User Handbook

HV04 - HV07 Models (ACS)

Stationary Air Compressors

GB ST 16048-00 Iss A 04/2003

This page is intentionally left blank
Contents

Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Introducing your new Compair UK Limited compressor . . . . . . . . . . . . . . . . . . . . . 5
1.2 Customer warranty terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Product development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Quality standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Model range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Terminology: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 General Health and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 The Health and Safety at Work Act, 1974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Before Working on Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 When Operating the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Potential Oil Health Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Packing Methods Fig. 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Lifting and Transportation Fig. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Weights and Dimensions Fig. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Air Dryer Unit Fig. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Installation and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Positioning Your Compressor - Basic Requirements . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Ventilation Fig. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Accessibility Fig. 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.5 Electrical Installation Fig. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.6 Check Direction of Motor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.7 Regulated Speed Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.8 RS Operation with Other Compair Vane Compressors . . . . . . . . . . . . . . . . . . . . . 15
5.9 Positioning of Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.10 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Compressor Assembly Fig. 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1 Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2 Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.3 High Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.4 Oil Life of Fluid Force Red 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.5 Oil Level Fig. 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.6 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.7 Pressure Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.8 Air Delivery Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2 Checking Procedure Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.3 Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4 Compressor operation Fig. 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.5 Starting - Continuous Mode Fig. 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.6 Starting - Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.7 Starting - Regulated Speed Fig. 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.8 Stopping - Single Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.9 Stopping - Regulated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ST 16048-00A 3
 Contents

8.10 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

8.11 Compressor Vent Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1 Standard Compressor Control Fig. 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2 Pressure Switch Fig. 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.3 Pressure Control - RS compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2 Routine Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.3 Check Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.4 Basic Service Fig. 18 and 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.5 Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.6 Oil Draining & Filter Replacement Fig. 18 and 20 . . . . . . . . . . . . . . . . . . . . . . . . 28
10.7 Oil Draining Fig. 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.8 Oil Filter Replacement Fig. 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.9 Oil filling / Top-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.10 Air Filter Replacement Fig. 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.11 Oil Separator Replacement Fig. 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.12 Clean Oil Cooler/After cooler Fig. 19 and 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.13 Panel Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.14 Electrical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.15 Check operation of over-temperature control unit Fig. 21 . . . . . . . . . . . . . . . . . . 29
10.16 Servicing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4 ST 16048-00A
1 Introduction

1 Introduction
1.1 Introducing your new Compair UK Limited
compressor
Note: These instructions comply with the latest European
Directives regarding content and are valid for machines carrying
Your new Hydrovane compressor has been designed and
manufactured to the exacting standards necessary to ensure the CE mark.
long-life, reliability and high performance. Compair UK Ltd are
world leaders in compressed-air technology using the most 1.5 Model range
modern techniques and plant available to give our customers the
following benefits: This handbook relates to all HV04 - HV07 compressors, model
types:
• Compact space saving design.
• Easy to position, install and operate. HV04 - HV07
• Economical to run, inexpensive and simple to service. V04ACS07-4035D000

• Quiet, smooth unobtrusive operation. V04ACS010-4035D000

• Proven reliability with the option of extended warranty V05ACS07-4035D000

periods. V05ACS10-4035D000
• Full support available from world-wide Distributor network. V07ACS07-4035S000
V07ACS10-4035S000
This user handbook should be used in conjunction with the parts/
service manual. V07ACS07-4035V000

IMPORTANT ! This publication refers to compressors with serial numbers:

BEFORE INITIAL START-UP ENSURE THAT THE V04-000001

COMPRESSOR OIL CHAMBER IS FILLED TO THE CORRECT V05-000001
LEVEL WITH A HYDROVANE APPROVED OIL. V07-000001

DO NOT OVERFILL. 1.6 Terminology:

Serial Number Signifies
1.2 Customer warranty terms Segment
All compressors, which are serviced by an authorised CompAir V Vane
UK Ltd Distributor are guaranteed for twelve months from the date 04, 05, 07 kW motor
of commissioning or eighteen months ex works, whichever is the
sooner. AC Air Centre
S Standard Control
The warranty excludes normal service parts, oil and wear items,
07, 10 Delivery pressure in bar
dirt ingress, cleaning of filters and fluid drain devices and the
tightening of electrical or other connections. Also excluded is the 40 400, volt
adjustment of pressure switches or the adjustment of any other 3 3 phase
control device shown in this handbook. Consequential damage of
any nature is not covered by the warranty. 5 50 Hz
D, S, V Direct On Line, Star/Delta, Variable Speed
‘Advance’ Five Year Warranty may not be available in all markets.
100 European specification (50 Hz)
Please refer to your CompAir UK Ltd Distributor for details.

PLEASE NOTE:

Your CompAir UK Ltd Distributor is able to offer a wide range of

compressors, dryers, filters and ancillary air-line system products.
Their engineers are fully trained and competent in all aspects of
compressor and air-system maintenance. If you need any
specialist help or service please contact your Distributor quoting
the MODEL TYPE and SERIAL NUMBER.

1.3 Product development

CompAir UK Ltd adopt a policy of continual product development.

The information in this handbook, whilst fully up to date when
issued, may be subject to change without notice.

1.4 Quality standards

CompAir UK Ltd Quality Management Systems are approved to

BS EN ISO 9001.

ST 16048-00A 5
 Introduction 1

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6 ST 16048-00A
2 Safety

2 Safety
2.1 General Health and Safety Precautions • Carefully unscrew the compressor filler plug. If any air or
oil escapes before the plug is fully removed stop! Do not
Please read carefully and proceed in accordance with the remove the plug until all pressure is lost.
following instructions before installation, operation, • Safety devices fitted to the compressor or air-line system
maintenance or repair of the compressor unit. should be checked at regular intervals and replaced if
faulty. They should not be tampered with or modified. Non
2.2 The Health and Safety at Work Act, 1974 return valves should not be used as isolation devices.

• In order to comply with your responsibilities under the • To ensure the compressor operates safely you must carry
above act, it is essential that the compressor is out the specified maintenance procedures.
transported, positioned, installed, operated and • Only approved lubricants should be used for flushing
maintained by competent persons in accordance with the
purposes.
instructions in this handbook.
• Extreme caution should be taken if the compressor has
• The standard build of all Compair UK Ltd products are not been subjected to severe operating temperatures or fire.
intended for use in either Explosive or Potentially Certain components may contain fluoroelastomer
Explosive Atmospheres as defined in the ATEX Directive
materials and under these conditions can leave extremely
94/9/EC. corrosive residues. Severe burns and permanent skin and
• A potentially Explosive atmosphere is an atmosphere tissue damage can be a result of skin contact.
which could become explosive due to local and • The Health and Safety information contained in this
operational conditions.
Handbook is only intended to give general guidelines.
• The compressor warranty will be invalidated if unapproved
spare parts or lubricants are used. Using such items may 2.4 When Operating the Compressor
cause the efficiency and service life of the compressor to
be reduced and could create a hazardous condition over • When in automatic mode the compressor may re-start
which Compair UK Ltd has no control. without warning.

• Failure to maintain the compressor correctly, or modifying • If an automatic re-start device is fitted (allowing the
it without prior approval from Compair UK Ltd, may also compressor to start when power is re-applied), or
create a hazardous condition. This will also invalidate the operation is controlled from a remote location, additional
warranty. warnings will be required.

• Read and fully understand the contents contained in the • Do not remove any plugs or release pipework when the
user handbook. compressor is running.

• Ensure that the user Handbook is not permanently • Do not attempt to open the starter enclosure while the
removed from the compressor. compressor is operating.

• Check that there are no signs of damage and/or oil leaks • Beware of hot surfaces, both the air-end and electric
from the air-end, cooler and associated pipework. motor are designed to run at elevated temperatures.

• After completing work, tools and foreign matter should be • Compressed air is potentially dangerous and can be fatal
removed from the compressor and its surrounding area. if misused. Do not allow compressed air jets, discharged
from any pipe or nozzle, to make contact with your body.
• In the unlikely event of a compressor fire, dry powder or
carbon dioxide fire extinguishers should be used. Never • Wear safety glasses and suitable clothing when using, or
use water. working in an area where compressed air is being used.
• Hazardous vapours/fumes can be produced if
2.3 Before Working on Compressor compressed air is used to remove chemicals, cleaning
agents and lubricants from equipment and components.
• Potentially dangerous volt ages are used to power this Suitable respiratory and extraction equipment may be
machine. Do not carry out any work until the isolator is
required in these circumstances. Never use compressed
locked in the off position. Fit a safety notice to the isolator air for cleaning personal clothing.
advising that work is being carried out and that the
isolator must not be switched on. If in doubt then a • Do not use air directly from compressors for breathing
qualified electrician may remove the fuses and keep in a purposes. If the air is to be used for human consumption
secure place until work is complete. then it must be subjected to further treatment to ensure
that the levels of contaminants, odour and moisture meet
• Ensure the compressor has been safely isolated from the the requirements of BS 4275 1974.
main air system and cannot be re-introduced until all work
has been completed. Fit a safety notice to the isolation • We recommend that the air supply to hand held air guns is
valve advising that work is being carried out. regulated to a lower pressure (refer to local Health and
Safety regulations).
• Do not undertake any work until the compressor and
receiver if fitted, have been relieved of all pressure. • Do not insert any object or part of body through any
opening of the compressor enclosure. Serious personal
• Wait until the compressors vent down cycle is complete.
injury and/or damage may result.
• Release any pressure contained in the aftercooler or
• Never run the compressor when any covers or guards are
associated pipework. missing, unless advised to do so in this handbook.
• Check that the compressor pressure gauge reads zero.
Do not proceed until it does.

ST 16048-00A 7
 Safety 2

2.5 Potential Oil Health Hazards 2.6 Warnings, Cautions and Notes

This section relates to Fluid Force oil. For other lubricants Warnings
refer to the Health and Safety Instructions issued with the
relevant product. WARNING ! is used in the text of this handbook to identify
specific hazards which can cause injury or death. This type of
• There are no significant hazards associated with this
hazard is identified below.
product when properly used and in the application for
which it was designed. Frequent and/or prolonged skin
contact may give rise to skin irritations and it is
recommended that protective gloves are worn. The Risk of electric shock
carcinogenic action of mineral oils should be brought to
the attention of all users. *
Risk of hazard or danger
• The oil may be hot so take care when carrying out oil
changes.
Risk of hot surfaces
• Do not keep oily rags in pockets or wear contaminated
clothing. Do not inhale fumes or vapours. Do not swallow.
Avoid eye contact. Eye protection must be worn
• Always wash hands after use and before eating, drinking
and smoking. Dust protection must be worn
• Ingestion - Do not induce vomiting because of the risk of
aspiration. Wash mouth out with water. Give 1/2 pint milk. Warning pressurised vessel
Seek immediate medical attention.
• Skin Contact - *Mildly irritating. Remove by wiping. Wash
Warning pressurised component or system
with soap and water. Apply emollient cream.
• Eye Contact - *Mildly irritating. Flush with copious Warning unit is remotely controlled and may start
amounts of warm water. Seek medical advice if without warning
necessary.
• Aspiration - If there is any suspicion of aspiration into the Read the instruction manual
lungs (for example during vomiting) admit to hospital
immediately. Do not operate the machine without the guard being
fitted
• Inhalation - Remove from exposure into fresh air. If
necessary give artificial respiration or oxygen. Seek Warning do not start the machine without
medical advice. consulting handbook
• Pressure injection - Obtain immediate medical attention,
even if injury appears minor. Lifting point

• Spillage - Soak up with absorbent clay.

Direction of rotation
• Waste Disposal - Oil, condensate, filter elements etc.
should be disposed of in accordance with local
regulations. Do not allow oil to contaminate water Cautions
supplies.
CAUTION ! is used in the text of this handbook to identify
* See Cautionary Notice SHW 397 ‘Effects of Mineral Oil on the incorrect procedures which can cause damage to the compressor.
Skin’ and MS(B) 5 ‘Skin Cancer Caused by Oil’ published by
the Health and Safety Executive. Notes

Note: is used in the text of this handbook to draw attention to

specific points of importance.

Compair declines all liability in the event of material damage or

bodily injury resulting from negligence in the application of these
precautions, from non-observation or lack of elementary
supervision in respect of handling, operation, servicing or repair,
even if not expressly stated in this instruction notice.

8 ST 16048-00A
3 Product Information

3 Product Information
3.1 Technical Data

Model Number HV04 HV05 HV07 HV07RS

PERFORMANCE
F.A.D. litres/sec (cfm) @ 7 bar 11 (24) 15 (32) 21 (44) 0 - 20 (0 - 42.5)
F.A.D. litres/sec @ 10 bar 9 (20) 12 (25) 17 (35)
Noise Level - dBA 66 66 67
Power - kW (hp) 4 (5.5) 5.5 (7.5) 7.5 (10)
Starter Type - Automatic DOL DOL SD
Starter Type - Inverter N/A Soft Start
Drive Type Direct
Operating Controls Continuous Run, Automatic Stop/Start Soft Start/
Variable
Compressor Rotation Speed - rev/min (60 Hz) 1460 1050 - 1980
Oil Capacity - litres 3
Ambient Temperature Range °C 0 to 45
Maximum Relative Humidity % 85 non-condensing
Air Discharge Temp - °C (above ambient) <6 <8 <10
FACTORY SETTINGS
Minimum Pressure Valve - bar 5.5 to 6.0
Pressure Switch, Max - bar 7.5 or 10.5
Pressure Switch, Differential - bar 1.0 to 1.5
Pressure Switch, anti re-start, Max - bar 3.0
Pressure switch, anti re-start differential- bar 2.0
Servo Valve - bar 8.0 or 11.0 9.0
Vacuum Relief Valve Half turn anti - clockwise
INSTALLATION
Air Outlet Size - Rp ¾
Minimum Room Volume - m3 15

Air Inlet/Outlet Area - m 2 0.3

Ventilation Rate - m3/h 2000

3
Cooling Air Flow m /h (cfm) 2209 (1300)
Std Ambient Temp Range - °C 0 - 45
Recommended Air Receiver Capacity - L 250
ELECTRICAL
Starter Panel IP Rating 5.5
RS Inverter IP Rating 4.1
380 V 60 Hz
Line Current - Amps 12.0 16.5
Cable Size - mm 2.5 4
Fuse Size - Amps 20M32 32
Phase Current - Amps 9.5
400 V 50 Hz
Line Current - Amps 13.0 18
Cable Size - mm (awg) (12) 4(12) 4
Fuse Size - Amps 20M32 25 25
Phase Current - Amps 10.4
440 V 60 Hz
Line Current - Amps 20.5
Cable Size - mm 4
Fuse Size - Amps 32
Phase Current - Amps 11.8

ST 16048-00A 9
 Product Information 3

Model Number HV04 HV05 HV07 HV07RS

460 V 60 Hz
Line Current - Amps 18
Cable Size - awg 12
Fuse Size - Amps 25
Phase Current - Amps

10 ST 16048-00A
 4 Transportation and Handling

4 Transportation and Handling

4.1 Introduction

Ensure that all means of transportation and/or lifting equipment

are adequate for purpose and are rated to exceed the full load of
the unit.

A fork lift or pallet truck are the most suitable means of

transportation, pay particular attention to ensure stability to
prevent the unit tilting over.

4.2 Packing Methods Fig. 1 & 2

435a398x

435a398

Fig. 2 - Export Packing

Fig. 1 - UK Packing

Fig. 3 - Lifting

4.3 Lifting and Transportation Fig. 3

Units are supplied in recyclable packaging, either remove the

clear polythene sheeting or clips that retain the wooden upper
sections to gain access.

ST 16048-00A 11
 Transportation and Handling 4

The specialised base pallet can be used to transport the unit to models can bolt onto it, creating a self contained air centre
the point of installation before removal, we recommend that two retaining the footprint, ensuring a supply of high quality air.
people should carry out this operation.
Consult your local dealer for details.
Remove four bolts from the underside of the base pallet, slide the
unit sideways just sufficiently to allow two resilient mountings to
be fitted to the base members front and rear.

With care, slide the unit gently from the pallet until the resilient
mountings rest on the floor, with the unit tilted slightly slide the
pallet from the underside and remove.

While the unit is held in this position fit the other two resilient
mountings to the other side of the front and rear base members.

Damage to the mountings may occur if you attempt to slide the

unit into position, lift and place the compressor in the desired
location.

4.4 Weights and Dimensions Fig. 4

Table 1 - Significant Dimensions

Compressor
Ref. Feature Unit HV04-07
A Width mm 470
B Length (overall) mm 680
C Height (overall) mm 1050
W4 Weight (VO4 & V05) kg 152
W5 Weight (VO7) kg 156
W7 Weight (VO7RS) kg 160 Fig. 5 - Unit Mounted on to Air Dryer (Aircentre)

Table 2 - Aircentre Dimensions

Compressor
Ref. Feature Unit HV04-07
A Width mm 520
B Length (overall) mm 800
C Height (overall) mm 1620
W4 Weight (VO4 & V05) kg 242
W5 Weight (VO7) kg 246
W7 Weight (VO7RS) kg 250

Fig. 4 - Dimensions

4.5 Air Dryer Unit Fig. 5

Available as an optional extra is an integrated thermal mass

refrigerant dryer and filter module, designed so that any of the

12 ST 16048-00A
5 Installation and Commissioning

5 Installation and Commissioning

5.1 Positioning Your Compressor - Basic THE INSTALLATION MUST MEET THE WIRING
Requirements REGULATIONS PRESENTLY IN PLACE.

Position the compressor in a room of adequate size on a firm Before connecting to the mains electrical supply ensure that the
surface, level in both planes within five degrees of the horizontal. system can sustain the additional electrical load. To ensure
Ensure the area has sufficient load-bearing capacity, normally it is reliable low resistance joints, make sure that your incoming supply
not necessary to bolt the unit down. cables are firmly secured to the starter terminals and that they are
of the correct cross sectional area.
Sufficient access for all routine service procedures should be
provided around the unit that allows easy viewing of the control Refer to starter and circuit diagrams before starting work. Note
panel and pressure gauge. carefully the instructions relating to earthing, fuses and size of
cable (refer to technical data).
Site the compressor as far as possible from sources of dirt, coarse
solids, abrasive particles, steam, liquids and gaseous impurities. Fuses to BS 88 (Type gG) must be used to protect the
Ensure adequate weather protection is provided if sited outdoors. compressor starter, refer to the sizes specified in “Technical Data”
on page 9 .
Any air connection made to the compressor outlet must be flexible
as the base incorporates resilient mountings. Circuit breakers are not recommended since they may not fully
protect the starter contacts in an overload condition.
5.2 Ventilation Fig. 6
5.5 Electrical Installation Fig. 8
Position the compressor in a well ventilated location. Do not
restrict the air-flow around the compressor. Do not allow the hot WARNING !
air discharge to re-circulate into the compressor or cooler intake.

Any cooling-air inlet (A) should be positioned low allowing BEFORE STARTING WORK, ENSURE THAT THE
unrestricted air-flow to the compressor intake. The warm-air outlet MAIN-LINE FUSES HAVE BEEN REMOVED FROM
(B) should be positioned high, and well away from the inlet, to THE DISTRIBUTION BOARD. PRECAUTIONS
ensure a positive cooling air-flow through the compressor. SHOULD BE TAKEN TO PREVENT THEM BEING
REFITTED UNTIL THE INSTALLATION IS
To achieve this, ensure the compressor is installed in a room of
the correct size and with sufficient ventilation. The compressor
COMPLETE.
must not be operated in ambient conditions other than indicated in (a) The starter must be connected to the mains electrical
section “Technical Data” on page 9. supply via a lockable, switched and suitably rated fused
isolator. The isolator should be positioned as near as
For maximum efficiency and reliability, the compressor should be possible to the compressor with clear unrestricted access.
operated in a moderate ambient temperature.
(b) To access the starter remove the top panel, release two
If the ambient temperature frequently falls below 0°C consult your quarter turn fasteners mounted horizontally at each side
CompAir UK Ltd Distributor. A different grade of oil may be of the front panel. Release another two fasteners
required. mounted vertically at the rear of the top panel and lift clear
of the unit.
Air ducting, if fitted, must not cover or restrict the cooling air flow (c) Pass the incoming cable through the entry hole on the
of the compressor. Total resistance of the system must not rear left hand side of the vertical plate, continue through
exceed 5mm w.g. (0.2in. water gauge). If the resistance is the bulkhead to enter the rear of the starter enclosure
expected to be greater than 5mm w.g. then fan assistance will be using suitable cable glands.
required.
(d) Alternatively and essential for RS units, cable entry can
be made through the base and vertically upwards into the
5.3 Accessibility Fig. 7 underside of the starter enclosure.

Sufficient clearance must be allowed on all sides of the (e) Unlock the starter door with the key provided and connect
compressor for servicing purposes. The minimum clearances the three mains supply cables to the contactor terminals
required are shown on the diagram. marked L1, L2 and L3, connect the earth cable to the
earth pin E.
5.4 Electrical Connections (f) Cable sizes specified are the minimum cross section
“Technical Data” on page 9 to suit a typical installation. If
WARNING ! the compressor is located a long way from the isolator
and/or the ambient temperature exceeds 35°C then the
cable size should be increased.
CONNECTION TO, OR INSTALLATION OF, AN
(g) Refer to IEE Regulations for electrical equipment installed
ELECTRICAL POWER SUPPLY MUST ONLY BE
in buildings to determine the size required, pay particular
CARRIED OUT BY AUTHORISED AND attention to the circuit diagrams provided.
QUALIFIED ELECTRICIANS. THEY MUST FULLY
(h) Check that the transformer fuse is positioned to suit the
UNDERSTAND AND ADOPT CORRECT AND supply voltage of the installation.
SAFE WORKING PRACTICES. ALL ASPECTS OF

ST 16048-00A 13
 Installation and Commissioning 5

(i) Ensure all electrical connections are tight, high voltage Table 3 - Accessibility
supply to contactors and incoming terminals are critical.
Dimension Units Distance
(j) Close the starter door, replace the top panel, switch the
isolator on. A mm 1000
B mm 1000
C mm 1500
D mm 1000
E mm 1000

Fig. 6 - Ventilation
Fig. 8 - Starter

5.6 Check Direction of Motor Rotation

WARNING !

READ HEALTH AND SAFETY PRECAUTIONS

BEFORE STARTING COMPRESSOR.

(a) Ensure that the compressor is filled correctly with

approved oil (Fluid Force Red 2000) and that all plugs are
re-fitted securely.
(b) With the mains isolator on, select either manual
(continuous run) mode position (i) or the off position (o) for
variable speed (RS) machines.
(c) The cooling fan in the rear of the unit can be used as a
visual aid to determine the correct rotation of the
compressor.
(d) To view the cooling fan remove the cabinet filter from the
lower half of the rear panel, the cooling fan can be viewed
through the mesh grill.
(e) Press the illuminated amber reset/start button mounted in
the control panel, compressor rotation is correct if the
cooling fan rotates in a clockwise direction.
(f) Rotation of the compressor is clockwise as viewed from
the intake end, this is in the opposite direction to the
normal clockwise rotation when viewed from the drive
Fig. 7 - Accessibility end.

If rotation is correct, the compressor pressure gauge will

immediately rise, for RS machines a momentary power supply will
rotate the cooling fan.

14 ST 16048-00A
5 Installation and Commissioning

If rotation is not correct the compressor pressure gauge will not 5.8 RS Operation with Other Compair Vane
rise, for RS machines the momentary power supply will rotate the Compressors
cooling fan in an anti-clockwise direction.
(a) Compair RS compressors may be operated efficiently in
CAUTION ! If direction of rotation is incorrect. conjunction with other Compair vane compressors fitted
with automatic stop-start control.
Stop the compressor immediately, serious
(b) Operation in conjunction with one other Compair vane
damage will occur if the motor is allowed to run in
compressor is simply achieved by adjusting the RS target
reverse! pressure to midway between the maximum and minimum
pressure settings of the other compressor. The RS
WARNING ! compressor will automatically assume the lead
compressor role.
IF DIRECTION OF ROTATION IS INCORRECT, (c) The use of the Compair 'SmartBox' is recommended
STOP THE COMPRESSOR AND LOCK THE when operating with more than two Hydrovane
ISOLATOR IN THE OFF POSITION. FIT A SAFETY compressors.
NOTICE TO THE ISOLATOR ADVISING THAT
Important Note: If the RS compressor is operated with other
WORK IS BEING CARRIED OUT ON THE Hydrovane standard single speed compressors feeding a
COMPRESSOR. common pressure system the maximum target pressure of the RS
compressor must be limited to the lowest maximum pressure of
• Open the starter door with the key provided to gain access to the single speed machine(s).
the starter terminals.
No attempt must be made to increase the operating pressure of
• Change over any two of the incoming cables connected to the the single speed machine(s).
starter terminals L1, L2 & L3 (Qualified person only).
5.9 Positioning of Pressure Transducer
• Close the starter enclosure door and lock with the key
provided to prevent unauthorised access.
(a) The pressure transducer sensing point is located in the
MInimum Pressure Valve Housing adjacent to the outlet
• Remove the safety notice and switch the mains electricity
from the compressor; this position is suitable for the
supply on.
majority of installations.
• Restart the compressor and verify that direction of rotation of (b) If the pipework from the compressor to the system is
both the compressor and cooling fan are correct. restricted or prone to pressure fluctuation the pressure
transducer signal may create excessive response from
• Replace the cabinet filter in the rear panel with the direction the speed control unit leading to rapid speed changes
arrow pointing inwards towards the cooling fan. and/or rapid stopping and starting of the motor.
(c) Should this condition occur re-locate the pressure
5.7 Regulated Speed Compressor Installation transducer sensing point further downstream (e.g. to a
manifold or ring main) where restriction/pressure
The compressor should be installed generally as instructed for a fluctuations are at a minimum.
standard fixed speed compressor of the same power (kW) rating.
(d) If the installation includes a receiver, consideration should
The installation should be completed by a Compair be given to piping the receiver pressure to the transducer.
authorised distributor and must comply with current wiring
regulations.

Electrical supply fuse sizes are the same as for standard fixed
speed compressors of the same power (kW) rating. Alternatively,
a circuit breaker of suitable size and with motor starting
characteristics may be used to protect the installation.

The maximum starting current under all starting conditions will not
exceed 150% motor full load current and will generally be no more
than 100% full load current.

The installation must be earthed in accordance with local

regulations. The use of RCD's is not recommended.

Water drain, filters or dryers fitted downstream of the compressor

discharge must be correctly sized to avoid excessive flow
restrictions to ensure stable operation of the speed control
system.

ST 16048-00A 15
 Installation and Commissioning 5

5.10 Wiring Diagrams

Starter type: 34687. Cct diagram 75049 Iss D

A1F Over Temperature Control PCB M3M Cooling Fan Motor
F1F Fuse - 1A(T) 250V - IEC127 R2F Compressor Over-temp Thermistor
F3F Fuse - 2A(T) 500V - EN 60269 R3F Motor Over-temp Thermistors
F4 Thermal Overload S1E Start/reset Push button
F5 Fan Thermal Switch S2A Auto/manual Selector Switch
H1 Hours Counter S3N Line Pressure Switch
H2/S1E Combined Ind Lamp ‘r’(Amber) / Start/reset Push button S4M Emergency Stop / Stop Switch
K1M Main Motor Contactor T1 Control Transformer 24v secondary
K2T Run On Timer Y1 Vent Solenoid Valve N.O.
M1M Main Drive Motor

Fig. 9 - Circuit Diagram - Up to 5.5kW 400V 50Hz DOL

16 ST 16048-00A
5 Installation and Commissioning

A1F Over-temp Control PCB Starter Type 34682. Cct Diag 74904 Issue C
F1F Fuse - 2A(T) 250V - IEC127 M1M Main Drive Motor
F3F Fuse - 2A(T) 500V - EN 60269 M3M Cooling Fan Motor
F4 Thermal Overload R2F Compressor Over-temp Thermistor
F5 Cooling Fan Motor Thermostat R3F Motor Over-temp Thermistor
H1 Hours Counter S1E Start/Reset Push button
H2/S1E Combined Ind Lamp ‘r’(Amber) / Start/reset Push button S2A Auto/Manual Selector Switch
K1M Line Contactor S3N Line Pressure Switch
K2M Delta Contactor S4M Emergency Stop/Stop Switch
K3M Star Contactor S5N Compressor Pressure Switch
K1L Mechanical Interlock (K2M to K3M) T1 Control Transformer - 24V Secondary
K4T Run-On Timer Y1 Vent Solenoid Valve N.O.
K5T Star-Delta Timer Y2 Rapid Vent Solenoid Valve N.C.

Fig. 10 - Circuit Diagram - 5.5/7.5kW 400V 50Hz S/D

ST 16048-00A 17
 Installation and Commissioning 5

Starter Type 34756. Cct Diag 75263 Issue B

A1F Over-temp Control PCB M1M Main Drive Motor
A2A Pressure selector/alarm PCB M2M Cooling Fan Motor
B1 Pressure Transducer 4-20mA, 10--36Vdc Q1F Circuit Breaker - 2 Pole, 6A
F2F Fuse 2A(T) IEC127 R2F Compressor Over-temp Thermistor
F3 Fan Over-temp Switch R3F Motor Over-temp Thermistors
F4 Overload Fan Motor S1E Reset Push button Switch
H1 Hours counter S2A On/Off Selector Switch
H2 Indicator Lamp ‘r’(Amber neon) S4E Emergency Stop Switch
H3 Alarm Lamp (red LED) on A2A S5P compressor Control Pressure Switch
K1M Isolating Contactor T1 Control Transformer - 24V Secondary
K2M Fan Motor Contactor U1 Variable Speed Drive. Lenze E82V752K4B
K2A Relay Module - MURR 52001, 24VAC, 17mA Y10 Vent Solenoid Valve - N.O.
Z1A 3 Phase AC input Choke (Optional)

Fig. 11 - Circuit Diagram - 7.5kW 400V 50Hz Variable speed

18 ST 16048-00A
6 General Description

6 General Description
6.1 Compressor Assembly Fig. 12 The compressor air intake is protected by an air intake filter (U)
and the oil system by oil filter (J). An oil level sight glass assembly
The unit comprises of a vertical single stage, oil flooded, rotary, (V) is mounted on the end of the starter unit (H)
sliding vane compressor driven by an electric motor mounted to a
base. It is supplied with control panel, starter, and combination oil Oil is drained from the air-end and cooler by removing drain plug
cooler/air after cooler with all accessories piped in and electrically (K) and opening the drain tap.
connected.
The compressor pressure gauge (F) is visible through an aperture
The intake cover (A) is assembled directly to the compressor (B) in the front panel.
which is fitted to the flange face (C) of drive motor (D). The rotor of
the compressor is mounted on the drive shaft of the motor. The The oil separator (E) is located on the top of the machine and
motor is bolted to the vertical column supported by the base. ensures that the air delivered through the minimum pressure
valve has an oil cleanliness of less than 2 ppm (parts per million
An electrically driven, impellor type, horizontally mounted fan (S) by weight). The air is delivered through the air delivery pipe (P) to
is located below the cooler matrix. (Q). This forces cooling air the after cooler.
through the combination oil cooler/air after cooler matrix. The
compressor controls (G) are mounted on the end of the starter The oil supply to the cooler is through oil feed pipe (R) with the
enclosure (H), and are visible through an aperture in the front cool oil return via oil return pipe (M). To ensure the compressor
panel. reaches the optimum operating temperature quickly a thermal by-
pass valve (N) allows the oil supply to by-pass the cooler on initial
For RS models the inverter drive (L) with the optional extra start up.
keypad control is mounted in the top of the vertical column,
underneath the top trim panel.

Fig. 12 - Compressor Assembly

ST 16048-00A 19
 General Description 6

6.2 Control Systems

Compressors can be operated either in automatic Stop/Start

mode or in continuous run mode.

Automatic Stop/Start Mode

This is the normal mode of operation giving maximum efficiency

and economy. Recommended for applications with fluctuating air
demands. With the auto mode selected the compressor will load/
unload and stop/start automatically in response to air demand.

If the motor restarts more than ten times per hour or continually
restarts within thirty seconds of stopping then the run-on timer
may be increased to reduce frequency. If after adjustment the
condition persists, switch to continuous run mode.

Continuous Run Mode

Recommended where excessive stop/starts occur and/or when

there are rapid changes of pressure in the air-line system. When
the continuous run mode is selected the compressor will continue
to operate, supplying air from full to zero flow rates.

Regulated Speed Operation

Regulated speed compressors are automatic stop/start operation

only. If the unit is subject to excessive stop/starts, consult
Compair for the possibility of fitting a continuous running option.

The Compair Regulated Speed Vane Compressor has been

designed to save energy and operating cost when compared with
a fixed speed compressor of similar size. The saving is achieved
by automatically regulating the compressor speed to precisely
match the compressor output to the system flow and pressure
requirements.

The system pressure is measured and converted into an electrical

signal by an integral pressure transducer. The compressor
Variable Speed Drive (VSD) unit senses the transducer signal and
adjusts the electric motor speed to maintain a constant ‘target’
pressure. If the system pressure rises above the target pressure
the electric motor speed will decrease, conversely, if the system
pressure falls below the target pressure the motor speed will
increase. The speed will vary between minimum and maximum
limits dependent upon flow requirements.

20 ST 16048-00A
7 Operating Parameters

7 Operating Parameters
7.1 Ambient Temperature

The compressor is designed to operate within a temperature Fluid Force Red 2000
range of 0°C and 45°C. Bulk Oil Temperature Maximum Oil Change Period
(Degree Celsius) (Hours Run)
If the ambient temperature frequently falls below 0°C then consult
your CompAir UK Ltd Distributor. Up to 90 2000
90 - 95 1500
7.2 Operating Temperatures 95-100 1000
100 - 110 500
Your compressor is designed to give optimum performance and
trouble free service life when the bulk oil temperature is Over 110 No guaranteed service life
maintained between 65°C and 85°C.
7.5 Oil Level Fig. 13
Certain operating conditions sustained over a period of time may
cause problems that effect the performance and reliability of this
The oil level should be checked by viewing the oil level in the sight
compressor. glass.

Problems may occur when compressors run for short periods on

low air demand where they don’t reach normal operating
temperatures.

Prolonged use under these conditions can cause condensation

build up within the compressor and may eventually lead to
emulsification of the oil.

Normal operating temperatures are reached in typically 15/20

minutes, to purge condensate from the compressor a longer
running period with a high air , usually a minimum of 60 minutes,
will be required.

Conditions or applications which prevent the compressor

temperature stabilising between these parameters should be
avoided.

Consult your local distributor or CompAir UK Redditch if you have

any particular concerns about operational characteristics of your
compressor.

7.3 High Operating Temperatures

Some of the reasons for high compressor oil temperatures are:

• Low oil level.
• Blocked oil cooler or cooler flow restrictions.
• Wrong type or grade of oil. Fig. 13 - Oil Level Sight Glass and Levels
• High ambient temperature.
The sight glass assembly (C) is mounted on the end of the starter
• Cooling fan stopped or operating incorrectly. panel, and is viewable through an aperture in the front trim panel.

If the bulk oil temperature frequently reads between 90°C -100°C The two glass windows show the oil level for different states of
then Fluid Force HPO should be used. operation with the level marks on the trim panel indicating as
follows:
Note: Compressor will stop automatically if temperature rises
above 110°C. A. This indicates the maximum oil level when the machine is
stopped and the oil allowed to settle.
7.4 Oil Life of Fluid Force Red 2000
B. This indicates the minimum oil level when the machine is
The standard oil is Fluid Force Red 2000, other Compair oils running.
(Fluid Force Clear and Fluid Force HPO) are available.
7.6 Noise Level
Consult your local Compair dealership for technical information.
Although the sound pressure level for these units is relatively low,
see“Technical Data” on page 9, they should be positioned where
noise will not be a problem. The use of ear defenders is

ST 16048-00A 21
 Operating Parameters 7

recommended above 85dBA or when working in close proximity to

compressors for extended periods.

7.7 Pressure Readings

The compressor pressure is displayed by the pressure gauge

located in the front panel.

7.8 Air Delivery Temperature

The air delivery temperature after it has passed through the air
aftercooler is typically 8°C above ambient.

22 ST 16048-00A
8 Operating Instructions

8 Operating Instructions
8.1 Introduction 8.5 Starting - Continuous Mode Fig. 14

WARNING ! Complete the checking procedure before starting.

Select continuous run mode, (section 8.4) the compressor is now

THE COMPRESSOR SHOULD ONLY BE ready to run.
OPERATED BY AUTHORISED PERSONS FULLY
TRAINED IN:- THE STARTING, STOPPING AND Press the amber reset/start button (B) and the motor will start.
EMERGENCY STOP PROCEDURES.
The compressor will now run continuously irrespective of either
BEFORE STARTING THE COMPRESSOR, READ the system pressure or system air demand.
THE ‘HEALTH AND SAFETY PRECAUTIONS’.
On initial start with no pressure in the system, the compressor
gauge will quickly rise but will not exceed the servo valve
8.2 Checking Procedure Before Starting pressure.

(a) Check lower sight glass is full. Once the system is fully charged the compressor gauge will vary
(b) Check filler and drain plugs are fitted securely. with fluctuations in the system air demand.

(c) Check for any signs of oil or water leaks.

8.6 Starting - Automatic Mode
(d) Check air-outlet valve is open and test-valve is closed.
(e) Check that the stop/emergency stop button is released. WARNING !
(f) Turn mains electricity supply on.
WHEN IN AUTOMATIC MODE THE
8.3 Operating Mode COMPRESSOR WILL RESTART WITHOUT
WARNING.
The CONTROL allows two operating modes: Continuous run or
automatic Stop/Start. (a) Complete checking procedure before starting.
(b) Select automatic (see section 8.4). The compressor is
8.4 Compressor operation Fig. 14 ready to run.
(c) Press the amber reset/start button (B), and the motor will
For continuous run, turn selector switch (A) to hand mode (i). start.

For automatic Stop/start, turn selector switch (A) to auto (ii).

On initial start-up, with no pressure in the air-line system, the line
pressure displayed on the pressure gauge will rise quickly to the
Note: The operating mode may be altered either when the minimum pressure valve setting
compressor is running, or when it has stopped.
Once the system is fully charged the compressor gauge will vary
with fluctuations in the system air demand.

If the system pressure rises to the compressor high pressure

setting then the automatic stopping sequence will begin. The run-
on timer starts and the compressor begins to run "off load", if there
is no demand for air during the run-on time the compressor will
stop.

The compressor will remain stopped until there is an air demand

that allows the system pressure to fall to the compressor low
pressure setting. For V07 models the compressor will not restart
until its internal pressure has fallen to below 1.5 bar.

If there is a demand for air during the run-on time, the stopping
sequence is cancelled and the compressor returns to full "on-
load" running.

8.7 Starting - Regulated Speed Fig. 15

Complete the checking procedure before starting.

Press the amber reset/start button (B) the compressor is now

ready to run.

Turn the selector switch (A) from position (0) to position (1) the
Fig. 14 - Compressor Operation compressor is now in running mode and will commence rotation if
the system pressure is below the target pressure.

ST 16048-00A 23
 Operating Instructions 8

On initial start with no pressure in the system, the compressor

gauge will quickly rise but will not exceed the servo valve
pressure.

The compressor speed will change automatically to suit the

pressure and flow demands of the system, the compressor gauge
will vary with fluctuations in the system air demand.

If system flow demand reduces and the system pressure rises

above the compressor target pressure the inverter speed control
will automatically stop the compressor after a short time delay.

Re-starting will occur automatically when the system pressure

drops below the compressor target pressure.

During operation of the compressor the hour's counter (C) will Paul. Is this the
record the total running hours.
same as the std
8.8 Stopping - Single Speed
control ?
To stop the compressor in either continuous run or automatic
stop/start, press the stop/emergency stop button (D).

The button will lock in the depressed position and stop the
compressor immediately, the offload solenoid will de-energise
allowing the compressor pressure to fall to zero in about 2 to 5
minutes.
Fig. 15 - Regulated Speed Control TBA
System pressure will remain high initially but will eventually fall,
the rate of decay will depend on equipment usage and the time
period the system remains idle.

Reset the stop/emergency stop button by twisting it clockwise

before re-start.

8.9 Stopping - Regulated Speed

To manually stop the compressor, rotate the selector switch (A)

from position (i) to position (ii), do not use the stop/emergency
stop button (D) unnecessarily.

System pressure will remain high initially but will eventually fall,
the rate of decay will depend on equipment usage and the time
period the system remains idle.

8.10 Emergency Stop

If an emergency occurs:

(a) Press the stop/emergency stop button (D in Fig. 14 and

Fig. 15).
(b) The button will lock in the depressed position and stop the
compressor immediately, the offload solenoid will de-
energise allowing the compressor pressure to fall to zero
in about 2 to 5 minutes.
(c) Clear any faults which may have occurred. Do not reset
until it is safe to do so.
(d) Reset the stop/emergency button by twisting it clockwise
before re-start.

8.11 Compressor Vent Down

After stopping, the compressor must be allowed to vent down

gradually, speeding up the de-pressurisation may cause oil carry
over or separator flooding.

24 ST 16048-00A
9 Adjustments

9 Adjustments
9.1 Standard Compressor Control Fig. 16 (h) Re-connect the pressure gauge and replace front and top
panels.
The compressor is fitted with one or two pressure switches, one (i) Switch mains electrical supply on.
for cut-in and cut-out of line pressure (A), the other (B) (if fitted)
reads oil chamber pressure (factory set do not alter) which (j) Start compressor and check switch settings for accuracy.
prevents pressurised restart. If further adjustments are required repeat setting
procedure.
Adjacent to the pressure switch(es) are one or two solenoid
valves, the single valve (C) vents down the compressor gradually
within 2 to 5 minutes when stopped.

The solenoid valve mounted closest to the front (D) will rapidly
vent the compressor within 2 to 5 seconds if the reset button is
pressed before gradual venting has occurred.

Pressure switches and solenoid valves are mounted on top of the

starter enclosure this is on the right hand side under the top panel
cover.

WARNING !

ISOLATE THE COMPRESSOR FROM THE MAINS

ELECTRICAL SUPPLY. LOCK THE ISOLATOR IN
THE OFF POSITION. FIT A SAFETY NOTICE TO
THE ISOLATOR ADVISING THAT WORK IS BEING
CARRIED OUT ON THE COMPRESSOR.

9.2 Pressure Switch Fig. 17

(a) To access the starter remove the top panel, release two
quarter turn fasteners mounted horizontally at each side
of the front panel. Release another two fasteners
mounted vertically at the rear of the top panel and lift clear
of the unit.
(b) If necessary remove the front panel, release a single Fig. 16 - Pressure Switch Locations (7.5kW
fastener from the left-hand side and a single screw just machine illustrated)
above the hour counter in the controls area. Disconnect
the pipe from the rear of the pressure gauge (push fitting)
and remove the front panel.
(c) Remove screw (A) and keyplate (B), for maximum line
pressure adjust screw (C) until the scale indicates 7.5 or
10.5 bar, this is the high or cut out pressure. For
differential pressure adjust screw (D) until the scales
indicates between 1.0 and 1.5 bar (factory setting), this is
the minimum, low or cut in pressure.
(d) Note that the maximum pressure (cut out) minus the
differential pressure equals the minimum (cut in)
pressure, high cut in pressures will increase the frequency
of start up.
(e) Adjust screw (C) until the ‘MAX’ scale indicates 7.2 bar.
This pressure should not be exceeded.
(f) Adjust screw (D) until the ‘DIFF’ scale gives required
differential.
Note: MAX pressure minus DIFF pressure equals
MINIMUM (cut-in) pressure.
Note: The differential pressure is factory preset to 1 bar Fig. 17 - Differential Pressure Switch Adjustment
to 1.5 bar.
Note: High cut-in pressures will increase frequency of
start-up.
(g) Refit keyplate (B) and screw (A).

ST 16048-00A 25
 Adjustments 9

9.3 Pressure Control - RS compressors

Compressors have default factory settings for inverter speed

control target pressure, compressor servo valve pressure and
motor speed.

V07RS operating pressure 8 bar, servo 9 bar, frequency 66 Hz,

maximum speed 1980 rpm, minimum speed 1050 rpm

The target pressure may be adjusted from the default setting in

the range of 6 to 10 bar for air compressors.

When operating at other than factory set pressures adjustments to

the compressor servo valve pressure setting and inverter speed
control unit frequency setting will be required.

A rotary selector switch is provided inside the starter to select the

required speed and frequency settings for the inverter drive to
match servo pressures that must be adjusted manually

User Warning

Compressor and inverter speed control adjustments should not be

attempted by the user and must be carried out by a CompAir
authorised service engineer. Failure to comply with this
requirement may invalidate the compressor warranty.

26 ST 16048-00A
10 Servicing

10 Servicing
10.1 Introduction 10.3 Check Compressor Operation

WARNING ! The drive end cover of the compressor has a facility to accept a
thermal probe to record the operating temperature of the unit.
With the need for specialised equipment we suggest that this task
READ HEALTH AND SAFETY PRECAUTIONS should be conducted by your local Distributor.
BEFORE YOU START ANY SERVICE WORK.
Assuming the compressor is serviced correctly the machine is
SERVICING OF THE COMPRESSOR MUST ONLY capable of operating in ambient temperatures up to a maximum of
BE CARRIED-OUT BY AUTHORISED PERSONS 45°C. At this ambient temperature the oil temperature will be
FULLY TRAINED AND COMPETENT IN THE typically 85°C to 90°C.
MAINTENANCE, MAINS ELECTRICAL SUPPLY
AND STARTER CONTROL EQUIPMENT OF When the compressor is working the temperature should be:-

COMPAIR COMPRESSORS. THEY MUST FULLY Initial start-up and warm-up period. < 70°C
UNDERSTAND AND ADOPT CORRECT AND Optimum working temperature. 80 - 90°C
SAFE WORKING PRACTICES.
High temperature. 90 -100°C
If you are unable to carry-out the work safely in the required Stop ! Consult your distributor. > 100°C
manner then your CompAir UK Ltd distributor will be pleased to
help. Check Compressor Pressure

Ensure genuine CompAir UK Ltd parts and approved oils are To check the compressor pressure, use the pressure gauge
used. located in the front panel.

To ensure the use of genuine parts during routine servicing, Check oil level
Compair UK have the following service kits available:
Check the oil level using the compressor oil level sight-glass fitted
1 KO 457 2000 hr/1 yr oil change kit to the end of the starter box, visible through the front panel. Refer
to Fig. 13 for a view and description of the oil level manifold and
2 KM 457 4000 hr/ 2 yr maintenance kit
indicator marks.
3 KT 457 Top - up kit

Contact your local distributor for availability.

10.2 Routine Service Schedule

The work listed in this section must be carried-out at the indicated

running-hours which must be regarded as a maximum. In dusty,
hot or humid conditions more frequent servicing may be
necessary.

This section shows the minimum service requirements for your

compressor. To ensure that the full compressor maintenance
programme is carried out, we recommend that your compressor is
regularly serviced by an authorised CompAir UK Ltd distributor.

Servicing (RS)

Servicing intervals and procedures are the same as specified for

the standard fixed speed compressor of the same power (kW)
rating.

In addition the metal cover surrounding the speed control unit

should be detached and any dirt or dust collected around the
control unit ventilator fan grille removed.

The speed control unit does not require any routine servicing.

After very long periods it is recommended that the speed control

unit capacitors and cooling fan(s) be replaced to ensure continued
reliability of the unit. Refer to CompAir Redditch Service
Department for details.

ST 16048-00A 27
 Servicing 10

To conduct the following routine tasks it is necessary to remove

the top and front panels including the lower right hand side steel
panel.

Remove the top panel by releasing two quarter turn fasteners

mounted horizontally at each side of the front panel. Release
another two fasteners mounted vertically at the rear of the top
panel and lift clear of the unit.

Remove the front panel by releasing a single fastener from the

left-hand side and a single screw just above the hour counter in
the control area. Disconnect the pipe from the rear of the pressure
gauge (push fitting) and remove the front panel.

Remove two hexagon headed screws mounted vertically upwards

into the bottom of the starter enclosure that secure the lower right
hand side steel panel ( Fig. 20(F))

Remove the two screws that retain the small cover plate on the
right hand side of the unit ( Fig. 20(E)) to gain access to the
bypass filter and impellor area behind the intake filter for cleaning.

Fig. 18 - Oil Filler Plug, Air Filter and Separator

Element Location

10.4 Basic Service Fig. 18 and 19

WARNING !

STOP THE COMPRESSOR AND ISOLATE FROM

THE MAINS ELECTRICAL SUPPLY. LOCK THE
ISOLATOR IN THE OFF POSITION. FIT A SAFETY
NOTICE TO THE ISOLATOR ADVISING THAT
WORK IS BEING CARRIED OUT ON THE
COMPRESSOR.
CLOSE THE AIR OUTLET VALVE TO ISOLATE
THE COMPRESSOR FROM THE AIRLINE
SYSTEM. FIT A SAFETY NOTICE TO THE VALVE
ADVISING THAT IT IS NOT TO BE OPENED.
DO NOT PROCEED UNTIL THE AIR PRESSURE Fig. 19 - Matrix Cleaning
GAUGE READS ZERO !
10.6 Oil Draining & Filter Replacement Fig. 18
CAUTION !When changing recommended oil and 20
types it is advisable to flush the compressor.
WARNING !
CAUTION !When changing to fluid force clear the
compressor must be flushed out with fluid force AVOID UNNECESSARY CONTACT WITH HOT OIL
prime. AND COMPONENTS. GLOVES ARE
RECOMMENDED IF DRAINING OIL WHEN THE
10.5 Panel Removal COMPRESSOR IS HOT!
Wait until the compressor vent down cycle is complete, vent
pressure from the air aftercooler and associated pipework. 10.7 Oil Draining Fig. 20

Check that the compressor pressure gauge reads zero before (a) Remove the filler plug Fig 18 (B) and bonded seal (A) to
carefully removing the filler plug and bonded seal. allow air to enter the compressor to aid drainage.

28 ST 16048-00A
10 Servicing

(b) Place a suitable container below the drain point and (b) Using a new separator smear a small amount of oil onto
remove the drain plug from the end of the tap (D), turn the the seal, screw in clockwise to tighten, hand tight only.
tap and allow the oil to drain from the compressor.
(c) When draining is complete turn the drain tap to the off 10.12 Clean Oil Cooler/After cooler Fig. 19 and 20
position and replace the drain plug in the tap.
(a) The cooler matrix airflow is from the inside to outside,
cleaning is best achieved by reversing the airflow to
10.8 Oil Filter Replacement Fig. 20
dislodge any accumulation of dirt.
(a) Unscrew the filter (C) in an anti-clockwise direction quickly (b) Using a low pressure air line, less than 2 bar pressure,
to avoid oil spillage from the canister, wipe up any spillage blow a jet of air over the whole area of the matrix (A). Dirt
and discard the old filter in a safe manner. dislodged can be removed using a vacuum cleaner placed
through the access to the bypass filter and impellor area
(b) Using a new filter smear a small amount of oil onto the
behind the cabinet filter (B) (Part No. 74695).
seal, screw in clockwise to tighten, hand tight only.
(c) Gain access to the rear of the cooling fan filter by means
10.9 Oil filling / Top-up of removable panel (E).
(d) Using a standard household vacuum cleaner, remove any
(a) Fill to the correct level shown for the top sight glass with dislodged debris through the access hole (E).
approved oil, use Fluid Force Red 2000 as the standard
oil, do not overfill. Note: All discarded items and waste oil must be disposed of in an
approved manner.
(b) Allow the oil level to stabilise, the oil filter holds about 1
litre, total capacity is 3 litres, drain a small amount of oil if
above the maximum fill line. 10.13 Panel Refitting
(c) Refit the filler plug Fig 18 (B) and bonded seal Fig 18 (A),
Re-connect the pressure gauge and refit the panels in reverse
renew the bonded seal if damaged and tighten using a
order (See “Panel Removal” on page 28.), test run the
spanner, do not over tighten.
compressor and check operation as in 10.3.

10.14 Electrical checks

WARNING !

WARNING !ISOLATE THE COMPRESSOR FROM

THE MAINS ELECTRICAL SUPPLY. LOCK THE
ISOLATOR IN THE OFF POSITION. FIT A SAFETY
NOTICE TO THE ISOLATOR ADVISING THAT
WORK IS BEING CARRIED OUT ON THE
COMPRESSOR.

(a) Open the starter panel door.

(b) Remove any terminal covers fitted to contactors and
incoming supply terminals.
Image under construction by SH
(c) Check for any signs of overheating and ensure that all
electrical connections are tightened to correct torque
settings, as per label on inside face of starter.
Note: Pay special attention to power connections and
cables connected to contactors and incoming terminals.
(d) Close the starter panel door and lock with the key
provided to prevent unauthorised access.

Clean and check electric motors

Fig. 20 - Oil Drain and Filter Location
WARNING !
10.10 Air Filter Replacement Fig. 18
(a) Remove any dust or dirt from motor bodies and motor air
To change the air filter element twist the cap of the air filter intake grill located under the compressor base.
container (D) anti-clockwise then lift vertically to expose the
element (Part No. 75155) inside. (b) Reinstate all covers.
(c) Remove safety notices.
Remove the old element and discard in a safe manner and
replace with a new element before replacing the cap.
10.15 Check operation of over-temperature
10.11 Oil Separator Replacement Fig. 18 control unit Fig. 21

(a) Unscrew the oil separator (C) in an anti-clockwise WARNING !

direction and discard in a safe manner.

ST 16048-00A 29
 Servicing 10

THE FOLLOWING FAULT FINDING PROCEDURE

SHOULD BE CARRIED OUT BY QUALIFIED AND
COMPETENT PERSONS ONLY.
THIS PANEL CONTAINS POTENTIALLY LETHAL
VOLTAGES. UNDER NO CIRCUMSTANCES
SHOULD YOU ATTEMPT TO TOUCH ANYTHING
INSIDE THE PANEL, OR ON THE CONTROL
PANEL DOOR UNLESS INSTRUCTED TO DO SO
IN THE FOLLOWING PROCEDURE.

(a) Isolate from the main power supply, for RS machines with
inverters, wait at least 10 minutes for capacitors to
discharge before starting work.
(b) Open the starter door with the key provided.
(c) Unscrew terminal 38 and remove the connecting wire.
(d) Re-instate the power supply.
(e) Yellow reset lamp should be illuminated.
(f) With the selector switch in the run position, press the start
button. The compressor should not start, the yellow reset
lamp should remain illuminated, but the green LED Fig. 21 - Over-Temperature Control Unit
marked COMP should be extinguished.
(g) Isolate from the main power supply, for RS machines with
inverters, wait at least 10 minutes for capacitors to
discharge before starting work.
(h) Re-connect the wire back in to terminal 38 and remove
wire from terminal 48.
(i) Re-instate the power supply.
(j) Yellow reset lamp should be illuminated.
(k) With the selector switch in the run position, press the start
button. The compressor should not start, the yellow reset
lamp should remain illuminated, but the green LED
marked MOTOR should be extinguished.
(l) Isolate from the main power supply, for RS machines with
inverters, wait at least 10 minutes for capacitors to
discharge before starting work.
(m) Re-connect the wire back to terminal 48.

CAUTION !
If the above sequence is not achieved then a fault
may have occurred which has damaged the OTC.
The compressor must not be operated until a
replacement OTC has been fitted and the above
procedure repeated.

(a) Close the starter door and lock with key provided.

30 ST 16048-00A
10 Servicing

10.16 Servicing Requirements

Note: The following preventive maintenance charts cover all Compair compressors using Compair Fluid Force Red 2000 oil. The work
to be carried out must be done on or before the hours shown for this action, or yearly, whichever is soonest.

Note: For service schedules using Compair Fluid Force Clear and Compair Fluid Force HPO, consult you local dealer, or contact
CompAir UK Redditch.

Read health and safety precautions before starting any work.

Service Schedule: Fluid Force Red 2000 (2000 hour oil change)

The bulk oil temperature must not exceed 90°C. If the oil is working above this temperature, the oil life will be reduced.

Note: When changing to Fluid Force Clear the compressor must be flushed out with Fluid Force Prime in order to comply with USDA H1
standard.

Note: The service life of the air filter and cabinet filter are an indication only, actual life durability will be dependant on the operating
conditions.

Preventative Maintenance Schedule Fluid Force Red 2000

First Every Every Every Every
Maintenance Actions Start up Daily Weekly 1000 2000 4000 12000 24000
hrs hrs hrs hrs hrs
Check sufficient access !
Check correct drive rotation ! !
Check torque electrical connections ! ! ! ! !
Check power on-load ! ! ! ! !
Check power off-load ! ! ! ! !
Check operation of over temperature unit ! ! ! ! !
Check operation of non-return valve (purs)
Check electrical motor for damage ! ! ! ! !
Check for loose electrical connections ! ! ! ! !
Check cables and earth are sound ! ! ! ! !
Check for motor vibration ! ! ! ! !
Check for secure cable glands ! ! ! ! !
Test unloader valve for operation ! ! ! ! !
Test vacuum relief valve for operation ! ! ! ! !
Test mpv for operation ! ! ! ! !
Test air delivery ! ! ! ! !
Check oil level at filler plug
Check for air leaks ! ! ! ! ! !
Check for oil leaks ! ! ! ! ! !
Check air filter ! !
Check servo pressure off-load ! ! ! !
Check clear of airborne contaminants ! ! ! ! ! ! ! !
Check oil temperature ! ! ! ! ! ! ! !
Check rsu temperature (ACE) ! ! ! ! ! ! ! !
Check ambient temperature ! ! ! ! ! ! ! !
Check oil level at sight glass ! ! ! ! ! !
Clean oil cooler ! ! ! ! ! !
Clean after cooler ! ! ! ! ! !

ST 16048-00A 31
 Servicing 10

Preventative Maintenance Schedule Fluid Force Red 2000

First Every Every Every Every
Maintenance Actions Start up Daily Weekly 1000 2000 4000 12000 24000
hrs hrs hrs hrs hrs
Clean external dirt from compressor ! ! ! ! ! !
Clean external dirt from motor ! ! ! ! ! !
Clean air filter
Clean cabinet filter (air logic) ! !
Clean servo valve !
Clean oil return plug (where able) ! ! ! !
Clean condensate drains
Clean solenoids ! ! ! ! !
Change air filter ! ! ! !
Change cabinet filter ! ! ! !
Drain and re-fill with oil ! ! ! !
Change oil filter (where applicable) ! ! ! !
Change mpv seals ! ! !
Change unloader valve seats ! ! !
Change vacuum valve seats ! ! !
Change pre-filter disc’s (955-975)
Check oil seal ! !
Check drive media
Check perishable oil pipes on top of compressor ! ! !
Change separator element(s) / cartridge ! ! !
Change thermal motor ! ! !
Change perishable oil pipes ! !
Check starter contactors ! ! !
Grease motor bearings if applicable !
Change drive media
Check motor insulation resistance !
Replace motor bearings !
Change oil return plug ! !
Change oil seal !
Change pressure gauge !

32 ST 16048-00A
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ST 16048-00A 33
 Servicing 10

Copyright © 2003
All rights reserved. The copyright of this document is the property of
CompAir UK Limited. No part of this publication may be reproduced, stored in
a retrieval system, or transmitted, in any form or by any means, electronic,
mechanical, photocopying, recording, or otherwise without the prior written
permission of the Technical Publications Department, CompAir UK Limited.

CompAir UK Limited
Claybrook Drive
Washford Industrial Estate
Redditch E-mail: [email protected]
Worcestershire Telephone: (01527) 525522
England Fax: (01527) 521140
B98 0DS

34 ST 16048-00A