DV Systems D20 Installation And Start-Up Manual Download

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D20, D20VSD, D20TD, D20TDVSD-C

Feb ‘14

- 1 -

Quick Start …………….............................................

Safety Precautions ……………………………………

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

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

Lubrication …………………………………………….

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

Start-up Procedures ………………………………….

Preventative Maintenance Schedule ……………….

Common Compressor Faults  ………………..…………  16
Variable Speed Drive   ………………………….…….      17
Separator Filter & Refrigerated Air Dryer   ………….

Trouble-Shooting Guide ………………………………

Warranty ………………………………………………..

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

Web:

www.dvsystems.ca

Fax:

(705) 728-4974

Email:

[email protected]

D20, D20VSD,

D20TD, D20TDVSD

Rotary Screw

Air Compressor

Units

- - -

Installation

And

Start-up Data

Contents:

Page:

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.

Summary of Contents for D20

Page 1: ...ributor or Authorized Service center You may contact the manufacturer directly as follows Phone 705 728 5657 Web www dvsystems ca Fax 705 728 4974 Email sales dvsystems ca D20 D20VSD D20TD D20TDVSD Rotary Screw Air Compressor Units Installation And Start up Data Contents Page Please read this manual before installing or using your Air Compressor Unit It contains valuable information that will help...

Page 2: ...the floor under the Unit is smooth level and capable of bearing the weight of the Compressor If installed in a compressor room ensure that the room is adequately ventilated Note Dimensions indicated are typical for all variations of D20 Series Units The D20 Series Screw Units are shipped with 3 Shipping Cleats painted in orange that must be removed prior to operating the Unit 2 Cleats are located ...

Page 3: ...nti Rotation Switch Operating the Unit in the reverse direction will cause irreparable damage The Inverter to the Motor is pre wired at the factory Remove the Front Door and pay close attention to the arrow located on the Motor indicating correct rotation Turn Unit on and immediately turn off using the Emergency Stop Button If the rotation is not correct simply change two of the motor leads to the...

Page 4: ...ury 2 Do not stop the Unit by use of a disconnect or breaker Using the Emergency Stop Button disconnect or breaker to stop the Unit will not allow the Unit to go through an unloading sequence and could result in damage to the Motor Starter or other electrical components Damage caused in this manner is not covered by the manufacturers Warranty Enter Up Down Escape Used in the programming and changi...

Page 5: ...d stops Shut off all power to the Unit before automatically do not come into attempting to repair or maintain contact with moving parts the Compressor Air compressed by the Unit is not Never breath untreated compressed suitable for inhaling It may contain air produced by the Compressor vapours harmful to your health Compressor Air End Motor and Never touch the Air End Motor or Tubing become hot wh...

Page 6: ...he product has been received contact the transport company immediately to file a claim Depending on the problem it may be wise to photograph the damage Also it may be wise to discuss with the carrier representative the time allotted to give notice of loss or damage to the product there may be guidelines which limit timeframes of same 4 Do not attempt further unpacking or operation of the product A...

Page 7: ...d and 3 feet above the Unit for easy access to the various sides this being for both the proper ventilation of the Unit and ease of servicing Ensure that the floor under the Unit is smooth level and capable of bearing the weight of the Compressor The Compressor must sit squarely on the floor If installed in a compressor room ensure that the room is adequately ventilated One Horsepower produces app...

Page 8: ...lation 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 Intake and Exhaust Ducting ...

Page 9: ...overfill See drawing below Use only DV Systems DEV 3000 Synthetic Oil available in both 1 US gallon 3 8 litre jugs or 5 US gallon 5 x 3 8 litre pails Any remaining oil may be used for top ups The MK D20 Maintenance Kit includes 2 DEV 3000 K1 2 x 1 Gal of Synthetic Oil 2 DSC 002196 Air Intake Filter 2 DSC 002197 Oil Filter 1 DSC 001148 Air Oil Separator Filter Do not attempt to operate the Unit wit...

Page 10: ...tems is installed in the electrical supply before the Compressor Unit The sales drawing found at the back of this booklet indicates the amp rating for the Unit This information is required in sizing a Disconnect Fuses and or a suitable Breaker As well an electrical schematic is enclosed for reference Electrical wiring and conduit from the building supply through the Compressor Cabinet and to the S...

Page 11: ...n the correct manner Irreparable damage will be done if the Unit rotates in the opposite direction This unit equips with Advanced Phase Detection which prevents unit from rotating in the reversed direction If the following error is visible on the Screen and the Unit will not start simply switch power leads L1 and L3 Press the Reset key on the Controller to reset the error message E 0090 Phase Sequ...

Page 12: ...ings Noted below is a chart outlining the interval at which the Motor should be lubricated this based on the Motor horsepower This must be part of a regular maintenance schedule Motor HP Interval Weight of Grease Volume of Grease in Hours Ounces Grams Cubic Inch Teaspoon 20 2 000 0 81 23 1 1 5 5 2 The above chart is based on a standard environment in which the Motor is operating of 40 C For other ...

Page 13: ...Unit will run up to approx 110 psi at which point the Motor will continue to run but not compress air 6 Once the Unit reaches 110 psi it will idle for 2 minutes and shut off 7 Open the Ball Valve slightly and allow the air to bleed from the Tank Once the pressure reaches approx 100 psi the Unit will start and begin to compress air after a short delay 8 Measure the amp draw as the Unit reaches maxi...

Page 14: ...ernal damage to components as well to combat this the oil must be changed more often than noted below When servicing the Air Compressor shut off all power to the Unit and drain it of air pressure It is the responsibility of the Compressor owner to ensure that a regular Maintenance Schedule is followed Note For Compressor Units used in an environment where the ambient temperature is above 90 F 32 C...

Page 15: ...ommendations on Page 12 Notes a For Compressor Units used in an environment where the ambient temperature is above 90 F 32 C or b where the Unit temperature runs regularly above 80 C 175 F the components marked with a 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 complet...

Page 16: ...ssed Code Description Most Common Items to Check E 0010 Emergency Emergency stop switch is pressed E 0070 Fan Motor Alarm Check electrical connections E 0082 Motor Overload Motor drawing high amps low voltage high pressure settings low oil level E 0083 Motor phase Imbalance Check motor connections in the control panel and motor connection box E 0090 Phase Sequence Rotation of Motor wrong sequence ...

Page 17: ...using the variable speed technology match the varying air demands and therefore have the ability to impact your energy consumption some energy providers have offered rebates when these Units are purchased Consult your local energy provider to determine if this applies Shown below is a D20 DENE Unit with a Variable Speed Drive VSD Interface The VSD Controller Interface is shown at right It provides...

Page 18: ...D20 D20VSD D20TD D20TDVSD C Feb 14 18 Variable Speed Drive cont d Operating Screen Typical Drive Status Indicators on Screen ...

Page 19: ...lt re occur contact the Distributor faulty operation component failure 25 Microprocessor watchdog faulty operation Reset the fault and restart the Unit fault component failure Contact Distributor 31 IGBT temperature IGBT Inverter Bridge overtemp protection has detected too Check loading hardware high a short term overload current Check motor size Make identification run 32 Fan cooling Cooling Fan ...

Page 20: ...ter the air is compressed but before it enters the Air Receiver This allows for what is termed a dry Tank More detailed information concerning the Dryer Unit is included in the Dryer manual The information contained in this manual is a quick reference only To Air Receiver Dryer Controls On Off Button From Air End LED s for Compressor Drain and Fan Test Programming Buttons Separator Filter Unit Mod...

Page 21: ...n the Unit is operating will run the Fan at full speed for several seconds after which the Unit will stop The LED will be on continually while the Fan runs at full speed As well as showing the dew point the readout may indicate several fault codes as suggested below The readout will indicate a variety of fault codes the most common being as follows Motors Typical Dryer Operation Typical Fault Code...

Page 22: ...lter Unscrew the Bowl from the assembly exposing the dirty Filter Element Twist the Filter Element until it comes loose Replace with a new 10 micron Separator Filter Element Clean any debris from the inside of the Bowl and re install Cat eye Gauge will return to green when Filter is once again under pressure Typical Separator Filter Arrow Indicates Direction of Air Flow Cat eye Gauge Green Filter ...

Page 23: ... start No power to the Unit Loose and or missing wires in the electrical circuit Emergency Stop Button pressed in Motor Overload is tripped Compressor over heated and stopped Compressor stopped by over pressure Unit has timed out shut off because pressure has not gone below cut in pressure of 100 psi Power interruption Check that power at the disconnect or breaker is on Also check any primary and ...

Page 24: ...il Thermo Valve is faulty Oil Filter is blocked Temperature Sensor is faulty Thermostat is faulty Pressure is too high Cabinet door panel is open off Check cooling air circulation Check the air circulation in and around the Unit Clean the Heat Exchanger Add oil as required Change to the factory recommended oil Check and repair as necessary Replace the Oil Filter Check the wiring to the Temperature...

Page 25: ...acity G Compressor Surges Restriction in Heat Exchanger or Hoses Pressure Transducer setting is incorrect or malfunctioning Blockage at Unit outlet Dryer is freezing up not allowing air to pass through Air Receiver is too small Flush out or replace Set pressure as per instructions or replace Check for obstructions in outlet piping Check that the Dryer parameters are correct Increase dew point to 2...

Page 26: ...ch defect occurred in normal service and is not the result of misapplication misuse abuse neglect incorrect maintenance accident or normal wear Normal maintenance items requiring routine replacement are not warranted Please refer to the appropriate service bulletin to determine normal maintenance requirements The warranty covers parts and labour for the warranty period excluding the Three Phase Ba...

Page 27: ...XHAUST AIR OUTLET 7 20 5 WEIGHT LBS SERVICE DOORS 3540 REMOVABLE 120 PSI 145 PSI 20 MOTOR 100 110 AMPS 82 D20 73 D20VSD F MAX C 105 subject to change without notice its product designs as a result specifications may be DV SYSTEMS INC is committed to continually improving F MIN AND 40 C 50 3 AMBIENT CONDITIONS 10 TO A SOLID LEVEL FLOOR USING ISOLATOR PADS 2 COMPRESSOR MUST BE LEVEL AND ANCHORED DOW...

Page 28: ...TOR RPM AIR END RPM NOMINAL SOUND 1 METRE dBA MOTOR VOLTAGE AIR RECEIVER GAL DRYER FILTER ELEMENT MICRON DISCONNECT FUSE TABLE VOLTAGE PHASE VARIABLE SPEED FIXED SPEED FUSE TYPE FUSE AMP FUSE TYPE FUSE AMP 200 3 J FAST ACTING DFJ 80 TIME DELAY 90 230 75 460 50 40 575 35 30 examination without the prior approval of DV SYSTEMS INC ALL DIMENSIONS ARE IN INCHES 1 1 OF 1 FRACTIONAL DIMENSIONS UNLESS OT...

Page 29: ... x 1 5 HHCS 4 23 SS 1515 M10 HC LOCKWASHER 8 24 DSC 200 BONDED WASHER 1 2 BSPP 1 25 DSC 262 BUSHING BSPP 1 4 FEM X 1 2 MALE 1 26 TIA 5200 SAFETY VALVE 200PSI 1 27 SS 45 1 2 13 X 1 125 HHCS 8 28 DSC 002189 ELBOW SWIVEL 3 4 BSPPM JIC12 1 29 DSC 175 PNEUMATIC FITTING STRAIGHT 1 8 X 6MM 1 30 DSC 163 STREET ELBOW 3 8 NPT 1 31 DD 00091 3 8 NPT X 1 2 DIA SWIVEL PNEU STRAIGHT 1 32 SS 9931 ELECTRICAL BUSHI...

Page 30: ...2002 5 16 18 THREADED INSERT 4 17 DSC 297 5 16 18 X 4 TAP BOLT 6 18 DSC 001294 ELBOW JIC 16 M 1 NPT M 1 19 DSC 002151 ADAPTER 1 NPT M JIC 12 1 02 08 12 NEW PRODUCT REV DATE REVISION DESCRIPTION 1 OF 1 FAN AND COOLER ASSEMBLY UNLESS OTHERWISE SPECIFIED parties for examination without the prior approval of DV SYSTEMS INC DECIMAL DIMENSION PCN NO D20 FAN ASSEMBLY ALL DIMENSIONS ARE IN INCHES ANGLES N...

Page 31: ...ISE SPECIFIED parties for examination without the prior approval of DV SYSTEMS INC DECIMAL DIMENSION PCN NO HOSES ALL DIMENSIONS ARE IN INCHES ANGLES N T S IMPORTANT NOTE This print is the confidential property of DV SYSTEMS INC 02 09 12 It is not to be used or reproduced in any manner nor submitted to other T VOICU FRACTIONAL DIMENSIONS DESCRIPTION OF DRAWING DRAWING NO SHT NO REV NAME OF PROJECT...

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