Hkl Ope Manual Eng

8/16/2019 Hkl Ope Manual Eng

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E-mail: info @dynaset.comDYNASET OY, Menotie 3,FIN-33470 Ylöjärvi, FINLAND

Tel.: +358 3 3488200 Fax: +358 3 3488222

MAY CHANGE WITHOUT PRIOR NOTICE

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HKL HYDRAULIC COMPRESSORS

HKLHYDRAULIC COMPRESSORS

OPERATING INSTRUCTIONS

HKL 400/8 - 24 (33)

HKL 801/8 - 26

HKL 1300/8-38 (46)

HKL 1800/8-46

HKL 2600/8-65 (82)

HKL 4100/8-113

HKL 5000/8-135

HKL 7500/8-132+12

HKL 7500/8-176+12

HKL 1800 / 8 - 46 - O - PE

HYDRAULIC VANE COMPRESSOR

MAXIMUM DISCHARGE, L/MIN

MAXIMUM DISCHARGE PRESSURE, BAR

NOMINAL HYDRAULIC FLOW, L/MIN

CONTROL SOLENOID VALVE FOR OFF-LOAD VALVE

AIR-TO-ELECTRIC OFF-LOAD CONTROL VALVE

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

2


1. SAFETY PRECAUTIONS AND WARNING STICKERS 3

2. GENERAL NOTES 4

3. CONSTRUCTION 4

4. PERFORMANCE 4

4.1 Lubrication system of the compressor 5

5. PRESSURE AND COMPENSATION RATIO 66. AIR AND OIL TEMPERATURES 6

7. AIR HUMIDITY 6

8. INSTALLATION 7-9

9.1 Open centre hydraulic system with variable displacement pump 89.2 Closed centre hydraulic system with variable displacement pump 89.3 Hydraulic system with constant placement pump 99.4 Hydraulic compressor without automatic speed control valve 99.5 Connection to the air supply system 9

9. OPERATION 10 10.1 Off-load mode 11

10. HYDRAULIC FLUIDS 11

11. COMPRESSOR OILS 11

12. COMPRESSOR MAINTENANCE 12-14

12.1 HKL service table 1212.2 Compressor block intake air filter 1212.2 Oil level check and change 1312.3 Oil return valves 13

12.4 AIr/Oil separator 1412.5 Pressure regulator 14

13. TROUBLE SHOOTING 15-16

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

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

16. PRODUCT DISPOSAL 20

17. PARAMETERS 21-22

18. MANUFACTURER’S LIMITED WARRANTY 23

19. DECLARATION OF CONFORMITY 24

20. NOTES 25

TABLE OF CONTENTS


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

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

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

EXTERME CLEANLINESS MUST BE MAINTAINED WHEN CARRYING OUT ANY DISASSEMBLING OR REPAIR OF HKL-COMPRESSOR AND HYDRAULIC SYSTEM. THIS IS CRUCIAL TO ENSURE SAFE, RELIABLE AND LONG-LIFEOPERATION 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 andexperienced personnel only.

SAFETY PRECAUTIONS

3


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.

BEWARE OF PRESSURE AIR.


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GENERAL NOTES

DYNASET hydraulic compressors are compact and integrated all-in-one units, especially designed for mobileinstallation. The only power source is a hydraulic system to provide compressor with required hydraulic fluidflow at demanded pressure.DYNASET hydraulic compressor transforms hydraulic power into a high quality compressed air.

Designed to meet regular compressed air demands, HK hydraulic compressors are used to power pneumatictools, for cleaning, flushing etc.

CONSTRUCTION

4


VANE COMPRESSOR BLOCK

1.INTAKE AIR FILTER 2.INTAKE/SERVO VALVES3.OIL CHAMBER 4.COMPRESSION CHAMBER 5.OIL COOLER 6.

OIL FILTER

1

12

11

2 3 4

5

6

7

810

9

7.AIR / OIL LABYRINTH8.COMPRESSED AIR 9.ROTOR 10.OIL SEPARATOR 11.OIL RETURN VALVE12.

MINIMUM PRESSURE /-NON RETURN VALVE

PERFORMANCE

Utilizing compact rotary vane technique, DYNASET hydraulic compressor of HKL-series is mobile unit

comprised of a hydraulic motor with incorporated automatic rotation speed control valve (up to HKL 1800)

and rotary vane compressor block. Compressor block includes stator-rotor unit, cooling and lubrication

systems, oil separator as well as unloading pressure regulator, attached to the air intake.

Hydraulic motor’s and compressor’s shafts are coupled when rotor runs inside of stator eccentrically.

When compressor’s rotor is revolved by a hydraulic motor, air is taken through a filter into a compressionchamber consisting of a stator and rotor.The rotor is provided with longitudinal slots in which vanes slide. Vanes are pushed against the stator bycentrifugal force, generated by rotation. During compressor’s rotation air is being compressed through theconstruction in volume comprised by walls of rotor, stator and vanes.Pressurization, cooling and lubrication are ensured by oil, injected into a compression chamber due the

pressure differential between compression chamber and oil sump. Thereat, separate oil pump is notrequired.

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

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

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

the compressor oil and compressed air.

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


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... PERFORMANCE

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

12. OIL COOLER

13. OIL FILTER14. SERVOVALVE15. THERMOSTAT16. PILOT OPERATED CHECK VALVE OF

PE-CONTROL VALVE (23) (OPTIONAL)17. OFF-LOAD VALVE (O)18. OIL LEVEL INDICATOR21. AFTERCOOLER (OPTIONAL)22. CONDENSATE SEPARATOR (OPTIONAL) 23. PE-CONTROL VALVE FOR OFF-LOAD VALVE

(OPTIONAL)

30. HYDRAULIC SOLENOID VALVE

SAFETY VALVE:Protects compressor against internal overpressure. The safety valve is adjusted to 12 bar.SERVOVALVE:Limits the maximum operational pressure during compressor’s continuous operation by closing theintake valve according to the increase of an internal pressure. The valve operates together with theOFF-LOAD VALVE.THERMOSTATIC BY-PASS VALVE:Forwards warming the oil to the operational temperature before opening the oil circulation through thecooler.OFF-LOAD VALVE (O, with or without a SOLENOID CONTROL VALVE ):When activated, drops compressor’s load and discharges internal pressure. AIR-TO-ELECTRIC (PE-) CONTROL VALVE FOR OFF-LOAD VALVE :

Provides operation control in accordance with pre-adjusted maximum and minimum pressure limitsin automatic mode.PE-valve and solenoid control valve for off-load valve are recommended when compressor is to bestarted under pressure (for instance, air tank in pressure line) or compressor is operated intermittently.i.e. stopped and restarted depending on a compressed air consumption.The devices decompress the pressure line enabling easy restart of the compressor.

LUBRICATION SYSTEM OF THE COMPRESSOR

COMPRESSOR OIL PERFOMS FOLLOWING FUNCTIONS:1. LUBRICATION Pressure differential (see above) makes the oil spread along grooves to the surfaces to be

lubricated. Separate oil pump not required.2. HERMETIZATION Oil, injected into the stator, seals rotor blades against stator’s wall and lubricates them.3. COOLING Compressor oil removes the compression heat from the stator.4. CAPACITY CONTROL Off-load automatics (servo valve - off-load valve) adjusts compressor’s flow rate according to

the air consumption hydraulically using compressor oil.

S

M

P

T

1

2

18

11

12

15

71 6

8

95 6

21 22

10

43

13

14

17

30

2316


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PRESSURE AND COMPRESSION RATIO

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

operational pressure + barometric pressure

barometric pressure

8 + 1,0135

1,0135= 8,89=

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

AIR HUMIDITY

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

Filled with specified compressor oil or corresponding, (ref. to “COMPRESSOR OILS”) unit is operated withoutany particular arrangements within ambient temperature range -5 ºC... + 40 ºC. If ambient temperature dropsbelow -5 ºC or raises over + 45 ºC, fill the compressor with synthetic oil or be kindly requested to contactDYNASET’s representative.According to the standard EN 1012-1 the maximum accepted temperature of oil is +100 ºC. In normal operationalconditions at ambient temperature of +20 ºC compressor oil’s temperature levels to 80 - 85 ºC.The temperature of the delivered compressed air exceeds ambient temperature by approx. 5 - 10 ºC.

AIR AND OIL TEMPERATURES

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P

T

INSTALLATION

DYNASET hydraulic compressor can be placed deliberately ensuring free air intake, sufficient cooling and aneasy access to the unit. Position of a compressor should be horizontal. To protect compressor against overheating,do not allow the warmed cooling air to be directed by cooling fan back to the compressor block. Compressor’slocation should be chosen as far as possible from any source of dust and heat. Protective cover against weather

and season impacts is recommended.Intake air should not contain any smoke, toxic or flammable gas/vapor. When necessary, intake pipe can befitted (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 orderto keep return oil pressure under 5 bar. Generally DYNASET’s T-line is to be connected directly to the returnline of a hydraulic system, when hydraulic fluid flows to the tank only through the return filter and cooler.Both filtering degree and cooling capacity of a hydraulic system should be sufficient (ref. to PARAMETERS).

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

After having been connected to the hydraulic system, DYNASET hydraulic compressor is to be started by directingthe oil flow to the unit’s pressure port by means of control valve - manual or solenoid. Even simple ball valveor 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 thenominal power output is achieved (ref. to PARAMETERS). Lower hydraulic pressure reduces compressed airpressure. Maximum hydraulic pressure is 250 bar (ref. to PARAMETERS). If the hydraulic system main pressureis higher, service pressure relief valve must be used.

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

It is possible to use DYNASET either as a mobile compressor and connect hydraulic powerwith 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 ahydraulic system are to be connected to the unit’s corresponding hydraulic ports. Theproper connection ensures correct rotation direction of the compressor and, by that, anappropriate cooling of the compressor block. Rotation in opposite direction is not allowed.Furthermore, cross-connection of hydraulic hoses damages hydraulic motor’s shaft seal.

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HKL

S

M

PT

T

CF

PP

LS LS

A

B

AUTOMATICROTATION SPEEDCONTROL VALVE

PV-SAE valve

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

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

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

PV SAE priority valve is designed for the

installation to main pressure linebetween SAE-flanges of main hydraulicpump. Pre-adjusted, independent fromother functions and priorised hydraulicflow for DYNASET-unit comes from thesolenoid valve.

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

1.Sandwich-mounted pressurecompensator with SAE-flangespecification;2.Solenoid valve 12/24V;3.Flow limiter;4.Pressure relief valve.

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

PRIORITY VALVE.

The rest of hydraulic pump’s capacity is available for all otherfunctions. Furthermore, pump’s control works together withDYNASET PV SAE priority valve.

1. OPEN CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

LS-valveHKL

S

M

PT

AUTOMATICROTATION SPEEDCONTROL VALVE

2. CLOSED CENTRE HYDRAULIC SYSTEM WITH VARIABLE DISPLACEMENT PUMP

The demanded hydraulic flow is to be ensured and controlled with a DYNASET

PRESSURE COMPENSATED LOAD SENSING (LS) VALVE.

DYNASET LS-valve includes following

components:

1.

Flow limiter;

2.

Solenoid valve 12/24V;

3.

Pressure relief valve;4.

Shuttle valve (OPTIONAL).

DYNASET LOAD SENSING VALVES:

LSV 40, LSV 60, LSV 95 and LSV 150LS-connection, pressure relief, max. hydraulic

flow 40, 60, 95 ja 150 l/min respectively.

DYNASET FLOW LIMITERS to the pressure line:

VR 40 PK - 1/2, max. 35 l/min, with pressure compensation;

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

ALSO AVAILABLE for closed centre hydraulic systems with variable displacement pump:DYNASET SOLENOID VALVE to the pressure line for remote starting.

SV 70 NC - 1/2 - 12 / 24 V max 70 l/min with LS -connection; SV 150 NC— 1 - 12 / 24 V max 150 l/min with LS -connection.

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... INSTALLATION


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HKL 2600 - 5000

PT

... INSTALLATION

HKL 400 - 1800

S

M

PT

When installing a compressor of given type to a hydraulic system, is to kept in mind that the allowed

nominal hydraulic flow should not be exceeded (Q hy_nom = Q hy_max).

HYDRAULIC COMPRESSORS WITHOUT AUTOMATIC SPEED CONTROL VALVE:

CONNECTION TO THE AIR SUPPLY SYSTEM

It is recommended to install distribution valve toa pressure line near the compressor in order toclean oil cooler and filter with a blow gun whennecessary.

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 toAP-port to keep the pressure drop minimal. The length of a pipeline, laid with the pipe of same diameter asAP-port, can be 50 m as maximum. For longer lines use larger diameter.

S

M

PT Moisture separator to the pressure line isoptional.

AUTOMATIC

ROTATION SPEEDCONTROL VALVE

3. HYDRAULIC SYSTEM WITH CONSTANT DISPLACEMENT PUMP

The demanded oil flow is to be ensured with

proper hydraulic pump choice. In systems withredundant hydraulic flow an installation with

DYNASET PRIORITY VALVE is recommended.

Installation with a standard pressure compensated

3-way valve should be avoided in order to close off

potential waving in hydraulic system.

ALSO AVAILABLE for hydraulic systems with

constant displacement pump:

DYNASET FREE CIRCULATION VALVE with solenoid

and pressure control, type VKV 90—3/4.

HKL 400 - 1800 HKL 2600 - 7500

PT

P

T

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10


Hydraulic flow rate marked on the compressor’s

nameplate is an absolute maximum and shouldnot be exceeded in any circumstances.A redundant hydraulic flow causes compressor’soverspeeding and may damage it.

OPERATION

Prior to starting the compressor check whether the unit is filled with oil. In non-operating and depressurized

compressor oil level is over the top point of sight glass. When necessary top up with the same oil as the unitis filled with. Replace and tighten the filler plug (Ref. to the instructions below).

Open the cut-off valve in compressor’s pressure line. Ensure from compressor’s pressure gauge that the unitis decompressed - when pressurized, compressor may start with difficulty*).With carrier’s engine running HKL-compressor is started with a hydraulic control valve. Compressor starts toproduce 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 nominaldischarge is achieved when the compressor is rotated by hydraulic flow adequate to the nominal rotationspeed.

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

* solenoid control valve for off-load valve; * pressure switch.

Q hy_nom = Q hy_calc + 2 l/min

Q hy_calc - CALCULATED CONSTANT FLOW

Q hy_nom - NOMINAL FLOW

Q hy_nom = Q hy_max

Compressed air is consumed according to the demand, when compressor’s delivery levels within 0 l/minto the maximum. If the compressed air is not used while compressor is running, off-load automatics (=

OFF-LOAD VALVE + SERVOVALVE) closes the intake valve and sets compressor’s internal pressure to 1 - 2bar (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 thecurrent air demand.

COMPRESSORS EQUIPPED WITH AN AUTOMATIC ROTATION SPEED CONTROL VALVEHKL400 - HKL1800

HYDRAULIC FLOW0 Q min

Q hy, l/min

CONTROL RANGE*

Q nom

Q pi, l/min

D I S C H A R G E

Q pi, min

Q pi, nom

Q max

COMPRESSORS WITHOUT AN AUTOMATIC ROTATION SPEED CONTROL VALVEHKL2600 - HKL5000

OFF-LOAD MODE

Compressor being rotated at full output,

automatic rotation speed control valve keeps

rotation speed constant when incoming

hydraulic oil flow (Q hy) can vary fromnominal demanded flow (Q nom) up to valueexceeding Q nom by 10 – 20 l/min dependingon compressor size.

0 Q min

Q hy, l/min

Q nom = Q max

Q pi, l/min

D I S C G A R G E

Q pi, min

Q pi, nom

HYDRAULIC FLOW


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ATTENTION !The compressor must be operated neither in smoky environment nor in conditions where toxic or flammablevapors could be aspirated.Compressor’s maximum pressure must not be exceeded in any circumstances.Compressed air delivered by a HKL-compressor must not be used as the breathing air, even if purified and

filtered. HKL-compressor is designed for air only and must not be used with any other gas.If the compressor is connected to the distribution network or consumer with a flexible hose, ensure that thehose is of proper diameter and pressure class. Damaged or worn hose should be replaced immediately.The sound-proof enclosure (if used) should be closed when compressor is in the operation.

... OPERATION

Check the compressor’s oil fill periodically: when the unit is in operation, the oil level must be over the

midlevel of the sight glass .

NEVER REMOVE THE OIL FILLER PLUG WHEN THE COMRESSOR IS RUNNING OR PRESSURIZED !

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

Synthetic and bio-oils can be used as well if their viscosity characteristics and lubricating efficiency arecorresponding 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 nearestDYNASET representative for an advice.

HYDRAULIC FLUIDS

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

ROTOROIL F4 compressor oil is recommended as most preferable lubricant. If ROTOROIL lubricants are not

available it is allowed to replace them with high quality rotary vane compressor oils of same viscosity classsupplied by other manufacturers, see table below. Pay attention to long-life oil exchange interval and life

span. All Dynaset compressors are equipped with thermostat for unexpected overheating and damages.

COMPRESSOR OILS

QUALITY AMBIENT OIL CHANGE SUPPLIER DETAILS TEMPERATURE MAX, HOURS

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

Prior to starting any maintenance or repair, ensure that the compressor is completely depressurised.

The pressure gauge in oil separator housing must indicate zero.

COMPRESSOR MAINTENANCE

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


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12


INTAKE AIR FILTER INTAKE AIR FILTER

In normal operating conditions the filterelement should be replaced after each 1000 hor with the interval of at least 6 months.

Filter site and cover should be cleaned.


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

DYNASET HKL-SERIES SERVICE TABLE

CHECK POINTS

Check oil level O I

Clean compressor air intake filter O I

Clean oil cooler and air after cooler O I

Clean oil return valve filters O I

Change air intake filter I

Tighten nuts and screws fixing thewires in the electric control panel

and in the motor terminal board O IReplace oil return valve filters I

Change oil filter: FG I

Change oil filter: F2 or F4 I

Oil change: Rotoroil 8000: FG I

Oil change: Rotoroil 8000: F2 or F4 I

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

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

Weeklyor

every

Monthlyor

every

Every 3months

or

Every 6months

or

Every 12months

or

Every 12months

or

Afterthefirst

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

NOTE: O = These operations must perform to a new device after the first 50 hours.

Within the first 300 hours of operation: Clean the oil return valves.

Oil cooler should be checked on a dailybasis and cleaned when necessary. To cleanthe cooler use AIR blow gun MODERATELY.

A clogged and dirty cooler causescompressor’s overheating.

COMPRESSOR MAINTENANCE

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13


MAINTENANCE

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

OIL FILTER ELEMENT SHOULD BE REPLACED AT EACH OIL CHANGE OR

AT LEAST AFTER EVERY 12 MONTHS.

OIL LEVEL CHECK AND CHANGE

1

2.12.1

2.2

3

ENSURE THAT THE COMPRESSOR IS COMPLETELY

DEPRESSURIZED !

Unscrew filler plug (1) slowly.

Attach proper fitting to the oil drain valve (2.1) and

open the valve. Drain the oil into the suitable pan.

(Oil drain valve could be replaced with a discharge

plug 2.2).

Shut off the valve (2.1) or replace and tighten the

plug (2.2) Fill the compressor with oil. Replace and

tighten filler plug 1. DO NOT FORGET GASKETS !

Start the compressor and let it operate few minutes.

Check oil level and top up if necessary.

ATTENTION !OIL SHOULD BE CHANGED WHEN THECOMPESSOR IS WARMED UP TO THENORMAL OPERATIONAL TEMPERATURE.

FACTORY-FILL OIL

Factory-fill oil must be changed after very first 200

(max.) operation hours.

Further on compressor oil is to be changed accordingto the oil quality and service time (ref. to

COMPRESSOR OILS above) or at least once a year.

OIL RETURN VALVES

Oil return filters should be cleaned

at the first oil change.

Further on, oil return filters should

be cleaned after each 500 h or

every three months. Replace oil

return filters after each 2500 h or

at least once a year.

OIL RETURN VALVE

MODEL OIL FILL

l HKL 400/8 - 24 (33) 2,5

HKL 801/8 - 26 2,0

HKL 1300/8-38 (46) 2,0

HKL 1800/8-46 3,5

HKL 2600/8-65 (82) 3,5

HKL 4100/8-113 10

HKL 5000/8-135 10

HKL 7500/8-176+12 19

OIL RETURN VALVE


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AIR / OIL SEPARATOR

SEPARATOR ELEMENTSEPARATOR ELEMENT

HKL 800 - HKL 2600 HKL 4100 - HKL 5000

PRESSURE REGULATION

Compressor’s output pressure is adjusted andtested at factory and usually does notrequired resetting.However, if re-adjustment is required, theprocedure is to be made as follows:1.Start the compressor.2.

Shut off the pressure line slowly when airpressure achieves the maximum. Note thepressure gauge’s reading *).3.Having removed parts, shown on the sketch,make the adjustment with the servo valve: 3.1 loosen locknut first 3.2 to increase pressure, tighten the

adjusting screw; to decrease pressure, loosen the

adjusting screw; 3.3 lock the setting with locknut.

SERVOVALVE

NOMINAL OUTPUT PRESSURE SERVOVALVE’S SETTINGOF A HYDRAULIC COMPRESSOR

bar bar

8 8,5 10 10,5

ATTENTION !ONLY THE QUALIFIED PERSONNEL ISALLOWED TO MAKE THE SETTING !

*)

A separate pressure gauge should be connected to the pressure line when making

the adjustment.

It is recommended to use the unit comprised of ball valve and pressure gauge as

shown on the alongside sketch.

SAFETY VALVE 12 BAR

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

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


MAINTENANCE

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15

1.1Malfunction of compressor’shydraulic control valve.1.2Compressor’s excessive internalpressure.

1.3Failure in hydraulic system.

1.4Air pressure in delivery linedisrupts compressor’s start.

1.1Check and repair.

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

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

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

2.COMPRESSOR STARTS

HARDLY

See 1.3

See 1.4

3.

AIR PRESSURE DOESNOT ACHIEVE

REQUESTED RATE.

3.1

Servo valve’s incorrect setting.

3.2Safety valve opens due to theeither the failure or incorrectsetting of servo valve.

3.3Failure in hydraulic system.

3.4

Air intake filter is clogged.

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

3.1

Check and adjust servo valve when necessary.

3.2.Check and adjust servo valve.

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

3.4

Check and replace.

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

TROUBLESHOOTING

1.COMPRESSOR DOES

NOT START WHILE

CARRIER’S ENGINE ISRUNNING AND

HYDRAULIC SYSTEM IS

ON.


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... TROUBLESHOOTING

5.EXCESSIVE OIL

CONSUMPTION

5.1Filters of the oil return valves areclogged.

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

5.1Check and clean / replace valves.

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

4.COMPRESSOR DOES

NOT PRODUCECOMPRESSED AIR =

RUNS UNLOADED

4.1Delivery line closed (i.e.OPEN/CLOSE valve is damaged) orpossible malfunction in pneumaticexecutor.4.2Servovalve’s failure or incorrectsetting (i.e. adjusted to thepressure lower than setting ofminimum pressure / non returnvalve).4.3Air intake valve does not open.

4.1Check and repair possible failure.

4.2.Check and repair possible failure.

4.3Check the valve and repair failure. Check also thewhole valve block to order to find out and repairpossible malfunctions.

6.COMPRESSOR’S

OVERHEATING.

6.1Dirty oil cooler.

6.2High ambient temperature.

6.3Low oil level.

6.4Due to the seizure of thermostaticby-pass valve, compressor oil doesnot circulate through oil cooler.

6.5Due to the insufficient coolingcapacity of a hydraulic system

hydraulic fluid warms thecompressor.

6.1Clean the oil cooler.

6.2Sufficient ventilation is to be arranged.

6.3Add compressor oil to the required level.

6.4Check and repair the valve.

6.5DYNASET OY offers wide range of hydrauliccomponents including oil coolers !

ATTENTION !

HKL-compressor is equipped with athermostat, which is to be used for stoppingthe compressor when the unit’s temperatureachieves thermostat’s constant set value.

Thermostat is to be connected to the stopvalve or alarm lamp in the Customer’s system

by Customer themselves.


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17


PLUG R 1/8”

PLUG M5

Prior the installationremove air filter’s cover.

A

A

3

2

SOLENOID CONTROL VALVE FOR OFF-LOAD VALVE (O)

1

2

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

HKL 800 - HKL 2600

ATTENTION !In HKL 4100 and HKL 5000the connection is placedon the right side of thecompressor block.

A.The offload valve (17) is to be attached into the connection (1) of R1/8” in oil separator (on the same side with AP-connection). Tighteningglue is used to make joint hermetic. Prior to the installation remove theplug 1/8” from the connection port.B.From-valve-to-compressor unload air tube (2) (6/4 teflon) is installed tothe connection M5 (3) with a swivel fitting and tightening glue as shownon sketches above. Prior to the installation remove the plug M5 fromthe connection port.The unload air tube is laid under the oil separator betweencompressor’s housing and air filter cover.Installation kit includes all necessary fittings and the nylon tube.The valve is equipped with a pre-installed fitting 1/8”.


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18


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

PE-control valve provides operation control in accordance with pre-adjusted by an incorporated pressure

switch maximum and minimum pressure limits in automatic mode.

16

23

PE-CONTROL VALVE FOR OFF-LOAD

VALVE IS COMPRISED OF TWO BASIC

ASSEMBLIES:

POS 16

Pilot operated check valve

POS 23PE-control valve, including following

components:

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

23.2 needle valve to adjust filling

time interval of air chamber 23.4

23.3 pressure switch, pre-adjusted

at factory (3 bar)

23.4 air chamber

Filling times for air chamber 23.4,

pre-adjusted at factory:

HKL 1300 14 - 15 sec

HKL 2600 20 sec

.....

HKL 5000 40 - 45 sec

23.3

IP65

PRESSURE SWITCH 23.3:

Contacts 1-2: NC, used when compressor is runas stand-alone unitContacts 1-4: NO, used when compressor isinstalled to a Customers’ system with severalexecutive units;

Control voltage max. 250 VPressure max. 10 bar

23.1

HYSTERESISLOCK

LOCKNUT OFPILOT VALVE

23.2

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


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19


When there is no air consumption compressor being on (i.e. delivery line is closed), air pressure in

compressor’s reservoir achieves its maximum, opening a pilot valve (23.1) and activating the off-loadmode.

Pilot operated check valve (16) opens and sends a signal to a compressor’ servov alve, which closes the air

intake valve.

An air chamber (23.4) is filled up with an air discharging from compressor’s reservoir until the pressure in

chamber achieves the pre-adjusted value for the opening of a pressure switch (3 bar). Pressure switch 23.3

opens de-energizing the solenoid valve (30) when the unit stops.

As soon as the compressed air is requested by a pneumatic consumer, i.e. delivery line is open - pressure in

air chamber (23.4) drops less than 3 bar, when the pressure switch closes, re-energizing the solenoid valve

(30) and restarting the compressor.

If the compressed air is requested the off-load mode being on, PE-valve drops the pressure in compressor’s

reservoir to the pre-adjusted value (set from the pilot valve to 5 - 6,5 bar depending on the unit’ size)opening the compressor’s intake valve, and the unit passes into the operation directly from the unloaded

mode.

16

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

23

23.2

23.1

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

23.3

23.4

+V

TIME

PRESSURE

3 BAR


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PRODUCT DISPOSAL

Conform to waste legislation, regulations and recommendations in waste disposal and waste recyclingissued 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 toother 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.


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PARAMETERS HKL - VANE COMPRESSORS

HKL 400 /8 - HKL 801/8 - HKL 1300/8 - HKL 1800/8 -

-24 -33 -26 -38 -46 -46

DISCHARGE CHARACTERISTICS

Flow rate at ref. conditions*,

max. l/min 400 800 1300 1800

Maximum pressure bar 8 8 8 8

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

HYDRAULIC CONNECTIONS

Pressure line P BSP 1/2” BSP 1/2” BSP 1/2” BSP 1/2”

Return line T BSP 1/2” BSP 1/2” BSP 1/2” BSP 1/2”

Drain line DR NO NO NO NO

HYDRAULIC POWER REQUIREMENTS

Minimum flow l/min 10 14 14 20 23 23

Maximum flow l/min 35 55 37 60 66 66

Pressure at nominal flow bar 210 170 210 210 170 210


Pressure when unloaded bar 140 120 140 150 130 150

HYDRAULIC FLUID REQUIREMENTS

Viscosity cSt 10 - 200 / optimum 25 - 35

Temperature ºC max. 70 **

Filter ratio, recommendation um min. 25

Cooling capacity, recommend. kW 2 2,8 2,2 3,2 4 4

OVERALL DIMENSIONS

Length mm 525 640 640 750Width mm 250 390 390 390

Height mm 325 540 540 600

WEIGHT kg 30 50 55 95

* According to ISO 1217(1996) at discharge pressure of 6 bar.

** REF. TO HYDRAULIC FLUIDS

21


HKL-COMPRESSORS, STANDARD DISCHARGE PRESSURE OF 8 BAR *

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


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PARAMETERS HKL - VANE COMPRESSORS

HKL 2600/8 - HKL 4100/8- HKL 5000/8- HKL 7500/8 -

-65 -82 -113 -135 -132 + 12 -176 + 12

DISCHARGE CHARACTERISTICS

Flow rate at ref. conditions*,

max. l/min 2600 4100 5000 7500


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

HYDRAULIC CONNECTIONS

Pressure line P BSP 3/4” BSP 3/4” BSP 3/4” BSP 1”

Return line T BSP 1” BSP 1” BSP1” BSP 1”

Drain line DR NO NO NO T15

HYDRAULIC POWER REQUIREMENTS

Minimum flow l/min 33 41 74 74 72 + 12 96 + 12

Maksimum flow l/min 65 82 113 135 144 188

Pressure at nominal flow bar 210 170 200 180 260 200

Maximum pressure bar 250 250 250 280 250

Pressure when unloaded bar 50 135 145 150 200 150

HYDRAULIC FLUID REQUIREMENTS

Viscosity cSt 10 - 200 / optimum 25 - 35

Temperature ºC max. 70 **

Filter ratio, recommendation um min. 25

Cooling capacity, recommend. kW 5 6,8 9,4 11,3

OVERALL DIMENSIONS

Length mm 790 870 870 1100 1100Width mm 390 495 495 850 850

Height mm 600 770 770 820 820

WEIGHT kg 103 185 185 325 330

* According to ISO 1217(1996) at discharge pressure of 6 bar.

** REF. TO HYDRAULIC FLUIDS

22


HKL-COMPRESSORS, STANDARD DISCHARGE PRESSURE OF 8 BAR *

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


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MANUFACTURER’S LIMITED WARRANTY

1. Warranty coverage All hydraulic accessories manufactured by

DYNASET OY are subject to the terms andconditions of this limited warranty. Products arewarranted to the original purchaser to be free fromdefects in materials or workmanship. Exclusionsfrom warranty are explained in item 8.

2. Beginning of warranty periodWarranty period begins from the delivery date ofthe product. Delivery is considered to be done onthe date when installation has been accomplishedor purchaser has taken the product in use.Product is considered as taken in use at the datewhen DYNASET OY has delivered the product topurchaser, unless separately agreed otherwise bywritten agreement.

3. Warranty periodWarranty period is twelve (12) months based onmaximum of 2000 hours usage during this timeperiod. In cases where the system is providedcomplete with certain special components (e.g.drive unit), those components are considered as asubject to their manufacturer’s warranty.

4. Warranty proceduresImmediately upon identifying a problem whichpurchaser believes to be a failure subject to theproduct’s limited warranty, purchaser must contactprimary to the seller of the product. Contact mustbe made as soon as possible, latest thirty (30)days after the problem was identified. Sellerand/or manufacturer technical staff determines thenature of the problem primarily by phone ore-mail. Purchaser commits to give necessaryinformation and to perform routine diagnosticprocedures in order to determine the nature of theproblem and necessary procedures.

5. Warranty repairsIf the product is found to be defective during thewarranty period, DYNASET OY will, at its option,either repair the product, author it to be repaired atits authorized workshop or exchange the defectiveproduct. If the product must be repaired elsewhere

than premises of DYNASET OY or authorizedworkshop, all costs excluded from this warranty(traveling and waiting hours, daily allowance,traveling expenses and uninstallation/reinstallationcosts) will be charged from the purchaser.

If the problem is not covered by this limitedwarranty, DYNASET OY has the right to chargepurchaser 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 berepaired, DYNASET OY gives Warranty ReturnNumber (WRN). Items being returned must beshipped, at the purchaser’s cost, adequatelypacked for shipment, to the DYNASET OY or toother location authored by DYNASET OY.Shipment documents must contain:

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

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

warranty period.

8. Exclusions from warrantyThis warranty shall not apply to:

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

b. Cost of maintenance, adjustments, installationor startup

c. Coating, hydraulic oil, quick couplings andinterconnection hoses (internal or external to systemassemblies)

d. Products altered or modified in a manner notauthorized by DYNASET OY in writing

e. Products which have been repaired duringwarranty period by others than DYNASET OY or itsauthorized workshop

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

product

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

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

© DYNASET OY, all rights reserved

23



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EC DECLARATION OF CONFORMITY

We hereby declare that the below-reference product design, structure and our manufacture form fulfills relevant, fundamental safety and health requirementswith the provisions in the Council Directive on mutual approximation of laws of theMember States on the safety of machines.

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

Apply conformity standards:

- CEN EN ISO 4413: EN ISO 4413:2010Hydraulic fluid power - General rules and safety requirements for systemsand 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 COMPRESSOR

TYPE NUMBERS: HKL400/8-24-xxx, HKL400/10-24,

HKL801/8-26-xxx,

HKL1300/8-38-xxx, HKL1300/8-46-xxx,

HKL1800/8-46-xxx,

HKL2600/8-65-xxx, HKL2600/8-82-xxx,

HKL4100/8-113-xxx,

HKL5000/8-135-xxx,

HKL7500/8-176+12-xxx (xxx + xx)

YLÖJÄRVI 26.07.2012

DYNASET Oy

Timo NieminenR&D Manager

24


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NOTES


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Hkl Ope Manual Eng

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Transcript of Hkl Ope Manual Eng