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DV Systems HDI Installation Maintenance And Service Manual Download Page 6

HDI-03-W 

Mar ‘15 

 

- 6 -

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.) 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Compressor Pump 

Compresses the air. 

Intercooler 

Allows the compressed air to 
cool while it transfers between 
the low and high pressure 
Cylinder. 

Beltguard 

Protects personnel from the 
moving parts of the Flywheel, 
Pulley, and Belts. 

Aftercooler Tube 

Allows the compressed air 
to cool as it transfers from 
the Pump to the Tank. 

Electric Motor 

Pressure Switch 

A Switch which starts and 
stops the Unit at a 
predetermined minimum 
and maximum pressure. 
 

Pressure Gauge 

Reflects Tank pressure. 
 

Safety Valve 

Protects the Tank if 
pressure is too high. 

Check Valve 

Allows the compressed air 
to enter the Tank, but 
prevents it from flowing 
back out. 

Air Receiver (Tank) 

Stores the compressed air. 

Magnetic Starter 

An electrical device which 
receives a signal from the 
Pressure Switch and 
allows power to flow to the 
Motor. 

Drain Valve 

Allows the Customer to 
drain moisture from the 
Tank. 

Ball Valve 

Discharge/outlet from 
Tank. 

 

Pump Components 

Please refer to the Compressor Pump Service Bulletin provided 
with your Unit to identify the part numbers, location, and 
quantities for your particular Pump model. 

Summary of Contents for HDI

Page 1: ...lease 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 Heavy Duty Industrial HDI Air Compressor Installat...

Page 2: ...e should be between 10 C and 40 C 50 F and 104 F Ensure that 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 Pump Rotation Refer to Page 10 Proper Oil Level Note The Unit is shipped with PR20 20 Weight Compressor Oil in the Pump Verify the proper level as indicated above bef...

Page 3: ...mpting any repair or maintenance work As the Unit starts and stops automatically do not come into contact with moving parts Shut off all power to the Unit before attempting any repair or maintenance work Air compressed by the Unit is not suitable for inhaling It may contain vapours harmful to your health Never directly inhale compressed air produced by the Compressor The Compressor Pump Motor and ...

Page 4: ...eplace Oil synthetic 3 Check lubrication of Motor Inspect Valve Assemblies in Cylinder Head s Inspect Check Valve Inspect Pressure Gauge Replace Belts 4 Replace Valve Discs and Springs 5 Replace CPR Unloader Kit 6 Replace Pressure Switch Replace Safety Valves on Pump and Tank Replace Pressure Gauge Notes 1 Air Filters are available separately or in a Maintenance Kit Consult your Pump bulletin 2 Mi...

Page 5: ...the damage be noticed only after the 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 unpac...

Page 6: ...o the Tank Electric Motor Pressure Switch A Switch which starts and stops the Unit at a predetermined minimum and maximum pressure Pressure Gauge Reflects Tank pressure Safety Valve Protects the Tank if pressure is too high Check Valve Allows the compressed air to enter the Tank but prevents it from flowing back out Air Receiver Tank Stores the compressed air Magnetic Starter An electrical device ...

Page 7: ...upport the weight of the Unit As well the sound level of the Unit may increase due to the harmonics created by the structure use Vibration Pads to lessen this If anchoring the Unit ensure that there is approx 0 75 cm between the Nut and the Compressor Foot as shown below Do not bolt down tightly Ensure that the floor under the Unit is smooth level and capable of bearing the weight of the Compresso...

Page 8: ...l Use of improper oil may negatively affect Compressor performance or shorten Unit life Resulting problems are not covered by the DV Systems Warranty With limited Compressor use or installing in a very humid environment condensation water may form in the Crankcase with the oil If this occurs change the oil more often than indicated on the Maintenance Schedule O Ring Proper Oil Level to bottom thre...

Page 9: ...ic Starter can be purchased separate from the Unit or factory mounted at the time of Unit manufacture Failure to correctly connect the Compressor to your building s electrical services may result in serious personal injury or damage to the equipment Before servicing the Unit ensure the power source has been shut down and locked off Read and understand the information contained in this manual befor...

Page 10: ...ur DV Systems Distributor or Service Centre for the location of the nearest authorized Motor Service Centre Why Hire a Licensed Electrician To ensure that your new DV Systems Unit works as designed and required you must ensure that it is correctly wired to your building service It is the responsibility of your Licensed Electrician to ensure that The Unit you purchased is suitable for your particul...

Page 11: ...nit unloaded for 30 minutes close the Ball Valve and allow the Unit to reach maximum operating pressure 7 Ensure that the Compressor shuts off at the factory preset maximum pressure and the head pressure is released through the Unloader at either the front of the Pump the CPR or at the Pressure Switch 8 Measure the amp draw as the Unit reaches maximum pressure 9 Once off check the Compressor and p...

Page 12: ...ing pressure of 200 psi 13 8 Bar Minimum working pressure of 30 psi 2 1 Bar Will not operate in temperatures below freezing Maintenance Service maintenance can only be done when the drain is not under pressure The internal screens must be cleaned periodically The RK AD 9400 Repair Kit is available Drain Port Reservoir Signal from Unloader Moisture from Tank Specifications Maximum working pressure ...

Page 13: ...emperature of the compressed air after it exits the Compressor Pump and before it enters the Tank The compressed air is cooled as it passes through the radiator style Aftercooler The air flow created by the Pump Flywheel provides the cooling action Specifications Die cast aluminum case Internal brass float registers oil level Lens allows viewing of oil level Suitable for use with voltages up to 23...

Page 14: ...alternating to take place The Lead Pressure Switch or PS1 regulates the starting of the Units and is therefore set at the maximum pressure setting In smaller Compressors this is generally the Switch with the Unloader The Lag Pressure Switch or PS2 is set at 5 to 10 psi less than the Lead Switch and will bring the second Unit on only if the pressure in the Tank goes below that of the cut in pressur...

Page 15: ... to make the Unit marginally quieter C Automatic Drain Drains the Compressor Tank on a regular basis Available as either pneumatic or electronic operated D Flex Hose Protects the building air lines from vibration caused by the Compressor and allows for any misalignment between the Compressor outlet and building piping E Separator Filter Acts as a pre filter to the Refrigerated Air Dryer Generally ...

Page 16: ...sor and b the length of piping Incorrectly sizing the piping will adversely affect the pressure or volume of air at the point of use Unit HP Length of Piping 0 100 100 200 200 1 1 2 3 1 5 1 7 1 1 10 1 1 1 15 1 1 1 25 1 1 1 30 1 1 1 Piping Material As with the correct sizing of the compressed air piping the material used must also be considered Though cost might be a concern correct air flow qualit...

Page 17: ...uded in the Dryer manual The information contained in this manual is a quick reference only Dryer Controls On Off Button LED s for Compressor Drain and Fan Test Programming Buttons ASD Dryer Unit Has a maximum inlet temperature of 120 F Must have approx 20 feet of piping between the Compressor outlet and Dryer inlet 3 Digit Readout HTD Dryer Unit Has a maximum inlet temperature of 180 F Should hav...

Page 18: ...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 Typical Fault Codes The readout will indicate a variety of fault codes the most common being as follows A t H Energy Saving Mode The Dew Point has been running at below 1 C for over 6 minutes The Unit will automatically ...

Page 19: ...ace a dirty Filter Element Shut the Compressor Unit off Bleed any compressed air from the system to ensure there is no pressure at the Filter Unscrew the Bowl from the assembly exposing the dirty Filter Element Twist the Filter Element until it comes loose Replace with a new Filter Element Clean any debris from the inside of the Bowl and re install Cat eye Gauge will return to green when Filter is...

Page 20: ...in the electrical circuit Starter Overload is tripped If an Oil Monitor is mounted on the Unit the oil level in the Pump could be too low Check that power at the disconnect or breaker is on Also check any fuses Drop pressure below the Pressure Switch cut in pressure Check that all wiring connections are tight With a wiring schematic check that all wiring is present and correct Reset the overload i...

Page 21: ...rn Main Bearings can usually be detected by noticeable end play on the Flywheel Replace the Main Bearings Worn Connecting Rod Bearing Inserts can be detected by removing a Valve and watching the Piston while moving the Flywheel by hand If the Flywheel can be moved at mid stroke without the Piston moving the Bearing Inserts or Connecting Rod may need to be replaced D Oil Passing Downstream of Unit ...

Page 22: ...nder Head Aftercooler Tube or Check Valve Maximum operating time based on an 8 hour day is 75 to 80 which related to 45 minutes per hour Clean Pump Move Compressor so Beltguard is a minimum of 18 away from nearest obstruction See Page 2 Correct rotation of the Flywheel See Page 10 Fix leaks Soap water mixture will assist in finding small leaks Clean or replace piping Replace Air Filter Refer to Lu...

Page 23: ... leak Use care when filling with oil Wipe any spills immediately Drain oil until proper level is reached Check Filler Plug Change O Ring Ensure Pipe Nipple and Cap are sealed Initially retorque fasteners to factory specs If leaks persist replace Gasket Use Loctite Form a Gasket on Head Bolts and Crankcase to Cylinder Bolts Inspect Crankshaft for any scratches or burrs Use emery cloth Replace Oil S...

Page 24: ...Genuine DV Systems parts and kits this including but not limited to Oil and Filters are property of the original owner The warranty is not transferrable DV Systems 5 Year Limited Motor Warranty 3 Phase Motors Only With the above noted Warranty DV Systems has also implemented a 5 Year Limited Motor Warranty for 3 Phase Motors This Warranty applies only to those Motors that are provided on and sold ...

Page 25: ... determine in its sole and reasonable discretion if a Product or part of a Product has been subject to Ordinary Wear and Tear This Warranty does not apply to Ordinary Wear and Tear In addition without limiting the foregoing this Warranty does not apply to all shipping and handling charges compressor pumps using other than the recommended compressor pump lubricant costs of removal replacement or re...

Page 26: ...ice Contract Contrat d entretien Yes Oui No Non Email As indicated above please forward this completed form to Tel que mentionné veuillez nous faire parvenir le formulaire complété a Email sales dvcompressors com Fax 705 728 4974 As well this form can be completed on line at www dvcompressors com Vous pouvez aussi trouver et remplir se formulaire sur notre site web www dvcompressors com Please com...

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