Dynaset HKL 801 User manual

HKL 400
HKL 801
HKL 1300
HKL 1800
HKL 2600
HKL 4100
HKL 5000
HKL 7500
06/18 rev 1.2
HYDRAULIC ROTARY VANE COMPRESSORS
USER MANUAL
Download PDF version from www.Dynaset.com/manuals Keycode: LZ4BYM

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Congratulations!
You have just purchased DYNASET hydraulic equipment!
The equipment allows you to maximize the productivity and
efficiency of your mobile machine. Read this User Manual
before using your new equipment. It contains important
information that will help you to take the full advance of the
technical features avaible in your equipment.
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Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
HYDRAULIC ROTARY VANE COMPRESSORS
TABLE OF CONTENTS
1. GENERAL 7
1.1. PRODUCT INFORMATION 7
1.2. PRODUCT IDENTIFICATION KEY 7
1.3. TYPE PLATE 9
1.4. HKL COMPRESSOR LINEUP 10
1.5. MAIN COMPONENTS OF HKL COMPRESSOR 11
2. SAFETY 13
2.1. SAFETY PRECAUTIONS 13
2.2. SAFETY EQUIPMENT 13
2.3. OPERATING SAFETY 14
2.4. MAINTENANCE SAFETY 15
2.5. WARNING LABELS 15
3. OPERATING PRINCIPLES 17
3.1. OPERATING DESCRIPTION 17
3.2. AUTOMATIC RPMCONTROL 20
3.3. LUBRICATION SYSTEM OF COMPRESSOR 20
3.4. PRESSURE AND COMPRESSION RATIO 20
3.5. PNEUMATICELECTRIC OFFLOAD VALVE 21
3.6. TEMPERATURE SWITCH 22
3.7. HYDRAULIC DIAGRAM 23
4. INSTALLATION 25
4.1. BEFORE INSTALLATION 25
4.1.1. HYDRAULIC SYSTEM OF A BASE MACHINE 25
4.1.2. DYNASET VALVES 32
4.2. INSTALLING DYNASET HYDRAULIC PRODUCT 33
4.2.1. PLACING DYNASET HYDRAULIC PRODUCT 33
4.2.2. INSTALLING DYNASET VALVES 33
4.2.3. CONNECTING HYDRAULIC HOSES 33
4.2.4. HYDRAULIC FLUIDS 35
4.3. INSTALLING HKL COMPRESSOR 35
4.3.1. MAXIMUM INCLINATIONS 35
4.3.2. CONNECTION TO THE AIR SUPPLY SYSTEM 36

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HYDRAULIC ROTARY VANE COMPRESSORS
TABLE OF CONTENTS
5. OPERATION 37
5.1. BEFORE STARTING THE COMPRESSOR 37
5.2. STARTING THE COMPRESSOR 38
5.3. AIR AND OIL TEMPERATURES 39
5.4. AIR HUMIDITY 40
5.5. COLD STARTS 41
5.6. OFFLOAD MODE 41
5.7. STOPPING THE COMPRESSOR 41
6. MAINTENANCE 43
6.1. MAINTENANCE INTERVALS 44
6.2. HYDRAULIC FLUIDS 44
6.3. COMPRESSOR OILS 45
6.4. CLEANING THE COMPRESSOR 46
6.5. OIL LEVEL CHECK 46
6.6. OIL UALITY CHECK 49
6.7. OIL AND OIL FILTER REPLACEMENT 49
6.8. OIL RETURN VALVES REPLACEMENT 52
6.9. AIROIL SEPARATING ELEMENT REPLACEMENT 53
6.10. REPLACING THE AIR FILTER ELEMENT 56
6.11. ADJUST THE OFFLOAD PRESSURE 57
6.11.1. ADJUSTING THE OFFLOAD PRESSURE IN STANDARD COMPRESSOR 58
6.11.2. ADJUSTING THE OFFLOAD PRESSURE IN OPE COMPRESSOR 58
6.12. TROUBLESHOOTING 63
7. MANUFACTURER’S LIMITED WARRANTY 65
8. PRODUCT DISPOSAL 67
9. DECLARATION OF CONFORMITY 69
10. TECHNICAL SPECIFICATIONS 71

Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
HYDRAULIC ROTARY VANE COMPRESSORS
TABLE OF PICTURES
Picture 1: Identication key for HKL .................................................................................................................................7
Picture 2: Type plate......................................................................................................................................................... 9
Picture 3: HKL compressor line-up .................................................................................................................................10
Picture 4: Main components of HKL compressor............................................................................................................. 11
Picture 5: Operating description: Air intake.................................................................................................................... 17
Picture 6: Operating description: Air compression and oil ltering................................................................................. 18
Picture 7: Operating description: Oil cooling .................................................................................................................. 19
Picture 8: The nominal discharge of HKL compressor......................................................................................................19
Picture 9: Automatic RPM-control.................................................................................................................................. 20
Picture 10: Pneumatic-electric o-load valve location...................................................................................................21
Picture 11: Temperature switch...................................................................................................................................... 22
Picture 12: Open centre hydraulic system with Load Sensing variable displacement pump ........................................... 26
Picture 13: Connection gure for open centre hydraulic system with Load Sensing variable displacement pump.......... 27
Picture 14: Closed centre hydraulic system with Load Sensing variable displacement pump .........................................28
Picture 15: Connection gure for closed centre hydraulic system with Load Sensing variable displacement pump........29
Picture 16: Hydraulic system with xed displacement pump .........................................................................................30
Picture 17: Connection gure for hydraulic system with xed discplacement pump......................................................31
Picture 18: Load Sensing valve LSV ................................................................................................................................32
Picture 19: Priority valve PV-SAE....................................................................................................................................32
Picture 20: Placing the compressor ................................................................................................................................33
Picture 21: Installing hydraulic hoses.............................................................................................................................33
Picture 22: P-line operational hydraulic ow..................................................................................................................34
Picture 23: Base machine pumps ................................................................................................................................... 34
Picture 24: Return line connection .................................................................................................................................34
Picture 25: Maximum inclination angle of HKL compressor............................................................................................ 35
Picture 26: Air supply system connection.......................................................................................................................36
Picture 27: Air supply line hose diameter and length..................................................................................................... 36
Picture 28: Oil level of the HKL compressor .................................................................................................................... 37
Picture 29: Starting the compressor...............................................................................................................................38
Picture 30: Normal operating ambient temperature ......................................................................................................39
Picture 31: Operating in extreme ambient temperatures............................................................................................... 40
Picture 32: Operation air humidity.................................................................................................................................40
Picture 33: Stopping the compressor.............................................................................................................................. 41
Picture 34: Depressurization of the HKL compressor.......................................................................................................43
Picture 35: Cleaning oli cooler........................................................................................................................................46
Picture 36: Location of oil ller cap ................................................................................................................................ 46
Picture 37: Oil level of the HKL compressor .................................................................................................................... 47

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HYDRAULIC ROTARY VANE COMPRESSORS
GENERAL
1. GENERAL
This manual contains general information about assembly, installation, operation
and maintenance of the DYNASET HKL hydraulic rotary vane compressor.
ATTENTION!
Read this user manual before installation, use or maintenance of the HKL
compressor to ensure proper handling, operation and maintenance right
from the beginning. Pay attention to warnings and safety instructions.
READ CHAPTER “2. SAFETY” for more information.
1.1. PRODUCT INFORMATION
HKL compressors are compact and integrated all-in-one units, especially designed
for mobile installation. The only power source is a hydraulic system to provide
compressor with required hydraulic fluid flow at demanded pressure.
HKL compressor converts the hydraulic power into high quality compressed air
and it can be installed in almost any working machine. HKL compressors are used
to power for example pneumatic tools, filling tires, air flushing, purge air protection
equipments, cleaning equipments and CAFS foam generation.
HKL compressors are designed to meet regular modern compressed air demands.
1.2. PRODUCT IDENTIFICATION KEY
The product identification key describes the characteristics of the DYNASET
product. The product identification key is on the product type plate which is
attached onto every DYNASET product.
Picture 1: Identification key for HKL
1.Product Goup HKL Hydraulic Rotary Vane Compressors.
2.Maximum Discharge. It is the maximum amout of air flow (l/min) that HKL
hydraulic compressor can produce at discharge pressure of 6 bar (according to
ISO1217(1996).)
3.Maximum Discharge Pressure. It is the maximum air pressure (bar) that HKL
hydraulic compressor can produce.
4.MAXIMUM hydraulic flow. It is the maximum hydraulic flow that HKL hydraulic
compressor is designed to run with. Do not exceed the maximum hydraulic
flow.

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HYDRAULIC ROTARY VANE COMPRESSORS
GENERAL
5.Control options (listed below)
Basic models:
HKL basic models are designed to run continuously, when compressor START/
STOP-sequenceisnot frequentlyrequiredand continuousair delivery isrequired.
Compressor START/STOP –sequence is executed by controlling hydraulic ON/
OFF valve on compressor’s pressure line. Restart of compressor is prohibited
before compressor chamber pressure is decreased under 3 bars.
Off-load valve (O):
HKL O-models are designed to run continuously. Air delivery is controlled by
off-load valve with external electric signal. When off-load valve is activated,
compressor’s servo valve and off-load valve closes the intake valve and
compressor starts to run on off-load mode. When compressor is stopped, restart
of compressor is prohibited before compressor chamber pressure is decreased
under 3 bars.
Pneumatic-electric off-load valve (O-PE):
HKL O-PE-models are designed to use to stop compressor when air delivery is
not required. Compressor START/STOP- sequence is controlled by controlling
hydraulic ON/OFF valve on compressor’s pressure line and air delivery is
controlled by compressor’s intake valve with integrated off-load valve. When
air delivery line is closed and pressurized air is not used, compressor is running
on off-load mode and chamber pressure starts to decrease until it is under 3
bars. When pressure is decreased under 3 bars, pneumatic-electric pressure
switch switches off the hydraulic valve and compressor stops. The delay on
stop-sequence of compressor is required to prevent compressor restart when
pressurized to avoid damages on vanes and stator.

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HYDRAULIC ROTARY VANE COMPRESSORS
GENERAL
1.3. TYPE PLATE
Type
Nr
Oil Flow
Manufacturer:
Dynaset Oy
33470 Ylöjärvi Finland
www.dynaset.com
[email protected]
Tel. [phone]
YearPressure
Code
Made in Finland
POWERED BY HYDRAULICS
HKL 2600/18 - 65 - O - PE
65 l/min
12345-6789Dxxxxxxxxx
210 bar 11/15
Qair = 2600 l/min
Pair = 10 bar
1
2
3
4
7
8
5
6
Picture 2: Type plate
The products type plate shows the following information.
1. Product identification key
2. Product code
3. Serial number
4. Maximum hydraulic flow
5. Maximum hydraulic pressure
6. Production month / year
7. Output air flow rate
and pressure.
8. Manufacturer’s contact
information

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HYDRAULIC ROTARY VANE COMPRESSORS
GENERAL
1.4. HKL COMPRESSOR LINE-UP
Picture 3: HKL compressor line-up
1. HKL 400
2. HKL 801 - HKL 1300
3. HKL 1800 - HKL 2600
4. HKL 4100 - HKL 5000
5. HKL 7500

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HYDRAULIC ROTARY VANE COMPRESSORS
GENERAL
1.5. MAIN COMPONENTS OF HKL COMPRESSOR
Picture 4: Main components of HKL compressor
1. Hydraulic motor
2. Hydraulic pressure line (P)
3. Hydraulic return line (T)
4. Oil cooler
5. Fan
6. Compressor block
7. Bracket
8. Air-oil separtor
9. Intake filter
10. Compressed air output (AP)
11. Oil filler cap
12. Oil filter
13. Oil level sight glass
14. Pressure gauge

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HYDRAULIC ROTARY VANE COMPRESSORS
GENERAL

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HYDRAULIC ROTARY VANE COMPRESSORS
SAFETY
2. SAFETY
2.1. SAFETY PRECAUTIONS
ATTENTION!
Operators and maintenance personnel must always comply with local
safety regulations and precautions in order to close out the possibility of
damages and accidents.
The pressure in both hydraulic and compressed air circuits of HKL is considerably
high. The technical condition of your equipment and hydraulic system should be
under constant observation.
WARNING
HIGH PRESSURE AIR AND OIL!
Can cause severe injuries.
Always wear appropriate clothing
and safety equipment.
Couplings, valves and hoses should be maintained tight and clean to avoid
possible leakages of pressure and hot blowouts. Hydraulic leakages must be
rectified immediately to avoid user and bystander injuries.
In order to avoid possible accidents, it is not allowed to clean or inspect HKL
compressor or pneumatic tools when hydraulic or/and pneumatic circuit is
pressurized. Prior to any cleaning, inspection and service, hydraulic system of your
base machine must be stopped and both hydraulic and pneumatic circuits must
be depressurized.
2.2. SAFETY EQUIPMENT
Always wear appropriate clothing and safety equipment such as safety goggles,
safety shoes and ear protection when operating the compressor.

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HYDRAULIC ROTARY VANE COMPRESSORS
SAFETY
2.3. OPERATING SAFETY
When operating the compressor, beware of machinery parts warmed by hot
hydraulic oil.
WARNING
RISK OF BURNS!
Parts of the unit, oil, and oil filler cap
can be hotter than 80 °C!
Wear personal safety equipment!
Never aim compressed air at a person.
WARNING
HIGH PRESSURE AIR!
Never aim compressed air at a person.
Can cause severe injuries.
ATTENTION!
Do not exceed the maximum pressure, temperature and load.

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HYDRAULIC ROTARY VANE COMPRESSORS
SAFETY
2.4. MAINTENANCE SAFETY
ATTENTION
Installation and service of both hydraulic and pneumatic equipment must
be performed by qualified and experienced personnel only.
NOTE!
When carrying out any maintenance to HKL compressor, keep the
components of the system clean. This is important to ensure safe, reliable
and longlife operation of your equipment.
Hydraulic system of a base machine should be maintained according to the service
program.
2.5. WARNING LABELS
Warning labels are included with each main product.
Product recipient is obligated to place warning labels on the DYNASET product.
Attach labels to visible and appropriate place onto or close to DYNASET product
where it’s easily seen. Clean surface with solvent detergent before attaching labels.
USE EAR PROTECTION
AND SAFETY
GOGGLES.
READ OPERA
TING
INSTRUCTIONS.
GENERAL CAUTION.
BEWARE OF HIGH
PRESSURE AIR.
BEWARE OF HO
T
SURFACE.
HIGH PRESSURE
OIL

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HYDRAULIC ROTARY VANE COMPRESSORS
SAFETY

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HYDRAULIC ROTARY VANE COMPRESSORS
OPERATING INSTRUCTIONS
3. OPERATING PRINCIPLES
3.1. OPERATING DESCRIPTION
Picture 5: Operating description: Air intake
1. The rotor of hydraulic compressors are driven by hydraulic motor.The rotation of
rotor creates suction and air starts to flow.
2. The air is sucked through the intake filter and intake valve into rotor-stator
assembly.

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HYDRAULIC ROTARY VANE COMPRESSORS
OPERATING INSTRUCTIONS
Picture 6: Operating description: Air compression and oil filtering
3. The Rotor-Stator assembly consists of a cylinder (stator) inside which turns a
rotor mounted eccentrically and tangentially to it. The rotor is equipped with
longitudinal grooves inside which the vanes are mounted. The vanes are kept
in contact with the internal surface of the stator by centrifugal force generated
by rotation.
4. Compressioniscreatedbythereductioninvolumeofthecompressionchambers
formed by the stator, the vanes and the rotor, during rotation.
5. The moving parts are held together and the machine is cooled and lubricated by
injecting oil. The oil is made to circulate by the difference in pressure between
the oil chamber and the inside of the compression chambers. The oil is filtered
before it is injected.
6. The air-oil mixiture travels to the air-oil separating element where the remaining
oil is filtered out. Compressed and filtered air continues to the air supply system
via AP-port. The recovered oil returns to the intake.

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HYDRAULIC ROTARY VANE COMPRESSORS
OPERATING INSTRUCTIONS
Picture 7: Operating description: Oil cooling
7. The heat generated by the compression of the air is transferred to the oil. Oil is
cooled by passing it through a special radiator which is cooled by an air flow
of a fan. Thermostatic by-pass valve controls the oil temperature during the
operation.
When supply line is closed and preset air pressure is reached, compressor starts
to run automatically in off-load mode. Pneumatically controlled intake valve is
closed and compressor’s internal pressure drops to 3 bar. Pressure in supply line
remains until supply line is opened.
When the compressed air is consumed, off-load automatic controls the intake
valve according to the current air demand.
The nominal discharge is achieved when the compressor is rotated by hydraulic
flow adequate to the nominal rotation speed.
HYDRAULIC FLOW (l/min)
0
DISCHARGE (l/min)
Q
pi_nom
Q
pi_min
Qhy_min Qhy_nom
Picture 8: The nominal discharge of HKL compressor

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HYDRAULIC ROTARY VANE COMPRESSORS
OPERATING INSTRUCTIONS
3.2. AUTOMATIC RPM-CONTROL
HKL 400, HKL 801 and HKL 1300 is equipped with automatic RPM-control.
HYDRAULIC FLOW (l/min)
0
DISCHARGE (l/min)
Q
AP, nom
Q
AP, min
Q
HY,min
Q
HY, nom
Q
HY, nom
+ (20-30%)
l/min
t
Picture 9: Automatic RPM-control
Automatic RPM-control keeps rotation speed constant. Incoming hydraulic oil flow
(Qhy) can vary from nominal demanded flow (Qhy, nom) up to value exceeding
Qhy, nom by 20-30% l/min depending on compressors size.
3.3. LUBRICATION SYSTEM OF COMPRESSOR
Compressor oil performs following functions:
1. LUBRICATION: Pressure differential makes the oil spread along grooves to the
surfaces to be lubricated. Separate oil pump is not needed.
2. HERMETIZATION:Injectedoilsealsrotorbladesagainststator’swallandlubricates
them.
3. COOLING: Compressor oil removes the compression heat from the stator.
4. CAPACITYCONTROL:Compressoroilisusedtocontroltheintakevalvewithservo
valve to adapt the amount of air taken in by compressor to the demand.
3.4. PRESSURE AND COMPRESSION RATIO
The rated absolute intake pressure is 1 bar (1000 hPa).
NOTE!
The reference barometric pressure at 0 m above sea level is 1,0135 bar,
when at 1000 m above sea level it drops to 0,9 bar.
Whenthedischarge(operational)pressureofHKL-compressoris8bar,compression
ratio is equal to:
operational pressure + barometric pressure
barometric pressure
8 + 1,0135
1,0135 = 8,89
=
The compression ratio for unit of (x) bar is calculated in the same way.