SDI-W

Feb ‘19

Standard Duty

Industrial

‘IS’ and ‘SDI’

Air Compressor

Installation,

Maintenance,

And

Service Data

DV Systems Inc.

490 Welham Road

Barrie, ON

L4N 8Z4

Tele: (705) 728-5657

Contents:

Safety Precautions

Preventative Maintenance Schedule

Unpacking and Inspection

Compressor Terminology

Installation – Mechanical

Lubrication

Installation - Electrical

Start-up Procedures

Compressor Unit Parts

Compressor Pumps

Trouble Shooting Guide

DV Systems Limited 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.

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Web: www.dvsystems.com

Email: [email protected]

Page:

8-9

10

11-12

13-15

16-19

20

5

6

7

2

3

4

SDI-W

Feb ‘19

Safety Precautions

To operate the Compressor Unit safely and correctly, we have opted to use the following symbols to make you aware of important points. These points relate to user safety and preventing equipment problems. Please pay close attention to these sections.

Important safety Information.

A hazard that may cause serious injury or loss of life. to avoid a situation that may cause minor injury.

Important information that indicates how to prevent damage to equipment, or how

Information that you should pay special attention to.

Area:

What to look for:

The following hazards may occur during the normal use of the equipment. Please read the following chart.

Hazard: Safeguards:

What may occur if precautions are not observed. How to avoid the hazard.

Tampering with the Unit while under full or partial pressure may cause an explosion.

Relieve all pressure from the Unit before attempting any repair or maintenance work.

As the Unit starts and stops automatically, serious injury may result from working on the Unit with the power still in the on position.

Shut off all power to the Unit before attempting any repair or maintenance work.

As the Unit starts and stops automatically, do not come into contact with moving parts.

Air compressed by the Unit is not suitable for inhaling. It may contain vapours harmful to your health.

Compressor capable of pressures > 50 psi.

The Compressor Pump, Motor, and Tubing become hot when running. Touching these areas may cause severe burns.

Shut off all power to the Unit before attempting any repair or maintenance work.

Never directly inhale compressed air produced by the Compressor.

Risk of injury, do not direct air stream at body.

Never touch the Pump, Motor, or

Tubing during or immediately after operation.

As the electrical components on the Unit are

General Purpose, there is a potential for explosion should vapours be present in the area.

The Compressor must be a minimum of 20 feet (6.1 meters) from any source of potentially explosive vapours.

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SDI-W

Feb ‘19

Preventative Maintenance Schedule

Noted below and to follow are general maintenance guidelines which must be followed and documented, this in accordance with the DV Warranty. It is based on an approximate Compressor usage of 40 hours per week. If your particular application varies from this, please adjust accordingly.

When servicing the Air Compressor, shut off all power to the Unit, and drain the Tank of air pressure. Always replace the Beltguard after adjusting the Belts or Pulleys.

Insist on Genuine DV

Systems parts and kits when maintaining your

Compressor Unit and

Pump.

Normal Maintenance

Drain moisture from Air Receiver

Check oil level and top up as required

Replace Air Filter

Replace Oil (mineral)

Check condition/alignment of Belts/Pulley

Check Safety Valves

Check that Unit unloads when shutting down

Clean and/or blow dust/dirt off Unit

Inspect Check Valve

Inspect Pressure Gauge

1

2

3





















Notes: 1. Air Filters are available separately or in the Maintenance Kit. Consult the Pump breakdown.

2. Mineral Oil is available separately or in the Maintenance Kit. Consult the Pump breakdown.

3. Belts and Pulleys are available through your local DV Systems Distributor.

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SDI-W

Feb ‘19

Unpacking and Inspection

Each DV Systems Air Compressor is carefully tested and inspected before shipment. Though every attempt is made to ensure the safe and complete shipment of our product, freight damage or misplacement of goods may occur.

Shipments of DV Systems products are the property of the

Consignee when the products leave our facility. DV Systems Inc. is not responsible for any damages or shortages caused to the product after it has left our shipping dock.

It is the responsibility of the receiver of the goods, either the Distributor or Customer, to ensure that the product has been shipped in full and has arrived in suitable condition. Damage to the product may not be visible at time of off-loading but may only become apparent upon unpacking or start-up.

Some areas to initially check are as follows:

a) Check for damage to the crating and/or packaging. b) Check for damage to the Beltguard. c) If the BeltGuard appears damaged, remove the Guard and turn the Flywheel by hand to ensure the

Crankshaft has not been bent, and the Belt drive is properly aligned and free of distortion. d) Check the Air Tank thoroughly for possible damage.

Should there be damage to the product or shortages in shipment:

5)

4)

1)

2)

3)

Stop any further unpacking or operation of the product.

Make note of the problem on the Freight Bill, should it concern a shortage or visible damage to the product.

Should 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.

Do not attempt further unpacking or operation of the product. Also, do not discard any packing material used.

A Loss or Damage Claim must be submitted to the carrier and supported by the following documents:

- Copy of Freight Bill of Lading

- Copy of the Invoice and Estimate to repair, in case of damage

- Damage Report

- Copy of photos, if applicable

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SDI-W

Feb ‘19

Compressor Terminology

Please refer to the picture below, as it identifies the major components of a typical Piston Air Compressor Unit and their function. A horizontal Unit is shown.

Compressor Pump

Compresses the air.

Aftercooler Tube

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

Beltguard

Protects personnel from the moving parts of the Flywheel,

Pulley, and Belts.

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

Check Valve

Installed between the

Aftercooler and the Tank, and 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.

Pump Components

Please refer to the Compressor Pump information provided in this manual to identify the part numbers, location, and quantities for your particular Pump model.

Ball Valve

Discharge/outlet from

Tank.

Drain Valve

Allows the Customer to drain moisture from the

Tank.

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SDI-W

Feb ‘19

DV Systems

Installation Kit

IK515

Installation – Mechanical

Location of the Unit.

Items to consider when installing the Unit are as follows:

 The Unit should be located in a dry, clean, cool, dust free, and well ventilated area. If possible, the

Compressor should be located in a separate room or area, away from the general operations of the shop.

 Allow a minimum of 18” around and 24” above the Unit, this being for both the proper ventilation of the Unit and ease of servicing.

Building

Wall, etc

Beltguard

Compressor

18” (0.5 m) minimum

(& Opposite)

 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.

 This unit must be anchored to the floor as indicated at above-right. DV Systems has available Installation Kits which include (4)

Vibration Isolator Pads, (1) Stainless Steel Flex

Hose, and Steel and Rubber Washers.

‘SDI’ Compressor

Horsepower

5 to 15 HP

 If installing the Unit on a mezzanine, ensure that the structure can safely support the weight of the Unit. The Vibration Pads will help to lessen the sound level of the Unit caused by harmonics created by the structure.

 All Compressor Units must be anchored and installed as shown below. Failure to do this will affect the Tank Warranty.

Compressor

Foot Anchor c/w

Hex Nut

(By

Installer)

½” Steel

Washer

(SS-1535)

½” Rubber

Washer

(SS-1536)

Floor

Isolator

Pad

(UDH-9700)

Never clamp or bolt Air Receiver Feet to the floor or support structure. Doing so can greatly increase stress on the Tank, causing it to weaken and/or fracture.

To reduce the risk of electric shock or injury, use indoors only.

The Compressor must not be operated in a confined area where the heat from the Unit cannot readily escape.

 If installed in a compressor room, ensure that the room is adequately ventilated. (One Horsepower produces approximately 2500 BTU/HR.)

Eg: 15 HP Unit x 2500 BTU/HP = 37,500 BTU/hour

 The ambient temperature should be between

50°F and 104°F (10°C to 40°C).

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Feb ‘19

Lubrication

Initial Start-up.

the Oil level on a monthly basis.

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

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 by removing the Cap at the Oil Drain as shown below. Running the Unit prior to draining the oil will ensure that the oil will drain relatively quickly.

Fill the Oil Reservoir to the center of the Oil Sight Glass as indicated below. Do not under or overfill.

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.

Proper Oil

Level

Oil Drain

The following oil is available from your DV Systems

Distributor.

DV Systems

Premium Mineral Oil

30 Weight: ‘PR-31-4’

Room (Ambient)

Temperature

Up to 90°F (32°C)

Condensation (water) may form in the Pump if the Compressor has limited use or is installed in a very humid environment. As the water will tend to settle on the bottom of the

Pump, drain the water from the Pump until you notice oil draining. Top up with new oil.

Also, change the oil more often than indicated on the Maintenance Schedule.

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

Kits c/w 30 Weight Mineral Oil

DV Systems Pumps Kit Part Number

DEV-20, 30, 30-1, 40 MK-40

DEV-55

DEV-100

MK-55

MK-100, MK-100-1*

*See page 15 to clarify Kit Part Number

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SDI-W

Feb ‘19

Installation - Electrical

General Information.

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 Breaker (by others than DV Systems) is installed in the electrical supply before the Compressor Unit.

A Magnetic Starter is an integral part of the

Compressor Unit circuit as it provides overload protection to the electric Motor. (The ‘IS5-4060-03’

Units have Motors equipped with an internal Overload, and a Starter is therefore not provided or required.)

Main Fuse

Box

 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 before installing or operating the Unit.

 This product must be connected to a grounded, metallic, permanent wiring system, or an equipment-grounding terminal or lead on the product.

Failure to observe any of the above precautions could result in severe personal injury or death, and/or damage to the Unit.

Fused Disconnect or Circuit Breaker

Magnetic

Starter

Typical Electrical Installation

Of a Compressor Unit

For 3 Phase Units:

Connect ground wire to Protective Earth terminal.

Bring power to L1, L2, L3.

See page 10 for start-up procedures.

For 1-Phase Units:

Connect ground wire to Protective Earth terminal.

Bring power to L1 and L2.

See page 10 for start-up procedures.

Motor

Typical Magnetic Starter Wiring

(Subject to Local Codes and Authorities)

Factory Wiring

To Motor

220 Volt Power

(#12 Wire)

Pressure

Switch

Coil

Protective

Earth

L1 L2 L3

Field

Ground

Motor

Ground

Typical Wiring at Pressure Switch

(‘IS5-4060-03’ Units Only)

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SDI-W

Feb ‘19

Installation – Electrical (cont’d)

Motors.

Wiring must be done in a manner that the full Motor nameplate voltage +/- 10% is available at the Motor terminals during start-up. In the case of 208 volt 3 phase electrics, the Unit must be 200 volts.

For single phase Motors, the voltage variance is 230 volts +/- 10%. A 208 volt power supply requires a transformer to increase the voltage to 230 volts.

Use of an incorrect Motor for your particular building service will result in premature Motor failure, something not covered by the DV

Systems or Motor manufacturers Warranty.

The Warranty that exists on the Electric Motor is that of the original Motor manufacturer. In the event of a Motor failure, contact your DV Systems Distributor or Service

Centre for the location of the nearest authorized Motor

Service Centre.

Pump Rotation.

The Compressor is to be wired in a manner that the rotation of the Pumps Flywheel causes the air to be blown from the Beltguard forward over the Pump. This coupled with the unobstructed area behind the

Beltguard of 18” (0.5 m) minimum, allows the Pump to cool properly.

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 particular buildings electrical service.

 Protective devices such as Magnetic Starters,

Fused Disconnects, etc have been sized and installed correctly.

 Any electrical accessories purchased with your

Compressor have been installed and wired correctly.

 The wiring of the Unit meets with all applicable codes and regulations.

 When completed, the Unit works in both a safe and correct manner.

Failure of the Compressor Unit due to an incorrect electrical installation is not covered by the manufacturers warranty.

When facing the Compressor

(as shown at right), the

Flywheel must rotate in a clockwise direction.

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SDI-W

Feb ‘19

Start-up Procedures

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

Initial Start-up

1) Ensure there is the correct amount of oil in the

Pump. Refer to the ‘Lubrication’ section (Page 7) in this manual for proper type and level of Oil.

2) Do a visual inspection of the Unit and ensure that all Bolt heads are sufficiently tightened. This must be done, as some fasteners may become loose in transit.

3) Turn the Compressor 'On' momentarily by positioning the Fused Disconnect or Breaker in the 'On' position. Ensure that the Flywheel is turning in the correct direction. See ‘Pump

Rotation’ (Page 9).

Do not place any materials near the

Compressor. Placing materials against or close to the Unit will limit the cooling required and could lead to premature failure.

6) Ensure that the Compressor shuts off at the factory pre-set maximum pressure, and the head pressure is released at the Pressure Switch.

7) Measure the amp draw as the Unit reaches maximum pressure.

8) Once off, check the Compressor and piping systems for any air leaks. Correct as required.

On Compressors with 3 phase power, switch

‘L1’ and ‘L3’ at the input into the Magnetic

Starter if the rotation is incorrect.

4) Open the Compressor’s Ball Valve and start the

Unit. Ensure that air is escaping to atmosphere.

Allow the Unit to operate in this fashion for 30 minutes. This lubricates the Pistons, Bearings, and all internal surfaces.

5) After having run the Unit unloaded for 30 minutes

(as noted in ‘4’ above), close the Ball Valve, and allow the Unit to reach maximum operating pressure.

Shut off all power to the Compressor Unit before attempting any repair or maintenance.

9) With the Unit shut off, check the oil level in the

Pump. Add oil as necessary.

10) After the Unit has run for 40 hours (or 2 weeks), ensure the Pump Bolts are snug.

During the first few days of operation, check the Unit periodically to ensure it is running smoothly. Should you have any concerns, contact your DV Systems Distributor.

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SDI-W

Feb ‘19

Compressor Unit Parts

Compressor Assembly Parts.

Noted below and on the following page are listings of the major components used in the Compressor Assemblies.

Please pay close attention to the model numbers of the Units to ensure that you choose the correct components.

5 to 7-½ HP Vertical Compressor Units.

Description: IS5-4060-03 IS5-5580 IS5-10080 IS7-10080

Pump Assembly

Intake Filter Assembly

Intake Filter Element

Beltguard Assembly

Motor Pulley – 1 Phase

Belt

Tank

Pressure Switch

DEV-40

PB-21175002

PB-21177012

EG-9493

DEV-55

PB-21175003

PB-21177010

EG-9494

DEV-100

See ‘Note A’

See ‘Note A’

EG-9491

DEV-100

See ‘Note A’

See ‘Note A’

EG-9491

PU-9235

BT-9039

PU-9234

BT-99

PU-9236

BT-9041

PU-9091

BT-9041

TA-9505 TA-9501 TA-9501 TA-9501

SSS-9003U115150 SSS-9003U115150 SSS-9003U115150 SSS-9003U115150

Pressure Gauge

Tank Safety Valve

Tank Drain Ball Valve

Tank Ball Valve

GA-250

TIA-5140

VA-9411

VA-9705

GA-250

TIA-5200

VA-9411

VA-9705

GA-250

TIA-5200

VA-9411

VA-9705

GA-250

TIA-5200

VA-9411

VA-9705

Check Valve CCV-9401 CCV-9406 CCV-9406 CCV-9406

Note A: The Filter Assembly and internal Filter Element were changed in 2012. The older style Element is still available, and the Filter Elements are not interchangeable. Please measure the Element to determine which

Filter Assembly, Filter Element, and Maintenance Kit is correct for your Pump.

Older Assembly Older Filter Element Older Filter Element Dimensions Older Maintenance Kit

PB-21176001

New Assembly

PB-21177013 4-1/8” OD x 2-3/4” ID x 2”H

New Filter Element New Filter Element Dimensions

MK-100

New Maintenance Kit

357-9401 357-9701 4-3/8” OD x 3” ID x 2-1/4” H MK-100-1

Maintenance Kits:

The appropriate Maintenance Kits for the 5 to 7-½ HP Units noted above having the ‘DEV-40’, ‘DEV-55’, and

‘DEV-100’ Pumps are as follows:

Pump Model:

DEV-40

Maintenance Kit:

MK-40

Filter Element:

(3) PB-21177012

Includes:

Oil:

(1) PR-31-4

DEV-55

DEV-100

MK-55

DEV-100

(2) PB-21177010

(2) PB-21177013

(1) PR-31-4

(1) PR-31-4

DEV-100 DEV-100-1 (2) 357-9701 (1) PR-31-4

Note: For the ‘DEV-100’ Pump, choose the appropriate Maintenance Kit based on the Filter Element dimensions as noted in the chart at ‘Note A’.

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Feb ‘19

Compressor Unit Parts (cont’d)

5 to 10 HP Horizontal Compressor Units.

Description: IS5-10080H IS7-100120 IS10-100120

Pump Assembly

Intake Filter Assembly

Intake Filter Element

Beltguard Assembly

Motor Pulley – 1 Phase

Belt

Tank

Pressure Switch

Pressure Gauge

Tank Safety Valve

Tank Drain Ball Valve

Tank Ball Valve

DEV-100

See ‘Note A’

See ‘Note A’

EG-9491

PU-9236

BT-9041

TA-9461-1

SSS-9003U115150

GA-250

TIA-5200

VA-9411

VA-9705

DEV-100

See ‘Note A’

See ‘Note A’

EG-9492

PU-9091

BT-9046

TA-9463-1

SSS-9003U115150

GA-250

TIA-5200

VA-9411

VA-9705

DEV-100

See ‘Note A’

See ‘Note A’

EG-9492

PU-9196

BT-9036

TA-9463-1

SSS-9003U115150

GA-250

TIA-5200

VA-9411

VA-9705

Check Valve CCV-9403 CCV-9408 CCV-9408

Note A: The Filter Assembly and internal Filter Element were changed in 2012. The older style Element is still available, and the Filter Elements are not interchangeable. Please measure the Element to determine which Filter Assembly, Filter Element, and Maintenance Kit is correct for your

Pump.

Older Assembly Older Filter Element Older Filter Element Dimensions Older Maintenance Kit

PB-21176001

New Assembly

PB-21177013 4-1/8” OD x 2-3/4” ID x 2”H

New Filter Element New Filter Element Dimensions

MK-100

New Maintenance Kit

357-9401 357-9701 4-3/8” OD x 3” ID x 2-1/4” H MK-100-1

Maintenance Kits:

The appropriate Maintenance Kit for the 5 to 10 HP Units noted above having the ‘DEV-100’ Pumps is as follows:

Pump Model:

DEV-100

Maintenance Kit:

DEV-100

Filter Element:

(2) PB-21177013

Includes:

Oil:

(1) PR-31-4

DEV-100 DEV-100-1 (2) 357-9701 (1) PR-31-4

Note: Choose the appropriate Maintenance Kit based on the Filter Element dimensions as noted above.

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SDI-W

Feb ‘19

 





Compressor Pump – DEV-40











No. Part Number:

1

PB-21175002

PB-21177012

Qty: Description:

3

3

Air Filter Assembly

Air Filter Element

No. Part Number:

6

7

PB-21166001

PB-21164004

Qty: Description:

1

1

Crankcase Breather

Oil Sight Glass

2

3

4

VRK-40

PB-21167002

PB-21161004

3

1

1

Valve Repair Kit

Oil Fill Plug

Oil Seal

8

9

PB-21177001

PB-21177020

GK-40

1

1

1

Fan Assembly

Shroud Assembly

Gasket Kit

5 PB-21212003 1 Flywheel OK-40 1 Overhaul Kit

Note: 1. The ‘VRK-40’ Valve Repair Kit includes the Valve Plates and the Gaskets necessary to install them.

2. The previous ‘DEV-40’ Pump did not have the Fan Assembly and Shroud Assembly. All other components remain the same.

3. ‘OK-40’ Overhaul Kit includes (1) Gasket Kit, (1) Ring Kit, (3) Valve Repair Kits, and (1) Oil Seal.

Maintenance Kits:

The appropriate Maintenance Kit for the ‘DEV-40’ Pump is the part number ‘MK-40 ’ and includes the following:

(3)

(1)

PB-21177012 Filter Elements

PR-31-4 30 Weight Mineral Oil – 4 litre jug

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Feb ‘19

Compressor Pump – DEV-55











  



No. Part Number:

1

2

PB-21175003

PB-21177010

PB-21167002

Qty: Description:

2

2

1

Air Filter Assembly

Air Filter Element

Oil Fill Plug

No. Part Number:

6

7

8

PB-21212004

VRK-55

TIA-5075

Qty: Description:

1

1

1

Flywheel

Valve Repair Kit

Safety Valve – 75 psi

3

4

PB-21164004

PB-21161005

1

1

Oil Sight Glass

Oil Seal

GK-55

OK-55

1

1

Gasket Kit

Overhaul Kit

5 PB-21166001 1 Crankcase Breather

Note: 1. ‘OK-55’ Overhaul Kit includes (1) Gasket Kit, (1) Ring Kit, (1) Valve Repair Kit, and (1) Oil Seal.

Maintenance Kits:

The appropriate Maintenance Kit for the ‘DEV-55’ Pump is the part number ‘ MK-55 ’ and includes the following:

(2)

(1)

PB-21177010 Filter Elements

PR-31-4 30 Weight Mineral Oil – 4 litre jug

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Feb ‘19

Compressor Pump – DEV-100





TIA-5200 Safety Valve

(Not Shown)



No. Part Number:





Qty: Description:



No. Part Number:



14

13

12

10 11





Qty: Description:

1

2

3

4

5

PB-21135001

PB-21166001

See ‘Note A’

See ‘Note A’

TIA-5075

PB-21164004

SGK-100

PB-21212006

8

1

2

2

2

1

1

1

Bearing Insert

Crankcase Breather

Air Filter Assembly

Air Filter Element

Safety Valve – 75 psi

Oil Sight Glass (Round)

Sight Glass Kit (Oval)

Flywheel

8

9

10

11

12

13

14

PB-11122004

PB-21124011

PB-21125004

PB-21125003

PB-21157006

PB-21125005

PB-11122001

GK-100

10

10

6

4

6

6

24

1

Copper Washer (See Note B)

Valve Assy (See Note B)

Intake Valve Cap Ring

Exhaust Valve Cap Ring

Valve Cover Gasket

Valve Cover

8 mm Washer

Gasket Kit 6

7 PB-21161006 1 Oil Seal

Note A: The Filter Assembly and internal Filter Element have changed. The older style Element is still available, and the Filter Elements are not interchangeable. Please measure the Element to determine which Filter Assembly, Filter Element, and Maintenance Kit is correct.

Note B: Please order (1) ‘PB-11122004’ Washer for every ‘PB-21124011’ Valve Assembly ordered.

Older Assembly Older Filter Element Older Filter Element Dimensions Older Maintenance Kit

PB-21176001

New Assembly

PB-21177013 4-1/8” OD x 2-3/4” ID x 2”H

New Filter Element New Filter Element Dimensions

MK-100

New Maintenance Kit

357-9401 357-9701 4-3/8” OD x 3” ID x 2-1/4” H MK-100-1

Maintenance Kits:

The appropriate Maintenance Kit for the ‘DEV-100’ Pump is as noted in the chart above and includes the appropriate Air Filter

Elements and (1) 4 litre jug of PR-31-4 30 Weight Mineral Oil.

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Feb ‘19

Trouble Shooting Guide

When servicing the Air Compressor, shut off all power to the Unit, and drain it of air pressure.

The ‘Conditions’, ‘Causes’, and ‘Suggested Corrections’ as indicated below and on the following page(s) are only a guideline for failures that we have found to be most common.

Though this information is provided in this booklet, it is assumed and expected that any personnel involved in the servicing of an Air Compressor Unit is knowledgeable with this type of equipment. Do not attempt to service a

Compressor Unit unless you are familiar with it, as there are many issues that may come into play, the most important being personal safety and the welfare of the Unit.

Should you have any questions, or require servicing to your Unit, please contact your local DV Systems

Distributor.

Condition: Cause: Suggested Correction:

A. Unit won’t start.

B. No or Insufficient Air

Flow.

No power to the Unit.

Loose and/or missing wires in the electrical circuit.

Starter Overload is tripped.

Pressure may not be low enough in the

Tank to allow the Unit to start.

Air Filter is dirty.

Loose Belts.

Pump Valves, Aftercooler, or Tank Check

Valve leaking, sticking, or plugged.

Air leaks at Compressor in in piping system.

Unit is too small for the compressed air requirements.

Check that power at the disconnect or breaker is on. Also, check any fuses.

Check that all wiring connections are tight.

With a wiring schematic, check that all wiring is present and correct.

Reset the overload in the Magnetic Starter.

Drop pressure below the Pressure Switch ‘cutin’ pressure.

Replace the Air Filter.

Tighten as required. Do not over-tighten.

Clean or replace.

Fix leaks. Soap/water mixture will assist in finding small leaks.

Contact your DV Systems Distributor for assistance.

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SDI-W

Feb ‘19

Trouble Shooting Guide (cont’d)

Condition:

C. Excessive Noise.

Cause:

Loose Beltguard, Flywheel or Motor Pulley.

Loose Valve in the Cylinder Head.

If noisy only during start-up, check for loose

Belts.

Unit not installed level.

Improper level or grade of oil in Pump.

Carbon or other foreign material on Piston head.

Normal sound amplified through floor or carried through remote air intake, when used.

If the Pump is knocking, and cannot be attributed to any of the above, the Bearings in the Pump may be worn.

D. Oil Passing Downstream of Unit and Excessive

Carbon Build-up.

Ambient temperature is too high.

Little or no air circulation around and over

Unit.

High percentage of running time.

Obstructed Air Filter.

Too much oil in the Pump.

Using wrong type of compressor oil.

Worn Valves.

Worn Piston Rings.

Suggested Correction:

Tighten as required.

Inspect the Valves. Ensure they are seated properly in the Cylinder Head. Reinstall, making sure that you re-torque as necessary.

Tighten Belts until no slippage is apparent.

Ensure the Unit is mounted level. Use Vibration

Pads.

Use correct DV Systems oil, and check that level is correct.

Clean top of Piston. Check Cylinder walls for scoring.

Mount Unit on Vibration Isolators. Insulate remote intake piping from building.

Worn 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.

Introduce cool air, better air flow, or move Unit to cooler location.

Check the air circulation around the Unit.

Ensure Flywheel rotation is correct, and there is

18” minimum around Unit.

Check for air leaks. If no air leaks are present, the Compressor may be too small for the application.

Clean or replace as necessary.

Reduce the amount of oil in the Pump.

Change to the factory recommended oil.

Check and replace as necessary.

Replace Piston Rings as necessary.

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SDI-W

Feb ‘19

Trouble Shooting Guide (cont’d)

Condition:

E. Appearance of Water in the Air Lines and/or Oil

‘milky’ in Colour.

F. Compressor Overheating.

G. Belts Roll Off Motor

Pulley and/or Flywheel.

H. Flywheel or Motor Pulley

Wobbles or Comes

Loose.

Cause:

Tank is not being drained regularly.

Unit is not being used enough to burn off any water in the Pump.

Undersized Unit for air requirements.

Dirt accumulation on outside of Pump.

Compressor too close to building wall/obstructions.

Pump rotating in wrong direction.

Air leaks on Unit or in air lines.

Remote air intake piping (if used) is too small or plugged.

Restricted Air Intake Filter.

Improper level or type of oil in Pump.

Worn or carbonned Valves in Cylinder Head,

Aftercooler Tube, or Check Valve.

Flywheel and Motor Pulley are not aligned.

If two or more Belts are used, Belts may not be matched set.

A nick or tear on the edge of a belt.

Belts do not match the Flywheel/Pulley groove (such as ‘A’ or ‘B’ section).

Clamping Bolt not tight on Flywheel.

Set Screw on Motor Pulley came loose.

Suggested Correction:

Drain the Tank on a daily basis. Purchase a

Tank Autodrain if required.

If using the Unit very infrequently, run for 30 minutes when used to burn off water.

An oil/water mixture can cause premature issues with the Pump. Check the oil regularly and change more often then suggested in the

Maintenance Schedule.

Maximum operating time, based on an 8 hour day, is 60%, which related to approx. 35 minutes per hour.

Clean Pump.

Move Compressor so Beltguard is a minimum of

18” away from nearest obstruction. See Page 7.

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 ‘Lubrication’ on Page 8.

Clean or replace as required.

Align using a straight edge.

Purchase a new set of matched belts.

Purchase a new set of matched belts.

Purchase a new set of Belts, paying close attention to ‘A’ or ‘B’ section requirement.

Tighten as required.

Take existing Set Screw out and purchase new one. Set Screws have Loctite coating, and can only be used once.

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SDI-W

Feb ‘19

Trouble Shooting Guide (cont’d)

Condition:

I. Crack in Air Receiver.

J. Compressor Pump

Seizes.

K. Oil Leaks or the

Appearance of Oil on the

Compressor.

L. Unloader at Pressure

Switch Does Not

Function, or Leaks When

Unit Operating.

M. Unloader Leaks

Constantly When Unit is

Not Operating.

Cause:

This condition is rare and can be caused by damage during transit or incorrect mounting on site.

Started without oil in the Pump.

Pump ran low on oil.

Worn Connecting Rod bearing Inserts.

Piston and Pin Assembly seized.

Worn Crankshaft Bearings.

Oil was spilled when filling the Pump.

Over-filling of the Pump with oil.

Leak at Oil Fill Plug.

Leak at Oil Drain.

Oil leak at Gaskets, Cap Screws, Cylinder

Head, Cylinder, or Crankcase.

Oil Seal leak.

Unloader may be dirty or faulty.

Suggested Correction:

Do not attempt to repair the Tank. Do not continue to operate the Compressor Unit.

Contact your local Distributor for further guidance.

The Pump will require a complete overhaul, at which time the defective parts must be replaced.

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 Forma-Gasket on Head Bolts and Crankcase to

Cylinder Bolts.

Inspect Crankshaft for any scratches or burrs.

Use emery cloth. Replace Oil Seal as required.

Clean, repair, or replace.

The Disc inside the Tank Check Valve is not seating properly, allowing the compressed air in the Tank to escape.

Clean or replace the Check Valve as required.

N. Intercooler Safety Valve

Pops Continuously.

Dirty or defective Valves will cause back pressure.

Intercooler clogged with carbon.

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Clean, repair or replace the Valves.

Clean or replace.

SDI-W

Feb ‘19

DV Systems Limited Warranty

‘Industrial Standard’ and ‘Standard Duty Industrial’ Air Compressors

Subject to the terms and conditions contained herein, DV Systems Inc. (the “Manufacturer”) warrants that the Air Compressor (the

“Product”) shall be free of defects in material and workmanship (the “Warranty”) for a period of two (2) years from the date of purchase, not to exceed thirty (30) months from the date of manufacture (the “Warranty Period”). This Warranty is subject to the following terms and conditions:

 when in use, the Product must be properly installed, operated, applied and maintained in accordance with procedures and recommendations outlined in the Manufacturer's instruction manuals;

 all claims under this Warranty must be brought to the attention of the Manufacturer within the Warranty Period;

 the Warranty shall continue to apply to any Product or part of the Product replaced or repaired under the Warranty for the remaining term of the Warranty Period as would have been applicable to the original Product or part of the Product;

 this Warranty is applicable to the original purchaser of the Product and is not transferable;

 this Warranty does not apply to a Product that is purchased outside Canada or the continental United States (the “Territory”); and

 any service on the Product must be performed by the Manufacturer or, if by another party, only with the prior written authorization of the Manufacturer.

If there is a defect in the material or workmanship of the Product to which the Warranty applies, the Manufacturer will repair or replace the Product or part of the Product determined to be defective by the Manufacturer, in its sole and reasonable discretion. This

Warranty applies only to parts and labour necessary to correct a defect in the Product. Shipping and/or travel charges, where applicable, shall be the responsibility of the customer.

This Warranty shall be deemed void if:

 any service on the Product is performed by any party other than the Manufacturer or his agent without the prior written authorization of the Manufacturer;

 the Product is not properly maintained as detailed in the Manufacturer's instruction manuals; or

 the Product is subject to misapplication, misuse, abuse, neglect, incorrect maintenance or accident.

This Product is subject to ordinary wear and tear (“Ordinary Wear and Tear”), which particularly applies to parts that are subjected to friction or that may generally have a known useful life [including but not limited to compressor pump rings, valves and bearings]. The

Manufacturer shall 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 repair of Product without previous authorization from Manufacturer;

 expenses incurred by a technician of the Manufacturer for travel or lodging

 damages resulting from transportation, installation, or servicing;

 products, parts, materials, components or accessories manufactured by parties other than the Manufacturer or supplied in connection with the sale of the Manufacturer's Product; and

 the cost of rental or loaner equipment provided to the customer while the Product is being assessed, repaired, or replaced.

To the maximum extent permitted by state, provincial or federal law, this warranty is in lieu of all other warranties, expressed or implied, including the implied warranties of merchantability and fitness for a particular purpose. In some jurisdictions, the duration of implied warranties is hereby expressly limited to the duration of the express warranty stated above.

To the maximum extent permitted by state, provincial, or federal law, in no event, whether as a result of breach of warranty or contract, tort (including negligence) strict liability or otherwise, shall the manufacturer be liable for indirect, special, incidental, or consequential damages, including but not limited to loss of use of the product or associated equipment, lost revenues or profits or cost of substitute equipment relating to or arising out of the use of the product or a claim under this warranty howsoever caused.

In order to make a claim under this Warranty, the customer must first call DV Systems Warranty Department at the number shown on this warranty.

All returns must be pre-authorized, returned 'Freight Prepaid', and accompanied by a 'Return Material Authorization (RMA) Number'.

All decisions made by the Manufacturer with regard to this Warranty shall be final. The Manufacturer will not be responsible for any claimed defective materials returned other than in accordance with this statement of policy or without its prior written authorization.

DV Systems Inc. - Canada

490 Welham Road,

Barrie, ON

L4N 8Z4

Tele: (705) 728-5657

© Copyright DV Systems Inc. 2019

Printed in Canada

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