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Hydrovane HV22 - User Manual

Hydrovane HV22
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User Handbook
HV04 - HV45 Models (ACE)
Stationary Air Compressors
ST 16135-00 Iss E 05/2009
GB

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Hydrovane HV22 and is the answer not in the manual?

Summary

Introduction

Support

Full support is available from your Hydrovane Distributor. Contact them for specialist help or service.

Customer Warranty Terms

Guaranteed for 12 months from commissioning or 18 months from shipment. Excludes wear items and consequential damage.

Product Development

Hydrovane adopts a policy of continual product development. Information may change without notice.

Quality Standards

Hydrovane Quality Management Systems approved to BS EN ISO 9001. Complies with European Directives.

Model Range

This handbook relates to ACE HV04-HV45 vertical range compressors and hypac models.

Product Terminology

Explains the segments of the product code and their meaning.

Safety

General Health and Safety Precautions

Instructions to follow before installation, operation, maintenance or repair of the compressor unit.

The Health and Safety at Work Act, 1974

Ensuring compliance with the Act by using competent persons and following handbook instructions.

Before Working on Compressor

Precautions to take before performing any work on the compressor, including isolation and pressure relief.

When Operating the Compressor

Guidelines for safe operation, including warnings about hot surfaces and compressed air.

Potential Oil Health Hazards

Hazards associated with Hydrovane approved oil, including skin irritation and recommended precautions.

First Aid Measures

Procedures for inhalation, skin contact, eye contact, and ingestion of oil or related substances.

Warnings, Cautions and Notes

Explanation of warning symbols (WARNING!, CAUTION!) and their significance.

Product Information

Operating Temperatures

Describes optimal operating temperatures for performance and service life.

High Operating Temperatures

Discusses reasons for high temperatures and automatic shutdown limits.

Noise Level

Notes on sound pressure levels and recommended positioning.

Technical Data HV04-HV07

Detailed technical specifications for HV04, HV05, HV07, and HV07RS models.

Technical Data HV11-HV22

Detailed technical specifications for HV11, HV15, HV18, HV22, and their RS variants.

Technical Data HV30-HV45

Detailed technical specifications for HV30, HV37, HV45, and their RS variants.

Transportation and Handling

Introduction

Guidance on carrying out lifting and transportation by authorised, trained personnel.

Lifting and Handling (Fig. 4.1 and Fig. 4.2)

Details on using fork lifts, pallet trucks, and avoiding damage during movement.

Model Weights

Table showing weights for various ACE HV04-HV45 compressors and hypac models.

Installation and Commissioning

Positioning Your Compressor - Basic Requirements

Guidelines for siting the compressor/hypac, including space, levelness, and environment.

Ventilation (Fig. 5.1)

Instructions on positioning for optimal cooling air-flow and avoiding re-circulation.

Electrical Connections

Warning about qualified electricians and ensuring the supply meets load requirements.

Electrical Installation (Fig. 5.2)

Detailed steps for connecting the compressor to the mains electrical supply via an isolator.

Check Direction of Motor Rotation

Procedure to verify correct motor rotation to prevent damage.

Regulated Speed Compressor Installation

Specific installation guidance for regulated speed compressors.

RS Operation with other Hydrovane Compressors

How to operate RS compressors efficiently with other Hydrovane units.

General Description

Compressor;Hypac (Fig. 6.1)

Overview of the ACE HV04-HV45 vertical range and hypac units.

Control Systems

Describes operating modes: Automatic Stop/Start, Continuous Run, and Regulated Speed.

Compressor Assembly (Fig. 6.2)

Detailed breakdown of the compressor unit components and their arrangement.

Electronic Controller

Explanation of the electronic controller's menu structures and access levels.

Operating Instructions

Introduction

Overview of operating instructions and safety warnings for authorised personnel.

Checking Procedure Before Starting

Essential checks to perform before starting the compressor.

Compressor Operation

Describes controller display, LED indicators, and basic operation.

Starting - Automatic Mode

Steps for starting the compressor in automatic mode and its behaviour.

Starting - Continuous Mode

Steps for starting the compressor in continuous run mode.

Starting - Regulated Speed

Starting procedure for variable speed models.

Stopping - All Models

Procedure for safely stopping the compressor.

Emergency Stop

How to use the emergency stop button and subsequent actions.

Compressor Vent Down

Explanation of the automatic compressor vent down process.

Operational Display Symbols

Explanation of symbols displayed on the controller for operational status.

LED Indicators (Fig 7.2)

Description of LED indicators and their meanings in different states.

Adjustments

Compressor Control (Fig. 8.1)

Overview of the Customer Menu (P10) for parameter settings.

Customer Menu (P10)

How to access and modify parameters in the Customer Menu.

Operating Mode (AUT;MO)

Instructions for setting the operating mode to Automatic or Continuous.

Pressure Adjustment - Single Speed

Procedure for adjusting load and unload pressures for single speed units.

Pressure Control - RS Compressors

Adjusting pressure settings for RS compressors.

Servo Valve (Fig. 8.2)

Procedure for adjusting the servo valve for pressure control.

Servicing

Introduction

Safety precautions and overview of servicing requirements.

Routine Service Schedule

Details the minimum service requirements and recommended intervals.

Servicing (RS)

Servicing intervals for RS units are the same as fixed speed units.

Check Compressor Operation

How to check compressor temperature and pressure during operation.

Check Compressor Pressure

Procedure to access and view the compressor pressure gauge.

Check oil level (Fig. 9.1)

Instructions for checking the oil level using the sight glass.

Basic Service

Steps for performing a basic service, including isolation and safety checks.

Access Panel Removal

How to remove the top panel for access to internal components.

Oil Draining and Filter Replacement (Fig. 9.2 and Fig. 9.3)

Procedure for draining oil and replacing the oil filter.

Oil Draining

Detailed steps for draining the compressor oil.

Oil Filter Replacement (Fig. 9.3)

Instructions for removing and fitting a new oil filter.

Oil filling; Top-up (Fig. 9.3)

Procedure for filling or topping up the compressor oil level.

Air Filter Replacement (Fig. 9.2)

Steps for replacing the air filter element.

Oil Separator Replacement (Fig. 9.2)

Procedure for replacing the oil separator.

Clean Oil Cooler;Aftercooler (Fig. 9.4)

Instructions for cleaning the oil cooler and aftercooler matrix.

Cabinet Air Filter

How to remove and replace the cabinet air filter.

Panel Refitting

Steps for refitting panels after servicing.

Electrical Checks

Safety precautions and checks for electrical connections.

Motor Cleaning

Instructions for cleaning the motor and air intake.

Servicing Requirements

Overview of preventive maintenance charts and service intervals.

Service Schedule: Fluid Force Red, Clear and HPO Oil

Details service schedules based on oil type and operating conditions.

Service Kits

List of additional kits available for full product support.

Fault Finding

Fault Finding

General information on how the controller monitors faults and identifies error types.

Shutdown Error (E)

List of shutdown error codes and their meanings.

Alarm Error (A)

List of alarm error codes for warnings that do not stop the compressor.

Run Inhibit Error (R)

Error codes that prevent the motor from starting.

Service Alarm Error (A)

Alarm indicating that routine service is due.

Fault Display Symbols

Explanation of symbols appearing on the controller display with fault codes.

Controller Menus

Overview of controller menus and access restrictions.

Oil Change Service Menu - P20

Menu configured for oil changes as part of a service agreement.

Service Engineers Menu - P21

Menu for authorised engineers for installation or maintenance.

Diagnostic Menu - P22

Menu for checking and testing controller inputs and outputs.

Drive Configuration Menu - P30

Menu for matching inverter drive and motor control features.

Factory Menu - P31

Master configuration menu for default settings.

Summary

Introduction

Support

Full support is available from your Hydrovane Distributor. Contact them for specialist help or service.

Customer Warranty Terms

Guaranteed for 12 months from commissioning or 18 months from shipment. Excludes wear items and consequential damage.

Product Development

Hydrovane adopts a policy of continual product development. Information may change without notice.

Quality Standards

Hydrovane Quality Management Systems approved to BS EN ISO 9001. Complies with European Directives.

Model Range

This handbook relates to ACE HV04-HV45 vertical range compressors and hypac models.

Product Terminology

Explains the segments of the product code and their meaning.

Safety

General Health and Safety Precautions

Instructions to follow before installation, operation, maintenance or repair of the compressor unit.

The Health and Safety at Work Act, 1974

Ensuring compliance with the Act by using competent persons and following handbook instructions.

Before Working on Compressor

Precautions to take before performing any work on the compressor, including isolation and pressure relief.

When Operating the Compressor

Guidelines for safe operation, including warnings about hot surfaces and compressed air.

Potential Oil Health Hazards

Hazards associated with Hydrovane approved oil, including skin irritation and recommended precautions.

First Aid Measures

Procedures for inhalation, skin contact, eye contact, and ingestion of oil or related substances.

Warnings, Cautions and Notes

Explanation of warning symbols (WARNING!, CAUTION!) and their significance.

Product Information

Operating Temperatures

Describes optimal operating temperatures for performance and service life.

High Operating Temperatures

Discusses reasons for high temperatures and automatic shutdown limits.

Noise Level

Notes on sound pressure levels and recommended positioning.

Technical Data HV04-HV07

Detailed technical specifications for HV04, HV05, HV07, and HV07RS models.

Technical Data HV11-HV22

Detailed technical specifications for HV11, HV15, HV18, HV22, and their RS variants.

Technical Data HV30-HV45

Detailed technical specifications for HV30, HV37, HV45, and their RS variants.

Transportation and Handling

Introduction

Guidance on carrying out lifting and transportation by authorised, trained personnel.

Lifting and Handling (Fig. 4.1 and Fig. 4.2)

Details on using fork lifts, pallet trucks, and avoiding damage during movement.

Model Weights

Table showing weights for various ACE HV04-HV45 compressors and hypac models.

Installation and Commissioning

Positioning Your Compressor - Basic Requirements

Guidelines for siting the compressor/hypac, including space, levelness, and environment.

Ventilation (Fig. 5.1)

Instructions on positioning for optimal cooling air-flow and avoiding re-circulation.

Electrical Connections

Warning about qualified electricians and ensuring the supply meets load requirements.

Electrical Installation (Fig. 5.2)

Detailed steps for connecting the compressor to the mains electrical supply via an isolator.

Check Direction of Motor Rotation

Procedure to verify correct motor rotation to prevent damage.

Regulated Speed Compressor Installation

Specific installation guidance for regulated speed compressors.

RS Operation with other Hydrovane Compressors

How to operate RS compressors efficiently with other Hydrovane units.

General Description

Compressor;Hypac (Fig. 6.1)

Overview of the ACE HV04-HV45 vertical range and hypac units.

Control Systems

Describes operating modes: Automatic Stop/Start, Continuous Run, and Regulated Speed.

Compressor Assembly (Fig. 6.2)

Detailed breakdown of the compressor unit components and their arrangement.

Electronic Controller

Explanation of the electronic controller's menu structures and access levels.

Operating Instructions

Introduction

Overview of operating instructions and safety warnings for authorised personnel.

Checking Procedure Before Starting

Essential checks to perform before starting the compressor.

Compressor Operation

Describes controller display, LED indicators, and basic operation.

Starting - Automatic Mode

Steps for starting the compressor in automatic mode and its behaviour.

Starting - Continuous Mode

Steps for starting the compressor in continuous run mode.

Starting - Regulated Speed

Starting procedure for variable speed models.

Stopping - All Models

Procedure for safely stopping the compressor.

Emergency Stop

How to use the emergency stop button and subsequent actions.

Compressor Vent Down

Explanation of the automatic compressor vent down process.

Operational Display Symbols

Explanation of symbols displayed on the controller for operational status.

LED Indicators (Fig 7.2)

Description of LED indicators and their meanings in different states.

Adjustments

Compressor Control (Fig. 8.1)

Overview of the Customer Menu (P10) for parameter settings.

Customer Menu (P10)

How to access and modify parameters in the Customer Menu.

Operating Mode (AUT;MO)

Instructions for setting the operating mode to Automatic or Continuous.

Pressure Adjustment - Single Speed

Procedure for adjusting load and unload pressures for single speed units.

Pressure Control - RS Compressors

Adjusting pressure settings for RS compressors.

Servo Valve (Fig. 8.2)

Procedure for adjusting the servo valve for pressure control.

Servicing

Introduction

Safety precautions and overview of servicing requirements.

Routine Service Schedule

Details the minimum service requirements and recommended intervals.

Servicing (RS)

Servicing intervals for RS units are the same as fixed speed units.

Check Compressor Operation

How to check compressor temperature and pressure during operation.

Check Compressor Pressure

Procedure to access and view the compressor pressure gauge.

Check oil level (Fig. 9.1)

Instructions for checking the oil level using the sight glass.

Basic Service

Steps for performing a basic service, including isolation and safety checks.

Access Panel Removal

How to remove the top panel for access to internal components.

Oil Draining and Filter Replacement (Fig. 9.2 and Fig. 9.3)

Procedure for draining oil and replacing the oil filter.

Oil Draining

Detailed steps for draining the compressor oil.

Oil Filter Replacement (Fig. 9.3)

Instructions for removing and fitting a new oil filter.

Oil filling; Top-up (Fig. 9.3)

Procedure for filling or topping up the compressor oil level.

Air Filter Replacement (Fig. 9.2)

Steps for replacing the air filter element.

Oil Separator Replacement (Fig. 9.2)

Procedure for replacing the oil separator.

Clean Oil Cooler;Aftercooler (Fig. 9.4)

Instructions for cleaning the oil cooler and aftercooler matrix.

Cabinet Air Filter

How to remove and replace the cabinet air filter.

Panel Refitting

Steps for refitting panels after servicing.

Electrical Checks

Safety precautions and checks for electrical connections.

Motor Cleaning

Instructions for cleaning the motor and air intake.

Servicing Requirements

Overview of preventive maintenance charts and service intervals.

Service Schedule: Fluid Force Red, Clear and HPO Oil

Details service schedules based on oil type and operating conditions.

Service Kits

List of additional kits available for full product support.

Fault Finding

Fault Finding

General information on how the controller monitors faults and identifies error types.

Shutdown Error (E)

List of shutdown error codes and their meanings.

Alarm Error (A)

List of alarm error codes for warnings that do not stop the compressor.

Run Inhibit Error (R)

Error codes that prevent the motor from starting.

Service Alarm Error (A)

Alarm indicating that routine service is due.

Fault Display Symbols

Explanation of symbols appearing on the controller display with fault codes.

Controller Menus

Overview of controller menus and access restrictions.

Oil Change Service Menu - P20

Menu configured for oil changes as part of a service agreement.

Service Engineers Menu - P21

Menu for authorised engineers for installation or maintenance.

Diagnostic Menu - P22

Menu for checking and testing controller inputs and outputs.

Drive Configuration Menu - P30

Menu for matching inverter drive and motor control features.

Factory Menu - P31

Master configuration menu for default settings.

Hydrovane HV22 Specifications

General IconGeneral
ModelHV22
TypeRotary Vane
Motor Power2.2 kW / 3 hp
Free Air Delivery21 cfm / 595 l/min
Weight141 kg
Noise Level69 dB(A)
Power22 kW
Air Flow Rate3.7 m³/min
Max Pressure10 bar
Tank CapacityNot Applicable

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