Hydrovane HV11 Instruction Manual

UserHandbook
HV11-HV15Models(ACE)
StationaryAirCompressors
ST16135-00 Iss A05/2006

ST16135-00A i
Contents
Contents
1Introduction.... ... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..1
1.1 Support.. ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..1
1.2 CustomerWarrantyTerms... ... ... .... .. .... ... .... .. .... ... .... .. ..1
1.3 ProductDevelopment.... ... ... ... .... .. .... ... .... .. .... ... .... .. ..1
1.4 QualityStandards... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..1
1.5 ModelRange... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..1
1.6 Terminology.. ... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..1
2Safety.. .... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..3
2.1 GeneralHealthand SafetyPrecautions... .. .... ... .... .. .... ... .... .. ..3
2.2 The Healthand Safetyat WorkAct, 1974 .. .. .... ... .... .. .... ... .... .. ..3
2.3 BeforeWorking on Compressor.. ... .... .. .... ... .... .. .... ... .... .. ..3
2.4 When Operatingthe Compressor. ... .... .. .... ... .... .. .... ... .... .. ..3
2.5 PotentialOilHealthHazards.. ... ... .... .. .... ... .... .. .... ... .... .. ..4
2.6 FirstAidMeasures. .. .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..4
2.7 Warnings,CautionsandNotes... ... .... .. .... ... .... .. .... ... .... .. ..4
3ProductInformation... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..5
3.1 Operating Temperatures.. ... ... ... .... .. .... ... .... .. .... ... .... .. ..5
3.2 High Operating Temperatures. ... ... .... .. .... ... .... .. .... ... .... .. ..5
3.3 NoiseLevel.. ... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..5
3.4 TechnicalData.. ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..6
4TransportationandHandling .. ... ... .... .. .... ... .... .. .... ... .... .. ..7
4.1 Introduction .. ... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..7
4.2 Lifting and handling (Fig.4.1and Fig.4.2). .. .... ... .... .. .... ... .... .. ..7
4.3 ModelWeights... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..7
5InstallationandCommissioning... ... .... .. .... ... .... .. .... ... .... .. ..9
5.1 Positioning YourCompressor-BasicRequirements.. .... .. .... ... .... .. ..9
5.2 Ventilation(Fig.5.1). .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..9
5.3 ElectricalConnections.... ... ... ... .... .. .... ... .... .. .... ... .... .. ..9
5.4 ElectricalInstallation (Fig.5.2)... ... .... .. .... ... .... .. .... ... .... .. .10
5.5 CheckDirection ofMotorRotation . ... .... .. .... ... .... .. .... ... .... .. .10
5.6 Regulated Speed CompressorInstallation . .. .... ... .... .. .... ... .... .. .11
5.7 RS OperationwithotherHydrovaneCompressors.... .... .. .... ... .... .. .11
6GeneralDescription... .... ... ... ... .... .. .... ... .... .. .... ... .... .. .13
6.1 Compressor/Hypac(Fig.6.1). ... ... .... .. .... ... .... .. .... ... .... .. .13
6.2 ControlSystems. ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. .13
6.3 CompressorAssembly(Fig.6.2).. ... .... .. .... ... .... .. .... ... .... .. .14
7OperatingInstructions. .... ... ... ... .... .. .... ... .... .. .... ... .... .. .15
7.1 Operating Instructions.... ... ... ... .... .. .... ... .... .. .... ... .... .. .15
7.1.1 Checking ProcedureBeforeStarting ... .. .... ... .... .. .... ... .... .. .15
7.1.2 Operating Mode .. .... ... ... ... .... .. .... ... .... .. .... ... .... .. .15
7.1.3 CompressorOperation.... ... ... .... .. .... ... .... .. .... ... .... .. .15
7.1.4 Starting -AutomaticMode. ... ... .... .. .... ... .... .. .... ... .... .. .16
7.1.5 Starting -ContinuousMode ... ... .... .. .... ... .... .. .... ... .... .. .16
7.1.6 Starting -RegulatedSpeed... ... .... .. .... ... .... .. .... ... .... .. .16
7.1.7 Stopping–All Models.. ... ... ... .... .. .... ... .... .. .... ... .... .. .16
7.1.8 Emergency Stop .. .... ... ... ... .... .. .... ... .... .. .... ... .... .. .16
7.1.9 CompressorVentDown... ... ... .... .. .... ... .... .. .... ... .... .. .16
7.2 OperationalDisplaySymbols. ... ... .... .. .... ... .... .. .... ... .... .. .17
8Adjustments... ... ... .... ... ... ... .... .. .... ... .... .. .... ... .... .. .19
(continued)

Contents
ii ST16135-00A
8.1 CompressorControl(Fig.8.1)... ... ... ... .... .. .... ... .... .. .... ... ..19
8.2 PressureAdjustments.. ... .... ... ... ... .... .. .... ... .... .. .... ... ..19
8.3 PressureControl–RSCompressors... ... .... .. .... ... .... .. .... ... ..20
9Servicing. ... .... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..21
9.1 Introduction.... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..21
9.2 RoutineServiceSchedule.. .... ... ... ... .... .. .... ... .... .. .... ... ..21
9.3 Servicing (RS).. ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..21
9.4 CheckCompressorOperation ... ... ... ... .... .. .... ... .... .. .... ... ..21
9.4.1 CheckCompressorPressure.... ... ... .... .. .... ... .... .. .... ... ..21
9.4.2 Checkoillevel(Fig.9.1). .... ... ... ... .... .. .... ... .... .. .... ... ..21
9.5 BasicService... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..22
9.6 AccessPanelRemoval. ... .... ... ... ... .... .. .... ... .... .. .... ... ..22
9.7 Oil DrainingandFilterReplacement(Fig.9.2and Fig.9.3).. .... .. .... ... ..22
9.8 Oil Draining.... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..22
9.9 Oil FilterReplacement(Fig.9.3). ... ... ... .... .. .... ... .... .. .... ... ..22
9.10 Oil filling/Top-up (Fig.9.3). .... ... ... ... .... .. .... ... .... .. .... ... ..23
9.11 AirFilterReplacement(Fig.9.2). ... ... ... .... .. .... ... .... .. .... ... ..23
9.12 Oil SeparatorReplacement(Fig.9.2)... ... .... .. .... ... .... .. .... ... ..23
9.13 Clean Oil Cooler/Aftercooler(Fig.9.4)... ... .... .. .... ... .... .. .... ... ..23
9.14 CabinetAirFilter... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..23
9.15 PanelRefitting .. ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..23
9.16 Electricalchecks... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..23
9.16.1 Clean motors... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..23
9.17 Servicing Requirements. ... .... ... ... ... .... .. .... ... .... .. .... ... ..24
9.18 ServiceSchedule:FluidForceRed2000 (2000 houroil change).. .. .... ... ..24
10 FaultFinding. .... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..27
10.1 FaultFinding ... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..27
10.2 ShutdownTripError(E)–Menu P03 ... ... .... .. .... ... .... .. .... ... ..27
10.3 Alarm(A)–MenuP04 .. ... .... ... ... ... .... .. .... ... .... .. .... ... ..27
10.4 RunInhibit(R) –Menu P05. .... ... ... ... .... .. .... ... .... .. .... ... ..27
10.5 FaultDisplaySymbols.. ... .... ... ... ... .... .. .... ... .... .. .... ... ..27
10.6 DiagnosticMenu P06 ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..27
10.7 Configuration MenuP07 ... .... ... ... ... .... .. .... ... .... .. .... ... ..28
10.8 SpeedRegulation Menu P08.... ... ... ... .... .. .... ... .... .. .... ... ..28
10.9 Calibration Menu P09.. ... .... ... ... ... .... .. .... ... .... .. .... ... ..28
10.10 AccessLevelConfigurationMenuP10 .. ... .... .. .... ... .... .. .... ... ..28
Contents(continued)

ST16135-00A 1
1Introduction
1Introduction
IMPORTANT !
BEFOREINITIALSTART-UP,ENSURETHATTHE
COMPRESSORISFILLEDWITHAHYDROVANEAPPROVED
OIL. DONOTOVERFILL.
1.1 Support
Fullsupport isavailablefromyourHydrovaneDistributor.Ifyou
needanyspecialisthelporservice,pleasecontactyour
DistributorquotingtheMODELTYPE andSERIALNUMBER.
1.2 CustomerWarrantyTerms
Allcompressors,whichareservicedbyanauthorisedHydrovane
Distributor, areguaranteedfor12monthsfromcommissioningor
18monthsfromthedateof shipment.
Thewarrantyexcludesnormalserviceparts,oilandwearitems,
dirtingress, cleaningoffiltersandfluiddraindevicesandthe
tighteningofelectricalorotherconnections.Alsoexcludedis
adjustment of theControllersettings.Consequentialdamageof
anynatureisnotcoveredbythewarranty.
An‘Advance’ 10yearwarrantyisavailableforapproved
installations,contact yourHydrovaneDistributorfordetails.
1.3 ProductDevelopment
Hydrovaneadoptapolicyof continualproduct development. The
informationinthisHandbook,whilst fullyuptodatewhenissued,
maybesubject tochangewithoutnotice.
1.4 QualityStandards
CompAirUKLtdQualityManagementSystemsareapprovedto
BS ENISO9001.
Theseinstructionscomplywiththelatest EuropeanDirectives
regardingcontentandarevalidformachinescarryingthe
CEmark.
CompAirUKLtd
ClaybrookDrive
WashfordIndustrialEstate
Redditch, Worcestershire
B980DS,England
Web: www.hydrovane.co.uk
[e-mail]
www.CompAir.com
E-mail: [e-mail]
Telephone: [phone]
Fax: [phone]
1.5 ModelRange
ThisHandbookrelatestoall ACEHV11-HV15vertical range
compressorsandHypacmodels.
HV11-HV15model types:
V11ACE08-4035S000 50Hzmodel
V11ACE10-4035S000 50Hzmodel
V11ACE08-2336D005 60Hzmodel
V11ACE10-2336D005 60Hzmodel
V11ACE08-5756D005 60Hzmodel
V11ACE10-5756D005 60Hzmodel
V15ACE08-4035S000 50Hzmodel
V15ACE10-4035S000 50Hzmodel
V15ACE08-2336D005 60Hzmodel
V15ACE10-2336D005 60Hzmodel
V15ACE08-5756D005 60Hzmodel
V15ACE10-5756D005 60Hzmodel
V15ACE10-4035V000 50Hzmodel
1.6 Terminology
Theproduct codesegmentssignifies:
VVane
11,15 kWmotor
ACE AirCentreElectronic
08,10 Deliverypressureinbars
23 230V
40 400V
57 575V
1, 3 Singlephase,3phase
5, 6 50Hz, 60Hz
D, S,V Direct OnLine, Star/Delta,Variable
Speed
000 EuropeanSpecification(50Hz)
005 USSpecification(60Hz)
Thispublicationreferstocompressorswithserialnumbersfrom:
V11-000001-0604
V15-000001-0604
1

ST16135-00A 3
2Safety
2Safety
2.1 GeneralHealthandSafetyPrecautions
Pleasereadcarefullyand proceed inaccordancewith the
following instructionsbeforeinstallation,operation,
maintenanceorrepairofthecompressorunit.
2.2 TheHealthandSafetyatWorkAct,1974
Inordertocomplywithyourresponsibilitiesundertheaboveact, it
isessentialthattheCompressoristransported,positioned,
installed,operatedandmaintainedbycompetentpersonsin
accordancewiththeinstructionsinthisHandbook.
Thestandardbuildof allHydrovaneproductsaredesignedto
compressclean,dry, atmosphericairandarenotintendedforuse
ineitherExplosiveorPotentiallyExplosiveAtmospheresas
definedin theATEX Directive94/9/EC.
ApotentiallyExplosiveatmosphereisanatmospherewhichcould
becomeexplosivedue tolocalandoperationalconditions.
TheCompressorwarrantywillbeinvalidatedifunapprovedspare
partsoroilsareused.Usingsuchitemsmaycausetheefficiency
andservicelifeoftheCompressortobereduced, andcould
createahazardousconditionoverwhichHydrovanehasno
control.
FailuretomaintaintheCompressorcorrectly,ormodifyingit
withoutpriorapprovalfromHydrovane, mayalsocreatea
hazardouscondition.Thiswillalsoinvalidatethewarranty.
Readandfullyunderstandthe contentscontainedintheUser
Handbook.
Ensurethat theUserHandbookisnot permanentlyremovedfrom
theCompressor.
Checkthattherearenosignsof damageand/oroilleaks fromthe
Compressor,coolerand associatedpipework.
Aftercompletingwork,toolsandforeignmattershouldbe
removedfromtheCompressoranditssurroundingarea.
IntheunlikelyeventofaCompressorfire, drypowderorcarbon
dioxidefireextinguishersshouldbeused. Neverusewater.
2.3 BeforeWorkingonCompressor
Potentiallydangerousvoltagesareusedtopowerthismachine.
Donot carryout anyworkuntilthe isolatorislockedintheoff
position. Fitasafetynoticetotheisolatoradvisingthat workis
being carriedout andthat theisolatormustnot beswitchedon. If
indoubt, aqualifiedelectricianmayremovethefusesandkeep
theminasecureplaceuntilworkiscomplete.
EnsuretheCompressorhasbeensafelyisolatedfromthemainair
systemandcannotbere-introduced untilall workhasbeen
completed. Fitasafetynoticetotheisolationvalveadvisingthat
workisbeingcarried out.
Donot undertakeanyworkuntiltheCompressorandreceiver,if
fitted,havebeenrelievedofallpressure.
WaituntiltheCompressor’sventdowncycleiscomplete.
Releaseanypressurecontainedintheaftercoolerorassociated
pipework.
CheckthattheCompressorpressuregaugereadszero.Donot
proceeduntilit does.
CarefullyunscrewtheCompressorfillerplug.If anyairoroil
escapesbeforetheplugisfullyremovedstop! Donot removethe
pluguntilall pressureislost.
SafetydevicesfittedtotheCompressororpipeworksystem
shouldbecheckedat regularintervalsandreplacedif faulty. They
shouldnot betamperedwithormodified.Nonreturnvalves
shouldnot beusedasisolationdevices.
ToensuretheCompressoroperatessafelyyoumust carryoutthe
specifiedmaintenanceprocedures.
Onlyapprovedoilsshouldbeusedforflushingpurposes.
ExtremecautionshouldbetakeniftheCompressorhasbeen
subjectedtosevereoperatingtemperaturesorfire.Certain
componentsmaycontainfluoroelastomermaterialsandunder
theseconditionscanleaveextremelycorrosiveresidues.Severe
burnsandpermanent skinandtissuedamagecanbearesult of
skincontact.
TheHealthandSafetyinformationcontainedinthisHandbookis
onlyintendedtogivegeneralguidelines.
2.4 WhenOperatingtheCompressor
Wheninautomaticmodethe Compressormayrestart without
warning.
Additionalwarningswillberequirediftheunit isconfiguredfor
remotestop/startortorestart afterpowerfailure.
Donotremoveanyplugsorreleasepipeworkwhenthe
Compressorisrunning.
Donotattempt toopenthestarterenclosurewhile the
Compressorisoperating.
Bewareofhot surfaces,boththeCompressorandelectricmotor
aredesignedtorun atelevatedtemperatures.
Compressedairispotentiallydangerousandcanbefatalif
misused.Donot allowcompressedairjets,dischargedfromany
pipeornozzle, tomakecontactwithyourbody.
Wearsafetyglassesandsuitableclothingwhenusingorworking
inanareawherecompressedairisbeingused.
Hazardousvapours/fumescanbeproducedifcompressedairis
usedtoremovechemicals,cleaningagentsandoilsfrom
equipment andcomponents. Suitable respiratoryandextraction
equipment maybe requiredinthesecircumstances.Neveruse
compressedairforcleaningpersonalclothing.
AirdischargedfromCompressorsisunsuitableforbreathing
purposes.Airforhumanconsumptionmustbesubjectedtofurther
treatment toensurethat contaminant levelsforodourand
moisturecontentmeet therequirementsofBS 42751974.
Werecommendthatairsupplytohand-heldairgunsisregulated
toalowerpressure(refertolocalHealthandSafetyregulations).
Donotinsertanyobjectoranypart of yourbodythroughany
openingof theCompressorenclosure. Seriouspersonal injury
and/ordamage mayresult.

Safety 2
4ST16135-00A
NeverruntheCompressorwithanycoversorguardsmissing,
unlessadvisedtodoso.
2.5 PotentialOil HealthHazards
ThissectionrelatestoHydrovaneapprovedoil. Forotheroils
refertotheHealth andSafetyInstructionsissuedwiththe
relevantproduct.
Therearenosignificant hazardsassociatedwiththisproduct
whenproperlyusedandintheapplicationforwhichit was
designed.Frequentand/orprolongedskincontactmaygiveriseto
skinirritationsanditisrecommendedthatprotectiveglovesare
worn. Thecarcinogenicactionofmineraloilsshouldbebroughtto
theattentionofallusers. *
Theoilmaybehot sotakecarewhencarryingout oil changes.
Donot keepoilyragsinpocketsorwearcontaminatedclothing.
Donot inhalefumesorvapours. Donotswallow.Avoideye
contact.
Alwayswashhandsafteruseandbeforeeating, drinkingand
smoking.
2.6 FirstAidMeasures
Inhalation-Removefromexposureintofreshair. If necessary
giveartificialrespirationoroxygen. Seekmedicaladvice.
SkinContact -*Mildlyirritating.Removebywiping. Washwith
soapandwater. Applyemollient cream.
EyeContact-*Mildlyirritating. Flushwithcopiousamountsof
warmwater.Seekmedicaladviceif necessary.
Ingestion-Donot inducevomitingbecauseof theriskof
aspiration.Washmouthoutwithwater. Give1/2pint milk. Seek
immediatemedicalattention.
FurtherMedical Treatment
Aspiration-If thereisanysuspicionof aspiration intothelungs
(forexampleduringvomiting)admit tohospitalimmediately.
Pressureinjection-Obtain immediatemedicalattention,evenif
injuryappearsminor.
Spillage-Soakupwithabsorbent clay.
WasteDisposal-Oil, condensate,filterelementsetc.shouldbe
disposedofin accordancewithlocalregulations.Donot allowoil
tocontaminatewatersupplies.
*SeeCautionaryNoticeSHW397‘EffectsofMineralOilonthe
Skin’and MS(B)5‘Skin CancerCaused byOil’ publishedby
theHealth and SafetyExecutive.
2.7 Warnings,CautionsandNotes
Definition
WARNING! isusedinthetext of thisHandbooktoidentify
specifichazardswhichcancauseinjuryordeath.Thistypeof
hazardisidentifiedbelow.
CAUTION! isusedin thetext toidentifyincorrect procedures
whichcancausedamagetotheCompressor.
Note: isusedin thetext todrawattentiontospecificpointsof
importance.
Hydrovanedeclinesall liabilityintheevent of materialdamageor
bodilyinjuryresultingfromnegligenceintheapplicationof these
precautions, fromnon-observationorlackofelementary
supervisioninrespectofhandling, operation,servicingorrepair,
evenifnot expresslystatedinthisinstructionnotice.
Riskof electricshock
Riskof hazardordanger
Riskof hotsurfaces
Eyeprotectionmustbeworn
Dustprotectionmustbeworn
Warningpressurisedvessel
Warningpressurisedcomponentorsystem
Warningunit isremotelycontrolledandmaystart
withoutwarning
Readtheinstructionmanual
Donot operatethemachinewithout theguardbeing
fitted
Warningdonotstartthemachinewithout
consultingHandbook
Liftingpoint
Directionofrotation

ST16135-00A 5
3Product Information
3Product Information
3.1 OperatingTemperatures
YourCompressorwillgiveoptimumperformanceandtrouble-free
servicelifewhenthebulkoiltemperatureismaintainedbetween
75°Cand85°C.
Certainoperatingconditionssustainedoveraperiodoftimemay
causeproblemsthat effect theperformanceandreliabilityofthis
Compressor.
Problems mayoccurwhen compressorsrunforshortperiodson
lowairdemandwheretheydon’treachnormaloperating
temperatures.
Prolongeduseundertheseconditionscancausecondensation
buildupwithintheCompressorandmayeventuallyleadto
emulsificationof theoil.
Normaloperating temperaturesarereachedintypically10/15
minutes. Topurge condensatefromthe Compressor,alonger
runningperiodwithahigh airdemandisneeded,usuallya
minimumof 60minuteswillberequired.
ConditionsorapplicationswhichpreventtheCompressor
temperaturestabilisingbetweentheseparametersshouldbe
avoided.
ConsultyourlocalHydrovaneDistributorifyouhaveanyparticular
concernsabout operationalcharacteristicsof yourCompressor.
3.2 HighOperatingTemperatures
Someof thereasonsforhighcompressoroiltemperaturesare:
• Lowoillevel.
•Blockedoilcoolerorcoolerflowrestrictions.
•Wrongtypeorgradeof oil.
•Highambienttemperature.
•Coolingfanstoppedoroperating incorrectly.
Note: Thecontrollerdisplaywillshowawarningwhenthe
Compressortemperaturereaches107°C.
Note: TheCompressorwillstopautomaticallyifthetemperature
risesabove110°C.
Ifthebulkoiltemperaturefrequentlyreads100°C,thenFluid
ForceHPOoilshouldbeused.
3.3 NoiseLevel
Although thesoundpressurelevelfortheseunitsisrelativelylow,
theyshouldbepositionedwherenoisewillnot beaproblem.

Product Information3
6ST16135-00A
3.4 TechnicalData
ModelNumber HV11 HV15 HV15RS
PERFORMANCE
F.A.D. litres/sec(cfm)@8bar 29(61) 38(81) 0 -39(0-83)
F.A.D. litres/sec@10bar 25(52) 33(71) 0 -25(0-52)
NoiseLevel-dBA 69 70 70
Power-kW(hp) 11(15) 15(20) 15(20)
StarterType-Automatic DOL&SD
StarterType-Inverter N/A Soft Start
DriveType Direct
OperatingControls ContinuousRun, AutomaticStop/Start,
ReducedEnergyVent System SoftStart/ Variable
CompressorRotationSpeed-rev/min(60Hz) 1450(1760) 990-2040
Oil Capacity-litres 6.0
Ambient TemperatureRange°C 0to45 0to40
MaximumRelativeHumidity% 85non-condensing
AirDischarge Temp-°C(aboveambient) <8 <10
FACTORYSETTINGS
MinimumPressureValve-bar 5.5to6.0
MinimumAirLinePressure-bar (PL) 7.5to9.5 7.5
MaximumAirLinePressure-bar (PU) 8.5to10.5 9.0
REVS DelayPeriod(secs) (Rt) 60(8bar) 90(10bar)
Run-on-TimetoStop(secs) (St) 10
PressureDisplayUnits (PD) 0(bar) (1=psi,2=kpa)
TemperatureDisplayUnits (Td) 0 =°C(1=°F)
ServoValve-bar 9.0or11.0 8.5
VacuumRelief Valve Oneturnanti-clockwise
INSTALLATION
AirOutletSize-Rp 3/4
MinimumRoomVolume-m325
AirInlet/OutletArea-m20.5
VentilationRate-m3/h 3400
Cooling AirFlowm3/h(cfm) 3702(2180)
RecommendedAirReceiverCapacity-L 275
COMPRESSOROIL
Approvedcompressoroil FluidForceRed2000&HPO
ELECTRICAL
Seeelectricaldatainsidethe starterdoor. 76103, 76196&76289

ST16135-00A 7
4Transportation andHandling
4Transportation andHandling
4.1 Introduction
Liftingandtransportationmust onlybecarriedoutbyauthorised
persons, fullytrainedintheuseof theequipmentemployed.
Ensurethatallmeansoftransportationand/orliftingequipment
areadequateforpurposeandareratedtoexceedthefullloadof
theunit.
4.2 Liftingandhandling(Fig.4.1andFig.4.2)
Aforkliftorpallettruckarethemostsuitablemeansof
transportation. Payparticularattentiontoensurestabilityto
prevent theunittiltingover.
Lift theHypacorCompressorandplaceit inthedesiredlocation.
Damagetothemountingsmayoccurifyouattempttoslidethe
Compressorintoposition.
4.3 ModelWeights
Table4.1showstheweightsfortheACEHV11-HV15
Compressorsandthe Hypacrange. Fig.4.1-ACEHV11-15 VerticalCompressor
Allweightsinkilos
Fig.4.2-ACEDHV11-15Hypac Compressor
Table4.1-ModelWeights
Compressor HV11 HV15 HV15RS
ACE 350 363 372
ACER 487 500 509
ACED 412 425 434
AERD 552 565 574

ST16135-00A 9
5InstallationandCommissioning
5InstallationandCommissioning
5.1 PositioningYour Compressor -Basic
Requirements
Werecommendanapprovedinstallationfromanauthorized
Hydrovanedistributorwithaserviceagreement tomaintain your
Compressor.
Position theCompressor/Hypacinaroomofadequatesizeona
firmsurface,levelinbothplaneswithinfivedegreesof the
horizontal.
Ensuretheareahassufficient load-bearingcapacity, normallyitis
notnecessarytobolttheunit down.
Sufficient access(1metre)forallroutineserviceprocedures
shouldbeprovided around theunit.
SitetheCompressor/Hypacasfaraspossiblefromsourcesof
dirt,coarsesolids,abrasiveparticles, steam,liquidsandgaseous
impurities.
Thisisanindustrialcompressorandisintendedforinstallationin
anindoorenvironment.
AnyairconnectionmadetotheCompressoroutletmust be
flexibleasthebaseincorporatesresilient mountings.
5.2 Ventilation(Fig.5.1)
Position theCompressor/Hypacinawellventilatedlocation.Do
notrestricttheair-flowaroundtheCompressor; Donotallowthe
hotairdischargetore-circulateintotheCompressorintake.
Anycooling-airinlet(A) shouldbepositionedlowallowing
unrestrictedair-flowtotheCompressorintake.Thewarm-air
outlet(B) shouldbepositionedhigh, andwellawayfromtheinlet,
toensureapositivecoolingair-flowthroughtheCompressor.
Formaximumefficiency andreliability, theCompressorshouldbe
operated inamoderateambienttemperature.If temperatures
frequentlyfallbelow0°C, consultyourHydrovaneDistributor.A
differentgradeof oil mayberequired.
Compressorairintakeandexhaustgrillshavecaptivenutsfitted
asstandardtoattachducting.
Airducting,iffitted,must notcoverorrestrict thecoolingairflow
of theCompressor.Totalresistanceof thesystemmustnot
exceed5mm w.g. (0.2in. watergauge). Ifresistanceisexpected
tobegreaterthan5mmw.g.thenfanassistancewillberequired.
Fig.5.1-Compressor Ventilation
5.3 ElectricalConnections
WARNING!
CONNECTIONTO,ORINSTALLATIONOF,AN
ELECTRICALPOWERSUPPLYMUSTONLY BE
CARRIEDOUTBY AUTHORISEDAND
QUALIFIEDELECTRICIANS. THEYMUSTFULLY
UNDERSTAND AND ADOPTCORRECTAND
SAFEWORKINGPRACTICES.ALLASPECTSOF
THEINSTALLATIONMUSTMEETTHEWIRING
REGULATIONSPRESENTLY INPLACE.
Beforeconnectingtothemainselectricalsupply, ensurethat the
systemcansustaintheadditionalelectricalload.Toensure
reliablelowresistancejoints,makesurethatyourincomingsupply
cablesarefirmlysecuredtothestarterterminalsandthattheyare
of correctsize.
Notethatthestarterdoorpanelshouldalwaysbesecuredbythe
supplied keyforsafetyreasonsand toprevent unauthorized
access.
Refertostartercircuit diagrams(locatedinsidethestarterdoor
panel)beforestartingwork. Notecarefullytheinstructionsgiven
forearthing, fusesandcablesize.
FusestoBS88(TypegG)must beusedtoprotect the
Compressorstarter, refertothesizesspecifiedonthestarter
circuitdiagrams.
Circuit breakersarenotrecommendedsincetheymaynot fully
protectthestartercontactsinanoverloadcondition.

InstallationandCommissioning5
10 ST16135-00A
5.4 ElectricalInstallation(Fig.5.2)
WARNING!
BEFORESTARTINGWORK,ENSURE THATTHE
MAIN-LINEFUSESHAVEBEENREMOVEDFROM
THE DISTRIBUTIONBOARD.PRECAUTIONS
SHOULDBE TAKENTOPREVENTTHEMBEING
REFITTEDUNTILTHEINSTALLATIONIS
COMPLETE.
Startercablesmust beconnectedtothemainselectricalsupply
viaalockable, switchedandsuitablyratedfusedisolator. The
isolatorshouldbepositionedasnearaspossible tothe
Compressorwithclear,unrestrictedaccess.
Toaccessthestarterterminals,unlock thestarterdoorpanelwith
thekeyprovided.Passtheincomingcablesthroughtheentryhole
inthefloorandconnectthethreemainssupplycablestothe
contactorterminalsmarkedL1,L2andL3, andconnecttheearth
cabletotheearthpinE. Ensuretheconnectionsaresecure.
Fig.5.2-ElectricalConnectionstoStarter
Terminal
Cablesizesspecified onthecircuitdiagramaretheminimumsize
tosuit atypicalinstallation. If the Compressorislocatedalong
wayfromtheisolatorand/ortheambienttemperatureexceeds
35°C,thecablesizeshouldbeincreased.
RefertoIEEERegulationsforelectricalequipmentinstalledin
buildingstodeterminethesizerequired,payparticularattentionto
thecircuitdiagrams provided.
Checkthat thetransformerfuseispositionedtosuit thesupply
voltageoftheinstallation.
Ensureallelectricalconnectionsaretight,highvoltagesupplyto
contactorsandincomingterminalsarecritical.
Closethestarterdoorandsecurewiththekeyprovided.
Replacethemainlinefuses.
5.5 Check Direction ofMotorRotation
WARNING!
READ HEALTHANDSAFETYPRECAUTIONS
BEFORESTARTINGCOMPRESSOR.
EnsurethattheCompressorisfilledwithapprovedoilandthat all
plugsarefittedsecurely.
Thecoolingfanintherearof theunit maybeusedasavisualaid
todetermine thecorrect rotation oftheCompressor.
Toviewthecoolingfan,removethecabinet filterfromthelower
half of therearpanel, thecoolingfancanbeviewedthroughthe
meshgrill.
Withthe mainsisolatoron, press thegreenstartbuttonmounted
inthecontrolpanel. Compressorrotationiscorrectifthecooling
fanrotatesinaclockwisedirection.
ForsinglespeedCompressors, if rotationiscorrect, the
Compressorpressuredisplaywill riseimmediatelyafterstarting.If
rotationisnotcorrect,theCompressorpressuredisplaywillnot
rise.
RotationforRSCompressorswillalwaysbecorrectduetothe
inverterdrive, howeverthecoolingfan must becheckedfor
correct clockwiserotation.
CAUTION!
Ifdirectionofrotationisincorrect,stopthe
Compressorimmediately.Seriousdamagewill
occurifthemotor isallowedtoruninreverse!
WARNING!
IFDIRECTIONOFCOMPRESSORORCOOLING
FAN ROTATIONISINCORRECT,STOPTHE
COMPRESSORAND LOCK THEISOLATORIN
THEOFF POSITION.FITASAFETY NOTICE TO
THEISOLATORADVISINGTHATWORKISBEING
CARRIEDOUTONTHECOMPRESSOR.
Openthestarterdoorwiththekeyprovidedtogain accesstothe
starterterminals.
Changeoveranytwoof theincomingcablesconnectedtothe
starterterminalsL1,L2andL3.
Closethestarterenclosuredoorandlockwiththekeyprovidedto
preventunauthorisedaccess.
Removethesafetynoticeandswitchthemainselectricitysupply
on.
RestarttheCompressorandverifythatdirectionofrotationofboth
theCompressorandcoolingfan arecorrect.
Replacethecabinet filterintherearpanelwiththedirectionarrow
pointinginwardstowardsthe coolingfan.

ST16135-00A 11
5InstallationandCommissioning
5.6 RegulatedSpeedCompressorInstallation
TheCompressorshouldbeinstalledgenerallyasinstructedfora
standardfixedspeedCompressorof thesamepower(kW)rating.
Electricalsupplyfusesizesarethesameasforstandardfixed
speedCompressorsof thesamepower(kW)rating.
Alternatively,acircuit breaker(TypeD)of suitablesizeandwith
motorstartingcharacteristicsmaybeusedtoprotect the
installation.
Themaximumstartingcurrentunderallstartingconditionswillnot
exceed150% motorfullloadcurrentandwillgenerallybenomore
than100%fullloadcurrent.
Theinstallationmustbeearthedinaccordancewithlocal
regulations.Theuseof RCDsisnot recommended.
Waterdrain,filtersordryersfitteddownstreamof theCompressor
dischargemust becorrectlysitedtoavoidexcessiveflow
restrictionstoensurestableoperationofthespeedcontrol
system.
5.7 RS OperationwithotherHydrovane
Compressors
HydrovaneRSCompressorsmaybeoperatedefficientlyin
conjunctionwithotherHydrovaneCompressorsfittedwith
automaticstop-startcontrol.
AdjusttheRSminimumairlinepressuretomidwaybetweenthe
maximumandminimumairlinepressuresettingsof the other
Compressor.TheRSCompressorwillautomaticallyassumethe
leadCompressorrole afterseveralcycles.
IMPORTANT NOTES: If theRSCompressorisoperatedwith
otherHydrovanestandardsingle speed Compressorsfeedinga
commonpressuresystem,theminimumairlinepressureof the
RSCompressormustbelimitedtothelowestmaximumairline
pressureofthesinglespeedmachine(s). Noattempt mustbe
madetoincreasetheoperatingpressureof thesinglespeed
machine(s).
Thepressuretransducersensingpointislocated inavalve
housingadjacent tothe outletfromtheCompressor.If the
pipeworkfromtheCompressortothesystemisrestricted,or
pronetoexcessivepressurefluctuation, rapidspeedchanges
and/orfrequent stoppingandstarting ofthemotormayoccur.
Shouldthisconditionarise, consult aHydrovaneDistributorwho
willarrangetore-sitethepressuretransducerlocation.
11

ST16135-00A 13
6General Description
6General Description
6.1 Compressor/Hypac (Fig.6.1)
ThisUserManualcoversthe HydrovaneACEHV11-HV15vertical
rangeofCompressors. The HypacrangecontainsaCompressor
andeitheraReceiveroranairdryerorboth, dependingonwhich
variant isrequired.
TheCompressoraloneisusedwhereairdemandisconstant and
doesnot exceed theoutput capacityoftheCompressor.
Anairdrierisusedtoprovidedryair(pressuredewpoint3°C)for
specialisedapplications
ACompressorplusreceiverisusedwhereairdemandfluctuates,
thereceiverstores275litresof air.Adriercanbecombinedwith
theCompressorplusReceiverforapplicationsrequiringlarge
volumesofdryair.
Figure6.1showsgeneral viewsof therange,theCompressor
assemblyisdetailedinPara6.3/Fig6.2, theairdrierissupplied
withitsownmanual.
Fig.6.1-General Views
6.2 ControlSystems
CompressorscanbeoperatedeitherinautomaticStop/Start
modeorin continuousrunmode.
AllunitsbenefitfromREVS (ReducedEnergyVentingSystem)to
minimisepowerconsumptionduringoperation.
Onstart upashort delaypreventsfullpressuredeliverytoreduce
motorpowerconsumed.
Withmaximumlinepressureestablishedtheventingsystem
lowerscompressorpressuretoprovidesubstantial cost savings
duetotheoffload powerreduction.
Duringoffloadrunontimeatminimumpressurethecompressor
willeitherstopwithnoairdemandorreturntoonloadrunningif
moreairisrequired.
AutomaticStop/StartMode
Thisisthenormalmode ofoperationgivingmaximumefficiency
andeconomy.Recommendedforapplicationswithfluctuatingair
demands. Withtheautomodeselected, theCompressorwillload/
unloadandstop/start automaticallyinresponsetoairdemand.
Motorrestartsareset to15timesperhour, therun-ontimewillbe
increasedtomaintainthisfrequency.
ContinuousRunMode
Whenthecontinuousrunmodeisselected,theCompressorwill
continuetosupplyairfromfull tozeroflowrates. Inthismodethe
energysavingbenefitsof REVSwill not bemaintained.
RegulatedSpeedOperation
Regulatedspeed Compressorsareautomaticstop/start operation
only.
TheHydrovaneRegulatedSpeedVaneCompressorsaves
energyandoperatingcostwhen comparedwithafixedspeed
Compressorof similarsize. Thesavingisachievedby
automaticallyregulatingtheCompressorspeedtopreciselymatch
theCompressoroutputtothesystemdemand.
If the systempressurerisesabovetheminimumairlinepressure
theelectricmotorspeedwill decrease, conversely, ifthesystem
pressurefallsbelowtheminimumairlinepressurethemotor
speedwillincrease. Thespeedwill varybetweenminimumand
maximumlimitsdependentuponsystemdemand.

GeneralDescription6
14 ST16135-00A
Fig.6.2-CompressorAssembly
6.3 Compressor Assembly(Fig.6.2)
Theunitcomprisesofaverticalsinglestage,oilflooded,rotary,
slidingvaneCompressordrivenbyanelectricmotormountedtoa
base. It issuppliedwithcontrolpanel,starter, andcombinationoil
cooler/airaftercoolerwithallaccessoriespiped inandelectrically
connected.
Theintakecover(A) isassembled directlytotheCompressor(B)
whichisfittedtotheflangefaceofthedrivemotor(C).Therotorof
theCompressorismountedonthedriveshaft of themotor.The
motorisboltedtotheverticalcolumnsupportedbythebase.
Anelectricallydriven,impellortype, horizontallymountedfan(D)
islocatedbelowthe combinationoilcooler/airaftercoolermatrix
(E).Thisdrawscoolingairthroughtheairfilter(F)andforcesit
throughthecoolermatrix.
TheCompressorcontrolpanel(G)ismountedonthefrontframe,
controlsareaccessiblethroughanapertureinthefrontdoor
panel.ThecontrollerisanelectronicdevicewithanLCD screen.
Anemergency stopbutton(X) islocatedonthefrontcontrol
panel.
ForRSmodels,theinverterdrive(H)ismountedinthestarter
compartment,behindthestarterpaneldoor(J).
TheCompressorairintakeisprotectedbyanairintakefilter(K),
andtheoilsystemisfilteredbyanoil filter(L).Anoil levelsight
glass (M)ismountedadjacenttotheoil filter.
TheCompressorisfilledandtopped up withoilvia theoilfiller(N).
Thesightglassshouldbefulltooverflowfromthelevelplugorifice
(O).
OilisdrainedfromtheCompressorandcoolerbyremovinga
drainplug(P) andopening thedraintap(Q).
TheCompressorpressuregauge(R)isvisiblewhenthetoppanel
isremoved.
Theoil separator(S) locatedonthe topensuresairdelivered
throughtheminimumpressurevalvehasanoilcleanlinessofless
than3ppm(partspermillionbyweight). Theairisdelivered
throughtheairdeliverypipe(T)totheaftercooler.
Theoil supplytothecooleristhroughoilfeedpipe(V)withthe
cool oilreturnviaoilreturnpipe(W)Foraquickwarmup,a
thermalby-passvalve(Y) allowstheoilsupplytoby-passthe
cooleroninitialstartup.

ST16135-00A 15
7Operating Instructions
7Operating Instructions
7.1 OperatingInstructions
WARNING!
READ HEALTHAND SAFETY PRECAUTIONS
BEFOREYOUSTARTANY SERVICEWORK.
THECOMPRESSORSHOULDONLYBE
OPERATEDBYAUTHORISEDPERSONS FULLY
TRAINEDINTHE STARTING,STOPPINGAND
EMERGENCYSTOPPROCEDURES.
7.1.1 Checking ProcedureBeforeStarting
(a) Check sight glassisfull.
(b) Check filler, drain/oillevelplugsarefittedsecurely.
(c) Check foranysignsofoil leaks.
(d) Check air-outletvalveisopen.
(e) Check thattheemergencystopbuttonisreleased.
(f) Turnmainselectricitysupplyon.
7.1.2 OperatingMode
Whenelectricityisfirstswitchedontheelectroniccontroller
(Fig7.2)displays allsymbolsand illuminatesbothgreenand red
LEDindicatorsforthreeseconds(Fig.7.1)
Fig.7.1-ControllerDisplay
Thedisplaythenshowsthesoftwareversioncodeforafurther
threesecondsbeforeshowingthenormaloperatingdisplay
ForsinglespeedCompressorsthecontrollerallowstwooperating
modes,automaticstop/startorcontinuousrun.
7.1.3 CompressorOperation
Automaticstop/start isset asdefault. Forcontinuousrunning
select Mo–MAN,usingthetouchsensitivesymbolbuttonsonthe
controllerpanel.
Select Mousingplusup/minusdownbuttons, press theenter
button,AUT willflash,pressplusup/minusdownbuttonto
change, press enterbuttontoselect.
TheoperatingmodemaybealteredwhentheCompressoris
runningorstopped.
Fig.7.2-Controller

OperatingInstructions7
16 ST16135-00A
PressPlusUp/MinusDownbuttonstoscrollthroughavailable
usermenucodesP00(viewonly).
(a) Mo-SelectAutomaticorManualControl
(b) Td–RSU* temperature(ViewOnly)
*Temperatureat dischargefromcompressionunit
Asadefault valuetheTd–temperatureappearsinthe
bottomof the display.
(c) PD–DeliveryPressure(ViewOnly)
(d) H1–HoursRun(ViewOnly)
(e) H2–LoadedHours(ViewOnly)
(f) H3–HoursRemainingtoService(ViewOnly)
Toselect andlockothermenuitems,scroll tothemenu required,
wheninviewpresstheENTERbutton, aflashingkeysymbolis
displayed.
Tocancelthelockedselectionandflashingkeysymbolpress the
ESCAPE (C)orreset button.
Duringoperation,thecontrollerrecordsthetotal runninghours,
thehoursrunon loadandcountsdowntothe nextservice
interval.
Theserviceintervalisset for2000hourswhenusingFluidForce
Red2000oil. Thisintervalwillbereduced iftheunit operates
abovetherecommendedtemperature.
7.1.4 Starting -AutomaticMode
PressthegreenSTARTbutton.TheCompressorwillstartif
systempressureisbelowthe minimumairlinepressureset point.
Oninitialstartwithnopressurein thesystem, thepressure
displaywillquicklyrisetothefulldeliverypressure.Duringthis
period, thegreenLEDwill becontinuouslyilluminated.
TheCompressorwillcontinuetorunandpressurewill varywithin
theairlinepressureset pointstomatchthesystemdemand.
If the systemdemandreducesand pressurerisestothemaximum
pressureset point, theREVS(ReducedEnergyVentingSystem)
sequencewillbegin.
If thereisanairdemandduringtheREVSrunontimesequence
theCompressorreturnstofullloadoperation.
If thereisnoairdemandduringtheREVSrunontimesequence
theCompressorwill stop.
Automaticrestartwilloccurwhensystempressurefallstothe
minimumairlinepressureset point.
7.1.5 Starting -ContinuousMode
PressthegreenSTARTbutton.TheCompressorwillstart, and
runcontinuouslywithintheairlinepressuresetpointstomatch
systemdemand.
Oninitialstartwithnopressurein thesystem, thepressure
displaywillquicklyrisetothemaximumairline pressureset point.
Duringthisperiod,thegreenLEDwillbecontinuouslyilluminated.
7.1.6 Starting -Regulated Speed
Forvariablespeedmodels, thestartingsequenceisthesameas
that shownforsinglespeedautomaticmodeexceptthat,instead
of theCompressorcontinuingtorunandpressurevaryingwithin
theairlinepressuresetpoints, theCompressorwillcontinueto
runandthespeedwill varyautomaticallytomatchsystem
demand.
Withnosystemdemandwhenrunningat minimumspeedthe
CompressorwillstopaftertheREVS ventingsequence.
Automaticrestart willoccurwhensystempressurefallstothe
minimumairlinesetpoint.
7.1.7 Stopping–All Models
TostoptheCompressor, press theredSTOPbutton, system
pressurewill remainhighinitially, but will fallgraduallywiththe
rateof decaydependingonsystemusage.
7.1.8 EmergencyStop
If anemergencyoccurs, press theEMERGENCYSTOPbutton.
Thebuttonwilllock inthedepressedpositionandstopthe
Compressorimmediately.
TheredLEDon thecontrollerwillflashquicklytogetherwith
displaysymbols.
Clearanyfaultsthatmayhaveoccurred.Donot reset untilitis
safetodoso.
Resettheemergencystopbuttonbytwistingclockwisebefore
restart.
PresstheRESETbuttononthecontrollertocanceltheredLED
anddisplaysymbols.
Operationoftheemergencystop buttonisrecordedinthe
controllererrorlog.
7.1.9 CompressorVentDown
VentingiscontrolledautomaticallybytheREVS systemforeither
operatingmodeforallmodels.