HKR HYDRAULIC SCREW COMPRESSORS OPERATING INSTRUCTIONS

Transcription

1 1 HKR HYDRAULIC SCREW COMPRESSORS HKR 500/10-29 HKR 800/10-43 HKR 1300/10-37 HKR 2000/10-53 HKR 2500/10-67 HKR 4000/ HKR 5000/ OPERATING INSTRUCTIONS

2 2 TABLE OF CONTENTS 2 1. SAFETY PRECAUTIONS AND WARNING STICKERS 3 2. PRODUCT DESCRIPTION 4 3. HKR GENERAL ASSEMBLY AND FUNCTIONING Compressor internal diagram Operating description Lubrication system of compressor Pressure and compression ratio Air and oil temperatures Air humidity 6 4. INSTALLATION Open centre hydraulic system with variable displacement pump Closed centre hydraulic system with variable displacement pump Hydraulic system with constant displacement pump Connection to the air supply system 9 5. OPERATION Off-load mode Hydraulic fluids Compressor oils Multigrade oil Temperatures and oil types Cold starts COMPRESSOR MAINTENANCE Oil level check through oil filler opening Oil change Oil filling Oil filter replacement Replace air-oil separating element Replacing the air filter element MAINTENANCE INTERVALS TROUBLESHOOTING PRODUCT DISPOSAL PARAMETERS WARRANTY DECLARATION OF CONFORMITY NOTES 23

3 3 SAFETY PRECATIONS This operating manual provides information on the method of working, the operation and maintenance of the HKR. Therefore, it must be used for operation and maintenance of the HKR. Read this operating manual carefully before the initial commissioning of the HKR, to ensure proper handling, operation and maintenance right from the beginning. Pay particular attention to all warning and safety instructions. The pressure in both hydraulic and compressed air circuits of HKR-compressor is considerably high. There at the technical condition of your equipment should be under constant scrutiny. Maximum pressure, temperature and load must never be exceeded. Operators and maintenance personnel must always comply with local safety regulations and precautions in order to close out the possibility of damages and accidents. Especially couplings, valves and hoses should be maintained tight and clean as well as kept under constant observation avoid possible leakages of pressure and hot blowouts. Hydraulic leakages must be rectified immediately to avoid user and bystander injuries. Follow all your local safety instructions related to the high pressure hydraulics. In order to exclude possible accidents, it is not allowed to clean or inspect HKR-compressor and pneumatic tools when hydraulic or/and pneumatic circuit is pressurized. Never aim compressed air at a person. Prior to any cleaning, inspection and service hydraulic system of your carrier machine must be stopped and both hydraulic and pneumatic circuits dissipated, for instance, by opening the blow gun. Always wear appropriate clothing and safety equipment such as goggles, ear protection and safety shoes at all times when operating by the compressor. When operating the compressor, beware of machinery parts warmed by hot hydraulic oil. EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISASSEMBLING OR REPAIR OF HKR-COMPRESSOR AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE AND LONG-LIFE OPERATION OF YOUR EQUIPMENT. Hydraulic system of a carrier machine should be maintained according to the service program. All installation and service of both hydraulic and electric equipment must be performed by qualified and experienced personnel only. WARNING STICKERS Dynaset dispatch department includes one (1) warning sticker bag per one (1) main product. Product recipient is obligated to fix determinate warning sticker to Dynaset product. Attach sticker to visible and appropriate place or close to Dynaset product where it s easily seen. Before attaching sticker clean surface with solvent detergent. READ OPERATING INSTRUCTIONS. GENERAL CAUTION. BEWARE OF HOT SURFACE. USE EAR PROTECTOR AND BEWARE OF PRESSURE AIR. GLOGGLES

4 4 This manual contains instructions and specifications for the assembly and operation of the DYNASET HKR screw compressor. PRODUCT INFORMATION DYNASET HKR hydraulic screw compressors are compact and integrated all-in-one units, especially designed for mobile installation. The only power source is a hydraulic system to provide compressor with required hydraulic fluid flow at demanded pressure. Dynaset hydraulic screw compressor transforms hydraulic power into a high quality compressed air. The screw compressor can be installed in almost any working machine. It is easy and simple to use. Dynaset HKR screw compressors are designed to meet regular modern compressed air demands. HKR hydraulic compressors are used to power pneumatic tools, filling tires, air flushing, purge air protection and cleaning equipment, CAFS foam generation, etc. HKR GENERAL ASSEMBLY AND FUNCTIONING AIR INTAKE Safety valve 2. Intake valve 3. Hydraulic motor 4. Temperature probe connection 5. Transport eyes 6. Dynaset type plate 7. Intake filter 8. Pneumatic control unit 9. Oil thermostat 10. Oil filler plug 11. Heat exchanger 12. By-pass check valve 13. Oil filter 14. Oil return line check 15. Minimum pressure valve 16. Compressed air outlet (AP) 17. Oil drain plug 18. Compressor block 19. Hydraulic pressure line (P) 20. Hydraulic return line (T) 21. Separator cartridge

5 5 COMPRESSOR INTERNAL DIAGRAM 3 1. Intake filter 2. Intake valve 3. Control block 4. Screw compressor 5. Separating tank with pre-separation 6. Air-oil separating element 7. Minimum pressure valve Air intake AP 9 12 P T Pressure line (P) Return line (T) 10 2 bar 8 8. Oil thermostat 9. Oil filter 10. Heat Exchanger 11. Safety valve 12. Hydraulic motor 13. Non-return valve 14. Air aftercooler (optional) 15. Water separator (optional) OPERATING DESCRIPTION The air drawn in flows via the intake filter 1 through the intake valve 2 into the compression chamber 4 of the compressor. In the compression chamber, the intake air is compressed and oil for lubrication and cooling is injected. The oil-air mixture then enters the separating tank 5 in which the majority of the oil is separated from the air. The air travels to the compressed air outlet via the air-oil separating element 6 and the minimum pressure valve 7 and travels into the compressed air system via the (optional ) air cooler 14 and (optional) water separator 15. In the air-oil separating element 6, the oil is filtered out down to a residual content of < 3 mg/m3 and is then conveyed back into the compressor housing via a nozzle and the non-return valve 13. When the compressor module is switched off, the minimum pressure valve 7 with a non-return function prevents backflow of the compressed air out of the system into the compression chamber in the discharge phase. During startup a faster pressure buildup is also ensured, which is required for optimum lubrication and oil separation. The heat resulting during compression is dissipated via the oil-air mixture. The oil circulation also results from the pressure difference between the outlet and inlet pressure. The optimum operating temperature for the oil is adjusted by the integrated oil thermostat 8. Depending on the oil temperature, the oil thermostat valve routes the oil flow via the oil cooler 10 or directly to the oil filter 9. The oil then flows via the oil filter 9 to the various injection points in the compressor block.

6 6 Compressor oil performs following functions: LUBRICATION SYSTEM OF COMPRESSOR 1. LUBRICATION: Pressure differential makes the oil spread along grooves to the surfaces to be lubricated. Separate oil pump is not needed. 2. HERMETIZATION: Oil, injected to screws surfaces in the stator, seales screws against each other and stator surface and lubricates them. 3. COOLING: Dynaset HKR screw compressor is equipped with oil heat exchager. The compressor s heat is transferred to hydraulic system with heat exchanger. HKR requires cooling capacity from carrier machines hydraulic system (ref. to PARAMETERS). PRESSURE AND COMPRESSION RATIO The rated absolute intake pressure is 1 bar ( Pa). (NOTE! The reference barometric pressure at 0 m above sea level is 1,0135 bar, when at 1000 m above sea level it drops to approx. 0,9 bar). When the discharge (operational) pressure of HKR-compressor is 10 bar, compression ratio is equal to: operational pressure + barometric pressure barometric pressure = ,0135 1,0135 The compression ratio for unit of (x) bar is calculated in the same way. = 10,00 AIR AND OIL TEMPERATURES Filled with specified compressor oil or corresponding, (ref. to COMPRESSOR OILS ) unit is operated without any particular arrangements within ambient temperature range -5 ºC ºC. If ambient temperature drops below -15 ºC or raises over + 45 ºC, fill the compressor with synthetic oil or be kindly requested to contact DYNASET s representative. AIR HUMIDITY Compressor can be operated at the relative humidity up to 90%, provided that the ambient temperature is within the above range. If air humidity exceeds 90%, please contact DYNASET s representative.

7 7 INSTALLATION DYNASET hydraulic compressor can be placed deliberately ensuring free air intake and an easy access to the unit. Position of a compressor should be horizontal maximum inclination 10 degrees. Compressor s location should be chosen as far as possible from any source of dust and heat. Protective cover against weather and season impacts is recommended. Intake air should not contain any smoke, toxic or flammable gas/vapor. When necessary, extra intake pipe can be fitted (the pipe should be measured properly in order to avoid load loss). DYNASET hydraulic compressor works installed into an original hydraulic system of any carrier machine. Additionally, return line must be connected to a hydraulic oil tank directly in the shortest possible way in order to keep return oil pressure under 5 bar. Generally DYNASET s T-line is to be connected directly to the return line of a hydraulic system, when hydraulic fluid flows to the tank only through the return filter and cooler. Both filtering degree and cooling capacity of a hydraulic system should be sufficient (ref. to PARAMETERS). It is possible to use DYNASET either as a mobile compressor and connect hydraulic power with quick couplings, or make a fixed installation on a carrier machine. To put DYNASET compressor into operation only pressure- (P) and return (T) lines of a hydraulic system are to be connected to the unit s corresponding hydraulic ports. The proper connection ensures correct rotation direction of the compressor. Rotation in opposite direction is not allowed. Furthermore, cross-connection of hydraulic hoses damages hydraulic motor s shaft seal and compressor. HKR T P HKR P T P T HKR Ensure that the oil flow is sufficient to run the unit, i.e. at least the nominal flow must be available. At the oil flow less that demanded nominal rate, compressor s delivery will be below the nominal. If the oil flow is too low, the lubrication of the compressor is insufficient and the unit could be damaged. In the case the oil flow is too high. Flow must be reduced either by dropping down the rotation speed of carrier machine hydraulic pump or using flow limiter valve. DYNASET priority valve is recommended. After having been connected to the hydraulic system, DYNASET hydraulic compressor HKR is to be started by directing the oil flow to the unit s pressure port by means of control valve - manual or solenoid. Even simple ball valve or three-way valve can be used. To ensure DYNASET s proper operation, the hydraulic pressure must be set to the level, at which at least the nominal power output is achieved (ref. to PARAMETERS). Lower hydraulic pressure reduces compressed air pressure. Maximum hydraulic pressure is 230 bar (ref. to PARAMETERS). If the hydraulic system main pressure is higher, service pressure relief valve must be used. Ensure also that your machine oil cooling is working properly when compressor is in operation. (ref. to PARAMETERS)

8 8 OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED PRIORITY VALVE. DYNASET PV SAE 3/4-1 1/4 -XX lpm T P - 12/24 V priority valve includes following components: 1. Sandwich-mounted pressure compensator with SAE-flange specification; 2. Solenoid valve 12/24V; 3. Flow limiter; 4. Pressure relief valve. PV SAE priority valve is designed for the PV-SAE valve installation to main pressure line between B SAE-flanges of main hydraulic pump. Preadjusted, independent from other functions LS LS CF and priorised hydraulic flow for DYNASETunit comes from the solenoid valve. P P HKR A The rest of hydraulic pump s capacity T is available for all other functions. Furthermore, pump s control works together with DYNASET PV SAE priority valve. ALSO AVAILABLE for open centre hydraulic systems with variable displacement pump: PRIORITY VALVE PV SAE ¾ - 1 ¼ - 12/24 V. DYNASET PRIORITY VALVE enables trouble-free operation of your DYNASET-unit simultaneously with other hydraulic executors. CLOSED CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP The demanded hydraulic flow is to be ensured and controlled with a DYNASET PRESSURE COMPENSATED LOAD SENSING (LS) VALVE. DYNASET LS-valve includes following components: 1. Flow limiter; 2. Solenoid valve 12/24V; 3. Pressure relief valve; 4. Shuttle valve (OPTIONAL). P LS LS-valve T P HKR DYNASET LOAD SENSING VALVES: LSV 40, LSV 60, LSV 95 and LSV 150 LS-connection, pressure relief, max. hydraulic flow 40, 60, 95 ja 150 l/min respectively. DYNASET FLOW LIMITERS to the pressure line: VR 40 PK - 1/2, max. 35 l/min, with pressure compensation; VR 95 PK - 3/4, max. 95 l/min, with pressure compensation. VRD 180 PK - 1, max. 180 l/min, with pressure compensation. ALSO AVAILABLE for closed centre hydraulic systems with variable displacement pump: DYNASET SOLENOID VALVE to the pressure line for remote starting. SV 70 NC - 1/2-12 / 24 V max 70 l/min with LS -connection; SV 150 NC / 24 V max 150 l/min with LS -connection.

9 9 HYDRAULIC SYSTEM WITH CONSTANT DISPLACEMENT PUMP T P The demanded oil flow is to be ensured with proper hydraulic pump choice. In systems with redundant hydraulic flow an installation with DYNASET PRIORITY VALVE is recommended. Installation with a standard pressure compensated 3-way valve should be avoided in order to close off potential waving in hydraulic system. HKR ALSO AVAILABLE for hydraulic systems with constant displacement pump: DYNASET FREE CIRCULATION VALVE with solenoid and pressure control, type VKV 90 3/4. ALSO AVAILABLE for closed centre hydraulic systems with variable displacement pump: DYNASET SOLENOID VALVE to the pressure line for remote starting. SV 70 NC - 1/2-12 / 24 V max 70 l/min with LS -connection; SV 150 NC / 24 V max 150 l/min with LS -connection. When installing a compressor to a hydraulic system, is to kept in mind that the allowed nominal hydraulic flow should not be exceeded (Qhy_nom = Qhy_max). CONNECTION TO THE AIR SUPPLY SYSTEM Compressor can be connected to the air supply system (or consumer) with a proper fitting and cut-off valve (options). The internal diameter of pipe / hose used for compressor s connection should be at least equal to AP-port to keep the pressure drop minimal. The length of a pipeline, laid with the pipe of same diameter as AP-port, can be 50 m as maximum. For longer lines use larger diameter.

10 10 OPERATION Prior to starting the compressor check whether the unit is filled with oil. In non-operating and depressurized compressor oil level is right. When necessary top up with the same oil as the unit is filled with. Replace and tighten the filler plug (Ref. to the instructions below). Open the cut-off valve in compressor s pressure line. Ensure that the unit is decompressed - when pressurized, compressor may start with difficulty*). With carrier s engine running HKR-compressor is started with a hydraulic control valve. Compressor starts to produce usable compressed air when hydraulic flow achieves the functional minimum rate, which is approx. a half of the nominal value (Ref.to the unit s nameplate as well as to the PARAMETRS). The nominal discharge is achieved when the compressor is rotated by hydraulic flow adequate to the nominal rotation speed. Hydraulic flow rate marked on the compressor s nameplate is an absolute maximum and should not be exceeded in any circumstances. A redundant hydraulic flow causes compressor s overspeeding and may damage it. Qpi, l/min Qpi, nom Qpi, min DISCGARGE Qhy_no m = Q hy_max 0 Qmin Qnom = Qmax Qhy, l/min HYDRAULIC FLOW OFF-LOAD MODE Compressed air is consumed according to the demand, when compressor s delivery levels within 0 l/min to the maximum. If the compressed air is not used while compressor is running, off-load automatics closes the intake valve and sets compressor s internal pressure to 1-2 bar (to prevent compressor oil from drain into the air filter) when the output drops to 0 l/min. When the compressed air is consumed, off-load automatic controls the intake valve according to the current air demand. ATTENTION! The compressor must be operated neither in smoky environment nor in conditions where toxic or flammable vapors could be aspirated. Compressor s maximum pressure must not be exceeded in any circumstances. Compressed air delivered by a HKR-compressor must not be used as the breathing air, even if purified and filtered. HKR-compressor is designed for air only and must not be used with any other gas. If the compressor is connected to the distribution network or consumer with a flexible hose, ensure that the hose is of proper diameter and pressure class. Damaged or worn hose should be replaced immediately. Check the compressor s oil fill periodically: The oil level must be between min and max. NEVER REMOVE THE OIL FILLER PLUG WHEN THE COMRESSOR IS RUNNING OR PRESSURIZED! Warning: The unit parts, oil, and screw plug can be hotter than 80 C! RISK OF BURNS! Wear personal safety equipment! MAX MIN

11 11 Wide range of standard hydraulic fluids can be used with the DYNASET hydraulic equipment. Depending on the operating temperature, following mineral hydraulic oils are recommended: ISO VG 32S for oil s operation temperature up to 70 C; ISO VG 46S for oil s operation temperature up to 80 C; ISO VG 68S for oil s operation temperature up to 90 C. HYDRAULIC FLUIDS Synthetic and bio-oils can be used as well if their viscosity characteristics and lubricating efficiency are corresponding to above mineral oils. Automatic transmission fluids and even engine oils can be used, provided that they are allowed to be used in hydraulic system of your carrier machine. To use special hydraulic fluids a with DYNASET equipment, please be kindly requested to contact nearest DYNASET representative for an advice. COMPRESSOR OILS DYNASET screw compressors should be operated with an oil that is suitable for special requirements. It must also be suitable in case of unfavourable operating conditions, such as pollution of the intake air and also in case of high ambient temperatures. Petroleum raffinates (mineral oils), synthetic oils as well as bio-degradable oils can be used as screw compressor oils. Compliance with oil viscosity is imperative; failure to do so poses a risk to the bearing service life. The oil in the compressor module must meet the following requirements, among others: - High ageing stability - High dispersive capacity - Flash point: above 200 C/392 F - Minimum foaming - High corrosion protection - Basic oil: Solvent raffinate - Operating temperature: up to 110 C/230 F - Viscosity class: ISO VG 68 In most cases, an oil of the viscosity class ISO VG 68 is required, but a minimum viscosity of approx. 10 cst (0.387 ft2/h) up to 30 cst (1.162 ft2/h) at operating temperature must be maintained. In this case, the possible reduction in the viscosity due to oil degeneration over the duration of operation must be taken into account. MULTIGRADE OIL Attention: - The use of multigrade oils can cause problems in the long run since viscosity improvers are destroyed over time. The oil is then no longer secured in the upper viscosity class and a thermal stability is no longer completely ensured. Therefore, the use of multigrade oils in Dynaset HKR compressors is not authorized. - Only use oils approved for screw compressors! - Use the same manufacturer and the same oil type as is currently in use in the HKR screw compressor. Note: Mixing different oils is not permissible.

12 12 Note: Guide values at 60% relative humidity and 10 bar ultimate pressure. TEMPERATURES AND OIL TYPES Ambient temperature of the compressor Classes of oil for compressors Compressor oil injection temperature Compressor outlet temperature QUALITY OIL CHANGE SUPPLIER ISO VG DETAILS MAX, HOURS Shell Corena 4S R or 12 months Shell synthetic oil Castrol Aircol SR or 12 months Shell synthetic oil Rarus SHC or 12 months Exxon Mobil synthetic oil COLD STARTS During compressor cold starts, the viscosity of the oil must enable the sufficient, immediate supply of the compressor with lubricant following starting while taking into account the higher pressure losses in the oil circulation which is still cold. Note: It s recommended when starting compressor in cold ambient temperatures that compressor air supply line is closed and compressor is run with off-load mode few minutes to make oil temperature raise.

13 13 COMPRESSOR MAINTENANCE DYNASET hydraulic compressors are low-maintenance units. Only normally wearing parts and materials should be replaced either when necessary or in accordance with a service program. Refer also to the TROUBLESHOOTING section. Prior to starting any maintenance or repair, ensure that the compressor is completely depressurized. OIL LEVEL CHECK THROUGH OIL FILLER OPENING Warning: The unit parts, oil, and screw plug can be hotter than 80 C! RISK OF BURNS! Wear personal safety equipment! Attention: - With hot oil, the oil level can be approx. 10 mm higher than with cold oil shortly after discharging. As a result, oil may escape when the screw plug is opened at the maximum oil level. In this case, close the screw plug again immediately and carefully remove the oil that has escaped. - Only check the oil level when the compressor system is in a horizontal position. Note: The screw cap of the oil filler neck is provided with a safety hole on the side from which oil or air escapes if there is any residual pressure in the separating tank. Wait briefly in this case. MAX MIN Switch off the system, prevent it from being switched back on without authorization, and bring it into a horizontal position. Wait for one minute at standstill. Unscrew the screw plug of the filler neck by hand with the oil level depressurized. Check the oil level. If necessary, top up oil of the same oil type and the same brand up to the maximum level. If required, fill up oil of the same oil type and the same brand up to the maximum level. Note: The oil filler neck is positioned so that it is not possible to overfill the system. Excess oil runs out of the filler neck again. Screw on the screw plug firmly by hand. Switch on the unit. Check the oil filling screw for leaks, if required, replace the O-ring. Carefully remove any excess oil that has escaped. The compressor system must be at operating temperature in this case. OIL CHANGE Switch off the system and prevent it from being switched back on without authorization. Depressurize the system completely. Slowly unscrew the screw plug of the oil filler neck by hand. Carefully unscrew the oil drain screw 1 and catch the used oil in a suitable container. Clean the oil drain screw 1 and screw in again. 1

14 14 OIL FILLING Only add oil when the compressor system is in a horizontal position. - Make sure to use recommended screw compressor oil. Add oil of the same oil type from the same manufacturer. Switching over to another oil type can require flushing of the compressor block. DYNASET also recommends replacing the oil filter at the time of an oil change. If necessary, replace the oil filter (see chapter Replace oil filter ). Bring the system into a horizontal position. Via the filler neck on the separating tank, add oil up to the maximum level and screw the screw plug firmly onto the filler neck by hand. Switch on the screw compressor and allow it to run for approx. three minutes. Oil level check: Top up the missing oil quantity again up to the maximum level. Attention: Dispose of the old oil filter cartridge in accordance with the applicable regulations. OIL FILTER REPLACEMENT Switch off the screw compressor system and prevent it from being switched back on without authorization. Depressurize the system completely. Remove the oil filter cartridge 1 with a suitable tool, e.g. oil filter strap wrench. Oil the seal 2 on the new oil filter cartridge 1 with oil of the same oil type as in the HKR screw compressor. The new oil filter cartridge 1 must be held vertically and filled with oil of the same oil type as in the compressor module before being screwed on. Screw the new oil filter cartridge onto the multiblock 3 and tighten by hand. No tool is required. Switch on HKR compressor. The oil filter must then be checked for leaks with the system running. Check the oil level (see chapter Oil level check via oil filler opening ), top up the missing oil quantity again up to the maximum level

15 15 REPLACE AIR-OIL SEPARATING ELEMENT Attention: Dispose of the old separating element in accordance with the applicable regulations. Switch off the screw compressor system and prevent it from being switched back on without authorization. Attention: Heavily soiled intake air or low-quality oil cause heavier soiling of the cartridge, which can result in the premature need for replacement. Note: Dispose of the used fine separator cartridges according to regulations. Switch off the screw compressor system and prevent it from being switched back on without authorization. Unscrew the air-oil separating element 1 with a suitable tool, e.g. oil filter strap wrench. Oil the seal on the new air-oil separating element 1 with oil of the same oil type as in the compact module screw compressor. Tighten the new air-oil separating element by hand. No tool is required. Switch on the HKR screw compressor The fine separator must be checked for leaks with the system running. 1 REPLACING THE AIR FILTER ELEMENT Attention: - Dirt and dust particles must not be permitted to get into the air inlet of the compressor module. - It is not permissible to clean the filter element; the filter element must always be replaced in case of soiling! - Dispose of the old air filter element according to the applicable regulations. Switch off the screw compressor system and prevent it from being switched back on without authorization. Screw off the wing nut 3 and remove the filter cover 2. Remove the old filter element 1. Carefully remove dust from the filter housing. Tighten the thumb nut. Switch on the HKR screw compressor. Test run and function test

16 16 MAINTENANCE INTERVALS Attention: The frequency of the maintenance intervals (replacement of oil, oil filter, fine separator cartridges as well as air filter element) varies with the application and the operating parameters. Therefore, depending on the model of the unit, Dynaset specify next maintenance intervals. These must be complied with on priority. The following table provides an overview of the reference values for the Dynaset HKR screw compressor. CHECK POINTS After the first Weekly or every Monthly or every Every 3 months or Every 6 months or 50 h 50 h 100 h 500 h 1000 h 2500 h Check oil level O I Clean compressor air intake filter O I Clean oil cooler and air after cooler O I Check oil level in separator tank O I I Listen for abnormal running noise during operation * I Check all connections for firm seating O I Change the air-oil separating element I Change oil filter I Oil change I Change filter element in intake air filter I Check system for leaks O I * Immediately switch off the compressor, have the deficiency remedied. Maintenance operations have to be performed at reduced Intervals in case of dusty environments. I = Inspect R = Replace, R*= Replace if necessary C = Clean Every 12 months or NOTE: O = These operations must perform to a new device after the first 50 hours. Within the first 300 hours of operation: Clean the oil return valves. NOTE: All installation and service of both hydraulics and electric equipment must be performing experienced personnel only. Every 2 years or needed

17 17 TROUBLESHOOTING 1. COMPRESSOR DOES NOT START WHILE CARRIER S ENGINE IS RUNNING AND HYDRAULIC SYSTEM IS ON. 1.1 Malfunction of compressor s hydraulic control valve. 1.2 Compressor s excessive internal pressure. 1.3 Failure in hydraulic system. 1.4 Air pressure in delivery line disrupts compressor s start. 1.1 Check and repair. 1.2 Check the minimum pressure/non return valve and repair possible blowing Check whether the hydraulic fluid flow and pressure are sufficient. Adjust when necessary Check the hydraulic motor for possible leakage. Replace motor if necessary. 1.4 Let off the pressure from the delivery line prior to staring the compressor. It is recommended to install the solenoid control valve for off-load valve, especially if the pneumatic system is provided with an air reservoir. 2. COMPRESSOR STARTS HARDLY See 1.3 See AIR PRESSURE DOES NOT ACHIEVE REQUESTED RATE. 3.1 Pneumatic control unit incorrect setting. 3.2 Safety valve opens due to the either the failure or incorrect setting of pneumatic control unit. 3.3 Failure in hydraulic system. 3.4 Air intake filter is clogged. 3.5 Oil separator s filter element(s) clogged. 3.1 Check and adjust when necessary Check and adjust pneumatic control unit Check whether the hydraulic fluid flow and pressure are sufficient. Adjust when necessary Check the hydraulic motor for possible leakage. Replace motor if necessary. 3.4 Check and replace. 3.5 Check and clean / replace filter element(s).

18 18 4. COMPRESSOR DOES NOT PRODUCE COMPRESSED AIR = RUNS UNLOADED 4.1 Delivery line closed (i.e. OPEN/CLOSE valve is damaged) or possible malfunction in pneumatic executor. 4.2 Pneumatic control unit failure or incorrect setting (i.e. adjusted to the pressure lower than setting of minimum pressure / non return valve). 4.3 Air intake valve does not open. 4.1 Check and repair possible failure Check and repair possible failure. TROUBLESHOOTING 4.3 Check the valve and repair failure. Check also the whole valve block to order to find out and repair possible malfunctions. 5. EXCESSIVE OIL CONSUMPTION 5.1 Filters of the oil return valves are clogged. 5.2 Oil separator s filter element(s) clogged. 5.1 Check and clean / replace valves Check and clean / replace filter element(s). 6. COMPRESSOR S OVERHEATING. 6.1 Dirty oil cooler. 6.2 High ambient temperature. 6.3 Low oil level. 6.4 Due to the seizure of thermostatic by-pass valve, compressor oil does not circulate through oil cooler. 6.5 Due to the insufficient cooling capacity of a hydraulic system hydraulic fluid warms the compressor. 6.1 Clean the oil cooler. 6.2 Sufficient ventilation is to be arranged. 6.3 Add compressor oil to the required level. 6.4 Check and repair the valve. 6.5 DYNASET OY offers wide range of hydraulic components including oil coolers!

19 19 Conform to waste legislation, regulations and recommendations in waste disposal and waste recycling issued by local authorities. 1. Precondition: Product is permanently useless or beyond repair. Before transportation get off all used agent (oil, cooling liquid) and dirty filters. Items requiring special handling can normally be done by authorized waste management facility if not: Separating the base materials, iron, copper, steel, electronics, removing paint, polyester resin, and insulation tape and/or plastics residues from all components. This waste material can now be recycled. 2. Deliver the recycling material to waste management facility. Note! Customer can send the DYNASET equipment for reuse or recycling to the Dynaset Oy or to other location determinate by Dynaset representative. Customer pays shipping cost. Equipment must be adequately packed for shipment. Shipment documents must contain purchaser s name and contact information. PRODUCT DISPOSAL

20 20 PARAMETERS PARAMETERS HKR - SCREW COMPRESSORS HKR 500 HKR 800 HKR1300 HKR2000 HKR2500 HKR4000 HKR5000 /10-29 /10-43 /10-37 /10-53 /10-67 / / DISCHARGE CHARACTERISTICS Flow rate at ref. conditions* max. l/min Maximum pressure bar Compressed air connection AP BSP 1/2" BSP 1/2" BSP 3/4" BSP 3/4" BSP 3/4" BSP 1" BSP 1" HYDRAULIC CONNECTIONS Pressure line P BSP 1/2" BSP 1/2" BSP 1/2" BSP 1/2" BSP 1/2" BSP 1 " BSP 1" Return line T BSP 1/2" BSP 1/2" BSP 1/2" ** BSP 1/2" ** BSP 1/2" ** BSP 1 1/4" BSP 1 1/4" Drain line D NO NO NO NO NO NO NO HYDRAULIC POWER REQUIREMENTS Minimum flow l/min Nominal flow l/min Maximum flow l/min Pressure at nominal flow bar Maximum pressure bar Pressure when unloaded bar HYDRAULIC FLUID REQUIREMENTS Viscocity cst / optimum Temperature C max. 70 *** Filter ratio, recommendation um min. 25 Cooling capacity requirement **** kw OVERALL DIMENSIONS Length mm Width mm Height mm WEIGHT kg * According to ISO 1217 (1996) at discharge pressure of 6 bar. ** Minimun return line hose/pipe inner diameter 19mm, (3/4 in.) *** REF. TO HYDRAULIC FLUIDS **** Minimum cooling capacity for HKR compressor on carrier machine

21 21 MANUFACTURER S LIMITED WARRANTY 1. Warranty coverage All hydraulic accessories manufactured by DYNASET OY are subject to the terms and conditions of this limited warranty. Products are warranted to the original purchaser to be free from defects in materials or workmanship. Exclusions from warranty are explained in item Beginning of warranty period Warranty period begins from the delivery date of the product. Delivery is considered to be done on the date when installation has been accomplished or purchaser has taken the product in use. Product is considered as taken in use at the date when DYNASET OY has delivered the product to purchaser, unless separately agreed otherwise by written agreement. 3. Warranty period Warranty period is twenty four (24) months based on maximum of 2000 hours usage during this time period. In cases where the system is provided complete with certain special components (e.g. drive unit), those components are considered as a subject to their manufacturer s warranty. 4. Warranty procedures Immediately upon identifying a problem which purchaser believes to be a failure subject to the product s limited warranty, purchaser must contact primary to the seller of the product. Contact must be made as soon as possible, latest thirty (30) days after the problem was identified. Seller and/or manufacturer technical staff determines the nature of the problem primarily by phone or . Purchaser commits to give necessary information and to perform routine diagnostic procedures in order to determine the nature of the problem and necessary procedures. 5. Warranty repairs If the product is found to be defective during the warranty period, DYNASET OY will, at its option, either repair the product, author it to be repaired at its authorized workshop or exchange the defective product. If the product must be repaired elsewhere than premises of DYNASET OY or authorized workshop, all costs excluded from this warranty (traveling and waiting hours, daily allowance, traveling expenses and uninstallation/reinstallation costs) will be charged from the purchaser. If the problem is not covered by this limited warranty, DYNASET OY has the right to charge purchaser of troubleshooting and repairing. 6. Delivery terms of warranty repair If the product is found possible to be defective under this limited warranty and it needs to be repaired, DYNASET OY gives Warranty Return Number (WRN). Items being returned must be shipped, at the purchaser s cost, adequately packed for shipment, to the DYNASET OY or to other location authored by DYNASET OY. Shipment documents must contain: - Purchaser s name and contact information - Receipt of original purchase - WRN code - Problem description 7. Warranty of repaired product Warranty period of the product repaired under this limited warranty continues to the end of original warranty period. 8. Exclusions from warranty This warranty shall not apply to: a. Failures due to normal wear and tear, improper installation, misuse, abuse, negligence, purchaser selection of improper product to intended use, accident, improper filtration of hydraulic oil or intake water or lack of maintenance b. Cost of maintenance, adjustments, installation or startup c. Coating, hydraulic oil, quick couplings and interconnection hoses (internal or external to system assemblies) d. Products altered or modified in a manner not authorized by DYNASET OY in writing e. Products which have been repaired during warranty period by others than DYNASET OY or its authorized workshop f. Costs of any other damage or loss, whether direct, indirect, incidental, special or consequential, arising out of the use of, or the inability to use, the product g. Telephone or other communications expense h. Product that is used in exceptional conditions, considered to cause excessive wear and tear i. Faults caused by nature phenomenon s like flood, thunder, etc. DYNASET OY, all rights reserved

22 22 EC DECLARATION OF CONFORMITY We hereby declare that the below-reference product design, structure and our manufacture form fulfills relevant, fundamental safety and health requirements with the provisions in the Council Directive on mutual approximation of laws of the Member States on the safety of machines. - Machine directive 2006/42/EC - Directive 97/23/EC European standards Pressure equipment. - LVD directive 2006/95/EC Apply conformity standards: - EN Safety of machinery Electrical equipment of machines. - CEN EN ISO 4413: EN ISO 4413:2010 Hydraulic fluid power - General rules and safety requirements for systems and their components. If device has changed by someone other than at the hands of manufacturer or his permission, this declaration is not valid. PRODUCT: HYDRAULIC SCREW COMPRESSOR SERIES ALL TYPE NUMBERS: HKRxxxxxxxx-xxxx-xxxx-xxxx-xxxx(xxx+xxx) YLÖJÄRVI DYNASET Oy Timo Nieminen R&D Manager

23 23 NOTES