DV Systems K100-C Installation Manual Download Page 1

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K100-C

Dec’15

- 1 -

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)

Web:

www.dvcompressors.com

(704) 799-0046 (USA)

Fax:

(705) 728-4974 (Canada)

Email:

[email protected] (Canada)

(704) 799-0355 (USA)

[email protected] (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.

K100

Rotary Screw

Air Compressor

Unit

- - -

Installation

And

Start-up Data

Summary of Contents for K100-C

Page 1: ...on 11 Installation Electrical 12 Start up Procedures 15 Preventative Maintenance Schedule 16 Compressor Storage 18 Common Compressor Faults 19 Variable Speed Drive 20 Air Filtration Refrigerated Air Dryer 23 Trouble Shooting Guide 26 Warranty 29 Please read this manual before installing or using your Air Compressor Unit It contains valuable information that will help in the receiving installation ...

Page 2: ...nd the Unit The Access Doors swing in a 36 915mm arc 48 1220mm on either side of the Unit and 60 1524mm above Unit The ambient temperature 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 48 1220mm 48 1220mm 48 1220mm...

Page 3: ...off using the Emergency Stop Button If the rotation is not correct simply change two of the motor leads at the Inverter Reservoir Couplings The K Series Screw Units are shipped with 3 Shipping Cleats under the Feet of the Oil Receiver 1 under Air End Bracket and 1 under the Motor These Cleats are installed simply to stop any lateral movement of the components during transportation The Cleats must ...

Page 4: ...ot 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 changing of oper...

Page 5: ...t 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 when running ...

Page 6: ...the Oil Receiver in the front right corner of the Unit and locate the Air End Bracket at the back of the Unit 2 Locate the orange Shipping Cleat under each Foot of the Oil Receiver and one Shipping Cleat under the Air End Bracket 3 Remove the Bolt and Washers from each Cleat and slide the Cleat out Note To remove the Cleats you may need to apply some sideways force on the top of the Receiver Motor...

Page 7: ...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 Also do not ...

Page 8: ...AF C 583 SAF Y 583 Canister Cyclone Element Included with Compressor 3 H 9037 2 Dia x 12 305mm L Long Flex ose 4 Advanced Air Pipe Systems 2 Diameter Pipe Contact Distributor for sizing 5 TA 400165 or TA 400200 Air Receiver 165 psi or 200 psi Safety Valves sized to application 6 SAF C 583 SAF S 583 Canister 3 Micron Element 7 ASD500 Refrigerated Air Dryer 8 SAF C 583 SAF E 583 Canister 0 01 Micron...

Page 9: ...220mm at the sides and 5 feet 1524mm 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...

Page 10: ...stallation 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: ...be approx 33 litres of Oil Do not under or 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 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 li...

Page 12: ...amps as indicated on the Sales Drawing b Fuses must be semi conductor J type fast acting It is your responsibility to ensure that the Compressor Unit is electrically connected in a safe and correct manner Any electrical work should be carried out by a competent Electrician and be done in such a way that it meets all applicable Codes and Regulations Ensure that a suitable Fused Disconnect or Breake...

Page 13: ...Air End Rotation It is critical that the Motor and Air End in the Rotary Screw Unit be turning in the correct manner as the Unit is not equipped with an Anti Rotation Switch Irreparable damage will be done if the Unit rotates in the reverse direction The correct rotation is as indicated at the Coupling area of the Unit Remove the Cover Plate from the Coupling area and pay close attention to the ar...

Page 14: ... efficiently Lubrication This is a ball bearing motor The bearings have been lubricated at the factory Motors that do not have regrease capability are factory lubricated for the normal life of the bearings 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 Wei...

Page 15: ...Fused Disconnect Breaker in the On Position Check that there is power to the Controller 5 Turn the Unit on momentarily by pressing the Start Button on the CSC300 Controller Immediately press the Emergency Stop Button to stop the Unit Ensure the Motor Air End are rotating in the correct direction See Motor Air End Rotation on Page 13 Also ensure the Cooling Fan is rotating correctly See Page 14 6 A...

Page 16: ...anged 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 32 C 90 F the components marked with a on the Maintenance Schedule on the fol...

Page 17: ... an environment where the ambient temperature is above 32 C 90 F 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 complete Oil change must be done every 8000 hours of Unit operation...

Page 18: ...Run the Unit for a minimum of 30 minutes under load before shutting down Switch the Unit off and allow for adequate ventilation in the room Turn off and lock the main power supply to the Unit Allow the Unit to cool down fully Disconnect the air and electrical connections to the Unit Remove drive motor fuses in order to prevent accidental start up If possible the placement of desiccant inside the U...

Page 19: ...ate until the Fault has been addressed 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...

Page 20: ...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 right is the Variable Speed Drive VSD Interface The VSD Controller Interface is shown at right It provides a means of o...

Page 21: ...K100 C Dec 15 21 Variable Speed Drive cont d Operating Screen Typical Drive Status Indicators on Screen ...

Page 22: ...he ambient temperature and motor load 15 Motor stalled Motor stall protection has tripped Check motor and load 16 Motor stalled Motor is over loaded Decrease motor load 17 Motor under load Motor under load temperature has tripped Check load 22 EEPRON Checksum Fault Parameter save fault Faulty operation Component failure Should the fault re occur contact the distributor 25 Microprocessor Watchdog F...

Page 23: ...nd previously on Page 8 is a typical installation showing the Compressor Air Receiver Refrigerated Air Dryer and Filters More detailed information concerning the Dryer Unit is included in the Dryer manual The information contained in this manual is a quick reference only Air Receiver Dryer Controls On Off Button LED s for Compressor Drain and Fan Test Programming Buttons Compressor Unit Refrigerat...

Page 24: ...s 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 Codes Energy Sav...

Page 25: ...crew 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 Needle Type Gauge will return to blue when Filter is once again under pressure Typical Separator Filter Arrow Indicates Direction of Air Flow AutoDrain Bowl which Contains Filter Element and Aut...

Page 26: ... Fuses Blown 2 Loose and or missing wires in the electrical circuit 3 Emergency Stop Button pressed in 4 Motor Overload is tripped 5 Compressor over heated and stopped 6 Compressor stopped by over pressure 7 Unit has timed out shut off because pressure has not gone below cut in pressure 8 Power interruption 1 Check that power at the disconnect or breaker is on Also check any primary and secondary ...

Page 27: ...blocked 8 Temperature Sensor is faulty 9 Thermostat is faulty 10 Pressure is too high 11 Cabinet door panel is open off 1 Check cooling air circulation 2 Check the air circulation in and around the Unit 3 Clean the Heat Exchanger 4 Add oil as required 5 Change to the factory recommended oil 6 Check and repair as necessary 7 Replace the Oil Filter 8 Check the wiring to the Temperature sensor Replac...

Page 28: ...lso the Unit could be oversized for the tank capacity G Compressor Surges 1 Restriction in Heat Exchanger or Hoses 2 Pressure Transducer setting is incorrect or malfunctioning 3 Blockage at Unit outlet 4 If present the Dryer is freezing up not allowing air to pass through 5 Air Receiver is too small 1 Flush out or replace 2 Set pressure as per instructions or replace 3 Check for obstructions in ou...

Page 29: ...application 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 Baldor Motors Labour is not covered in the 4 year extended Baldor M...

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