DV Systems K100-C Installation Manual

Rotary screw air compressor unit

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K100

Rotary Screw

Air Compressor

Unit

- - -

Installation

And

Start-up Data

If you require assistance, please contact your local DV Systems Distributor or Authorized Service

center. You may contact the manufacturer directly as follows:

Phone:

(705) 728-5657 (Canada)

(704) 799-0046 (USA)

Fax:

(705) 728-4974 (Canada)

(704) 799-0355 (USA)

Quick Start ............................................................

Safety Precautions ..........................................

Shipping Cleats .............................................

Unpacking and Inspection .................................

Installation – Mechanical ..................................

Lubrication ....................................................

Installation – Electrical .....................................

Start-up Procedures ........................................

Preventative Maintenance Schedule ...................

Compressor Storage .......................................

Common Compressor Faults ................................ 19

Variable Speed Drive .......................................

Air Filtration & Refrigerated Air Dryer ...................

Trouble-Shooting Guide ....................................

Warranty ........................................................

Please read this manual before

installing or using your Air

Compressor Unit. It contains

valuable information that will

help in the receiving,

installation, use, and

maintenance of the Unit.

Please keep this manual in a

safe place for future reference.

All of the information, policies, and

procedures in this reference manual apply

exclusively to DV Systems.

Web:

www.dvcompressors.com

Email:

sales@dvcompressors.com (Canada)

orders@dvcompressors.com (USA)

- 1 -

K100-C

Dec'15

Table of Contents

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Summary of Contents for DV Systems K100-C

Page 1 All of the information, policies, and procedures in this reference manual apply exclusively to DV Systems. If you require assistance, please contact your local DV Systems Distributor or Authorized Service center. You may contact the manufacturer directly as follows: Phone:...
Page 2: Quick Start
K100-C Dec’15 Quick Start Mechanical Installation. (Refer to Page 8) The Unit should be located in a dry, clean, cool, dust free, and well ventilated area. Allow a minimum of: • 48” (1220mm) in front of and behind the Unit. The Access Doors swing in a 36”...
Page 3 K100-C Dec’15 Quick Start (cont’d) Shipping Cleats. (1of 3) Cleats at (Refer to Page 6) Oil Receiver The ‘K Series’ Screw Units are shipped Locate the Orange with (3) Shipping Cleats under the Feet Cleats located under of the Oil Receiver, (1) under Air End each Foot of the Oil Bracket, and (1) under the Motor.
Page 4: Unit Operation
K100-C Dec’15 Quick Start (cont’d) Unit Operation. Shown below is the ‘CSC300’ Controller which regulates the operation of the Unit. It is used to start and stop the Unit, and it provides information as to system pressure, temperature, etc. Starting the Unit: Press the ‘Start’...
Page 5: Safety Precautions
K100-C Dec’15 Safety Precautions In order to operate the Compressor Unit safely and correctly, we have opted to use the following symbols to make you aware of important points. These points relate to user safety and preventing equipment problems. Please pay close attention to these sections.
Page 6 Dec’15 Shipping Cleats Your DV Systems ‘K Series’ Rotary Screw Compressor is shipped with several Shipping Cleats that must be removed prior to the initial start-up. The Shipping Cleats are installed during assembly of the Unit simply to stop any lateral movement of the Air End, Motor, etc during shipping.
Page 7: Unpacking And Inspection
Shipments of DV Systems products are the property of the Consignee when the products leave our facility. DV Systems Inc. is not responsible for any damages or shortages caused to the product after it has left our shipping dock.
Page 8: Installation - Mechanical
K100-C Dec’15 Installation – Mechanical The Importance of a Proper Installation As with all Air Compressors, a proper installation is key to both a) long Compressor life and b) quality compressed air. A Compressor Unit not installed correctly, and coupled with a poor maintenance program, can be plagued with costly issues not covered by the manufacturer’s warranty.
Page 9: Location Of The Unit
K100-C Dec’15 Installation – Mechanical (cont’d) Moving of the Unit. When moving the Air Compressor, the forklift or hand lift forks go under the Unit from the directions as indicated. Please be advised that care must be taken when moving and positioning the Unit as it may be top heavy.
Page 10 K100-C Dec’15 Installation – Mechanical (cont’d) Shown below are items which assist in making a good installation. These are both intake and exhaust ductwork, helping the Unit to a) draw in clean outside air and b) exhaust the warmer air away from the Unit. The warmer air may be used, with the inclusion of a damper in the exhaust ducting, to warm the interior of the building during the colder months of the year.
Page 11: Initial Start-Up
Oil level on a monthly basis. limited, without oil. Use only DV Systems ‘DEV-3000’ Synthetic Oil. Also, do not mix the ‘DEV-3000’ with any other lubricant. Subsequent Oil Changes. Drain the existing oil from the Unit. (Please be advised...
Page 12: Installation - Electrical
Ensure that a suitable Fused Disconnect or Breaker Unit is electrically connected in a safe and correct (by others than DV Systems) is installed in the manner. Any electrical work should be carried out electrical supply before the Compressor Unit.
Page 13 In the event of a Motor failure, contact premature Motor failure, and is not your DV Systems Distributor or Service Centre for the covered by the DV Systems or Motor location of the nearest authorized Motor Service Centre.
Page 14 K100-C Dec’15 Installation – Electrical (cont’d) Cooling Fan Rotation. To ensure that the Unit operates at optimum Power Wires to temperatures, a Cooling Fan is located on the top of Starter the Unit to draw warm air from the Cabinet Enclosure.
Page 15: Start-Up Procedures
K100-C Dec’15 Start-up Procedures Do not attempt to operate the Unit without first checking whether there is oil in the Oil Reservoir. Add oil as required. Serious damage may result from use, however limited, without oil. 4) Place the Fused Disconnect / Breaker in the ‘On’...
Page 16: Preventative Maintenance Schedule
Noted on the following pages are general Maintenance guidelines based on average working conditions. Should the Unit be worked under extreme conditions, please contact your DV Systems Distributor for further input. As well, all maintenance/service work must be carried out by a qualified Technician.
Page 17 ‘#’ must be changed twice as often (example: in 4000 hours instead of 8000), and not as noted above. b) The DV Systems Oil used in the Rotary Screw Units is rated as an 8000 hour Oil. A complete Oil change must be done every 8000 hours of Unit operation, or every 12 months, whichever occurs first.
Page 18 Remove any desiccant that was previously placed inside the Unit Cabinet. Complete the ‘Start-up Procedures’ as noted on Page 15 of this manual. If you have any questions concerning any of the above items or require assistance, please contact your local DV Systems Distributor or Service Center. - 18 -...
Page 19 K100-C Dec’15 Common Compressor Faults Common Faults. Noted below are the most common Faults experienced. ‘CSC300’ Alarms. There is an issue with the Unit, but it will still operate. Code: Description: Most Common Items to Check: A:0083 Motor phase imbalance...
Page 20: Variable Speed Drive
Variable Speed Drive Your DV Systems ‘K Series’ Rotary Screw Compressor Unit may be equipped with a Vacon ‘Variable Speed Drive’, or ‘VSD’. A Compressor with an integral VSD can handle the constant loads for an extended period of time (running at close to 100% duty cycle), but it can also run at slower speeds to accommodate lower air demands at other times of the day.
Page 21 K100-C Dec’15 Variable Speed Drive (cont’d) Operating Screen Typical Drive Status Indicators on Screen - 21 -...
Page 22 K100-C Dec’15 Variable Speed Drive (cont’d) Common VSD Fault Codes Noted below are the most common fault codes that may appear on the VSD. For a more thorough list, please check the manual which deals exclusively with the Vacon Variable Speed Drive and which accompanied the Unit.
Page 23 K100-C Dec’15 Air Filtration and Refrigerated Air Dryer Your Unit may have been shipped with a variety of Filters and a Refrigerated Air Dryer, these to assist in providing good quality air to your point of use. Shown below (and previously on Page 8) is a typical installation showing the Compressor, Air Receiver, Refrigerated Air Dryer, and Filters.
Page 24 K100-C Dec’15 Air Filtration and Refrigerated Air Dryer (cont’d) Motors. Typical Dryer Operation. The Dryer will operate as follows: Pressing the ‘On/Off’ Button for 3 seconds will start the Unit • There is a time delay of up to 2 minutes before the Refrigerant Compressor starts.
Page 25: Filter Element Replacement
K100-C Dec’15 Air Filtration and Refrigerated Air Dryer (cont’d) Typical Separator Filter. As previously noted, the Separator Filter should be located between the Compressor and the Refrigerated Dryer. It contains a 10 micron Separator Element which protects the Dryer Unit by removing liquids and solid particles 10 microns and larger.
Page 26: Troubleshooting Guide
Compressor Unit unless you are familiar with it, as there are many issues that may come into play, the most important being personal safety and the welfare of the Unit. Should you have any questions, or require servicing to your Unit, please contact your local DV Systems Distributor/Service Center.
Page 27 K100-C Dec’15 Trouble Shooting Guide (cont’d) Condition: Cause: Suggested Correction: B. No or Insufficient Air Flow. 1. Air Filter is dirty. 1. Replace the Air Filter. 2. Oil Separator is blocked. 2. Replace the Oil Separator. 3. Intake Valve is faulty.
Page 28 K100-C Dec’15 Trouble Shooting Guide (cont’d) Condition: Cause: Suggested Correction: E. Intake Valve Leaks Oil Intake Valve Seal leaks. Repair using an Intake Valve Repair Kit. When Unit Stops. Intake Valve stuck in open position or 3 Way Repair or replace the Intake Valve or 3 Way Solenoid not working properly.
Page 29 Oil changes must be done more frequently. B) Oil Filter must be changed every 4000 hours (not to exceed 6 months) from the date of initial start-up using the appropriate DV Systems part. When operating in adverse conditions, Oil Filter changes must be done more frequently.