or dirt from motor bodies and motor air intake
grills.
Lubricate motor bearings as per manufacturers instructions, see
service manual.

Reinstate all covers, remove safety notices, turn mains electrical

supply on and open air-outlet valve. Test run compressor, check
pressure and Inspect for oil leaks.

Fig 9.6 - Separator Element Location

ST15948-00A

Page 19

hydrovane

9.0 Servicing

9.5 Servicing Requirements

The following preventative maintenance charts cover all hydrovane
compressors using hydrovane FLUID FORCE RED 2000, CLEAR,
HPO or an APPROVED OIL.
The work to be carried out must be done on or before the hours
shown for this action, or every 12 months, whichever is soonest.
Tables 9.1 for 2000 hour oil change periods and 9.2 for 4000 hour oil
change are shown in entirety, shaded items are hydrovane distributor maintenance tasks only.
NOTE ! Certain items may not be applicable to all units.
READ HEALTH AND SAFETY PRECAUTIONS BEFORE
STARTING ANY WORK.

9.6 Service Schedule: Fluid Force Red, Clear and

HPO Oil
For normal ambient conditions bulk oil temperatures must not exceed 90C (194F) (100C/212F for HPO oil) when using 2000
hour oil change periods.
In higher ambient conditions using 4000 hour oil change periods
HPO oil should not exceed 90C (194F) . In extreme ambients HPO
oil should be used at the 2000 hour oil change periods.
If the oil is working above these temperatures the oil life will be significantly reduced.
If changing to FLUID FORCE CLEAR flush the compressor with
FLUID FORCE PRIME in order to comply with USDA H1 standard.
The service life of the air filter and cabinet filter are an indication
only, actual life durability will depend on the operating conditions.

9.7 Service Kits

Additional kits available for full product support are as follows:
Motor bearing kit, 24000 hour/10 year, use KBH090 (V01-V02) or
KBH112 (V04).

Page 20

ST15948-00A

9.0 Servicing

hydrovane

Table 9.1 Service Schedule Fluid Force Red, Clear and HPO (2000 hour change period)
Maintenance Actions

Install

Every
Day

Every
Week

Every
2000
Hours

Every
6000
Hours

Every
24000
Hours

Site-sufficient access for service

Siteprotected from weather

Siteadequate ventilation

Siteambient temperature within limit

Sitedust free ambient

Check/torque electrical connections

Check oil level at filler plug/sight glass

Check correct drive rotation

Check for air leaks

Check for oil leaks

Check air intake filter/clean if necessary

Check power on-load

Check power off-load

Check oil temperature

Check RSU temperature

Check servo pressure off-load

Check motor gland/cables secure

Check motor for damage

Check motor/starter for loose connections

Check motor cables and earth

Check motor for vibration

Check flexible oil pipes

Check oil seal for leakage

Check drive media/key

Check starter contactors

Check motor insulation resistance

Check combi cooler matrix

Clean any external dirt from compressor

Clean any external dirt from motor

Clean cabinet filter

Clean solenoids
Change separator element
Change 2000 hour oil

Change oil filter

Change air intake filter

Change cabinet filter

Change unloader valve seals

Change MPV seals

Change vacuum valve seals

Change flexible pipes

Change thermal motor

Grease motor bearings (if applicable)

Full air end inspection (internal)

Clean servo filter

Change drive media/key

Change oil seal

Change pressure gauge

Change motor bearings

Full operational test/check

Filter element fitted to Hypac units only

ST15948-00A

Page 21

hydrovane

9.0 Servicing

Table 9.2 Service Schedule Fluid Force HPO (4000 hour change period)
Maintenance Actions

Install

Every
Day

Every
Week

Every
4000
Hours

Every
20000
Hours

Site-sufficient access for service

Siteprotected from weather

Siteadequate ventilation

Siteambient temperature within limit

Sitedust free ambient

Check/torque electrical connections

Check oil level at filler plug/sight glass

Check correct drive rotation

Check for air leaks

Check for oil leaks

Check air intake filter/clean if necessary

Check power on-load

Check power off-load

Check oil temperature

Check RSU temperature

Check servo pressure off-load

Check motor gland/cables secure

Check motor for damage

Check motor/starter for loose connections

Check motor cables and earth

Check motor for vibration

Check flexible oil pipes

Check oil seal for leakage

Check drive media/key

Check starter contactors

Check motor insulation resistance

Check combi cooler matrix

Clean any external dirt from compressor

Clean any external dirt from motor

Clean solenoids

Change separator element

Change 4000 hour oil

Change oil filter

Change air intake filter

Change cabinet filter

Change unloader valve seals

Change MPV seals

Change vacuum valve seals

Change flexible pipes

Change thermal motor

Grease motor bearings (if applicable)

Clean cabinet filter

Full air end inspection (internal)

Clean servo filter

Change drive media/key

Change oil seal

Change pressure gauge

Change motor bearings

Full operational test/check

Filter element fitted to Hypac units only

Page 22

ST15948-00A

10.0 Fault Finding

10.1 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 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
then your hydrovane distributor will be pleased to help.

hydrovane
b) Air-end, check:Oil level too low.
Wrong type or grade of oil.
Oil cooler blocked.
Prolonged running off-load.

10.4 Low Air Output

Symptom
Malfunction of air-tools/equipment.
Pressure gauges reading low.
Rapid pressure loss from air-end on stopping.
Rapid pressure loss from air-line when compressor switched off.

The range of minor faults which may occur with your hydrovane compressor can be grouped under the following categories.

Cause

10.2 High Pressure

Restriction in airline, valve closed.

Minimum pressure valve stuck closed.

Symptom
Air-end pressure gauge reads:>7.8 bar/113 psi (07-PUAS), >10.8 bar/157 psi (10-PUAS)

Air intake filter blocked.

Pressure control valve stuck in open position.
Separator element blocked.
Action

Air-receiver pressure gauge reads:>10.4 bar/151 psi) (PURS),

Air-end safety valve blowing (PURS)
High temperature, high power, low air-output
Cause
Safety valve setting too high.
Pressure control valve stuck.
MPV not operating correctly.
Blocked pressure control valve or filter.
Pressure switch faulty.
Action
Check that air-end pressure gauge returns to ZERO when compressor
is switched off, if not, renew.
Replace pressure-control valve. (PUAS only).
Check that air-receiver pressure gauge returns to ZERO when receiver is fully de-pressurised. if not replace. (PURS only).
Check pressure switch is set correctly. (PURS and PUAS, where
fitted).

10.3 High Temperature

Symptom
Very hot to touch.
High power, low air-output, high oil discharge.
Compressor cuts-out.
Oil life reduction.
Compressor seizes.
Cause
Incorrect oil level.
Unapproved oil, incorrect grade of oil being used.
Dirty or blocked cooler.
Re-circulation of hot air or lack of ventilation.
Thermostatic valve stuck in closed position.
Incorrect stator/rotor end clearance.
Oil relief valves leaking.
Internal oil passage blocked.
Oil return plug blocked.
Internal high pressure to low pressure leak
Action
Check temperature in thermometer pocket. If >95oC/203oF then:a) Compressor location, check:Ambient temperature too high (>40oC/104oF)
Air-intake temperature too high.
Air-intake located near heat source.
Excessively dusty conditions.

ST15948-00A

Carry-out air delivery test.

If less than specification, check air-end for:Blocked air-intake filter.
Blocked separator element.
M.P.V. stuck closed.
Air leaks from air-end.
If correct, check air-line system for:Excessive air demand.
Air leak in air-line system.
Restriction in air-line system.
Pipework/equipment too small.

10.5 Compressor Stops

Symptom
Compressor stops unexpectedly
Cause
Pressure switch set low.
Over-temperature fault.
Motor overload tripped.
Supply voltage low.
Compressor seizing.
Action
Re-adjust pressure switch.
Rectify overtemperature fault.
Re-set motor overload.
Check supply voltage status.
Check compressor functionallity.

10.6 Excessive Oil Consumption

Symptom
Oil visible in tools and equipment.
Excessive oil usage.
Possible high oil temperature.
Possible high power absorption.
Cause
Wrong type or grade of oil.
Compressor over filled or not sited level.
Excessive air demand.
Separator element fractured and/or o-ring damaged.
Blocked oil return filters.
Excessive condensate in oil chamber
Action

Page 23

10.0 Fault Finding

hydrovane

Quantify oil discharge rate.

If >5ppm, check for:Wrong type or grade of oil.
Ambient temperature >40oC/104oF
Air-intake temperature too high.
Compressor not positioned on a level site.
Blocked oil-return plug.
Faulty separator element.
If within specification, check for:Excessive air demand.
Air leaks in air-line system.
Too many stop/start cycles per hour (PURS only)

10.7 Low Operating Temperature.

In addition to the four main categories, running the compressor
below its optimum operating temperature may cause an additional problem on PURS models. If the compressor fails to reach
its optimum temperature water vapour drawn in from atmosphere
condenses inside the oil chamber.
Symptom
High oil discharge but oil level does not fall.
High power, low air-output.
Compressor seizes.
Cause
Wrong/poor location for compressor.
Low duty cycle, insufficient demand.
Compressor operating temperature too low.
Action
Remove oil drain plug, if water drains out before oil then you have
a problem.
Time the duty cycle, if compressor switches off within 15 minutes
and is not called upon to restart within 2 hrs. then duty cycle is too
short.
If duty cycle is too short then either:a) Fit Short-run auto timer, Hydrovane Part No. HFP 06.
or
b) Run compressor fully on-load for at least one hour every week.

Page 24

ST15948-00A

Copyright 2011
All rights reserved. The copyright of this document is the property of
Gardner Denver Ltd. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted, in any form or
by any means, electronic, mechanical, photocopying, recording, or
otherwise without the prior written permission of the Technical
Publications Department, Gardner Denver Ltd.

Gardner Denver Ltd

Claybrook Drive
Washford Industrial Estate
Redditch
Worcestershire B98 0DS
United Kingdom.

hydrovane USA
1301 North Euclid Avenue
Princeton, IL 61356
United States of America
Tel (866) 994-8807
Fax (800) 443-7790

Tel: (01527) 525522

Fax: (01527) 521140
hydrovane Canada
871 Cranberry Court
Oakville, Ontario L6L 6J7
Canada
Tel (905) 848-0688
Fax (905) 847-8124

www.hydrovane.co.uk
[email protected]
www.compair.com
e-mail [email protected]

ST15948-00A