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3.0 Installation                                                                                                     

 

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3.0 Installation 

CAUTION ! 

 

LIFTING AND TRANSPORTATION MUST ONLY 
BE CARRIED OUT BY AUTHORISED PERSONS. 

ENSURE ALL EQUIPMENT EXCEEDS THE FULL 
LOAD OF THE UNIT. 

3.1 Lifting and Handling  

A fork lift or pallet truck are the most suitable means of moving 
the product. Pay particular attention to ensure stability to prevent 
the unit tilting over. 

Lift the hypac or compressor and place in the desired location, 
damage to mountings may occur if you slide the compressor into 
position. 

3.2 Compressor Location 

Position the compressor/hypac in a room of adequate size on a 
firm surface, level in both planes within five degrees of the 
horizontal.  

Ensure the area has sufficient load-bearing capacity, provide 
access, 1 metre/3.3 ft for routine service procedures around and 
above the unit. 

Site the compressor/hypac away from sources of dirt, coarse 
solids, abrasive particles, steam, liquids and gaseous impurities.  

This is an industrial compressor and is intended for installation in 
an indoor environment. 

Any air connection made to the compressor outlet must be 
flexible as the base incorporates resilient mountings. 

3.3 Compressor Ventilation (Fig.3.1) 

Position the compressor/hypac  in a well ventilated location. Do 
not restrict the air-flow around the compressor  or  allow the hot 
air discharge to re-circulate into the compressor intake.  

 

 

Fig 3.1 Compressor Ventilation 

Any cooling-air inlet (A) should be positioned low allowing 
unrestricted air-flow to the compressor intake. The warm-air 
outlet (B) should be positioned high, and well away from the 
inlet, to ensure a positive cooling air-flow through the 
compressor. 

 

For maximum efficiency and reliability, the compressor should be 
operated in a moderate ambient temperature. If temperatures 
frequently fall below 0°C (32°F), a  different grade of oil may be 
required.{Recommended HPO 198) 

Compressor air intake and exhaust grills have captive nuts fitted 
as standard to attach ducting. 

Air ducting, if fitted, must not cover or restrict the cooling air flow 
of the compressor. Total resistance of the system must not 
exceed  50 mbar. If resistance is expected to be greater, fan 
assistance will be required. 

3.4 Electrical Connections 

WARNING ! 

 

 

CONNECTION TO, OR INSTALLATION OF, AN 
ELECTRICAL POWER SUPPLY MUST ONLY BE 
CARRIED OUT BY QUALIFIED ELECTRICIANS. 
THE INSTALLATION MUST MEET THE WIRING 
REGULATIONS PRESENTLY IN PLACE.

 

Before connecting to the mains electrical supply, ensure that the 
system can sustain the additional electrical load. To ensure 
reliable low resistance joints, make sure that your incoming 
supply cables are firmly secured to the starter terminals and that 
they are of correct size. 

NOTE !

 The starter door panel should always be secured by the 

supplied key for safety reasons and to prevent unauthorized 
access. 

Refer to starter circuit diagrams (located inside the starter door 
panel) before starting work. The instructions given for earthing, 
fuses and cable size are important. 

Fuses to BS 88 (Type gG) must be used to protect the starter, 
refer to the sizes specified on the starter circuit diagrams. 

Circuit breakers are not recommended since they may not fully 
protect the starter contacts in an overload condition. 

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. 

3.5 Electrical Installation (Fig 3.2) 

WARNING ! 

 

BEFORE STARTING WORK ENSURE THAT THE 
MAIN-LINE FUSES HAVE BEEN REMOVED 
FROM THE DISTRIBUTION BOARD. 
PRECAUTIONS SHOULD BE TAKEN TO 
PREVENT THEM BEING REFITTED UNTIL THE 
INSTALLATION IS COMPLETE. 

Starter cables must be connected to the mains electrical supply 
via a lockable, switched and suitably rated fused isolator. The 
isolator should be positioned as near as possible to the 
compressor with clear, unrestricted access. 

To access starter terminals, unlock the starter  door panel and 
pass incoming cables through the entry hole in the floor for 
HR04-HR07. 

Connect the three mains supply cables to the terminals marked 
L1, L2 and L3, and connect the earth cable to the earth terminal 
E. Ensure the connections are secure. 

Refer to IEEE Regulations for electrical equipment installed in 
buildings to determine the size required, pay particular attention 
to the circuit diagrams provided. 

  B 

Summary of Contents for HR04

Page 1: ...HR04 HR07 Models User Handbook Original Instructions CC1132751D 10 2018 GB...

Page 2: ......

Page 3: ...3 Compressor Assembly Fig 4 2 12 4 4 Electronic Controller 12 5 0 Operating Instructions 13 5 1 Checking Procedure Before Starting 13 5 2 Operator Control Keys Fig 5 1 13 5 3 Status Display Lights 13...

Page 4: ...17 7 8 Oil Separator Fig 7 1 17 7 9 Oil Cooler Aftercooler Fig 7 2 18 7 10 Cabinet Air Filter Fig 7 2 18 7 11 Electric Motor 18 7 12 Electrical Connections 18 7 13 Service Schedule 18 8 0 Controller...

Page 5: ...odel HR04ER07 4035S000 50Hz model HR04ED07 4035S000 50Hz model HR04ERD07 4035S000 50Hz model HR04E07 5736D005 60Hz model HR04E10 2036D005 60Hz model HR04E10 4035S000 50Hz model HR04ER10 4035S000 50Hz...

Page 6: ...Warning unit is remotely controlled and may start without warning Read the instruction manual Do not operate the machine the machine without the guard being fitted Warning do not start the machine wi...

Page 7: ...ed over a period of time may cause problems that affect the performance and reliability of this compressor Problems may occur when compressors run for short periods on low air demand where they don t...

Page 8: ...ETTINGS Nominal Pressure bar psi 7 0 or 10 0 102 or 145 7 0 102 Minimum Pressure Valve bar psi 5 5 to 6 0 80 to 87 Load Cut in Pressure bar psi 6 5 or 9 5 94 or 138 7 0 102 Unload Cut out Pressure bar...

Page 9: ...low of the compressor Total resistance of the system must not exceed 50 mbar If resistance is expected to be greater fan assistance will be required 3 4 Electrical Connections WARNING CONNECTION TO OR...

Page 10: ...otation is correct by observing pressure rise on the compressor gauge Cooling fan operation is clockwise all RS units have automatic stop start cooling fans that cut in at 85 C 185 F operating tempera...

Page 11: ...ir demands The compressor will load unload and stop start automatically in response to air demand Motor restarts are set to 10 times per hour for single speed units and 30 times for RS units Run on ti...

Page 12: ...d adjacent to the oil filter The compressor is filled and topped up with oil via the oil filler P The sight glass O will be full when oil overflows from the level plug orifice Q Oil is drained from th...

Page 13: ...ssure are viewed here The third row shows status fault and warning messages The HYDROVANE Pro is fitted with two light signals green red Flashing system is ready the motor may start up automatically a...

Page 14: ...sure set point the REVS Reduced Energy Venting System sequence will begin If there is an air demand during the REVS run on time sequence the compressor returns to full load operation If there is no ai...

Page 15: ...IN POINT or p2 TARGET PRESSURE RS e RUN ON TIME f AUTOMATIC OPERATION g ENABLE REMOTE START h TIMER CONTROL i p2 TIMER CONTROL j AUTO RESTART k POWER LOSS TIME l START UP DELAY m DRYER PRE RUN n RS48...

Page 16: ...this is the basis for accurate timer operations Go to the TIMER CONTROL sub menu use the or key to select from seven different timer units The status line of each switching unit is as follows a b c d...

Page 17: ...SAFETY NOTICE 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 ADVISING THAT IT IS NOT TO BE...

Page 18: ...special attention to power connections cables connected to contactors and incoming terminals and ensure all earthing wiring is present and undamaged Close the starter panel door and lock with the key...

Page 19: ...d X X X X Check motor conduit cables secure X X X X Check motor for damage X Check motor starter for loose connections X X X X Check motor for vibration X X X X Check flexible control pipes X X X Chec...

Page 20: ...motor for damage X Check motor starter for loose connections X X X Check motor for vibration X X X Check flexible control pipes X X Check oil seal for leakage X X Check drive media key X Check starte...

Page 21: ...t now starts automatically after a previously set time f WARNING START IN Alternating with AFTER DRYER PRE RUN The unit has been switched on and is ready The unit starts automatically after the dryer...

Page 22: ...he Engineering Department Gardner Denver Ltd Web www hydrovaneproducts com www gardnerdenver com E mail sales compair com hydrovane nfo uk gardnerdenver com CC1132751D hydrovane USA 1301 North Euclid...

Page 23: ......

Page 24: ...ons for hydrovane Various Applications Global Expertise Gardner Denver Ltd Claybrook Drive Redditc h Worc estershire B98 ODS UK T 44 0 1527 525522 838200 E hydrovane info uk gardnerdenver com www hydr...

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