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

Dynaset Oy | Menotie 3, FI-33470 Ylöjärvi, Finland | tel: [phone] | inf[email protected] | www.dynaset.com 3
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

Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
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

7
Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
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.

8Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
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.

9
Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
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

10 Dynaset Oy | Menotie 3, 33470 Ylöjärvi | puh. 03 3488 200 | [email protected] | www.dynaset.com
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