Hertz HDD Series User manual

HDD - HVD DIRECT
DRIVE SERIES
5-75 kW
INSTRUCTION MANUAL

HERTZ KOMPRESSOREN
Revision Status
R06 –Revision : March 2022
Compilation, Editing & Publications
R & D Department

1GENERAL.................................................................................................................................................. 1
1.1 Foreword........................................................................................................................................1
1.2 Cautions .........................................................................................................................................1
1.3 Copyright........................................................................................................................................1
1.4 Warranty and Liability.....................................................................................................................1
1.5 Type Approval and Genuine Spare Parts ......................................................................................2
1.6 Technical Service...........................................................................................................................2
1.7 Descriptions and Warnings ............................................................................................................2
2SAFETY ..................................................................................................................................................... 3
2.1 Operating Conditions .....................................................................................................................3
2.2 Unauthorized Modifications/Changes ............................................................................................3
2.3 Compressed Air Line Connections.................................................................................................4
2.4 Fire and Explosion Risk .................................................................................................................4
2.5 Moving Parts ..................................................................................................................................5
2.6 Combustible and Sharp Surfaces ..................................................................................................5
2.7 Combustible and Irritant Substances.............................................................................................6
2.8 Electrical Accidents........................................................................................................................6
2.9 Important Points Before You Begin................................................................................................7
2.10 Compressor and Environmental Cleaning ..................................................................................... 7
2.11 Personal Protection and Safety......................................................................................................7
2.12 Safety and Warnings......................................................................................................................8
2.13 Recommendations .........................................................................................................................9
2.14 Air Filter........................................................................................................................................10
2.15 Safety and Protection Systems....................................................................................................10
2.16 Noise Protection...........................................................................................................................10
2.17 Environmental Conscience ..........................................................................................................10
3COMPRESSOR OPERATION.................................................................................................................11
3.1 General View of HDD 22 Direct Drive..........................................................................................11
3.2 Compressor Operation.................................................................................................................12
3.2.1 Drive and Control.........................................................................................................................12
3.2.2 Pressure System .........................................................................................................................13
3.3 Intake and Control System...........................................................................................................15
3.3.1 Intake System..............................................................................................................................15
3.3.2 Intake Control System .................................................................................................................16
3.4 Cooling and Lubrication System ..................................................................................................16

4OPTIONAL COOLING SYSTEMS...........................................................................................................18
4.1 Water Cooled Systems: ...............................................................................................................18
4.1.1 Compact Soldered Heat Exchangers (CSHE).............................................................................18
4.1.2 Filters...........................................................................................................................................19
4.1.3 Cleaning CSHE............................................................................................................................19
4.1.4 Storage........................................................................................................................................19
4.1.5 Exchanger Maintenance:.............................................................................................................19
4.2 Heat Recovered Systems ............................................................................................................20
4.2.1 Heat Recovery in Air Cooled Screw-Type Compressors ............................................................20
5TECHNICAL DATA ................................................................................................................................. 22
5.1 Technical Specifications of the Compressor................................................................................22
5.2 Plates located on your compressor..............................................................................................27
5.2.1 Plate on the Case........................................................................................................................27
5.2.2 Plate on the Oil Tank...................................................................................................................27
5.2.3 Plate on the Oil Tank (with ASME)..............................................................................................28
5.2.4 Label on the Motor Lubricated.....................................................................................................29
5.3 HDD-HVD Series P&ID Diagrams...............................................................................................30
6TRANSPORTATION, HANDLING, INSTALLATION..............................................................................31
6.1 Transportation and Handling........................................................................................................31
6.1.1 Transportation..............................................................................................................................31
6.1.2 Handling.......................................................................................................................................31
6.1.3 Storage........................................................................................................................................34
6.1.4 Long Term Storage......................................................................................................................34
6.2 Compressor Placement and Connections ...................................................................................35
6.3 Compressor Room Ventilation .....................................................................................................38
6.4 Electrical Connection ...................................................................................................................38
6.4.1 HDD-HVD Series Cable Section Table .......................................................................................39
6.5 Compressor Layout Plans............................................................................................................41
7OPERATION............................................................................................................................................44
7.1 General.........................................................................................................................................44
7.2 Some Compressor Equipment.....................................................................................................44
7.3 Start-up Procedure.......................................................................................................................45
7.4 Daily Start Procedure...................................................................................................................46
7.5 Compressor Start-up in cold and after long shutdowns...............................................................47

8FAILURES ............................................................................................................................................... 48
8.1 General.........................................................................................................................................48
8.2 Failures, Reasons and Solutions .................................................................................................49
9MAINTENANCE.......................................................................................................................................57
9.1 Safety during maintenance ..........................................................................................................58
9.2 Periodical Maintenance Check List..............................................................................................58
9.2.1 Daily Maintenance.......................................................................................................................58
9.2.2 Every 125 hours operation ..........................................................................................................58
9.2.3 Every 2000 hours operation or 6 months ....................................................................................59
9.2.4 Every 4000 hours operation or 12 months ..................................................................................59
9.2.5 Every 8000 hours operation or 12 months ..................................................................................59
9.2.6 Every 16000 hours operation or 24 months ................................................................................60
9.3 Maintenance Instructions .............................................................................................................60
9.3.1 Compressor Oil............................................................................................................................60
9.3.2 Oil Replacement..........................................................................................................................62
Replace the oil in the compressor at suitable intervals for the oil type used. ........................................62
9.3.3 Oil Filter Replacement.................................................................................................................63
9.3.4 Panel filter and control box filter replacement .............................................................................64
9.3.5 Air filter replacement....................................................................................................................65
9.3.6 Air filter replacement....................................................................................................................65
9.3.7 Replacement of Separator Element ............................................................................................66
9.3.8 Maintenance of the Cooling Radiator..........................................................................................68
9.3.9 Maintenance Of The Separator Oil Return Line (Scavenge) ......................................................69
9.3.10 Intake Valve Maintenance Kit......................................................................................................70
9.3.11 Thermostatic Valve Maintenance Kit and Thermal Element Replacement.................................72
9.3.12 Minimum Pressure Valve Maintenance Kit Replacement ...........................................................73
9.3.13 Motor Maintenance......................................................................................................................74
9.3.14 Bearing Grease............................................................................................................................74
9.3.15 Coupling replacement and adjustment........................................................................................75

FIGURES
Figure 1 Safety and Warnings............................................................................................................................8
Figure 2 HDD Direct Drive Model ..................................................................................................................11
Figure 3 Direct Drive System...........................................................................................................................12
Figure 4 Pressure System................................................................................................................................13
Figure 5 Intake system.....................................................................................................................................15
Figure 6 Cooling and Lubricating System........................................................................................................17
Figure 7 Water Cooled System........................................................................................................................18
Figure 8 Heat Recovery System......................................................................................................................20
Figure 9 Installation of Heat Recovery System................................................................................................21
Figure 10 Plate on the Case ............................................................................................................................27
Figure 11.a. Plate on the Oil Tank ..................................................................................................................27
Figure 12 Label on the Motor...........................................................................................................................29
Figure 13 Transportation of Compressor with Forklift......................................................................................31
Figure 14 Transportation of Compressor with Forklift......................................................................................32
Figure 15 Transportation of Compressor with Hanger.....................................................................................32
Figure 16 Transportation of Compressor with Hanger.....................................................................................33
Figure 17 Compressor Placement in Room.....................................................................................................35
Figure 18 HDD 37 Model Overview .................................................................................................................47
Figure 19 Oil Filling ..........................................................................................................................................62
Figure 20 Oil Discharge ...................................................................................................................................62
Figure 21 Oil Filter Replacement .....................................................................................................................63
Figure 22 Panel Filter and Control Box Filter Replacement ............................................................................64
Figure 23 Air Filter Replacement .....................................................................................................................65
Figure 24 Air Filter Replacement .....................................................................................................................65
Figure 25 Separator Element Replacement.....................................................................................................66
Figure 26 Separator Element Replacement.....................................................................................................67
Figure 27 Radiator Cleaning...........................................................................................................................68
Figure 28 Scavenge Line.................................................................................................................................69
Figure 29 Coupling Replacement ....................................................................................................................75

TABLES
Table 1 Descriptions and Warnings...................................................................................................................2
Table 2 Main Parts of HDD 22 Direct Drive Model .........................................................................................11
Table 3 Technical Specifications of the HDD Series .......................................................................................22
Table 4 Technical Specifications of the HVD Series .......................................................................................24
Table 5 Schedule of Equivalent Pipe Lengths.................................................................................................37
Table 6 HDD-HVD Cable Sections ..................................................................................................................39
Table 7 Failures and Solutions.........................................................................................................................49
Table 8 Periodical Maintenance Schedule.......................................................................................................76
Table 9 Maintenance Records.........................................................................................................................77

GENERAL
1
1 GENERAL
1.1 Foreword
HERTZ KOMPRESSOREN combines quality, reliability and availability with 50 years of experience
and serves to its customers in the best way with the machine it has developed.
Thank you for choosing our product.
These operating instructions contain all information on the installation, maintenance and safely use
of your product.
Please read this manual. Do not use your product before reading.
1.2 Cautions
The compressor must be used only by the authorized persons.
Please obey all the safety measures and instructions for operation set forth herein. To do so will not
only allow minimizing the risk of potential accidents, but also elongate the usable life of your
machine.
1.3 Copyright
All rights of these operating instructions are reserved by HERTZ KOMPRESSOREN. The manual
may not be entirely or partially reproduced, changed and distributed in any manner.
1.4 Warranty and Liability
Before installation and operation of the compressor, be sure that this manual has been duly read by
the authorized personnel (mechanics, maintenance staff and all users).
Due to the complex nature of the compressor, its operation by the unauthorized people may
result in accidents and injuries, and make the machine out of warranty.
The compressor would be out of warranty in the following cases:
➢Any change or modification on the compressor or control unit without a prior consent of
HERTZ KOMPRESSOREN.
➢Operation or maintenance by the unauthorized people,
➢Use of any spare parts not approved by HERTZ KOMPRESSOREN,
➢Improper installation of the security and safety devices,
➢Operation of the compressor in contradistinction with the instructions for use and safety
measures.

GENERAL
2
1.5 Type Approval and Genuine Spare Parts
All the parts and components of the compressors are EC certified and supported with the “European
Community Statement of Compliance” for satisfaction of all the applicable standards and type
approvals.
HERTZ KOMPRESSOREN may not be kept responsible for any possible
accidents and damages to arise out of the use of non-approved spare parts.
Only Use the HERTZ approved parts and components for your safety and
security.
1.6 Technical Service
Please do not hesitate to get contact with our technical service for any problems with your
compressor.
HERTZ KOMPRESSOREN USA, Inc.
3320 Service St.
Charlotte, NC 28206
Phone : [phone]
Fax : [phone]
E-Mail : [e-mail]
1.7 Descriptions and Warnings
Table 1 Descriptions and Warnings
Symbols
Descriptions
High risks and important warnings.

Explanations on specific cases.
➢
Overall comments and general listing.

SAFETY
3
2 SAFETY
2.1 Operating Conditions
➢Make sure that use and maintenance of your compressor are made by an authorized person.
➢Do not use your compressor until these operating instructions have been understood.
➢Do not neglect the maintenance of your compressor.
➢Only air and inert gases can be used with this compressor (for more detail, please contact your
authorized service representative).
➢Use your compressor in environments with a temperature range of 35 0F (+2 0C) and 110 0F (+43
0C). (In the case of different temperatures, please contact your authorized service representative.)
➢For other operating conditions not specified in the operating instructions please note that the written
consent of HERTZ COMPRESSOR is required.
➢When you allow other people to use your compressor make sure the individuals have read these
instructions.
➢In case of failure to comply with the conditions described in the operating instructions, remember
that there may be large-scale accidents where your compressor becomes unusable and fatal
injuries.
➢If you think that there is a security breach or fault related to the compressor;
•Do not start your compressor.
•Report to the authorized person as soon as possible.
•Hang a warning sign related to the case to a portion of the compressor that can be seen.
•Make sure that the power cables are not connected so that your compressor is not used by
third parties.
2.2 Unauthorized Modifications/Changes
➢Do not make any modification/change on your compressor without consent of HERTZ
KOMPRESSOREN.
➢Unauthorized changes may cause malfunction and a reduction in the life of your compressor as well
as serious injury.
Remember that your compressor may be out of warranty as a result of changes
made without the consent of HERTZ COMPRESSOREN.

SAFETY
4
2.3 Compressed Air Line Connections
➢To obtain maximum efficiency from compressor; make sure that you are using equipment that
comply with the specifications of your compressor.
➢Ensure that compressed air line elements are connected properly, sealed and that this line is not
exposed to high temperatures. Also keep the mentioned fasteners away from environments with
dust, chemical fumes, moisture and corrosion.
➢Stop your compressor before you remove or replace compressed air line components (filters, etc.).
Make sure that the compressed air within the compressor is discharged (check the gauge).
➢Make sure no living thing can approach to the compressed air line outlet of the compressor and take
the necessary security measures.
➢Do not use the compressed air for any purpose cleaning, joking, etc. on any living thing.
➢Do not try to breathe in the compressed air and do not use it for ventilation.
➢Do not change the safety valve settings and pressure switch. Be sure to make periodic checks.
➢Do not close the outlet valve while the compressor is running or do not operate your compressor
when the outlet valve is closed. Otherwise, your compressor can be stopped with the high pressure
error.
2.4 Fire and Explosion Risk
➢Do not keep any flammable chemicals around or on top of your compressor. If you see such an item
around your compressor, clean this item immediately.
➢In any danger of fire, turn off your compressor, make sure the main switch is turned off. Eliminate all
the factors that may cause fire. Do not allow approaching with combustible materials next to your
compressor.
➢Do not allow formation of oil slick outside of the compressor cabinet. In necessary cases, clean
these areas with special cleaning non-combustible materials.
➢In any maintenance, cleaning or other operations like these of your compressor, make sure that all
power cables are unplugged.
➢Make sure that your compressor's electrical and pressure connections remain in good condition.
When you identify damaged cable or pipes, turn off the compressor, than change them and check
these connections frequently.
➢Always keep a filled and maintained fire extinguisher next to your compressor.
➢Be sure that all the electrical cables belonging to compressor are installed and there is no cable
looseness and breaks. Replace any broken and loose cables immediately for the purpose of safety.

SAFETY
5
➢Do not place combustible materials such as a piece of cloth, sawdust, paper-like solids around your
compressor.
➢Do not operate compressor without creating adequate ventilation condition.
➢Do not operate your compressor on over-capacity unless modified.
2.5 Moving Parts
➢Do not operate the compressor when the coupling and fan casings are removed.
➢Keep your hands, arms and clothes away from rotating parts as much as possible. When there is a
situation that requires you to approach rotating parts, be sure that you are not wearing baggy
clothes.
➢Make sure that the main power cord is disconnected in advance so that your compressor is not
started during repair and maintenance unintentionally.
➢The running compressor can be turned off quickly with the effect of the intake fan. In such a case,
make sure that do not let your hands and fingers from pinching.
➢When running your compressor, keep all the living things away from the compressor to protect them
against damage that may be caused by jetting and exploding.
➢If you will use your compressor with remote control make sure that the necessary warning indicators
show this status. In this way, a user near your compressor will be aware of the situation and
understand that he/she should stand at a necessary safety distance.
➢In order to prevent accidents that may occur due to lubricants such as oil, water etc. always keep the
area around your compressor, the cantilever floors such as stairs clean.
➢While controlling inside of the machine, ensure adequate lighting for the rotating parts to be seen.
2.6 Combustible and Sharp Surfaces
➢Some parts in your compressor (screw unit, radiator, separator tank, oil filter, etc.) can reach high
temperatures during operation and can cause burns if contacted. Do not touch these surfaces.
➢Do not ignore that the oil used in the system while the compressor is running may reach high
temperatures.
➢In the event of oil leakage from your compressor, disconnect the main power by shutting down via
the emergency switch without manual intervention.
➢Never contact or make any move towards your compressor during operation. Do not use objects
such as rod, cable, stick etc. for this purpose.
➢Stay away from all air outlets of your compressor (safety and relief valves, nozzles, etc.). Do not
forget that the air discharged from the air outlets is hot and may cause injury.

SAFETY
6
➢While authorized personal is doing any work related to your compressor, wear protective helmets,
glasses and gloves.
➢Always keep a first aid kit in the work area of your compressor and consult a doctor even in the
slightest injury.
2.7 Combustible and Irritant Substances
➢Never inhale the compressed air. Remember that this could cause serious injury or death.
➢Never connect the compressed air to a respiratory equipment or device.
➢Never discharge the compressed air to an environment where living things exist.
➢Run your compressor only in environments with adequate ventilation.
➢Install your compressor away from all kinds of combustive, dusty, humid, chemical environments
such as sandblasting machine, oven and machinery making chemical processes.
➢Industrial machine oil is used in compressor. Avoid any contact with eyes and skin that may occur
with such oil. In case of contact, rinse immediately with plenty of water.
2.8 Electrical Accidents
➢In addition to the advice and information in this guide, you must install your compressor in
accordance with all national and international standards. All electrical wiring connections of your
compressor must be performed by qualified technicians.
➢Make sure that your compressor is grounded properly. Make sure that the grounding cable is
connected to the point marked in the electric panel of the compressor.
➢Keep your body, your hand tools and conductive materials away from the parts of your compressor
where electrical current passes through.
➢When performing maintenance, repair or adjustment associated with electrical components, make
sure that your feet are not on the wet ground and you are working on an insulating material.
➢Try to do all works associated with electrical components with your right and single hand. Thus, the
risk of the current to reach the heart in a possible electrical leakage will be reduced.
➢Repair and corrective actions should be performed in a dry, clean, ventilated environment on an
insulating layer.
➢While the compressor is running, keep the door of the electrical cabinet absolutely shut, if you need
to open the door, stop your compressor and power off via the main switch.
➢Check all connections carefully after the installation before the first run of your compressor.

SAFETY
7
2.9 Important Points Before You Begin
➢Thoroughly check your compressor before you start the compressor. If you think that something is
wrong with your compressor, do not start the compressor.
➢Make sure that all protection and security pieces are in place. Do not start your compressor without
replacing the damaged parts or completing the missing parts.
➢If the compressor is large enough for a person to enter in it or if the relevant persons are performing
tasks inside, inform the other staff about this situation and keep the doors of the compressor open.
➢Make sure that there is no one inside before closing the doors of the compressor.
➢Make sure that the moving parts within the compressor work without any friction.
2.10 Compressor and Environmental Cleaning
➢Make sure to stop the compressor and cut the energy completely before cleaning your compressor.
➢To prevent a possible fire, keep your compressor away from the dust, oil, garbage and oil machine.
Keep the flammable liquids away from sparks and heat and store them in a separate containers
➢If there is any leakage in your compressor, have it repaired by informing your authorized service as
soon as possible.
2.11 Personal Protection and Safety
Company managers should ensure that all required standards and rules are complied with on the use of
compressors.
➢Do not approach your compressor with damaged and loose clothing. Otherwise, the clothes may get
caught on the moving parts and may cause serious injury.
➢If deemed appropriate or in cases of necessity take extra security measures such as glasses,
gloves, helmets.
➢In cases that will prevent you from making healthy decisions (drugs, alcohol use, fatigue, etc.) do not
approach and start your compressor.
➢Do not wear a headset to listen to music or the radio while
operating your compressor.
➢Keep your hands and body away from the moving parts in
the compressor. Otherwise, accidents which may cause
serious injury may occur.
➢Do not operate compressor without installing the shields.

SAFETY
8
2.12 Safety and Warnings
Safety precautions are described as "danger-warning" in necessary conditions.
Figure 1 Safety and Warnings
Safety Sign
Description
Rotating Parts!
Hot Surface!
High voltage!
Equipment starts automatically

SAFETY
9
Read the safety and protection precautions before starting the compressor.
➢Keep clean any warning signs, and make sure that they are readily visible on the compressor.
➢Clean the warning signs with soap and water and dry with a soft cloth.
➢Replace any damaged warning signs. Complete any missing warning signs.
➢After removal of any part or component with warning sign thereon, make sure that the
warning sign is replaced after replacement of the same part or component.
Place the new warning signs on clean and dry surfaces. Make sure that no air bubbles are
left between the sign and the surface.
2.13 Recommendations
➢Make sure that the shields are installed after any repair, maintenance and adjustment done on your
compressor.
➢After any repair, maintenance and adjustment on the compressor be sure that there would be
left no part, component, cleaning materials and hand tools around the compressor.
➢Be sure that the moving parts are not in touch of the other parts.
➢Be sure that all the electrical wires are properly connected to the right points on the compressor.
➢When the compressor would not be used for a long time, store it in a dry and warm place.
Safety Sign
Description
Wear earpieces!
Rotational direction of Coupling!
Please read the operating
instructions!

SAFETY
10
2.14 Air Filter
➢The air filter is exclusively for the air intake and may not be used for any other purpose.
➢Do not attempt any punching or cutting works on the air filter.
➢Avoid impact and attempts that may damage the filter in the course of filter maintenance.
2.15 Safety and Protection Systems
➢Motor over current control system
➢Fan motor over current control system
➢Phase order, shortage and imbalance control system
➢Main motor PTC relay
➢Screw high temperature control system
➢High pressure control system
➢Separator dirtiness warning system
➢Air filter dirtiness warning system
➢High pressure safety valve
➢Emergency stop button
➢Service warning system
➢Alarm warning system
2.16 Noise Protection
Thanks to the special sound insulated cabinets of HERTZ HDD and HVD Direct Drive Series, the
noise level of the compressor in operating condition has been minimized.
2.17 Environmental Conscience
Take care of the cleaning for environmental preservation, and act in compliance with the
respective laws and regulations. Keep the below listed waste materials away from the nature. Take
action to properly dispose of them.
➢Used waste oil, grease and all other excessively polluted materials,
➢Cleaning substances,
➢Accumulated oil resulting from condensed oil steams.

COMPRESSOR OPERATION
11
3 COMPRESSOR OPERATION
3.1 General View of HDD 22 Direct Drive
Figure 2 HDD Direct Drive Model
Table 2 Main Parts of HDD 22 Direct Drive Model
REF
PART NAME
REF
PART NAME
1
Control Unit
8
Water Separator
2
Fan
9
Oil Filter
3
Fan Housing
10
Min. Pressure Valve
4
Radiator
11
Intake Valve
5
Air Filter
12
Air-Oil Separator
6
Vibration Pad
13
Air end
7
Thermostatic Valve
14
Bellhousing

COMPRESSOR OPERATION
12
3.2 Compressor Operation
HERTZ HDD and HVD Direct Drive Series which is the screw air compressor series of HERTZ that is
built with quality components and durability that has been proven for years.
3.2.1 Drive and Control
HERTZ HDD and HVD Direct Drive Series compressors are powered by an electric motor which
provides the mechanical drive force required for the screw unit to produce the compressed air. This
system comprises of a frame, motor, screw unit, flexible coupling.
HERTZ HDD and HVD Direct Drive Series compressors are operated and controlled by an electronic
control system. Satisfying any applicable legal conditions, this control system is under the liability of
HERTZ COMPRESSOR.
Figure 3 Direct Drive System

COMPRESSOR OPERATION
13
3.2.2 Pressure System
The pressure system comprises of a screw unit, separator, tank, separator and minimum pressure
valve and oil return (scavenge) line circuit.
When there is pressure inside the compressor, do not attempt to remove any
cover or part. First stop the compressor, and be sure that the entire pressure is
eliminated.
➢The air –oil mixture received from the screw unit is delivered to the separator tank.
➢The separator tank has been designed as to reduce the airborne oil.
Figure 4 Pressure System