CompAir HV04 Parts List And Service Manual
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CompAir HV04 Parts List And Service Manual

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Parts List/Service Manual
HV04 - HV07 Models (ACS)
Stationary Air Compressors
ST 16049-00 Iss A 05/2003

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Summary of Contents for CompAir HV04

  • Page 1 Parts List/Service Manual HV04 - HV07 Models (ACS) Stationary Air Compressors ST 16049-00 Iss A 05/2003...
  • Page 3 Parts List/Service Manual HV04 - HV07 Models (ACS) Stationary Air Compressors ST 16049-00 Iss A 05/2003...
  • Page 4 This page is intentionally left blank...

  • Page 5: Table Of Contents

    Local CompAir UK Ltd Distributor ........
  • Page 6 Contents Starter (34756) 7.5 kW 50/60Hz Variable Speed ......52 Starter (34724) 7.5kW 230/460V 60Hz ....... . . 54 Starter (34787) 4kW 230V 60Hz .

  • Page 7: Introduction

    About this Publication Model range This publication contains parts lists and service information, This handbook relates to all HV04 - HV07 compressors, model please read it carefully before you attempt to service or carry out types: adjustments on the compressor.

  • Page 8: Ownership Records

    Introduction 1 Ownership Records Model Number: ..........Serial Number: ..........R.P.M: ....................Maximum Bar: ..........Local CompAir UK Ltd Distributor Name: ..........Contact: ..........Address: ..........Telephone: ....................Fax: ....................Email: ..........ST 16049-00A...

  • Page 9: Service Kits

    1 Introduction Service Kits Only use genuine CompAir UK Ltd parts and approved oils. Oils must not be mixed. Service kits contents Item Part Number Quantity Description Chapter Location KO457 Kit Oil Change 75155 Air filter element 75279 Oil Filter 9824 ‘O’...
  • Page 10 Introduction 1 75334-01 Stator shim U 4K 75334-02 Stator shim U 4K 34775 Stator shim pack 75327-01 Stator shim L5 75327-02 Stator shim L5 75328-01 Stator shim U5 75328-02 Stator shim U5 75329-01 Stator shim L5 75329-02 Stator shim L5 75330-01 Stator shim U5 75330-02...

  • Page 11: Key To Symbols Used

    1 Introduction Key to symbols used Torque Setting Nm. Spanner Require (mm) A/F 22mm Grease Required Allen Key Required (mm) Silco Silco (Specification) Loctite Required and Lubricate With Sump Oil Specification Number Recommended Oils Recommended Grease Fluid Force 2000 Silkolene Fluid Force HPO Motor Grease Fluid Force Clear...
  • Page 12 Introduction 1 This page is intentionally left blank ST 16049-00A...

  • Page 13: Adjustments And Testing

    2 Adjustments and Testing 2 Adjustments and Testing Minimum Pressure Valve (Fig. 1) Note: 10 bar machine details are in brackets. Start compressor. Open outlet valve fully to atmosphere with silencer fitted. Check the lowest pressure gauge reading obtainable. This should be 5.5 - 6.6 bar.

  • Page 14: Oil Temperature

    Pressure indicated on the compressor gauge should not fall below 6.5 bar (9.5 bar). Nozzle orifice Model C.F.M. Dia 'A Test nozzle diameter must be reamed to a tolerance of No Sizes HV04 ± 0.025 mm. No Sizes HV04 Leakage Check 3.52-01 HV05 2.69-02 HV05 23.6...
  • Page 15 2 Adjustments and Testing Press PRG key to return to the LED monitor. Continuous running option Press the Function/Data Select key until the required LED If the flow demands of the system result in continual and rapid display appears, e.g. motor speed. stopping and starting of the motor the compressor speed control Re-lock keypad (see below).
  • Page 16 Adjustments and Testing 2 This page is intentionally left blank ST 16049-00A...

  • Page 17: Fault Finding

    Servicing of the compressor must only be carried-out by authorised persons fully trained and competent in the maintenance of CompAir UK Ltd compressors. They must fully understand and adopt correct and safe working practices. Text in Light Green (Greyed out) is not applicable to these machine models.

  • Page 18: High Temperature

    Fault Finding 3 Low or No Air Delivery Remove intake end cover to inspect Blades seized Free blades/slots condition of rotor and blades Internal air leaks Shim breakdown Dismantle compressor to examine rotor/ Check temperature, flow in compressor stator unit and power Replace stator shims High Temperature...

  • Page 19: Unusual Noise Or Vibration During Running

    3 Fault Finding Oil Mist From Air Intake When Stopping and/or Rapid Venting Unloader valve Remove air filter and observe where mist Replace unloader valve body worn exits when machine is stopping body Vacuum valve Remove air filter and observe where mist Replace vacuum valve seal/ seal leaking exits when machine is stopping...

  • Page 20: Motor Overload Or High Power Consumption

    Fault Finding 3 Motor Overload or High Power Consumption Cause Cause Diagnosis Cause Action (Level 1) (Level 2) (Level 3) High pressure Fit pressure gauge in test point and check Check/adjust servo setting internal pressure Compressor Fit thermometer in oil filler pocket and See C overheating check maximum temperature...

  • Page 21: Parts List

    4 Parts List 4 Parts List This section contains a list of parts and servicing information. The illustrations used are from a HV07 machine (V07ACS07-4035S000), but will generally apply to all variations of the type. Where types and quantities differ, these are indicated. ST 16049-00A...

  • Page 22: Panels

    M4 Locknut 75235 Logo ‘hydrovane’ MN1704 M4 Locknut 75136 Foam Front Cover 75133 Front Cover 75238 Model Number Badge ‘hv04’ 75237 Model Number Badge ‘hv05’ 75236 Model Number Badge ‘hv07’ 75266 Model Number Badge ‘hv07rs’ 34404 Pressure Gauge assembly 34404 Clamp &...
  • Page 23 4 Parts List Fig. 3 - Panels ST 16049-00A...

  • Page 24: Air Intake End

    Parts List 4 Air Intake End Quantity Item Part Number Description 74603 Intake Cover 75099 ‘O’ Ring MS 706-12 Cap screw M6 x 12 M6 Washer - Heavy Gauge MCE4-8 Circlip External 3/16 Washer 0071 MPV Seat 71760 MPV Non Return Valve 57842 MPV Piston 57588...
  • Page 25 4 Parts List 435a401 Fig. 4 - Air Intake End ST 16049-00A...

  • Page 26: Air End

    Parts List 4 Air End Quantity Item Part Number Description 9831 ‘O’ Ring 74601 Non-drive-end Cover 9708 ‘O’ Ring 75205 Barrel Coupling 9613 ‘O’ Ring 52866 Filter 75246 Quadralip seal 74611 Unloader Valve Piston 74886 Unloader Spring Support MRP2.5-22 Roll Pin 75021 Unloader Return Spring 75034...
  • Page 27 4 Parts List 435a402 Fig. 5 - Air End ST 16049-00A...

  • Page 28: Air End (Cont'd)

    Parts List 4 Air End (Cont’d) Quantity Item Part Number Description 57596 Vacuum Valve Seat 9706 ‘O’ Ring 58607 Avdel Seal 5mm 74617 Vacuum Valve Housing 9704 ‘O’ Ring 9705 ‘O’ Ring 74616 Vacuum Valve Piston 57596 Vacuum Valve Seal RO2000-79 Spring 73215...
  • Page 29 4 Parts List 435a402 Fig. 6 - Air End (Cont’d) ST 16049-00A...

  • Page 30: Rotor Stator Unit (Rsu)

    MS706-10 M6 x 10 Skt Head 74604 Main Housing Consult you Compair distributor Retain the blades ( ) in position in the rotor ( ) using rubber bands. 4.12 Dismantling the Rotor Stator Unit (RSU) Remove rotor blades ( ).
  • Page 31 4 Parts List 435a403 Fig. 7 - Rotor Stator Unit (RSU) ST 16049-00A...

  • Page 32: Rotor Stator Unit (Cont'd)

    Parts List 4 4.13 Rotor Stator Unit (cont’d) Quantity Item Part Number Description 74607 Impingement Cowl 56302 Shim 57027 Tension Pin 56302 Valve Plate AGS203B 4BA Lock Washer FS702-3 4BA x 3/8 Skt Head Screw 75223 Pipe Stator Discharge 74921 Blade 4kW 7 bar &...
  • Page 33 4 Parts List 435a403 Fig. 8 - Rotor Stator Unit (cont’d) ST 16049-00A...

  • Page 34: Drive End

    Parts List 4 4.14 Drive End Quantity Item Part Number Description MS112-40 M12 X 40 Hex Head Screw MW12 M12 Washer Zinc Coated 74925-10 Motor 4kW 74924-10 Motor 5.5kW 74624-10 Motor 7.5kW (and RS) 75359-65 Motor 4kW 60Hz 75357-65 Motor 5.5kW 60Hz 75119-65 Motor 7.5Kw 60Hz 7 bar 75355-65...
  • Page 35 4 Parts List 435a404 Fig. 9 - Drive End ST 16049-00A...

  • Page 36: Cooler Matrix And Fan Assembly

    Parts List 4 4.15 Cooler Matrix and Fan Assembly Quantity Item Part Number Description 74685 Fan Unit 50Hz 75120 Fan Unit 60Hz 74688 Pipe: Cooler-filter 74687 Pipe: Filter-cooler 71432 Cooler (Shell) 74693 Pipe: Air Outlet 6520 Cable Tie 200mm MS108-16 Screw hex 75227 Fan Bracket...
  • Page 37 4 Parts List 435a406 Fig. 10 - Cooler Matrix and Fan Assembly ST 16049-00A...

  • Page 38: Oil Filter And Manifold

    Parts List 4 4.16 Oil Filter and Manifold Quantity Item Part Number Description 56633 Outlet Tap 52866 Oil filter MS2106-12 M6 x 12 Poz Pan Head Screw 75042 Pipe: Filter-compressor 74686 Pipe: Compressor-filter 75215 Stud Coupling 15mm 74669 Oil Filter Manifold 74891 Oil filter insert 75022...
  • Page 39 4 Parts List 435a407 Fig. 11 - Oil Filter and Manifold ST 16049-00A...

  • Page 40: Inverter And Oil Level Manifold

    Parts List 4 4.17 Inverter and Oil Level Manifold Quantity Item Part Number Description 75275 VSD bracket (RS) 75278 VSD cover 75269 Inverter 7.5Kw, 400V (RS) MS706-16 Screw (RS) Washer (RS) MS706-16 Screw (RS only) Washer (RS only) 9617 Bonded Seal 5/8 9754 ‘O’...
  • Page 41 4 Parts List 435a410 Fig. 12 - Inverter and Oil Level Manifold ST 16049-00A...

  • Page 42: Chassis

    Parts List 4 4.18 Chassis Quantity Item Part Number Description 75041 Anti-vibration mount 75128 End plug 74694 Base 75127 Plinth MW10 Washer 10mm MS110-20 M10 x 20 hex screw 75132 Cooler bracket MS108-16 M8 x 16 hex head screw Washer 8mm Starter (for clarity only, refer to Fig.5.3 and Fig.19) MS2106-12 M6 x 12 Poz pan hd screw...
  • Page 43 4 Parts List 435a412 Fig. 13 - Chassis ST 16049-00A...

  • Page 44: Control Group Dol And Star Delta

    Parts List 4 4.19 Control Group DOL and Star Delta Quantity Item Part Number Description Cut in/out Line Pressure Switch Pressurised re-start prevention switch Vent-down solenoid Rapid vent-down solenoid Oil Level Sight Glass Assembly 73215 ¼ ” x 6mm Push-in elbow 10-12 14-16 7,8,17...
  • Page 45 4 Parts List Fig. 14 - Pipes and Connectors DOL Fig. 15 - Pipes and Connectors Star/Delta ST 16049-00A...

  • Page 46: Parts Modifications

    Parts List 4 4.20 Parts Modifications Parts Modifications Serial No. Prefix Compressor(s) New Part(s) Old Part(s) Service Bulletin ST 16049-00A...

  • Page 47: Starter Units

    5 Starter Units 5 Starter Units This section contains Starter Units parts and servicing information. ST 16049-00A...

  • Page 48: Typical Starter Unit

    Starter Units 5 Typical Starter Unit The following table shows the application and part numbers of starter units contained in this section. 34682 7.5kW 400V 50Hz Star Delta V04ACS07-4035D000 V04ACS10-4035D000 V05ACS07-4035D000 V05ACS10-4035D000 V07ACS07-4035D000 V07ACS10-4035D000 34687 5.5kW 400V 50Hz DOL V04ACS07-4035S000 V04ACS10-4035S000 V05ACS07-4035S000 V05ACS10-4035S000...
  • Page 49 5 Starter Units 435a408 Fig. 16 - Typical Starter Unit ST 16049-00A...

  • Page 50: Starter (34687) 5Kw 400V 50 Hz Dol

    Starter Units 5 Starter (34687) 5kW 400V 50 Hz DOL Quantity Item Part Number Description 53287 Pressure switch 73841 Solenoid Valve (NO) 73215 R1/8” - 6mm 90° Elbow 73213 G1/4” - 6mm Legris coupling 16mm Cable gland Pressure switch cable Solenoid cap 56122 Run on timer...
  • Page 51 5 Starter Units Fig. 17 - Starter (34687) 5kW 400V 50 Hz DOL ST 16049-00A...

  • Page 52: Starter (34682) 7.5Kw 400V 50 Hz Star/Delta

    Starter Units 5 Starter (34682) 7.5kW 400V 50 Hz Star/Delta Quantity Item Part Number Description 53287 Pressure switch 73841 Solenoid Valve (NC) Solenoid Valve (NO) 73215 R1/8” - 6mm 90° Elbow 73213 G1/4” - 6mm Legris coupling 16mm Cable gland Pressure switch cable Solenoid cap Run on timer...
  • Page 53 5 Starter Units Fig. 18 - Starter (34682) 7.5kW 400V 50 Hz Star/Delta ST 16049-00A...

  • Page 54: Starter (34756) 7.5 Kw 50/60Hz Variable Speed

    Starter Units 5 Starter (34756) 7.5 kW 50/60Hz Variable Speed Quantity Item Part Number Description Solenoid Valve (NO) 73215 R1/8” - 6mm 90° Elbow 16mm Cable gland Solenoid cap 59344 OTC board DIN rail x 245 mm long 74249 Emergency stop push button MS704-30 M4 x 30 mm long socket head cap screw H604S24V...
  • Page 55 5 Starter Units Fig. 19 - Starter (34756) 7.5 kW 50/60Hz Variable Speed ST 16049-00A...

  • Page 56: Starter (34724) 7.5Kw 230/460V 60Hz

    Starter Units 5 Starter (34724) 7.5kW 230/460V 60Hz Quantity Item Part Number Description 53287 Pressure switch 73841 Solenoid Valve (NO) 73215 R1/8” - 6mm 90° Elbow 73213 G1/4” - 6mm Legris coupling 16mm Cable gland Pressure switch cable Solenoid cap DIN rail x 245 mm long 74249 Emergency stop push button...
  • Page 57 5 Starter Units Fig. 20 - Starter (34724) 7.5kW 230/460V 60Hz ST 16049-00A...

  • Page 58: Starter (34787) 4Kw 230V 60Hz

    Starter Units 5 Starter (34787) 4kW 230V 60Hz Quantity Item Part Number Description 53287 Pressure switch 73841 Solenoid Valve (NO) 73215 R1/8” - 6mm 90° Elbow 73213 G1/4” - 6mm Legris coupling 16mm Cable gland Pressure switch cable Solenoid cap DIN rail x 245 mm long 74249 Emergency stop push button...
  • Page 59 5 Starter Units Fig. 21 - Starter (34787) 4kW 230V 60Hz ST 16049-00A...

  • Page 60: Starter Units Part Modifications

    Starter Units 5 Starter Units Part Modifications Starter Units Part Modifications Serial No. Prefix Compressor(s) New Part(s) Old Part(s) Service Bulletin ST 16049-00A...
  • Page 61 This page is intentionally left blank...
  • Page 62 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.
  • Page 64 CompAir UK Ltd. High Wycombe Hughenden Avenue High Wycombe Buckinghamshire HP13 5SF United Kingdom Tel. ++ 44 (01) 1494 605-0 CompAir UK Ltd. Redditch Claybrook Drive Washford Industrial Estate Redditch Worcestershire United Kingdom B98 0DS Tel. ++ 44 (0) 1527 525522 www.compair.com...

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