Hertz HGS 2-15 Service manual

HGS 2-15
OPERATOR HANDBOOK

1
TABLE OF CONTENTS:
1. CHAPTER SAFETY
1.1INTRODUCTION 2
1.2 PERSONEL PROTECTIVE EQUIPMENTS 2
1.3 PRESSURE LINE CONNECTIONS 2
1.4 FIRE AND EXPLOSION RISK 2
1.5MOVINGPARTS 3
1.6 HOT AND SHARP SURFACES 3
1.7 FLAMMABLE AND IRRITANT MATERIALS 3
1.8 RISK OF ELECTRIC SHOCK 4
1.9 LIFTING AND HANDLING 4
1.10SUGGESTIONS 5
1.11 AIR RECEIVER 5
2. CHAPTER INSTALLATION, ASSEMBLY
2.1 INSTALLATION AND CONNECTIONS 6
2.2 COMPRESSOR ROOM VENTILATION 6
2.3 ELECTRICAL CONNECTIONS 6
2.4 COMPRESSOR LAYOUT (BELT DRIVEN) 7
2.5 COMPRESSOR LAYOUT (DIRECT DRIVE) 8
3. CHAPTER TECHNICAL DATA
3.1 TECHNICAL DATA 10
3.2DIMENSIONS 11
4.CHAPTEROPERATION
4.1GENERAL 12
4.2 FUNCTION EXPLANATIONS 12
4.3 OPERATION OF THE COMPRESSOR 13
4.4 START UP (COMMISIONING) 14
4.5 DAILY OPERATION 15
4.6 STOPPING THE COMPRESSOR 15
5.CHAPTERMAINTENANCE
5.1GENERAL 16
5.2DAILYMAINTENANCE 16
5.3 PERIODIC MAINTENANCES 16
5.4 MAINTENANCE INSTRUCTIONS 17
COMPRESSOR OIL 17
OIL AND OIL FILTER REPLACEMENT 18
PANEL FILTER REPLACEMENT 19
INTAKE FILTER REPLACEMENT 19
SEPARATOR ELEMENT REPLACEMENT 20
OIL RETURN LINE MAINTENANCE 20
COOLER MAINTENANCE 21
MOTOR MAINTENANCE 21
6. CHAPTER TROUBLESHOOTING
6.1INTRODUCTION 22
6.2 PROBLEMS AND SOLUTIONS 22
7. CHAPTER L8-CONTROL PANEL 26

2
1. CHAPTER
SAFETY
1.1 INTRODUCTION
9Pay attention to all the safety and operation regulations mentioned in this handbook, this way
the accident probability will be minimized and the life of machine will increase.
9Do not make any modification on the machine without taking the approval of Manufacturer.
9Prior the assembly, starting and maintenance of the machine ensure that the handbook is
carefully read by related personnel (operators, maintenance personnel etc).
9Ensure that the maintenance and operation of the machine is only made by competent
personnel with sufficient training.
9In case the directives, processes and safety regulations are not complied; it may cause
accidents, damage and injuries.
9If the operation of the compressor is not safe;
oNever start it.
oNotify this situation to other related persons.
oPut a warning label explaining this situation on a visible place of compressor.
oIn order to avoid the uninformed operation of the compressor; turn off the main circuit
breaker or remove power cables.
1.2 PERSONAL PROTECTIVE EQUIPMENT
The company officials should be very sensitive and careful for ensuring that the operators of the
compressor take all personal safety precautions and to comply with all related standards.
1.3 PRESSURE LINE CONNECTIONS
9In order to efficiently run the compressor; make sure that all devices and equipment you have
chosen are in conformity with the compressor’s capacity and operation pressure. Select
suitable filter, piping and air hose. Our sales and service personnel will help you in this matter.
9Make sure that none of the air circuit equipment and connections are leaking, deliberately
misassembled and are not subject to excessive heat variations and are not subjected to dust,
gas, humidity etc. type of corrosive environmental factors.
9Stop the compressor before removal of any connection or equipment (filter etc.) and make
sure that internal pressure is completely discharged (check that the oil receiver is empty and
the pressure gauge value is at 0). In order to avoid any damage and injury, after shutting off
the compressor wait for the decrease of the foam of the oil in oil receiver. Do not forget that
when there is pressure in the oil receiver and in case of removal of oil tap or some other
element; the hot and compressed oil may splash and cause injuries.
9Keep the human beings and living things away from the exit of compressed air (nozzle, blow
out exit, exhaust etc) and take necessary safety precautions.
9Do not spray compressed air on human beings. Do not use compressed air in personal
cleaning.
9Do not breathe the compressed air of the compressor. Do not use it for ventilation purpose.
9Do no make jokes with air hose for avoiding severe accident and injuries.
9Do not vary the pressure adjustment of pressure switch and safety valve. Periodically carry
out the functional checking of safety valve.
1.4 FIRE AND EXPLOSION RISK
9Do not allow accumulation of oil, petrol, thinner, solvent etc. inside and around the
compressor. Clean immediately if you see.
9In case of potential fire hazard, immediately turn off the compressor and switch off the main
switch. Afterwards, remove all reasons that may cause flame, spark and other fire constituting
reasons. Do not allow smoking in your environment.
9Never allow accumulation of oil on the insulating material inside the cowling, on the outer
surface of compressor or within the compressor cabinet. If necessary obtain a cleaner that
may clean these accumulations. When needed remove the insulating material and replace.
Never use inflammable material in cleaning process.
9Switch off the power of the compressor in case of repair, cleaning or other treatment in the
cabinet.

3
9Maintain the electrical and pressure connections in good condition. Immediately replace the
damaged cables or hoses. Maintain these connections clean and regularly.
9Ensure that there is not any loose or broken electrical cable at any point of the compressor.
Remove this cable in case of risk of electricity.
9Prior to welding remove sound insulation materials.
9Keep a full fire extinguishing fire bottle that is continuously traced near the compressor.
9Keep away fatty fabric, chips, paper etc. type of litters from the compressor.
9Do not operate the compressor when there is not suitable ventilation.
9Never run the compressor if it is not manufactured specially for severe environmental
conditions.
1.5 MOVING PARTS
9Do not operate the compressor while the doors are open or belt and fan guards are not
installed.
9Keep your hands, arms and cloths especially the sleeves and skirt ends away from the moving
parts of the machinery accessory. Wear tight clothes and cap.
9When compressor is running, the cowlings may rapidly open with the effect of the cooling fan.
Take attention to avoid dropping of cowlings on your head or foots.
9Keep away all personnel away from compressor against possible splashes and explosion.
9In order to avoid accidental operation of the compressor by some one; prior repair,
maintenance or adjustment processes remove the main power cable of the compressor from
main switch or lock the circuit beaker.
9If the compressor is remote controlled; ensure that this situation is indicated by a warning label
on compressor and informed at the remote control room.
9Protect the footed floors and corridors around the compressor from oil and water to avoid
slipping or falling.
9Provide sufficient lighting for making the moving parts visible at the place of operation.
1.6 HOT AND SHARP SURFACES
9Some equipments (airend unit, cooler, separator, oil filter etc) operating inside the compressor
may heat up that may cause burns in case of contact. In the meanwhile oil is hot during
operation. Do not contact such surfaces.
9If you see oil splash from any place do not try to prevent this by your hand. Only stop the
compressor by pressing emergency stop button and switch off the main switch.
9Do not put your head or your hands, legs inside the compressor for checking any thing. Do not
use a stick, bar, wire etc.
9Do not use your hands for checking belt- pulley group, fan propeller, suction valve etc. Do not
try to stop rotating and jointed parts by your hands and legs. Your fingers may rupture.
9Stay away from all discharge points (safety and discharge valves, exhausts, nozzles etc.) that
have a direct air outlet from compressor. The released air may be very hot.
9Wear protective gloves and banner if you are working on or in the compressor.
9Keep a first aid kit at the compressor room. In case of any injury contact the doctor. Do not
ignore small scratches and cuts that may cause infection complications.
1.7 FLAMMABLE AND IRRITANT MATERIALS
9Do not inhale the compressed air out of compressor.
DIRECTLY INHALING THE COMPRESSED AIR MAY CAUSE SEVERE INJURY AND
DEATH. NEVER APPLY THE COMPRESSED AIR TO MOUTH, EYES AND EARS.
9Never connect the compressed air directly to the respiratory equipment and to the lines of this
equipment.
9Do not discharge the air of compressor into the rooms that accommodate human being.
9Only operate the compressor at sections (arranged as a compressor room) with sufficient
ventilation.
9Place the compressor away from the sandblasting furnace (pulverous), heater furnace (hot),
boiler furnace (humid), dye-chemical finish units (chemical and corrosive) and all kinds of
medium that have inflammable, explosive gases not make any suction.
9Industrial oil is used in the compressor. Avoid eye and skin contact of this oil. Wash the
contact place with plenty of water. For lubrication specification of your compressor see the
lubrication section of this handbook.

4
1.8 RISK OF ELECTRIC SHOCK
9Along with the information and recommendations in this handbook; your compressor should
be installed in conformity to all related national and international standards. The electrical
wiring works must be performed by a qualified electrician.
9Ensure that sufficient grounding is made and the grounding cable is connected to portion
marked with on the compressor body.
9Keep away your body, hand tools and electrically conductive materials from the current
conducting equipment and cable connections.
9In case of adjustment or repair on the compressor electrical component; ensure that your feet
are not wet and try to stand on an insulated place such as a wooden pallet.
9Try to make all kinds of repair and adjustment work with single and with right hand if possible.
Therefore, the risk of flowing electrical current from the hearth in case of shock is minimized.
9Make repair and adjustment work at a well laminated, dry, clean and in good ventilated
environments.
9Always keep the electric cabin’s door closed. If you need to open it; stop the compressor and
remove electrical power from main circuit breaker.
9During the start up, check all equipments and it connections again.
1.9 LIFTING AND HANDLING THE COMPRESSOR
9Lift the compressor by forklift. The forklift blade entry place at the bottom is easy to see.
9Before lifting the compressor, make sure that the forklift blade is well balanced.
9Ensure that he forklift does not lift the compressor excessively; move slowly and carefully.
9If you should lift the compressor with palette, ensure that the compressor is fixed to the palette
first. Never lift the compressor, if the compressor is not properly mounted on the palette or the
connections are damaged. Otherwise, you may cause injuries and damage.
9If the forklift is not available, lift it by crane as shown in figure.
9Before lifting the device, make sure that no damage or rupture at the welding points that the
lifting belt will pass.
9Retighten the bolts and screws that may be loosened during transportation.
9Make sure that all kinds of lifting belts, hooks etc. are in good condition and capable of
carrying the weight of compressor. If you do not know the weight of the compressor, check it.
9Be careful to avoid the damage of compressor. In case of bumping and falling, damage may
occur at the internal components of compressor.
9Make sure that there is no body underneath the compressor during lifting. Be careful.
9Do not over lift the compressor.
9The operator carrying out the lifting process should see the compressor while suspended.
9Make sure that the floor of the compressor is strong enough to carry the compressor weight.

5
1.10 SUGGESTIONS
9After repair, maintenance and adjustment works make sure that there is not any spare part,
cleaning material or hand tool are left inside.
9Make sure that all the guards are installed after repair, maintenance or adjustment works.
9Make sure that none of the moving parts are in contact with any component.
9Do not leave unplugged electric conducting cables.
9If the compressor will not be used for a long time; it should be stored at dry and warm
environment. The oil in the oil tank should be discharged and the screw unit has to be
lubricated with a protective lubricant against corrosion. If the compressor have belt driving the
belts must be removed or completely loosened.
1.11 AIR RECEIVER
9Air receivers are to collect air, do not use for any other purposes. Do not exceed the pressure
value indicated on the name plate.
9The floor on which the compressor is mounted should be capable of carrying the weight of
compressor and should be flat.
9Technical specifications of the receiver are written on the name plate
9Water must be discharged from the valve beneath the receiver for daily maintenance
9Without any written approval of the factory, do not make any welding on the receiver
9Do not make any cutting and piercing on the receiver
9The designed value of corrosion tolerance is 0,5 mm
9The receivers were tested up to 1,5 times the working pressure
According to regional regulations every year pressure test must be done to check the air
receiver. Please consult your local distributor or technical service
9Welding points should be checked by eye regularly. If any extraordinary point is seen inform
the distributor immediately
9During the maintenances avoid any impact and operation that will damage the receiver.

6
2. CHAPTER INSTALLATION & ASSEMBLY
2.1 INSTALLATION OF THE COMPRESSOR AND CONNECTIONS
9The floor on which the compressor is mounted should be capable of carrying the weight of
compressor and should be flat and dry. There is no need to fixing (anchorage bolt etc) to the
floor.
9The compressor room should be easily accessible and sufficiently illuminated.
9For adequate service, the compressor room should have a clearance of at least 1.5 m from
ceiling and 1m from the wall.
9Fire and corrosion causing conditions should be prevented in the operation region.
9No pipe load (swaggering connections or tensions arise from environmental variations) should
be relayed to compressor by external connections.
9Make sure that the air supply equipment is suitable to the operating pressure of the piping and
fittings and is damage free.
9Select the diameter of the air supply, dryer and line filters according to your air supply
capacity. (It is beneficiary to select piping of big diameter considering future development of
your company).
9Establish a separate line for condense discharge of your filter and dryer and air tanks (water
discharge line); this way the floor of the compressor operating place does not unnecessarily
get wet.
9Put an air exit and electric box in your compressor room for general purpose
9Your compressor is manufactured for indoor operation.
9In case of different needs in relation to compressor or air supply contact service or sale
representative.
2.2 COMPRESSOR ROOM VENTILATION
9In order to maintain the operation temperature at a specific value, place your compressor at a
place that adequate air flow is provided. The temperature that compressor operates should be
at least 2 and at most 40 °C. Do not place your compressor where the temperature is less
than + 2 °C and if necessary heat the compressor room.
9If you think that there will not be sufficient amount of air flow in the room of operation; it is
necessary to make room ventilation or you must discharge the outgoing hot air the
compressor to outside. When doing this, the outgoing hot air of compressor should not return.
For this reason the hot air outlet and room air inlet should not be on the same side. If
necessary use a fan for discharging the hot air from the room. Place this fan to the closest
point of the compressor hot air outlet
9Avoid not expose the compressor cooler to direct sun light or regional strong winds.
9Avoid the compressor room being subjected to heat or dust emitted by central heating boiler
or generator type of equipment.
2.3 ELECTRICAL CONNECTIONS
9Ensure that the electrical installation of your compressor is performed by a qualified
electrician.
9Your compressor is designed to operate with three phase system. The voltage and frequency
data are written on the template of your compressor and in the “Technical data” part of this
handbook. Suitable cross sections for supply cable selection are shown in “3.2 Energy cable
dimension “section.
9Your compressor is designed to operate in + 2 to + 40 °C ambient temperature and at most
1000 meters above the sea level. At higher altitudes, some corrections must be made by
taking into account of environmental conditions. The data related with this is shown in detail at
the maintenance “motor maintenance” section 5 of this handbook.
9Attach the grounding cable to the outer side of compressor with a screw marked with .
Ensure that the grounding line operates properly.
Working without grounding may be dangerous for the work safety of the personnel
and compressor. In case of failure and critical situation, please properly install your
grounding line in order to prevent death

7
9POWER CABLE SPECIFICATIONS (3x380V-400V AC)
MODEL POWER (HP/KW) CABLE CROSS SECTION
(mm²) MAIN FUSE CURRENT (A)
HGS 2 3 / 2,2 4 x 2,5 mm2 (Maksimum 25m) 10 A
HGS 3 4 / 3 4 x 2,5 mm2 (Maksimum 25m) 10 A
HGS 4 5,5 / 4 4 x 2,5 mm2 (Maksimum 25m) 20 A
HGS 5 7 / 5,5 4 x 4 mm2 (Maksimum 25m) 25 A
HGS 5D 7 / 5,5 4 x 4 mm2 (Maksimum 25m) 25 A
HGS 7 10 / 7,5 4 x 4 mm2 (Maksimum 25m) 25 A
HGS 11 15 / 11 4 x 6 mm2 (Maksimum 25m) 40 A
HGS 15 20 / 15 4 x 10 mm2 (Maksimum 25m) 40 A
9The above mentioned Cable Cross-Section and Main Fuse data are given for 380V / 400V AC
Power Supply and maximum 25m Power Cable length. If the Power Supply Voltage is different
and/or Power Cable length is longer than 25m than you may need to use different Main Fuses
and/or larger cross-section area Power Cables. In this case please apply to our Service
Department.
2.4 COMPRESSOR LAYOUT (BELT DRIVEN MODELS)
As shown in the figure compressor has mainly two units, compressor group and air receiver.
Compressor group is ready to run with all necessary equipments. For start-up it is only needed to
make the electric and air connections.
Compressor group includes electric board, control panel, motor, compressor unit, cooler, fan and
filters.