Manuel Hetrz

HSC – HSC FRECON DIRECT DRIVE
FRECON PLUS
INSTRUCTION MANUAL
EC DECLARATION OF CONFORMITY
HERTZ KOMPRESSOREN GERMANY
Ahlen – GERMANY
Revision status
R00 – First Edition : January 2013
Printed in Germany
Compiled, Approved & Issued by
R&D DEPARTMENT
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1 GENERAL ................................................................................................................................................ 11
1.1 Preface ......................................................................................................................................... 11
1.2 Precautions .................................................................................................................................. 11
1.3 Copyright © .................................................................................................................................. 11
1.4 Warranty and Obligation .............................................................................................................. 11
1.5 Type Approval and Original Spare Parts ..................................................................................... 12
1.6 Technical Service ......................................................................................................................... 12
1.7 Descriptions and Warnings .......................................................................................................... 12
2 SAFETY ................................................................................................................................................... 13
2.1 Terms of Use ................................................................................................................................ 13
2.2 Unauthorized Modification ............................................................................................................ 13
2.3 Compressed Air Line Connections............................................................................................... 14
2.4 Fire and Explosion Risk ............................................................................................................... 14
2.5 Moving Parts ................................................................................................................................ 15
2.6 Hot and Sharp Surfaces ............................................................................................................... 15
2.7 Flammable and Irritating Substances........................................................................................... 16
2.8 Electrical Shock ............................................................................................................................ 16
2.9 Check Before Starting .................................................................................................................. 17
2.10 Compressor and Around Cleaning ............................................................................................... 17
2.11 Personal Protection and Safety.................................................................................................... 17
2.12 Safety and Warning ...................................................................................................................... 18
2.13 Suggestions .................................................................................................................................. 20
2.14 Air filter ......................................................................................................................................... 20
2.15 Safety and Protection System ...................................................................................................... 20
2.16 Noise Protection ........................................................................................................................... 21
2.17 Environmental Protection ............................................................................................................. 21
3 DESIGN AND FUNCTION ....................................................................................................................... 22
3.1 General View of HSC 22 Direct Drive .......................................................................................... 22
3.2 General View of HSC 75 Direct Drive .......................................................................................... 23
3.3 Operation of the Compressor ....................................................................................................... 24
3.3.1 Drive and Control System ............................................................................................................ 24
3.3.2 Pressure System ......................................................................................................................... 24
3.4 Intake and Control System ........................................................................................................... 26
3.4.1 Intake System .............................................................................................................................. 28
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3.4.2 Intake Control System ................................................................................................................. 28
3.5 Cooling and Lubricating Systems................................................................................................. 29
4 Optional Cooling Systems .................................................................................................................... 31
4.1 Water cooled system: ................................................................................................................... 31
4.1.1 Brazed Heat Exchangers (BPHE) ............................................................................................... 32
4.1.2 Construction of BPHE: ................................................................................................................. 32
4.1.3 Design Conditions and Approvals: .............................................................................................. 32
4.1.4 Mounting: ..................................................................................................................................... 33
4.1.5 Strainers ...................................................................................................................................... 33
4.1.6 Insulations (Optional) ................................................................................................................... 33
4.1.7 Cleaning of The BPHE ................................................................................................................ 34
4.1.8 Storage ........................................................................................................................................ 34
4.1.9 Compressor Cooling Water Type: ............................................................................................... 34
4.1.10 Heat Exchanger Maintenance: .................................................................................................... 35
4.1.11 Technical Data of Heat Exchanger: ............................................................................................. 36
4.2 Heat Recovery Systems ............................................................................................................... 37
4.2.1 Technical Data of Heat Recovery Model: .................................................................................... 39
5 Control Units........................................................................................................................................... 40
5.1 Logik 8 Control Unit ...................................................................................................................... 40
5.1.1 Buttons ......................................................................................................................................... 40
5.1.2 Compressor Operation ................................................................................................................ 40
5.1.3 Maintenance Counter .................................................................................................................. 41
5.1.4 Working Hour Counters ............................................................................................................... 42
5.1.5 Compressor Parameters and Values .......................................................................................... 43
5.1.6 Alarm Code Description of Compressor ...................................................................................... 44
5.2 HEC 40 Control Unit ..................................................................................................................... 45
5.2.1 HEC 40 Display Navigation ......................................................................................................... 46
5.2.2 HEC40 Screen Display ................................................................................................................ 46
5.2.3 HEC 40 Operation Mode ............................................................................................................. 48
5.2.3.1 Selecting Operating Modes .................................................................................................. 48
5.2.3.2 Compressor Stop Procedure ................................................................................................ 48
5.2.3.3 Compressor Start Procedure ............................................................................................... 49
5.2.3.4 Compressor Unloading and Reloading ................................................................................ 49
5.2.3.5 Compressor Stopping and Restarting .................................................................................. 49
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5.2.4 Alarms and Warnings .................................................................................................................. 49
5.2.5 Alarm History ............................................................................................................................... 51
5.3 L25S Control Unit ......................................................................................................................... 51
5.3.1 Buttons ......................................................................................................................................... 52
5.3.2 Using Control Unit........................................................................................................................ 52
5.3.2.1 User Parameter Settings and Service Hours Counter ......................................................... 52
5.3.2.2 Maintenance Hours .............................................................................................................. 54
5.3.2.3 Checking Hours and Information.......................................................................................... 55
5.3.2.4 Alarm History ........................................................................................................................ 57
5.3.2.5 Compressor Configuration Settings ..................................................................................... 58
5.3.2.6 Selection of Current Temperature, Pressure Units and Language ...................................... 59
5.3.2.7 Entering Parameter Password ............................................................................................. 60
5.3.2.8 Parameter List (Customer Level) ......................................................................................... 61
5.3.2.9 Warning Alarms and Failure Messages ............................................................................... 64
5.3.2.10 Alarms with Immediate Compressor Shut Off ...................................................................... 65
5.4 L30P Control Unit ......................................................................................................................... 67
5.4.1 Main Screen Display .................................................................................................................... 68
5.4.2 Control Unit Info Display .............................................................................................................. 69
5.4.3 Alarms .......................................................................................................................................... 74
5.4.3.1 Alarm Messages with Immediate Compressor Shut Off ...................................................... 74
5.4.3.2 Alarm Messages with Compressor Shut Off After 30 sec Unload Run ................................ 75
5.4.3.3 Maintenance Messages ....................................................................................................... 75
5.4.3.4 Warning Alarms .................................................................................................................... 76
5.4.3.5 Messages Visualized into Alarm List Only ........................................................................... 77
6 TECHNICAL DATA ................................................................................................................................. 78
6.1 Technical Data of Compressor..................................................................................................... 78
6.2 Plates on the Compressor ............................................................................................................ 79
6.2.1 Plate on the Canopy .................................................................................................................... 79
6.2.2 Plate on the Oil Tank ................................................................................................................... 79
6.2.3 Sticker on the Motor .................................................................................................................... 80
6.3 Technical Data of HSC ................................................................................................................. 81
6.4 Technical Data of HSC FRECON ................................................................................................ 82
6.5 Technical Data of FRECON PLUS ............................................................................................... 83
7 TRANSPORT, STORAGE, INSTALLATION .......................................................................................... 86
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7.1 Shipping and Transport ................................................................................................................ 86
7.1.1 Shipping ....................................................................................................................................... 86
7.1.2 Transport ..................................................................................................................................... 86
7.1.3 Storage ........................................................................................................................................ 88
7.2 Installation of the Compressor and Connections ......................................................................... 89
7.3 Compressor Room Ventilation ..................................................................................................... 91
7.4 Electrical Connections .................................................................................................................. 92
7.4.1 HSC Power Cable Cross Section Area ....................................................................................... 92
7.4.2 HSC FRECON Power Cable Cross Section Area ....................................................................... 93
7.4.3 FRECON PLUS Power Cable Cross Section Area ..................................................................... 94
7.5 Installation Drawings .................................................................................................................... 95
8 OPERATION .......................................................................................................................................... 100
8.1 General ....................................................................................................................................... 100
8.2 Some of the Compressor Equipment ......................................................................................... 100
8.3 First Start Up .............................................................................................................................. 101
8.4 Daily Operation........................................................................................................................... 102
8.5 Operating Compressor After Long Term Stopped and Cold Weather ....................................... 103
9 TROUBLESHOOTING ........................................................................................................................... 105
9.1 General ....................................................................................................................................... 105
9.2 Troubleshooting, Reasons and Solutions .................................................................................. 106
10 MAINTENANCE ..................................................................................................................................... 114
10.1 Safety During Maintenance ........................................................................................................ 114
10.2 Periodic Maintenance ................................................................................................................. 115
10.2.1 Daily Maintenance ..................................................................................................................... 115
10.2.2 Weekly Maintenance ................................................................................................................. 115
10.3 Maintenance Instructions ........................................................................................................... 117
10.3.1 Compressor Oil .......................................................................................................................... 117
10.3.2 Oil Change ................................................................................................................................. 118
10.3.3 Oil Filter Change ........................................................................................................................ 119
10.3.4 Panel Filter Change ................................................................................................................... 119
10.3.5 Air Filter Change ........................................................................................................................ 120
10.3.6 Separator Element Change ....................................................................................................... 122
10.3.7 Cooling Radiator Maintenance .................................................................................................. 123
10.3.8 Separator Oil Return Line (Scavenge) Maintenance................................................................. 123
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10.3.9 Motor Maintenance .................................................................................................................... 123
10.3.10 Bearing Lubricating .................................................................................................................... 124
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Figure 1 HSC 22-D Safety Warnings ...............................................................................................................18
Figure 2 HSC 75-D Safety Warning .................................................................................................................19
Figure 3 General View of HSC 22 Direct Drive Model .....................................................................................22
Figure 4 General View of HSC 75 Direct Drive Model .....................................................................................23
Figure 5 Drive System ......................................................................................................................................24
Figure 6 Pressure System of HSC 22 Direct Drive Model ..............................................................................25
Figure 7 Pressure System of hsc 75 Direct Drive Model ..............................................................................25
Figure 8 FRECON 5/7 PLUS Compact Model .................................................................................................26
Figure 9 Intake System of HSC 22 Direct Drive Model ....................................................................................27
Figure 10 Intake System of HSC 75 Direct Drive Model ..................................................................................27
Figure 11 Cooling and Lubricating System of HSC 22 Direct Drive Model ....................................................29
Figure 12 Cooling and Lubricating System of HSC 75 Direct Drive Model ....................................................29
Figure 13 Logik 8 Control Unit .........................................................................................................................40
Figure 14 HEC 40 Control Unit ........................................................................................................................45
Figure 15 L25S Control Unit.............................................................................................................................51
Figure 16 L30P Control Unit.............................................................................................................................67
Figure 17 L30P Main Screen Display ..............................................................................................................68
Figure 18 Plate on the Canopy ........................................................................................................................79
Figure 19 Plate on the Oil Tank .......................................................................................................................79
Figure 20 Sticker on the Motor .........................................................................................................................80
Figure 21 HSC 75 Direct Drive Model Transported by Forklift ........................................................................86
Figure 22 FRECON 7 PLUS Model Transported by Forklift ............................................................................87
Figure 23 FRECON 7 PLUS Model Transported by Lifting Lug ......................................................................87
Figure 24 HSC 75 Model Transported by Lifting Lug ......................................................................................88
Figure 25 Installation of the Compressor to the Room ....................................................................................89
Figure 26 Genera view of INV 5/7+ with tank and dryer model .....................................................................104
Figure 27 Oil Level Hose ................................................................................................................................118
Figure 28 Oil Filter Replacement ...................................................................................................................119
Figure 29 Panel Filter Replacement ..............................................................................................................120
Figure 30 Type of Air filter for 7,5 - 10 HP powered compressor .................................................................120
Figure 31 Type of air filter for 30 - 50 HP powered compressor ....................................................................121
Figure 32 Type of air filter for 60 - 100 HP powered compressor ..................................................................121
Figure 33 Air filter type used in 125 - 430 HP compressors ..........................................................................121
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Table 1 Symbol and Descriptions ....................................................................................................................12
Table 2 Safety Warnings ..................................................................................................................................19
Table 3 Main Parts of HSC 22 Direct Drive Model...........................................................................................22
Table 4 Main Parts of HSC 75 Direct Drive Model...........................................................................................23
Table 5 Logik 8 Control Unit.............................................................................................................................40
Table 6 Logik 8 Parameters .............................................................................................................................43
Table 7 Alarms and Warning Codes ................................................................................................................44
Table 8 HEC40 Control Unit.............................................................................................................................45
Table 9 HEC40 Screen Display .......................................................................................................................46
Table 10 HEC40 Alarms ..................................................................................................................................50
Table 11 L25S Control Unit ..............................................................................................................................51
Table 12 Warnings ...........................................................................................................................................65
Table 13 L30P Control Unit ..............................................................................................................................67
Table 14 L30P Main Screen Display ................................................................................................................68
Table 15 Main Menu Display............................................................................................................................70
Table 16 L30P Compressor Setup Menu .........................................................................................................71
Table 17 L30P Pressure Setup ........................................................................................................................71
Table 18 L30P Temperature Settings ..............................................................................................................72
Table 19 L30P Working hour parameter ..........................................................................................................72
Table 20 Alarm messages with immediate compressor shut off .....................................................................74
Table 21 Alarm Messages with Compressor Shut Off After 30 sec Unload Run ............................................75
Table 22 Maintenance Messages ....................................................................................................................75
Table 23 Warning Alarms.................................................................................................................................76
Table 24 Messages visualized into alarm list only ...........................................................................................77
Table 25 Technical Data of Compressor .........................................................................................................78
Table 26 Technical Data of HSC Series ..........................................................................................................81
Table 27 Technical Data of HSC FRECON Series ..........................................................................................82
Table 28 Technical Data of FRECON PLUS Series ........................................................................................83
Table 29 Maximum possible line length for 7 Bar ............................................................................................84
Table 30 Maximum possible line length for 10 Bar ..........................................................................................84
Table 31 Maximum possible line length for 13 Bar ..........................................................................................85
Table 32 Equivalent Pipe Length Table ...........................................................................................................91
Table 33 HSC Cable Cross Section Area ........................................................................................................92
Table 34 HSC FRECON Cable Cross Section Area ........................................................................................93
Table 35 FRECON PLUS Cable Cross Section Area ......................................................................................94
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Table 36 Troubleshooting and Solution .........................................................................................................106
Table 37 Periodic Maintenance Schedule ....................................................................................................116
Table 38 Typical Physical Properties of Smartoil...........................................................................................118
Table 39 Maintenance Records .....................................................................................................................125
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1 GENERAL
1.1 Preface
HERTZ KOMRESSOREN provide customers with quality, trust and experience service. Supplies
well designed products with long life and safe equipment.
Thank you for using HERTZ products.
This instruction manual has all the information about installation, maintenance and safety usage of
the compressor.
Please read this instruction manual carefully. Do not use the product before reading the
manual.
1.2 Precautions
Only authorized and trained personnel have to operate the compressor!
Pay attention to all the safety and operation instruction mentioned in this manual. Thus the accident
probability will be minimized and the life time of product will increase.
1.3 Copyright ©
Copyright © by HERTZ KOMPRESSOREN All rights reserved. No part of this publication may be
reproduced or distributed in any form or by any means, or stored in a data base or retrieval system,
without the prior written permission of the publisher.
1.4 Warranty and Obligation

Before the assembly, starting and maintenance of the compressor ensure that the manual is
carefully read by related persons (technicians, operator, maintenance personnel and all other users).
Since the compressor is a complicated machine; performed maintenance by unauthorized or non-

trained person will cause undesired damage and injuries and abolish all warranty conditions.
Moreover if any failure occurs for the reason below, product will be out of warranty;
Ø Making any modification on the compressor or control system without taking the approval of
HERTZ KOMPRESSOREN,
Ø Maintenance and operation made by unauthorized persons,
Ø Using spare parts that is not manufacture by HERTZ KOMPRESSOREN,
Ø Improper installation of safety and protection devices,
Ø Operating the compressor disregarding the safety and operating instruction.
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1.5 Type Approval and Original Spare Parts
HERTZ HSC – HSC FRECON / FRECON PLUS Direct Drive Series have the type of approval for all
components qualified by “EC Declaration of Conformity”.
Using spare parts without approval of HERTZ KOMPRESSOREN, reserves the right of exclusion
from liability for personal injury and material damage.
For your own health and safety use only HERTZ certificated spare parts.
1.6 Technical Service

Do not hesitate to contact our technical service for all your technical problems.
59227 Ahlen, In der Schlinge 6 / Deutschland
Telefon : +49 (2382) 889 089-0 (PBX)
Fax : +49 (2382) 889 089-22
E-Mail : info@hertz-kompressoren.de
Web : http://www.hertz-kompressoren.com/
1.7 Descriptions and Warnings

Table 1 Symbol and Descriptions
Symbol Descriptions
Indicates high risk.
˜ Indicates individual instruction about the resulting situation.
Ø Indicates general comments and lists.
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2 SAFETY
2.1 Terms of Use

Ø Ensure that the operation and maintenance of the compressor done by authorized person.
Ø Learn how to operate and work safely with the compressor.
Ø Always keep the compressor good condition.
Ø The compressor must be used for compressing air or noble gas (Helium, Argon etc.) only. Do not
use compressor with different type of gases.
0 0
Ø The compressor must be used at ambient temperatures between 0 C and +43 C . (For different
ambient temperatures, contact to the service)
Ø Any other use not as specified requires the explicit written consent from HERTZ KOMPRESSOREN.
Ø Before allowing other person to use the compressor, explain how to operate and have them read
this manual before operation.
Ø In case the directives, processes and safety regulations are not compliance; it may cause accidents,
damage and deathly injuries.
Ø If the operation of the compressor is not safe;
· Never start it.

· Notify this situation to authorized person.
· Put a warning label explaining this situation on a visible place of the compressor.
· In order to avoid the uninformed or accidentally operation of the compressor; turn off the
main circuit breaker or remove power cables.
2.2 Unauthorized Modification

Ø Do not make any modification on the machine without taking the approval of HERTZ
KOMPRESSOREN.
Ø Unauthorized modifications on the compressor may impair the function and/or safety and affect
compressor life. This will cause a disadvantage or risk for the working of the compressor, personal
injury or accidents.
In case of unauthorized modifications, HERTZ KOMPRESSORENR has the right for avoiding
terms of warranty.
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2.3 Compressed Air Line Connections
Ø In order to efficiently run the compressor; make sure that all devices and equipment you have
chosen are in conformity with the compressor’s capacity and operation pressure.
Ø Make sure that none of the air circuit equipment and connections are leaking, deliberately
misassembled and are not subjected to excessive heat variations, dust, gas, humidity etc. type of
corrosive environmental factors.
Ø Stop the compressor before removal of any connection or equipment (filter etc.) and make sure that
internal pressure is completely deflated (by checking the manometer (pressure gauge)).
Ø Keep the people and living things away from the exit of compressed air (nozzle, blow out exit etc)
and take necessary safety precautions.
Ø Do not use compressed air on anybody for any purpose (cleaning, levity etc).
Ø Do not breathe the compressed air of the compressor. Do not use it for ventilation purpose.
Ø Do not vary the pressure adjustment of safety pressure switch and safety valve. Periodically carry
out the functional checking of safety valve.
Ø Do not close the outlet valve when the compressor is running or do not start the compressor while
the outlet valve is closed. Your compressor may stop due to overpressure error.
2.4 Fire and Explosion Risk

Ø Do not allow accumulation of oil, petrol, thinner, solvent etc. inside and around the compressor.
Clean immediately if you see.
Ø In case of potential fire hazard, immediately turn off the compressor and switch off the main switch.
Take necessary precautions and remove all factors that may cause flame, spark and other fire
triggering reasons.
Ø Never allow accumulation of oil on the outer surface of compressor or within the compressor
cabinet. If necessary obtain a cleaner that may clean these accumulations. Never use inflammable
material in cleaning process.
Ø Switch off the power of the compressor in case of repair, cleaning or other treatment in the cabinet
Ø Keep the electrical and pressure circuit connections in good condition. Immediately replace the
damaged cables or hoses. Keep these connections clean and regularly check them.
Ø Ensure that there is not any loose or broken electrical cable at any connection of the compressor.
Remove this cable in case of risk of electrical accidents.
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Ø Prior to welding remove sound insulation materials.
Ø Keep a full fire extinguisher that is periodically checked near the compressor.
Ø Keep away easy flammable fatty fabric, chips, paper etc. from the compressor.
Ø Do not operate the compressor when there is not suitable ventilation.
Ø Never run the compressor if it is not manufactured specially for severe environmental conditions.
2.5 Moving Parts

Ø Do not operate the compressor while coupling and fan guards are not installed.
Ø Keep your hands, arms and clothes away from rotating parts. Wear tight clothes and cap for
necessary conditions.
Ø In order to avoid accidentally operation of the compressor by someone; before repair, maintenance
or adjustment processes remove the main power cable of the compressor from main switch or lock
the circuit breaker.
Ø Keep away all personnel away from compressor against possible splashes and explosion.
Ø If the compressor is remote controlled; ensure that remote control situation is indicated by warning
label on the compressor. Thus user near the compressor can understand the situation and stop off
the safety distance.
Ø Protect the footed floors around the compressor from oil and water to avoid slipping or falling.
Ø Provide well lighting for making the rotating and moving parts visible at the place of operation.
2.6 Hot and Sharp Surfaces

Ø Some equipments (air-end unit, radiator, separator tank, oil filter etc.) operating inside the
compressor may heat up and contacting with these surfaces cause burnings. Do not contact these
surfaces.
Ø Do not ignore that oil used by the system is getting hot during the operation.
Ø If you see any oil leakages from any place do not try to prevent this by your hand. Only stop the
compressor by pressing emergency stop button and switch off the main switch.
Ø Do not put your head, your hands or legs on the compressor for checking anything. Do not use a
stick, wire etc.
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Ø Stay away from all discharge points that have a direct air outlet from compressor. The released air
may be very hot.
Ø Wear personal protective equipment including gloves and head covering when working in, on or
around the compressor.
Ø Keep a first aid kit handy. Seek medical promptly in case of injury. Do not ignore small cuts and
burns as they may lead to infection.
2.7 Flammable and Irritating Substances

Ø Never breath the compressed air. Do not forget that, this situation can cause serious injuries and
death.
Ø Never connect the compressed air directly to the respiratory equipments and its lines.
Ø Do not discharge the compressed air into the rooms that accommodate human being.
Ø Only operate the compressor at environment with sufficient ventilation.
Ø Place the compressor away from the sandblasting furnace (pulverous), heater furnace (hot), boiler
furnace (humid), dye-chemical finish units (chemical and corrosive) and all kinds of medium that
have inflammable, explosive gases for not to make any suction.
Ø Industrial oil is used in the compressor. Avoid eye and skin contact with the oil. In case of contact,
wash the contact place with plenty of water. For lubrication specification of your compressor see the
lubrication section of this handbook.
2.8 Electrical Shock

Ø Along with the information and recommendations in this instruction manual; the compressor should
be installed in conformity to all related national and international standards. The electrical wiring
works must be performed by a qualified electrician.
Ø Ensure that the proper grounding is made and the grounding cable is connected to portion marked
with in the compressor control cubicle.
Ø Keep away your body, hand tools and electrically conductive materials from the conductive
equipment and cable connections.
Ø In case of adjustment or repair on the compressor’s electrical component; ensure that your feet are
not wet and try to stand on an insulated place such as a wooden pallet.
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Ø Try to make all kinds of repair and adjustment work with only right hand if possible. Thus, the risk of
electrical current flow through the hearth is minimized, in case of an electrical accident.
Ø Repairs and adjustment works should be done one non-conductive layer, at dry, clean, good
ventilated environments.
Ø Keep the electric box door closed. For opening it; stop the compressor and remove electrical power
connections from main circuit breaker.
Ø Check all equipment and connections again before the first start.
2.9 Check Before Starting

Ø Be sure to check the compressor before operation. Do not operate the compressor if there is
something wrong with it.
Ø Ensure all guards and shields are in place before operating the compressor. Replace any parts that
are damaged or missing.
Ø Before operating the compressor stay at the safety distance.
Ø If your compressor is big enough to accommodate persons, in case the related person / persons are
performing any work inside, inform the other personnel and keep the doors open. Prevent
accidentally running of the machine and injury of the person inside.
Ø Make sure that there is nobody inside before closing the doors.
Ø Make sure that none of the moving parts are in contact with any component.
2.10 Compressor and Around Cleaning

Ø Be sure to stop and to cut the energy of the compressor before cleaning.
Ø Keep the compressor clean and free of accumulated dirt, grease and trash to avoid a fire. Store
flammable fluids in proper containers and cabinets away from sparks and heat.
Ø Check and repair any leakage immediately. Inform the service.
2.11 Personal Protection and Safety

Business executives of the company should be very sensitive and careful to ensure that the operators of the
compressor take all personal safety precautions and they are in compliance with all related safety standards.
Ø Do not wear loose, torn or bulky clothing around the machine. that may be cause serious personal
injuries.
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Ø Use additional safety items like safety helmet, safety
goggles, gloves, etc as required.
Ø Do not operate the compressor or any equipment attached

to it while under the influence of alcohol, medication and
drugs or fatigued.
Ø Do not wear headphones to listen music or radio while

operating the compressor.
Ø Keep your hands and body away from rotating parts, such as the cooling fan or flywheel. Any
contact with rotating parts can cause severe personal injury.
Ø Do not run the compressor without safety guards. Install safety guards securely before operation.
2.12 Safety and Warning
Importance of safety is expressed as “danger-warning” under necessary conditions.
Figure 1 HSC 22-D Safety Warnings
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Figure 2 HSC 75-D Safety Warning
Table 2 Safety Warnings
Safety Warnings Description
Rotating Part!
Hot Surface!
High Voltage!
Rotational direction of Coupling!
Wear ear protector!
Read Instruction Manual!
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Pay attention to” Personal safety & protection” part before operating or working on the compressor.
Ø Keep warning and caution labels clean and free from obstruct material.
Ø Clean warning and caution labels with soap and water, then dry with a soft cloth.
Ø Replace damaged or missing warning and caution labels with new ones.
Ø If a component with warning and caution label(s) affixed is replaced with a new part, make sure the
new label(s) is (are) attached on the same location(s) as the replaced component.
Ø Mount new warning and caution labels by applying to a clean dry surface and pressing any bubbles
to the outside edge.
2.13 Suggestions
Ø Make sure that all the guards and shelters are installed after repair, maintenance or adjustment
works.
Ø After repair, maintenance and adjustment works, make sure that there is not any spare part,
cleaning material and hand tool are left inside.
Ø Make sure that none of the moving parts are in contact with any component.
Ø Do not leave unplugged electric cables.
Ø If compressor will not be used for a long time, it should be stored in a dry and warm environment.
2.14 Air filter

Ø Air filters are used for to collect air, do not use for any other purposes.
Ø Do not make any cutting and piercing on the receiver.
Ø During the maintenance avoid any impact and operation that will damage the receiver.
2.15 Safety and Protection System

Ø Motor overload shutdown
Ø Fan motor overload shutdown
Ø Phase sequence shutdown
Ø PTC for main motor
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Ø High air-end discharge pressure shutdown
Ø High discharge pressure shutdown
Ø Change seperator element indicator
Ø Air filter change warning
Ø Pressure relief valve
Ø Emergency Stop Button
Ø Service Warning System
Ø Alarm Warning System
2.16 Noise Protection

HERTZ HSC – HSC FRECON / FRECON PLUS Direct Drive Series have special sound isolation
canopy for providing the best noise protection. With these canopies noise level decreased the best
limit.
2.17 Environmental Protection

Obey local environmental disposals regulations or laws to avoid polluting the environment. Keep
away from the environmental materials that listed below.
Ø Used oil, grease and contaminated materials;
Ø Materials for cleaning;
Ø Condensation that revealed in the comp.
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3 DESIGN AND FUNCTION
3.1 General View of HSC 22 Direct Drive
Figure 3 General View of HSC 22 Direct Drive Model
Table 3 Main Parts of HSC 22 Direct Drive Model
REF PART NAME REF PART NAME
1 Control Unit 9 Thermostatic Valve

2 Air Filter 10 Oil filter
3 Intake Valve 11 Separator
4 Motor 12 Water Seperator
5 Vibration Pad 13 Fan
6 Bell Housing 14 Fan Housing
7 Air-end 15 Air outlet valve
8 Oil Tank 16 Radiator
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3.2 General View of HSC 75 Direct Drive
Figure 4 General View of HSC 75 Direct Drive Model
Table 4 Main Parts of HSC 75 Direct Drive Model
REF PART NAME REF PART NAME
1 Motor 7 Water Seperator

2 Oil Filter 8 Bell Housing
3 Radiator 9 Motor Frame
4 Air Filter 10 Fan
5 Oil Tank 11 Vibration Pad
6 Air-end 12 Fan Housing
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3.3 Operation of the Compressor
Series of HERTZ screw air compressor HSC – HSC FRECON / FRECON PLUS Direct Drive has
proven its quality and reliability over years is an heavy duty, with limited maintenance screw type air
compressor.
3.3.1 Drive and Control System

An electric motor is used to operate HERTZ HSC – HSC FRECON /FRECON PLUS Direct Drive
Series Compressors. Electric Motor provides mechanical drive to air-end unit for producing
compressed air. This system is composed chassis, air-end unit, motor, coupling and bell housings.
HERTZ HSC – HSC FRECON /FRECON PLUS compressor Series operated and controlled by
electronic control system. This control system legal rights belongs to HERTZ KOMPRESSOREN.
Figure 5 Drive System
3.3.2 Pressure System

Pressure system is composed of; air-end unit, separator tank, separator, minimum pressure valve
and oil return line (scavenge).
Do not remove any lid or part when there exists pressure inside compressor. First stop
the compressor and ensure that all pressure is discharged.
Ø Compressed air-oil mixture coming from air-end unit goes to separator tank.
Ø The separator tank decreases the oil that air carries by its structural property.
24
Figure 7 Pressure System of hsc 75 Direct Drive Model Figure 6 Pressure System of HSC 22 Direct Drive Model
25
Ø The air-oil mixture in the separator tank goes to the separator filter. The separator filter keeps the
particles by its structural property. Only air can penetrate in.
Ø During this filtering process, a small amount of oil mist becomes to liquid and drain with its gravity to
bottom of filter.
Ø The oil under separator passes through the scavenge line by the pressure difference between tank
and air-end unit is sent back to air-end unit.
Ø The minimum pressure valve on the cover of separator tank keeps the pressure at 2 - 2,5 bars when
the compressor is at load. This pressure value is necessary for oil circulation.
Ø The minimum pressure valve prevents the return of compressed air from the line to compressor
during the compressor is switched off or operating at idle. When the compressor is first started up, if
the line pressure (external pressure) is less then 4 bars, the minimum pressure valve keeps the
separator tank pressure at 4 bars until the pressure is equal to external pressure.
Ø In case of any failure and blockage there is a safety valve for preventing against excessive rise of
separator tank pressure.
0
Ø When the air-end unit's temperature reaches to 108 C for stopping the compressor, there is a
temperature sensor. By means of the data received from sensor, electronic controller unit stops the
compressor.
3.4 Intake and Control System

It provides the operation of the compressor at
adjusted pressure interval by eliminating the
hazardous dust that the compressor may absorb
from external environment. That system has two
subsystem named intake system and intake control
system.
Figure 8 FRECON 5/7 PLUS Compact Model
26
Figure 10 Intake System of HSC 75 Direct Drive Model Figure 9 Intake System of HSC 22 Direct Drive Model
27
3.4.1 Intake System
The dusts inside the air absorbed by the compressor enter everywhere that oil penetrate with their
corrosive effects and corrodes them. The life of bearings, o-rings and the gaskets are rapidly
decreased due to increased friction. In addition with the corrosive effect of dust, the blocked filters
absorb less air and the capacity of the compressor drops, operating temperature rises and this
adversely affects negatively the internal accessories of compressor and the hoses rapidly hardened,
bearings are corroded, oil is more rapidly contaminated as cooling air and intake air is limited.
Shortly, the cleaning and maintenance activities not performed on time causes energy loss (financial
loss) instead of saving.
Intake system is composed of panel filter outside of the compressor, the intake filter inside your
compressor and connection hose.
3.4.2 Intake Control System

The intake control system is composed of; intake valve, solenoid valves, control air line hoses and
safety pressure switch. In the systems with electronic controller unit or inverter, pressure sensors are
used for obtaining pressure data.
The aim of intake control system is to operate the compressor in most economic way.
Ø During the start up of compressor, the intake system keep closed and prevents
unnecessary loading and establish an impact free start up.
Ø When the demanded pressure value is reached, it closes the intake again and enables the
rotation of compressor motor by wasting minimum power. Instead of rapid start up and
stopping, only the air intake of the compressor is blocked and economic operation is
supplied.
Ø According the pressure on the utility line, the electronic controller unit or pressure switch
commands to intake valve. The intake valve closes and opens the compressor’s air intake
this way.
Ø When the compressor is stopped the pressure in the separator tank moves in the opposite
direction tries to turn the air-end in opposite direction. The intake valve at this moment
operates as a check valve and closes intake and prevents the backward rotation of air-end
and splashing of the oil backwards.
28
3.5 Cooling and Lubricating Systems
The cooling system of the compressor is composed; radiator, cooling fan, oil filter, seperator filter,
connection hoses and piping. Some models have optionally thermostatic valve.
Figure 11 Cooling and Lubricating System of HSC 22

Direct Drive Model
Figure 12 Cooling and Lubricating System of HSC 75
Direct Drive Model
29
Ø The pressure in separator tank pushes the oil to cooler, from cooler to oil filter and from there on to
the low pressure side in the air-end unit.
Ø Oil passes through oil filter before entering air-end unit and harmful particles are separated
Ø Big amount of oil injected on the rotors of inside air-end unit; this provides the sealing by getting
stuck on rotors while the rotors are compressing air. This oil at the same time lubricates the bearings
of rotors
At screw compressors oil have three basic functions:
· Acts as a cooler by absorbing the heat formed by friction of rotors and compression of air in
the air-end unit.
· Establishes sealing by forming an oil film between the stator and rotors.
· Lubricates the bearing of rotors.
Ø Air-oil mixture is injected into separator tank from air-end unit. As a result of special design of the
separator tank and by means of air flow within tank the oil particles in the air-oil mixture combine
with each other become heavy and they are thrown to the inner surface of tank. Thus, the oil does
not completely attack to the separator and it works comfortably and long.
Ø The oil mist remaining in air is kept by the filter when passing through the separator filter.
Ø The air which is free from oil passes through the after cooler and is sent to the air line.
Ø The remaining oil in the separator tank is cooled in the oil cooler and again sent to oil filter.
Separator tank have three functions:
· Making pre-oil separation process with its special design,
· Preserving the compressor oil,
· Preserving the separator filter.
30
4 Optional Cooling Systems
HERTZ KOMPRESSOREN has two type optional cooling system:
1. Water cooled system
2. Heat recovery system
4.1 Water cooled system:

Water cooled systems are cooling the oil at the oil circuit and the air at the compressed air outlet with heat
exchanger. This system is optional at HERTZ screw compressor series. These systems designed relevant to
compressor capacity with special heat exchanger for efficient system cooling.
Heat Exchanger: Cooling the oil at the oil circuit and the compressed air.
31
4.1.1 Brazed Heat Exchangers (BPHE)
The front plate of brazed heat exchangers (BPHE) is marked with an arrow. The purpose of this marker is to
indicate the front side of the BPHE and the location of the inner and outer circuits/channels. With the arrow
pointing up, the left side (port F1, F3) is the inner circuit and the right side (port F2, F4) is the outer circuit.
The outer circuit has a slightly lower pressure drop as it contains more channel. Ports F1/F2/F3/F4 are
situated on the front of the heat exchanger.
4.1.2 Construction of BPHE:

The BPHE is in principle built up by a plate package of corrugated channel plates between front and rear
cover-plate package. The cover plate packages consist of sealing plates, blind rings and cover plates.
During the vacuum-brazing process, a brazed joint is formed that every contact point between two plates.
The design creates a heat exchanger that consists of two separate circuits.
Sealing plates are used to seal off the space between the cover plate and the first and the last channel plate.
The number of cover plates varies, with the type of the compressor. Materials that used at heat exchanger of
the compressor are stainless steel and vacuum brazed with pure copper.
4.1.3 Design Conditions and Approvals:

Please check the label on the heat exchanger for detailed explanation.
BPHE’s are approved by a number of independent bodies. These are;
· Europe, Pressure Equipment Directive (PED)

· USA, Underwriters Laboratories (UL)
· Japan, The High Pressure Gas Safety Institute of Japan (KHK)
· Lloyds Register, Great Britain;
· Det Norske Veritas (DNV), Norway;
· American Bureau of Shipping (ABS), USA;
· Korean Register of Shipping (KR), Korea.
For approved unit the data on the label must not be exceeded.
32
4.1.4 Mounting:
Never expose the unit to pulsations or excessive cyclic pressure or temperature changes. It is also important
that no vibrations are transfers to the heat exchanger. If there is a risk of this, install vibration absorbers.
Also we advise to use a rubber mounting strip between the BPHE and the mounting clamp. In different
versions and locations, are available on the BPHEs as an option.
1. Supported from the bottom
2. Sheet metal bracket (rubber insert between bracket and exchanger)
3. Crossbar and bolts (rubber insert between crossbar and exchanger)
4. Equipped with mounting stud bolts on the front or back cover plate
4.1.5 Strainers
If any of the media contains particles larger than 1 mm (0.04 inch), we recommend that a strainer with a size
of 16-20 mesh (number of openings per inch) is installed before the exchanger. The particles could
otherwise block the channels, causing bad performance, increased pressure drop and risk of freezing.
4.1.6 Insulations (Optional)

Insulation for Refrigerant Applications
BPHE insulation is recommended for evaporators, condensers or district heating

applications. For refrigeration, use extruded insulation sheets. For this option
please contact HERTZ customer service.
Insulation for Heating Applications
For heating applications, various types of insulation boxes can be used. The
working temperature range defines which insulation is recommended. For this
option please contact HERTZ customer service.
33
4.1.7 Cleaning of The BPHE
Thanks to the normally very high degree of turbulence in BPHEs there is a self-cleaning effect in the
channels. However, in some applications the fouling tendency can be very high. In such cases it is always
possible to clean the exchanger by circulating a cleaning liquid. Use a tank with weak acid, 5% phosphoric
acid or, if the exchanger is frequently cleaned, 5% oxalic acid. Pump the cleaning liquid through the
exchanger. For optimum cleaning, the cleaning solution flow rate should be a minimum of 1.5 times to
normal flow rate, preferably in a back flush mode. After use, do not forget to rinse the heat exchanger
carefully with clean water. A solution of 1-2% sodium hydroxide (NaOH) or sodium bicarbonate (NaHCO 3)
before the last rinse ensures that all acid is neutralized. Clean at regular intervals. For further information
about cleaning of the BPHE please consult HERTZ technical service.
4.1.8 Storage
BPHEs are to be stored dry. The temperature should not below 17°C and not over 50°C.
4.1.9 Compressor Cooling Water Type:

Water used for system cooling must be non precipitated, relevant pH value and separated from mud or
particles that clogged pipes. Following table shows the chemical values of relevant compressor cooling
water type. Do not use sea water for cooling water. Sea water have harmful effects and damage to the
compressor parts especially heat exchanger. In case of using sea water, HERTZ KOMPRESSOREN has the
right for avoiding terms of warranty.
Corrosion Resistance of Water Composition:
pH mg/l ≥6
Chloride (Cl)* mg/l ≤300
Free Chlorine (Cl2) mg/l <1
Total Hardness mg/l 4-8,5
Water Pollution NTU 1
Total Molten content mg/l 15
Organic substance content mg/l 0,1
Living organism % 0
* Acceptable temperature values for amount of Chloride

0 0 0 0
Chloride Content 60 C 80 C 120 C 130 C
= 10 ppm +
= 25 ppm + +
= 50 ppm + +
= 80 ppm + + +
= 150 ppm + +
= 300 ppm +
34
Besides at low temperatures cooling water which stored outside the facilities can be freeze. For protecting
cooling water to be frozen, use anti-freeze or internal storage heater into the tank.
4.1.10 Heat Exchanger Maintenance:
· Always mount the heat exchanger vertical position.

· Pay attention to liquid inlet placed at the heat exchanger be opposite sided.
· For protecting heat exchanger for clogging, place filter which keeping particles larger than 1mm, to
the cold water inlet.
· When heat exchanger performance decreases; clean the heat exchanger with non-flammable
cleaner (detergent or weak acid) opposite circulation to the normal flow direction. If necessary
remove the heat exchanger. After cleaning heat exchanger must be rinse with water.
COMPRESSOR
PIPE DIAMETER A B C D E F H
MODEL
F1 F2
Air Cooled F1 F2 F3 F4 F1 / F4 F2 / F3
F4 F3
HSC 132
2 ½” 2” 2” 2 ½” 374 364 284,5 274,5 56,1 80,2 35 25
HSC FRECON 132
HSC 160
2 ½” 2” 2” 2 ½” 374 364 284,5 274,5 56,1 80,2 35 25
HSC FRECON 160
HSC 200
2 ½” 2” 2” 2 ½” 374 364 284,5 274,5 56,1 101,6 35 25
HSC FRECON 200
HSC 250
2 ½” 2” 2” 2 ½” 374 364 284,5 274,5 56,1 123 35 25
HSC FRECON 250
HSC 315
2 ½” 2” 2” 2 ½” 374 364 284,5 274,5 56,1 165,8 35 25
HSC FRECON 315
35
4.1.11 Technical Data of Heat Exchanger:
PIPE
COMPRESSOR MODEL A B C D E F G H
DIAMETER
Air Cooled
HSC 15
HSC 18
HSC FRECON 15B
1 ¼” 287 117 234 63 29 62,9 6 24
HSC FRECON 18
HSC FRECON 22
HSC FRECON 25
HSC 22
HSC 30
HSC 30B 1 ¼” 287 117 234 63 29 74,6 6 24
HSC FRECON 30
HSC FRECON 37
HSC 45B
HSC 45
HSC FRECON 45 1 ¼” 287 117 234 63 29 98 6 24
HSC 50
HSC FRECON 50
HSC 75
HSC FRECON 75
2” 393 243 324 174 56,1 125 3 25
HSC 75B
HSC FRECON 75B
HSC 110
2” 393 243 324 174 56,1 195,2 3 25
HSC FRECON 110
Oil Cooled
HSC 15
HSC 18
HSC FRECON 15B
1 ¼” 287 117 234 63 29 62,9 6 24
HSC FRECON 18
HSC FRECON 22
HSC FRECON 25
HSC 22
HSC 30
HSC 30B 1 ¼” 376 119 320 63 47 48,8 6 24
HSC FRECON 30
HSC FRECON 37
HSC 45B
1 ¼” 376 119 320 63 47 71,2 6 24
HSC 45
HSC FRECON 45
HSC 50
HSC FRECON 50
HSC 75 1 ¼” 376 119 320 63 47 93,6 6 24
HSC FRECON 75
HSC 75B
HSC FRECON 75B
HSC 110
1 ¼” 376 119 320 63 47 138,4 6 24
HSC FRECON 110
HSC 132
1 ¼” 376 119 320 63 47 138,4 6 24
HSC FRECON 132
HSC 160
1 ¼” 376 119 320 63 47 160,8 6 24
HSC FRECON 160
HSC 200
2” 525 243 456 174 56,1 101,6 4 25
HSC FRECON 200
HSC 250
2” 525 243 456 174 56,1 124,5 4 25
HSC FRECON 250
HSC 315
2 ½” 525 243 430 148 56,1 184,8 3 35
HSC FRECON 315
36
4.2 Heat Recovery Systems
Heat Recovery at the Air Cooled Screw Compressors
• At air cooled screw compressors, air used for cooling oil and compressed air at the system.
0
• While this system is working cooling air at the compressor, temperature increases up to +40-50 C
of ambient temperature and exhausted.
Heat Recovery at the Water Cooled Screw Compressors

• At water cooled compressors (reciprocated, screw etc.), water cooling compressor parts and
pressured liquid gases (Air, N2, CO2, CH4 etc.) with heat exchanger.
• Obtained heated water used for ambient heating, industrial cleaning, boiler embodiment and
veneering.
Heat recovery system is optional at HERTZ screw compressor series. These systems designed relevant to
compressor capacity with special heat exchanger and special heat recovery line for efficient system cooling
and heat recovery.
a- Ambient Heating:
The easiest way of heat recovery at oil or liquid cooled type screw compressors is using the heated, cooling
air by compressor. At the same time heat transferred to the place of use by air line system.
b- Utility Water Heating:

Adding heat exchanger to the oil circuit, air cooled screw compressor producing heated water for any
purposes. For this heat exchanger plates or safe type heat exchanger can be used. This usage can be
changed where heated water using for bath, wash water, room heating, manufacture or cleaning.
37
Important notice about the usage of heat exchanger at the heat recovery system:
· Always mount the heat exchanger vertical position.

· Pay attention to liquid inlet placed at the heat exchanger be opposite sided.
· For protecting heat exchanger for clogging, place filter which keeping particles larger than 1mm, to
the cold water inlet.
· When heat exchanger performance decreases; clean the heat exchanger with non-flammable
cleaner (detergent or weak acid) opposite circulation to the normal flow direction. If necessary
remove the heat exchanger. After cleaning heat exchanger must be rinse with water.
38
4.2.1 Technical Data of Heat Recovery Model:
MODEL PIPE DIAMETER A B C D E F G H
Heat Recovery
HSC 15B
HSC 18
HSC 22
HSC FRECON 15B 1 ¼” 376 119 320 63 47 93,6 6 24
HSC FRECON 18
HSC FRECON 22
HSC FRECON 25
HSC 30
HSC 30B
HSC 37 1 ¼” 376 119 320 63 47 138,4 6 24
HSC FRECON 30
HSC FRECON 37
HSC 45
HSC 45B
HSC 55
HSC FRECON 45 1 ¼” 376 119 320 63 47 160,8 6 24
HSC FRECON 50
HSC FRECON 55
HSC FRECON 60
HSC 75
HSC FRECON 75
1 ¼” 376 119 320 63 47 250,4 6 24
HSC 75B
HSC FRECON 75B
HSC 90
HSC 110
HSC FRECON 90 2” 525 243 456 174 56,1 101,6 4 25
HSC FRECON 110
HSC FRECON 125
HSC 132
2” 525 243 456 174 56,1 101,6 4 25
HSC FRECON 132
HSC 160
2” 525 243 456 174 56,1 124,5 4 25
HSC FRECON 160
HSC 200
2” 525 243 456 174 56,1 147,4 4 25
HSC FRECON 200
HSC 250
2” 525 243 456 174 56,1 193,2 4 25
HSC FRECON 250
HSC 315
2 ½” 525 243 430 148 56,1 282,4 3 35
HSC FRECON 315
39
5 Control Units
5.1 Logik 8 Control Unit
Table 5 Logik 8 Control Unit
Ref Description
1 Info Display
2 Warning LED
3 Start
4 Stop
5 Reset
6 Alarm
Figure 13 Logik 8 Control Unit
5.1.1 Buttons
Start : Runs compressor.
Stop : Stops compressor.
Reset : Shows working temperature, working hours, resets alarms, verify the modifications of set
values.
X10 LED : Multiplicative factor x10.

X100 LED : Multiplicative factor x100.
5.1.2 Compressor Operation
Ø When compressor connected the power supply, the display shows
Ø By pushing the button, the compressor starts and screen shows working pressure
Ø In case the pressure reaches the set value, pressure switch gets open and the screen shows the
blinking message during the counting of the unload stop timer, p15 (unload running time).
40
If the pressure switch is still open at the end of the countdown, message comes to be fixed . If the
pressure switch closes during the countdown the unload stop timer (p15) reset.
Ø By pushing the button the compressor stops and the screen shows .
Ø Every time the compressor switches from “ON” into “OFF” by the button, the load solenoid valve
goes for 30 sec. and the screen shows blinking message. While the message is blinking it
is possible to restart the compressor by pushing button. After 30 sec. compressor switching Off
and screen message come to fixed. The multiplicative factor LED x10 starts flashing and the timer
sets On parameter (P17) starts. During the countdown, restart is not possible by pushing .
When the timer (P17) is elapsed, LED “x10” switches off.
Ø About the compressor alarm information, on the screen related alarm code shown.
When seeing display advance via buttons on the right , press simultaneously to the frame buttons.
First press left hand side button simultaneously press the other one.
When seeing display advance via buttons on the right press one after another.
After pressing the mentioned buttons, compare the display with the manual to verify. So you can advance
step by step. Also not to confuse step number is written on the left side of the display.
5.1.3 Maintenance Counter
When compressor is running, pushing shortly, the display shows maintenance timers.
1 (Working Pressure)
2 (Working Temperature)
3 Hours to the next air filter change.
4 Hours to the next oil filter change.
5 Hours to the next seperator filter change.
41
6 Hours to the next oil change.
7 Check compressor.
8 (Running Screen)
If the number to be displayed have more than 3 digits or 2 digits with negative (-) sign, the multiplicative
factor LED “x10” or “x100” is emitting. For example; 1800 hour shown on the display and “x10”
LED blinking. If the maintenance hours passed, display shows passed hours with negative digits.
(If x10 LED blinking, this means maintenance passed 10 hours.) No buttons pushed for a minute
display goes main screen automatically.
5.1.4 Working Hour Counters
When the compressor is running, push buttons. The display shows working hours.
1- (Working Pressure)
2- (Total Working Hours)
3- (Load Working Hours)
4- (Running Screen)
42
5.1.5 Compressor Parameters and Values
Table 6 Logik 8 Parameters
CODE DESCRIPTION SET VALUE
Pressure Control
0
(0 = Transducer, 1 = Pressure Switch)
Top Range Pressure Transducer 15 Bar
High Pressure Alarm 8,8 – 11 – 14,3 Bar
Stop Pressure 7,5 – 10 – 13 Bar

Start Pressure 6,5 – 9 – 12 Bar
Offset Pressure Transducer 0

0
Max. Temperature Set 110 C
0
High Temperature Alarm Set 105 C
0
Forewarning High Temperature Set 100 C
0
Low Temperature Set 0 C
0
Temperature Sensor Offset 0 C
Star Timer 5 sec
Star/Delta Switching Timer 50 msec
Load Delay Timer 2 sec

Unload Stop Timer 2 min
Unload Stop Timer Variable 0
Stop Timer 30 sec
Air Filter Change Time 2000 h
Oil Filter Change Time 2000 h
Seperator Change Time 4000 h
Oil Change Time 2000 h
Check Compressor 2000 h
Starts / Hours Allowed to the Motor 6
Low Voltage Alarm 1
RL5 Set Value 0
0
Fan On (RL5) 85 C
0
Delta T Fan Off (RL5) 10 C
43
Attention : P18-P22 countdown identify the motor running time, when the countdown is elapsed the timer will go on as negative
counting.
5.1.6 Alarm Code Description of Compressor

Table 7 Alarms and Warning Codes
CODE DESCRIPTION
ALARMS
Data Fault (Loading Factory Defaults)
Phase Fault
Main Motor Overloaded
High Working Temperature
Forewarning high temperature
Temperature Sensor is defective

Low Temperature (Ambient temperature less than
value)
Low Power Supply
Compressor will be running load/unload without
stopping (Within 1 hour reached set value)

Security Pressure Switch opened
Pressure over set P03
Pressure Transducer / Pressure Switch Failure
Emergency Stop Button Pushed
WARNINGS
Change Air Filter
Change Oil Filter
Change Seperator
Change Oil
(Fixed) Compressor stopped / Stand-by
(Blinking) Compressor waiting for stop timer
For resetting troubleshooting or warning alarm push button.
44
5.2 HEC 40 Control Unit
Figure 14 HEC 40 Control Unit
Table 8 HEC40 Control Unit
BUTTON DESCRIPTION FUNCTION
Displays next parameter,
MENU Resets faults,
Select/Save adjusted value.
Starts the compressor,

RUN
Increase the value.
Stops the compressor,

STOP
Decrease the value.
45
5.2.1 HEC 40 Display Navigation
Usually the upper display shows the pressure-1 value or the pressure switch-1 position. The lower display
shows the temperature-1. Other values are scrolled by pressing the MENU button. For better clarity,
the upper display will show the parameter name and the lower display will show the parameter value. Some
parameters are longer than 1 display. For these parameters, when MENU button is pressed the
parameter name appears on the upper display. When MENU button is released the parameter value is
shown on both displays.
In the occurrence of a fault condition, the fault code will appear on the upper display.
5.2.2 HEC40 Screen Display

Table 9 HEC40 Screen Display
MESSAGE DESCRIPTION MODE
bar
Stop pressure and working pressure set value Display
set
FrQ Main Frequency Display
L12 L1-L2 phase to phase voltage Display
SHA Hours remaining to service A Display / Program / Alarm
SHB Hours remaining to service B Display / Program / Alarm
SHC Hours remaining to service C Display / Program / Alarm
46
SHD Hours remaining to service D Display / Program / Alarm
SHE Hours remaining to service E Display / Program / Alarm
R-H Total running hours (on load + off load) Display
L-H Total load running hours (LOAD contactor active) Display
o/o Load hours / total running hours percentages Display
E-t Motor PTC value or switch mode Display
t-2 Number 2 temperature sensor data or switch mode Display
d-p Differential Pressure Display
n-- Remaining starts for the last hour Display
rEL Software version Display
n-C Switch off mode Display
N-O Switch on mode Display
SEP Waiting for seperator filter pressure drop Display
STP Remote stop mode Display
RUN Remote start mode Display
47
aL1 Alarm code 01 Display
a99 Alarm code 99 Display
aH9 Alarm History, 9 th Alarm Display
p99 Program parameter 99 Program
usr Enter Password Program
seL Select Parameter Program
5.2.3 HEC 40 Operation Mode
5.2.3.1 Selecting Operating Modes

At power-up, the unit will turn all lights on for 3 seconds in order to allow lamp check. Then it goes in the
STOP mode and the stop led turns on. The compressor may be run through Remote Start signal (upper
display shows rUn for 5 seconds) or by pressing the RUN button. If safety timer has not elapsed, the
run led will flash until expiration of the timer. Then if the pressure is below the start pressure limit then the
compressor will run.
In the occurrence of an alarm the compressor stops immediately and the upper display shows the
alarm code. A comprehensive list of alarm codes is given in chapter 3.6.2.4.
The compressor may be stopped with Remote Stop signal (upper display shows StP for 5 seconds) or
the STOP button.
5.2.3.2 Compressor Stop Procedure

STOP LED starts flashing. If the compressor is loaded, then the LOAD relay will release and the compressor
continues to run during safety timer or unload timer (whichever is longer). At this step, operation may be
resumed by pressing the RUN button. If STOP button is pressed during compressor operating, it
will immediately stops. The stop LED flashes until the compressor comes to complete stop.
48
When STOP button is pressed, if the compressor is running unloaded, then it will continue to
run until expiration of unload timer. The compressor may be immediately stopped by pressing
again the STOP button.
5.2.3.3 Compressor Start Procedure

If mains phase voltages and frequency are between preset limits and the phase order is correct then
POWER led will turn on. The compressor may run only when the power led is on. Otherwise it cannot run.
The Run mode of operation is selected by pressing the RUN button or by sending REMOTE
START/STOP signal (if enabled). At this position, when the pressure falls below Start Pressure (or pressure
switch closes) the unit decides to run the compressor.
Before running the compressor the STAR relay output becomes active. After Delay Between Relays Timer
LINE relay will be activated. Thus the motor starts in star mode. After Star Timer the STAR relay opens and
after Star/Delta Transition Timer the DELTA relay operates. After Timer before Loading the LOAD relay
operates and the compressor starts producing compressed air.
5.2.3.4 Compressor Unloading and Reloading

When the pressure reaches Stop Pressure (or pressure switch opens) then the LOAD relay opens and the
compressor runs unloaded during Unload Timer. If the pressure falls below P05 Start Pressure before the
expiration of the timer, then the LOAD relay energizes again.
5.2.3.5 Compressor Stopping and Restarting

If the pressure stays over the Start Pressure limit (or pressure switch opened) during Unload Timer, then the
DELTA relay will release. After Delay between Relays timer, the LINE relay releases. In this situation, the
RUN led starts flashing. The compressor cannot run again before the expiration of Safety Timer. The
maximum number of starts that the compressor may perform in one hour is adjusted with Maximum Starts
per Hour parameter. If the maximum start count is reached, then the compressor stopping is disabled and it
will continue to run unloaded until the end of 1 hour period.
5.2.4 Alarms and Warnings

Abnormal situations in the compressor are evaluated under 3 different categories as alarms, warnings and
service requests. Warnings are lowest level fault conditions and generate only visual warning, not affecting
the compressor operation. Alarms are highest level fault conditions and cause the compressor to stop
immediately, the alarm relay to become active (if enabled by programming) and visual warning to occur. If
any fault condition occurs, the fault code will appear on the upper display and the related fault category led
turns on. (warning, alarm or service)Alarms and warnings may be reset by pressing the MENU button.
The EMERGENCY STOP alarm cannot be reset by pressing buttons, the alarm signal must be removed.
Service warnings may affect the compressor operation depending on the amount exceeding the
service period.
49
Table 10 HEC40 Alarms
SYMBOL CODE DESCRIPTION FAILURE TYPE
AL1 01 Security Pressure Switch Opened ALARM

AL2 02 Outlet Air Pressure Sensor-1 High Pressure ALARM
AL3 03 Outlet Air Pressure Sensor -1 Sensor Fail ALARM
AL4 04 Outlet Air Temperature Sensor -1 High Temperature Alarm ALARM
AL5 05 Outlet Air Temperature Sensor -1 High Temperature Warning WARNING
AL6 06 Outlet Air Temperature Sensor -1 Sensor Fail ALARM
AL7 07 Outlet Air Temperature Sensor -1 Low Temperature ALARM
AL8 08 Fan Motor High Temperature ALARM
AL9 09 Motor PTC High Temperature ALARM
A10 10 Voltage Unbalance ALARM
A11 11 High Voltage ALARM
A12 12 Low Voltage ALARM
A13 13 High Frequency ALARM
A14 14 Low Frequency ALARM
A15 15 Phase Sequence Fail ALARM
A16 16 Air Filter Clogged WARNING
A17 17 Maximum starts per hour Exceeded WARNING
A18 18 Emergency Stop ALARM
A19 19 Internal Warning WARNING
A20 20 P1-P2 Pressure Difference ALARM
A21 21 Pressure Sensor-2 High Pressure ALARM
A22 22 Pressure-2 Sensor Fail ALARM
A23 23 High Temperature-2 / Delta (tS2-tS1) ALARM
A24 24 Temperature-2 Sensor Fail ALARM
A25 25 Low Temperature-2 ALARM
A26 26 Separator filter differential pressure switch opened. WARNING
A27 27 Delta Temperature (T2-T1) Warning WARNING
A28 28 Main Motor Thermal ALARM
A29 29 Pressure-2 Sensor-Low Pressure Alarm ALARM
SHA 100 Service A Period Elapsed. SERVICE
SHb 101 Service B Period Elapsed. SERVICE
SHC 102 Service C Period Elapsed. SERVICE
SHd 103 Service D Period Elapsed. SERVICE
SHE 104 Service E Period Elapsed. SERVICE
Stp 200 Remote Stop -
50
5.2.5 Alarm History
Controller keeps last 9 Alarms occurred in its memory and user may check this list any time. Each new alarm
added to first position of this list which means Alarm list is stored in a permanent memory. So it does not
disappear during power off. An alarm is added to this list if it is different from last alarm and compressor runs
more than 6 minutes after last alarm.
5.3 L25S Control Unit
Figure 15 L25S Control Unit
Table 11 L25S Control Unit
Ref Description
1 Info Display
2 Alarm / Warning LED
3 Start
4 Stop
5 Enter
6 Down
7 Up
51
5.3.1 Buttons
Start: Runs compressor.
Stop: Stops compressor.
Up: Increase parameter values and moves up among parameters.
Down: Decrease parameter values and moves down among parameters.
Enter: Approves the values to be adjusted and erases the alarms.
Warning LED: Shows running and failure positions of compressor.
Info Display: While running routinely on first row, working

pressure and air-end temperature on second row, current
position (load, unload, stand-by).
5.3.2 Using Control Unit
When you see display advance by pressing the buttons on right hand press attached buttons
simultaneously.
Press simultaneously.
Press one after other.
To be sure compare the display with manual so you can advance step by step. Also not to be confused step number is
written on the left side of display.
5.3.2.1 User Parameter Settings and Service Hours Counter
Pressed
No. Screen Display Description
Button
52
Pressed
No. Screen Display Description
Button
53
Pressed
No. Display Screen Description
Button
5.3.2.2 Maintenance Hours
Pressed
Button
3 Air Filter Change Counter
4 Oil Filter Change Counter
54
Pressed
Button
5 Separator Filter Change Counter
6 Oil Change Counter
7 Compressor Control Counter
8 Bear Lubricating Counter
5.3.2.3 Checking Hours and Information
Pressed
Button
55
Pressed
Button
2 Total Running Hours
3 Load Running Hours
4 Onload / Total working hours rate
5 Start per hour
6 Flow Rate
Controller Unit Software release

7
number
56
Pressed
Button
5.3.2.4 Alarm History
Pressed
Button
Last 20 alarms can be check on tis

menu. Last alarm showing first,
1 oldest alarm showing last. Thus
the major reasons of failures can
be understand.
2 Last Alarm
If there are not 20 alarms in, it

3 goes back to menu display.
57
5.3.2.5 Compressor Configuration Settings
Pressed
Button
58
Pressed
Button
5.3.2.6 Selection of Current Temperature, Pressure Units and Language
Pressed
Button
Factory setting is (ºC); press down

3
button to change (ºF)
Verify with selection enter

4 accepted and it goes next step
59
Pressed
Button
Factory setting is BAR; press

5
down button to change PSI
Verify with selection enter

6 accepted and it goes next step
Language chosen with up or down

buttons. (Italian, English, French,
7 German, Spanish, Portuguese,
Turkish and Russian can be
selected.)
Tuşlara basılarak tarih ve zaman

ayarı yapılır ve onay tuşuna
8
basılarak bir sonraki ayara geçilir.
Change date and time up or down

9 buttons.
5.3.2.7 Entering Parameter Password
Pressed
Button
First press down and up then

simultaneously press to enter
1 the menu where access
password is asked. For user
choose the first password level.
60
Pressed
Button
Note: In any step of the menu, if press for five (5) second it goes back to main menu. Also if no button
pressed for two (2) minutes it goes back to main menu.
5.3.2.8 Parameter List (Customer Level)
61
Wt6: Timer on RL6
Wt7: Timer off RL6
Total Hours: Working hours of main motor.
Load Hours: Working hours of solenoid valve "on".
% Working HRS: Load / Total hours.
Starts per hour: Motor start counter of previous hour.
Flow Rate: Flow rate.
SW Release: Number of software release.
Ø Restart (MAN: Manual restart / AUTO: Auto restart)
In case of power supply lack the compressor will restart automatically or manually. Not advised users that
have voltage problems.
Ø Phase Check (YES: Active / NO: Deactivate)
If phase check deactivate, any problem that happen in phases can damage motor. The phases controller
unit deactivated if select "no" (This option is only for service using) If you want to use this option please
inform the service otherwise your product will be out of warranty.
62
Ø Low Voltage (YES: Active / NO: Deactivate)
This option for controlling the controller unit supply voltage. If voltage increase or decrease in any reason,
controller unit shows an alarm and inform the user.
Ø Serial Nr.
The serial number of compressor saved here.
Set the automatic start and stop of the compressor. On the second row the LCD visualizes the message
"OFF-ON" by the button up and/or down select.
OFF: If you need to start and stop the compressor by the relevant buttons; confirming this selection by the
button the LCD shift back to the message "clock timer".
ON: If you need to start and stop the compressor operated by timer; confirming this selection byy the button
the LCD visualized the message: DAY1 (1 means Monday and 7 Sunday)
By the buttons up and/or down select the day and confirm it by ; on the second row LCD visualizes the
message
1 ON 00:00 – OFF 00:00
With the 1st ON hour (hour and minute) blinking: Set it by the button up and/or down; confirming it by ,
the first OFF hour starts blinking and it get automatically the data set on the first ON hours and so on till the
last OFF hour (for every day of the week three on/off selections are available). Confirming the last off hour of
the day selected, the LCD visualizes the request to SET THE NEXT DAY; repeat the same procedure for all
7 days of the week. If you need to copy the setting of the previous day, after you have confirmed the day,
push in sequence the buttons and . If you need cancel the setting after the day has been
confirmed, push in sequence the buttons and . After the last OFF hour of the 7th day has been
confirmed, the LCD visualized the following message “DLS TIME: NO- YES” ( Default YES.)
YES: The summer changes into DLS time the last Sunday on March and October, at 2:00 am in March, at
3:00 am in October.
NO: The change summer / DLS Time is not operated.
· The setting range of each hour is between 00:00 to 23:59.
63
· If the 3. OFF hour goes over 23:59, the setting shift to the next day and it's indicated on the upper
row where the message change from “DAY1” change into “DAY1-2” .
· If the setting of “OFF” hour is the same of previous "ON" hour, this setting is not taken into
consideration.
EXAMPLE:
A) Set the hours on three levels
1 ON 07:30 – OFF 12:30 - 2 ON 13:30 – OFF 17:30 - 3 ON 18:30 – OFF 23:30
B) Set the hours on two levels
C) Set the hours on one level
In case the compressor stops by timer, it's possible to force starting by pushing the start button for 3
seconds.
5.3.2.9 Warning Alarms and Failure Messages

When you see failure message on display press to reset.
Compressor is ready to run.
Compressor is loaded.
Compressor is unloaded.
Compressor stopped automatically.
64
5.3.2.10 Alarms with Immediate Compressor Shut Off
Table 12 Warnings
Alarm Code Screen Display Description
Alarms with Immediate Compressor Shut Off

AL01 Emergency Stop Emergency stop button opened.
AL02 Motor Overload Thermal motor opened.
AL03 Fan Overload Thermal fan opened.
AL04 No Phase One or more phases are missed longer than 300 msec.
AL05 Wrong Phase Phase inverted.
AL07 Input Power Fault All digital inputs opened.
AL11 High Pressure Working pressure over set.
AL12 Temp. Probe Failure Air-end temperature probe failure.
AL13 High Air-End Temp. Air-end temperature over set.
AL14 Low Air-End Temp. Air-end temperature probe lower than set.
AL18 Power Fault In case of power off and compressor set as manual restart.
AL19 Controller Failure The controller is not working properly.
AL20 PTC Motor Motor winding temperature over set.
AL21 Security Press. Switch Security pressure switch opened..
AL22 Input IN7 Open Input 7 opened.
AL25 Separator Filter Separator filter differential pressure switch opened.

Alarms with Compressor Shut Off After 30 Seconds Unload Run
AL26 Press. Transd. Failure Pressure transducer failure.
AL28 Low Voltage Check the power supply.
Timer CAF elapsed; alarm detected only if the parameter Safety is
AL29 Security
set YES.
AL30 High Air-End Temp. Air-end temperature over set.
Warnings
AL35 Setting Data Failure Default data loaded.
AL36 Air Filter Air filter pressure switch close.
AL39 Low Voltage Check the power supply.
AL40 High Voltage Check the power supply.
65
Alarm Code Screen Display Description
Take power off and on again to the controller; if the fault goes on,
AL41 Clock Failure
contact service.
AL42 RS232 Failure Communication interrupted.
AL43 MAX. Starts/hour Starts/hour has reached the value set in parameter Starts/hour.
Maintenance Messages
AL50 Change Air Filter Counter of the timer set into menu 6 parameter CAF elapsed.
AL51 Change Oil Filter Counter of the timer set into menu 6 parameter COF elapsed.
AL52 Change Sep. Filter Counter of the timer set into menu 6 parameter CSF elapsed.
AL53 Change Oil Counter of the timer set into menu 6 parameter C-- elapsed.
AL54 Check Compressor Counter of the timer set into menu 6 parameter C-h elapsed.
AL55 Bearing Lubricate Bearing Lubricate period.
66
5.4 L30P Control Unit
Figure 16 L30P Control Unit
Table 13 L30P Control Unit
Ref Description
1 Alarm
2 Maintenance Time Warnings
3 Working Hours
4 Start
5 Stop
6 Reset
7 Function Buttons
67
5.4.1 Main Screen Display
Figure 17 L30P Main Screen Display
Table 14 L30P Main Screen Display
Ref Description
Compressor on (blinking if the compressor is going to stop or run; it's not visualize
1
if the compressor is off)
2 Compressor load
3 Working Pressure
4 Pressure Unit (bar/PSI)
5 Stop Pressure
5.1 Start Pressure
6 Set Pressure
8 Fan on
9 Air-end Temperature
0 0
10 Temperature Unit ( C / F)
14 Remote control and multiunit operation
15 Wireless Connection
16 Area of the data from the inverter
17 Pressure Levels
18 M/S working
68
In case of alarm, the area with inverter data is changed into the indication of the alarm (message and
eventual symbol) and the red light on the left side of the LCD lightens.
NOTE: Changing start-stop-set pressure: Push the button (SEL) to select the data to change; push the
button F2 (CHANGE) to enable the modification. At this time change the value by the buttons F1 and F2 and
confirm by F3 (CHANGE). In anytime shift back to the main visualization by the button F4 (ESC).
5.4.2 Control Unit Info Display
· Main Menu
From the main visualization, pushing F3 enter into the main menu visualizing all the menu below
Flow bar indicating the end of menu or

parameters. Through the buttons F1 and F2
flow up/down all the menu; by F3 enter into
each submenu; by F4 shift back to the
previous visualization.
The Logik 30-P controller is provided with 3 password levels. (Level 1, Level 2, Level 3)
Menu and parameters under password are visualized till the proper code is loaded.
69
Table 15 Main Menu Display
Ref Description
1 Password
2 Visualization Setup
3 Compressor Setup
4 Compressor Data
5 Pressures
6 Temperatures
8 Working Timer
9 Maintenance
10 Working Hours
11 Alarms
12 Reset
13 Weekly Timer
14 Drive
· Password
Password levels selected by F1 and F2 buttons and entered by F3 button.
First select the password level you need to enter by the

buttons F1 and F2; enable the enter or modification by
the buttons F3 and F4, select each character by the
buttons F1 and F2 and shift to the next by F3. Once the
last character has been selected, push the button F3
and the password level selected will be enabled. Once
the password level is enabled, the LCD visualize the
main menu on “Visualization setup”. In case you enter a
wrong password code, the LCD visualizes the message
“PASSWORD WRONG” and shift back to the previous
visualization.
· Visualization Setup
This menu (available without password) allows to set:

language, scale of pressures and temperatures, LCD
contrast, date and time, automatic DLS/Summer time.
Once the data to change has been selected by F1 and
F2, push F3 to enable the modification. The information
on the bottom of the LCD, over each button, indicate
the possible functions.
70
· Compressor Setup
This menu allows to set the compressor operation and enable the alarms and warnings.
Table 16 L30P Compressor Setup Menu
COMPRESSOR SETTINGS
Parameter Description Content Value Set Password
S01 *Restart Aut = Automatic / Man = Manual Auto/Man Man 1-2-3

YES= Control Phase enabled
S04 Control Phase YES/NO YES 1-2-3
NO= Control phase disabled
YES=Low tension alarm and warning enabled
S06 Low Voltage YES/NO YES 1-2-3
NO= Low tension alarm and warning disabled
* Manual: in case of black out, the compressor doesn't restart automatically and the LCD visualizes the message "POWER OFF".
Automatic: in case of black out, once the power comes again, the controller restart automatically with a delay time set on Wt5; during Wt5 the LCD
visualizes the message WAIT.
The modification of the default data is recorded into the alarms buffer and it's cancelled only by General Resetting.
· Pressure
Menu pertinent to all pressure parameters. Enter into the menu by F3 (ENTER) and select the parameters
paying attention to the different password levels. It’s possible to flow up/down all the parameter by F1 and F2
and enable the setting by F3 (ENTER); for each parameter it’s possible to change the value by F1 and F2
and confirm by F3 (ENTER).
Table 17 L30P Pressure Setup
PRESSURE
WP3 P. Stop Stop Auto/Man 10 bar 1-2-3

WPS Set pressure Working Pressure set value YES/NO 9,0 bar 1-2-3
WP4 P. Start Start Pressure YES/NO 8,5 bar 1-2-3
· Temperature
Into this menu is possible to set all the temperature parameters. Enter into the menu by F3 (ENTER) and
select the parameters paying attention to the different password levels. It’s possible to flow up/down all the
parameter by F1 and F2 and enable the setting by F3 (ENTER); for each parameter it’s possible to change
the value by F1 and F2 and confirm by F3 (ENTER).
71
Table 18 L30P Temperature Settings
TEMPERATURE

0
WT5 Low Temperature Low air-end temperature -10 ÷ +15 0 C 1-2-3
· Working Hour
Into this menu it’s possible to set the timer for the compressor operation.
Table 19 L30P Working hour parameter
WORKING HOUR
Parameter Description Value Set Password
Wt6 On RL6 1 ÷ 10 sec 2 sec 1-2-3

Wt7 Off RL6 1 ÷ 10 min 3 min 1-2-3
· Maintenance
Into this menu there are two submenu selectable by F1 and F2; by the button F3 (ENTER) into the following
submenu:
1- Maintenance Timer (password level 1-2-3)

2- Maintenance List (password level 1-2-3)
Maintenance Timer
Into this menu it’s possible to set and reset all maintenance timer.
Selecting the rows by F1 and F2 and confirming by F3
(ENTER) the maintenance SET and RESET is
enabled as shown in the following example about the
timer to change the air filter.
CAF = Change Air Filter

COF = Change Oil Filter
CSF = Change Seperator Filter
C-- = Change Oil
C-h = Check Compressor
The following example is valid for all the other maintenance timer into this menu.
72
The functions on the bottom of LCD are always joined to
the buttons F1 - F2 - F3 - F4. Shift back to the previous
visualization by function ESC.
Maintenance List
Into this submenu are recorded the last 20 reset of

maintenance timer, indicating both day and time of the
reset. By F1 and F2 flow up/down the records into this
submenu. Shift back to previous visualization by the
function ESC (F4).
· Working Hours
This menu (Password level 1-2-3) visualizes the counter of
the working hours, load working hours, percentage of
working hours and number of starts/hour. The working hours
are the addiction of ON hours of the line contactor (RL1).
The load hours are the addiction of the ON hours of the load
solenoid valve (RL4). The working % is got by dividing the
ON hours of RL4 to the ON hours of RL1 in the last 100
working hours of RL1: the percentage is updated every 5
minutes. Starts/hours are the number of starts the motor has
made in the previous hour.
· Alarms
This menu (available without password) visualizes the last

20 alarms detected. The 21st alarm erases the first one
and following. Each alarm reports date and time of
detection.
73
5.4.3 Alarms
5.4.3.1 Alarm Messages with Immediate Compressor Shut Off
Table 20 Alarm messages with immediate compressor shut off
CODE DESCRIPTION REASON
1 Emergency Stop Emergency stop button open (IN1)
2 Thermal Motor Thermal motor open (IN2)
3 Thermal Fan Thermal fan open (IN3)
4 Door Open IN 5 open if it is configured as Micro door (S11=2)
5 Missing Phase One or more phase is missed over 400ms
6 Wrong Phase Phase reversed (check every motor starting)
7 Sec. Press. Switch All the inputs IN1 ÷ IN6 open
8 High Pressure Working pressure over set WP2
9 Temp. Probe Failure Air-end temperature probe failure
10 High Temperature Air-end temperature over set WT1
11 Low Temperature Air-end temperature lower than set WT5

Signaled on power up in case of power off while compressor was
12 Power Off
on and selected as manual restart
13 RS 232 Nr.1 Failure Communication to the control unit interrupted.
Power supply to the controller lower than 9V; reset accepted only
14 Low Voltage
when power over 10,5.
62 IN9 Open Parameter S12 = 2 (Shut off alarm)
Motor off and current 20 % higher than set TA2 or motor on and
63 Ampere Transd. Failure current 10 % lower than set TA2 (Ampere transducer enabled
S10=1)
Motor absorption over set TA2 (Ampere transducer enabled
64 High Motor Current
S10=1)
Temperature over set STA1 - compressor shut off if the auxiliary
66 High Safety Temp.
probe is set as absolute temperature (S09=1)
74
5.4.3.2 Alarm Messages with Compressor Shut Off After 30 sec Unload Run
Table 21 Alarm Messages with Compressor Shut Off After 30 sec Unload Run
20* Separator filter Differential pressure switch separator filter open (IN6)
21 Motor Temperature Input PTC open
22 Press. Transd. Failure Working pressure transducer failure

Timer CAF elapsed, alarm detected only if the parameter Safety is
23 Safety
set YES
Auxiliary temperature probe failure if the aux. probe is set as
68 Aux. T. Probe Failure
absolute temperature (S09=1)
Delta P. over set SP2 once Wt8 is elapsed and the auxiliary
71 Sep. Filter Alarm
pressure transducer enabled (S08=1)
Auxiliary pressure transducer failure with auxiliary pressure
73 Aux. Transd. Failure
enabled (S08=1)
80 Driver Shut Off Shut off signal from serial connection and/or IN10 open
82 Drive Board Failure Drive board failure

No communication to the driver; check serial wiring and setting to
83 Drive No Comm.
the drive
*The alarm "Separator Filter" is generated only if the compressor is loading, the pressure is higher than WP2 and the timer Wt8 is elapsed.
5.4.3.3 Maintenance Messages
Table 22 Maintenance Messages
50 Change Air filter Timer of parameter CAF into menu MAINTENANCE elapsed
51 Change Oil Filter Timer of parameter COF into menu MAINTENANCE elapsed
52 Change Seperator Filter Timer of parameter CSF into menu MAINTENANCE elapsed
53 Change Oil Timer of parameter C--F into menu MAINTENANCE elapsed
54 Check Compressor Timer of parameter C-h into menu MAINTENANCE elapsed
75
5.4.3.4 Warning Alarms
(Can not shut off compressor)
Table 23 Warning Alarms
30 Data Lost Default data are loaded on the controller.
31 Air Filter IN5 closed if it is configured as air filter pressure switch (S11=1)
Temperature over set WT2; automatic reset when temperature is
32 Temperature Warning
below WT2 –5°C
Power supply to the controller below 10,5V; automatic reset when
33 Low Voltage Warning
the power rise over 12V
Power supply to the controller over 20.3V; automatic reset when
34 High Voltage
the power goes down below 19.3V
35 RS 232 Nr. 2 Failure Communication is interrupted with other compressors
Inform the compressor will never stop till the expiration of 1 hour
36 Max. starts/Hour
time from the first start
60 Dryer Alarm IN7 Open = RL9 and RL10 Off
61 Thermal Dryer IN8 Open = RL9 and RL10 Off
Start and stop of the compressor have to be operated manually;
65 Clock Failure the Master/Slave operation timer are controlled by the micro
controller
Temperature over set STA2 if the auxiliary probe is configured as
67 Safety T. Warning absolute temperature; automatic reset, reset when the
temperature goes down the set value
Temperature over set STT1 – reset with temperature below set

69 Delta Temp.
STT1- 5 °C if the auxiliary probe is set as differential temperature
Temperature over set STD1 – reset with temperature below set

70 High Dryer Temp.
STD1- 5 °C if the auxiliary probe is configured as dryer (S09=3)
Delta P. over set SP3; automatic reset with delta P < SP3- 0,2 bar
72 Sep. Filter Warning
and auxiliary transducer enabled (S08=1)
74 DLS / Summer Time Time setting on power up or time change
75 IN9 Open Input IN9 open. (If it's configured as warning (S12=1))
Auxiliary temperature probe failure if it is configured as differential

79 Aux. T. Probe Failure
temperature (S09=2)
81 Drive Alarm Drive stopped, follow the alarm message from the drive
76
5.4.3.5 Messages Visualized into Alarm List Only
Table 24 Messages visualized into alarm list only
48 Manual Restart Restart set from automatic into manual
49 Auto Restart Restart set from manual into automatic
77
6 TECHNICAL DATA
6.1 Technical Data of Compressor

Table 25 Technical Data of Compressor
Compressor Type / Serial Number
Maximum Working Pressure Bar
Minimum Working Pressure Bar
3
Capacity m /min
Operating Voltage V
Operating Frequency Hz
0 0
Ambient Temperature (between +0 C / +43 C)
0
Average Operating Temperature (between 75-96 C)
0
Air Outlet Temperature C
3
Cooler Fan Flow Rate m /h mmSS
Noise Level dB (A)
Drive Type
Coupling Type
Starting System STAR / DELTA FREQUENCY INVERTER SOFT STARTER
Cooling System AIR COOLED WATER COOLED
Weight kg
Dimensions (LxWxH) mm
Main Motor Type / Serial Number
Air-end Type / Serial Number
Main Motor Plate Data rpm kW A
Fan Motor Plate Data rpm kW A
Oil Type
Oil Capacity l
Oil Filter Type
Panel Filter Type
Air Filter Type
Separator Type
78
6.2 Plates on the Compressor
6.2.1 Plate on the Canopy
Figure 18 Plate on the Canopy
6.2.2 Plate on the Oil Tank
Figure 19 Plate on the Oil Tank
79
6.2.3 Sticker on the Motor
Figure 20 Sticker on the Motor
80
6.3 Technical Data of HSC
Table 26 Technical Data of HSC Series
MOTOR POWER DIMENSIONS AIR OUTLET PIPE
MODEL WEIGHT (kg)
(kW/HP) LxWxH (mm) DIAMETER (inch)
HSC 22D 22/30 1250x850x1465 1" 485
HSC 30BD 30/40 1550x1030x1750 1 1/4" 742
HSC 37D 37/50 1550x1030x1750 1 1/4" 742
HSC 45BD 45/60 2000x1200x1810 1 1/2" 1461
HSC 55D 55/75 2000x1200x1810 1 1/2" 1520
HSC 75D 75/100 2000x1200x1810 1 1/2" 1670
HSC 75BD 75/100 2500x1400x2037 2" 2200
HSC 90D 90/125 2500x1400x2037 2" 2240
HSC 110D 110/150 2500x1400x2037 2" 2640
HSC 132D 132/180 2750x1750x2000 2 1/2" 2970
HSC 160D 160/220 2750x1750x2000 2 1/2" 3080
HSC 200D 200/270 3250x2250x2450 NW 80 4920
HSC 250D 250/340 3250x2250x2450 NW 100 5600
HSC 315D 315/430 3250x2250x2450 NW 100 5920
81
6.4 Technical Data of HSC FRECON
Table 27 Technical Data of HSC FRECON Series
MODEL WEIGHT (kg)
(kW/HP) LxWxH (mm) DIAMETER (inch)
HSC FRECON 22D 22/30 1250x850x1465 1" 485
HSC FRECON 37D 37/50 1550x1030x1750 1 1/4" 742
HSC FRECON 50D 50/70 2000x1200x1810 1 1/2" 1200
HSC FRECON 60D 60/80 2000x1200x1810 1 1/2" 1385
HSC FRECON 75BD 75/100 2000x1200x1810 1 1/2" 1450
HSC FRECON 75D 75/100 2500x1400x2037 2" 1900
HSC FRECON 90D 90/125 2500x1400x2037 2" 2020
HSC FRECON 125D 125/170 2500x1400x2037 2" 2380
HSC FRECON 150D 150/200 2750x1750x2000 2 1/2" 2875
HSC FRECON 180D 180/240 2750x1750x2000 2 1/2" 3080
HSC FRECON 220D 220/300 3250x2250x2450 NW80 4760
HSC FRECON 275D 275/370 3250x2250x2450 NW100 5600
HSC FRECON 315D 315/430 3250x2250x2450 NW100 5920
82
6.5 Technical Data of FRECON PLUS
Table 28 Technical Data of FRECON PLUS Series
MODEL WEIGHT (kg)
(kW/HP) LxWxH(mm) DIAMETER (inch)
1810x650x1442*
FRECON 5 PLUS 5/7 1530x650x1442** 1/2" 320
1100x650x950*** 235
1850x650x1442*
FRECON 7 PLUS 7/10 1905x650x1442** 1/2" 340
1100x650x950*** 255
1798x730x1675*
FRECON 11 PLUS 11/15 1798x730x1675** 3/4" 515
1172x730x1000*** 305
1798x730x1675*
FRECON 15 PLUS 15/20 1798x730x1675** 3/4" 555
1172x730x1000*** 345
FRECON 18 PLUS 18/25 1250x850x1465 1" 465
FRECON 22 PLUS 22/30 1250x850x1465 1" 500
FRECON 30 PLUS 30/40 1550x1030x1750 1 1/4" 695
FRECON 37 PLUS 37/50 1550x1030x1750 1 1/4" 715
FRECON 45 PLUS 45/60 1550x1030x1750 1 1/4" 945
FRECON 55 PLUS 55/75 2000x1200x1810 1 1/2" 1290
FRECON 75 PLUS 75/100 2000x1200x1810 1 1/2" 1390
FRECON 90 PLUS 90/125 2500x1400x2037 2" 2020
FRECON 110 PLUS 110/150 2500x1400x2037 2" 2380
FRECON 132 PLUS 132/180 2500x1750x2000 2 1/2" 2555
FRECON 160 PLUS 160/220 2500x1750x2000 2 1/2" 2760
FRECON 200 PLUS 200/270 3250x2250x2450 NW100 4460
FRECON 250 PLUS 250/340 3250x2250x2450 NW100 5600
FRECON 315 PLUS 315/430 3250x2250x2450 NW100 6000

* with dryer, ** with air tank, *** without air tank
83
Table 29 Maximum possible line length for 7 Bar
COMPRESSOR Maximum possible line length according to the pipe diameter (meter)
Pressure Capacity 1/2'' 3/4'' 1'' 1 1/4'' 1 1/2'' 2'' 2 1/2'' 3'' 4''
0,83 43 194 615
1,1 25,7 115 365
1,7 11,5 51,5 163
2,6 23,5 74,4 298
3,1 17 53,5 215
3,6 13 40,6 163,3 349,4
5,1 21,4 85,7 183,4
6,2 15 59,7 127,8 418,8
7,2 11,3 45,3 97 317,6
7 Bar 8,1 36,4 77,9 255,4
9,6 26,6 57 186,5 687,5
12,4 16,5 35,4 116 428
13,8 29 95,3 351,3
16,5 21 68,5 252,5
19,5 15,3 50,3 185,3 414
23,2 36,5 134,4 300
27,4 26,8 98,8 220,7
36,3 16 58,7 131 493
43 42,9 95,9 360,4

0,65 93,7 420
0,85 57 255,7
1,35 24,2 108,6 344
2 11,7 52,5 166,3
2,5 35,2 110 440
3 24,8 78,5 314,5
4,3 40,3 161,6 345,8
5,1 29,4 117,8 252,2
6 21,8 87,2 186,7
10 Bar 6,7 17,7 71 152 499
8,1 12,5 50 107 351
10,8 29,4 62,9 206,3
11,2 27,5 58,8 192,8
13,5 19,5 41,6 136,5 503
17 27 89 328,5
20,5 19,2 63 232
24 14 47 173,5
28,5 34,3 126,3 282
35,8 22,5 82,8 185
84
0,5 193
0,7 104 466
1,1 45 202
1,7 20 90,3 285,8
2,1 13,6 61 193,4
2,6 41 130 521,6
3,5 23,7 75,1 301
4,3 16 51,3 205,5
5,3 34,9 139,7 299
13 Bar 5,6 31,5 126 270
7 20,8 83,5 178,7
9 52,5 112 367,8
9,4 48,4 103,5 339,4
11 36 77,4 253,7
14 23,2 49,6 162,4 598,7
16,5 17 36,6 119,8 441,8
20 12 25,6 84 309,5
24 18,3 59,9 220,9
29 12,9 42,2 155,6 347,7
85
7 TRANSPORT, STORAGE, INSTALLATION
7.1 Shipping and Transport
7.1.1 Shipping
Ø When the compressor is received, it should be checked for any missing part or damage.
Ø The transport company and HERTZ KOMPRESSOREN must be notified of any damage on the
packing or the compressor.
7.1.2 Transport
Figure 21 HSC 75 Direct Drive Model Transported by Forklift
Ø Lift the compressor by forklift.
Ø Before lifting the compressor, make sure that the forklift blade is well balanced.
86
Figure 22 FRECON 7 PLUS Model Transported by Forklift
Figure 23 FRECON 7 PLUS Model Transported by Lifting Lug
87
Figure 24 HSC 75 Model Transported by Lifting Lug
Ø Ensure that he forklift does not lift the compressor excessively; move slowly and carefully.
Ø If you should lift the compressor with palette, ensure that the compressor is fixed to the palette first.
Never lift the compressor, if the compressor is not properly mounted on the palette or the
connections are damaged. Otherwise, you may cause injuries and damage.
Ø If the forklift is not available, lift it by crane and lifting lug as shown in figure 24 and figure 25.
Ø Retighten the bolts and screws that may be loosened during transportation.
Ø Make sure that all kinds of lifting belts, hooks etc. are in good condition and capable of carrying the
weight of compressor. If you do not know the weight of the compressor, check it.
Ø Make sure that the floor of the compressor is strong enough to carry the compressor weight.
7.1.3 Storage
If compressor has to be stored before installation, do not unpack and store in the following conditions:
0 0
· Temperature must be between 0 C and 50 C for storage.
· Storage area must be dry, under a roof and protected against the weather, vibration and shock.
· HERTZ KOMPRESSOREN products are suitable for a maximum storage period of 6 months. More
than 6 months stored products; oil, oil filter and separator must be change.
88
7.2 Installation of the Compressor and Connections
Figure 25 Installation of the Compressor to the Room
Ø The floor on which the compressor is mounted should be capable of carrying the weight of
compressor and should be flat and dry. Place your compressor on this surface. There is no need to
fixing (anchorage bolt etc) to the floor.
Ø The compressor room should be easily accessible and sufficiently illuminated.
Ø For sufficient service, the compressor room should have a clearance of at least 1.5 m from ceiling
and 1 m from the wall.
Ø Fire and corrosion causing conditions should be prevented in the operation region.
Ø Any pipe load (stretch connections or tensions arise from environmental variations) should be
relayed to compressor by external connections. For this purpose an outlet hose is being delivered
with the compressor. Connect this hose to right after the outlet valve.
Ø If the air supply is above the compressor level, do not enter the compressor connection pipe to the
main pipe from the bottom. The water formed at the compressor outlet may return back during
stopping and idle operation and may impair the o-rings and gaskets of Minimum Pressure Valve.
89
Ø Make sure that the air supply equipment is suitable to the operating pressure of the piping and
fittings and is damage free.
Ø Select the diameter of the air supply, dryer and line filters according to your air supply capacity. (It is
beneficially to select piping of big diameter considering future development of the company).
Ø Establish a separate line for condense discharge of your filter and dryer and air tanks (water
discharge line); this way the floor of the compressor operating place does not unnecessarily get wet.
Ø Put an air exit and electric box in your compressor room for general purpose.
Ø The compressor is manufactured for indoor operation. Suitable room set up plan is shown in figure
20.
Ø In case of different needs in relation to compressor or air supply contact service or sale
representative.
Ø Determine air supply taking into consideration of the company conditions. It will be beneficial to use
a ring line instead of flat line. The pressure drop at the end of flat lines may cause pressure drops, in
case of intermediate high consumption or periodical shock consumption receiver line.
You may find the ideal pipe diameter of your air supply by the following formula:
οܲ ൈ ݀ ହ ൈ ܲ
‫ ܮ‬ൌ
ͶͷͲ ൈ ܳ௖ଵǤ଼ହ
L = The length of pipe line (meter)
DP = Permitted pressure drop (Suggested to be 0,3 bar)
d = Pipe internal diameter (mm)
P = Compressor Outlet pressure (bar)(manometer pressure + ambient pressure)
Qc = Compressor Capacity (liter/second)
Ø The valve, reduction, elbow, tee etc type of products used at the air supply may cause pressure
drop. When installing your system you may include the pressure drop of each connection element in
your calculation. For this, you may approximately find how much length of piping is corresponding to
each element from the equivalent pipe length table. After summing up all elements, you may
calculate the pressure drop of the installation by adding to the end of pipe line.
90
Table 32 Equivalent Pipe Length Table
Equivalent Pipe Length
Pipe Internal Diameter (mm)
TYPE 25 40 50 80 100 125 150
Gate Valve 0,3 0,5 0,7 1 1,5 2 2,5

Angular Elbow 1,5 2,5 3,5 5 7 10 15
Elbow 0,3 0,5 0,6 1 1,5 2 2,5
Wide Elbow 0,15 0,25 0,3 0,5 0,8 1 1,5
Tee 2 3 4 7 10 15 20
Reducer (2/1) 0,5 0,7 1 2 2,5 3,5 4
Example: In order for the pressure loss to stay at same level as you found 100 meter of pipe length and
internal pipe diameter of 25 mm and 8 each elbows, 6 each tee and 2 each gate valve in your installation:
(8x0.3) + (6x2) + (2x 0.3) = 15 meters.
If you use the above components you may install 100-15= 85 meter maximum pipe line.
7.3 Compressor Room Ventilation

Ø In order to maintain the operation temperature at a specific value, place your compressor at a place
that adequate air flow is provided. The temperature that compressor operates should be at least 2
and at most 40 °C. Do not place your compressor where the temperature is less then + 2 °C and if
necessary heat the compressor room.
Ø If you think that there will not be sufficient amount of air flow in the room of operation; it is necessary
to make room ventilation or you must discharge the outgoing hot air the compressor to outside.
When doing this, the outgoing hot air of compressor should not return. For this reason the hot air
outlet and room air inlet should not be on the same side.
Ø When making duct at the compressor’s hot air exit, the most important thing is ,duct should not be
narrower then the dimension of compressor hot air outlet cowling and it should not be long or curly
to cause resistance.
Ø In case of the compressor operating in the room without duct and to demand to discharge the hot air
inside the room by a fan; simply there will be fan with similar capacity of the fan on the compressor.
Place this fan to the closest point of the compressor hot air outlet.
Ø If the area that the clean air will enter is roughly 1.5-2 times of the compressor intake grid area, it is
practically sufficient.
91
Ø Avoid not expose the compressor cooling radiator to direct sun light or regional strong winds.
Ø Avoid the compressor room being subjected to hazardous gas and vapor, heat or corrosive dust
emitted by central heating boiler or generator type of equipment.
7.4 Electrical Connections

Ensure that the electrical installation of your compressor is performed by a qualified electrician. In the
enclosed number 2 booklet; your compressor’s electrical wiring diagrams, installation figures and spare part
list are included.
Your compressor is designed to operate with three phase system. The voltage and frequency data are
written on the template of your compressor and in the “Technical data” part of this handbook. Suitable cross
sections for power cable selection are shown in following tables.
7.4.1 HSC Power Cable Cross Section Area

Table 33 HSC Cable Cross Section Area
MODEL CROSS SECTION AREA*

2 2
HSC-22D 3x25 mm + 16 mm
2 2
HSC-30BD 3x25 mm + 16 mm
2 2
HSC-37D 3x25 mm + 16 mm
2 2
2 2
HSC-55D 3x50 mm + 25 mm
2 2
HSC-75D 3x70 mm + 35 mm
2 2
2 2
HSC-90D 3x70 mm + 35 mm
2 2
HSC-110D 3x95 mm + 50 mm
2 2
HSC-132D 3x120 mm + 70 mm
2 2
HSC-160D 3x150 mm + 70 mm
2 2
HSC-200D 3x240 mm + 120 mm
2 2
HSC-250D 2x(3x150 mm + 70 mm )
2 2
HSC-315D 2x(3x185 mm + 95 mm )
* This recommended cross-section area is up to 25m power cable. For different power cable lengths, power cable cross section area must be changed.
About this situation contact to your service.
92
7.4.2 HSC FRECON Power Cable Cross Section Area
Table 34 HSC FRECON Cable Cross Section Area

2 2
HSC FRECON-22D 3x16 mm + 10 mm
2 2
2 2
2 2
2 2
HSC FRECON-75BD 3x70 mm + 35 mm
2 2
2 2
2 2
2 2
2 2
2 2
2 2
HSC FRECON-275D 2x(3x120 mm + 70 mm )
2 2
HSC FRECON-315D 2x(3x185 mm + 95 mm )
93
7.4.3 FRECON PLUS Power Cable Cross Section Area
Table 35 FRECON PLUS Cable Cross Section Area

2
FRECON 5 PLUS 4 x 4 mm
2
2
2
2
2 2
FRECON 22 PLUS 3x25 mm + 16 mm
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
2 2
FRECON 250 PLUS 2x(3x150 mm + 70 mm )
2 2
FRECON 315 PLUS 2x(3x185 mm + 95 mm )
94
7.5 Installation Drawings
95
Compressor Model A B C D E
FRECON 5 PLUS
FRECON 7 PLUS
FRECON 11 PLUS
FRECON 15 PLUS
1035 750 1250 - 1000
FRECON 18 PLUS
FRECON 22 PLUS
HSC 22D
HSC FRECON 22D
HSC 30BD
HSC 37D
FRECON 30 PLUS 750 500 713 713 1000
HSC FRECON 37D
FRECON 37 PLUS
HSC 45BD
HSC 55D
HSC 75D
HSC 75BD
HSC FRECON 50D
HSC FRECON 60D
937,5 937,5 1000
HSC FRECON 75D
HSC FRECON 75BD
1000 1000
HSC FRECON 90D
HSC FRECON 125D
FRECON 55 PLUS
FRECON 75 PLUS
HSC 90D
HSC 110D
1150 1150 1000
FRECON 90 PLUS
FRECON 110 PLUS
96
97
Compressor Model A B C D E
HSC 132D
HSC 160D
HSC FRECON 150D
755 755 1000
HSC FRECON 180D
FRECON 132 PLUS
FRECON 160 PLUS
HSC 200D
HSC 250D 1000 1000
HSC 315D
HSC FRECON 220D
HSC FRECON 275D - - 1000
HSC FRECON 315D
FRECON 200 PLUS
FRECON 250 PLUS
FRECON 315 PLUS
98
Compressor
A B C D E
Model
FRECON 5 PLUS
1000 800 370
FRECON 7 PLUS
750 1000
FRECON 11 PLUS
500 1015 440
FRECON 15 PLUS
Compressor
A B C D E
Model
FRECON 5 PLUS
1100 370
FRECON 7 PLUS
750 1000 1000
FRECON 11 PLUS
1015 440
FRECON 15 PLUS
99
8 OPERATION
8.1 General
In order to enable you to easily see the operation and adjustment values of the compressor, an
electronic controller unit is installed to the system. The electrical and mechanical precautions have
been taken for establishing of operational safety. Some of the equipments of the compressor are
described below for your information.
8.2 Some of the Compressor Equipment

Ø Control Unit: It is an electronic unit that all adjustments are made and failures, maintenance hours
are traced.
Ø Air-end Unit: This part of the compressor produces compressed air.
Ø Motor: Supplies mechanical drive for air-end unit.
Ø Intake Valve: It placed in the air-end unit. It controls the air intake of the compressor and operating
the compressor load or unload.
Ø Control Solenoid Valve: When the compressor reaches to adjusted pressure values, it controls the
air that goes to intake valve and makes the compressor operate at unload.
Ø Safety Valve: When the pressure in tank increased very high in case of failure, it releases the
pressure and establishes safety. Once a month when compressor is shut off, pull up the ring at the
top of the valve and release. By doing this protecting safety valve and gasket stick together.
Ø Minimum Pressure Valve: It provides the pressure remain at 2 - 3 bars in the seperator tank. In
addition in case of idle operation and switching of compressor; it prevents the system pressure to
penetrate back to the seperator tank.
Ø Radiator: Cooling the outlet air and the oil in the compressor oil line.
Ø Emergency Stop Button: Press this for stopping the compressor in case of emergency. It is
designed to remain locked when the button is depressed. For unlocking the button slowly rotate it in
clockwise.
Ø Manometer: Indicates the pressure.
Ø Pressure Sensor: It converts pressure data into binary format by electronically way and informs the
controller unit.
100
Ø Temperature Sensor: It converts temperature data into resistance value and informs the controller
unit.
Ø PTC: It placed between motor winding. stops the compressor when motor windings get high
temperature to protect to windings.
Ø Pressure Switch: In case of any failure to increase system pressure than the settings it shutdown
the compressor.
8.3 First Start Up

Ø Check the electrical and air line connections before first start up the compressor.
Ø Check that the compressor’s cooling air inlets and outlets are not closed. Do not cover your
compressor with cloth, nylon etc. Do not operate if covered.
Ø Inside electrical panel of your compressor there is a “phase control relay” that continuously checks
the electrical phase. In case the phases are connected in wrong order and if there is unbalance or
interruption in your voltage, the phase control relay will prevent operation of the compressor. In this
case, a signal behind the control panel that indicates the phase error warns you. When the phases
are connected reverse, switch off the energy and switch the position of main cables of the
compressor. In case of interruption or phase unbalance, as this problem is related with the network
contact an electrician or related institution.
Ø When the energy and air lines of your compressor are completed, inform your service for
commissioning. Our service will perform the general inspections, start up the compressor and supply
you beneficial information related to your compressor and its maintenance. If you want to start up
the compressor by yourself read this handbook very carefully. Performing an erroneous process
may be hazardous for your compressor facility or the personnel working in this region.
Ø Check the oil level. On the separator tank body there is a transparent hose for easily seeing the oil
level. Check the oil level when compressor is stop position. During operation the oil level may vary.
Ø If the oil level is missing, complete it. Information related to oil is described in chapter 8.
(MAINTENANCE) item "Compressor Oil".
Ø Check the internal components and connections of the compressor. Make sure that during
transportation it has not been damaged.
Ø Check the internal components and connections of the compressor. Make sure that during
transportation it has not been damaged. The running direction control of compressor: should be
made during commissioning. For this, remove necessary covers.
Ø By looking at the air-end of the compressor; press the “Start “button and run the compressor for a
short while (1-2 seconds) and stop it by pressing emergency stop button. When looked from air-end
101
side, it should rotate to air-end shaft direction. (That is indicated by an arrow on top of the air-end
body).
Ø If the rotation direction is correct, be sure to outlet valve of compressor is fully open.
Ø By closing the valve at the outlet of the air receiver allows the tank to fill.
Ø See that the pressure is rising from the compressor control unit screen or from the manometer over
the control panel.
Ø See that the pressure reaches the adjusted value and the compressor is getting idle.
Ø If the value of the air pressure in tank does not decrease to load level; compressor will automatically
stop at idle after a short time. After waiting a couple of minutes, by opening the tank outlet valve
observe that the compressor is loading at demanded pressure level.
Ø After 10-15 minutes, check the operating temperature of the compressor and see that it is normal
(80-90 °C depends on the ambient temperature). Switch off the energy of compressor by stopping
and check internal accessory of compressor by eye. This is very important against the probability of
oil leak or loosening.
Ø All the functions and reliability of the compressor has been tested after manufacture. The above
mentioned information of commissioning is against the probability of your compressor being
damaged during transportation. If you cannot see a failure status after all controls you can start up
the compressor.
8.4 Daily Operation

At normal days before running your compressor you may perform some simple checks and
afterwards run it. The maintenance activities are explained in the section 8. (Maintenance) “Daily
Maintenance” part.
Ø Observe that there is no failure warning signal on compressor panel.
Ø Observe that there is no oil leak or damage by looking at the internal accessory.
Ø Run the compressor and observe how it works for short time.
Ø Look at the front panel and observe that operating pressure and temperature values are normal.
Ø While the compressor running on load, observe the oil flow at oil return line (scavenge).
These simple checks may cause you to early detection of failures and save you from loss of time for
unnecessary stopping.
102
8.5 Operating Compressor After Long Term Stopped and Cold Weather
Ø Oil placed in air-end unit, oil line and radiator drip off with the effect of gravity and accumulate in the
oil tank.
Ø When compressor is shut off water accumulate down of the tank and get together.
Ø Especially temperatures under zero, frozen water under the tank can prevent oil circulation. So this
cause dangerous situation. Also water can freeze in air-end unit and valves and ice sticks the parts
together. This prevents the operation. To understand not any water remain under the tank, open the
oil drain valve and see oil coming out of it. If oil not coming water or oil in front of the valve must be
frozen. Certainly in this condition do not operate the compressor. Firstly warm the compressor room.
0
Ø Getting the compressor room temperature 5-10 C in a short time, not getting the air-end unit and
motor bearing grease temperature same.
Operation:
· Provide the compressor temperature at least 7 °C. (for thawing of ice)
· Turn the coupling to the rotation direction by hand 10 -15 cycle. (Before that, be sure that the
compressor is switched off.)
· Remove the intake valve and add enough (regarding the air-end dimension, enough for all the unit
lubricating) warmed compressor oil. (40-50 °C) (change about the compressor type approximately
0,5-2 kg)
· After replacing the intake valve; again turn the coupling by hand, 10-15 cycle.
· Operate the compressor short time and after 2-3 sec of loading stop the compressor.
· Again turn the coupling by hand, 10-15 cycle. (Before this be sure that the compressor is switched
off.)
· Again operate the compressor. After that compressor oil circulation must be run perfect.
· In first minute pay attention the compressor operation conditions. When changes happened at the
operation sound (especially raising acute sound) stop the compressor immediately.
· After operating the compressor see the loading and increase of the pressure.
· When compressor on load increase of pressure and temperature cause fault risk decreases.
103
Figure 26 Genera view of INV 5/7+ with tank and dryer model
104
9 TROUBLESHOOTING
9.1 General
The information in this section is based on the experience gained by the service activities and tests
conducted at factory.
The indications and reasons of failures are ordered according to the results obtained from the
warnings of our company and the experience of the service personnel.
According to the structure of the compressor, as the systems and failures are interrelated; prior
making any repair or part replacement the reason of failure should be determined.
For the problems to be encountered, it is beneficial to make an eye inspection.
Good Tracing of failure, prevents the undesired damages that may occur during repair.
Firstly;
· Unless otherwise specified do all the controls when compressor is shut off.
· Check the electrical connections for the possibility of looseness.
· Check the parts that may be influenced from short circuit and heat.
· Check the damage and looseness that may form at air and oil circuit hoses, pipes and connections.
If you have tried all the ways described in this handbook for eliminating the failure and the problem
still continues; please contact our company or service department.
From the point of your speed and reliability having all kinds of corrective action,
maintenance and repair works to be done at our service companies is the best way for your
compressor and your facility.
All kinds of works carried out without sufficient knowledge may cause wrong results,
unnecessary interruptions of your facility or more costly damages.
105
9.2 Troubleshooting, Reasons and Solutions
Table 36 Troubleshooting and Solution
TROUBLESHOOTING REASON SOLUTION
No Electrical Power Check the voltage from input terminal block

Control or input fuse is blown, main
Check the fuses.
switch tripped
Voltage is low, unstable or opposite Check the control unit warnings.

Compressor does not
operate. Compressor has stopped for any kind
Check the control unit warnings.
of failure.
After Stopping, compressors don't work

Compressor is running without
for 1 min. for discharging of internal
discharging internal pressure
pressure. After 1 min. try again.
This problem can be encountered on
connection made thinner cable due to
voltage loss. When your compressor is in
stop position, measure the input voltage
The cross section of power cable is
and while measuring run the compressor. If
insufficient.
the voltage decrease 5 % (380>360) and
below the cable cross sections insufficient.
Make the connection with a suitable cross
section.
If the line voltage is 5 % less than the
compressor factory adjusted voltage, the
Low voltage.
problem may arise from the network or the
established power of your facility.
0
If the ambient temperature is less than 0 C
Compressor is hardly Low ambient temperature the oil may thicken and this may enforce
working. the operation of your compressor.
After de-energizing the compressor check
whether the coupling is free rotating. The
Motor or air-end has mechanical
rotation is more difficult than normal there
problem.
may be mechanical damage at motor or at
air-end unit. Inform the service.
The intake valve is closed at first run up. If
there is a mechanical problem, it may stay
open. This way the compressor tries to
start up against load and hardly speeds up.
When the compressor is at stop and there
Intake valve failure.
is no internal pressure, observe that the
intake valve is fully closed. The valve might
be stuck at open position. Inform the
service.
106
Check the air filter and change if

Air filter clogged.
necessary.
The star delta setting might be changed.

Check the settings (4-8 second). By
engaging the compressor, check the
contactors at the starter box. At the end of
Compressor does not transfer from star
adjusted period, the k3 (star) contactor
to delta.
should release and k2 (delta) contactor
should extract. If it does not, the contactor
coil connection could be loose or the coil
could be burned.
The Intake Valve May Be Stuck. O-Rings

Intake valve fault.
And Gaskets May Be Damaged
Compressor does not
produce air. As the o-ring and gaskets of the minimum
pressure valve are damaged, it can not
keep the internal pressure. If internal
Minimum pressure valve is defected. pressure does not rise, the intake valve
can not open and the compressor can not
be engaged. Replace the gaskets and o-
rings.
Check whether the solenoid valve receives

the control energy (while operating
The solenoid valve is defected. compressor). If the energy is normal, the
solenoid coil is burned down, replace the
coil.
Check the hoses and connections. Replace

Leakage at the air line connections.
if damaged.
Pressure set values changed. Check the pressure settings.
It may get stuck when intake valve is open.

Intake valve defected.
Inform the service.
Compressor exceeds set
pressure. Check whether the control energy is
coming to solenoid valve (in delta
operation). If the energy is normal, the
Solenoid valve is defected.
solenoid coil is burned down. Replace the
coil.
107
In order to observe that the compressor can

reach the maximum pressure; slowly close
The consumption of your system is the outlet valve. Observe that the pressure is
higher than compressor capacity. increasing and the compressor working at
offload. If the pressure does not rise, there
must be another failure. Inform the service.
Leakage at the air line connections. Check the air line and air connections
Compressor can not reach
the maximum pressure. Check the intake filter by stopping the
Chocked air filter element.
compressor. Replace if dirty.
This may happen in cases when the intake

Intake valve fault. valve gets stuck and open a little. Inform the
service.
If the air-end unit is damaged, a different

Air-end unit failure.
operation noise is heard. Inform the service.
While the compressor operating at load,

observe the oil flow from scavenge tracing
hose. If the oil is not passing, stop the
Scavenge Orifice is blocked. compressor. Clean the scavenge orifice with
compressed air. Observe the oil flow after
operating the compressor. Complete the oil
level.
If you see oil coming from the air tank during

Separator element is damaged. water discharge, replace the separator
element.
Check the oil circuit connections of the

compressor. At the point of leak, oil deposits
Compressor excessively
might be seen on floor. By checking the
loses oil. Oil leakage at the compressor body.
coupling and connections at oil circuit,
tighten them. If the oil leak is not prevented,
inform the service.
When ambient temperature more than +40

0
Compressor is exposed to high heat. C and compressor unit directly on the sun
light oil gets thinner and oil loss increases.
Pay attention to use recommended oil.

Not used recommended oil. Because different type oil usage later on
make the compressor unusable.
108
Pressure settings have been Check the working pressure setting and
changed. safety pressure switch settings.
When the compressor is working at full load,
observe the internal pressure gauge. If the
Separator clogged. internal and external pressure difference is
close to 1,5 bar, separator is clogged.
Replace the separator.
Intake valve may be stuck when opened.
Safety valve discharges. Intake valve defected.
Inform the service.
Check whether the solenoid valve receives
the control energy (while operating
Solenoid valve is defected. compressor). If the energy is normal, the
solenoid coil is burned down, replace the
coil.
Safety valve or its adjustment is If the safety valve opens before the adjusted
defected. value replace it.
Observe that the overload relay is adjusted
according to the motor nameplate. Observe
that (on full load) the motor current is normal
Overload relay setting is changed. and stable (the current difference between
the phases should be less than 10 %)
If the relay opens before the adjusted value it
is defected. Replace it.
Low Voltage
Compressor exceeds the adjusted

For this situation take the precautions.
Main motor overload relay pressure.
stops the compressor.
When the compressor is working at full load,
observe the internal pressure gauge. If the
It can be understood by noisy operation.

Air-end Unit damaged.
Inform the service.
If the operating currents are above normal
the motor may be excessively overloaded,
listen to the sound of motor and also check
Main motor has a problem.
the body temperature. The motor may be
damaged.. There may be bearing problem.
Inform the service.
109
Dropping something during maintenance into

the separetor tank that cause clogged at the
oil line. During maintenance pay attention to
When compressor idle
this situation. Unoriginal oil filters can be
operating temperature gets Clogged at the oil line or oil filter.
resist of oil flow. If the operating ambient of
higher.
the compressor have dusts or abrasive
gases; oil, oil filter or seperator filter can
effect badly.
The idle time setting has been

Check the idle time settings.
changed.
The compressor does not
If the idle time of compressor is shorter than
stop after idle time.
Compressor is reloaded before the the adjusted waiting time, the compressor
end of the idle time. will not stop at idle as it will be reloaded. This
is normal situation.
Observe that the overload relay is adjusted

according to the motor nameplate. Observe
that (on full load) the motor current is normal
Overload relay setting is changed. and stable (the current difference between
the phases should be less than 10 %)
If the relay opens before the adjusted value it
is defected. Replace it.
Check that the compressor is ventilated

Fan motor overload relay good. Replace the blocked panel and intake
Panel filter or the cooler cells blocked.
stops the compressor. filters. Clean the cooler and fan impellers. Do
The air inlet is obstructed.
not close hot air outlet. If you are using
culvert, do not reduce the dimension.
If the currents are above normal the motor

may be excessively loaded. Listen to the
noise of motor while the cowlings are open
There is a problem at the fan motor. and check the body temperature. The motor
may be damaged. There may be a bearing
problem. Inform the service.
110
Working Pressure set values

Check the pressure sets.
changed.
Pressure Safety Switch When the compressor is working at full load,

stopped the compressor. observe the internal pressure gauge. If the
Check that all mechanical connections are

tightened properly (the tightness of motor,
The mechanical connection are loose.
air-end, coupling and fan connections has a
big importance from the point of safety).
Compressor operate noisy Listen to the sound of motor while the

Motor bearings have mechanical
than normal. cowlings are open. If you hear a bad noise
problem.
from bearings inform the service.
Air-end unit has a mechanical It makes an easily distinguishable noise

problem. during operation. Inform the service.
Low oil level. Check the oil level and fill if necessary.
High Ambient Temperature Check the ambient temperature.
Intake window of compressor room may be

smaller than the compressors intake area.
The hot air outlet can not be discharged out
of compressor room healthily. The cooler
Ventilation is insufficient.
may be directly subject to sun light and there
Compressor operate hotter may be strong wind opposite to the hot air
than normal. outlet. Check and take necessary
precautions.
Cooler cells or fan impellers are dirty /

Check and clean.
clogged.
Air filter chocked / clogged. Check and replace.
Mechanical problem at the air-end It could be understood by noisy. Inform the

unit. service.
111
It may release the air back of the minimum

Minimum pressure valve is defected. pressure valve. Replace the gasket and o-
The internal pressure does
rings.
not stop drop at idle
operation
The intake valve does not close. Inform the
Intake valve fault.
service.
Recommended oil or original separator Pay attention to use recommended oil or

not used. original separator.
Ambient humidity is too high Try to decrease the ambient humidity
The oil looses its This point must be taken into consideration
There is dust, gas etc. in the
characteristics and the when determining the compressor room in
environment that impair the property of
separator gets blocked sandblasting casting chemical and paint /
oil.
rapidly chemical finishing facilities.
At the compressors that operate near the
boiler rooms, generator room or at areas
Always operating at high ambient
with insufficient ventilation, the operating
temperature.
temperature adversely affects the life of
separator.

Low Voltage.
If the star delta period is adjusted

shorter than normal, it gets loaded up
before full speed and the contactor
contacts are subjected to excessive
The contactor contacts
rapidly wear out (Rapidly Star delta period is short current. As a result of this, the contacts
stick). may stick and your motor may burn.
The star delta period is 4-8 seconds
(according to compressor type). Do not
adjust it for shorter period. Replace your
old contacts with new ones.
The electrical resistances of the non

original contact sets are very low. For
Original contact set is not used.
providing original spare parts contact
service.
112
Temperature settings changed. Check temperature settings.
Check the ambient temperature and take

High ambient temperature.
due precautions.
Intake window of compressor room may be

smaller than the compressors intake area.
The hot air outlet can not be discharged
out of compressor room healthily. The
Insufficient ventilation.
cooler may be directly subject to sun light
and there may be strong wind opposite to
the hot air outlet. Check and take
necessary precautions.
Low oil level. Check the oil level and add if necessary.
The compressor stops due

Oil filter clogged. Change the oil filter.
to heat.
When the oil color gets dark that shows the

life of oil completed. If you have to replace
The life of oil expired.
the oil more than normal, review you’re
operating conditions.
Air filter is dirty / clogged. Change the air filter.
Panel filter is clogged. Check, clean or replace.
Cooler cell or fan impellers clogged /

Check and clean.
dirty.
The outlet culvert is very long or it gets

Check and take due precautions.
narrow.
Canopy opened. Close the canopy.
Check the motor bearings and replace if

Motor bearings have a problem.
When the pressure reaches necessary.
the high limit the
compressor operates noisy.
Air-end unit has mechanical problem. Inform the service.
113
10 MAINTENANCE
Read instruction manual carefully before the maintenance. Maintenance done by authorized person
extended the compressor life.
Before the maintenance be sure that the compressor switch off and the compressed air in the
compressor discharged.
Since your compressor is complicated machine maintenance activities performed by

unauthorized and non trained personnel will abolish all guarantee and may cause undesired
damage and injuries.
For maintenance of the compressor contact to HERTZ KOMPRESSOREN service

department.

59227 Ahlen, In der Schlinge 6 / Deutschland
Telephone : +49 (2382) 889 089-0 (PBX)
Fax : +49 (2382) 889 089-22
E-Mail : info@hertz-kompressoren.de
Web : http://www.hertz-kompressoren.com/
10.1 Safety During Maintenance

Ø Before the maintenance, be sure that disconnect the power supply and release the compressed air
on the tank. Put a warning sign about the maintenance, seen surface of the compressor.
Ø After turning off, wait for compressor to cool down. Contact with the hot surfaces can causes
injuries.
Ø Before maintenance make sure that internal pressure is released.
Ø Be aware of the circuits. Check them if there is any current passing the circuit. Especially main
switch has current flow even if it is turned off. Only energize the components when it is obviously
stated.
114
Ø Unless powered off, while compressor stopped some parts still has high voltage.
Ø Make sure all safety devices, isolating and electrical protection devices are reinstalled after
maintenance.
Ø Only authorized personnel are responsible for maintenance and repair of the compressor.
10.2 Periodic Maintenance
10.2.1 Daily Maintenance

Ø Check the compressor oil level.
There is a transparent hose for indicating oil level on the separator tank body. Check the oil level
when the compressor is stopped (during operation oil level may vary). If oil is missing refill it. If you
are frequently adding up oil, this means that there is a problem with your compressor. In order to
understand this; review the section Troubleshooting Section.
Ø During operation, check the failure warnings and operating values from control panel.
10.2.2 Weekly Maintenance

Ø Clean the panel and intake filter of the compressor by compressed air.
Ø Check / Clean the cooler cells by compressed air.
Ø Check the oil level.
Ø Check the internal accessory against oil leak or damages by eye.
115
Table 37 Periodic Maintenance Schedule
21000
3000
6000
MAINTENANCE
Oil and Oil Filter Replacement R R R

Panel Filter Replacement R R R
Air Filter Replacement R R R
Electrical Connection Check / Control R R R
Oil / Air Leakage Control R R R
Radiator Cleaning (with air) R R R
Motor Bearing Lubrication R R R
Separator Tool Change R
Elliptical Air Filter Service Tool Change R
Dryer Maintenance R
Intake Valve Service Tool Change R
MBV Service Tool Change R
Termik element change R
Air-end unit revision R
Motor revision R
116
10.3 Maintenance Instructions
10.3.1 Compressor Oil

Ø In our products HERTZ SMARTOIL 3000 type of oil is being used. This oil is specially produced by
taking into account of compressor operation type as you will see below.
Ø As the chemical structures and contributions of different types of oils are different; mixing them with
each other or using them in the compressor may cause a severe damage with a high cost.
Ø Do not put any oil additive in the compressor oil as in the motor oils. As the oil that you use has been
prepared specially for the compressor; it already includes this type of additives.
Ø In case of using engine oil, hydraulic oil etc; these two types will get mixed and become paste
consistency and this immediately impairs all the filters of your compressor. If you keep operating this
way, there may be stationary damages in your air-end unit in a few days.
Ø For this reason do not keep other lubricating oils beside your compressor. Because, your
maintenance operator may accidentally use it.
Ø In addition if you are in need of long life synthetic oil; contact our service and sales departments.
HERTZ Smartoil 3000
HERTZ Smartoil 3000 is high quality oil developed for screw type compressors. As the property of
separation from water and air is outstandingly developed and as it has a good oxidation resistance; it
is an ideal oil to be used in screw type compressors.
· Oxidation Resistance: High temperatures are formed during compression of air. The oil that does
not have oxidation resistance starts to leave oxidized impurities at some points. This causes
decrease in efficiency and increase in maintenance costs. HERTZ SMARTOIL 3000 prevents the
oxidation or minimizes the expense due to the additives included.
· Protecting the parts against corrosion: By protecting the parts against corrosion it lengthens their
service life.
· The Property of High Separation from Air: By rapidly separating from air it prevents the
cavitations and contributes the increase of compression.
· Gasket Compliance: Compliance with all the gaskets used in the compressor.
· Health and Job Safety: The skin contact of used oil should be especially avoided and in case of
contact must be washed with soap and water.
117
· Environmental Protection: Never pour the used oil to soil and water channels. Do not burn. If
possible accumulate them at a defined collection point and remove them per legal regulations.
· Typical Physical Properties:
Table 38 Typical Physical Properties of Smartoil.
HERTZ Smartoil 3000 6000
ISO Viscosity Degree 46 68

0
Kinematic Viscosity @ 40 C cSt. 46 68
Viscosity Index 104 148
0
Density @ 15 C kg/l 0.874 0.859
0
Flowing Point C -30 -33
0
Flaring Point C 210 240
10.3.2 Oil Change

Ø Switch off the compressor.
Ø If the compressor is already cold, first run it 5-10 minutes for

warming up of oil and switch it off again.
Ø Wait for 3-5 minutes for internal pressure discharge and oil to
strain down.
Ø Remove the old element by filter tool.
Ø Discharge the oil completely by opening the oil discharge

valve. After the oil flow is finished, close the oil outlet valve.
Ø Replace the oil filter by filling the new oil.
Ø Fill the new oil upper level.
Ø Complete the connections by installing oil charging plug and

Figure 27 Oil Level Hose
internal pressure hose.
Ø Run the compressor for a few minutes for checking the internal accessory leaks.
Ø After switching off the compressor wait for the fall down of oil and check the oil level. If it incomplete
refill it.
118
10.3.3 Oil Filter Change
Change oil filter every 2000 hours. If in 6 months 2000 hour of usage time not completed, change
the filter once in 6 months. Also change the filter every time changing of the oil.
For replacing the oil filter;
· Stop the compressor and wait until internal pressure

discharged.
· Remove the old element by filter tool.
· Clean the surface where contact of filter gasket.
· Fill up the new filter element with oil and lubricate its gasket
slightly.
· Place the new element and manually tighten.
· Avoid harming the filter cartridge.
· Restart the compressor and check whether or not there is

any leakage. Figure 28 Oil Filter Replacement
Only use original spare parts for avoiding damage of the oil filter element and your
compressor. The maximum pressure values of other type filer elements may not be
sufficient.
10.3.4 Panel Filter Change

Ø The ventilation fan of your compressor is need of high amount of free air. As a result of operation of
this fan, the dust in the compressor operating ambient is absorbed. Based on the dustiness degree
of the ambient your panel filter may be rapidly clogged.
Ø When the panel filter is clogged, the cooling air amount is decreased and the compressor operating
temperature is increased. In addition when the panel filter is clogged, as the suction speed will
increase the dust particles can hardly pass through the filter.
Ø Frequently clean the panel filter. For doing this remove the filter cover by removing the bolts and
clean with compressed air (internal to external). After cleaning replace the filter. Structural property
of Panel filter a bit lubricated. Not cleaning for a long time cause none cleanable dust and oil mixture
concretion. In this situation change the filter.
119
Figure 29 Panel Filter Replacement
For replacing the panel filter:
· After switching off the compressor remove the screws connecting the top perforate to intake
cowling.
· Remove the old panel filter, replace the new filter. Tighten the screws connecting the top
perforate to the intake cowling.
10.3.5 Air Filter Change

Ø The intake filter inside the compressor prevents to obstruct the dust entry into compressor. Clean
the filter by spraying compressed air (internal to external).
Ø As the air filter is more sensitive than the panel filter, if the panel filter is not properly cleaned it may
rapidly get clogged.
The filter replacement should be made once every 2000 hours or

once every 6 months as an average.
For changing air filter:
For 7,5 - 10 HP powered machines;
· Pull out the air filter cover.
· Take out the old filter.
· If necessary clean the chamber with lint less cloth. Figure 30 Type of Air filter for 7,5 - 10 HP
powered compressor
· Replace the new filter.
· Replace the cover, tighten.
120
· Restart the air filter counter..
· Change the filter every 2000 hour.
For 30 - 50 HP powered machines;
· Loosen the clamps at the connections.
· Pull out the air filter.
· If necessary clean the chamber with lint less cloth.
· Replace new filter.

Figure 31 Type of air filter for 30 - 50 HP
· Replace the filter tighten the clamps. powered compressor
· Open the air filter cover by unlatching.
· Remove the old filter.
· If necessary clean the chamber with lint less

cloth.
· Replace new filter. Figure 32 Type of air filter for 60 - 100 HP powered
compressor
· Replace the cover, latch.
· Restart the air filter counter.
· Change the filter every 2000 hour.
Figure 33 Air filter type used in 125 - 430 HP compressors
121
· Stop the compressor. By removing the washer which tighten the filter upper cover, take of the upper
cover and filter.
· Clean the lower cover of the filter internal surface with a piece of cloth. Do not clean these mess with
compressed air. (Messes can flee into intake valve.)
· Replace the new filter and close the upper cover. Be sure that filter placed correctly between the
upper and lower covers.
· Place the up cover washers and nuts.
· If keep the inner element of spare air filter in stock preserve on its own box and clean area.
10.3.6 Separator Element Change

Change the separator element every year. Cleaning the filter is impossible. If compressor works
more than 4000 hours, change the filter every 4000 hours. If differences between internal and
external pressure is more than 1,5 bar even if time is not the changing to the separator, change it.
For changing the separator element;
Atom type separator used for 30 - 50 HP powered machines;
· Stop the compressor and see the internal pressure is zero.
· Take out the old separator element with filter tool.
· Grease the new separator element gasket.
· Replace the filter and tighten by hand.
· Check the leakage on the gaskets and the connections by operating the compressor.
Separator used for 60 - 430 HP powered machines;
· By stopping the compressor close the outlet valve.
· Observe that all the internal pressure
· Remove all the elements that connected to the seperator cover, cover bolts and cover.
· Remove the seperator element.
· Check whether or not there are any burrs in the tank and if necessary clean.
· Remove the bottom and top separator gaskets and clean the clingrit gasket residues on separator
cover and tank.
122
· Replace the new lower gasket.
· Avoid dropping fabric, oakum or foreign materials inside the separator tank.
· Place the new seperator element.
· Replace the lubricated upper gasket.
· Replace the cover the way of removing.
· Replace and tighten the lubricated cover bolts.
· Make the equipment connections properly and strongly that you removed from separator cover
previously.
· Check the compressor that gaskets and connections have any leakage while operating.
10.3.7 Cooling Radiator Maintenance

Ø For keeping the cooler clean, you should not hinder the cleaning of the panel filter.
Ø As the cooling air passes between the cells of the cooler, small amount of dust goes between the
cooler cells and this start to block the cells. Clean this by spraying compressed air between the cells
from the opposite of cooler (from outside to inside).
Ø When the dust between the cells mixes with oil, it may get hardened by sticking. In this case clean
this by spraying an industrial cleaner between the cooler cells.
10.3.8 Separator Oil Return Line (Scavenge) Maintenance

Ø When the separator filter is separating the air from oil, some quantity of oil penetrates into the oil
filter element. This oil is recovered to the system by return line.
Ø When the compressor is operating at load, the oil flow from the scavenge hose should be seen.
Ø If the orifice in the scavenge line gets blocked, the oil level in tank rapidly decrease an oil penetrate
into the compressed air system.
Ø When discharging water underneath the air receiver; in case you observe oil or during some checks
the oil level is decreasing, the scavenge line may be blocked. By stopping the compressor remove
the scavenge line and clean the orifice on the scavenge line by compressed air.
Ø Do not expand the diameter of the scavenge orifice, otherwise the capacity of your compressor
decreases.
10.3.9 Motor Maintenance

For long life and effective use of the electrical motors you should consider a few important points.
123
Ø Make the grounding of the compressor properly.
Ø Do not change the pressure related with the compressor operation, current and time adjustments.
When the adjusted value is exceeded, the motor current will increase as the load will increase. This
situation may cause burning down of your motor.
Ø Do not use products like the separator and oil filters that have complete their service life. The
maintenance activities that are no performed on time, will force the system mechanically and
therefore increase the load of your motor and compressor and shorten its life.
Ø Keep the cooling fan, ventilation channels and the screen of the protective cover clean.
Ø Your elevation from sea level and medium temperature directly affects the cooling coefficient of the
motor. In standard, your motor operates without problem at 1000 meters altitude and at 40 C°
ambient temperature. You may have to review the loading ratio at higher altitudes and warmer
places.
ALTITUDE 1000 1500 2000 2500 3000 3500 4000 meter
% 100 98 95 91 87 83 78
TEMPERATURE 30 35 40 45 50 55 60 °C
% 100 100 100 97 93 87 82
10.3.10 Bearing Lubricating

Ø In standard motors up to 55 KW-75 HP power by use of ZZ series bearings the maintenance has
been lubrication free. But up to that motor power bearing lubrication must be renewed. The
information about type and amount of lubricant that used for bearing lubrication is written on the
motor plate. If not use water proofed lithium based type lubricant (KLUBER ASONIC GHY72, ESSO
MOBIL UNIREX N3 or equivalent values). While your compressor is being produced it is filled with
motor bearing lubricant. If there in nothing else is indicated on the motor plate; renew your motors
bearing lubricant in every 2000 hours (although this may change due to medium temperature and
other effects).
Ø If you did not operate your compressor for a long time, renew the bearing lubricant before first start
up.
124
Table 39 Maintenance Records
MAINTENANCE RECORDS
Compressor Type
Serial Number
DATE HOURMETER MAINTENANCE EXPLANATION PERSONNEL NAME
125
126

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HSC – HSC FRECON DIRECT DRIVE

R00 – First Edition : January 2013

Compiled, Approved & Issued by

Thank you for using HERTZ products.

1.4 Warranty and Obligation

Since the compressor is a complicated machine; performed maintenance by unauthorized or non-

Ø Maintenance and operation made by unauthorized persons,

Ø Using spare parts that is not manufacture by HERTZ KOMPRESSOREN,

Ø Improper installation of safety and protection devices,

Ø Operating the compressor disregarding the safety and operating instruction.

1.6 Technical Service

Telefon : +49 (2382) 889 089-0 (PBX)

Fax : +49 (2382) 889 089-22

1.7 Descriptions and Warnings

Indicates high risk.

˜ Indicates individual instruction about the resulting situation.

Ø Indicates general comments and lists.

2.1 Terms of Use

Ø Learn how to operate and work safely with the compressor.

Ø Always keep the compressor good condition.

Ø If the operation of the compressor is not safe;

· Never start it.

2.2 Unauthorized Modification

2.4 Fire and Explosion Risk

Ø Do not operate the compressor when there is not suitable ventilation.

2.5 Moving Parts

2.6 Hot and Sharp Surfaces

2.7 Flammable and Irritating Substances

Ø Only operate the compressor at environment with sufficient ventilation.

2.8 Electrical Shock

2.9 Check Before Starting

Ø Before operating the compressor stay at the safety distance.

2.10 Compressor and Around Cleaning

Ø Check and repair any leakage immediately. Inform the service.

2.11 Personal Protection and Safety

Ø Do not operate the compressor or any equipment attached

Ø Do not wear headphones to listen music or radio while

2.12 Safety and Warning

Importance of safety is expressed as “danger-warning” under necessary conditions.

Figure 1 HSC 22-D Safety Warnings

Table 2 Safety Warnings

Safety Warnings Description

Rotational direction of Coupling!

Wear ear protector!

Read Instruction Manual!

Ø Do not leave unplugged electric cables.

2.14 Air filter

Ø Do not make any cutting and piercing on the receiver.

2.15 Safety and Protection System

Ø Fan motor overload shutdown

Ø Phase sequence shutdown

Ø PTC for main motor

Ø High discharge pressure shutdown

Ø Change seperator element indicator

Ø Air filter change warning

Ø Pressure relief valve

Ø Emergency Stop Button

Ø Service Warning System

Ø Alarm Warning System

2.16 Noise Protection

2.17 Environmental Protection

Ø Used oil, grease and contaminated materials;

Ø Materials for cleaning;

Ø Condensation that revealed in the comp.