HK 425100 400V - Compressor Airpress - Free user manual and instructions

USER MANUAL HK 425100 400V Airpress

Operating instructions

Please read this instruction manual carefully before use.

1.0 Prefatory note page 22
2.0 Safety instructions page 23
3.0 Placing page 24
3.1 Electric connection page 24
3.2 Air connection page 25
4.0 First use page 25
5.0 Operation page 26
6.0 Maintenance page 27
7.0 Possibilities of failure page 29
8.0 Technical details page 30

LEGENDA (subject to modification)

a manual pressure switch
b reducing valve setting
c push bow
d coupling reduced pressure receiver
e safety valve
f bonnet for engine and fan
non return valve
h stopvalve reduced pressure
i gauge reduced pressure
j plug for extra connection
k pressure gauge for pressure of air
I drain tap for condensation water
m air filter bonnet
filler cap for lubrication oil (Airpress)
o drain plug for lubrication oil
p reset button thermal protection
q air outlet
belt protector
s discharge line
t pressure pipe
U V-belt

ATTENTION

To be able to use this compressor installation properly, a number of measurements must be taken. The following points will contribute to making you a satisfied user of this installation.

1.0 PREFATORY NOTES

Buying your AIRPRESS compressor installation, you have become the owner of a compressor installation with a high performance and reliability level. Correct use and regular maintenance will increase the life of the compressor.

In this manual you will find operation and maintenance instructions. Read it carefully and keep it as a guide to your compressor.

The compressor has been built to supply compressed air. In particular the appliance cannot be used to produce air to be breathed by humans or used on direct contact with foodstuffs. The appliance must be used only for the purpose for which it was specifically designed. All other uses are to be considered incorrect and therefore unreasonable. The manufacturer cannot be held responsible for any damage resulting from improper, incorrect or unreasonable use. This machine is not suitable for external installation.

2.0 SAFETY INSTRUCTIONS

Important: please read and observe the following safety instructions before using the machine.

• Nobody must be allowed to use the compressor unless they have read the instruction manual and have been instructed in the regulations to follow for correct and safe use.
• The machine must be used by adults only. Use of the compressor by apprentices of not less than 16 years of age must be supervised by an adult authorised to use the machine.
• Keep children and visitors away from the working area.
• Be cautious when using compressed air. Never aim the air flow at people or animals. Do not use compressed air to clean clothing.
• Compressed air is not suitable to inhale.
• Do not wear loose clothing or neckties that can get caught in moving parts. Preferably wear safety goggles, nonslip footwear and Wear protective hair covering to contain long hair.
• Only use the machine outside in dry, well-ventilated surroundings and do not expose the machine to rain.
• The compressor should be placed in such way that all points, destined to carry it will really do so. Take also care of a horizontal position.
• This machine is not fit for continuous running, but service for 30% per 60 minutes.
• Keep your work area clean and well lighted.
• Do not use the machine in areas where fumes from paint, solvents or flammable liquids pose a potential hazard.
• Do not exceed the maximum operating pressure and only use the machine in an ambient temperature between +5^ and +40^ .
• Never attempt to tamper with the protections of the log splitter or to operate the machine without these.
• The working parts of the machine can become hot during operation. Let the machine cool down after use.
• After each use the tank must be vented and the moisture collected in the tank must be bled. Not bleeding the tank can lead to leakage and may cause a dangerous situation.
• Check that the electric circuit is adequately protected and that it corresponds with

the power, voltage and frequency of the motor. Check that there is a ground connection and a regulation differential switch upstream.

• Use cables with an adequate section and avoid use of free and inadequately insulated connections.
• Never open the pushbutton box on the motor. Should this be necessary, contact a qualified electrician.
• Make sure that the machine and the cable never come in contact with water.
• Treat the power cable with care. Do not attempt to move the machine by pulling the cable. Do not yank the cable to unplug it; keep the cable away from excessive heat, oil and sharp objects.

• Never leave the machine unattended with the power supply "on". Also disconnect the power cable when:

• you leave the machine, even for a short time

• not in use
• carrying out maintenance work

• changing attachment or moving the machine.

• WARNING: the warnings, cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

• Only those persons who are aware of how to use the compressor by having read this manual, should use the machine. Injudicious use may cause danger.
  See page 42 / 43 for explanation of danger plates.

3.0 PLACING

The AIRPRESS compressor should be placed in such way that all points, destined to carry it will really do so. Take also care of a horizontal position.

The engine should get sufficient cooling air; so never cover the ventilating openings. Place the compressor in a cool dustfree space. Never place the compressor in a room where will be sprayed. Paint spray will clog the air filter and will also deposit on the compressor. Mind that the drain tap for condensation water (I) and the level gauge will always remain attainable. We suggest to leave a space of approximately 30 cm for ventilation and maintenance.

Notice: Insufficient air supply, too high temperature and fouling of the air filter reduce the efficiency of the compressor considerably.

3.1 ELECTRIC CONNECTION

At the factory the machine is already fully equipped with cables. The machine now has to be connected to your own electricity supply. Connect the machine to a separate group. Beware that voltage and amperage of your electric circuit meet the needs of the motor. Use only cables with the right diameter. The factory suggests to use cables of at least 2.5 qmm.

It is well advised to place a main switch between the compressor installation and the electric circuit, so you can shut off all the electricity before maintenance. Use only

skilled personnel for electric connections. Before first use first read chapters 3.2 and 4.0.

3.2 AIR CONNECTION

Best use for connection of the compressor to an air circuit a flexible hose, to isolate vibrations from the machine. The diameter of the hose must meet the connection of the ball cock. The quick coupling supplied has to be mounted with tape on the outlet of the reducing valve (on cock (h)).

4.0 FIRST USE

1. Check if the instructions mentioned above have been executed.
2. Check the oil level of the compressor (see chapter 6.0 point 3.). Possibly oil has been lost during transport. Fill if necessary with AIRPRESS compressor oil.

Avoid the use of extension cables. If you use them, unroll them completely and use cables of sufficient capacity.

Table for extension cables:

For 230 volt: For 400 volt:

0 - 10 meter: 3 × 1 1/2 mm^2

10 - 25 meter: 3 × 2 1/2 mm^2

0 - 25 meter: 4 × 1 1/2 mm^2

25 - 50 meter: 4 × 21/2 ~mm^2

Compressor with direct drive:

• Switch on the compressor by means of the pressure switch (a).
• The compressor will now operate, unless the air receiver is still under pressure (k).
• Switch the machine, during operation, exclusively off by means of the button on the automatic pressure switch (a); the pressure circuit will be vented and the compressor can start again uncharged.

H 85 without air tank and with 0/1 switch on junction box on the motor.

Compressor with V-belt drive:

• Check tension on the V-belt. At the right tension the V-belt (u) can easily be turned by hand approximately 45 degrees. If necessary, improve tension. See chapter 6.0 point 5.
• Let the compressor run for a short while so you can check if the turning direction is correct (see arrow on belt protector (r)) (only valid for model 400 V). If the motor runs in the wrong direction, switch two phases of the electric plug. Disconnect electricity!
• For daily operation of the compressor, see chapter 5.0.

5.0 OPERATION

Compressor with direct drive:

1. The automatically operating compressor will stop at a pressure of 8 - 10 bar. When air is used again and the pressure in the tank falls to 6 - 8 bar, the compressor will start again.
2. Most pneumatic machines are suitable for an operating pressure of about 7 bar. For some applications this pressure is even lower. To be able to set the right pressure, the compressor is provided with a reducing valve (b). This valve can set the pressure of the air receiver (of course never higher than the pressure in the air receiver).
3. The setting of the reducing valve is done as follows:

a. Pull up the button (b) of the pressure switch.
b. Switch the button to set the right pressure (to the left to lower the pressure, to the right to increase it).
c. Press button down again after setting to lock the button.

1. Two extra plugs (j) are fitted to the tank, which can be used to get an extra pressure connection.

The points mentioned above are not valid for the H 85. The compressor H 85 is executed with an adjustable safety valve and runs continuously.

Compressor with V-belt drive:

1. Check if the pressure switch (a) is turned off. Connect electricity. Turn on the pressure switch. If the air pressure in the air tank is lower than the 'switch on pressure', the compressor will turn itself on, until maximum pressure has been reached. Is the pressure in the tank higher than the 'switch on pressure' the machine will not start, but will be stand by to start when the pressure drops to low.
2. When switching of the compressor, first switch the pressure switch to "0" before turning off the electricity. The pressure switch takes the pressure off the air circuit, so that the compressor can run freely when it starts again. This prevents damage to the motor.
3. The electric motor of your compressor is protected against burning by a thermal overload device. This device turns off the motor automatically, if the motor should get overloaded, or if one phase should fall out. By pressing the reset button on the thermal overload device after a short time, the compressor will function again.

ATTENTION!

Checking the oil level and refreshing the oil does not apply to the oil free models HLO 110/6, HLO 200/25, HLO 215/25, HLO 300/50 and HLO 300/100.

6.0 MAINTENANCE

Before carrying out any maintenance jobs it is obligatory to stop the machine and disconnect it from the power mains.

1. After the first 50 operating hours and then every 250 operation hours the oil should be refreshed. Turn off the oil drain plug (o) and also remove the filler cap (n). Collect the oil. If the oil does not come out any longer, switch on the drain plug again and refill the oil (through filler cap) until the oil has reached the correct level.

Compressor with direct drive: the right oil level is between the two marks on the dipstick.

Compressor with V-belt drive: has an oil inspection glass on the pump. The oil level should be between the red dot on the inspection glass and the upper side of the inspection glass.

Always respect the regulations in force for disposing of old oil!

1. Regularly drain condensation water. The drain tap is situated at the bottom of the tank (I). Draining with pressure in the tank is the easiest way. Some compressors have an after cooler with its own drain plug. Also from this device the condensation water should be drained regularly (is not valid for the H 85).

Condensate must be disposed of in conformity with the local regulations in force (not in the sewer!).

As an alternative you can place an oil/water separator.

1. The oil level should also be checked regularly. For the right oil level see point 1. If necessary refill with AIRPRESS compressor oil, order No 36398 (1/2 l) or order No 36380 (2 l). Checking daily can prevent a lot of troubles!

Use oil of the same type as that already in the machine; do not mix different types of oil!

1. The air filter element (m) should be cleaned or changed regularly. This change depends on the amount of fouling and should be done more often in dusty situations and less often in a clean situation. For cleaning the filter element, take out the filter container with the filter. Then clean the filter by blowing off the dust.

Only for compressor with V-belt drive:

1. The V-belt should be checked after every 1000 hours. At the right tension, the V-belt can easily be turned 45 degrees by hand. If tension is too high, strong corrosion will occur or eventually the spindle of motor or pump may break. At too little tension, the efficiency of the compressor decreases considerably.

Tightening the V-belt as follows:

Dismount the belt protector (r).

Unscrew the fastening bolts on the motor sledge.

Remove the V-belt.

Place the motor at the right distance from the pump. Make sure that the pulley of the motor runs in the same line parallel with the flywheel on the pump (see drawing). Tighten the fastening bolts and replace the V-belt. Worn V-belts should be replaced by new ones with the same size.

After + / - 10 operating hours

tighten the head bolts of the V-belt driven piston compressors according to following table:

Compressor	Pump Bolt Tightening		moment min. (Nm)	Tightening moment max. (Nm)
HL/HK 310-100	2800/3800 M8	22,45 27,43
HL/HK 425-100	2800/3800 M8	22,45 27,43
HK 425-200	2800/3800 M8	22,45 27,43
HK 600-200	3800	M8 22,45 27,43
HK 700-300	5900/B	M10 45,28 55,34
HK 1000-500	6000	M10 45,25 55,34
HK 1000-500	7000 (version >01-12-2010)	M12 77,10 94,23

Note: Regular maintenance of your compressor will increase durability and reliability.

ATTENTION!

Checking the oil level and refreshing the oil does not apply to the oil free models HLO 110/6, HLO 200/25, HLO 215/25, HLO 300/50 and HLO 300/100.

works daily weekly	kly every	every	250 hours 1000	hours
draining condensation water
check oil level
clean air filter
refresh oil (first time after 50 hours)
check V-belt

7.0 POSSIBILITIES OF FAILURE

1 Compressor does not run at starting pressure:

* blown fuse

• renew the fuse

• tank at pressure

• discharge

• motor broken

• repair/renew

• thermal failure

• reset thermal relay

• defective pressure switch

• repair/renew

2 Repeating thermal failure:

* blown fuse

• renew fuse

* loose wire

• repair

• pressure switch does not release air circuit

• repair/renew valve

• too low voltage

• remove extension cable or use heavier

• overloading

• reduce loading

3 Compressor keeps blowing off air:

• defective non-return valve

• repair/renew

4 Too little air production:

• dirty air filter - clean/renew filter

• tighten V-belt

• V-belt too loose

• renew

• defective valves

5 Leaking safety valve:

• pressure too high

• set pressure switch

• defective safety valve

• renew

8.0 TECHNICAL DETAILS

Type	Order number	Number of cylinders	Number of stages	Hp	Motorpower	kW	Volt (50 Hz)	Air tank capacity (litre)	Crank case capacity (litre)	Operating pressure (bar)	Maximum pressure (bar)	Sound pressure level dB (A)	Air intake capacity (L/min.)	Protected with (amp.)	Service (per hour)	Weight (kg)	Dimensions (l×wh) mm
H 85*	36528	1	1	0,6	0,49	230		0,25		8	70	85	10	30%	12	34x20x30
H 200/6	36542	1	1	1,5	1,1	230	6		6	8	83	200	16	30%	17	410x230x470
H 260/10	36544	1	1	2	1,5	230	10	0,5	6	10	78	300	16	30%	22	370x350x600
H 280/25	36540	1	1	2	1,5	230	25	0,4	8	10	77	280	16	30%	32	700x340x650
H 280/50	36541	1	1	2	1,5	230	50	0,4	8	10	77	280	16	30%	41	800x420x720
H 125/6	36546	1	1	1	0,75	230	50	0,3	6	8	80	125	16	30%	16	500x240x470
H 300/25	36549	1	1	2	1,5	230	25	0,5	6	8	78	300	16	30%	23	595x350x600
HLO 200/25	36739	1	1	1,5	1,1	230	25		6	8	78	200	16	30%	23	600x275x590
HLO 215/25	36740	1	1	1,5	1,1	230	25		6	8	78	215	16	30%	23	600x275x590
HLO 300/50	36745	1	1	2	1,5	230	50		6	8	83	300	16	30%	35	820x335x660
HL 215/25	36539	1	1	1,5	1,1	230	25	0,25	6	8	78	215	16	30%	24	600x275x590
HK 280/50	36551	1	1	2	1,5	400	50	0,4	8	10	77	280	16	30%	41	800x420x720
HL 310/25	36839	1	1	2	1,5	230	25	0,25	6	8	76	310	16	30%	25	595x350x600
HL 310/90	36632	2	1	2	1,5	230	90	1,25	8	10	68	310	16	30%	60	970x390x800
HL 310/100	36532	2	1	2	1,5	230	100	1,25	6	8	68	310	16	30%	62	1070x390x800
HK 310/100	36502	2	1	2	1,5	400	100	1,25	6	8	68	310	10	30%	62	1070x390x800
HL 350/30	36847	1	1	2,5	1,8	230	30	0,5	6	8	78	350	16	30%	29	670x340x700
HK 360/25	36553	1	1	2,5	1,8	400	25	0,5	6	8	80	360	16	30%	29	595x350x600
HL 360/50	36548	1	1	2,5	1,8	230	50	0,5	6	8	80	360	16	30%	37	830x380x720
HL 360/60	36850	1	1	2,5	1,8	230	60	0,5	7	9	80	360	16	30%	39	630x520x1000
HL 375/100	36844	2	1	2,5	1,8	230	100	0,5	6	8	73	375	16	30%	63	1230x435x740
HL 425/50	36843	2	1	3	2,25	230	50	0,5	6	8	94	425	25	30%	45	750x330x660
HL 425/90	36666	2	1	3	2,2	230	90	1,25	8	10	73	425	20	30%	67	970x390x800
HL 425/100	36566	2	1	3	2,2	230	100	1,25	8	10	73	425	20	30%	69	1070x390x800
HK 425/100	36501	2	1	3	2,2	400	100	1,25	8	10	73	425	16	30%	69	1070x390x800
HK 425/200	36563	2	1	3	2,2	400	200	1,25	8	10	73	425	16	30%	96	1500x450x1100
HK 600/200	36564	2	1	4	3	400	200	1,5	8	10	74	600	16	30%	125	1500x450x1100
HK 700/300	36568	2	2	5,5	4,1	400	270	1,75	8	10	78	700	20 slow	30%	180	1520x590x1260
HK 1000/500	36569	2	2	7,5	5,5	400	500	2,8	8	10	80	1000	25 slow	30%	280	2030x680x1400

Modelchanges reserved
All compressors are provided with Euro-Norm (CE-Choice)

FRANÇAIS

TABLE DES MATIERES

1.0 Introduction page 31
2.0 Consignes de sécurité page 32
3.0 Installation page 34
3.1 Installations electriques page 34
3.2 Installation de la conduction d'air page 34
4.0 Mise en service page 35
5.0 Commande page 36
6.0 Entretien page 37
7.0 Possibilities de pannes page 39
8.0 Données techniques page 40

LEGENDE

Modelchangesreserved
All compressors are provided with Euro-Norm (CE-Choice)

(NL)

Waste electrical products should not be disposed of with household waste. Please recycle where facilities exist. Check with your Local Authority or retailer for recycling advice.

(F)

The plates fitted on the compressor unit are part of the machine; they have been applied for safety purposes and must not be removed or spoiled for any reason.

Seller's signature Firmstamp seller

For claims against the guarantee, please send us the machine/the apparatus with the completed guarantee certificate and invoice free of charge.

Land/Land/Country/Pays/Pais

GARANTIEBEPALINGEN

The machine/apparatus supplied carries a 12 month guarantee, starting from the day of purchase. If any breakdowns occur within this period, caused by material or structural defects, this guarantee will cover parts as well as labour costs. This guarantee will not cover claims if:

• The instructions in this manual have not been observed.
• The machine / apparatus has been modified in such a way that it no longer functions properly, not even when damaged parts are replaced with the proper components.
• Damage is due to frost, dropping, impact, unauthorized disassembly, improper connection to the electricity grid etc.
• Damage is due to the use of extension leads thinner than 2,5mm^2 (only 230 volts). If the guarantee claim is accepted, the machine/apparatus will be repaired and returned free of charge. No other damages will be paid.

CONDITIONS DE GARANTIE

EC-declaration of conformity

We, Airpress, P.O. Box 114, 8900 AC Leeuwarden, The Netherlands, taking full responsibility, declare that the products

compressors H/HL/HK/HLO

to which this declaration refers, comply with directives 2006/42/EC - 2004/108/EC - 2006/95/EC -

2009/105 - 2000/14EC and normatives EN 1012-1 - EN 60204-1 - EN 60335-1 - EN 55014-1 - EN

61000-3-2 - EN 61000-3-3

The Netherlands, Leeuwarden, 10-03-2010

2006/42/EC - 2004/108/EC - 2006/95/EC - 2009/105 - 2000/14EC

EN 1012-1 - EN 60204-1 - EN 60335-1 - EN 55014-1 - EN 61000-3-2 - EN 61000-3-3

Paises Bajos, Leeuwarden, el 10-03-2010

2006/42/EC - 2004/108/EC - 2006/95/EC - 2009/105 - 2000/14EC

EN 1012-1 - EN 60204-1 - EN 60335-1 - EN 55014-1 - EN 61000-3-2 - EN 61000-3-3

Paese Bassi, Leeuwarden, 10-03-2010

E.J. de Vries

paint spraying
- inflating tyres
- greasing
- blasting
water spraying
- pneumatic tools

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