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

USER MANUAL HK 425100 400V Airpress

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 g non return valve h stopvalve reduced pressure i gauge reduced pressure j plug for extra connection k pressure gauge for pressure of air l drain tap for condensation water m air filter bonnet n filler cap for lubrication oil (Airpress) o drain plug for lubrication oil p reset button thermal protection q air outlet r 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.

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.23 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 +5ºC and +40ºC. 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 with24 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.

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 (l) 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 only25 skilled personnel for electric connections. Before first use first read chapters 3.2 and 4.0.

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)).

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:

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 5.0.26

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.

4. 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 300/100.27

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!

2. Regularly drain condensation water. The drain tap is situated at the bottom of the

tank (l). 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.

3. 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!

4. 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:

5. 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).28 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-

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.

MAINTENANCE TABLE29 works daily weekly every every

250 hours 1000 hours draining condensation water ▀ check oil level ▀ clean air filter ▀ refresh oil (first time after 50 hours)

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

• pressure switch does not release - repair/renew valve air circuit

• 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

• V-belt too loose - tighten V-belt

• defective valves - renew 5 Leaking safety valve:

• pressure too high - set pressure switch

• defective safety valve - renew3031 FRANÇAIS

Danger plates 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.