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 hydrovane

IMPORTANT ! 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 compres- 501PURS10-2415D400, 501PURS10-4035D400
sors, dryers, filters and ancillary air-line system products. Their engi-
neers are fully trained and competent in all aspects of compressor 501PUTS10-2216D305, 501PUTS10-2415D300
and air-system maintenance. If you need any specialist help or ser- 501PUTS10-4035D300
vice please contact your hydrovane distributor quoting the MODEL,
501PUTS10-2415D400, 501PUTS10-4035D400
TYPE and SERIAL NUMBER.
502PURS10-2415D300, 502PURS10-2415D300
1.2 Customer Warranty Terms 502PURS10-2235D300, 502PURS10-4035D300
All hydrovane compressors, which are serviced by an authorised 502PURS10-2415D400, 502PURS10-4035D400
hydrovane distributor are guaranteed for twelve months from the
date of commissioning or eighteen months ex works, whichever is 502PUTS10-2415D300, 502PUTS10-4035D300
the sooner.
502PUTS10-2415D400, 502PUTS10-4035D400
The warranty excludes normal service parts, oil and wear items, dirt
ingress, cleaning of filters and fluid drain devices and the tightening 504PUAS07-3835S110, 504PUAS10-3835S110
of electrical or other connections. Adjustment of pressure switches 504PUAS10-4135S110
or any other control device are not covered by the warranty. 504PUAS10-2235D110, 504PUAS07-4035D110
Consequential damage of any nature is not covered by the warranty. 504PUAS10-4035D110

504PUAS07-4035D210, 504PUAS10-4035D210
1.3 Product Development
504PURS10-4035D100, 504PURS10-4035D110
Hydrovane adopt a policy of continual product development. The 504PURS10-4035D200, 504PURS10-4035D210
information in this handbook, whilst fully up to date when issued,
may be subject to change without notice. 504PRDS10-4035D200

1.4 Quality Standards 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.
1.6 Product Terminology
These instructions comply with the stipulation of European
Directive 2006/42/EC concerning machine safety and are valid for 5, V Series, Vane
machines carrying the CE label. 01,02,04 kW Motor
PUAS Package Unit Aftercooler Starter
Gardner Denver Ltd PURS Package Unit Receiver Starter
Claybrook Drive PUTS Package Unit Tripod Starter
Washford Industrial Estate 07, 10 Delivery pressure in bars
Redditch 22, 40 Voltage
Worcestershire B98 0DS 1, 3 Single/Three phase
United Kingdom 5, 6 50/60Hz
D, S Direct on Line, Star/Delta
Tel +44 (0)1527 525522
200, 400 Revision number
Fax +44 (0)1527 521140
This publication refers to compressors with serial numbers from:
Web www.hydrovane.co.uk
[email protected] 501-017883-0810 (400 builds/MK5)
www.compair.com 502-023294-0810 (400 builds/MK5)
E-mail [email protected] 504-009513-0809 (200 builds/MK3)

ST15948-00A Page 1
hydrovane 1.0 Introduction

Page 2 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 fol-
lowing instructions before installation, operation, maintenance 2.4 When Operating the Compressor
or repair of the compressor unit.
When in automatic mode the compressor will re-start without
2.2 The Health & Safety at Work Act 1974 warning.

If an automatic re-start device is fitted (allowing the compressor to

In order to comply with your responsibilities under the above act, it is
start when power is re-applied), or operation is controlled from a re-
essential that the compressor is transported, positioned, installed,
mote location, additional warnings will be required.
operated and maintained by competent persons in accordance with
the instructions in this handbook. 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 de-
Failure to maintain the compressor correctly, or modifying it without signed to run at elevated temperatures.
prior approval from hydrovane may also create a hazardous condi-
tion. This will also invalidate the warranty. Compressed air is dangerous and can be fatal if misused. Do not al-
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 com-
After 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 We recommend that the air supply to hand held air guns is regulated
not carry out any work until the isolator is locked in the off position. Fit to a lower pressure (refer to local health and safety regulations).
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 quali- Do not insert any object or part of body through any opening of the
fied electrician may remove the fuses and keep them in a secure compressor enclosure. Serious personal injury and/or damage may
place until work is complete. 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 sub-

jected to severe operating temperatures or fire. Certain components
may contain fluoroelastomer materials and under these conditions
can leave extremely corrosive residues. Severe burns and perma-
nent skin and tissue damage can be a result of skin contact.

ST15948-00A Page 3
hydrovane 2.0 Safety

2.5 Potential Oil Health Hazards 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 identi-
product. fied below.

There are no significant hazards associated with this product when

properly used and in the application for which it was designed. Fre-
quent and/or prolonged skin contact may give rise to skin irritations Risk of electric shock
and it is recommended that protective gloves are worn. The carcino-
genic action of mineral oils should be brought to the attention of all
users. * 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 Risk of hot surfaces
not inhale fumes or vapours. Do not swallow. Avoid eye contact.

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. Dust protection must be worn
Wash mouth out with water. Give ½ pint milk. Seek immediate medi-
cal attention.

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

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

water. Seek medical advice if necessary. Warning pressurised component or system

Aspiration - If there is any suspicion of aspiration into the lungs (for

example during vomiting) admit to hospital immediately.
Warning unit is remotely controlled and may start without
Inhalation - Remove from exposure into fresh air. If necessary give warning
artificial respiration or oxygen. Seek medical advice.

Pressure injection - Obtain immediate medical attention, even if in- Read the instruction manual
jury appears minor.

Spillage - Soak up with absorbent clay.

Do not operate the machine without the guard being fitted
Waste Disposal - Oil, condensate, filter elements etc. should be dis-
posed of in accordance with local regulations. Do not allow oil to con-
taminate water supplies.
Warning do not start the machine without
* See Cautionary Notice SHW 397 ‘Effects of Mineral Oil on the consulting handbook
Skin’ and MS(B) 5 ‘Skin Cancer Caused by Oil’ published by the
Health and Safety Executive.
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 spe-

cific points of importance.

Hydrovane declines all liability in the event of material damage or

bodily injury resulting from negligence in the application of these pre-
cautions, from non-observation or lack of elementary supervision in
respect of handling, operation, servicing or repair, even if not ex-
pressly 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 75-
85°C (167-185°F).

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 min-

utes, to purge condensate from the compressor a longer running pe-
riod 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 75-85°C
(167-185°F) to avoid condensation forming within the compressor.

For PURS models a short run auto timer (HFP06) is available to ex-
tend and automate the full load running period, other models should
adopt the running period as recommended above.

Conditions or applications which prevent the compressor tempera-

ture 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 tempera-
tures 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 110°C (230°F).

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 Page 5
hydrovane 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)
Noise level 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 Direct on Line, Star/Delta
Drive Type Direct
Operating Controls Continuous Run, Automatic Stop/Start
Rotational Speed 50Hz rev/min 1450 2900 1450
Ambient Temperature Range ºC (ºF) 0-40 (32-104)
Maximum Relative Humidity % 85 non-condensing
Maximum air discharge temp above ambient, without aftercooler ºC (ºF) 50 (122)
Maximum air discharge temp above ambient, with aftercooler ºC (ºF) <10 (50)
Factory Settings
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)
Installation
Air Connection Size Rp 3/8 ½
Minimum Room Volume m³ 10 12
Room Air Inlet / Outlet area m² 0.3
Cooling Air Flow Rate m³/hr (cfm) 1500 (883) 1800 (1060)
Recommended Air Receiver Capacity Litre (gallon) 75 (19.8) 200 (52.8)
Compressor Oil
Approved Compressor Oil FF Red 2000 (Mineral) & HPO (Synthetic)
Oil Capacity 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 77693
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 77693

Starter Reference 220V 1PH 50Hz (PURS) 400/MK5 35209-01 35209-02

Circuit Diagram 220V 1PH 50Hz (PURS) 400/MK5 77693
Starter Reference 400V 3PH 50Hz (PURS) 400/MK5 35209-03 35209-04 35209-05
Circuit Diagram 400V 3PH 50Hz (PURS) 400/MK5 77693

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 ST15948-00A
4.0 Transportation and Handling hydrovane

4.1 Introduction
Ensure all lifting equipment and means of transportation are se-
curely 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 com-

pressor. 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)
A Length 700 (27.56) 1100 (41.31)
B Width 270 (10.63) 536 21.10)
C Height 470 (18.50) 562 (22.13)
Receiver Mounted (PURS)
- Weight 77 (170) 145 (320)
A Length 1120 (44.09) 1410 (55.51)
B Width 300 (11.81) 455 (17.91)
C Height 730 (28.74) 990 (38.98)
Receiver Mounted with Dryer (PURDS)
Fig 4.4 - PURS Dimensions - Weight 93 (205) 156 (344)

A Length 1153 (45.39) 1420 (55.91)

B Width 320 (12.60) 459 (18.07)

C 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 WARNING !
hydrovane distributor with a service agreement to maintain your
compressor. CONNECTION TO, OR INSTALLATION OF, AN ELECTRICAL
POWER SUPPLY MUST ONLY BE CARRIED OUT BY
Position the compressor in a room of adequate size on a firm sur-
AUTHORISED AND QUALIFIED ELECTRICIANS. THEY MUST
face, level in both planes within five degrees of the horizontal.
FULLY UNDERSTAND AND ADOPT CORRECT AND SAFE
Ensure the area has sufficient load-bearing capacity, normally it is WORKING PRACTICES . ALL AS P E C T S OF THE
not necessary to bolt the unit down. INSTALLATION MUST MEET THE WIRING REGULATIONS
PRESENTLY IN PLACE.
Sufficient access (1 metre/3.3 ft) for all routine service procedures
should be provided all around and above the unit. Before connecting to the mains electrical supply ensure that the sys-
tem can sustain the additional electrical load. To ensure reliable low
Site the compressor away from sources of dirt, coarse solids, abra- resistance joints, make sure that your incoming supply cables are
sive particles, steam, liquids and gaseous impurities. firmly secured to the starter terminals and that they are of the correct
cross sectional area.
This is an industrial compressor and is intended for installation in an
indoor environment. Refer to starter and circuit diagrams before starting work. Note care-
fully the instructions relating to earthing, fuses and size of cable.
5.2 Ventilation (Fig. 5.1)
Fuses to BS88 (type gG) must be used to protect the starter, refer to
Position the compressor in a well ventilated location. Do not restrict sizes specified on the circuit diagrams.
the air-flow around the compressor or allow the hot air discharge to
re-circulate into the compressor intake. Circuit breakers are not recommended since they may not fully pro-
tect the starter contacts in an overload condition
Any cooling-air inlet (A) should be positioned low allowing unre-
stricted air-flow to the compressor intake. The warm-air outlet (B) 5.4 Electrical Installation (Fig 5.2, 5.3, 5.4)
should be positioned high, and well away from the inlet, to ensure a
positive cooling air-flow through the compressor. WARNING!
For maximum efficiency and reliability, the compressor should be Remove starter cover (Fig 5.2).
operated in a moderate ambient temperature. If temperatures fre-
quently fall below 0°C (32°F), consult your hydrovane distributor. A Single phase Compressors must be connected to the mains electri-
different grade of oil may be required. cal supply via a lockable, switched and fused isolator positioned
near to the compressor with clear unrestricted access.
Air ducting, if fitted, must not cover or restrict the cooling air flow of
the compressor. Total resistance of the system must not exceed The mains cable of all models are colour coded as follows:
5mm w.g. (0.2in. water gauge). If resistance is expected to be
greater than 5mm w.g. then fan assistance will be required. BROWN LIVE, terminal 3/L2
BUE NEUTRAL, terminal 5/L3
GREEN/YELLOW 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). Con-
nect 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 con-
nections 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 fit-
ted 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).

If not correct, pressure will not rise and the pressure gauge will read
Fig 5.2 Starter Cover 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 The compressor can be supplied with a dryer kit. This comprises of
with oil cooler (B), driven by an electric motor (C). This assembly is an air-end, complete with cooler, driven by an electric motor. This
mounted to either an air receiver (D) or tripod (E) together with the assembly is mounted to an air receiver together with the pressure
pressure switch (F) and starter box (R). switch and starter box.

The air enters the compressor through an air filter (G). The air is The air leaving the after cooler is feed into a water drain (Q) and two
compressed with the air-end pressure displayed by pressure gauge filters (P), were solids and oil are removed. The air then enters the
(H). It is then discharged through the air outlet pipe (J) and the membrane dryer (S), where it is passed down hollow microfibre
non-return valve (K) into the air receiver (D). membranes. As air travels along the individual fibres, water vapour
contained within the air diffuses through the walls of the fibres and
Fitted into the air receiver is a safety valve (L), drain valve (M), pres- collects on the outside. The air entering the receiver is now ultra dry.
sure 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 ther-
mometer 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 re-
ceiver 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.

Push the green start button (A).

THE COMPRESSOR SHOULD ONLY BE OPERATED BY
AUTHORISED PERSONS FULLY TRAINED IN:- THE STARTING The compressor will start immediately and run continuously irre-
AND STOPPING PROCEDURES. spective of either the pressure in the air-line system or the air
demand.
BEFORE STARTING THE COMPRESSOR, READ THE ‘HEALTH
AND SAFETY PRECAUTIONS’. 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
7.2 Checking Procedure Before Starting pressure will rise slowly and fluctuate with air demand.

Check oil level. If there is no demand for air the air-line pressure will rise until the
pressure control valve lifts and the pressure stabilises.
Check filler and drain plugs are fitted securely.

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 de-
mand. When the pressure falls to the differential setting of the pres- Fig 7.2 V01-V04 Tripod/PUTS/PUAS
sure switch the compressor will immediately restart.

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 Stop compressor.
MAKING ANY ADJUSTMENTS.
8.5 Pressure Switch Adjustment (Fig. 8.2, 8.3)
Adjustment procedures shown must only be carried out by
authorised persons fully trained and competent in the maintenance Close air-outlet valve (A).
of hydrovane compressors.
Start compressor, allow pressure to rise until compressor cuts-out
If you are not able to carry out the work safely, contact your (stops).
hydrovane distributor.
WARNING !
8.2 Pressure Control Valve (PUAS)
ISOLATE THE COMPRESSOR FROM MAINS ELECTRICAL
Pressure control valves are pre-set and cannot be adjusted, if faulty SUPPLY. LOCK THE ISOLATOR IN THE OFF POSITION. FIT A
they must be replaced. SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS
Factory settings 07 bar models 7.3-7.8 (106-113 psi) BEING CARRIED OUT ON THE COMPRESSOR.
10 bar models 10.3-10.8 (149-157 psi)
Condor Pressure Switch (Fig 8.2)
8.3 Pressure Switch (Fig. 8.1) Remove pressure-switch cover.
The pressure switch (C) is located in the air receiver and is pre-set at To adjust the cut-out higher (stop) pressure; turn the screw marked
the factory. The recommended cut-out pressure (high pressure (P1) towards:-
switch setting) is a maximum and must not be exceeded. The cut-in
pressure (re-start pressure switch setting) may be adjusted to suit minus (-) to reduce cut-out pressure; compressor stops at a lower
your application. pressure.

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) 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 To adjust the lower cut-in (start) pressure; turn screw marked (P2)
electrical supply. 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 recom-
plus (+) to increase differential and restart the compressor at a lower
mend that you do not fit a non-return valve in your air-line system.
pressure.
If a non-return valve is essential for your application then the
Re-fit pressure-switch cover, switch mains electrical supply on.
air-supply to the switch must be relocated after the non-return valve.
Start compressor and carry-out check settings procedure.

MAX

DIFF
Fig 8.1 - Pressure Switch Location

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 Stop the compressor
maximum pressure will not normally need adjustment. The differen-
tial pressure can be re-set to give the correct cut-in pressure re- WARNING !
quired by the air system. Before adjustment is attempted ensure
that there are no leaks in the pipework system. ISOLATE THE COMPRESSOR FROM MAINS ELECTRICAL
SUPPLY. LOCK THE ISOLATOR IN THE OFF POSITION. FIT A
Remove the pressure switch control unit cover to expose the pres-
SAFETY NOTICE TO THE ISOLATOR ADVISING THAT WORK IS
sure switch (A).
BEING CARRIED OUT ON THE COMPRESSOR.
Remove grommet (B), keyplate retaining screw (C), remove
Remove the pressure switch control unit cover to expose the run-on
keyplate (D).
timer (A).
Maximum Pressure Adjustment
Adjust timer K2T to the required run on time (1-10 minutes). The
Adjust screw (E) until the MAX scale indicates 7.2 bar (104 psi) on 7 timer is pre-set at the factory for 2 minutes. Do not set the timer to
bar compressors or 10.2 bar (148 psi) on 10 bar compressors, these less than 30 seconds
pressures should not be exceeded.
Re-fit pressure switch cover, switch mains electrical supply on.
Differential Pressure Adjustment 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.

Position suitable container beneath condensate drain valve (B).

SERVICING OF THE COMPRESSOR MUST ONLY BE
CARRIED-OUT BY AUTHORISED PERSONS FULLY TRAINED
WARNING !
AND C O M P E TE N T I N THE MAINTENANCE , M AI N S
ELECTRICAL SUPPLY AND STARTER CONTROL EQUIPMENT THE AIR RECEIVER IS PRESSURISED, TAKE GREAT CARE
OF HYDROVANE COMPRESSORS. THEY MUST FULLY WHEN CARRYING OUT THE NEXT OPERATION.
UNDERSTAND AND ADOPT CORRECT AND SAFE WORKING
PRACTICES. Carefully open drain valve and allow pressure to fall slowly to zero.
Collect all condensate drained from receiver.
If you are unable to carry-out the work safely in the required manner
then your hydrovane distributor will be pleased to help. Note: Condensate may contain traces of oil and must be
disposed of in an approved manner.
Use gen u ine parts and FLUID FORCE RED 2000 or an
APPROVED OILS during routine servicing, the following service Close drain valve (B) and open air outlet valve (A).
kits are available.

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 run-
ning-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 com-
pressor 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 thermom-
eter pocket.

Assuming the compressor is serviced correctly the machine is ca-

pable of operating in ambient temperatures up to a maximum of
40°C (104°F). At this ambient the bulk oil temperature measured at
the filler plug should be 70-90°C (158-194°F) .

Check oil temperature. When the compressor is working the tem-

perature should be:-

Initial start-up and warm-up period. < 70°C (158°F)

Optimum working temperature. 75-85°C (167-185°F)

High temperature. 90-100°C (194-212°F)

Stop ! See fault finding section. >100°C (212°F)

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 9.0 Servicing

9.4 Basic Service Procedures Remove air filter (D), and filter support (E) from clip (F) if fitted.

Clean separator casing and inside of filter cover.

WARNING !
Vacuum clean or blow dust out of filter using low pressure, clean dry
STOP THE COMPRESSOR AND ISOLATE FROM MAINS air. Renew the filter if it cannot be cleaned satisfactorily.
ELECTRICAL SUPPLY. LOCK THE ISOLATOR IN THE OFF
POSITION. FIT A SAFETY NOTICE TO THE ISOLATOR Refit filter support (E), air filter (D), secure in clip (F) if fitted, refit filter
ADVISING THAT WORK IS BEING CARRIED OUT ON THE cover (A), reconnect pipe (B).
COMPRESSOR.

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-out-

let valve (A).

Carefully unscrew oil filler plug (B), remove filler plug (B), retain
bonded seal (C).
Fig 9.3 - V01-V02 Intake Filter
Fill compressor to overflow with FLUID FORCE RED 2000 or an
APPROVED OIL, do not overfill

Note: Oils must not be mixed

Air Intake Filter Replacement (Fig 9.3, 9.4)
Examine bonded seal, if not damaged refit to filler plug.
The air filter (D) is located beneath the filter cover (A). Disconnect
Refit seal and filler plug, tighten to 25 Nm. 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 Fig 9.4 - V04 Intake Filter
vent pressure from the receiver and associated pipework.

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 be-
neath oil drain plug (D).
Carefully vacuum clean the oil cooler matrix (A), aftercooler if fitted
Carefully remove drain plug (D) and discard bonded seal (C). Collect
and guard rings (B).
all the oil that drains from the compressor.
Vacuum clean or blow dust from motor (C) and motor grill, using low
Note: Any waste oil collected must be disposed of in an
pressure, clean dry air.
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 Fig 9.7 - Oil Change Procedure
of in an approved manner.

Fit a new separator element. Ensure that the `O` ring (E) is in place. Electrical Checks
Do not over tighten.

Refit end cover (B). Ensure cover is positioned correctly and bolt WARNING !
holes are in line. Be careful not to damage `O` ring (D) when refitting.
Remove the starter panel and pressure switch covers.
Refit cap head screws (A). Tighten to 6 Nm.
Check for any signs of overheating and ensure that all electrical con-
nections 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 distribu-
tor 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 ex-
ceed 90°C (194°F) (100°C/212°F 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 90°C (194°F) . 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 sig-
nificantly 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)
Every Every Every
Every Every
Maintenance Actions Install 2000 6000 24000
Day Week
Hours Hours Hours
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 at filler 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 if 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/starter for loose connections X X X X
Check motor cables and earth X X X X
Check motor for vibration X X X X
Check flexible oil pipes X
Check oil seal for leakage X X
Check drive media/key X
Check starter contactors 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 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 cabinet filter X X X
Change unloader valve seals X X
Change MPV seals X X
Change vacuum valve seals 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/key X
Change oil seal X
Change pressure gauge X
Change motor bearings X
Full operational test/check X X X X
Filter element fitted to Hypac units only X

ST15948-00A Page 21
hydrovane 9.0 Servicing

Table 9.2 Service Schedule Fluid Force HPO (4000 hour change period)
Every Every
Every Every
Maintenance Actions Install 4000 20000
Day Week
Hours Hours
Site-sufficient access for service X
Site–protected from weather X
Site–adequate ventilation X X X X X
Site–ambient temperature within limit X X X X X
Site–dust free ambient X X X X X
Check/torque electrical connections X X X
Check oil level at filler plug/sight glass X X X X X
Check correct drive rotation X X
Check for air leaks X X X X
Check for oil leaks X X X X
Check air intake filter/clean if necessary X X
Check power on-load X X X
Check power off-load X X X
Check oil temperature X X X X
Check RSU temperature X X X X
Check servo pressure off-load X X X
Check motor gland/cables secure X X X
Check motor for damage X X X
Check motor/starter for loose connections X X X
Check motor cables and earth X X X
Check motor for vibration X X X
Check flexible oil pipes X
Check oil seal for leakage X
Check drive media/key X
Check starter contactors X
Check motor insulation resistance X
Check combi cooler matrix X X X
Clean any external dirt from compressor X X X X
Clean any external dirt from motor X X X X
Clean cabinet filter X
Clean solenoids X X
Change separator element X X
Change 4000 hour oil X X
Change oil filter X X
Change air intake filter X X
Change cabinet filter X X
Change unloader valve seals X X
Change MPV seals X X
Change vacuum valve seals 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/key X
Change oil seal X
Change pressure gauge X
Change motor bearings X
Full operational test/check X X X
Filter element fitted to Hypac units only X

Page 22 ST15948-00A
10.0 Fault Finding hydrovane

10.1 Introduction b) Air-end, check:-

Oil level too low.
WARNING ! Wrong type or grade of oil.
Oil cooler blocked.
READ HEALTH AND SAFETY PRECAUTIONS BEFORE YOU Prolonged running off-load.
START ANY SERVICE WORK.
10.4 Low Air Output
Servicing of the compressor must only be carried-out by authorised
persons fully trained and competent in the maintenance of hydrovane Symptom
compressors. They must fully understand and adopt correct and safe
working practices. Malfunction of air-tools/equipment.
Pressure gauges reading low.
If you are unable to carry-out the work safely in the required manner Rapid pressure loss from air-end on stopping.
then your hydrovane distributor will be pleased to help. Rapid pressure loss from air-line when compressor switched off.
The range of minor faults which may occur with your hydrovane com- Cause
pressor can be grouped under the following categories.
Restriction in airline, valve closed.
10.2 High Pressure Minimum pressure valve stuck closed.

Symptom Air intake filter blocked.

Pressure control valve stuck in open position.
Air-end pressure gauge reads:- Separator element blocked.
>7.8 bar/113 psi (07-PUAS), >10.8 bar/157 psi (10-PUAS)
Action
Air-receiver pressure gauge reads:-
>10.4 bar/151 psi) (PURS), Carry-out air delivery test.
Air-end safety valve blowing (PURS) If less than specification, check air-end for:-
High temperature, high power, low air-output Blocked air-intake filter.
Blocked separator element.
Cause M.P.V. stuck closed.
Air leaks from air-end.
Safety valve setting too high.
Pressure control valve stuck. If correct, check air-line system for:-
MPV not operating correctly. Excessive air demand.
Blocked pressure control valve or filter. Air leak in air-line system.
Pressure switch faulty. Restriction in air-line system.
Pipework/equipment too small.
Action

Check that air-end pressure gauge returns to ZERO when compressor 10.5 Compressor Stops
is switched off, if not, renew.
Symptom
Replace pressure-control valve. (PUAS only).
Check that air-receiver pressure gauge returns to ZERO when re- Compressor stops unexpectedly
ceiver is fully de-pressurised. if not replace. (PURS only).
Check pressure switch is set correctly. (PURS and PUAS, where Cause
fitted).
Pressure switch set low.
10.3 High Temperature Over-temperature fault.
Motor overload tripped.
Symptom Supply voltage low.
Compressor seizing.
Very hot to touch.
High power, low air-output, high oil discharge. Action
Compressor cuts-out.
Re-adjust pressure switch.
Oil life reduction.
Rectify overtemperature fault.
Compressor seizes.
Re-set motor overload.
Cause Check supply voltage status.
Check compressor functionallity.
Incorrect oil level.
Unapproved oil, incorrect grade of oil being used. 10.6 Excessive Oil Consumption
Dirty or blocked cooler.
Re-circulation of hot air or lack of ventilation. Symptom
Thermostatic valve stuck in closed position.
Incorrect stator/rotor end clearance. Oil visible in tools and equipment.
Oil relief valves leaking. Excessive oil usage.
Internal oil passage blocked. Possible high oil temperature.
Oil return plug blocked. Possible high power absorption.
Internal high pressure to low pressure leak
Cause
Action
Wrong type or grade of oil.
Check temperature in thermometer pocket. If >95oC/203oF then:- Compressor over filled or not sited level.
Excessive air demand.
a) Compressor location, check:- Separator element fractured and/or o-ring damaged.
Ambient temperature too high (>40oC/104oF) Blocked oil return filters.
Air-intake temperature too high. Excessive condensate in oil chamber
Air-intake located near heat source.
Excessively dusty conditions. Action

ST15948-00A 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 addi-
tional 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 hydrovane USA

Claybrook Drive 1301 North Euclid Avenue
Washford Industrial Estate Princeton, IL 61356
Redditch United States of America
Worcestershire B98 0DS
United Kingdom. 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