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DV Systems HDI Installation Maintenance And Service Manual Download Page 8

HDI-03-W 

Mar ‘15 

 

- 8 -

Lubrication 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Oil Filler Plug 

Initial Start-up. 

Each Compressor Unit built is extensively tested at the 
factory before shipment. The Unit is shipped with the 
original oil in it as used for testing purposes. 
 
Check the oil level and for any oil leaks on a daily 
basis. This must be done when the Unit is off. Top up 
the Oil level on a monthly basis. 
 
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. 
 
Fill the Oil Reservoir to the bottom thread at the Oil 
Filler Plug. Do not under or overfill. See drawing below. 
 

 

Do not attempt to operate the Unit without 
first checking whether there is oil in the 
Pump Crankcase. Add oil as required. 
Serious damage may result from use, 
however limited, without oil. 

 

 

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 thread of Oil Fill Port) 

Section Through Crankcase 

At Oil Fill Port 

The following oils are available from your DV 
Systems Distributor. 

 

DV Systems 
Premium 

Mineral

 Oils 

Room (Ambient) 
Temperature 

20 Weight:  ‘PR-20-4’ 

Up to 90°F (32°C)  

30 Weight:  ‘PR-31-4’ 

Above 90°F (32°C) 

 

DV Systems Premium 

Synthetic 

Oil 

is 

used in high heat or high duty applications or 
when Beltguard Aftercoolers are used. 

20 Weight:  ‘OJ-2000’ 

 

The following Maintenance Kits are available from 
your DV Systems Distributor. The Kits include both 
the Oil and Filters. 

 

Kits c/w 20 Weight 

Mineral

 Oil 

DV Systems Pumps 

Kit Part Number 

123, 223 

MK-223  

247 

MK-247 

447 

MK-447 

 
Kits c/w 20 Weight 

Synthetic

 Oil 

DV Systems Pumps 

Kit Part Number 

247 

MKS-247  

447 

MKS-447 

 

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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