DV Systems HDI Installation Maintenance And Service Manual

Heavy duty industrial air compressor

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Heavy Duty

Industrial

('HDI')

Air Compressor

Installation,

Maintenance,

And

Service Data

DV Systems Inc. - Canada

490 Welham Road

Barrie, ON

L4N 8Z4

Tele:

(705) 728-5657

Fax:

(705) 728-4974

Contents:

Quick Start

Safety Precautions

Preventative Maintenance Schedule

Unpacking and Inspection

Compressor Terminology

Installation – Mechanical

Lubrication

Installation – Electrical

Start-up Procedures

Compressor Unit Accessories

Compressed Air System Design

Refrigerated Air Dryers

Compressed Air Filter Assemblies

Trouble-Shooting Guide

DV Systems Limited Warranty

Warranty Registration

Web:

www.dvcompressors.com

Email: sales@dvcompressors.com

- 1 -

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.

DV Systems Ltd. - US

128-B Talbert Road

Mooresville, NC

28117

Tele:

Fax:

HDI-03-W

Mar '15

Page:

9-10

12-14

15-16

17-18

20-23

24-25

(704) 799-0046

(704) 799-0355

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Summary of Contents for DV Systems HDI

Page 1 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. DV Systems Inc. - Canada DV Systems Ltd. - US 490 Welham Road 128-B Talbert Road Barrie, ON...
Page 2: Quick Start
HDI-03-W Mar ‘15 Quick Start Mechanical Installation. (Refer to Page 7) The Unit should be located in a dry, clean, cool, dust free, and well ventilated area. Allow a minimum 18” behind the BeltGuard and around the Unit. The ambient temperature should be between 10°...
Page 3: Safety Precautions
HDI-03-W Mar ‘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 4: Preventative Maintenance Schedule
Noted below are general maintenance guidelines which must be followed and documented, this in accordance with the DV Systems Warranty. It is based on an approximate Compressor usage of 30 hours per week. If your particular application varies from this, please adjust accordingly.
Page 5: 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 6: Compressor Terminology
HDI-03-W Mar ‘15 Compressor Terminology Please refer to the picture below, as it identifies the major components of a typical Piston Air Compressor Unit and their function. (Some Units may vary slightly from this design, eg. gas powered or base mounted Units.)
Page 7: Installation - Mechanical
Compressor. The Compressor must sit squarely on the floor. DV Systems has available Installation Kits which include (4) Vibration Isolator Pads and (1) The Compressor must not be operated in a Stainless Steel Flex Hose.
Page 8: Initial Start-Up
Serious damage may result from use, however limited, without oil. Use only DV Systems Premium Compressor Oil. Also, do not mix the DV Systems oil with any other lubricant. Oil Changes. Drain the existing oil from the Unit. Running the Unit prior to draining the oil will ensure that the oil will drain relatively quickly.
Page 9: Installation - Electrical
Compressor to your building's electrical Ensure that a suitable Fused Disconnect or Breaker (by services may result in serious personal others than DV Systems) is installed in the electrical injury or damage to the equipment. supply before the Compressor Unit.
Page 10: Pump Rotation
Installation – Electrical (cont’d) Why Hire a Licensed Electrician? Motors. To ensure that your new DV Systems Unit works as Ensure that the voltage on your site is reflected on the designed and required, you must ensure that it is Motor nameplate, +/- 10%.
Page 11: Start-Up Procedures
Pump Bolts. Refer to the appropriate Pump Bulletin for torque values. During the first few days of operation, check the Unit periodically to ensure it is running smoothly. Should you have any concerns, contact your DV Systems Distributor. - 11 -...
Page 12 HDI-03-W Mar ‘15 Compressor Unit Accessories ‘AD-9400’ Pneumatic Autodrain. The ‘AD-9400’ Pneumatic Autodrain is designed to drain moisture from the Compressor Tank each time the Unit reaches maximum pressures and shuts off. It receives its signal as the Unit unloads once the Unit has shut down.
Page 13 Maximum working pressure of 175 psi (12.08 Bar). Reduces the temperature of the compressed air by approx. 100° F. Use only the DV Systems ‘OJ2000-K1’ Synthetic Oil in the Compressor Pump. Maintenance. The Beltguard Aftercooler must be cleaned with compressed air on a regular basis.
Page 14 HDI-03-W Mar ‘15 Compressor Unit Accessories (cont’d) Alternator Relays on Duplex Compressor Units. An Alternator Relay is used with a Duplex Compressor Unit, namely a Unit with two Pumps and two Motors on one large Tank. Coupled with two Magnetic Starters, the Alternator Relay allows the Pumps to alternate back and forth.
Page 15 HDI-03-W Mar ‘15 Compressed Air System Design In designing a compressed air system, there are several factors that must be considered. Though cost may be a factor in most designs, it cannot be the final determining factor, especially where air quality, air volume, and air pressure are critical.
Page 16 These have become relatively easy to install, cost ¾” ¾” 1” affective, and will last for many years. ¾” ¾” 1” Contact your DV Systems Distributor, as DV Systems 7-½ ¾” 1” 1-¼” offers Transair piping systems. 1” 1-¼” 1-½”...
Page 17 Refrigerated Air Dryers As discussed earlier, a Refrigerated Air Dryer may be part of your compressed air system. Shown below are two Refrigerated Air Dryer models that are available through DV Systems, namely the ‘ASD’ and ‘HTD’ Dryers. ‘ASD’ Dryer Unit ‘HTD’...
Page 18 HDI-03-W Mar ‘15 Refrigerated Air Dryers (cont’d) 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 19: Filter Element Replacement
HDI-03-W Mar ‘15 Compressed Air Filter Assemblies Typical Filter Assembly. As indicated previously, suitable filtration may be critical applications where a) a Refrigerated Air Dryer is used, and b) where good quality air is required downstream. Shown below is a typical Filter Canister with the ‘Cat-eye’...
Page 20: 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.
Page 21 Ensure the Unit is mounted level. Use Vibration Pads. Improper level or grade of oil in Pump. Use correct DV Systems oil, and check that level is correct. Carbon or other foreign material on Piston Clean top of Piston. Check Cylinder walls for head.
Page 22 HDI-03-W Mar ‘15 Trouble Shooting Guide (cont’d) Condition: Cause: Suggested Correction: E. Appearance of Water in Tank is not being drained regularly. Drain the Tank on a daily basis. Purchase a the Air Lines and/or Oil Tank Autodrain if required.
Page 23 HDI-03-W Mar ‘15 Trouble Shooting Guide (cont’d) Condition: Cause: Suggested Correction: I. Crack in Air Receiver. This condition is rare, and can be caused by damage during transit or incorrect mounting Do not attempt to repair the Tank. Do not on site.
Page 24 The ‘7 Year Limited Warranty’ applies only to those Pump Assemblies that: are provided on and sold as a complete DV Systems ‘HDI’ Heavy Duty Cast Iron Compressor Unit. Pumps sold as ‘separate sale items’ or being installed on Units having the ‘IS’ or ‘SDI’ designation are governed by their own Warranty applicable to that product.
Page 25 In order to make a claim under this Warranty, the customer must first call DV Systems Warranty Department at the number shown on this warranty.
Page 26 Veuillez compléter ce formulaire et le retourne a Systems Inc. via email, fax, or mail. Failure to DV Systems Inc. par courrier électronique, fax ou la return this Registration will result in a One Year poste. A l’absence de nous fournir ce formulaire, la Unit/Pump/Motor Warranty only.

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