Hydrovane Pro User manual

User Manual (Original Instructions)
HYDROVANE Pro
Electronic Controller
Stationary Air Compressors
GB
CC1092267A 04/2013

Attention: Important for RS compressors
Risk of electric shock from charged capacitors!
Always disconnect the system from the power supply
and then wait a further 10 minutes before touching
electrical components. The power capacitors take this
time to discharge.
Check the DC bus voltage at the system terminal strip
of the inverter by measuring between the +DC and -DC
terminals and the chassis. The exact position can be
found in the operating manual of the inverter, the
voltage must read zero for all three measurements.
Controller Ref: CC1054325 Single Speed (SS)
Software version HPro-V1.02
Controller Ref: CC1068566 Regulated Speed (RS)
Software version HPro-RS-V1.04
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.

Contents
Contents
1 Operator Controls.................................................................................................................................................5
1.1 Keys...............................................................................................................................................................5
1.2 Status indicator (display / light signals).............................................................................................................5
1.2.1 Speed indicator in the display...............................................................................................................5
1.2.2 Status messages in display...................................................................................................................5
1.3 Displaying / changing values ...........................................................................................................................6
1.3.1 Selecting values...................................................................................................................................6
1.3.2 Changing values...................................................................................................................................6
1.4 Selecting language..........................................................................................................................................6
1.5 Setting pressure..............................................................................................................................................6
1.6 Setting time/date (timer) ..................................................................................................................................7
1.6 Menu structure (values are examples) .............................................................................................................8
2 Operating & Maintenance......................................................................................................................................9
2.1 Starting the unit...............................................................................................................................................9
2.2 Emergency stop button....................................................................................................................................9
2.3 Switching off the unit.......................................................................................................................................9
2.4 On-load/off-load..............................................................................................................................................9
2.5 Warning/fault messages..................................................................................................................................9
2.5.1 Warning messages...............................................................................................................................9
2.5.2 Fault messages....................................................................................................................................9
2.6 Maintenance.................................................................................................................................................10
2.7 Programming maintenance intervals..............................................................................................................10
2.8 Total/load hours counter................................................................................................................................10
3 Additional Functions...........................................................................................................................................11
3.1 [CONTROL MENU] sub-menu.......................................................................................................................11
3.1.1 Operating modes................................................................................................................................11
3.1.2 Second pressure range (p
2
)................................................................................................................11
3.1.3 Dryer pre-run......................................................................................................................................11
3.1.4 RS 485 communication.......................................................................................................................11
3.1.5 Automatic re-start...............................................................................................................................11
3.1.6 Unlimited autom. re-start after power loss............................................................................................12
3.2 [FAULT MEMORY]sub-menu.........................................................................................................................12
3.3 [TIMER CONTROL]sub-menu.......................................................................................................................12
3.3.1 Setting for timer units..........................................................................................................................12
3.3.2 Pressure changeover setting...............................................................................................................13
3.4 [LIMIT VALUES] sub-menu............................................................................................................................14
3.5 [OPTIONAL IN-/OUTPUTS] sub-menu...........................................................................................................14
3.5.1 Inputs.................................................................................................................................................14
3.5.2 Outputs..............................................................................................................................................15
3.6 Locking / unlocking code...............................................................................................................................16
3.7 Replacing the HYDROVANE Pro...................................................................................................................16
3.8 Remote control..............................................................................................................................................17
3.8.1 Remote control for pressure changeover.............................................................................................17
3.8.2 Enabling on-load operation.................................................................................................................17
3.8.3 On-load/off-load remote control...........................................................................................................18
3.8.4 Enabling on-load operation.................................................................................................................19
3.8.5 Remote start / stop.............................................................................................................................19
4 Error Rectification...............................................................................................................................................21
4.1 Safety Regulations........................................................................................................................................21
4.2 Warnings......................................................................................................................................................21
4.3 Faults...........................................................................................................................................................21
4.4 Checklist.......................................................................................................................................................21
4.5 Table of faults / warnings...............................................................................................................................21

1.0 Operator Controls
CC1092267A 5
1 Operator con trols / arr angeme nt
1.1 Keys
When power is applied the controller display illuminates
to show compressor output values and status
messages.
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.
1.2 Status indicator (display / light
signals)
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 be used in the 1st row:
p
2
Second pressure range
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 (red,
green).
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.
1.2.1 Speed indicator in the display
The speed is displayed in the 2nd row of the display. If the
menu navigation is displayed, the speed display is faded
out.
Examples of speed displayed:
[ _________❚___ ] 3290rpm
Speed in controlled range.
[ ❚____________ ] 1300rpm
Speed in lower controlled range,
minimum speed not yet reached.
[ |___________ ] 1280rpm
Minimum speed reached.
[ ___________| ] 3650rpm
Maximum speed reached.
1.2.2 Status messages in display
The status messages are shown in the 3rd row of the
display. With longer texts, the indication may 'alternate'.
Status messages:
INITIALIZATION VSD...
The compressor's supply voltage has been switched on.
The control system is being initialised and is setting up
communication to the inverter (VSD).
READY TO START
The unit is ready to start and can be switched on (see
Section 2.1).
WARNING START WITH ...
alternating with
... PRESSURE REQUIREMENT
The unit has been switched on and is ready. The unit starts
automatically following the pressure requirement from your
system.

1.0 Operator Controls
6 CC1092267A
WARNING START AFTER ...
alternating with
... DE-PRESSURISE
The unit has been switched on and is ready. However
the internal unit pressure is above the start-up
protection level. Once the unit has been de-
pressurised, the compressor starts automatically.
WARNING START WITH ...
alternating with
... TIMER CONTROL
The unit has been switched on and is ready. The
compressor is now waiting for start approval from the
timer (see Section 3.3)
WARNING START BY ...
alternating with
... REMOTE OPERATION
The unit has been switched on and is ready. Remote
unit operations have been activated in the control menu.
The unit starts via a remote signal (see Section 3.8).
WARNING START IN xxs
alternating with
... AFTER POWER LOSS
A power loss has caused the unit to shut down. The
'automatic restart' function has been selected in the
control menu. The unit now starts automatically after a
previously set time (see Section 3.1.5)
WARNING START IN
alternating with
... AFTER DRYER PRE-RUN
The unit has been switched on and is ready. The unit
starts automatically after the dryer pre-run (see Section
3.1.3).
MOTOR START PHASE
The unit has been switched on and the motor is starting
ON-LOAD
The compressor is on-load (see Section 2.4).
OFF-LOAD
The Compressor is running off-load (see Section 2.4).
OFF-LOAD XXs
Compressor is running off-load and will shut down in
XX seconds (see Section 2.4).
SOFT STOP TIME in xxs
The system has been switched off. The unit stops after
the soft-stop time of xx seconds.
FAULT: <fault text>
The unit has been shut down due to a fault. You will
find explanations of the fault texts in Section 4.
WARNING <warning text>
There is a warning in place. Ignoring a warning may result
in a fault and shut down the compressor. You will find
explanations of the warning texts in Section 4.5.
MAINTENANCE DUE
A maintenance interval is about to lapse or has already
done so, you will find more details in Section 2.6.
1.3 Displaying / changing values
1.3.1 Selecting 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 + keys
at the same time.
Use the or keys to switch between the following sub-
menus:
[MAINTENANCE SCHED.]
[CONTROL MENU]
[FAULT MEMORY]
[TIMER CONTROL]
[LIMIT VALUES]
[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, you must press the + keys at
the same time.
To exit the main menu, you must press the + keys at
the same time again.
1.3.2 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, then press the key again to
confirm the value.
1.4 Selecting language
Change the language by pressing the + or +
keys. Press these keys at the same time until the right
language appears.
1.5 Setting pressure
Compressor control/speed is achieved using a pressure
transducer signal to the controller and/or inverter PID to
match output to system demand.
In the [CONTROL MENU] menu you have to set the
maximum pressure CUT-OUT POINT and the minimum
pressure CUT-IN POINT or TARGET PRESSURE.
In the range between the CUT-IN POINT or TARGET
PRESSURE and CUT-OUT POINT the output or speed of
the compressor is controlled or regulated to match the
compressed air requirement.
Example:
CUT-OUT POINT 8.5 bar (123 psi)
CUT-IN POINT (SS) 7.5 bar (109 psi)
TARGET PRESSURE (RS) 8.0 bar (116 psi)

1.0 Operator Controls
CC1092267A 7
The output of the compressor is controlled between
these points or speed is regulated so that the set
pressure of 8.0 bar (116 psi) is maintained.
When pressure reaches the CUT-OUT POINT of 8.5
bar (123 psi), the compressor switches to off-load.
If pressure falls to the CUT-IN POINT of 7.5 bar (109
psi), the compressor is switched back into on-load.
Maximum pressure is set in the [CONTROL MENU]-
sub-menu. The + keys have to be pressed at the
same time. You are then taken to the main menu. Use
the key to switch to the [CONTROL MENU] sub-
menu, then press the key.
The CUT-OUT POINT menu item now appears on the
display. Pressing the key causes the value to flash.
Increase or decrease this value using the or
keys, confirm the value set by pressing the key.
Note
The controller checks that the value set can be used.
The maximum pressure CUT-OUT POINT must be at
least 0.2 bar more than the CUT-IN POINT or TARGET
PRESSURE.
You may therefore have to set the minimum pressure
first. To keep the number of stop/starts to a minimum,
the difference between the CUT-OUT POINT and CUT-
IN POINT or TARGET PRESSURE should not be too
small.
Minimum pressure is set in the [CONTROL MENU]
sub-menu press the key to go to the CUT-IN POINT
or TARGET PRESSURE menu item.
Pressing the key causes the value to flash.
You can increase or decrease this value using the
or key, confirm the value set by pressing the key.
CUT-OUT POINT
CUT-IN POINT
TARGET PRESSURE
ON-LOAD
Fig. 1 Pressure Settings
1.6 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.

1.0 Operator Controls
8 CC1092267A
1.7 Menu structure (values are examples)
+
SS = SINGLE SPEED / RS = REGULATED SPEED
INPUT 1: FAN FAULT
INPUT 2-5 FREE:
OUTPUT 1 OFF
OUTPUT 2 FAN TEMP CONTROL
INTERNAL TRANSDUCER OFF
DESIGN PRESS 8.0bar
START PROTECT 2.0bar
HEAVY STARTUP (SS) 3.5bar
EXT. LIMIT (RS) 2000RPM
FINAL TEMP WARN 107ºC
FINAL TEMP MAX 110ºC
MIN START TEMP 0ºC
SOFT STOP 2s
MAX START PER HOUR 10
FAN ON TEMP 85°C
FAN OFF TEMP 75°C
FAN RUN ON 180s
STAR DELTA TIME (SS) 1s
SOFTWARE: HPro-Vx.xx
PROFILES 1-7 & p
2
1-7 NONE SET
TH 08.02.07 13:55:41
1 _______________________ 00:00 00:00:
7 _______________________ 00:00 00:00:
p
2
1 _____________________ 00:00 00:00:
p
2
7 ______________________00:00 00:00
ERRORS 1-20 READ ONLY
02!EM-STOP 12345h
01!EM-STOP 12300h
CUT-OUT POINT 8.5bar
CUT-IN POINT (SS) 7.5bar
TARGET PRESSURE (RS) 8.0bar
p
2
CUT-OUT POINT 8.5bar
p
2
CUT-IN POINT (SS) 7.5bar
p
2
TARGET PRESSURE (RS) 8.0bar
RUN ON TIME 60s
AUTOMATIC OPERATION
ENABLE REMOTE-START OFF
TIMER CONTROL OFF
p
2
TIMER CONTROL OFF
AUTO RESTART OFF
POWER LOSS TIME 2s
START-UP DELAY 5s
DRYER PRE-RUN 0min
RS485-PROTOCOL ModBus
RS485-BAUDRATE 19200
RS485-ADDRESS 1
[MAINTENANCE SCHED]
[CONTROL MENU]
[OPTIONAL IN-/OUTPUTS]
[LIMIT VALUES]
TOTAL RUNNING 12345h
LOADED HOURS 10987h
AIR FILTER IN 2000h
OIL FILTER IN 2000h
SEPARATOR IN 4000h
OIL CHANGE IN 4000h
OIL TYPE FF2000/CLEAR
SHUTDOWN DEACTIVATED
+
+
+
+
+
[TIMER CONTROL]
[FAULT MEMORY]

2.0 Operating & Maintenance
CC1092267A 9
2 Operations
2.1 Starting the unit
Caution
If the unit is ready, i.e. the green LED is flashing, the
compressor may automatically start at any time.
Use the isolator to switch the unit on.
If warning or fault messages appear in the third row of the
display, these first have to be rectified and confirmed
using the key.
Then start the unit by pressing the key on the
HYDROVANE Pro.
2.2 Emergency stop button
The EMERGENCY stop button is located below the
HYDROVANE Pro. Only use the emergency stop button
to shut down the unit in real emergencies. When shutting
down normally, always use the key.
2.3 Switching off the unit
The unit is switched off by pressing the key on the
HYDROVANE Pro. However the unit will only stop after a
2-second soft-stop.
The soft-stop is preset to protect the compressor.
2.4 On-load/off-load
Descriptions of the CONTINUOUS OPERATION and
AUTOMATIC OPERATION modes can be found in
section 3.1.1.
OFF-LOAD:
If there is no pressure requirement from the system with
the unit in CONTINUOUS OPERATION, it switches to
OFF-LOAD. This means that the motor and compressor
run but no air is delivered into the system.
The unit behaves differently in AUTOMATIC OPERATION
mode. If there is no pressure requirement, the compressor
switches to OFF-LOAD. The unit is switched off after a run-
on time that is shown on the display. If there is another
pressure requirement during the run-on time, the unit is
automatically switched on.
ON-LOAD:
If the unit is in ON-LOAD, air is delivered into the system.
2.5 Warning/fault messages
Warning and fault messages are shown in the third row of
the display. The red light signal flashes at the same time.
A table containing messages and suggestions for how to
remedy them is in Section 4.5.
2.5.1 Warning messages
If there are warnings, the red light signal flashes slowly.
The unit does not automatically shut down when there
are warnings. However ignored warnings may cause
faults.
Rectify what is causing the warning and press the key
to cancel the warning.
2.5.2 Fault messages
Fault messages result in the unit automatically shutting
down or do not permit the unit to be started.
Once you have rectified the problem, you must confirm
by pressing the key.

2.0 Operating & Maintenance
10 CC1092267A
2.6 Maintenance
Maintenance intervals are preset when the compressor is
supplied, more information is available in the unit's user
handbook.
It may be necessary to adjust maintenance intervals to
suit ambient conditions. For example, the air filter‘s level
of contamination depends on the compressor's intake
conditions.
The HYDROVANE Pro allows the operator to program
various maintenance intervals (see section 2.7).
If there is a maintenance interval at +200h (hours), the
compressor is not automatically shut down. The
MAINTENANCE DUE message appears on the display.
If you want the compressor to automatically shut down
when a maintenance interval is due, you have to set this
function.
Go to the [MAINTENANCE SCHED.] sub-menu. Go to
the last SHUTDOWN OFF menu item, press the key.
The OFF value starts to flash. By pressing the key you
can change the value to ON, confirm by pressing the
key.
The compressor now automatically shuts down when the
-100h maintenance interval is displayed.
Once maintenance is complete the interval should be
reprogrammed back to 2000h. Confirm the maintenance
message using the key.
2.7 Programming maintenance intervals
To program a maintenance interval, go to the
[MAINTENANCE SCHED.] sub-menu. Here you can
program the maintenance intervals for:
AIR FILTER IN 2000h
OIL FILTER IN 2000h
SEPARATOR IN 4000h
OIL CHANGE IN 4000h
Go to the menu item required and press the key, the
value then starts to flash. Use the or key to set the
value to an interval of 0….9999, confirm your entry with
the key.
If you do not want the maintenance intervals to be
monitored, program the intervals to more than 9999
hours in the various menu items. ---- appears on the
display. The maintenance interval is then blocked.
Note
Values shown are examples only, those used in your unit
may be different.
2.8 Total/load hours counter
Press the + keys at the same time to reach the
main menu. Press the key, you are now in the
[MAINTENANCE SCHED.] sub-menu. Use the or
keys to go to the various menu items.
The total hours counter states the time for which your unit
has been in on-load and off-load.
The load hours counter states the time for which your unit
has been in on-load.
Note
The total and load hours are lost if the HYDROVANE Pro
is replaced.