Hydrovane HV22 Instruction Manual

UserHandbook
HV11-HV22Models(ACE)
StationaryAirCompressors
ST16135-00 Iss C08/2007

ST16135-00C 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 ProductTerminology. .... ... ... ... .... .. .... ... .... .. .... ... .... .. ..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
7.3 LEDIndicators(Fig7.2)... ... ... ... .... .. .... ... .... .. .... ... .... .. .17
(continued)

Contents
ii ST16135-00C
8Adjustments. .... ... ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..19
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:FluidForceRed,Clearand HPOOil.. ... .... .. .... ... ..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 ... ... .... ... ... ... .... .. .... ... .... .. .... ... ..28
10.7 Configuration MenuP07 ... .... ... ... ... .... .. .... ... .... .. .... ... ..28
10.8 SpeedRegulation Menu P08.... ... ... ... .... .. .... ... .... .. .... ... ..28
10.9 Calibration Menu P09.. ... .... ... ... ... .... .. .... ... .... .. .... ... ..28
10.10 Access LevelConfiguration Menu P10.. ... .... .. .... ... .... .. .... ... ..28
10.11 RSMotorMap Menu P12.. .... ... ... ... .... .. .... ... .... .. .... ... ..28
10.12 RSInverterDriveMapMenu P13 ... ... ... .... .. .... ... .... .. .... ... ..28
Contents(continued)

ST16135-00C 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-HV22vertical range
compressorsandhypacmodels.
V11ACE08-4035S300 50Hzmodel
V11ACE10-4035S300 50Hzmodel
V11ACE08-2336D305 60Hzmodel
V11ACE10-2336D305 60Hzmodel
V11ACE08-5736D305 60Hzmodel
V11ACE10-5736D305 60Hzmodel
V11ACE08-4035V300 50/60Hzmodel
V15ACE08-4035S300 50Hzmodel
V15ACE10-4035S300 50Hzmodel
V15ACE08-2336D305 60Hzmodel
V15ACE10-2336D305 60Hzmodel
V15ACE08-5736D305 60Hzmodel
V15ACE10-5736D305 60Hzmodel
V15ACE08-4035V300 50/60Hzmodel
V15ACE08-2035V300 50/60Hzmodel
V18ACE08-4035S000 50Hzmodel
V18ACE10-4035S000 50Hzmodel
V18ACE08-2336D005 60Hzmodel
V18ACE10-2336D005 60Hzmodel
V18ACE08-5736D005 60Hzmodel
V18ACE10-5736D005 60Hzmodel
V22ACE08-4035S000 50Hzmodel
V22ACE10-4035S000 50Hzmodel
V22ACE08-2336D005 60Hzmodel
V22ACE10-2336D005 60Hzmodel
V22ACE08-5736D005 60Hzmodel
V22ACE10-5736D005 60Hzmodel
V22ACE08-4035V000 50/60Hzmodel
V22ACE08-2035V000 50/60Hzmodel
1.6 ProductTerminology
Theproduct codesegmentssignifies:
VVane
11,15,18, 22 kWmotor
ACE AirCentreElectronic
08,10 Deliverypressureinbars
20 200V
23 230V
40 400V
57 575V
3 3 phase
5, 6 50Hz, 60Hz
D, S,V Direct OnLine, Star/Delta,Variable
Speed
000,100,200,300 EuropeanSpecification(50Hz)
005,105,205,305 USSpecification(60Hz)
Thispublicationreferstocompressorswithserialnumbersfrom:
V11-000301-0706 -300firstbuild
V15-000352-0705 -300firstbuild
V18-000013-0705 -35040 sheetmetalkit
V22-000041-0705 -35040 sheetmetalkit

ST16135-00C 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.
Thecompressorwarrantywillbe invalidatedif unapprovedspare
partsoroilsareused.Usingsuchitemsmaycausetheefficiency
andservicelifeofthecompressortobereduced,andcouldcreate
ahazardousconditionoverwhichHydrovanehasnocontrol.
Failuretomaintainthecompressorcorrectly,ormodifyingit
withoutpriorapprovalfromHydrovane, mayalsocreatea
hazardouscondition.Thiswillalsoinvalidatethewarranty.
Readandfullyunderstandthe contentscontainedintheUser
Handbook.
Ensurethat theUserHandbookisnot permanentlyremovedfrom
thecompressor.
Checkthattherearenosignsof damageand/oroilleaks fromthe
compressor,coolerandassociatedpipework.
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’svent downcycleiscomplete.
Releaseanypressurecontainedintheaftercoolerorassociated
pipework.
Checkthatthecompressorpressuregaugereadszero. Donot
proceeduntilit does.
Carefullyunscrewthecompressorfillerplug. Ifanyairoroil
escapesbeforetheplugisfullyremovedstop! Donot removethe
pluguntilall pressureislost.
Safetydevicesfittedtothecompressororpipeworksystem
shouldbecheckedat regularintervalsandreplacedif faulty. They
shouldnot betamperedwithormodified.Nonreturnvalves
shouldnot beusedasisolationdevices.
Toensurethecompressoroperatessafelyyoumustcarryout the
specifiedmaintenanceprocedures.
Onlyapprovedoilsshouldbeusedforflushingpurposes.
Extremecautionshouldbetakenifthecompressorhasbeen
subjectedtosevereoperatingtemperaturesorfire.Certain
componentsmaycontainfluoroelastomermaterialsandunder
theseconditionscanleaveextremelycorrosiveresidues.Severe
burnsandpermanent skinandtissuedamagecanbearesult of
skincontact.
TheHealthandSafetyinformationcontainedinthisHandbookis
onlyintendedtogivegeneralguidelines.
2.4 WhenOperatingtheCompressor
Wheninautomaticmodethe compressormayrestartwithout
warning.
Additionalwarningswillberequirediftheunit isconfiguredfor
remotestop/startortorestart afterpowerfailure.
Donotremoveanyplugsorreleasepipeworkwhenthe
compressorisrunning.
Donotattempttoopenthestarterenclosurewhilethecompressor
isoperating.
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. Seriouspersonalinjury
and/ordamage mayresult.

Safety 2
4ST16135-00C
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
WARNING! isusedinthetext toidentifyspecifichazardswhich
cancauseinjuryordeath. Thistypeofhazardisidentifiedbelow.
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

ST16135-00C 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: Thecompressorwillstopautomaticallyif thetemperature
risesabove110°C.
Ifthebulkoiltemperaturefrequentlyreads100°C,thenFluid
ForceHPOoilshouldbeused.
3.3 NoiseLevel
Although thesoundpressurelevelfortheseunitsisrelativelylow,
theyshouldbepositionedwherenoisewillnot beaproblem.

Product Information3
6ST16135-00C
3.4 TechnicalData
ModelNumber HV11 HV15 HV18 HV22 HV11RS HV15RS HV22RS
PERFORMANCE
F.A.D.litres/sec(cfm)@8bar 29(61) 38(81) 49(104) 60(127)
F.A.D.litres/sec(cfm)@10bar 25(52) 33(71) 42(90) 52(110)
F.A.D.litres/sec(cfm)@6bar 31(66) 41(87) 65(137)
NoiseLevel-dBA 69 70 70 71 69 70 71
Power-kW (hp) 11(15) 15(20) 18(25) 22(30) 11(15) 15(20) 22(30)
StarterType AutomaticDOL&SD InverterSoft Start
DriveType Direct
OperatingControls ContinuousRun, AutomaticStop/Start,
ReducedEnergyVentSystem
Variable
RotationSpeed-rev/min50Hz(60Hz) 1450(1760) 870-1650 870-1650
AmbientTemperatureRange°C 0to45 0 to40
MaximumRelativeHumidity% 85non-condensing
AirDischargeTemp-°C(aboveambient) <8 <10 <8 <10
FACTORYSETTINGS
MinimumPressureValve-bar 5.5to6.0
MinimumAirLinePressure-bar (PL) 7.5or9.5 8.0
MaximumAirLinePressure-bar (PU) 8.5or10.5 8.5
REVSDelayPeriod(secs) (Rt) 60(8bar)90(10bar) 60
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 9.0
VacuumReliefValve Oneturnanti-clockwise
INSTALLATION
AirOutlet Size-Rp 3/4 1 1 3/4 1
MinimumRoomVolume-m325 35 35 25 35
AirInlet/Outlet Area-m20.5
VentilationRate-m3/h 3400
CoolingAirFlowm3/h(cfm) 3100(1825) 4500(2649) 3100(1825) 4500
(2649)
RecommendedAirReceiverCapacity-L 272
COMPRESSOROIL
Approvedcompressoroil FluidForceRed2000&HPO
OilCapacity-litres 7.0 7.5 7.0 7.5
ELECTRICAL
Starterreference400V50HzSD 34994 34998 -
Circuitdiagram400V50Hz 76849 76856 -
Starterreference230-575V60HzDOL 34995 34999 -
Circuitdiagram230-575V60Hz 76850 76857 -
Starterreference400/460V50/60HzRS - 34966 35000
Circuitdiagram400/460V50/60HzRS - 76851 76858
Starterreference200V50/60HzRS - - 34997 35001
Circuitdiagram200V50/60HzRS - - 76852 76859

ST16135-00C 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.
Damagetomountingsmayoccurif youattempt toslidethe
compressorintoposition.
4.3 ModelWeights
Table4.1showstheweightsfortheACEHV11-HV22
compressorsand thehypacrange. Fig.4.1-ACEHV11-22 VerticalCompressor
Allweightsinkilograms
Fig.4.2-ACEDHV11-22Hypac Compressor
Table4.1-ModelWeights
Model ACE ACER ACED AERD
HV11 384 521 446 586
HV15 397 534 459 599
HV18 481 618 543 683
HV22 494 631 556 696
HV11RS 393 528 453 593
HV15RS 406 541 466 606
HV22RS 520 657 582 722

ST16135-00C 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/hypacasfaraspossiblefromsourcesofdirt,
coarsesolids,abrasiveparticles,steam,liquidsandgaseous
impurities.
Thisisanindustrialcompressorandisintendedforinstallationin
anindoorenvironment.
Anyairconnectionmadetothecompressoroutletmustbeflexible
asthebaseincorporatesresilient mountings.
5.2 Ventilation(Fig.5.1)
Position thecompressor/hypacinawellventilatedlocation.Do
notrestricttheair-flowaroundthecompressor; Donot allowthe
hotairdischargetore-circulateintothecompressorintake.
Anycooling-airinlet(A) shouldbepositionedlowallowing
unrestrictedair-flowtothecompressorintake.Thewarm-airoutlet
(B) shouldbepositionedhigh, andwellawayfromtheinlet, to
ensureapositivecoolingair-flowthrough thecompressor.
Formaximumefficiency andreliability,thecompressorshouldbe
operated inamoderateambienttemperature.If temperatures
frequentlyfallbelow0°C, consultyourHydrovaneDistributor.A
differentgradeof oil mayberequired.
Compressorairintakeandexhaustgrillshavecaptivenutsfitted
asstandardtoattachducting.
Airducting,iffitted,must notcoverorrestrict thecoolingairflow
of thecompressor. Totalresistanceofthesystemmust not
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 ST16135-00C
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.
Ensurethatthecompressorisfilledwithapprovedoilandthatall
plugsarefittedsecurely.
Thecoolingfanintherearof theunit maybeusedasavisualaid
todetermine thecorrect rotation ofthecompressor.
Toviewthecoolingfan,removethecabinet filterfromthelower
half of therearpanel, thecoolingfancanbeviewedthroughthe
meshgrill.
Withthe mainsisolatoron, press thegreenstartbuttonmounted
inthecontrolpanel. Compressorrotationiscorrectifthecooling
fanrotatesinaclockwisedirection.
Forsinglespeedcompressors, ifrotationiscorrect,the
compressorpressuredisplaywillriseimmediatelyafterstarting.If
rotationisnotcorrect,thecompressorpressuredisplaywillnot
rise.
RotationforRScompressorswillalways becorrect duetothe
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
THEISOLATORADVISINGTHATWORK ISBEING
CARRIEDOUTONTHECOMPRESSOR.
Openthestarterdoorwiththekeyprovidedtogain accesstothe
starterterminals.
Changeoveranytwoof theincomingcablesconnectedtothe
starterterminalsL1,L2andL3.
Closethestarterenclosuredoorandlockwiththekeyprovidedto
preventunauthorisedaccess.
Removethesafetynoticeandswitchthemainselectricitysupply
on.
Restartthecompressorandverifythatdirectionof rotationof both
thecompressorandcoolingfanarecorrect.
Replacethecabinet filterintherearpanelwiththedirectionarrow
pointinginwardstowardsthe coolingfan.

ST16135-00C 11
5InstallationandCommissioning
5.6 RegulatedSpeedCompressorInstallation
Thecompressorshouldbeinstalledgenerallyasinstructedfora
standardfixedspeedcompressorofthesamepower(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,filtersordryersfitted downstreamofthecompressor
dischargemust becorrectlysitedtoavoidexcessiveflow
restrictionstoensurestableoperationofthespeedcontrol
system.
5.7 RS OperationwithotherHydrovane
Compressors
HydrovaneRScompressorsmaybeoperatedefficientlyin
conjunctionwithotherHydrovanecompressorsfittedwith
automaticstop-startcontrol.
AdjusttheRSminimumairlinepressuretomidwaybetweenthe
maximumandminimumairlinepressuresettingsof the other
compressor.TheRScompressorwill automaticallyassumethe
leadcompressorroleafterseveralcycles.
IMPORTANT NOTES: If theRScompressorisoperatedwith
otherHydrovanestandardsingle speed compressorsfeedinga
commonpressuresystem,theminimumairlinepressureof the
RScompressormust belimitedtothelowest maximumairline
pressureofthesinglespeedmachine(s). Noattempt mustbe
madetoincreasetheoperatingpressureof thesinglespeed
machine(s).
Thepressuretransducersensingpointislocated inavalve
housingadjacent tothe outletfromthecompressor.If the
pipeworkfromthecompressortothesystemisrestricted,orprone
toexcessivepressurefluctuation,rapidspeedchangesand/or
frequentstoppingandstartingof themotormayoccur.
Shouldthisconditionarise, consult aHydrovaneDistributorwho
willarrangetore-sitethepressuretransducerlocation.

ST16135-00C 13
6General Description
6General Description
6.1 Compressor/Hypac (Fig.6.1)
ThisUserManualcoversthe HydrovaneACEHV11-HV22vertical
rangeofcompressors.Thehypacrangecontainsacompressor
andeitherareceiveroranairdryerorboth,dependingonthe
installationrequired.
Thecompressoraloneisusedwhereairdemandisconstantand
doesnot exceed theoutput capacityofthecompressor.
Anairdrierisusedtoprovidedryair(pressuredewpoint3°C)for
specialisedapplications.
Whereairdemandfluctuatesacompressorplusreceiverisused
tostorelargequantitiesof air.Adriercanbecombinedwiththe
compressorandreceiverforapplicationsrequiringlarge volumes
of dryair.
Figure6.1showsgeneral viewsof typicalunits,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, thecompressorwill load/
unloadandstop/start automaticallyinresponsetoairdemand.
Motorrestartsaresetto15timesperhour,singlespeedunits
shouldbelimitedto8timesperhour.
Run-ontimetostopcanbeincreasedtoreduceorlimitmotor
restart frequencytothelowerlevelrequired.
ContinuousRunMode
Whenthecontinuousrunmodeisselected,thecompressorwill
continuetosupplyairfromfull tozeroflowrates. Inthismodethe
energysavingbenefitsof REVSwill not bemaintained.
RegulatedSpeedOperation
Regulatedspeedcompressorsareautomaticstop/startoperation
only.
TheHydrovaneRegulatedSpeedVane compressorsavesenergy
andoperatingcostwhencomparedwithafixedspeed
compressorofsimilarsize.Thesavingisachievedby
automaticallyregulatingthecompressorspeedtopreciselymatch
thecompressoroutput tothe systemdemand.
If the systempressurerisesabovetheminimumairlinepressure
theelectricmotorspeedwill decrease, conversely, ifthesystem
pressurefallsbelowtheminimumairlinepressurethemotor
speedwillincrease. Thespeedwill varybetweenminimumand
maximumlimitsdependentuponsystemdemand.

GeneralDescription6
14 ST16135-00C
Fig.6.2-CompressorAssembly
6.3 Compressor Assembly(Fig.6.2)
Theunitcomprisesofaverticalsinglestage,oilflooded,rotary,
slidingvane compressordrivenbyanelectricmotormountedtoa
base. It issuppliedwithcontrolpanel,starter, andcombinationoil
cooler/airaftercoolerwithallaccessoriespiped inandelectrically
connected.
Theintakecover(A) isassembled directlytothecompressor(B)
whichisfittedtothe flange faceof thedrivemotor(C). Aflexible
couplingdrivesthecompressorrotorfromthemotordriveshaft
enclosedinside thebellhousing(U).Themotorisboltedtothe
vertical columnsupportedbythe base.
Anelectricallydriven,impellortype, horizontallymountedfan(D)
islocatedbelowthe combinationoilcooler/airaftercoolermatrix
(E).Thisdrawscoolingairthroughtheairfilter(F)andforcesit
throughthecoolermatrix.
Thecompressorelectroniccontroller(G)withanLCD screenis
mountedinthestarter(J).Anemergencystopbutton (X) is
locatedonthefront controllerpanel.
ForRSmodels,theinverterdrive(H)ismountedinsidethestarter
compartment,behindthestarterpaneldoor(J).
Thecompressorairintakeisprotected byanairintakefilter(K),
andtheoilsystemisfilteredbyanoil filter(L).Anoil levelsight
glass (M)ismountedadjacenttotheoil filter.
Thecompressorisfilledandtoppedupwithoilviatheoil filler(N).
Thesightglassshouldbefulltooverflowfromthelevelplugorifice
(O).
Oilisdrainedfromthecompressorandcoolerbyremovingthe
drainplug(P) andopening thedraintap(Q).
Thecompressorpressuregauge(R)isvisiblewhenthetoppanel
isremoved.
Theoil separator(S) locatedonthe topensuresairdelivered
throughtheminimumpressurevalvehasanoilcleanlinessofless
than3ppm(partspermillionbyweight). Theairisdelivered
throughtheairdeliverypipe(T)totheaftercooler(E) before
dischargefromtheunit.
Theoil supplytothecooleristhroughoilfeedpipe(V)withthe
cool oilreturnthrough oilreturnpipe(W)Foraquick warmup, a
thermalby-passvalve(Y) allowstheoilsupplytoby-passthe
cooleroninitialstartup.

ST16135-00C 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 ST16135-00C
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.Thecompressorwillstart if
systempressureisbelowthe minimumairlinepressureset point.
Oninitialstartwithnopressurein thesystem, thepressure
displaywillquicklyrisetothefulldeliverypressure.Duringthis
period, thegreenLEDwill becontinuouslyilluminated.
Thecompressorwillcontinuetorunandpressurewillvarywithin
theairlinepressureset pointstomatchthesystemdemand.
If the systemdemandreducesand pressurerisestothemaximum
pressureset point, theREVS(ReducedEnergyVentingSystem)
sequencewillbegin.
If thereisanairdemandduringtheREVSrunontimesequence
thecompressorreturnstofull loadoperation.
If thereisnoairdemandduringtheREVSrunontimesequence
thecompressorwillstop.
Automaticrestartwilloccurwhensystempressurefallstothe
minimumairlinepressureset point.
7.1.5 Starting -ContinuousMode
PressthegreenSTARTbutton.Thecompressorwillstart, andrun
continuouslywithintheairlinepressureset pointstomatch
systemdemand.
Oninitialstartwithnopressurein thesystem, thepressure
displaywillquicklyrisetothemaximumairline pressureset point.
Duringthisperiod,thegreenLEDwillbecontinuouslyilluminated.
7.1.6 Starting -Regulated Speed
Forvariablespeedmodels, thestartingsequenceisthesameas
that shownforsinglespeedautomaticmodeexceptthat,instead
of thecompressorcontinuingtorun andpressurevaryingwithin
theairlinepressuresetpoints,thecompressorwillcontinuetorun
andthespeedwillvaryautomaticallytomatchsystemdemand.
Withnosystemdemandwhenrunningat minimumspeedthe
compressorwillstopaftertheREVSventingsequence.
Automaticrestart willoccurwhensystempressurefallstothe
minimumairlinesetpoint.
7.1.7 Stopping–All Models
Tostopthecompressor,presstheredSTOPbutton,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.