DV Systems G20 Installation And Start-Up Data Download

Page: 1 / 37

G2030-II-C

Mar ‘17

- 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)

G20 (T) (TD),

G25 (T) (TD) &

G30 (T) (TD)

Rotary Screw

Air Compressor

Units

- - -

Installation

And

Start-up Data

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

Safety Precautions ……………………………………

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

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

Lubrication …………………………………………….

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

Start-up Procedures ………………………………….

Preventative Maintenance Schedule ……………….

Common Compressor Faults ……………..…………

Variable Speed Drive ………………………….……. 18
Separator Filter & Refrigerated Air Dryer ………….

Trouble-Shooting Guide ………………………………

Warranty ………………………………………………..

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 G20

Page 1: ... Precautions 5 Unpacking and Inspection 6 Installation Mechanical 7 Lubrication 10 Installation Electrical 11 Start up Procedures 14 Preventative Maintenance Schedule 15 Common Compressor Faults 17 Variable Speed Drive 18 Separator Filter Refrigerated Air Dryer 21 Trouble Shooting Guide 24 Warranty 27 Contents Page Please read this manual before installing or using your Air Compressor Unit It cont...

Page 2: ... 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 Note Dimensions indicated are typical for all variations of G Series Units ie base mounted and horizontal 18 458 mm Fusible Disconnect Refer to page 11 for proper sizing Installation Kit IK515 F...

Page 3: ...ase Sequence Error will appear on the Controller Screen if the phase sequence is incorrect If this occurs simply switch the incoming leads L1 and L3 at the Control Panel Note Units with serial number 077690 and earlier may be equipped with Anti Rotation Switches E 0902 Anti Rotation will appear on the Controller Screen if the rotation is incorrect If this occurs change L1 and L3 at the Control Pan...

Page 4: ... 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 changing of op...

Page 5: ...hut 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 runnin...

Page 6: ...t 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 no...

Page 7: ... 18 458mm around and 3 feet 915mm 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 Ho...

Page 8: ...on 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 Base Mounted Unit ...

Page 9: ...G2030 II C Mar 17 9 Installation Mechanical cont d Intake and Exhaust Ducting Tank Mounted Unit ...

Page 10: ...or top ups The MK G20 30 1 Maintenance Kit includes 1 5 US Gallon Oil DEV 3000 2 Oil Filter DSC 624 1 Air Oil Separator Filter DSC 001148 2 Air Filter DSC 001961 1 In Line Filter DSC 612 The MK G20 30 1 Kit is appropriate for Units of serial number 37162 and higher Use MK G20 30 Kit for Units of serial number 37135 and lower Do not attempt to operate the Unit without first checking whether there i...

Page 11: ...al Information 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 Switch in the Compressor Control Panel must be rated for...

Page 12: ...otating in the reverse 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 Sequence Note If the Motor is replaced or Motor Leads are re wired visually check for correct Motor Rotation before installing the belts Conduit Opening Do not attempt to operat...

Page 13: ...this based on the Bearing Sizes This must be part of a regular maintenance schedule Motor HP Interval in Hours Drive End Opposite Drive End Weight of Grease Volume of Grease Weight of Grease Ounces Grams In3 Teaspoon Ounces Grams 20 25 30 2 000 0 61 17 1 2 3 9 0 23 7 2 Drive End would be the end that is connected to the driven device air end Opposite Drive End would be the end that is connected to...

Page 14: ...aches 120 psi 8 3bar it will idle for 8 or 10 minutes and shut off For VSD units the unit 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 6 9bar the Unit will start and begin to compress air after a short delay For VSD units this pressure is 10 psi below the cut out pressure 8 Measure the amp draw...

Page 15: ...t 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 32 C 90 F the components marked with a on the chart ...

Page 16: ... 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 or every 12 months whichever occurs first Please refer to the Warranty on Page 27 for further information c If a component during a regular inspection has proven to be defective or unfit for regular operation it must be repai...

Page 17: ...e 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 order of...

Page 18: ...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 G Series Unit with a Variable Speed Drive VSD Interface The VSD Controller Interface is shown at right It provides a mea...

Page 19: ...in the manual Default page of the graphical display is set to Multimonitor On this Multimonitor page 9 drive status items are displayed Output Frequency The output frequency to the motor Frequency Reference The frequency reference to motor control It varies between min and max frequency Analogue Input 2 The input speed signal as a percentage of the used range Motor Current The measured current at ...

Page 20: ...r stall Motor stall protection has tripped Check Motor and load 16 Motor over temperature Motor is overloaded Decrease motor load 17 Motor under load Motor under load temperature has tripped Check load 32 Fan cooling Fan speed does not match the speed reference Check drive fan Contact Distributor Fan life time 50 000 h is reached 41 IGBT temperature The calculated IGBT temperature is too high Chec...

Page 21: ...rmed a dry Tank Drains will discharge automatically under pressure It is recommended that pneumatic drain tubes be anchored and filtered as per your local municipality regulations 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 C...

Page 22: ...t 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 Codes Energy ...

Page 23: ...nister Head Install the new O ring making sure it is properly seated Place the new 1 micron Separator Filter Element into the Bowl the filter is self centring Screw the Canister with the Element inside it to the Canister Head until the indicators line up Gauge will return to green when Filter is once again under pressure Typical Separator Filter Arrow Indicates Direction of Air Flow Dual Indicatin...

Page 24: ...o 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 secondar...

Page 25: ... 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 sensor R...

Page 26: ...t could be oversized for the tank capacity 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 parameter...

Page 27: ...isapplication 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...

Page 28: ...ITIONS 10ºC 50ºF MIN 40ºC 104ºF MAX 4 APPROACH TEMP FROM TANK 5ºC 41ºF MODEL NO HP PRESSURE PSI SCFM MAX PRESSURE NOMINAL SOUND 1 METRE MOTOR NAMEPLATE AMP WEIGHT LBS 3 PHASE 200V 230V 460V 575V G20 20 100 120 82 67 dBA 53 46 23 18 4 1120 125 145 73 G25 25 100 120 100 68 dBA 65 56 28 22 7 1120 125 145 91 G30 30 100 120 116 69 dBA 78 68 34 27 1120 125 145 106 IMPORTANT NOTE This print is the confid...

Page 29: ...ONDITIONS 10ºC 50ºF MIN 40ºC 104ºF MAX 4 APPROACH TEMP FROM TANK 5ºC 41ºF MODEL NO HP PRESSURE PSI SCFM MAX PRESSURE NOMINAL SOUND 1 METRE MOTOR NAMEPLATE AMP AIR RECEIVER GAL DRYER FILTER ELEMENT WEIGHT LBS 3 PHASE 200V 230V 460V 575V G20TD 20 100 120 82 67 dBA 53 46 23 18 4 120 ASD 100 115V 60Hz 11 6A 1 MICRON 1683 125 145 73 G25TD 25 100 120 100 68 dBA 65 56 28 22 7 120 ASD 100 115V 60Hz 11 6A ...

Page 30: ...S 10ºC 50ºF MIN 40ºC 104ºF MAX 4 APPROACH TEMP FROM TANK 5ºC 41ºF MODEL NO HP PRESSURE PSI SCFM 120 145 PSI NOMINAL SOUND 1 METRE MOTOR NAMEPLATE VOLTAGE WEIGHT LBS 3 PHASE 100 CAP 70 CAP 40 CAP 200V 230V 460V 575V G25VSD 25 110 120 100 70 40 68 dBA 65 56 28 22 7 1195 135 145 96 67 38 G30VSD 30 110 120 116 81 46 69 dBA 78 68 34 27 1195 135 145 112 78 45 FUSE TABLE VOLTAGE PHASE FUSE TYPE FUSE AMP ...

Page 31: ...MBIENT CONDITIONS 10ºC 50ºF MIN 40ºC 104ºF MAX 4 APPROACH TEMP FROM TANK 5ºC 41ºF MODEL NO HP PRESSURE PSI SCFM 120 145 PSI NOMINAL SOUND 1 METRE MOTOR NAMEPLATE VOLTAGE AIR RECEIVER GAL DRYER FILTER ELEMENT WEIGHT LBS 3 PHASE 100 CAP 70 CAP 40 CAP 200V 230V 460V 575V G25TDVSD 25 110 120 100 70 40 68 dBA 65 56 28 22 7 120 ASD 100 115V 60Hz 11 6A 1 MICRON 1758 135 145 96 67 38 G30TDVSD 30 110 120 1...

Page 32: ...TOR HARNESS G20 25 200V G30 200V MOTOR HARNESS G20 230V MOTOR HARNESS G20 460V MOTOR HARNESS G20 G25 575V MOTOR HARNESS G25 230V G30 200V MOTOR HARNESS G25 460V MOTOR HARNESS G30 460V MOTOR HARNESS G30 575V MTR HARN G25VSD 200V G25 30VSD 230V MTR HARNESS G25 30VSD 460V MOTOR HARNESS G25 30VSD 575V 1 20 DSC 001142 M16 2 0 X 30MM GR12 9 SHCS 4 21 DSC 001110 AIR END PLATE 1 22 SS 33 3 8 16 X 4 HHCS 1...

Page 33: ...ALVE INLET 1 31 DSC 002882 O RING G SERIES A O INLET 1 32 DSC 122 BONDED WASHER 1 1 4 BSPP 1 33 DSC 121 ADAPTER R3 4 JIC12 4 34 SS 01926 3 8 16 X 1 3 4 SHCS 4 35 DSC 624 OIL FILTER 1 36 DSC 002881 MANIFOLD ASSEMBLY G SERIES II 1 37 DSC 628 MANIFOLD SCAVENGE LINE O RING 1 38 DSC 288 MANIFOLD ASSEMBLY O RING 1 39 DSC 567 ADAPTER R3 4 JIC8 1 40 DSC 002886 1 2 STEEL TUBE OIL RETURN 1 41 DSC 001667 COP...

Page 34: ...Y 13 DSC 110 PNEUMATIC TEE 1 4 BSPP X 8MM 1 14 DSC 712 THERMO VALVE CAP 1 15 DSC 711 THERMO VALVE CAP O RING 1 16 DSC 120 BONDED WASHER 3 4 BSPP 3 17 DSC 567 ADAPTER R3 4 JIC8 1 18 DSC 001564 ADAPTER 1 4 BSPPM 1 4 NPTF 1 19 TIA 5165 SAFETY VALVE 1 4 165 PSI 1 20 DSC 158 PNEUMATIC ELBOW 1 4 BSPP X 6MM 1 21 DSC 427 BONDED WASHER 3 8 2 22 DSC 278 ADAPTER 3 8 BSPM X 1 4 BSPF 2 23 DSC 377 PNEUMATIC ELB...

Page 35: ...ject to change without notice F1 F2 0 24VAC F3 1 2 24 VAC XO5 T P C CSC300 2 0 0 12 16 15 13 BLK WHT RSS 17 X13 XO9 RELAY OUTPUTS MICROPROCESSOR 11 S 14 3 PHASE X12 L1 L2 L3 a CT1 X11 b c CT2 X10 a C C R1 R2 R3 XO8 RELAY OUTPUTS C R4 R5 R6 XO7 PROGRAMMABLE C R7 R8 C RELAY OUTPUTS ANA O ANA G DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 C AN1 AN1 AN2 AN3 C AN2 C AN3 L1 L2 XO6 L1 L2 6 11 X01 DIGITAL INPUTS X02 A...

Page 36: ...IRING 230 NA 5 1 5 1 5 200 T1 T2 T3 1 6 2 4 3 5 230V MOTOR WIRING 200V MOTOR WIRING MOTOR WIRING 24 VAC XO5 T 0 24VAC P F1 F2 L1 L2 F3 C CSC300 1 2 2 0 0 10 15 14 12 BLK WHT 16 X13 XO9 RELAY OUTPUTS 9 S 13 3 PHASE X12 L1 L2 L3 a CT1 X11 b c CT2 X10 a C C R1 R2 R3 XO8 RELAY OUTPUTS C R4 R5 R6 XO7 PROGRAMMABLE C R7 R8 C RELAY OUTPUTS ANA O ANA G DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 C AN1 AN1 AN2 AN3 C AN...

Page 37: ... 0 10 15 14 12 BLK WHT 16 X13 XO9 RELAY OUTPUTS 9 S 13 3 PHASE X12 L1 L2 L3 a CT1 X11 b c CT2 X10 a C C R1 R2 R3 XO8 RELAY OUTPUTS C R4 R5 R6 XO7 PROGRAMMABLE C R7 R8 C RELAY OUTPUTS ANA O ANA G DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 C AN1 AN1 AN2 AN3 C AN2 C AN3 L1 L2 XO6 L1 L2 3 4 6 5 9 X01 DIGITAL INPUTS X02 ANALOGUE INPUTS X03 E 10 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 30 VACON100 VFD CO...

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