Introduction ‘The 23 series Mydrovane Compressors ae il sealed sliding vane rotary sir comrestors directly driven by electric motors. Operation and routine maintenance only are detailed in this booklet, dono attempt {Fy further work wes the appropriate instructions are available, The use of approved lubricants ‘a tothe compressor ang the maintenance sehedule must be stretiy adhared to. A careful eheck on compressor runing hours should therefore be kept Installation-Si Comper temperate tensed its parted max ot 104°C (220"F1 Te compresor ‘The compreso: must be lvl in both plane Pipework Connections The shutolt valve supplied should be fttad betwen the compressor outlet and the pipework 2 Anion should be connected in the line ater she shut-off valve 3. Thesizea! pinework used must be large enough to reduce fret\on and subsequent pressure rp 10 # nium, A drop lag and automatic drsin water trap should be fitted in the pipework system s0 that any Condensation forming in the pipes cannot drain Back to the comaressor The ar main should slope down away from the comprestor to ad condensate drainage, A sop of 2% is urualy sufficient 6. Anairline fittad with 3 blow gun should be nstlied close tothe commavessar s0 thet theo 00ler, gir aftercooler ond sr into filter may be cleaned periodically 2, Branch pipes to individual equioment must sinays be taken from the top of the ar main 8. Water apr should be fitted as far away from the camprasior ands loge to the point of af usage 2s possible 8, Where ext ary ai i essential t may be found mecesrary to Fit an ai drier in she pipework 10. When a pressure site is instal ina stop-start or multiple compressor installation this must be fited to tno air eealver (or sie line after al rertictions of vaver, ter, ete Electrical Connections 1. Comaresior shouldbe connected to sitabe supply vis a switched and fused isolator 2. Make electri! connections ss shown in the WIFING DIAGRAM’ noting sugested incoming 3, Setmotor overload switch tothe value shown in the WIRING DIAGRAM 4 Check overiond is revet 5. Ona muitipie compressor system, plug in connection leads between compressa starters t0 form {8 clae80 loap. A maximum wire size of 0.7 mm should be used 6. On amultinie compressor system, eet red switches on starter PC. Boards (whore applicabe) for the required operation, ether Sequential —setting'S', or Cascade — setting ‘C° For single ‘compressor stop-start conte, sat red switch to 'C’ postion NOTE: In multipia compressor systms, all switches must have the same setting, CAUTION: Directian of compressor rotation it CLOCKWISE looking on the DRIVE END of the comoressor. Incorrect rotation will cause srious damage and requires immediate shut ‘down, To change direction of rotation, change aver any two of the the incoming wire B.S, T. 2. Tocheck sirection af compressor rotation ona stop-start unit, or in multiple compressor systams, switen mode selector to "MANUAL. and press ‘START’ button. Press stop button ‘ahen direction of rotation is determinedSettings and Adjustments WARNING: WORK ON ELECTRICAL EQUIPMENT MUST BE CARRIED OUT BY SUITABLY QUALIFIED PERSONNEL. Servo Valve The sero waive is foctory pre-set to give 8 ful aad working pressure of either 7 bar (100 ibin#)* oF tO bee (150 Iotfn? IW aslight correction to the operating pressure is found t0 be necessary, adjusiment may be made by ‘moans of the sevo adjusting serow situated near the bate ofthe oll chamber atthe intake end ‘Adjustment should be made withthe compresor at normal working temperature 1. Close shut-off valve. Turn modo selector switch (where fitted) to "MANUAL position, Press 2. Slacken sero locket 3. Adjust servo adjuster to:— 17 bar (112 lin? | to obtains ful load working pressure of 7 bat (100 Ii 10.7 bar 1155 Ibt/in?) to obtain a ful load working pressure of 10 bar (160 Ibt/n?)* Screw adjuster CLOCKWISE to INCREASE or ANTI-CLOCKWISE to DECREASE pressure (Open and close shut-off valve 1 check setting between adjustments Tighten servo locknut when corrct setting i abteined “THE SPECIFIED WORKING PRESSURE OF THE INDIVIDUAL COMPRESSOR MUST NOT BE EXCEEDED. Cycle Time Setting Tha eycl times are factory preset via two adjustable potentiometers (RV and V2, sterter PC. Board mounted 29 the following approximate value: avi 5 seconds intial start-up delay ava 0 conde, or the pariod of oFF-load running ater which the compressor will top. NOTE: Adjustment to the evele time settings should not be attempted without frst referring to ‘he detailed instructions given in the Power Manager’ Contra Kit Manus Pressure Switch Setting Prosure switches PSI and PS? are factory pre-set to the valuss shown below st Maximum Pressure 7.2 bar (108 Ihr? 10.2 bar (155 tin? Pse Minicnum Pressure 5.5 bar (20 Ibtn?) St must be st 10 a higher pressure then PS2 to ensute corect apereion af eeu NOTE: Adjustment to the aressure switch settings should not be attempted without fist referring to the detailed inetructions given inthe ‘Power Manager” Contrl Kit ManualCompressor Operation CAUTION: BEFORE INITIAL START-UP OF NEW COMPRESSOR, READ “INSTALLATION.” CHECK OIL LEVEL AND TOP UP AS NECESSARY, CHECK DIRECTION OF ROTATION OF COMPRESSOR ON INITIAL START-UP, SEE ‘ELECTRICAL CONNECTIONS, Standard Control (Continual Running Operation only) START 1. Switch on power 2. Close snutott vaive 3. Pres star button 4, When compressor or reached maximum pressure, open shut of value STOP 1, Close shut-off valve 2, Press stop button. 3. Laneshutoff valve closed to clear the 0 separator. Automatic Stop Start Control START 1. Switch on power. Open shutoff va. 2) Sllactmade of operon us scr switch, or B. Ssiect AUTO’ for automatic stop stat operation, This «the recommended mode for maximum economy where there is 8 fuetuating sit demand 3. Select "LEAD" on white selector. Compresior will not start if sant i let in unmarked position 4. Prose stat button, (There will boa short dolay before start up NOTE: WHEN SWITCHING OVER DIRECTLY FROM ‘MANUAL’ TO ‘AUTO, THE ‘COMPRESSOR WILL STOP BRIEFLY BEFORE AUTOMATICALLY RESTARTING IN "AUTO" MODE, WHEN SWITCHING DIRECTLY FROM AUTO” TO MANUAL’, COMPRESSOR WILL CONTINUE RUNNING. sToP 1. Press stop button Multiple Compressor Control NOTE: Ensure all switches om starter PC, Boards have been st to the recuired aparation, either ‘Sequential of ‘Cascade, see ‘ELECTRICAL CONNECTIONS, START 4. Switch on power, Open shutol valves 2. Int, swt blue selectors on al system compressors to "AITO" position 3. Push al start buttons. 44. Determine whicn compresior to start fest, then switch its white selector 10 "LEADY, There vwll bea short delay before start up. 5, I 'Seaquentia’ control has been selected, return white switch to she unmarked postion after compressor has started 6. 1 Cascade’ contro! has been selacted, leave white switeh in ‘LEAD pesition, sToP 1, Push al top buttonsVETVICING SAFETY PRECAUTIONS ‘BEFORE WORKING ON THE COMPRESSOR, ENSURE THAT IT IS ISOLATED FROM THE MAINS ELECTRICITY SUPPLY, ENSURE COMPRESSOR IS NOT PRESSURISED. WAIT TILL, ‘THE PRESSURE GAUGE READS ZERO THEN SLOWLY REMOVE THE FILLER PLUG. IF OIL. STARTS BUBBLING OUT BEFORE THE PLUG HAS BEEN REMOVED, THE UNIT IS STILL PRESSURISED. DO NOT REMOVE THE PLUG UNTIL THE PRESSURE HAS BEEN LOST. Nore: IN ANY MULTIPLE COMPRESSOR INSTALLATION INDIVIDUAL COMPRESSORS CAN BE ISOLATED FOR ROUTINE MAINTENANCE, OTHER SYSTEM COMPRESSORS WILL CONTINUE ‘TO OPERATE. 110 VOLTS WILL STILL BE PRESENT IN THE STARTER. REFER TO SPECIAL INSTRUCTIONS GIVEN IN POWER MANAGER CONTROL KIT MANUAL. Air Intake Filter 1. Unscrew and remove the iter serbw which is situated a the non-drve en ofthe compressor and collet the fibre washer, 2. Withdraw the Hltor cover and collect the filer element. 3. _Glean the elamunt by blowing off accumulated dirt with low pressure clean dry air or renew the clement it ncessay. Thoroughly een the iter cover, 4. Place the element inthe eover and porition ageinst the compressor casing ensuring that the 5. Secure the assembly withthe filter serew and fibre washer. Oil Cooler and Air Aftercooler Te cooler sections and aftercooler metrix must be carefully cleaned, at the period detailed in ‘COMPRESSOR MAINTENANCE” by blowing out accumulated dirt with compressed air The aftercooler drain Filter should be sevice in secordance with the manufacturers natactins. Oil Return Vaive 1. Remove serens and eolect instruction plate. Discard gasket from behind t 2. Unscrew and remove ot return vai and discard bonded sea 3. Unscrew titer assembly from valve body and collect Filter disc and oritiee pate emove cirlip from valve body and collect backing discs and filter plug. scar Hite plug Thoroughly clean all components in white sprit or paratin ensuring entices n valve body, filter die and aritce plate ar fee fom bloesage Position ontice plate and filter disc in threaded end of valve body, Refit fier assembly Position backing disen valve body followed by new lite plug and second backing dss, Refit 8, With new bonded seal ftted, cette return valve to oil ehamber 9. With new gasker in postion, elit instruction plate and secure withthe srewsElectric Motors Routine maintenance on electric motors ie. greasing of bearinge ee, should be carried out in accordance Oil Filter 1. Drain hel a detailed in "OIL ORAINING AND FILLING 2. Unsere the to serene and remove th ol ter cove, Discard cover gasket, Remove ol fitr clement om Boren ol enero 2. Wash the titer emt in white sii or paraffin and wipe dry, Wipe ou the iter bor inthe oi chamber 4. Replace oi fiver elament in i chamber bore 5. itn new gske, rubber bonded side acing amay trom te oll amber 1m poston, etit at titer cover ana secre withthe to eres 6. Falwith ou 8 detaled in “OIL ORAINING AND FILLING: Oil Draining and Filling NOTE: _This's best accomplished as soan as possible after shut down, 1. trolate compressor from main electricity supply 2. When the pressure gauge reade 2r0 slowy remove the ol file plug to ensure that there is no pressure remaining in the unit and t0 allow venting to the ol chamber. Ifo! starts Bubbling aut bere te filer pug fully emoved thi indicates that some presure stl remains inthe comaresior and the filler plug must not be removed until ths pressure has been lost 3. Remove the two drain plugs situated in the base of the el chamber. Drain the al into a ruitable eceptace 4, Rett and tighten the din plug, ensuring that new bonded seals are tito 5. Fillthe comprasior with ol a specified in "APPROVED LUBRICANTS” to the top ofthe fill lug hoe 6. Replace the filler plug complete with new seal and run the compressor for aporoximately 10 s8conds, lt until the air pressure gauge reads zero and repeat operation 2 7. Recheck oi love! ond top up 9s necessary to top of filler plug hoe,Maintenance Schedule Peni sow | Bev | fey er sev 1 "so | 2000 OPERATION SY | Hours | Hoursa ‘heck OW Level x |x ‘ean Air take Filter x Giean Oil Goo x x Clean Air Atercooier x Clean Ou Return Valve x Crean OW Fit x (Change Air Intake Fater Element x "Change OH x shouldbe regarded as maximum. Ifthe compressor is working “WHEN USING A SPECIFIED APPROVED LUBRICANT OTHER THAN HYDROVANE 2000, THE OlL CHANGE PERIOD IS AMENDED TO 400 HOURS. ‘4 EVERY 2,000 HOURS RUNNING OR ONE YEAR WHICHEVER OCCURS FIRST Replacement Service Parts T Location | oescriprion | ory | pant no, Air Intake Element | ong Futer | Fabre Washes 1 802 { Orne, Gosker 3306 N Becui Bonded Ses ' 9613 Valve Fre Ps v 2081 + “ — OF Fee dad S20) 1 9619 Pn | Bons 1 . Drain Play Bonded Sea 2 9613 04 Futer Gasket 1 9304 4 = | 4 Al ahows ised em are available in an O1L CHANGE KIT forthe 2000 hour sewerApproved Lubricants 7 > 1 | 5.13 2le8 e @e\eie\ei|ee | cri t o- fx hom | oo | 2 fon [149] oe ve o éie]*® [So] "20 | oo “ |_| 1 [Ten v9 | 30 | 9°] cra] | "o0"] "so sex = io fe |e he[>| Se [es rc ‘or equivalents are generally necemary © 400 Hour Oit Charge IMPORTANT: IN ORDER TO RETAIN ITS 2000 HOUR OIL. CHANGE CHARACTERISTIC HYDROVANE 2000 MUST NOT BE MIXED WITH ANY OTHER APPROVED LUBRICANT. WHEN CHANGING FROM A STANDARD (400 HOUR) OIL. TO HYDROVANE 2000, THE INITIAL OIL CHANGE MUST 8 MAE AT 400 HOURS, SUBSEQUENT OIL CHANGES MAY THEN BE MADE AT THE RECOMMENDED 2000 HOUR INTERVALS. Data Digpiacemer 10.9 ites (23 1%) ‘osed on 150 1217 (8S 1571), 10.1 tre (21.6 F%/ mint Normal Operating Pressure 7 bor (100 tatin®) Option avaiable) 10 ber (150 ffi?) Motor Power 44 6.5 np) Oit Capacity 2.4 ites (6 pints) Moximutn OM Temperature 104% 220°) Sotety Valve Settings 7 ber Operating Pressure 2.6 bor (125 latin?) 10 bar Operating Pressure 12 bar (175 toffint) Air Outlet PU wees? *hinimum Recommended Pine Size (un to 1000 "11 "LD. AFTERCOOLER DATA Air Discharge Temperature ZC above ambient Pressure Dron (0.07 bor 1 tin?) Air Outlet wrease. “hn view of possibility of addtional or demands boing added ‘a Targer pipe size may be considered on orginal nealaton,wesbeiqg BuinMaintenance Record Date Hours run Work carried out __ Date Hours run Work carried outDate Hours run _ Work ca ied out HOM 23 The Hydrwvane Compr: ssor Company Limited Claybrook Drive Washford industrial Fst ate, Redditch Worcestershire, Enghinc B98. ODS Telephone Redditch (0 27) 255 x 339343 ISSUE 2 JAN 1983