Hydrovane HR04 Instruction Manual

HR04-HR07 Models
User Handbook
(Original Instructions)
CC1132751D 10/2018
GB

Contents
Contents
1.0 Introduction......................................................................................................................5
1.1 Customer Support.................................................................................................................................5
1.2 Warranty Terms....................................................................................................................................5
1.3 Product Development...........................................................................................................................5
1.4 Quality Standards.................................................................................................................................5
1.5 Model Range ........................................................................................................................................5
1.6 Product Terminology ............................................................................................................................5
1.7 Warnings, Cautions and Notes.............................................................................................................5
2.0 Product Information.........................................................................................................7
2.1 Health and Safety Precautions.............................................................................................................7
2.2 Compressor Performance ....................................................................................................................7
2.3 Operating Temperatures ......................................................................................................................7
2.4 Noise Level...........................................................................................................................................7
2.5 Technical Data HR04-HR07................................................................................................................8
3.0 Installation........................................................................................................................9
3.1 Lifting and Handling..............................................................................................................................9
3.2 Compressor Location ...........................................................................................................................9
3.3 Compressor Ventilation (Fig.3.1)..........................................................................................................9
3.4 Electrical Connections..........................................................................................................................9
3.5 Electrical Installation (Fig 3.2) ..............................................................................................................9
3.6 Compressor Rotation..........................................................................................................................10
3.7 RS Operation with other Compressors...............................................................................................10
4.0 General Description.......................................................................................................11
4.1 Compressor/Hypac (Fig.4.1) ..............................................................................................................11
4.2 Control Systems .................................................................................................................................11
4.3 Compressor Assembly (Fig.4.2)............................................. ...........................................................12
4.4 Electronic Controller ...........................................................................................................................12
5.0 Operating Instructions ..................................................................................................13
5.1 Checking Procedure Before Starting..................................................................................................13
5.2 Operator Control Keys (Fig 5.1) .........................................................................................................13
5.3 Status Display/Lights..........................................................................................................................13
5.4 Speed Indication (Variable Speed/RS)...............................................................................................13
5.5 Displaying Values...............................................................................................................................13
5.6 Changing Values ................................................................................................................................14
5.7 Language Selection............................................................................................................................14
5.8 Setting Time/Date (Timer) ..................................................................................................................14
5.9 Starting Automatic Operation .............................................................................................................14
5.10 Starting Continuous Operation.........................................................................................................14
5.11 Starting Regulated Speed/RS ..........................................................................................................14
5.12 Stopping All Models..........................................................................................................................14
5.13 Emergency Stop...............................................................................................................................14
5.14 Compressor Vent Down ...................................................................................................................14
6.0 Adjustments...................................................................................................................15
6.1 Compressor Control (Fig 6.1).............................................................................................................15
6.2 Operation Selection............................................................................................................................15
6.3 Operator Menus..................................................................................................................................15
6.4 Pressure Adjustment ..........................................................................................................................15
6.5 Pressure Control RS Compressors....................................................................................................15
6.6 Servo Valve (Fig 6.2)..........................................................................................................................16
6.7 Setting Timer Units.............................................................................................................................16
7.0 Maintenance...................................................................................................................17
7.1 Routine Service ..................................................................................................................................17
7.2 Service Kits.........................................................................................................................................17
7.3 Service Instructions ............................................................................................................................17
7.4 Panel Removal ...................................................................................................................................17
7.5 Oil Filling/Draining (Fig.7.1)................................................................................................................17

Contents
7.6 Oil Filter (Fig 7.1)................................................................................................................................17
7.7 Air Filter (Fig.7.1)................................................................................................................................17
7.8 Oil Separator (Fig.7.1)........................................................................................................................17
7.9 Oil Cooler/Aftercooler (Fig.7.2)...........................................................................................................18
7.10 Cabinet Air Filter (Fig 7.2) ................................................................................................................18
7.11 Electric Motor....................................................................................................................................18
7.12 Electrical Connections......................................................................................................................18
7.13 Service Schedule..............................................................................................................................18
8.0 Controller Messages......................................................................................................21
8.1 Status Messages ................................................................................................................................21
8.2 Warning/Faults....................................................................................................................................21

1.0 Introduction
_________________________________________________________________________________________
CC1132751D 5
1.0 Introduction
1.1 Customer Support
Full support is available from your Hydrovane Distributor. If you
need any specialist help or service, please contact your
Distributor quoting the MODEL, TYPE and SERIAL NUMBER.
1.2 Warranty Terms
All compressors, which are serviced by an authorised Hydrovane
Distributor, are guaranteed for 12 months from commissioning or
18 months from the date of shipment.
Warranty excludes normal service parts, oil and wear items, dirt
ingress, cleaning of filters and fluid drain devices. Tightening of
electrical and/or other connections and adjustment of controller
settings are also excluded.
Consequential damage of any nature is not covered by the
warranty.
An ‘Advance’ warranty is available for approved installations,
contact your Hydrovane Distributor for details.
1.3 Product Development
Hydrovane adopt a policy of continual product development. The
information in this Handbook, whilst fully up to date when issued,
may be subject to change without notice.
1.4 Quality Standards
Hydrovane Quality Management Systems are approved to BS
EN ISO 9001.
These instructions comply with the latest European Directives
regarding content and are valid for machines carrying the CE
mark.
Each machine has its own unique EC Declaration of Conformity
supplied within the documentation pack.
Gardner Denver Ltd
Claybrook Drive
Washford Industrial Estate
Redditch
Worcestershire B98 0DS
United Kingdom
Tel: [phone]
Web: www.hydrovaneproducts.com
www.compair.com
E-mail: [email protected]
[email protected]
1.5 Model Range
This Operating Instructions relates to all enclosed HR04-HR07
vertical range compressors and hypac models. Commencing
from the original models as listed below.
HR04E07-2036D005 60Hz model
HR04E07-4035S000 50Hz model
HR04ER07-4035S000 50Hz model
HR04ED07-4035S000 50Hz model
HR04ERD07-4035S000 50Hz model
HR04E07-5736D005 60Hz model
HR04E10-2036D005 60Hz model
HR04E10-4035S000 50Hz model
HR04ER10-4035S000 50Hz model
HR04ED10-4035S000 50Hz model
HR04ERD10-4035S000 50Hz model
HR04E10-5736D005 60Hz model
HR05E07-2036D005 60Hz model
HR05E07-4035S000 50Hz model
HR05ER07-4035S000 50Hz model
HR05ED07-4035S000 50Hz model
HR05ERD07-4035S000 50Hz model
HR05E07-5736D005 60Hz model
HR05E10-2036D005 60Hz model
HR05E10-4035S000 50Hz model
HR05ER10-4035S000 50Hz model
HR05ED10-4035S000 50Hz model
HR05ERD10-4035S000 50Hz model
HR05E10-5736D005 60Hz model
HR07E07-2036D005 60Hz model
HR07E07-4035S000 50Hz model
HR07ER07-4035S000 50Hz model
HR07ED07-4035S000 50Hz model
HR07ERD07-4035S000 50Hz model
HR07E07-5736D005 60Hz model
HR07E10-2036D005 60Hz model
HR07E10-4035S000 50Hz model
HR07ER10-4035S000 50Hz model
HR07ED10-4035S000 50Hz model
HR07ERD10-4035S000 50Hz model
HR07E10-4035V000 50Hz model
HR07ER10-4035V000 50Hz model
HR07ED10-4035V000 50Hz model
HR07ERD10-4035V000 50Hz model
HR07E10-4636V005 60Hz model
HR07E10-5736D005 60Hz model
The last three digits of the product code represent mark number
changes, you may receive a unit with numbers higher than those
shown above.
1.6 Product Terminology
The product code segments signifies:
HR Hydrovane Regeneration
04, 05, 07 kW motor (IE3 50/60Hz)
E, ER, ED, ERD Enclosed, on Receiver, w/Dryer,
on Receiver w/Dryer
07, 10 Delivery pressure in bars
20, 40, 46, 57 Voltage, tri-rated motors
3 Three phase
5, 6 50 or 60Hz
D, S, Direct On Line, Star/Delta
V Variable Speed or RS
000,100,200,300 Revision number European
005,105,205,305 Revision number USA
This publication refers to compressors with serial numbers from:
HR04-000001-1409
HR05-000001-1409
HR07-000001-1409
All models are fitted with a new electronic controller, part
number CC1054325 (STD) or CC1068566 (RS).
1.7 Warnings, Cautions and Notes
WARNING ! Is used to identify specific hazards which can cause
injury or death as identified below.
Risk of electric shock
Risk of hazard or danger
Risk of hot surfaces

1.0 Introduction
_________________________________________________________________________________________
6CC1132751C
Dust protection must be warn
Warning pressurised vessel
Warning pressurised component or system
Warning unit is remotely controlled and may start
without warning
Read the instruction manual
Do not operate the machine the machine without
the guard being fitted
Warning do not start the machine
without consulting handbook
Lifting point
Direction of rotation
CAUTION ! Is used to identify incorrect procedures which can
cause damage to the compressor.
NOTE ! Is used to draw attention to specific points of
importance.

2.0 Product Information
_________________________________________________________________________________________
CC1132751C7
2.0 Product Information
NOTE !
PLEASE READ CAREFULLY AND PROCEED BY
FOLLOWING THESE INSTRUCTIONS BEFORE
INSTALLATION, OPERATION, MAINTENANCE
OR REPAIR OF THE COMPRESSOR UNIT.
2.1 Health and Safety Precautions
To comply with your responsibilities under the Health & Safety at
Work Act 1974, it is essential that the compressor is operated
and maintained by competent persons in accordance with the
instructions in this handbook.
The standard build of all Hydrovane products are designed to
compress clean, dry, atmospheric air and are not intended for
any other purpose.
The compressor warranty will be invalidated if unapproved spare
parts or oils are used. Using such items may cause the efficiency
and service life of the compressor to be reduced, and could
create a hazardous condition over which Hydrovane has no
control.
Failure to maintain the compressor correctly, or modifying it
without prior approval from Hydrovane, may create a hazardous
condition. This will also invalidate the warranty.
Read and fully understand the contents contained in the User
Handbook, ensure that it is not permanently removed from the
compressor.
Hydrovane declines all liability in the event of material damage
or bodily injury resulting from negligence in the application of
these precautions, from non-observation or lack of elementary
supervision in respect of handling, operation, maintenance or
repair, even if not expressly stated in this instruction notice.
2.2 Compressor Performance
Your compressor will give optimum performance and trouble-free
service life when the bulk oil temperature is maintained between
75-85°C (167-185°F).
Certain operating conditions sustained over a period of time may
cause problems that affect 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 compressor and may eventually lead to
emulsification of the oil.
Normal operating temperatures are reached in typically 10/15
minutes. To purge condensate from the compressor, a longer
running period with a high air demand is needed, usually a
minimum of 60 minutes will be required.
Conditions or applications which prevent the compressor
temperature stabilising between these parameters should be
avoided.
RS units have automatic stop/start cooling fans that cut in at 85°C
(185°F) operating temperature.
Consult your local Hydrovane Distributor if you have any
particular concerns about operational characteristics of your
compressor.
2.3 Operating Temperatures
Assuming the compressor is serviced correctly, the machine is
capable of operating in ambient temperatures up to a maximum
of 45°C (113°F) (40°C/104°F RS).
When the compressor is working, the temperature 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)
Some of the reasons for high compressor oil temperatures are:
a) Low oil level.
b) Blocked oil cooler or cooler flow restrictions.
c) Wrong type or grade of oil.
d) High ambient temperature.
e) Cooling fan stopped or operating incorrectly.
NOTE ! The controller display will show a warning when the
compressor temperature reaches 107°C (225°F).
NOTE ! The compressor will stop automatically if the
temperature rises above 110°C (230°F).
If the bulk oil temperature frequently reads 100°C (212°F) then
Fluid Force HPO oil should be used.
2.4 Noise Level
Although the sound pressure level for these units is relatively
low, they should be positioned where noise will not be a
problem.

2.0 Product Information
_________________________________________________________________________________________
8CC1132751C
2.5 Technical Data HR04-HR07
Model Number HR04 HR05 HR07 HR07RS
PERFORMANCE DATA (50Hz)
F.A.D. litres/sec (cfm) @ 7 bar/102 psi
11.42 (24.20)
15.35 (32.52)
21.23 (45.00)
20.53 (42.50)
F.A.D. litres/sec (cfm) @ 10 bar/145 psi
9.50 (20.10)
12.75 (27.02)
17.34 (36.75)
17.37 (36.80)
PERFORMANCE DATA (60Hz)
F.A.D. litres/sec (cfm) @ 7 bar/102 psi
10.05 (21.30)
15.06 (31.90)
18.17 (38.50)
20.53 (42.50)
F.A.D. litres/sec (cfm) @ 10 bar/145 psi
8.35 (17.70)
10.34 (21.90)
14.21 (30.10)
17.37 (36.80)
PERFORMANCE
Power - kW (hp)
4.0 (5.5)
5.5 (7.5)
7.5 (10)
Noise Level - dBA
67
69
Starter Type
DOL (60Hz) and SD (50Hz)
Inverter
Drive Type
Direct
Operating Controls
Continuous Run, Automatic Stop/Start,
Reduced Energy Vent System
Variable
Rotation Speed - rev/min 50Hz (60Hz)
1450 (1760)
1100 *-2150 *
Ambient Temperature Range °C (°F) 0 to 45 (32 to 113)
0 to 40
(32 to 104)
Maximum Relative Humidity %
85 non-condensing
Air Discharge Temp - °C (°F) above ambient
<6 (43)
<8 (46)
<10 (50)
FACTORY SETTINGS
Nominal Pressure – bar (psi)
7.0 or 10.0 (102 or 145)
7.0 (102)
Minimum Pressure Valve – bar (psi)
5.5 to 6.0 (80 to 87)
Load/Cut-in Pressure – bar (psi)
6.5 or 9.5 (94 or 138)
7.0 (102)
Unload/Cut-out Pressure – bar (psi)
7.5 or 10.5 (109 or 152)
7.5 (109)
Servo Valve – bar (psi)
8.0 or 11.0 (116 or 160)
8.0 (116)
Vent Down Run Time @ 7 bar – sec
60
Vent Down Run Time @ 10 bar – sec
90
Pressure Display Units
0 (bar) (1 = psi, 2 = kpa)
Temperature Display Units
0 = °C (1 = °F)
Vacuum Relief Valve
1.5 turns anti-clockwise
INSTALLATION
Dimensions D x W x H –mm
685 x 630 x 1078
Weights - kg
220
230
Air Outlet Size - Rp
3/4
Minimum Room Volume - m3
15
Air Inlet/Outlet Area - m2
0.3
Ventilation Rate - m3/h
2000
Cooling Air Flow m3/h (cfm)
1850 (1089)
Recommended Air Receiver Capacity - litres
250
COMPRESSOR OIL
Approved compressor oil
Fluid Force Red 2000 (Mineral) and HPO (Synthetic)
Oil Capacity – litres
3
ELECTRICAL
Starter reference 200/575V 3PH 60Hz DOL
CC1118983
Circuit diagram 200/575V 3PH 60Hz DOL
CZ77996
Starter reference 400V 3PH 50Hz SD
CC1054889
Circuit diagram 400V 3PH 50Hz SD
CZ77989
Starter reference 400/460 3PH 50/60Hz RS
CC1054890
Circuit diagram 400/460V 3PH 50/60Hz RS
CZ77990
*Alternative speed settings may be required depending on application and duty cycle

3.0 Installation
_________________________________________________________________________________________
CC1132751C 9
3.0 Installation
CAUTION !
LIFTING AND TRANSPORTATION MUST ONLY
BE CARRIED OUT BY AUTHORISED PERSONS.
ENSURE ALL EQUIPMENT EXCEEDS THE FULL
LOAD OF THE UNIT.
3.1 Lifting and Handling
A fork lift or pallet truck are the most suitable means of moving
the product. Pay particular attention to ensure stability to prevent
the unit tilting over.
Lift the hypac or compressor and place in the desired location,
damage to mountings may occur if you slide the compressor into
position.
3.2 Compressor Location
Position the compressor/hypac in a room of adequate size on a
firm surface, level in both planes within five degrees of the
horizontal.
Ensure the area has sufficient load-bearing capacity, provide
access, 1 metre/3.3 ft for routine service procedures around and
above the unit.
Site the compressor/hypac away from sources of dirt, coarse
solids, abrasive particles, steam, liquids and gaseous impurities.
This is an industrial compressor and is intended for installation in
an indoor environment.
Any air connection made to the compressor outlet must be
flexible as the base incorporates resilient mountings.
3.3 Compressor Ventilation (Fig.3.1)
Position the compressor/hypac in a well ventilated location. Do
not restrict the air-flow around the compressor or allow the hot
air discharge to re-circulate into the compressor intake.
Fig 3.1 Compressor Ventilation
Any cooling-air inlet (A) should be positioned low allowing
unrestricted air-flow to the compressor intake. The warm-air
outlet (B) should be positioned high, and well away from the
inlet, to ensure a positive cooling air-flow through the
compressor.
For maximum efficiency and reliability, the compressor should be
operated in a moderate ambient temperature. If temperatures
frequently fall below 0°C (32°F), a different grade of oil may be
required.{Recommended HPO 198)
Compressor air intake and exhaust grills have captive nuts fitted
as standard to attach ducting.
Air ducting, if fitted, must not cover or restrict the cooling air flow
of the compressor. Total resistance of the system must not
exceed 50 mbar. If resistance is expected to be greater, fan
assistance will be required.
3.4 Electrical Connections
WARNING !
CONNECTION TO, OR INSTALLATION OF, AN
ELECTRICAL POWER SUPPLY MUST ONLY BE
CARRIED OUT BY QUALIFIED ELECTRICIANS.
THE INSTALLATION MUST MEET THE WIRING
REGULATIONS PRESENTLY IN PLACE.
Before connecting to the mains electrical supply, ensure that the
system can sustain the additional electrical load. To ensure
reliable low resistance joints, make sure that your incoming
supply cables are firmly secured to the starter terminals and that
they are of correct size.
NOTE ! The starter door panel should always be secured by the
supplied key for safety reasons and to prevent unauthorized
access.
Refer to starter circuit diagrams (located inside the starter door
panel) before starting work. The instructions given for earthing,
fuses and cable size are important.
Fuses to BS 88 (Type gG) must be used to protect the starter,
refer to the sizes specified on the starter circuit diagrams.
Circuit breakers are not recommended since they may not fully
protect the starter contacts in an overload condition.
Water drain, filters or dryers fitted downstream of the
compressor discharge must be correctly sized to avoid
excessive flow restrictions to ensure stable operation of the
speed control system.
3.5 Electrical Installation (Fig 3.2)
WARNING !
BEFORE STARTING WORK ENSURE THAT THE
MAIN-LINE FUSES HAVE BEEN REMOVED
FROM THE DISTRIBUTION BOARD.
PRECAUTIONS SHOULD BE TAKEN TO
PREVENT THEM BEING REFITTED UNTIL THE
INSTALLATION IS COMPLETE.
Starter cables must be connected to the mains electrical supply
via a lockable, switched and suitably rated fused isolator. The
isolator should be positioned as near as possible to the
compressor with clear, unrestricted access.
To access starter terminals, unlock the starter door panel and
pass incoming cables through the entry hole in the floor for
HR04-HR07.
Connect the three mains supply cables to the terminals marked
L1, L2 and L3, and connect the earth cable to the earth terminal
E. Ensure the connections are secure.
Refer to IEEE Regulations for electrical equipment installed in
buildings to determine the size required, pay particular attention
to the circuit diagrams provided.
A
B

3.0 Installation
10 CC1132751C
If the compressor is located a long way from the isolator and/or
the ambient temperature exceeds 35°C (95°F), the cable size
should be increased.
Check that the transformer fuse is positioned to suit the supply
voltage of the installation.
Ensure all electrical connections are tight, high voltage supply to
contactors and incoming terminals are critical.
Close the starter door and secure with the key provided before
replacing the main line fuses.
Fig 3.2 Starter Connections
3.6 Compressor Rotation
CAUTION !
BEFORE INITIAL START-UP ENSURE THE
COMPRESSOR IS FILLED WITH A HYDROVANE
APPROVED OIL. DO NOT OVERFILL OR MIX
OILS.
With the mains isolator on, press the green start button on the
control panel and watch the pressure gauge.
Rotation is correct if the pressure display rises immediately, after
a few seconds if no pressure is displayed rotation is incorrect.
WARNING !
SERIOUS DAMAGE WILL OCCUR IF THE UNIT
IS ALLOWED TO RUN IN REVERSE. IF
ROTATION IS INCORRECT, STOP AND ISOLATE
FROM THE ELECTRICAL SUPPLY.
Open the starter door and change over any two of the incoming
cables connected to the starter terminals L1, L2 and L3.
Close and lock the starter door to prevent unauthorised access
and switch the mains electricity supply on.
Restart the compressor and verify that direction of rotation is
correct by observing pressure rise on the compressor gauge.
Cooling fan operation is clockwise, all RS units have automatic
stop/start cooling fans that cut in at 85°C (185°F) operating
temperature.
Remove the cabinet filter from the lower half of the rear panel to
view the cooling fan through the mesh grill.
3.7 RS Operation with other Compressors
Hydrovane RS compressors may be operated efficiently in
conjunction with other Hydrovane compressors fitted with
automatic stop-start control.
Adjust the RS minimum air line pressure to midway between the
maximum and minimum air line pressure settings of the other
compressor. The RS compressor will automatically assume the
lead compressor role after several cycles.
NOTE ! If the RS compressor is operated with other Hydrovane
standard single speed compressors feeding a common pressure
system, the minimum air line pressure of the RS compressor
must be limited to the lowest maximum air line pressure of the
single speed machine(s). No attempt must be made to increase
the operating pressure of the single speed machine(s).
The pressure transducer sensing point is located in a filter
housing adjacent to the outlet from the compressor. If the
pipework from the compressor to the system is restricted, or
prone to excessive pressure fluctuation, rapid speed changes
and/or frequent stopping and starting of the motor may occur.
Should this condition arise, consult a Hydrovane Distributor who
will arrange to re-site the pressure transducer location.
E L1 L2 L3

4.0 General Description
_________________________________________________________________________________________
CC1132751C 11
4.0 General Description
4.1 Compressor/Hypac (Fig.4.1)
This manual covers Vertical HR04-HR07 compressors, hypac’s
combine either a receiver, air dryer or both, depending on the
installation required.
A compressor without ancillary equipment is used where air
demand is constant and does not exceed the output capacity of
the unit.
4.2 Control Systems
Compressors can be operated in either automatic stop/start (set
as default) or in continuous operation.
All units benefit from REVS (Reduced Energy Venting System)
and Smart Servo to minimise power consumption during
operation.
On start up a short delay prevents full pressure delivery to
reduce motor power consumed.
With maximum line pressure established the venting system
lowers compressor pressure to provide substantial cost savings
due to the off-load power reduction.
Smart servo control isolates the servo and vacuum valve feeds
during full load operation to reduce losses and maximise
compressor efficiency.
During off-load run on time at minimum pressure the compressor
will either stop with no air demand or return to on-load running if
more air is required.
Automatic Operation
This is the normal operation selected giving maximum efficiency
and economy for applications with fluctuating air demands. The
compressor will load/unload and stop/start automatically in
response to air demand.
Motor restarts are set to 10 times per hour for single speed units
and 30 times for RS units.
Run-on time to stop can be increased to reduce or limit motor
restart frequency to lower levels if required.
Continuous Operation
When in continuous operation the compressor will supply air
from full to zero flow rates. The energy saving benefits of REVS
will not be maintained.
An air dryer is used to provide dry air (pressure dew point
3°C/37°F) for specialised applications.
Where air demand fluctuates a compressor with receiver is used
to store large quantities of air. A dryer can be combined with the
compressor and receiver for applications requiring large volumes
of dry air.
Figure 4.1 shows general views of typical units, the compressor
assembly is detailed in Section 4.3 / Fig 4.2, the air dryer is
supplied with its own manual.
Regulated Speed (RS) Operation
Regulated speed compressors are automatic stop/start operation
only.
The RS compressor saves energy and operating cost when
compared with a fixed speed compressor of similar size. The
saving is achieved by automatically regulating the compressor
speed to precisely match the compressor output to the system
demand.
If the system pressure rises above the unload pressure the
electric motor speed will decrease, conversely, if the system
pressure falls below the load pressure the motor speed will
increase. The speed will vary between load and unload limits
dependent upon system demand.
E ER ED ERD
Fig 4.1 General Views

4.0 General Description
12 CC1132751C
4.3 Compressor Assembly (Fig.4.2)
The unit comprises of a single stage, oil flooded, rotary, sliding
vane compressor driven by an electric motor mounted to a base.
It is supplied with control panel, starter, and oil cooler/air
aftercooler with all accessories piped in and electrically
connected.
The intake cover (A) is assembled directly to the compressor (B)
which is fitted to the motor flange (C). A flexible coupling drives
the compressor rotor from the motor drive shaft, enclosed inside
the bell housing (D). The motor is bolted to the vertical column
supported by the base.
An electrically driven, impellor type, horizontally mounted fan (E)
is located below the combination oil cooler/air aftercooler matrix
(F). This draws cooling air through the air filter (G) and forces it
through the cooler matrix.
The electronic controller (H) with an LCD screen is mounted in
the starter (J). An emergency stop button (K) is located on the
front controller panel.
For RS models, the inverter drive (L) is mounted inside the
starter compartment, behind the starter panel door (J).
The compressor air intake is protected by an air intake filter (M),
and the oil system is filtered by an oil filter (N). An oil level sight
glass (O) is mounted adjacent to the oil filter.
The compressor is filled and topped up with oil via the oil filler
(P). The sight glass (O) will be full when oil overflows from the
level plug orifice (Q).
Oil is drained from the compressor and cooler by removing the
drain plug (R).
The compressor pressure gauge (S) is visible when the front
panel is open.
Oil separator (T) located on the compressor separator manifold
ensure air delivered through the minimum pressure valve has a
cleanliness of less than 3 ppm (parts per million by weight).
Air is delivered through the air delivery pipe (U) to the after
cooler (F) before discharge from the unit.
The oil supply to the cooler is through oil feed pipe (V) with the
cool oil return through oil return pipe (W) For a quick warm up, a
thermal by-pass valve (Y) allows the oil supply to by-pass the
cooler on initial start up.
4.4 Electronic Controller
Controllers have menu structures that contain all the parameters
and settings for safe operation of the compressor.
a) [MAINTENANCE SCHED]
b) [CONTROL MENU]
c) [FAULT MEMORY]
d) [TIMER CONTROL]
e) [LIMIT VALUES]
f) [OPTIONAL IN/OUTPUTS]
All menus are available to view, the [MAINTENANCE SCHED]
and [LIMIT VALUES] are reserved for fully trained personnel and
require a service or master code for entry.
Further explanation on menu structures is given in the following
sections, 5.0 Operating Instructions and 6.0 Adjustments.
Fig 4.2 Compressor Assembly
A
H
B
D
C
V
F
E
P O Q M
J K U
T
N
W
S
R
Y
G
L

5.0 Operating Instructions
_________________________________________________________________________________________
CC1132751C 13
5.0 Operating Instructions
WARNING !
THE COMPRESSOR SHOULD BE OPERATED
BY AUTHORISED PERSONS FULLY TRAINED IN
THE STARTING, STOPPING AND EMERGENCY
STOP PROCEDURES.
5.1 Checking Procedure Before Starting
a) Check oil sight glass is full.
b) Check filler, drain/oil level plugs are fitted securely.
c) Check for any signs of oil leaks.
d) Check air-outlet valve is open.
e) Check that the emergency stop button is released.
f) Turn mains electricity supply on.
5.2 Operator Control Keys (Fig 5.1)
When power is applied the controller display illuminates to show
compressor output values and status messages.
Fig 5.1 Controller
The two keys on the left above and below the green and red
LED’s have a single function:
Start key.
Stop key.
The three keys on the right next to the display have a dual
function:
+ Call up or exit menu / sub-menu.
Switch to next sub-menu / menu item, or reduce a value.
Switch to previous sub-menu / menu item, or increase a
value.
Reset/Enter key.
In a menu / sub-menu, the reset key functions as an
enter key
5.3 Status Display/Lights
The controller is fitted with a three-row display.
The first row permanently displays compressor discharge
temperature and system pressure.
The following symbols may also appear.
p2 Second pressure range / timer active
Remote start / stop activated
The second row is reserved for menu items, values like the total
service hours and set values like nominal pressure are viewed
here.
The third row shows status, fault and warning messages.
The HYDROVANE Pro is fitted with two light signals (green,
red).
Flashing, system is ready, the motor may start up
automatically at any time.
Lit up permanently, the drive motor is running
Flashing slowly, warning, maintenance due
Flashing rapidly, fault, unit is stopped until fault has been
rectified
The red light signal only goes out once the warning or fault has
been rectified and confirmed using the Reset/Enter key.
During operation, the controller records the total running hours,
the hours run on load and counts down to the next service
interval.
The controller service interval is set for 2000 hours when using
Fluid Force Red 2000 oil. This interval will be reduced if the unit
operates above the recommended temperature.
5.4 Speed Indication (Variable Speed/RS)
The speed is displayed in the second row of the display. If the
menu navigation is displayed, the speed display is faded out.
Examples of speed displayed:
a) [ _______ ▌____] 3290 rpm
Speed in controlled range.
b) [ ▌____________] 1300 rpm
Speed in lower controlled range, minimum speed not yet
reached.
c) [ |◄ ____________] 1280 rpm
Minimum speed reached.
d) [ ____________ ►| ] 3650 rpm
Maximum speed reached
5.5 Displaying Values
You can display values, e.g. total hours, and set the control
system, e.g. cut-in and cut-out times, in the sub-menu.
To reach the main menu, you must press the and keys at
the same time.
Use the or keys to switch between the following sub-
menus:
a) [MAINTENANCE SCHED]
b) [CONTROL MENU]
c) [FAULT MEMORY]
d) [TIMER CONTROL]
e) [LIMIT VALUES]
f) [OPTIONAL IN/OUTPUTS]
Enter a sub-menu by pressing the key.
Use the or keys to go to a menu item.
To exit the sub-menu, press the and keys at the same
time.

5.0 Operating Instructions
14 CC1132751C
To exit the main menu, you must press the and keys at the
same time.
5.6 Changing Values
Enter the sub-menu and then the menu item containing the value
you wish to change.
Press the key, the value flashes. Press the or key to
change the value. Press the key again to confirm the value.
5.7 Language Selection
Change the language by pressing the + or + keys.
Press these keys at the same time until the right language
appears.
5.8 Setting Time/Date (Timer)
The HYDROVANE Pro will retain its settings after a power loss
lasting about two to three weeks. If power is lost for longer
periods, the timer's time and date are lost and have to be re-
entered.
Press the + keys at the same time. Use the key to go to
the [TIMER CONTROL] sub-menu and press the key. The
date and time are displayed in the following format:
TU 30.10.07 12:10:34
Press the key, the left-hand value (day of the week) starts to
flash. Use the or keys to select, confirm by pressing the
key.
All values can now be set in succession using this procedure.
When the last value (seconds) has been set, the timer is active,
exit the menu by pressing the + keys twice at the same
time. For further settings see Section 6.7.
5.9 Starting Automatic Operation
WARNING !
IN AUTOMATIC OPERATION COMPRESSORS
WILL RESTART WITHOUT WARNING.
Press the key, the compressor will start if system pressure is
below the load/cut-in pressure set point.
On initial start with no pressure in the system, the pressure
display will quickly rise to the full delivery pressure. During this
period, the green LED will be continuously illuminated.
The compressor will continue to run and pressure will vary within
the load/cut-in and unload/cut-out pressure set points to match
the system demand.
If system demand reduces and pressure rises to the unload/cut-
out pressure set point, the REVS (Reduced Energy Venting
System) sequence will begin.
If there is an air demand during the REVS run on time sequence
the compressor returns to full load operation.
If there is no air demand during the REVS run on time sequence
the compressor will stop.
Automatic restart will occur when system pressure falls to the
load/cut-in pressure set point.
5.10 Starting Continuous Operation
Press the key, the compressor will start, and run continuously
within the load/cut-in and unload/cut-out pressure set points to
match system demand.
On initial start with no pressure in the system, the pressure
display will quickly rise to the unload/cut-out pressure set point.
During this period, the green LED will be continuously
illuminated.
5.11 Starting Regulated Speed/RS
For variable speed models, the starting sequence is the same as
single speed automatic operation except that, the compressor
speed will vary automatically to match system demand.
With no system demand when running at minimum speed the
compressor will stop after the REVS venting sequence.
Automatic restart will occur when system pressure falls to the
load/cut-in pressure set point.
5.12 Stopping All Models
To stop the compressor, press the key, system pressure will
remain high initially, but will fall gradually with the rate of decay
depending on system usage.
5.13 Emergency Stop
If an emergency occurs, press the EMERGENCY STOP button.
The button will lock in the depressed position and stop the
compressor immediately.
The red LED on the controller will flash quickly with the FAULT
EM-STOP message displayed.
Clear any faults that may have occurred. Do not reset until it is
safe to do so.
Reset the emergency stop button by twisting clockwise before
restart.
Press the key on the controller to cancel the red LED and
FAULT EM-STOP message.
Operation of the emergency stop button is recorded in the
controller error log.
5.14 Compressor Vent Down
Venting is controlled automatically by the REVS system for
either operation selected.

6.0 Adjustments
_________________________________________________________________________________________
CC1132751C 15
6.0 Adjustments
6.1 Compressor Control (Fig 6.1)
The compressor controller has Operator Menus with parameter
settings that can be modified within set limits to suit system
requirements.
The controller has a built-in time delay to prevent pressurised
restart that inhibits the automated motor start sequence and
controls the vent solenoids.
The venting system (REVS) is controlled by solenoid valves
mounted on the starter enclosure under the top panel cover.
A normally closed solenoid valve (A) controls compressor
delivery pressure using the REVS start system to reduce power.
The normally open solenoid valve (B) vents the compressor
during the REVS sequence for off-load power savings and after
stopping allows quick restart if required.
The normally open solenoid valve (C) isolates the servo and
vacuum valve feeds during full load operation to reduce losses
and maximise compressor efficiency.
System pressure is shown on the controller, compressor
pressure can only be viewed on the gauge fitted to the drive end
cover.
Fig 6.1 Solenoid Locations
6.2 Operation Selection
The controller has AUTOMATIC OPERATION stop/start set as
default to achieve maximum efficiency. Go to the [CONTROL
MENU] sub-menu and use the key to go to the AUTOMATIC
OPERATION menu item.
Press the key the AUTOMATIC OPERATION value starts to
flash. Use the key to switch to CONTINUOUS OPERATION,
confirm by pressing the key.
6.3 Operator Menus
To alter default values in menus, or view error codes, press the
and keys together.
Use the button to switch to the [CONTROL MENU] or [FAULT
MEMORY] sub-menu then press the key to select.
In the [CONTROL MENU] the CUT-OUT POINT menu item
appears on the display. Press the key, the value will flash.
Increase or decrease this value using the or key, confirm
the value set by pressing the key.
Press the or key to scroll though available parameter
settings, press the key to select.
a) CUT-OUT POINT
b) CUT-IN POINT or TARGET PRESSURE (RS)
c) p2 CUT-OUT POINT
d) p2 CUT-IN POINT or p2 TARGET PRESSURE (RS)
e) RUN-ON TIME
f) AUTOMATIC OPERATION
g) ENABLE REMOTE-START
h) TIMER CONTROL
i) p2 TIMER CONTROL
j) AUTO RESTART
k) POWER LOSS TIME
l) START-UP DELAY
m) DRYER PRE-RUN
n) RS485-ProTOCOL
o) RS485-BAUDRATE
p) RS485-ADDRESS
A selected item will flash, press the or key to change a
value or select an alternative, press the key to select.
The [FAULT MEMORY] retains the most recently recorded
warning or fault and the hours when the event occurred. The last
warning or fault recorded is always at the top.
In order to distinguish between faults and warning messages,
faults are marked with an exclamation (!). Use the or key
to switch between the individual memory areas in the fault
memory.
See Section 8.0 Controller Messages for warnings and faults.
6.4 Pressure Adjustment
WARNING !
PRESSURE ADJUSTMENTS SHOULD BE MADE
BY TRAINED SERVICE ENGINEERS. FAILURE
TO COMPLY WITH THIS REQUIREMENT MAY
INVALIDATE THE COMPRESSOR WARRANTY.
Press the and keys together. Use the key to switch to
the [CONTROL MENU] sub-menu, press the key to select.
The unload CUT-OUT POINT appears first, press the key, the
value will flash, press the or key to change the value to the
desired pressure and press the key to select.
Press the key to switch to the load CUT-IN POINT, press the
key the value will flash, press the or key to change the
value to the desired pressure and press the key to select.
The load/cut-in pressure should be set 0.5 bar (7 psi) below the
nominal pressure required and unload pressure 0.5 bar (7 psi)
above, servo valve pressure is 1.0 bar (14.5 psi) above the
nominal.
Both parameters load/cut-in and unload/cut-out pressure must
be set on the controller together with manual servo adjustment to
ensure that the compressor functions correctly.
6.5 Pressure Control RS Compressors
The load/cut-in (TARGET) and unload/cut-out pressure may be
adjusted from the default settings shown in 2.0 Product
Information in the range of 6, 7, 8, 9 or 10 bar (87, 102, 116, 130
or 145 psi).
In the [CONTROL MENU] match the load/cut-in (TARGET)
pressure to the nominal bar figure required, the unload/cut-out
CUT-OUT POINT pressure 0.5 bar (7 psi) above, servo valve
pressure is 1.0 bar (14.5 psi) above the nominal.
Manual servo valve adjustment is necessary to match pressure
selected on the controller.
A C B

6.0 Adjustments
16 CC1132751C
6.6 Servo Valve (Fig 6.2)
The servo valve controls pressure when there is no demand for
air, settings shown in Section 2.0 Product Information are a
maximum and must not be exceeded.
Access to the servo valve requires the cabinet front door to be
opened, the top cover panel, the intake filter and the intake filter
support to be removed.
Fig 6.2 Servo Valve
If the servo needs adjustment or a lower pressure is required
then carry out the following procedure.
a) Turn the electrical supply on at the isolator, disconnect
the air outlet valve from the system and fit an air
silencer.
b) Select continuous operation from the [CONTROL
MENU], start the compressor open the outlet valve and
allow to warm up.
c) Release locknut (A), turn grub screw (B) anti-clockwise
for two turns and close the outlet valve.
d) Screw in grub screw (B) clockwise to increase pressure
to the desired setting, allow pressure to stabilise.
e) Open and close the outlet valve, allow pressure to
stabilise, check the pressure gauge reading.
f) If low turn grub screw (B) clockwise to increase or anti-
clockwise to decrease pressure.
g) With the correct pressure showing on the gauge secure
the servo locknut (A).
h) Reset the compressor from continuous operation back to
automatic stop/start operation.
Stop the compressor, isolate from electrical supply and remove
air silencer, re-connect the outlet valve to the system.
6.7 Setting Timer Units
The time and date will have been set as described in Section
5.8, this is the basis for accurate timer operations.
Go to the TIMER CONTROL sub-menu, use the or key to
select from seven different timer units. The status line of each
switching unit is as follows:
a) b) c) d)
1 ____________00:00 00:00
a) Unit no.
b) Days of the week [SMTWTFS] = Sunday, Monday
c) Switch-in point
d) Switch-out point
If there are no days of the week selected in the switching unit
line, the switching unit is not active. The switching unit only
becomes active when the day of the week is set.
When the key is pressed, the first underscore _ starts to flash.
You can now use the key to set the first day of the week
(Sunday). Then use the key to confirm the day of the week.
The next underscore _ then starts to flash. If you do not want to
confirm a day of the week as set, press the key.
You can run through all seven days of the week in this way.
Once you have confirmed the last day of the week (Saturday),
the first unit of the switch-in point starts to flash. You can either
set this using the or key. Once the last unit of the switch-
out point has been confirmed, the whole timer unit is activated.
The next step is to go to the [CONTROL MENU] sub-menu and
then the TIMER CONTROL menu item. You will now see the
default setting TIMER CONTROL OFF. Press the key, the
OFF value starts to flash. Use the key to change the value to
ON. Press the key again to confirm the entry. The timer is
now switched on, press the key to activate.
Timer unit setting examples are explained below.
Switching unit 1 not active:
1 _______ 00:00 00:00
The unit should run Monday to Friday between 7.30 am and 4.15
pm.
2 _MTWTF_ 07:30 16:15
a) b) c)
a) Days of the week Monday to Friday
b) Switch-in point
c) Switch-off point
B
A

7.0 Maintenance
_________________________________________________________________________________________
CC1132751D 17
7.0 Maintenance
WARNING !
SERVICING MUST ONLY BE CARRIED-OUT BY
TRAINED SERVICE ENGINEERS COMPETENT IN THE
MAINTENANCE, MAINS ELECTRICAL SUPPLY AND
STARTER EQUIPMENT
7.1 Routine Service
The work listed must be carried-out at the indicated running
hours, which must be regarded as a maximum. In dusty, hot or
humid conditions, more frequent servicing may be necessary.
On RS units after long periods, speed control unit capacitors and
cooling fan(s) should be replaced to ensure reliability of the unit.
7.2 Service Kits
If you are unable to carry-out the work safely in the required
manner, your Hydrovane Distributor will be pleased to help.
Use genuine parts and approved oils during routine servicing,
the following service kits are available:
Oil change kit, 2000 hour/12 months, use KOHR457.
Maintenance kit, 4000 hour/2 year, use KMHR457 or
KMHR457LS. Serial numbers: HR04-000210-1605, HR05-
000445-1605 & HR07-000790-1601.
Full overhaul/top-up kit, 20000 hour/10 year, use KTHR4,
KTHR5, KTHR7 (inc. KWHR457) use with KMHR kit.
Additional kits available for full product support are as follows:
Solenoid valve kit, 8000 hour/4 year, use KSVDOLHR457,
KSVSDHR457.
Contactor kit, non-scheduled item, use KCHR457DOL,
KCHR457RS, KCHR457SD
Electrical kit, 20000 hour/10 year, use KEHR457DOL,
KEHR457RS, KEHR457SD
Oil Seal and Wear sleeve kit, 20000 hour/10 year, use
KWHR457 (Inc in KT KIT).
Motor bearing kit (HEBEI Motor), 20000 hour/10 year, use
KBH132 (HR04), KBV132 (HR05/07)
7.3 Service Instructions
WARNING !
STOP THE COMPRESSOR AND ISOLATE FROM THE
MAINS ELECTRICAL SUPPLY. LOCK THE ISOLATOR
IN THE OFF POSITION. FIT A SAFETY NOTICE
ADVISING THAT WORK IS BEING CARRIED OUT ON
THE COMPRESSOR.
CLOSE THE AIR OUTLET VALVE TO ISOLATE THE
COMPRESSOR FROM THE AIRLINE SYSTEM. FIT A
SAFETY NOTICE ADVISING THAT IT IS NOT TO BE
OPENED.
DO NOT PROCEED UNTIL THE AIR PRESSURE
GAUGE READS ZERO !
AVOID UNNECESSARY CONTACT WITH HOT OIL
AND COMPONENTS. GLOVES ARE
RECOMMENDED IF DRAINING OIL WHEN THE
COMPRESSOR IS HOT!
7.4 Panel Removal
Unlock and open the hinged front door panel to allow removal of
the top panel. Remove any fixing screws and pull the top panel
from the location slots and lift clear of the compressor.
7.5 Oil Filling/Draining (Fig.7.1)
Remove filler plug (A) with bonded seal (B), remove and retain
the level plug (C).
Place a suitable container below the oil drain point, remove drain
plug (D) with bonded seal (E) and allow oil to drain.
When draining is complete, replace the drain plug and clean
away any oil spillages.
Fill with approved oil to overflow from the level plug. Stop filling,
replace the level and filler plugs, and clean away any spillage.
If the oil filter has been replaced, run the compressor for a short
time (30 seconds) and re-check the oil level.
Fig 7.1 Filler Plug, Air Filter, Separator, Oil Drain
and Filter
7.6 Oil Filter (Fig 7.1)
Unscrew oil filter (F) anti-clockwise, minimise spillage from the
canister and discard in a safe manner.
Using a new filter, smear a small amount of oil onto the seal,
screw in clockwise, hand tight only.
7.7 Air Filter (Fig.7.1)
Remove M6 Nut (G) with bonded seal (H), remove the cover
plate. Lift off the air filter element (J) and discard in a safe
manner.
Using a new air filter element, replace over filter support and fix
the cover plate back on with, nut and bonded seal.
7.8 Oil Separator (Fig.7.1)
Unscrew oil separator (K) anti-clockwise and discard in a safe
manner.
Using a new separator, smear a small amount of oil onto the
seal, screw clockwise, hand tight only.
A B
C
DE
F
K
G H
J

7.0 Maintenance
18 CC1132751C
7.9 Oil Cooler/Aftercooler (Fig.7.2)
Undo and remove the fixing screws that secure the dryer vent
panel to rear side panel.
With the internal face of matrix (A) exposed use low pressure air
(2 bar/29 psi) and brush and blow over the whole area.
Internal filters (C) are positioned inside the starter enclosure and
should be replaced at regular service intervals.
Vacuum up debris from the cooler and fan ducting area behind
the cabinet filter frame (B) before replacing the filter frame.
Fig 7.2 Intake and Cooler Matrix
7.10 Cabinet Air Filter (Fig 7.2)
Remove the filter frame (B) located in the rear panel by sliding
upwards, pull the bottom edge forward to clear retaining lips.
Refit in the reverse sequence.
7.11 Electric Motor
Remove any dust or dirt from motor bodies and air intake cowls
located under the compressor base.
7.12 Electrical Connections
Open the starter panel door and remove any terminal covers
fitted to contactors and incoming supply terminals.
Check for any signs of overheating and ensure that all electrical
connections are tight.
Pay special attention to power connections, cables connected to
contactors and incoming terminals and ensure all earthing wiring
is present and undamaged.
Close the starter panel door and lock with the key provided to
prevent unauthorised access.
All discarded items and waste oil must be disposed of in an
approved manner.
On completion of the service refit all panels, remove safety
notices and switch the mains electricity on and open the outlet
valve.
7.13 Service Schedule
The following maintenance charts cover all compressors using
Hydrovane Fluid Force Red 2000, Clear and HPO oils.
NOTE ! Certain items may not be applicable to all units, shaded
items are Distributor maintenance tasks only.
For normal ambient conditions bulk oil temperatures must not
exceed 90°C/194°F (100°C/212°F for HPO oil) with 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 conditions
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
significantly reduced.
CAUTION !
When changing recommended oil types, it is advisable to flush
the compressor with the oil to be used, drain then refill to remove
contaminated oil, do not mix oils.
A
C
B

7.0 Maintenance
_________________________________________________________________________________________
CC1132751C 19
Service Schedule Fluid Force Red, Clear and HPO Oil (2000 hour change period)
Maintenance Actions Install Weekly
Every
2000
Hours
Every
4000
Hours
Every
20000
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
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
X
Check for oil leaks
X
X
X
X
X
Check air intake filter/clean if necessary
X
X
X
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 conduit/cables secure
X
X
X
X
Check motor for damage
X
Check motor/starter for loose connections
X
X
X
X
Check motor for vibration
X
X
X
X
Check flexible control pipes
X
X
X
Check oil seal for leakage
X
X
X
Check drive media/key
X
Check starter contactors
X
X
Check motor insulation resistance
X
Check combi cooler matrix
X
X
X
X
Check solenoid valve operation
X
X
X
Clean cabinet filter
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
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 starter enclosure filter
X
X
X
Change unloader valve seals
X
Change MPV seals
X
X
Change vacuum valve seals
X
Change flexible control pipes
X
X
Change thermal motor
X
X
Grease motor bearings (if applicable)
X
X
Full air end inspection (internal)
X
Change drive coupling element
X
Change oil seal
X
Change wear sleeve
X
Change pressure gauge
X
Change motor bearings
X
Full operational test/check
X
X
X
X

7.0 Maintenance
20 CC1132751C
Service Schedule for Fluid Force HPO Oil (4000 hour change period)
Maintenance Actions Install Weekly
Every
4000
Hours
Every
20000
Hours
Site-sufficient access for service
X
Site–protected from weather
X
Site–adequate ventilation
X
X
X
X
Site–ambient temperature within limit
X
X
X
X
Site–dust free ambient
X
X
X
X
Check/torque electrical connections
X
X
X
Check oil level at filler plug/sight glass
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
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 conduit/cables secure
X
X
X
Check motor for damage
X
Check motor/starter for loose connections
X
X
X
Check motor for vibration
X
X
X
Check flexible control pipes
X
X
Check oil seal for leakage
X
X
Check drive media/key
X
Check starter contactors
X
X
Check motor insulation resistance
X
Check combi cooler matrix
X
X
X
Check solenoid valve operation
X
X
Clean cabinet filter
X
X
X
Clean any external dirt from compressor
X
X
X
X
Clean any external dirt from motor
X
X
X
X
Change separator element
X
X
Change 2000 hour oil
X
X
Change oil filter
X
X
Change air intake filter
X
X
Change cabinet filter
X
X
Change starter enclosure filter
X
X
Change unloader valve seals
X
Change MPV seals
X
X
Change vacuum valve seals
X
Change flexible control pipes
X
X
Change thermal motor
X
X
Grease motor bearings (if applicable)
X
X
Full air end inspection (internal)
X
Change drive coupling element
X
Change oil seal
X
Change wear sleeve
X
Change pressure gauge
X
Change motor bearings
X
Full operational test/check
X
X
X