hydraulic compressors operating...

1E-mail: info @dynaset.comDYNASET OY, Menotie 3,

FIN-33470 Ylöjärvi, FINLANDTel.: +358 3 3488200 Fax: +358 3 3488222

MAY CHANGE WITHOUT PRIOR NOTICE

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HKL HYDRAULIC COMPRESSORS

HKLHYDRAULIC COMPRESSORS

OPERATING INSTRUCTIONS

HKL 400/8 - 24 (33)

HKL 801/8 - 26

HKL 1300/8-38 (46)

HKL 1800/8-46

HKL 2600/8-65 (82)

HKL 4100/8-113

HKL 5000/8-135

HKL 7500/8-132+12

HKL 7500/8-176+12

HKL 1800 / 8 - 46 - O - PE

HYDRAULIC VANE COMPRESSOR

MAXIMUM DISCHARGE, L/MIN

MAXIMUM DISCHARGE PRESSURE, BAR

NOMINAL HYDRAULIC FLOW, L/MIN

CONTROL SOLENOID VALVE FOR OFF-LOAD VALVE

AIR-TO-ELECTRIC OFF-LOAD CONTROL VALVE

June 2014 JLeHKL HYDRAULIC COMPRESSORS

DEAR CUSTOMER!Thank you for choosing Dynaset product from Finland. We appreciate your product expertise andare convinced, our product is efficient and profitable for you.This product is high technology design with latest hydraulic R&D knowledge bringing highperformance in compact size, providing long lasting reliable use for customers all over the world.

2


1. SAFETY PRECAUTIONS AND WARNING STICKERS 3

2. GENERAL NOTES 4

3. CONSTRUCTION 4

4. PERFORMANCE 4

4.1 Lubrication system of the compressor 5 5. PRESSURE AND COMPENSATION RATIO 6

6. AIR AND OIL TEMPERATURES 6

7. AIR HUMIDITY 6

8. INSTALLATION 7-9 9.1 Open centre hydraulic system with variable displacement pump 8 9.2 Closed centre hydraulic system with variable displacement pump 8 9.3 Hydraulic system with constant placement pump 9 9.4 Hydraulic compressor without automatic speed control valve 9 9.5 Connection to the air supply system 9

9. OPERATION 10 10.1 Off-load mode 11

10. HYDRAULIC FLUIDS 11

11. COMPRESSOR OILS 11

12. COMPRESSOR MAINTENANCE 12-14 12.1 HKL service table 12 12.2 Compressor block intake air filter 12 12.2 Oil level check and change 13 12.3 Oil return valves 13 12.4 AIr/Oil separator 14 12.5 Pressure regulator 14

13. TROUBLE SHOOTING 15-16

14. SOLENOID CONTROL VALVE FOR OFF-LOAD VALVE (O) 17

15. AIR TO ELECTRIC (PE) CONTROL FOR OFF-LOAD VALVE 18-19

16. PRODUCT DISPOSAL 20

17. PARAMETERS 21-22

18. MANUFACTURER’S LIMITED WARRANTY 23

19. DECLARATION OF CONFORMITY 24

20. NOTES 25

TABLE OF CONTENTS

HKL HYDRAULIC COMPRESSORSJune 2014 JLe

The pressure in both hydraulic and compressed air circuits of HK-compressor is considerably high. There at the technical condition of your equipment should be under constant scrutiny. Operators and maintenance personnel must always comply with local safety regulations and precautions in order to close out the possibility of damages and accidents.

Especially couplings, valves and hoses should be maintained tight and clean as well as kept under constant observation avoid possible leakages of pressure and hot blowouts. Hydraulic leakages must be rectified immediately to avoid user and bystander injuries. Follow all your local safety instructions related to the high pressure hydraulics.

In order to exclude possible accidents, it is not allowed to clean or inspect HK-compressor and pneumatic tools when hydraulic or/and pneumatic circuit is pressurized. Prior to any cleaning, inspection and service hydraulic system of your carrier machine must be stopped and both hydraulic and pneumatic circuits dissipated, for instance, by opening the blow gun.Always wear appropriate clothing and safety equipment such as goggles, ear protection and safety shoes at all times when operating by the compressor. When operating the compressor, beware of machinery parts warmed by hot hydraulic oil.

EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISASSEMBLING OR REPAIR OF HKL-COMPRESSOR AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE AND LONG-LIFE OPERATION OF YOUR EQUIPMENT.

Hydraulic system of a carrier machine should be maintained according to the service program.All installation and service of both hydraulic and electric equipment must be performed by qualified and experienced personnel only.

SAFETY PRECAUTIONS

3


WARNING STICKERSDynaset dispatch department includes one (1) warning sticker bag per one (1) main product. Product recipient is obligated to fix determinate warning sticker to Dynaset product. Attach sticker to visible and appropriate place or close to Dynaset product where it’s easily seen. Before attaching sticker clean surface with solvent detergent.

READ OPERATING INSTRUCTIONS. GENERAL CAUTION. BEWARE OF HOT SURFACE. USE EAR PROTECTOR. BEWARE OF PRESSURE AIR.


GENERAL NOTES

DYNASET hydraulic compressors are compact and integrated all-in-one units, especially designed for mobile installation. The only power source is a hydraulic system to provide compressor with required hydraulic fluid flow at demanded pressure.DYNASET hydraulic compressor transforms hydraulic power into a high quality compressed air.Designed to meet regular compressed air demands, HK hydraulic compressors are used to power pneumatic tools, for cleaning, flushing etc.

CONSTRUCTION

4


VANE COMPRESSOR BLOCK

1.INTAKE AIR FILTER2.INTAKE/SERVO VALVES3.OIL CHAMBER4.COMPRESSION CHAMBER5.OIL COOLER6.OIL FILTER

1

12

11

2 3 45

6

7

810

9

7.AIR / OIL LABYRINTH8.COMPRESSED AIR9.ROTOR10.OIL SEPARATOR11.OIL RETURN VALVE12.MINIMUM PRESSURE / -NON RETURN VALVE

PERFORMANCE

Utilizing compact rotary vane technique, DYNASET hydraulic compressor of HKL-series is mobile unit comprised of a hydraulic motor with incorporated automatic rotation speed control valve (up to HKL 1800) and rotary vane compressor block. Compressor block includes stator-rotor unit, cooling and lubrication systems, oil separator as well as unloading pressure regulator, attached to the air intake. Hydraulic motor’s and compressor’s shafts are coupled when rotor runs inside of stator eccentrically.

When compressor’s rotor is revolved by a hydraulic motor, air is taken through a filter into a compression chamber consisting of a stator and rotor.The rotor is provided with longitudinal slots in which vanes slide. Vanes are pushed against the stator by centrifugal force, generated by rotation. During compressor’s rotation air is being compressed through the construction in volume comprised by walls of rotor, stator and vanes. Pressurization, cooling and lubrication are ensured by oil, injected into a compression chamber due the pressure differential between compression chamber and oil sump. Thereat, separate oil pump is not required.

The compressed air/oil mixture is discharged from the rotor-stator unit passing through a labyrinth, where most of the oil is separated from the air due to the continuous changes of direction. The remaining oil is trapped at the separator’s inlet and furthers on filter element condensates it by coalescing effect. The recovered oil returns to the intake.

The oil-free compressed air leaves the compressor through a minimum pressure / non-return valve. The valve prevents the air from leaving the compressor until the necessary internal pressure will be achieved in order to ensure proper hermetization and cooling. The same valve also prevents the compressed air, already contained in the system, to return into the compressor.

The fan, mounted on a motor shaft and placed inside of an oil cooler, maintains the proper temperature of the compressor oil and compressed air.

The quantity of air, aspirated by the compressor is regulated / limited by the intake valve, hydraulically controlled by servo valve.


... PERFORMANCE

1. COMPRESSOR BLOCK2. OIL SUMP, PRIMARY SEPARATION3. INTAKE FILTER4. INTAKE VALVE5. AIR / OIL SEPARATOR6. MINIMUM PRESSURE / NON-RETURN VALVE7. SAFETY VALVE 12 BAR8. VACUUM RELIEF VALVE9. OIL DRAIN VALVE10. OIL RETURN VALVE11. THERMOSTATIC BY-PASS VALVE12. OIL COOLER

13. OIL FILTER14. SERVOVALVE15. THERMOSTAT16. PILOT OPERATED CHECK VALVE OF PE-CONTROL VALVE (23) (OPTIONAL)17. OFF-LOAD VALVE (O)18. OIL LEVEL INDICATOR21. AFTERCOOLER (OPTIONAL)22. CONDENSATE SEPARATOR (OPTIONAL) 23. PE-CONTROL VALVE FOR OFF-LOAD VALVE (OPTIONAL) 30. HYDRAULIC SOLENOID VALVE

SAFETY VALVE:Protects compressor against internal overpressure. The safety valve is adjusted to 12 bar.SERVOVALVE:Limits the maximum operational pressure during compressor’s continuous operation by closing the intake valve according to the increase of an internal pressure. The valve operates together with the OFF-LOAD VALVE.THERMOSTATIC BY-PASS VALVE:Forwards warming the oil to the operational temperature before opening the oil circulation through the cooler.OFF-LOAD VALVE (O, with or without a SOLENOID CONTROL VALVE ):When activated, drops compressor’s load and discharges internal pressure. AIR-TO-ELECTRIC (PE-) CONTROL VALVE FOR OFF-LOAD VALVE :Provides operation control in accordance with pre-adjusted maximum and minimum pressure limits in automatic mode.PE-valve and solenoid control valve for off-load valve are recommended when compressor is to be started under pressure (for instance, air tank in pressure line) or compressor is operated intermittently. i.e. stopped and restarted depending on a compressed air consumption. The devices decompress the pressure line enabling easy restart of the compressor.

LUBRICATION SYSTEM OF THE COMPRESSOR

COMPRESSOR OIL PERFOMS FOLLOWING FUNCTIONS:1. LUBRICATION Pressure differential (see above) makes the oil spread along grooves to the surfaces to be lubricated. Separate oil pump not required. 2. HERMETIZATION Oil, injected into the stator, seals rotor blades against stator’s wall and lubricates them. 3. COOLING Compressor oil removes the compression heat from the stator. 4. CAPACITY CONTROL Off-load automatics (servo valve - off-load valve) adjusts compressor’s flow rate according to the air consumption hydraulically using compressor oil.

S

MP

T

1

2

18

11

12

15

7

168

9 5 621 22

10

43

13

14

17

30

2316


5HKL HYDRAULIC COMPRESSORS

June 2014 JLe

PRESSURE AND COMPRESSION RATIOThe rated absolute intake pressure is 1 bar (100 000 Pa). (NOTE! The reference barometric pressure at 0 m above sea level is 1,0135 bar, when at 1000 m above sea level it drops to approx. 0,9 bar).When the discharge (operational) pressure of HKL-compressor is 8 bar, compression ratio is equal to:

operational pressure + barometric pressurebarometric pressure

8 + 1,01351,0135 = 8,89=

The compression ratio for unit of 12 bar is calculated in the same way.

AIR HUMIDITYCompressor can be operated at the relative humidity up to 90%, provided that the ambient temperature is within the above range. If air humidity exceeds 90%, please contact DYNASET’s representative.

Filled with specified compressor oil or corresponding, (ref. to “COMPRESSOR OILS”) unit is operated without any particular arrangements within ambient temperature range -5 ºC... + 40 ºC. If ambient temperature drops below -5 ºC or raises over + 45 ºC, fill the compressor with synthetic oil or be kindly requested to contact DYNASET’s representative.According to the standard EN 1012-1 the maximum accepted temperature of oil is +100 ºC. In normal operational conditions at ambient temperature of +20 ºC compressor oil’s temperature levels to 80 - 85 ºC.The temperature of the delivered compressed air exceeds ambient temperature by approx. 5 - 10 ºC.

AIR AND OIL TEMPERATURES

6



PT

INSTALLATION

DYNASET hydraulic compressor can be placed deliberately ensuring free air intake, sufficient cooling and an easy access to the unit. Position of a compressor should be horizontal. To protect compressor against overheating, do not allow the warmed cooling air to be directed by cooling fan back to the compressor block. Compressor’s location should be chosen as far as possible from any source of dust and heat. Protective cover against weather and season impacts is recommended. Intake air should not contain any smoke, toxic or flammable gas/vapor. When necessary, intake pipe can be fitted (the pipe should be measured properly in order to avoid load loss).

DYNASET hydraulic compressor works installed into an original hydraulic system of any carrier machine.Additionally, return line must be connected to a hydraulic oil tank directly in the shortest possible way in order to keep return oil pressure under 5 bar. Generally DYNASET’s T-line is to be connected directly to the return line of a hydraulic system, when hydraulic fluid flows to the tank only through the return filter and cooler. Both filtering degree and cooling capacity of a hydraulic system should be sufficient (ref. to PARAMETERS).

Ensure that the oil flow is sufficient to run the unit, i.e. at least the nominal flow must be available. At the oil flow less that demanded nominal rate, compressor’s delivery will be below the nominal. If the oil flow is so excessive, that the automatic speed control valve is unable to handle it, the unit could be damaged. In the latter case the oil flow is to be reduced either by dropping down the rotation speed of hydraulic pump or using flow limiter valve. DYNASET priority valve is recommended.

After having been connected to the hydraulic system, DYNASET hydraulic compressor is to be started by directing the oil flow to the unit’s pressure port by means of control valve - manual or solenoid. Even simple ball valve or three-way valve can be used. To ensure DYNASET’s proper operation, the hydraulic pressure must be set to the level, at which at least the nominal power output is achieved (ref. to PARAMETERS). Lower hydraulic pressure reduces compressed air pressure. Maximum hydraulic pressure is 250 bar (ref. to PARAMETERS). If the hydraulic system main pressure is higher, service pressure relief valve must be used.

Ensure also that your machine oil cooling is working properly when DYNASET is in operation.

It is possible to use DYNASET either as a mobile compressor and connect hydraulic power with quick couplings, or make a fixed installation on a carrier machine.

To put DYNASET compressor into operation only pressure- (P) and return (T) lines of a hydraulic system are to be connected to the unit’s corresponding hydraulic ports. The proper connection ensures correct rotation direction of the compressor and, by that, an appropriate cooling of the compressor block. Rotation in opposite direction is not allowed. Furthermore, cross-connection of hydraulic hoses damages hydraulic motor’s shaft seal.

7



HKL

SM

PT

T

CF

PP

LS LS

A

B

AUTOMATICROTATION SPEEDCONTROL VALVE

PV-SAE valve

DYNASET hydraulic compressors are designed for easy integration into hydraulic system of any type.

DYNASET PV SAE 3/4 - 1 1/4 -XX lpm - 12/24 V priority valve includes following components:

ALSO AVAILABLE for open centre hydraulic systems with variable displacement pump: PRIORITY VALVE PV SAE ¾ - 1 ¼ - 12/24 V.

PV SAE priority valve is designed for the installation to main pressure line between SAE-flanges of main hydraulic pump. Pre-adjusted, independent from other functions and priorised hydraulic flow for DYNASET-unit comes from the solenoid valve.

DYNASET PRIORITY VALVE enables trouble-free operation of your DYNASET-unit simultaneously with other hydraulic executors.

1.Sandwich-mounted pressure compensator with SAE-flange specification;2. Solenoid valve 12/24V;3.Flow limiter;4.Pressure relief valve.

The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED PRIORITY VALVE.

The rest of hydraulic pump’s capacity is available for all other functions. Furthermore, pump’s control works together with DYNASET PV SAE priority valve.

1. OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

LS-valveHKL

SM

PT


2. CLOSED CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED LOAD SENSING (LS) VALVE.

DYNASET LS-valve includes following components:1.Flow limiter;2.Solenoid valve 12/24V; 3.Pressure relief valve;4.Shuttle valve (OPTIONAL).

DYNASET LOAD SENSING VALVES:LSV 40, LSV 60, LSV 95 and LSV 150LS-connection, pressure relief, max. hydraulic flow 40, 60, 95 ja 150 l/min respectively.

DYNASET FLOW LIMITERS to the pressure line:VR 40 PK - 1/2, max. 35 l/min, with pressure compensation;

VR 95 PK - 3/4, max. 95 l/min, with pressure compensation.VRD 180 PK - 1, max. 180 l/min, with pressure compensation.

ALSO AVAILABLE for closed centre hydraulic systems with variable displacement pump:DYNASET SOLENOID VALVE to the pressure line for remote starting. SV 70 NC - 1/2 - 12 / 24 V max 70 l/min with LS -connection; SV 150 NC— 1 - 12 / 24 V max 150 l/min with LS -connection.

8


... INSTALLATION


HKL 2600 - 5000

PT

... INSTALLATION

HKL 400 - 1800

SM

PT

When installing a compressor of given type to a hydraulic system, is to kept in mind that the allowed nominal hydraulic flow should not be exceeded (Qhy_nom = Qhy_max).

HYDRAULIC COMPRESSORS WITHOUT AUTOMATIC SPEED CONTROL VALVE:

CONNECTION TO THE AIR SUPPLY SYSTEM

It is recommended to install distribution valve to a pressure line near the compressor in order to clean oil cooler and filter with a blow gun when necessary.

Compressor can be connected to the air supply system (or consumer) with a proper fitting and cut-off valve (options). The internal diameter of pipe / hose used for compressor’s connection should be at least equal to AP-port to keep the pressure drop minimal. The length of a pipeline, laid with the pipe of same diameter as AP-port, can be 50 m as maximum. For longer lines use larger diameter.

SM

PT Moisture separator to the pressure line is optional.


3. HYDRAULIC SYSTEM WITH CONSTANT DISPLACEMENT PUMP

The demanded oil flow is to be ensured with proper hydraulic pump choice. In systems with redundant hydraulic flow an installation with DYNASET PRIORITY VALVE is recommended.

Installation with a standard pressure compensated 3-way valve should be avoided in order to close off potential waving in hydraulic system.

ALSO AVAILABLE for hydraulic systems with constant displacement pump:DYNASET FREE CIRCULATION VALVE with solenoid and pressure control, type VKV 90—3/4.

HKL 400 - 1800 HKL 2600 - 7500

PT

P

T


June 2014 JLe

10


Hydraulic flow rate marked on the compressor’s nameplate is an absolute maximum and should not be exceeded in any circumstances. A redundant hydraulic flow causes compressor’s overspeeding and may damage it.

OPERATIONPrior to starting the compressor check whether the unit is filled with oil. In non-operating and depressurized compressor oil level is over the top point of sight glass. When necessary top up with the same oil as the unit is filled with. Replace and tighten the filler plug (Ref. to the instructions below).

Open the cut-off valve in compressor’s pressure line. Ensure from compressor’s pressure gauge that the unit is decompressed - when pressurized, compressor may start with difficulty*).With carrier’s engine running HKL-compressor is started with a hydraulic control valve. Compressor starts to produce usable compressed air when hydraulic flow achieves the functional minimum rate, which is approx. a half of the nominal value (Ref.to the unit’s nameplate as well as to the PARAMETRS). The nominal discharge is achieved when the compressor is rotated by hydraulic flow adequate to the nominal rotation speed.

ATTENTION !The minimum allowed rotation speed of rotary vane compressor is 1200 rpm, corresponding to the minimum hydraulic flow - refer to pages 21 and 22 of the manual. *)When the compressor is to be started under pressure (for instance, air reservoir in pressure line) or the unit is used intermittently stopping and restarting it several times according to the air demand, following accessories are recommended: * solenoid control valve for off-load valve; * pressure switch.

Qhy_nom = Qhy_calc + 2 l/min Qhy_calc - CALCULATED CONSTANT FLOW Qhy_nom - NOMINAL FLOW

Qhy_nom = Qhy_max

Compressed air is consumed according to the demand, when compressor’s delivery levels within 0 l/min to the maximum. If the compressed air is not used while compressor is running, off-load automatics (= OFF-LOAD VALVE + SERVOVALVE) closes the intake valve and sets compressor’s internal pressure to 1 - 2 bar (to prevent compressor oil from drain into the air filter) when the output drops to 0 l/min.When the compressed air is consumed, off-load automatic controls the intake valve according to the current air demand.

COMPRESSORS EQUIPPED WITH AN AUTOMATIC ROTATION SPEED CONTROL VALVEHKL400 - HKL1800

HYDRAULIC FLOW0 Qmin

Qhy, l/min

CONTROL RANGE*

Qnom

Qpi, l/minD

ISCH

ARG

E

Qpi, min

Qpi, nom

Qmax

COMPRESSORS WITHOUT AN AUTOMATIC ROTATION SPEED CONTROL VALVEHKL2600 - HKL5000

OFF-LOAD MODE

Compressor being rotated at full output, automatic rotation speed control valve keeps rotation speed constant when incoming hydraulic oil flow (Qhy) can vary from nominal demanded flow (Qnom) up to value exceeding Qnom by 10 – 20 l/min depending on compressor size.

0 Qmin

Qhy, l/min

Qnom = Qmax

Qpi, l/min

DIS

CGA

RGE

Qpi, min

Qpi, nom

HYDRAULIC FLOW


11


ATTENTION !The compressor must be operated neither in smoky environment nor in conditions where toxic or flammable vapors could be aspirated.Compressor’s maximum pressure must not be exceeded in any circumstances.Compressed air delivered by a HKL-compressor must not be used as the breathing air, even if purified and filtered. HKL-compressor is designed for air only and must not be used with any other gas. If the compressor is connected to the distribution network or consumer with a flexible hose, ensure that the hose is of proper diameter and pressure class. Damaged or worn hose should be replaced immediately.The sound-proof enclosure (if used) should be closed when compressor is in the operation.

... OPERATION

Check the compressor’s oil fill periodically: when the unit is in operation, the oil level must be over the midlevel of the sight glass .NEVER REMOVE THE OIL FILLER PLUG WHEN THE COMRESSOR IS RUNNING OR PRESSURIZED !

Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic equipment.Depending on the operating temperature, following mineral hydraulic oils are recommended: ISO VG 32S for oil’s operation temperature up to 70 °C; ISO VG 46S for oil’s operation temperature up to 80 °C; ISO VG 68S for oil’s operation temperature up to 90 °C.

Synthetic and bio-oils can be used as well if their viscosity characteristics and lubricating efficiency are corresponding to above mineral oils. Automatic transmission fluids and even engine oils can be used, provided that they are allowed to be used in hydraulic system of your carrier machine.To use special hydraulic fluids a with DYNASET equipment, please be kindly requested to contact nearest DYNASET representative for an advice.

HYDRAULIC FLUIDS

ATTENTION !Do not mix together lubricants neither of different specification nor of different brand!

ROTOROIL F4 compressor oil is recommended as most preferable lubricant. If ROTOROIL lubricants are not available it is allowed to replace them with high quality rotary vane compressor oils of same viscosity class supplied by other manufacturers, see table below. Pay attention to long-life oil exchange interval and life span. All Dynaset compressors are equipped with thermostat for unexpected overheating and damages.

COMPRESSOR OILS

QUALITY AMBIENT OIL CHANGE SUPPLIER DETAILS TEMPERATURE MAX, HOURS

ROTOROIL 8000 F4 - 30 ... + 45ºC 2.500 or 12 months Dynaset synthetic oilCorena S4R - 10 ... + 45ºC 2.500 or 12 months Shell synthetic oilRarus SHC 1020 - 10 ... + 45ºC 2.500 or 12 months Exxon Mobil synthetic oil

Prior to starting any maintenance or repair, ensure that the compressor is completely depressurised. The pressure gauge in oil separator housing must indicate zero.

COMPRESSOR MAINTENANCE

DYNASET hydraulic compressors are low-maintenance units. Only normally wearing parts and materials should be replaced either when necessary or in accordance with a service program.Refer also to the TROUBLESHOOTING section.


12


INTAKE AIR FILTERINTAKE AIR FILTER

In normal operating conditions the filter element should be replaced after each 1000 h or with the interval of at least 6 months.

Filter site and cover should be cleaned.


NOTE: All installation and service of both hydraulics and electric equipment must be performing experienced personnel only.

DYNASET HKL-SERIES SERVICE TABLE

CHECK POINTS

Check oil level O I Clean compressor air intake filter O I Clean oil cooler and air after cooler O I Clean oil return valve filters O I

Change air intake filter I Tighten nuts and screws fixing the wires in the electric control panel and in the motor terminal board O I Replace oil return valve filters I Change oil filter: FG I Change oil filter: F2 or F4 I Oil change: Rotoroil 8000: FG I Oil change: Rotoroil 8000: F2 or F4 I

Maintenance operations have to be performed at reduced Intervals in case of dusty environments.

50 h 50 h 100 h 500 h 1000 h 1000 h 2500 h

Weekly or

every

Monthly or

every

Every 3 months

or

Every 6 months

or

Every 12 months

or

Every 12 months

or

After the first

Neglecting recommended services may cause device malfunction and Dynaset warranty is anymore valid. Perform given maintenance in time according to next table.

NOTE: O = These operations must perform to a new device after the first 50 hours. Within the first 300 hours of operation: Clean the oil return valves.

Oil cooler should be checked on a daily basis and cleaned when necessary. To clean the cooler use AIR blow gun MODERATELY. A clogged and dirty cooler causes compressor’s overheating.

COMPRESSOR MAINTENANCE

June 2014 JLe

13


MAINTENANCE

OIL LEVEL SHOULD BE CHECKED AT EACH STARTING :Compressor standing still: OVER THE TOP POINT OF A SIGHT GLAS (3).Compressor running: OVER THE MIDLEVEL OF A SIGHT GLAS (3).

OIL FILTER ELEMENT SHOULD BE REPLACED AT EACH OIL CHANGE OR AT LEAST AFTER EVERY 12 MONTHS.

OIL LEVEL CHECK AND CHANGE

1

2.12.1

2.2

3

ENSURE THAT THE COMPRESSOR IS COMPLETELY DEPRESSURIZED !Unscrew filler plug (1) slowly.Attach proper fitting to the oil drain valve (2.1) and open the valve. Drain the oil into the suitable pan.(Oil drain valve could be replaced with a discharge plug 2.2). Shut off the valve (2.1) or replace and tighten the plug (2.2) Fill the compressor with oil. Replace and tighten filler plug 1. DO NOT FORGET GASKETS !

Start the compressor and let it operate few minutes. Check oil level and top up if necessary.

ATTENTION !OIL SHOULD BE CHANGED WHEN THE COMPESSOR IS WARMED UP TO THE NORMAL OPERATIONAL TEMPERATURE.

FACTORY-FILL OILFactory-fill oil must be changed after very first 200 (max.) operation hours.Further on compressor oil is to be changed according to the oil quality and service time (ref. to COMPRESSOR OILS above) or at least once a year.

OIL RETURN VALVES

Oil return filters should be cleaned at the first oil change.

Further on, oil return filters should be cleaned after each 500 h or every three months. Replace oil return filters after each 2500 h or at least once a year.

OIL RETURN VALVE

MODEL OIL FILL l HKL 400/8 - 24 (33) 2,5 HKL 801/8 - 26 2,0HKL 1300/8-38 (46) 2,0 HKL 1800/8-46 3,5HKL 2600/8-65 (82) 3,5HKL 4100/8-113 10HKL 5000/8-135 10HKL 7500/8-176+12 19

OIL RETURN VALVE


14


AIR / OIL SEPARATOR

SEPARATOR ELEMENTSEPARATOR ELEMENT

HKL 800 - HKL 2600 HKL 4100 - HKL 5000

PRESSURE REGULATIONCompressor’s output pressure is adjusted and tested at factory and usually does not required resetting.However, if re-adjustment is required, the procedure is to be made as follows:1.Start the compressor.2.Shut off the pressure line slowly when air pressure achieves the maximum. Note the pressure gauge’s reading *).3.Having removed parts, shown on the sketch, make the adjustment with the servo valve: 3.1 loosen locknut first 3.2 to increase pressure, tighten the adjusting screw; to decrease pressure, loosen the adjusting screw; 3.3 lock the setting with locknut.

SERVOVALVE

NOMINAL OUTPUT PRESSURE SERVOVALVE’S SETTINGOF A HYDRAULIC COMPRESSOR

bar bar

8 8,5 10 10,5

ATTENTION !ONLY THE QUALIFIED PERSONNEL IS ALLOWED TO MAKE THE SETTING !

*)A separate pressure gauge should be connected to the pressure line when making the adjustment.It is recommended to use the unit comprised of ball valve and pressure gauge as shown on the alongside sketch.

SAFETY VALVE 12 BAR

In normal ambient conditions oil separator elements should be replaces at each 10 000 operation hours or when pressure loss or oil consumption increases considerably.In heavy conditions exchange interval should be shortened.

REF. TO THE DATA SHEETS FOR SPECIFIC UNIT !!!


MAINTENANCE

June 2014 JLe


15

1.1Malfunction of compressor’s hydraulic control valve.1.2Compressor’s excessive internal pressure.

1.3Failure in hydraulic system.

1.4Air pressure in delivery line disrupts compressor’s start.

1.1Check and repair.

1.2Check the minimum pressure/non return valve and repair possible blowing.

1.3.1Check whether the hydraulic fluid flow and pressure are sufficient. Adjust when necessary.1.3.2Check the hydraulic motor for possible leakage. Replace motor if necessary.

1.4Let off the pressure from the delivery line prior to staring the compressor.It is recommended to install the solenoid control valve for off-load valve, especially if the pneumatic system is provided with an air reservoir.

2.COMPRESSOR STARTS HARDLY

See 1.3

See 1.4

3.AIR PRESSURE DOES NOT ACHIEVE REQUESTED RATE.

3.1Servo valve’s incorrect setting.

3.2Safety valve opens due to the either the failure or incorrect setting of servo valve.

3.3Failure in hydraulic system.

3.4Air intake filter is clogged.

3.5Oil separator’s filter element(s) clogged.

3.1Check and adjust servo valve when necessary.

3.2.Check and adjust servo valve.

3.3.1Check whether the hydraulic fluid flow and pressure are sufficient. Adjust when necessary.3.3.2Check the hydraulic motor for possible leakage. Replace motor if necessary.

3.4Check and replace.

3.5Check and clean / replace filter element(s).

TROUBLESHOOTING

1.COMPRESSOR DOES NOT START WHILE CARRIER’S ENGINE IS RUNNING AND HYDRAULIC SYSTEM IS ON.


16


... TROUBLESHOOTING

5.EXCESSIVE OIL CONSUMPTION

5.1Filters of the oil return valves are clogged.

5.2Oil separator’s filter element(s) clogged.

5.1Check and clean / replace valves.

5.2.Check and clean / replace filter element(s).

4.COMPRESSOR DOES NOT PRODUCE COMPRESSED AIR = RUNS UNLOADED

4.1Delivery line closed (i.e. OPEN/CLOSE valve is damaged) or possible malfunction in pneumatic executor.4.2Servovalve’s failure or incorrect setting (i.e. adjusted to the pressure lower than setting of minimum pressure / non return valve). 4.3Air intake valve does not open.

4.1Check and repair possible failure.

4.2.Check and repair possible failure.

4.3Check the valve and repair failure. Check also the whole valve block to order to find out and repair possible malfunctions.

6.COMPRESSOR’S OVERHEATING.

6.1Dirty oil cooler.

6.2High ambient temperature.

6.3Low oil level.

6.4Due to the seizure of thermostatic by-pass valve, compressor oil does not circulate through oil cooler.

6.5Due to the insufficient cooling capacity of a hydraulic system hydraulic fluid warms the compressor.

6.1Clean the oil cooler.

6.2Sufficient ventilation is to be arranged.

6.3Add compressor oil to the required level.

6.4Check and repair the valve.

6.5DYNASET OY offers wide range of hydraulic components including oil coolers !

ATTENTION !

HKL-compressor is equipped with a thermostat, which is to be used for stopping the compressor when the unit’s temperature achieves thermostat’s constant set value.

Thermostat is to be connected to the stop valve or alarm lamp in the Customer’s system by Customer themselves.


17


PLUG R 1/8”

PLUG M5

Prior the installation remove air filter’s cover.

A

A3

2

SOLENOID CONTROL VALVE FOR OFF-LOAD VALVE (O)

1

2

The valve being activated, compressor’s load and internal pressure are dissipated.

HKL 800 - HKL 2600

ATTENTION !In HKL 4100 and HKL 5000 the connection is placed on the right side of the compressor block.

A.The offload valve (17) is to be attached into the connection (1) of R 1/8” in oil separator (on the same side with AP-connection). Tightening glue is used to make joint hermetic. Prior to the installation remove the plug 1/8” from the connection port.B.From-valve-to-compressor unload air tube (2) (6/4 teflon) is installed to the connection M5 (3) with a swivel fitting and tightening glue as shown on sketches above. Prior to the installation remove the plug M5 from the connection port.The unload air tube is laid under the oil separator between compressor’s housing and air filter cover.Installation kit includes all necessary fittings and the nylon tube.The valve is equipped with a pre-installed fitting 1/8”.


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AIR-TO-ELECTRIC (PE-, 23) CONTROL VALVE FOR OFF-LOAD VALVEPE-control valve provides operation control in accordance with pre-adjusted by an incorporated pressure switch maximum and minimum pressure limits in automatic mode.

16

23

PE-CONTROL VALVE FOR OFF-LOAD VALVE IS COMPRISED OF TWO BASIC ASSEMBLIES:

POS 16Pilot operated check valve

POS 23PE-control valve, including following components:

23.1 pilot valve (4 - 10 (13) bar)

23.2 needle valve to adjust filling time interval of air chamber 23.4

23.3 pressure switch, pre-adjusted at factory (3 bar)

23.4 air chamber

Filling times for air chamber 23.4, pre-adjusted at factory:

HKL 1300 14 - 15 sec

HKL 2600 20 sec.....

HKL 5000 40 - 45 sec

23.3

IP65

PRESSURE SWITCH 23.3:

Contacts 1-2: NC, used when compressor is run as stand-alone unitContacts 1-4: NO, used when compressor is installed to a Customers’ system with several executive units;

Control voltage max. 250 VPressure max. 10 bar

23.1

HYSTERESISLOCK

LOCKNUT OFPILOT VALVE

23.2

ATTENTION !PILOT VALVE’s (23.1) HYSTERESIS IS ADJUSTEDAT FACTORY ! DO NOT RE-ADJUST !


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When there is no air consumption compressor being on (i.e. delivery line is closed), air pressure in compressor’s reservoir achieves its maximum, opening a pilot valve (23.1) and activating the off-load mode.Pilot operated check valve (16) opens and sends a signal to a compressor’ servov alve, which closes the air intake valve.An air chamber (23.4) is filled up with an air discharging from compressor’s reservoir until the pressure in chamber achieves the pre-adjusted value for the opening of a pressure switch (3 bar). Pressure switch 23.3 opens de-energizing the solenoid valve (30) when the unit stops. As soon as the compressed air is requested by a pneumatic consumer, i.e. delivery line is open - pressure in air chamber (23.4) drops less than 3 bar, when the pressure switch closes, re-energizing the solenoid valve (30) and restarting the compressor.

If the compressed air is requested the off-load mode being on, PE-valve drops the pressure in compressor’s reservoir to the pre-adjusted value (set from the pilot valve to 5 - 6,5 bar depending on the unit’ size) opening the compressor’s intake valve, and the unit passes into the operation directly from the unloaded mode.

16

(30) HYDR.S O L E N O I D

23

23.2

23.1

AIR-TO-ELECTRIC CONTROL VALVE (PE-, 23) FOR OFF-LOAD VALVE

23.3

23.4

+V

TIME

PRESSURE

3 BAR


PRODUCT DISPOSAL

Conform to waste legislation, regulations and recommendations in waste disposal and waste recycling issued by local authorities.

1. Precondition: • Product is permanently useless or beyond repair. • Before transportation get off all used agent (oil, cooling liquid) and dirty filters.

Items requiring special handling can normally be done by authorized waste management facility, if not:

• Separating the base materials, iron, copper, steel, electronics, removing paint, polyester resin, and insulation tape and/or plastics residues from all components. • This ‘waste material’ can now be recycled. 2. Deliver the recycling material to waste management facility.

Note! Customer can send the DYNASET equipment for reuse or recycling to the Dynaset Oy or to other location determinate by Dynaset representative. • Customer pays shipping cost. • Equipment must be adequately packed for shipment. • Shipment documents must contain purchaser’s name and contact information.



June 2014 JLe

PARAMETERS HKL - VANE COMPRESSORS

HKL 400 /8 - HKL 801/8 - HKL 1300/8 - HKL 1800/8 - -24 -33 -26 -38 -46 -46

DISCHARGE CHARACTERISTICSFlow rate at ref. conditions*, max. l/min 400 800 1300 1800Maximum pressure bar 8 8 8 8

COMPRESSED AIR CONNECTION AP BSP 1”2 BSP 1/2” BSP 1/2” BSP 3/4”

HYDRAULIC CONNECTIONSPressure line P BSP 1/2” BSP 1/2” BSP 1/2” BSP 1/2”Return line T BSP 1/2” BSP 1/2” BSP 1/2” BSP 1/2”Drain line DR NO NO NO NO

HYDRAULIC POWER REQUIREMENTSMinimum flow l/min 10 14 14 20 23 23Maximum flow l/min 35 55 37 60 66 66Pressure at nominal flow bar 210 170 210 210 170 210 Maximum pressure bar 250 250 250 250Pressure when unloaded bar 140 120 140 150 130 150

HYDRAULIC FLUID REQUIREMENTS Viscosity cSt 10 - 200 / optimum 25 - 35Temperature ºC max. 70 **Filter ratio, recommendation um min. 25Cooling capacity, recommend. kW 2 2,8 2,2 3,2 4 4

OVERALL DIMENSIONSLength mm 525 640 640 750Width mm 250 390 390 390Height mm 325 540 540 600

WEIGHT kg 30 50 55 95

* According to ISO 1217(1996) at discharge pressure of 6 bar.** REF. TO HYDRAULIC FLUIDS

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HKL-COMPRESSORS, STANDARD DISCHARGE PRESSURE OF 8 BAR *

*) models of 7 - 13 bar discharge pressure available by request


PARAMETERS HKL - VANE COMPRESSORS

HKL 2600/8 - HKL 4100/8- HKL 5000/8- HKL 7500/8 - -65 -82 -113 -135 -132 + 12 -176 + 12

DISCHARGE CHARACTERISTICSFlow rate at ref. conditions*, max. l/min 2600 4100 5000 7500Maximum pressure bar 8 8 8 8

COMPRESSED AIR CONNECTION AP BSP 3/4” BSP 1” BSP 1” BSP 1 1/4”

HYDRAULIC CONNECTIONSPressure line P BSP 3/4” BSP 3/4” BSP 3/4” BSP 1”Return line T BSP 1” BSP 1” BSP1” BSP 1”Drain line DR NO NO NO T15

HYDRAULIC POWER REQUIREMENTSMinimum flow l/min 33 41 74 74 72 + 12 96 + 12Maksimum flow l/min 65 82 113 135 144 188Pressure at nominal flow bar 210 170 200 180 260 200Maximum pressure bar 250 250 250 280 250Pressure when unloaded bar 50 135 145 150 200 150

HYDRAULIC FLUID REQUIREMENTS Viscosity cSt 10 - 200 / optimum 25 - 35Temperature ºC max. 70 **Filter ratio, recommendation um min. 25Cooling capacity, recommend. kW 5 6,8 9,4 11,3

OVERALL DIMENSIONSLength mm 790 870 870 1100 1100Width mm 390 495 495 850 850Height mm 600 770 770 820 820

WEIGHT kg 103 185 185 325 330

* According to ISO 1217(1996) at discharge pressure of 6 bar.** REF. TO HYDRAULIC FLUIDS

22


HKL-COMPRESSORS, STANDARD DISCHARGE PRESSURE OF 8 BAR *

*) models of 7 - 13 bar discharge pressure available by request


MANUFACTURER’S LIMITED WARRANTY

1. Warranty coverageAll hydraulic accessories manufactured by DYNASET OY are subject to the terms and conditions of this limited warranty. Products are warranted to the original purchaser to be free from defects in materials or workmanship. Exclusions from warranty are explained in item 8.

2. Beginning of warranty periodWarranty period begins from the delivery date of the product. Delivery is considered to be done on the date when installation has been accomplished or purchaser has taken the product in use. Product is considered as taken in use at the date when DYNASET OY has delivered the product to purchaser, unless separately agreed otherwise by written agreement.

3. Warranty periodWarranty period is twelve (12) months based on maximum of 2000 hours usage during this time period. In cases where the system is provided complete with certain special components (e.g. drive unit), those components are considered as a subject to their manufacturer’s warranty.

4. Warranty proceduresImmediately upon identifying a problem which purchaser believes to be a failure subject to the product’s limited warranty, purchaser must contact primary to the seller of the product. Contact must be made as soon as possible, latest thirty (30) days after the problem was identified. Seller and/or manufacturer technical staff determines the nature of the problem primarily by phone or e-mail. Purchaser commits to give necessary information and to perform routine diagnostic procedures in order to determine the nature of the problem and necessary procedures.

5. Warranty repairsIf the product is found to be defective during the warranty period, DYNASET OY will, at its option, either repair the product, author it to be repaired at its authorized workshop or exchange the defective product. If the product must be repaired elsewhere than premises of DYNASET OY or authorized workshop, all costs excluded from this warranty (traveling and waiting hours, daily allowance, traveling expenses and uninstallation/reinstallation costs) will be charged from the purchaser.

If the problem is not covered by this limited warranty, DYNASET OY has the right to charge purchaser of troubleshooting and repairing.

6. Delivery terms of warranty repairIf the product is found possible to be defective under this limited warranty and it needs to be repaired, DYNASET OY gives Warranty Return Number (WRN). Items being returned must be shipped, at the purchaser’s cost, adequately packed for shipment, to the DYNASET OY or to other location authored by DYNASET OY. Shipment documents must contain:

- Purchaser’s name and contact information- Receipt of original purchase- WRN code- Problem description

7. Warranty of repaired productWarranty period of the product repaired under this limited warranty continues to the end of original warranty period.

8. Exclusions from warrantyThis warranty shall not apply to:

a. Failures due to normal wear and tear, improper installation, misuse, abuse, negligence, purchaser selection of improper product to intended use, accident, improper filtration of hydraulic oil or intake water or lack of maintenance

b. Cost of maintenance, adjustments, installation or startup

c. Coating, hydraulic oil, quick couplings and interconnection hoses (internal or external to system assemblies)

d. Products altered or modified in a manner not authorized by DYNASET OY in writing

e. Products which have been repaired during warranty period by others than DYNASET OY or its authorized workshop

f. Costs of any other damage or loss, whether direct, indirect, incidental, special or consequential, arising out of the use of, or the inability to use, the product

g. Telephone or other communications expenseh. Product that is used in exceptional conditions, considered to cause excessive wear and tear

i. Faults caused by nature phenomenon’s like flood, thunder, etc.

© DYNASET OY, all rights reserved

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EC DECLARATION OF CONFORMITY

We hereby declare that the below-reference product design, structure and ourmanufacture form fulfills relevant, fundamental safety and health requirements with the provisions in the Council Directive on mutual approximation of laws of the Member States on the safety of machines.

- Machine directive 2006/42/EC - Directive 97/23/EC European standards Pressure equipment. - LVD directive 2006/95/EC

Apply conformity standards:

- CEN EN ISO 4413: EN ISO 4413:2010Hydraulic fluid power - General rules and safety requirements for systems and their components.

If device has changed by someone other than at the hands of manufacturer or hispermission, this declaration is not valid.

PRODUCT: HYDRAULIC COMPRESSOR

TYPE NUMBERS: HKL400/8-24-xxx, HKL400/10-24, HKL801/8-26-xxx,HKL1300/8-38-xxx, HKL1300/8-46-xxx, HKL1800/8-46-xxx,HKL2600/8-65-xxx, HKL2600/8-82-xxx, HKL4100/8-113-xxx,HKL5000/8-135-xxx,HKL7500/8-176+12-xxx (xxx + xx)

YLÖJÄRVI 26.07.2012 DYNASET Oy

Timo Nieminen R&D Manager

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25


NOTES


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