HDI-03-W

Mar ‘15

Contents: Page:
Quick Start 2
Heavy Duty Safety Precautions 3
Preventative Maintenance Schedule 4
Industrial Unpacking and Inspection 5

(‘HDI’) Compressor Terminology

Installation – Mechanical
6
7
Air Compressor Lubrication 8
Installation – Electrical 9-10
Installation, Start-up Procedures 11
Maintenance, Compressor Unit Accessories
Compressed Air System Design
12-14
15-16
And Refrigerated Air Dryers 17-18
Compressed Air Filter Assemblies 19
Service Data Trouble-Shooting Guide 20-23
DV Systems Limited Warranty 24-25
Warranty Registration 26

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.

DV Systems Inc. - Canada DV Systems Ltd. - US

490 Welham Road 128-B Talbert Road
Barrie, ON Web: www.dvcompressors.com Mooresville, NC
L4N 8Z4 28117
Email: sales@dvcompressors.com
Tele: (705) 728-5657 Tele: (704) 799-0046
Fax: (705) 728-4974 Fax: (704) 799-0355
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 HDI-03-W
Mar ‘15
Quick Start

Mechanical Installation.
(Refer to Page 7)

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

Allow a minimum 18” behind the BeltGuard and

around the 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
24”

18”

18”
18”

Lubrication. Pump Rotation.

(Refer to Page 8) (Refer to Page 10) The arrow below
indicates the correct
rotation of the Flywheel.

Proper Oil
Level

Note: The Unit is shipped with ‘PR20’ 20

Weight Compressor Oil in the Pump.
Verify the proper level as indicated
above before starting.

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 HDI-03-W
Mar ‘15
Safety Precautions

In order 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 information that

Important safety Information. indicates how to prevent
Information that you should
A hazard that may cause damage to equipment, or how
pay special attention to.
serious injury or loss of life. to avoid a situation that may
cause minor injury.

The following hazards may occur during the normal use

of the equipment. Please read the following chart.

Area: Hazard: Safeguards:

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

Relieve all pressure from the Unit

Tampering with the Unit while under full or partial
before attempting any repair or
pressure may cause an explosion.
maintenance work.

As the Unit starts and stops automatically, serious Shut off all power to the Unit before
injury may result from working on the Unit with the attempting any repair or maintenance
power still in the on position. work.

Shut off all power to the Unit before

As the Unit starts and stops automatically, do not
attempting any repair or maintenance
come into contact with moving parts.
work.

Air compressed by the Unit is not suitable for

Never directly inhale compressed air
inhaling. It may contain vapours harmful to your
produced by the Compressor.
health.

The Compressor Pump, Motor, and Tubing Never touch the Pump, Motor, or
become hot when running. Touching these areas Tubing during or immediately after
may cause severe burns. operation.

As the electrical components on the Unit are The Compressor must be a minimum
General Purpose, there is a potential for explosion of 20 feet (6.1 meters) from any source
should vapours be present in the area. of potentially explosive vapours.

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 HDI-03-W
Mar ‘15
Preventative Maintenance Schedule

Noted below are general maintenance guidelines which must be followed and documented, this in accordance
with the DV Systems Warranty. It is based on an approximate Compressor usage of 30 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 re-install the Beltguard after adjusting the Belts or Pulleys.

Every 3 Months

Every 6 Months
Insist on Genuine DV

Year Maint.

3 Year Maint.

4 Year Maint.

5 Year Maint.

6 Year Maint.

7 Year Maint.
1 Year Maint.
Systems parts and kits

Monthly
when maintaining your Weekly
Compressor Unit and
Daily

Pump.
Notes

nd

rd

th

th

th

th
st
Normal Maintenance

2
Drain moisture from Air Receiver

Check oil level and top up as required

Replace Air Filter 1

Replace Oil (mineral) 2
‘Normal Maintenance’
Check condition/alignment of Belts/Pulley
items at left to be carried out
regularly throughout the years.
Check Safety Valves

Check that Unit unloads when shutting down

Clean and/or blow dust/dirt off Unit

Replace 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. Mineral Oil is available separately or in a Maintenance Kit. Consult your Pump bulletin.
3. Synthetic Oil is available separately or in a Maintenance Kit. Consult your Pump bulletin.
4. Belts are available through your local DV Systems Distributor.
5. Valve Discs and Springs are available separately or in a Kit. Consult your Pump bulletin.
6. The CPR Unloader Assembly and Kit is noted in your Pump bulletin.

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Mar ‘15
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:

1) Stop any further unpacking or operation of the product.
2) Make note of the problem on the Freight Bill, should it concern a shortage or visible
damage to the product.
3) 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.
4) Do not attempt further unpacking or operation of the product. Also, do not discard
any packing material used.
5) 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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Mar ‘15
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 Intercooler

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

Aftercooler Tube Beltguard

Allows the compressed air Protects personnel from the
to cool as it transfers from moving parts of the Flywheel,
the Pump to the Tank. Pulley, and Belts.

Electric Motor

Check Valve Pressure Switch

Allows the compressed air A Switch which starts and
to enter the Tank, but stops the Unit at a
prevents it from flowing predetermined minimum
back out. and maximum pressure.

Pressure Gauge
Reflects Tank pressure.

Safety Valve
Protects the Tank if
pressure is too high.

Ball Valve
Discharge/outlet from
Tank.

Air Receiver (Tank) Magnetic Starter Drain Valve

Stores the compressed air. An electrical device which Allows the Customer to
receives a signal from the drain moisture from the
Pressure Switch and Tank.
allows power to flow to the
Motor.

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.

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Mar ‘15
Installation – Mechanical

Location of the Unit.

Items to consider when installing the Unit are as
If installing the Unit on a mezzanine, ensure
follows: that the structure can safely support the weight
of the Unit. As well, the sound level of the Unit

The Unit should be located in a dry, clean, cool, may increase due to the harmonics created by
dust free, and well ventilated area. If possible, the the structure; use Vibration Pads to lessen this.
Compressor should be located in a separate
room or area, away from the general operations
If anchoring the Unit, ensure that there is
of the shop. approx. ¼” (0.75 cm) between the Nut and the
Compressor Foot (as shown below). Do not

Allow a minimum of 18” around and 24” above bolt down tightly.
the Unit, this being for both the proper ventilation ¼” (0.75 cm)
of the Unit and ease of servicing. Compressor Gap
Foot

18” (0.5 m) Isolator

Building minimum Pad
Wall, etc Floor
Beltguard

Compressor
(& Opposite)

Never clamp or bolt Air Receiver Feet to the

floor or support structure. Doing so can

Ensure that the floor under the Unit is smooth, greatly increase stress on the Tank, causing
level and capable of bearing the weight of the it to weaken and/or fracture.
Compressor. The Compressor must sit squarely
on the floor.

DV Systems has available Installation Kits which

include (4) Vibration Isolator Pads and (1) The Compressor must not be operated in a
Stainless Steel Flex Hose. 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).
DV Systems ‘HDI’ Compressor
Many common Compressor problems can be
Installation Kit Horsepower
attributed to the location or installation of the Unit.
IK515 5 to 15 HP Make sure the Unit is in a suitable location, and
installed correctly.
IK2530 25 and 30 HP

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 HDI-03-W
Mar ‘15
Lubrication

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 Do not attempt to operate the Unit without
basis. This must be done when the Unit is off. Top up first checking whether there is oil in the
the Oil level on a monthly basis. Pump Crankcase. Add oil as required.
Serious damage may result from use,
Use only DV Systems Premium Compressor Oil. Also, however limited, without oil.
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.
Use of improper oil may negatively affect
Fill the Oil Reservoir to the bottom thread at the Oil Compressor performance or shorten Unit life.
Filler Plug. Do not under or overfill. See drawing below. Resulting problems are not covered by the
DV Systems Warranty.

Oil Filler Plug

With limited Compressor use or installing in a

very humid environment, condensation
Proper Oil Level
(to bottom thread of Oil Fill Port) (water) may form in the Crankcase with the
oil. If this occurs, change the oil more often
O Ring
than indicated on the Maintenance Schedule.

Section Through Crankcase The following Maintenance Kits are available from
At Oil Fill Port your DV Systems Distributor. The Kits include both
the Oil and Filters.

The following oils are available from your DV Kits c/w 20 Weight Mineral Oil
Systems Distributor. DV Systems Pumps Kit Part Number
DV Systems Room (Ambient) 123, 223 MK-223
Premium Mineral Oils Temperature
247 MK-247
20 Weight: ‘PR-20-4’ Up to 90°F (32°C)
447 MK-447
30 Weight: ‘PR-31-4’ Above 90°F (32°C)
Kits c/w 20 Weight Synthetic Oil
DV Systems Premium Synthetic Oil is DV Systems Pumps Kit Part Number
used in high heat or high duty applications or
when Beltguard Aftercoolers are used. 247 MKS-247
20 Weight: ‘OJ-2000’ 447 MKS-447

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 HDI-03-W
Mar ‘15
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 must be carried out by
a competent Electrician, and be done in such a way
that it meets all applicable Codes and Regulations.
Failure to correctly connect the
Compressor to your building's electrical
Ensure that a suitable Fused Disconnect or Breaker (by services may result in serious personal
others than DV Systems) is installed in the electrical injury or damage to the equipment.
supply before the Compressor Unit.

Before servicing the Unit, ensure the power
A Magnetic Starter must be an integral part of the source has been shut down and locked off.
Compressor Unit circuit as it provides overload
protection to the electric Motor. A Magnetic Starter can
Read and understand the information
be purchased separate from the Unit, or factory- contained in this manual before installing
mounted at the time of Unit manufacture. or operating the Unit.

Failure to observe any of the above

precautions could result in severe personal
injury or death, and/or damage to the Unit.
Main Fuse
Box

Fused Disconnect L1 L2 L3
or Circuit Breaker
Correct Pump
Rotation

Magnetic
Starter

Coil

Pressure
Switch

Motor

Typical Electrical Installation Typical Magnetic Starter Wiring

Of a Compressor Unit (Subject to Local Codes and Authorities)

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Mar ‘15
Installation – Electrical (cont’d)
Motors. Why Hire a Licensed Electrician?

Ensure that the voltage on your site is reflected on the To ensure that your new DV Systems Unit works as
Motor nameplate, +/- 10%. In the case of 208 volts 3 designed and required, you must ensure that it is
phase electrics, the Unit must be 200 volt 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
Use of an incorrect Motor for your particular Compressor have been installed and wired
building service will result in premature Motor correctly.
failure, something not covered by the DV
The wiring of the Unit meets with all applicable
Systems or Motor manufacturers Warranty. codes and regulations.

When completed, the Unit works in both a safe
and correct manner.
The Warranty that exists on the Electric Motor is that of
the original Motor manufacturer. In the event of a Motor Failure of the Compressor Unit due to an incorrect
failure, contact your DV Systems Distributor or Service electrical installation is not covered by the
Centre for the location of the nearest authorized Motor manufacturer’s warranty.
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.

When facing the Compressor

(as shown at right), the
Flywheel must rotate in a
clockwise direction.

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 HDI-03-W
Mar ‘15
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) Remove the Oil Filler Plug, and ensure that there
is sufficient Oil in the Crankcase. Refer to the
‘Lubrication’ section (Page 8) in this manual for
Do not place any materials in close proximity
proper type and level of Oil.
to the Compressor. Placing materials against
or close to the Unit will limit the cooling
2) Replace the Oil Filler Plug, and use a
required, and could lead to premature failure.
crescent wrench to tighten snug plus 1/4 turn.

3) Do a visual inspection of the Unit, and ensure

6) After having run the Unit unloaded for 30
that all Bolt heads are sufficiently tightened. This
minutes, close the Ball Valve, and allow the Unit
must be done, as some fasteners may become
to reach maximum operating pressure.
loose in transit.
7) Ensure that the Compressor shuts off at the
4) Turn the Compressor 'On' momentarily by
factory preset maximum pressure, and the head
positioning the Fused Disconnect or Breaker in
pressure is released through the Unloader at
the 'On' position. Ensure that the Flywheel is
either the front of the Pump (the ‘CPR’) or at the
turning in the correct direction. See the ‘Pump
Pressure Switch.
Rotation’ (Page 10).
8) Measure the amp draw as the Unit reaches
maximum pressure.

9) 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.

Shut off all power to the Compressor Unit

5) Open the Compressor’s Ball Valve, and start the before attempting any repair or maintenance.
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. 10) With the Unit shut off, check the oil level in the
Pump. Add oil as necessary.

11) After the Unit has run for 40 hours (or 2 weeks),
retorque the Pump Bolts. Refer to the appropriate
Pump Bulletin for torque values.

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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 HDI-03-W
Mar ‘15
Compressor Unit Accessories

‘AD-9400’ Pneumatic Autodrain.

The ‘AD-9400’ Pneumatic Autodrain is designed to drain moisture from the Compressor Tank each time the Unit
reaches maximum pressures and shuts off. It receives its signal as the Unit unloads once the Unit has shut down.
Reservoir
Specifications.

Maximum working pressure of 200 psi (13.8 Bar).

Minimum working pressure of 30 psi (2.1 Bar).

Will not operate in temperatures below freezing. Signal from
Unloader
Maintenance. Moisture from

Service/maintenance can only be done when the drain is Tank
not under pressure.

The internal screens must be cleaned periodically.

The ‘RK-AD-9400’ Repair Kit is available.

Drain
‘KK-9840-1’ Electronic Autodrain. Port

The ‘KK-9840-1’ Electronic Autodrain is designed to drain moisture from the Compressor Tank based on an
internal timer. The timer is an electrical device which requires 120-60-1 power to operate, and can be plugged into
a standard outlet. A 6 foot (1.8 m) power cord is supplied.
Electronic
Specifications. Timer

Maximum working pressure of 230 psi (16 Bar).

Includes manual Ball Valve and Filter.

Drain duration can be set between .05 to 10 seconds.

Operating cycle time (time between discharges) can be
set between 1 to 45 minutes. Condensate
Discharge

UL and CSA approved.

Will not operate in temperatures below freezing. Ball
Valve
Maintenance.

Service/maintenance can only be done when the drain is
not under pressure.

The internal wire mesh filter must be cleaned Internal Wire
periodically. Mesh Filter

‘KK-9860’ Zero Loss Autodrain.

The ‘KK-9860’ Zero Loss Autodrain is designed to drain moisture from the Compressor Tank once the cavity
inside the Autodrain has become full. This eliminates the unnecessary draining of the Tank and purging of
compressed air. The Autodrain is an electrical device that requires a 120-60-1 power supply, and is supplied with
a 6 foot (1.8 m) power cord.
Specifications.

Maximum working pressure of 175 psi (12 Bar).

Includes manual Ball Valve and Filter.

IP65 Electrical Protection Rating.

Will not operate in temperatures below freezing.

Maintenance.

Service/maintenance can only be done when the drain is not under
pressure.

The internal wire mesh filter must be cleaned periodically.

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Mar ‘15
Compressor Unit Accessories (cont’d)

‘OM-9400’ Oil Monitor.

The ‘OM-9400’ Oil Monitor provides a means of ensuring that there is sufficient oil in the Pump during normal
Compressor Unit operation. It contains a Micro-switch which registers the level of the oil in the Pump. Should the
level of the oil drop below a preset level, the Micro-switch will open, causing the Unit to shut off.

The Oil Monitor is an electrical device, and requires 120 or 230 volts to operate. On Units where the voltage is
460 or 575, a Step-down Transformer or alternate power source must be provided by a Licensed Electrician. The
Electrician must ensure that the wiring of the Monitor(s) meet with all applicable codes and regulations.

Please be advised that, in some instances, the Level Indicator may read as ‘Low’ on the Monitor. This is
acceptable. Please test the Monitor regularly to ensure it is functioning correctly.

Specifications. Oil Level

Indicator

Die cast aluminum case.

Internal brass float registers oil level.

Lens allows viewing of oil level.

Suitable for use with voltages up to 230 v ac.

Maximum working pressure of 25 psi (1.72
Bar). Electrical
Connection
Maintenance.

Test the Monitor on a regular basis to ensure it
is working properly.

To do this, simply turn the Test Knob in a
counter-clockwise direction, there-by leading
the Switch to believe the oil level is too low,
and shutting the Unit off.

Electrical Access
Panel Test Knob
Beltguard Aftercooler.
A Beltguard Aftercooler is used to decrease the temperature 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.

Maximum working pressure of 175 psi (12.08
Bar).

Reduces the temperature of the compressed
air by approx. 100°F.

Use only the DV Systems ‘OJ2000-K1’
Synthetic Oil in the Compressor Pump.

Maintenance.

The Beltguard Aftercooler must be cleaned
with compressed air on a regular basis.

Use only DV Systems ‘OJ2000-K1’ Synthetic
Oil in the Pump to inhibit carbon build-up in the
Valves. Beltguard
Aftercooler

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Mar ‘15
Compressor Unit Accessories (cont’d)

Alternator Relays on Duplex Compressor Units.

An Alternator Relay is used with a Duplex Compressor Unit, namely a
Unit with two Pumps and two Motors on one large Tank. Coupled with
two Magnetic Starters, the Alternator Relay allows the Pumps to
alternate back and forth. This is necessary to spread the compressed air
load over the two Pumps.

Designating the Pump and Motor assemblies on the Tank as being Unit
#1 and Unit #2 allows the 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’ pressure of ‘PS2’. (For example, this will occur when the Unit is
started at 0 psi in the Tank.)

Duplex Units having voltages of 460 or 575 have a Step-down Transformer and Primary and Secondary Fusing.

Shown below is a typical schematic for a Duplex Unit c/w (2) Magnetic Starters and Alternator Relay.

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Mar ‘15
Compressed Air System Design

In designing a compressed air system, there are several factors that must be considered. Though cost may be a
factor in most designs, it cannot be the final determining factor, especially where air quality, air volume, and air
pressure are critical.

Shown below is a typical layout of a compressed air system.

E G

B B C
F H

Item: Component: Description:

Is the heart of the compressed air system. Ensure it is sized properly

A Air Compressor for the application, installed in a correct and safe manner, and in
maintained according to the maintenance guidelines.
Absorb any vibration caused by the normal operation of the Unit, allow
B Vibration Isolators for any irregularities in the floor, and help to make the Unit marginally
quieter.
Drains the Compressor Tank on a regular basis. Available as either
C Automatic Drain
pneumatic or electronic operated.
Protects the building air lines from vibration caused by the
D Flex Hose Compressor, and allows for any misalignment between the
Compressor outlet and building piping.
Acts as a pre-filter to the Refrigerated Air Dryer. Generally a ‘Cyclone’
E Separator Filter
or 10 micron Filter.
Removes the moisture from the compressed air by lowering the
F Refrigerated Air Dryer
temperature of the air to a few degrees above freezing.
Removes oil from the compressed air. Available in 1.0 micron and
G Coalescing Filter
0.01 micron.
Separates the oil from the moisture drained by the Compressor Tank,
Refrigerated Air Dryer, and Filters. Oil is trapped by internal Filters,
H Oil Water Separator
while the separated water is allowed to be dispensed to the building
drain.
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Mar ‘15
Compressed Air System Design (cont’d)

Compressed Air Piping.

A good compressed air system not only includes the items as noted on the previous page, but it also deals with
the design of the compressed air piping system in the building. Several factors that ensure a correct air system
design are as follows:

Use a full loop piping layout whenever possible. This limits pressure losses.

Run the Compressor and distribution system at high pressure. Regulate the air pressure at the point of
use.

Use a suitable size of piping (based on Compressor CFM and length of piping) to keep the total pressure
drop in the system below 1 psi.

Always take drops from the top of the main headers.

Join pipe lengths with tees in order that additional drops can be added easily at a later date.

Piping material must meet all applicable provincial/state and federal codes and regulations.

Correct Piping Size. Piping Material.

As noted above, determining the correct size of As with the correct sizing of the compressed air
piping is based on a) the size of the Compressor and piping, the material used must also be considered.
b) the length of piping. Incorrectly sizing the piping Though cost might be a concern, correct air flow,
will adversely affect the pressure or volume of air at quality, safety, and longevity are factors that will out-
the point of use. weigh the initial cost.

Length of Piping Many types of piping can and have been used in
Unit
compressed air systems. These include (but are not
HP 0’ – 100’ 100’ – 200’ 200’ + limited to) PVC, iron, galvanized iron, and copper
½ ½” ½” ½” piping.

1 ½” ½” ½” Until recently, copper pipe has proven to be the best

material available to date for a compressed air
1-½ ¾” ¾” ¾”
system. There are now available piping systems
2 ¾” ¾” ¾” which include the piping and all necessary fittings.
These have become relatively easy to install, cost
3 ¾” ¾” 1” affective, and will last for many years.
5 ¾” ¾” 1”
Contact your DV Systems Distributor, as DV Systems
7-½ ¾” 1” 1-¼” offers Transair piping systems.
10 1” 1-¼” 1-½”
15 1” 1-¼” 1-½”
25 1-¼” 1-½” 1-½”
30 1-¼” 1-½” 1-½”

The size and materials used in the piping system may be

governed by local Codes or Regulations. Please consult local
authorities to ensure that your system design meets with all
applicable criteria.

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Mar ‘15
Refrigerated Air Dryers

As discussed earlier, a Refrigerated Air Dryer may be part of your compressed air system. Shown below are two
Refrigerated Air Dryer models that are available through DV Systems, namely the ‘ASD’ and ‘HTD’ Dryers.

‘ASD’ Dryer Unit ‘HTD’ Dryer Unit

Has a maximum inlet temperature of
Has a maximum inlet temperature of
120°F. 180°F.

Must have approx. 20 feet of piping
Should have approx. 5 feet of piping
between the Compressor outlet and between the Compressor outlet and
Dryer inlet. Dryer inlet, this simply for servicing of the
Units.

More detailed information concerning the Dryer Unit is included in the Dryer manual. The information contained in
this manual is a ‘quick reference’ only.

Dryer Controls.

LED’s for
Compressor,
Drain, and Fan

3 Digit
Readout
On/Off
Button

Test/Programming
Buttons

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 HDI-03-W
Mar ‘15
Refrigerated Air Dryers (cont’d)

Typical Dryer Operation.

The Dryer will operate as follows:

• Pressing the ‘On/Off’ Button for 3 seconds will start the Unit
• There is a time delay of up to 2 minutes before the Refrigerant Compressor starts.
• The Condenser Fan will start approx. 20 to 30 seconds there-after.
• The Fan will not normally run at full speed, this indicated by a flashing LED
• The readout will initially show ambient temperature indicated by 3 horizontal bars on the readout
• Once the Fan and Compressor start, the dew point of the Unit will decrease to approx. 1°C, this indicated
by 1 or no horizontal bars.
• Pressing the ‘On/Off’ Button (when the Unit 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.)

ON The Unit is ON with a normal load and is operating correctly.

• 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:

Energy Saving Mode.

ESA • The Dew Point has been running at below -1°C for over 6
minutes.
• The Unit will automatically restart operation at 6°C.

Temperature Probe Alarm.

• The Temperature Probe is not working properly. It may

PF I not be connected to the Board, or the Probe may be

defective.
• Replace the Probe if necessary.

High Temperature Alarm.

• The Dew Point has been running at above 12.5°C for
over 6 minutes. The Unit must be manually turned off and

H t A on.
• The fault could be caused by a dirty radiator, high
ambient temperature, a faulty Fan, or a faulty refrigerant
Compressor, to name only a few.

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 HDI-03-W
Mar ‘15
Compressed Air Filter Assemblies

Typical Filter Assembly.

As indicated previously, suitable filtration may be critical applications where a) a Refrigerated Air Dryer is used,
and b) where good quality air is required downstream. Shown below is a typical Filter Canister with the ‘Cat-eye’
Indicator. Also, shipped with the Filter Element is a label as shown below right. Affix the label to the outside of the
Canister, as it indicates the correct Filter Element when it comes time to re-order.

Arrow Indicates Cat-eye Gauge

Direction of Air Flow Green = Filter Element is Clean
Red = Filter Element is Dirty

The label shown above is included with the

replacement Filter Element, and should be
affixed to the outside of the Bowl for future
reference.

Bowl which Contains

AutoDrain Filter Element and
AutoDrain

Filter Element Replacement.

To replace 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 once again under pressure.

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 HDI-03-W
Mar ‘15
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. No power to the Unit. Check that power at the disconnect or breaker
is on. Also, check any fuses.

Pressure may not be low enough in the Drop pressure below the Pressure Switch ‘cut-
Tank to allow the Unit to start. in’ pressure.

Loose and/or missing wires in the electrical Check that all wiring connections are tight.
circuit. With a wiring schematic, check that all wiring is
present and correct.

Starter Overload is tripped. Reset the overload in the Magnetic Starter.

If an Oil Monitor is mounted on the Unit, the Check the oil level and add oil as required.
oil level in the Pump could be too low.

B. No or Insufficient Air Air Filter is dirty. Replace the Air Filter.

Flow.
Restricted air intake piping if a remote air Clean the intake Filter and piping.
intake is used.

Loose Belts. Tighten as required. Do not over-tighten.

Pump Valves, Aftercooler, or Tank Check Clean, repair, or replace.

Valve leaking, sticking, or plugged.

Air leaks at Compressor in piping system. Fix leaks. Soap/water mixture will assist in
finding small leaks.

Unit is too small for the compressed air Contact your DV Systems Distributor for
requirements. assistance.

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 HDI-03-W
Mar ‘15
Trouble Shooting Guide (cont’d)

Condition: Cause: Suggested Correction:

C. Excessive Noise. Normal sound amplified through floor or Mount Unit on Vibration Isolators. Insulate
carried through remote air intake, when remote intake piping from building.
used.

Loose Beltguard, Flywheel or Motor Pulley. Tighten as required.

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

If noisy only during start-up, check for loose Tighten Belts until no slippage is apparent.
Belts.

Unit not installed level. Ensure the Unit is mounted level. Use Vibration
Pads.

Improper level or grade of oil in Pump. Use correct DV Systems oil, and check that
level is correct.

Carbon or other foreign material on Piston Clean top of Piston. Check Cylinder walls for
head. scoring.

If the Pump is knocking, and cannot be Worn Main Bearings can usually be detected by
attributed to any of the above, the Bearings noticeable end play on the Flywheel. Replace
in the Pump may be worn. 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 Ambient temperature is too high. Introduce cool air, better air flow, or move Unit
of Unit and Excessive to cooler location.
Carbon Build-up.
Little or no air circulation around and over Check the air circulation around the Unit.
Unit. Ensure Flywheel rotation is correct, and there is
18” minimum around and 24” above Unit.

High percentage of running time. Check for air leaks. If no air leaks are present,
the Compressor may be too small for the
application.

Obstructed Air Filter or air intake piping (if Clean or replace as necessary.
remote air intake is used).

Too much oil in the Pump. Reduce the amount of oil in the Pump.

Using wrong type of compressor oil. Change to the factory recommended oil.

Worn Valves. Check and repair as necessary.

Worn Piston Rings. Replace Piston Rings as necessary.

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 HDI-03-W
Mar ‘15
Trouble Shooting Guide (cont’d)

Condition: Cause: Suggested Correction:

E. Appearance of Water in Tank is not being drained regularly. Drain the Tank on a daily basis. Purchase a
the Air Lines and/or Oil Tank Autodrain if required.
‘milky’ in Colour.
Unit is not being used enough to burn off If using the Unit very infrequently, run for 30
any water in the Pump. 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.

F. Compressor Over- Undersized Unit for air requirements. Maximum operating time, based on an 8 hour
heating. day, is 75% to 80%, which related to 45 minutes
per hour.

Dirt accumulation on outside of Pump. Clean Pump.

Compressor too close to building Move Compressor so Beltguard is a minimum of

wall/obstructions. 18” away from nearest obstruction. See Page 2.

Pump rotating in wrong direction. Correct rotation of the Flywheel. See Page 10.

Air leaks on Unit or in air lines. Fix leaks. Soap/water mixture will assist in
finding small leaks.

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

Restricted Air Intake Filter. Replace Air Filter.

Improper level or type of oil in Pump. Refer to ‘Lubrication’ on Page 8.

Worn or carbonned Valves in Cylinder Head, Clean or replace as required.

Aftercooler Tube, or Check Valve.

G. Belts Roll Off Motor Flywheel and Motor Pulley are not aligned. Align using a straight edge.
Pulley and/or Flywheel.
If two or more Belts are used, Belts may not Purchase a new set of matched belts.
be matched set.

A nick or tear on the edge of a belt. Purchase a new set of matched belts.

Belts do not match the Flywheel/Pulley Purchase a new set of Belts, paying close
groove (such as ‘A’ or ‘B’ section). attention to ‘A’ or ‘B’ section requirement.

H. Flywheel or Motor Pulley Clamping Bolt not tight on Flywheel. Tighten as required.
Wobbles or Comes
Loose. Set Screw on Motor Pulley came loose. Take existing Set Screw out and purchase new
one. Set Screws have Loctite coating, and can
only be used once.

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 HDI-03-W
Mar ‘15
Trouble Shooting Guide (cont’d)

Condition: Cause: Suggested Correction:

I. Crack in Air Receiver. This condition is rare, and can be caused by

damage during transit or incorrect mounting
on site. Do not attempt to repair the Tank. Do not
continue to operate the Compressor Unit.
Contact your local DV Distributor for further
guidance.

J. Compressor Pump Started without oil in the Pump.

Seizes.
Pump ran low on oil.

Worn Connecting Rod bearing Inserts.

The Pump will require a complete overhaul, at
Piston and Pin Assembly seized. which time the defective parts must be replaced.

Worn Crankshaft Bearings.

High ambient temperature or very high duty

cycle.

K. Oil Leaks or the Oil was spilled when filling the Pump. Use care when filling with oil. Wipe any spills
Appearance of Oil on the immediately.
Compressor.
Over-filling of the Pump with oil. Drain oil until proper level is reached.

Leak at Oil Fill Plug. Check Filler Plug. Change O Ring.

Leak at Oil Drain. Ensure Pipe Nipple and Cap are sealed.

Oil leak at Gaskets, Cap Screws, Cylinder Initially, retorque fasteners to factory specs. If
Head, Cylinder, or Crankcase. leaks persist, replace Gasket. Use Loctite Form-
a-Gasket on Head Bolts and Crankcase to
Cylinder Bolts.

Oil Seal leak. Inspect Crankshaft for any scratches or burrs.

Use emery cloth. Replace Oil Seal as required.

L. Unloader Does Not Unloader may be dirty or faulty. Clean, repair, or replace.
Function, or Leaks When
Unit Operating. If using a CPR, the Pump may not be Ensure the Pump is operating at a minimum of
turning fast enough for CPR Valve to close. 500 rpm.
Minimum rpm for CPR Valve to close is 500
rpm.

M. Unloader Leaks The Disc inside the Tank Check Valve is not Clean or replace the Check Valve as required.
Constantly When Unit is seating properly, allowing the compressed
Not Operating. air in the Tank to escape.

N. Intercooler Safety Valve Dirty or defective Valves will cause back Clean, repair or replace the Valves.
Pops Continuously. pressure.

Intercooler clogged with carbon. Clean or replace.

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 HDI-03-W
Mar ‘15
DV Systems Limited Warranties
Heavy Duty Industrial Air Compressors

DV Systems 7 Year Limited Pump Warranty.

DV Systems has implemented a 7 Year Limited Pump Warranty, this being unprecedented in the Piston
Compressor market. The Warranty reflects the DV Systems commitment to providing quality Air Compressor
Units to our Customers, this being the cornerstone of our long history in building Heavy Duty Industrial Air
Compressors.

The ‘7 Year Limited Warranty’ applies only to those Pump Assemblies that:

are provided on and sold as a complete DV Systems ‘HDI’ Heavy Duty Cast Iron Compressor Unit. Pumps
sold as ‘separate sale items’ or being installed on Units having the ‘IS’ or ‘SDI’ designation are governed by
their own Warranty applicable to that product.

have been manufactured by DV Systems after January 1, 2007.

have been registered with the manufacturer within thirty (30) days from the date of purchase or 7 months from
the date of manufacture (whichever occurs first), this done by returning the completed ‘Warranty Registration
Card’ by email, fax, or post or by registering the warranty online at www.dvcompressors.com.

have been maintained in accordance with the DV Systems ‘Preventative Maintenance Schedule’ as provided
here-in.

have been maintained and serviced using only ‘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 as a complete DV Systems ‘HDI’ Heavy Duty Cast Iron Compressor Unit. Motors
sold as ‘separate sale items’ or being installed on Units having the ‘IS’ or ‘SDI’ designation are governed by
their own Warranty applicable to that product.

are provided on ‘HDI’ Units manufactured by DV Systems after January 1, 2007.

have been registered (along with the Compressor Unit) with DV Systems within thirty (30) days from the date
of purchase or 7 months from the date of manufacture (whichever occurs first), this done by returning the
completed ‘Warranty Registration Card’ by email, fax, or post or by registering the warranty online at
www.dvcompressors.com.

have been maintained in accordance with the manufacturer’s recommendations as provided with the Unit.

are property of the original owner. The warranty is not transferrable.

The ‘Five Year Limited Motor Warranty’ includes repair parts / Motor assemblies only, this at the discretion of DV
Systems. Any costs of labour, shipping, or travel incurred are not included in the Limited Warranty.

Please note that single phase Motors are explicitly excluded from this Warranty.

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 HDI-03-W
Mar ‘15
DV Systems Limited Warranty
Heavy 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 one (1) year from the date of purchase, not to exceed
eighteen (18) 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.

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 for travel or lodging beyond a 100 kilometre (60 mile) distance or 1 hour driving time from the
nearest DV Systems Authorized Service Centre;
• 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 DV Systems Ltd. - US

490 Welham Road, 128-B Talbert Road
Barrie, ON Mooresville, NC
L4N 8Z4 28117
Tele: (705) 728-5657 Tele: (704) 799-0046
Fax: (705) 728-4974 Fax: (704) 799-0355
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 HDI-03-W
Mar ‘15
DV Systems ‘HDI’ Unit Warranty Registration

Please complete this form and return to DV Veuillez compléter ce formulaire et le retourne a
Systems Inc. via email, fax, or mail. Failure to DV Systems Inc. par courrier électronique, fax ou la
return this Registration will result in a One Year poste. A l’absence de nous fournir ce formulaire, la
Unit/Pump/Motor Warranty only. garantie standard de 1 ans demeura seulement
pour l’unité/pompe/moteur.

Unit is installed at: To Be Completed by Installer/Service Technician.

Unité est installée à : A remplir par l’installateur/technician.

Name: Compressor Model:

Nom: Modele du Compresseur:

Title: Serial Number:

Fonction: Numero de serie:

Company: Installation Date:

Entreprise: Date d’installation:

Address: Installer’s Name:

Addresse: Nom de l’installateur:
Installer’s Company:
Nom de l’entreprise:
City:
Ville:

Prov/State: Unit Purchased From:

Prov/Etat: Lieu d’achat:

Who Will Service Unit?

Postal/Zip:
Responable du d’entretien?

Telephone:

Service Contract? Yes No

Fax:
Contrat d’entretien? Oui Non

Email:

As indicated above, please forward this completed Tel que mentionné veuillez nous faire parvenir le
form to: formulaire complété a:

Email: sales@dvcompressors.com
Fax: (705) 728-4974

As well, this form can be completed on-line at Vous pouvez aussi trouver et remplir se formulaire
www.dvcompressors.com sur notre site web www.dvcompressors.com

DV Systems Inc. - Canada DV Systems Ltd. - US

490 Welham Road, 128-B Talbert Road
Barrie, ON Mooresville, NC
L4N 8Z4 28117
Tele: (705) 728-5657 Tele: (704) 799-0046
Fax: (705) 728-4974 Fax: (704) 799-0355
© Copyright DV Systems Inc. 2014
Printed in Canada

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