ELECTRIC AIR COMPRESSOR

Model HY3200S

User Manual

Page 2 Original

CONTENTS

SECTION

1 – SAFETY

2 – MACHINE SPECIFIC SAFETY

3 – PART LOCATIONS - SPECIFICATIONS

4 – STORING, UNPACKING, SITING & OPERATION

5 – MAINTENANCE

6 – TROUBLESHOOTING

7 – PRODUCT DISPOSAL

8 – DECLARATIONS of CONFORMITY

9 – CONTACT DETAILS

10 – MANUAL UPDATES

Page

N

o

3 – 4

4 – 8

8

9 – 11

12 – 13

14 – 16

16

17

17

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1. SAFETY

1.1. General safety notes.

1.1.1. The operator of the machine is responsible for, and has a duty of care in making sure that the machine is operated safely and in accordance with the instructions in this user manual. Keep the manual safe and pass it on if the machine is loaned/sold to another user.

1.1.2. Please note the following safety points.

1.1.2.1. The machine should never be left it in a condition which would allow an untrained or unauthorised person/s to operate this machine.

1.1.2.2. All due care and diligence should be taken by the operator for the safety of and with regard to those around whilst using the machine.

1.1.2.3. Some or all of the following - warning signs, symbols and/or PPE pictograms may appear throughout this manual. You MUST adhere to their warning/s. Failure to do so may result in personal injury to yourself or those around you.

The FOLLOWING safety notes will help avoid or reduce risk of injury or death.

Indicates a hazard, which, if not avoided, could result in serious injury or death.

Indicates a hazard, which, if not avoided, could result in serious injury.

Indicates a hazard which, if not avoided, might result in minor or moderate injury.

Indicates a situation that could easily result in equipment damage.

READ & Keep the manual safe and pass it on if the machine is loaned/sold to another user.

You MUST fully read instructions to make sure you use and operate machine safely

Appropriate Personal Protective Equipment (PPE)

MUST be worn at all times when machine is in use or being repaired.

ALWAYS keep the working area clear of non-essential people to include but not limited to children, the elderly and vulnerable persons.

NEVER ALLOW an untrained person to use this machine.

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1.2. Vibrations (where applicable).

1.2.1. Prolonged use of hand held (operated) machines will cause the user to feel the effects of/from vibrations. These vibrations can lead to white finger

(Raynaud's phenomenon) or carpal tunnel syndrome. This condition reduces the ability of the hand to feel and regulate temperature, causing numbness and heat sensations and may cause nerve damage and circulatory tissue death.

1.2.2. Not all factors that lead to white finger disease are known, but cold weather, smoking and other diseases that affect blood vessels and blood circulation as well as large and long-lasting impact of shocks are considered factors called in the formation of white finger. Note the following to reduce the risk the white finger and carpal tunnel syndrome to reduce:

1.2.3. Wear gloves and keep your hands warm

1.2.4. Take regular breaks

1.2.5. All of the above precautions may help reduce the risk of white finger disease but not rule out carpal tunnel syndrome. Long-term and regular users are therefore recommended to observe the condition of your hands and fingers.

Seek medical attention immediately if any of the above symptoms should occur.

1.3. Noise.

1.3.1. The operating noise of the machine can damage your hearing. Wear hearing protection such as earplugs or ear defenders to protect your hearing. Long- term and regular users are advised to have hearing checked regularly. Be especially vigilant and cautious when wearing hearing protection because your ability to hear alarm warnings will be reduced.

1.3.2. Noise emissions for this equipment is unavoidable. Carry out noisy work at approved times and for certain periods. Limit the working time to a minimum.

For your personal protection and protection of people working nearby it is also advisable for them to wear hearing protection.

1.3.3. See CERTIFICATE of CONFORMITY section for Outdoor Noise declaration of conformity.

2. MACHINE SPECIFIC SAFETY

2.1. Safety labels

RISK OF ELECTRIC SHOCK

Caution: before doing any work on the compressor it must be disconnected from the power supply.

RISK OF HIGH

TEMPERATURES

Caution: the compressor contains some parts which might reach high temperatures.

RISK OF ACCIDENTAL START-

UP

Attention, the compressor could start automatically in case of a power failure and and power being restored.

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2.2. Safety.

2.2.1. Never touch moving parts.

2.2.1.1. Never place your hands, fingers or other body parts near the compressor’s moving parts.

2.2.2. Never operate without all guards in place.

2.2.2.1. Never operate this compressor without all guards or safety features in place and in proper working order. If maintenance or servicing requires the removal of a guard or safety features, be sure to replace the guards or safety feature before resuming operation of the compressor.

2.2.3. Always wear eye protection.

2.2.3.1. Always wear safety goggles or equivalent eye protection. Compressed air must never be aimed at anyone or any part of the body.

2.2.4. Protect yourself against electric shock.

2.2.4.1. Prevent body contact with grounded surfaces such as pipes, radiators, ranges and refrigeration enclosures. Never operate the compressor in damp or wet locations.

2.2.5. Disconnect the compressor.

2.2.5.1. Always disconnect the compressor from the power source and remove the compressed air from the air tank before servicing, inspecting, maintaining, cleaning, replacing or checking any parts.

2.2.6. Avoid unintentional starting.

2.2.6.1. DO NOT carry the compressor while it is connected to its power source or when the air tank is filled with compressed air. Be sure the knob of the pressure switch in the “off” position before connecting the compressor to its power source.

2.2.7. Store compressor properly.

2.2.7.1. When not in use, the compressor should be stored in dry place. Keep out of reach of children. Lock-out the storage area. 2.2.8. Keep work the area clean.

2.2.8.1. Cluttered areas invite injuries. Clear all work areas of unnecessary tools, debris, furniture et

2.2.8.2. Keep children away.

2.2.8.3. DO NOT let visitors contact compressor extension cable. All visitors should be kept safely away from work area.

2.2.9. Dress properly.

2.2.9.1. DO NOT wear loose clothing or jewelry. They can be caught in moving parts. Wear protective hair covering to contain long hair.

2.2.10. Don’t abuse power cable.

2.2.10.1. Never yank it to disconnect from receptacle. Keep power cable from heat, oil and sharp edges.

2.2.11. Maintain compressor with care.

2.2.11.1. Follow instructions for lubricating. Inspect cable periodically and if damaged, have repaired by authorized service facility.

2.2.11.2. Inspect extension cables periodically and replace if damaged.

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2.2.12. Outdoor use extension cables.

2.2.12.1. When compressor in used outdoors, use only extension cables intended for use outdoors and so marked.

2.2.13. Stay alert.

2.2.13.1. Watch what you are doing. Use common sense. DO NOT operate compressor when you are tired.

2.2.13.2. Compressor should never be used by you if you are under the influence of alcohol, drugs or medication that makes you drowsy.

2.2.14. Check damaged parts and air leak.

2.2.14.1. Before further use of the compressor, a guard or other part is damaged should be carefully checked to determine that it will operate properly and perform its intended function.

2.2.14.2. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, air leak, and any other conditions that may affect its operation.

2.2.14.3. If guards or other parts are damaged they should be properly repaired or replaced by an authorized service centre unless otherwise indicated elsewhere in this instruction manual. Have defective pressure switches replaced by authorized service centre.

2.2.14.4. DO NOT use compressor if switch does not turn it on and off.

2.2.15. Handle compressor correctly.

2.2.15.1. Operate the compressor according to the instructions provided herein. Never allow the compressor to be operated by children, individuals unfamiliar with its operation or unauthorized personnel.

2.2.16. Keep all screws, bolts and covers tightly in place.

2.2.16.1. Keep all screws, bolts, and plates tightly mounted. Check their conditions periodically.

2.2.17. Keep motor air vent clean.

2.2.17.1. The motor air vent must be kept clean so that air can freely flow at all times. Check for dust build-up frequently.

2.2.18. Operate compressor at the rated voltage.

2.2.18.1. Operate the compressor at voltages specified on their nameplates. If using the compressor at a higher voltage than the rated voltage, it will result in abnormally fast motor revolution and may damage the unit and burn out the motor.

2.2.19. Never use a compressor which is defective or operating abnormally.

2.2.19.1. If the compressor appears to be operating unusually, making strange noises, or otherwise appears defective, stop using it immediately and arrange for repair the repair to be carried out by an authorised service centre.

2.2.20. DO NOT wipe plastic parts with solvent.

2.2.20.1. Solvents such as petrol, thinner, benzene, carbon tetrachloride, and alcohol may damage and crack plastic parts. DO NOT wipe them with such solvents. Wipe plastic parts with a soft cloth lightly dampened with soapy water and dry thoroughly.

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2.2.21. Use only genuine replacement parts.

2.2.21.1. Replacement parts that are not original may void your warranty and can lead to malfunction and resulting injuries. Genuine parts are available from your dealer.

2.2.22. DO NOT modify the compressor.

2.2.22.1. DO NOT modify the compressor. Always contact the authorized service centre for any repairs. Unauthorized modification may not only impair the compressor performance but may also result in accident or injury to repair personnel who DO NOT have the required knowledge and technical expertise to perform the repair operations correctly.

2.2.23. Turn off the pressure switch when the compressor is not used.

2.2.23.1. When the compressor is not used, turn the knob of the pressure switch off, disconnect it from the power source and open the drain cock to discharge the compressed air from the air tank.

2.2.24. NEVER touch hot surface.

2.2.24.1. To reduce the risk of burns, DO NOT touch tubes, heads, cylinder and motors.

2.2.25. DO NOT direct the air stream toward any part to anyones face or body parts.

2.2.25.1. Risk of injury, DO NOT direct air stream at persons or animals.

2.2.26. Drain tank.

2.2.26.1. Drain tank daily or after 4 hours of use.

2.2.26.2. Open drain fitting and tilt compressor to empty accumulated water.

2.2.27. DO NOT stop compressor by pulling out the plug.

2.2.27.1. Use the “auto/off” knob of pressure switch.

2.2.27.2. Use only recommended air handling parts acceptable for pressure not less than 125 psi (8.6 bar)

2.2.27.3. Risk of bursting. Use only recommended air handling parts acceptable for pressures not less than 125 psi (8.6 bar).

2.2.28. Replacement parts.

2.2.28.1. When servicing use only genuine Hyundai replacement parts, all repairs should be conducted only by authorized service centre.

2.2.29. Earthing/Grounding instructions.

2.2.29.1. This compressor should be earthed/grounded while in use to protect the operator from electric shock. The compressor is equipped with a three core cable and three-prong grounding type plug to fit the proper grounding type receptacle.

2.2.29.2. The green (or green and yellow) conductor in the cable is the earthing/grounding wire. NEVER connect the green (or green and yellow) wire to a live terminal.

2.2.30. Extension cable.

2.2.30.1. Use only three core cables that have three-prong grounding type plugs and three-pole receptacles that accept the compressor’s plug.

Replace or repair damaged cable. Make sure your extension cable is in good condition. When using an extension cable, be sure to use one heavy

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enough to carry the current your product will draw. An undersized cable will cause a drop in line voltage resulting in loss of power and overheating.

To avoid electric shock hazard. NEVER use this compressor with a damaged or frayed electrical cable or extension cable. Inspect all electrical cables regularly. NEVER use in or near water, or in any other environment where an electric shock is possible.

3. PART LOCATIONS – SPECIFICATION

3.1. Part locations.

1 – Compressor unit

4 – Power - Pressure switch

7 – Feet

10 – Oil level sight glass

3.2. Specifications.

Voltage/Amps– V/A

Frequency – Hz

Motor – hp

Motor Speed – rpm

Drive type

Net weight – Kg

Assembled size

– L x W x H mm

Temperature range -

°C

2 – Belt guard

5 – Pressure gauge

8 – Condensate drain valve

11 – Oil cap – dipstick

3 – Electric motor

6 - Direct compressed air outlet

9 – Pressure relief valve

12 – Air filter

230/13

50

3

1000

Belt

110

Model HY3200S

1460 x 460 x 1140

Tank material

Tank capacity – l/g

L/min/cfm

Output pressure regulation

Maximum pressure - psi/Bar

Cut-out pressure –

Psi/Bar

Cut-in pressure – psi/Bar

0°

~

+25°

Rolled steel

200/52.8

400/14

None

145/10

145/10

116/8

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4. STORING, UNPACKING, SITING & OPERATION

4.1. Storing the packed and unpacked compressor.

4.1.1. If the compressor is not used and left unpacked it will need to be stored in a dry place at a temperature between +5°C and + 45°C and sheltered from the weather.

If the compressor has been unpacked and waiting to be used, you must protect it from dust by covering it with a suitable cover.

If the compressor is not going to be used for long periods, the oil should be replaced and its operational efficiency should be checked.

4.2. Unpacking & siting.

4.2.1. Remove the compressor from its packaging and make sure that is has not been damaged during transport.

4.2.2. Take care to transport the compressor correctly, DO NOT overturn it or lift it with hooks or ropes.

4.2.3. Remove and replace the plastic blanking plug and replace it with the oil level dipstick (2).

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4.2.4. Check oil level referring to the MAX & MIN marks on the dipstick, or the oil level inspection window (2).

4.2.5. Position the compressor on a flat surface or with a maximum permissible inclination of 10° and in a dry and well aired place. DO NOT store in a location which has an explosion hazard.

4.2.6. If the surface is inclined and smooth, make sure that the compressor does not move whilst in operation, if it does move we advise that DO NOT secure it to the ground rigidly, instead use 4 anti-vibration supports (not supplied).

4.2.7. If the compressor is to be mounted on brackets or a shelf top, you MUST make sure it cannot fall by securing it in a suitable way.

4.2.8. To make sure that the compressor has adequate ventilation and efficient cooling, the compressor’s belt guard must be at least 100 cm (1 metre) from any wall.

4.3. Operation.

4.3.1. Starting.

4.3.1.1. Check that the mains power matches that indicated on the electrical data-plate. The permissible tolerance range is +/- 5 % of the stated value.

4.3.1.2. Turn pressure switch knob to position “0”. Fit the plug into a suitable power socket which is protected by a 30mA RCD and start the compressor by turning the pressure switch knob into position “I”.

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4.3.1.3. The compressor is fully automatic and is controlled by the pressure switch which stops it when tank pressure reaches maximum value and restarts it when it falls to minimum value. The pressure difference between maximum and minimum values is usually about 2 bar (29 psi).

4.3.1.4. The compressor stops when it reaches 10 bar (145 psi – maximum operating pressure) and restarts automatically when the pressure inside the tank drops to 8 bar (116 psi).

4.3.1.5. After connecting the compressor to an air-line, allow the compressor to reach maximum pressure and check how the machine is operating.

4.3.1.6. This compressor is supplied with a thermal-breaker, located on the side of the terminal box onto of the motor. When the breaker is tripped, wait for a few minutes and then press to reset the breaker.

4.3.2. Adjusting the operating pressure.

4.3.2.1. This is a fixed pressure machine – therefore there is no facility to adjust the output pressure on this machine.

4.3.3. Hints for efficient operation.

4.3.3.1. For efficient operation of the machine at full continuing load and at maximum operating pressure, make sure the temperature of the work environment indoors does not exceed +25°C.

4.3.3.2. We advise that you to use the compressor at 70% maximum duty per hour at full load as this allows for efficient long term operation of the product.

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5. MAINTENANCE

DO NOT carry out any maintenance unless you are suitable qualified to do so.

If in any doubt please contact your dealer for advice and guidance.

5.1. Before attempting any maintenance jobs on the compressor, make sure of the following:

5.1.1. That the unit is unplug from the electrical supply.

5.1.2. The master power switch in position “0”.

5.1.3. There is NO pressure in the air tank.

5.2. After every 50 hours of duty;

5.2.1. We advise you to dismantle the air filter (1) and clean the filtering element by blowing it through with compressed air.

5.2.2. It is recommended that you replace the filter element as required and more often if the compressor operates in a dusty environment.

5.3. The compressor generates condensate water which accumulates in the tank.

5.3.1. The condensate in the tank must be drained at least once a week, by opening the drain tap (1) under the tank.

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5.3.2. You MUST take care if there is compressed air inside the cylinder since the condensate water could flow out with considerable force. Recommended pressure: 1 – 2 bar max.

5.3.3. Condensate from compressors that are oil lubricated must not be drained into the sewer or dispersed in the environment as it contains oil.

5.4. Oil change and topping up with oil.

5.4.1. The compressor is filled with synthetic oil.

5.4.2. We recommend a full change of oil in the pumping element within the first

100 hours of duty.

5.4.3. Unscrew the oil drain plug (1) on the housing cover, allow all the oil to flow out, and re-screw the plug.

5.4.4. Pour oil into until it reaches the level indicated on the dipstick or through indicator glass (2).

5.4.5. Once a week check the oil level of the pump and top up as required.

5.4.6. Use SAE 15W40 mineral oil and change after every 100 hours.

5.4.7. DO NOT drain used oil into the sewer or dispose of it in the environment.

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6. TROUBLESHOOTING

DO NOT carry out any troubleshooting unless you are suitable qualified to do so.

If in any doubt please contact your dealer for advice and guidance.

6.1. Important notes.

6.1.1. DO NOT on any account unscrew any connection while the tank is pressurised – always check if the tank is pressure free.

6.1.2. DO NOT drill holes, weld or purposely deform the compressed air tank.

6.1.3. DO NOT do any maintenance on the compressor unless you have disconnected the power plug.

6.1.4. Temperature operating ambient range is 0°C +25°C.

6.1.5. DO NOT aim jets of water or inflammable liquids on the compressor.

6.1.6. DO NOT place inflammable objects near the compressor.

6.1.7. During down-times, turn the pressure switch to position “0” (OFF).

6.1.8. Never aim the air jet at people or animals.

6.1.9. DO NOT transport the compressor while the tank is pressurised.

6.1.10. Be careful with regard to some parts of the compressor such as the head and delivery tubes, as they can reach high temperatures. DO NOT touch these parts to avoid burns.

6.1.11. You MUST only transport/move the compressor, by lifting or pulling it with the appropriate grips or handles (where applicable) or with the use of a fork lift truck or other suitable means.

Due to the weight of this machine You MUST exercise caution when moving and siting this machine.

6.1.12. Keep children and animals well away from the machine operating area.

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6.1.13. If using the compressor for painting:

6.1.13.1. DO NOT work in closed environments or near to naked flames.

6.1.13.2. Make sure there is adequate exchange of air at the place of work.

6.1.13.3. Protect your nose and mouth with an appropriate mask.

6.1.14. If the electrical cable or plug are damaged, DO NOT use the compressor and contact an authorised service centre to replace the faulty element with an original spare part.

6.1.15. If the compressor is located on a shelf or on a top above floor height, it must be secured to prevent it falling while in operation.

6.1.16. DO NOT put objects or your hands inside the protective grilles to avoid injury to yourself or damaging the compressor.

6.1.17. DO NOT use the compressor as a blunt object toward things or animals, to avoid serious damage.

6.1.18. When you have finished using the compressor, always remove the plug from the power socket.

6.2. Loss of air in valve under pressure switch.

6.2.1. This is caused by poor air seal of the check valve – take the following actions:

6.2.1.1. Isolate compressor from the electrical supply.

6.2.1.2. Discharge all pressure from the tank

6.2.1.3. The valve is located at the opposite end from the power switch. Unscrew the hexagon-head of the valve (A).

6.2.1.4. Carefully clean both the rubber disk (B) and its seat.

6.2.1.5. Refit all parts accurately.

6.3. Air losses.

6.3.1. These can be caused by poor tightness of a union – check all unions, wetting them with soapy water. Air leaks will cause the soapy liquid to bubble.

6.3.2. Tighten any loose unions.

6.4. Compressor does not start.

6.4.1. If the compressor has trouble starting, check the following :

6.4.1.1. Does mains power match that of the data-plate? – Make sure supply is correct.

6.4.1.2. Are power cable extensions of adequate diameter or length? – Check and change as required.

6.4.1.3. Is the work environment too cold? (under 0°C) – Raise the ambient temperature to within 0°C +25°C.

6.4.1.4. Has the thermal-breaker tripped? – Reset trip.

6.4.1.5. Is there enough oil to ensure lubrication? – Check and top up as required.

6.4.1.6. Is there a known good power supply? – Check that no trips have operated and that all fuses are in good condition.

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6.5. Compressor does not stop.

6.5.1. If the compressor does not stop when maximum pressure is reached, the tank safety valve comes will operate. Turn off machine contact your nearest service centre and have the valve repaired.

7. PRODUCT DISPOSAL

7.1. When it becomes necessary to dispose of your machine please contact your local authority for the disposal advice, or take unit to your local recycling centre.

7.2. You MUST make sure that all unused oil, fuel and batteries are disposed of correctly either beforehand or at amenity centre.

7.3. Waste Electrical Electronic Equipment (WEEE). Certain products contain waste which should not be disposed of in your domestic waste. You MUST recycle WEEE in accordance with your local authority or recycling centre.

7.4. The following symbol means that you should NOT place items with this symbol on the product into your domestic waste.

7.5. Unwanted packaging materials should be sorted and taken to a recycling centre to be disposed of in a manner which is compatible with the environment.

7.6. The following symbol means that you should ‘Reduce – Reuse – Recycle’.

7.7. Should you pass this product onto another user either sold or loaned you MUST pass on this user manual. This will make sure that all other users can use and maintain the machine safely.

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8. DECLARATIONS of CONFORMITY

8.1. Air Compressors

8.1.1. Electric

8.1.1.1. 87/404/EEC –

8.1.1.2. 2002/95/EC –

8.1.1.3. 2004/108/EC –

8.1.1.4. 2006/42/EC –

8.1.1.5. 2006/95/EC –

9. CONTACT DETAILS

9.1. POSTAL ADDRESS

Simple Pressure Vessel Directive

Restriction of Hazardous Substances Directive

Electromagnetic Compatibility Directive

Machinery Directive

Low Voltage Directive

Genpower Ltd, Isaac Way,

London Road, Pembroke Dock,

Pembrokeshire, SA72 4RW. UK.

9.2. TELEPHONE

9.3. FAX

9.4. TECHNICAL E-MAIL

+44 (0) 1646 687880

+44 (0) 1646 686198

9.5. WEBSITE

10. MANUAL UPDATES [email protected] www.hyundaipowerequipment.co.uk

10.1. Our manuals are constantly being reviewed and updated. However if should you find an error, omission or something you find unclear please contact your dealer for assistance.

10.2.

10.3.

Our latest manuals are also placed online.

We reserve the right to make any modifications without prior notice whenever necessary.

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GENPOWER LTD

Isaac Way, London Road

Pembroke Dock, UNITED KINGDOM, SA72 4RW

T: +44 (0) 1646 687 880 F: +44 (0) 1646 686 198

E: [email protected]

www.hyundaipowerequipment.co.uk