Devair HDI-01 Manuel

HDI-01

Mar ‘07

All of the Policies and Procedures in this reference manual apply

exclusively to Devair Inc., here-in after referred to as Devair.

If you require assistance, contact your Devair Distributor or Authorized Service Centre. If you wish to contact

Devair directly or need to locate your closest Distributor, please reach us at :

Phone: (705) 728-5657 Fax: (705) 728-4974 Email: sales@dvair.ca Web: www.dvair.ca

...

‘Heavy Duty

Industrial’

(HDI)

Air Compressor

Installation

Maintenance

and Service

Data

...

Contents

Contact Information

Safety Precautions

Preventative Maintenance

Unpacking & Inspection

Unit Identification

Compressed Air System Design

Compressor Terminology

Installation - Mechanical

Pump Lubrication

Installation - Electrical

Accessories - Pneumatic Autodrain

Accessories - Electronic Autodrain

Accessories - Oil Monitor

Accessories - Beltguard Aftercoolers

Accessories - Duplex Alternator Relays

Initial Start-Up Procedures

Trouble Shooting

Devair Warranty Statement

Page

Cover

3-4

11-12

15-16

20-23

As the owner of a new Devair Air

Compressor Unit, it is your

responsibility to ensure that it is

installed correctly, as well as

maintained and serviced on a

regular basis. Information has been

included in this booklet to not only

familiarize you with your Unit, but

also to guide you in the installation,

maintenance, and trouble-shooting

of your Unit.

It is important that you read this

information, and keep it handy for

future reference.

Distributed by: CENTRAIR Air Systems & Supplies

68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458

[email protected] www.centrair.ca

All manuals and user guides at all-guides.com

all-guides.com

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

read the following chart.

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.

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 Compressor with

the power still in the on position.

Shut off all power to the Unit before attempting to

repair or maintain the Compressor.

What to look for. How to avoid the hazard

What may occur if precautions are not

observed.

Area: Hazard: Safeguards:

Important safety information. A

hazard that may cause serious

injury or loss of life.

Important information that indicates

how to prevent damage to

equipment, or to avoid a situation

that may cause minor injury.

Information that you should pay

special attention to.

NOTE

- 2 -

Safety Precautions

As the Unit starts and stops automatically, do not come

into contact with moving parts.

Shut off all power to the Unit before attempting to

repair or maintain the Compressor.

Air compressed by the Unit is not suitable for inhaling. It

may contain poisonous vapours harmful to your health.

Never directly inhale compressed air produced by

the Compressor.

Compressor Air End, Motor, and Tubing become hot

when running. Touching these areas may cause

severe burns.

Never touch the Air End, Motor, or Tubing during or

immediately after operation.

As the electrical compo-nents on the Compressor are

General Purpose and the Motor is Totally Enclosed

(TEFC), there is a potential for explosion, should

vapours be present in the area.

The Compressor must be a minimum of 20 Feet (6.1

Metres) from any source of potentially explosive

vapours.

20FT

6.1m

HDI-01

Mar ‘07

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

Noted below and to follow are the general maintenance guidelines which must be followed and

documented, this in accordance with the Warranty. It is based on the approximate Compressor usage of 40

hours per week. If your particular application varies from this, please adjust accordingly.

Daily Weekly Monthly Every 3

Months

Every 6

Months Yearly

Preventative Maintenance Schedule

HDI-01

Mar ‘07

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.

First Year Maintenance

Second Year Maintenance

Third Year Maintenance

Drain Air Receiver.

Check that Unit unloads when shutting down.

Replace Oil (mineral).

Check lubrication of Motor. Consult literature.

Check Oil level (and top up as required).

Clean and/or blow dust/dirt off Unit.

Check condition/alignment of Belts, Pulley, Flywheel

Inspect Valve Assemblies.

Replace Air Filter.

Replace oil (synthetic).

Check Safety Valves.

Inspect Check Valve.

Inspect Pressure Gauge.

Air Filters are available in the Maintenance Kit. Consult your Pump Bulletin for the appropriate Kit number.

Mineral Oil is available in the Maintenance Kit. Consult your Pump Bulletin for the appropriate Kit number.

Synthetic Oil is available in the Maintenance Kit. Consult your Pump Bulletin for the appropriate Kit number.

- 3 -

In the 2nd year of operation, the items as noted in the ‘First Year Maintenance’ must be done as well as the following:

In the 3rd year of operation, complete the items as noted in the ‘First Year Maintenance’.

Replace Valve Discs and Springs. (Replace Valve Assemblies as required.)

Replace Belts.

Belts are available through your local Devair Distributor.

Valve Discs and Springs are available through your local Devair Distributor. Consult your Pump Bulletin for

the appropriate Kit number.

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

Preventative Maintenance Schedule

HDI-01

Mar ‘07

Fourth Year Maintenance

Sixth Year Maintenance

Fifth Year Maintenance

Seventh Year Maintenance

- 4 -

In the 4th year of operation, the items as noted in the ‘First Year Maintenance’ must be done as well as the following:

In the 6th year of operation, the items as noted in the ‘First Year Maintenance’ must be done as well as the following:

In the 5th year of operation, complete the items as noted in the ‘First Year Maintenance’ on Page 3.

In the 7th year of operation, complete the items as noted in the ‘First Year Maintenance’ on Page 3.

Replace Valve Discs and Springs. (Replace Valve Assemblies as required.)

Replace CPR Kit.

Replace Pressure Switch.

Replace Safety Valves on Pump and Tank.

Replace Pressure Gauge.

Replace Belts.

Belts are available through your local Devair Distributor.

Valve Discs and Springs are available through your local Devair Distributor. Consult your Pump Bulletin for

the appropriate Kit number.

The ‘CPR’ (Centrifugal Pressure Release) is the Unloader which may be located on the front of the Pump.

The CPR Assembly and Repair Kit part numbers are located in your Pump Bulletin.

Belts are available through your local Devair Distributor.

Valve Discs and Springs are available through your local Devair Distributor. Consult your Pump Bulletin for

the appropriate Kit number.

Insist on Genuine Devair Parts and Kits

when maintaining your Devair Compressor

Pump and Unit.

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

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 Belt Guard.

b) If the Belt Guard appears damaged, remove the Guard and turn the Flywheel by

hand to ensure the Crankshaft has not been bent, and that the Belt Drive is properly

aligned and free of distortion.

c) Check the Air Tank and attached Legs for possible damage.

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

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 time-frames 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

Unpacking and Inspection

Each Devair ‘HDI’ 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 Devair products are the property of the Consignee when the

products leave our facility. Devair Inc. is not responsible for any damages or

shortages caused to the product after it has left our shipping dock.

NOTE

- 5 -

HDI-01

Mar ‘07

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

In the event that you must contact your Devair Distributor or Service Center (to purchase kits, parts, etc.),

you will be asked for the model number and serial number of your Compressor Unit and Pump. As well, you

may be asked for a copy of your Bill of Sale from the vendor from whom you purchased the Unit.

All of this information is required to ensure that you obtain the correct parts and/or service for your Devair

‘HDI’ Compressor Unit.

Electrics of Unit:

Date Purchased:

Pump Nameplate

Unit Nameplate

Serial Number of Pump:

Model Number of Pump:

Serial Number of Unit:

Model Number of Unit: Example: VAV-5062-69

Example: 12345 AB

Example: 230volt/60/3phase

Example: 447

Example: 54321

Unit Identification

12345 AB 175 psi

i) When a flammable liquid is sprayed, there may be danger of fire

or explosion, especially in a closed area.

Ii) Read operating instructions.

Iii) Arcing parts. Keep the Compressor at least 20 feet from explosive vapours.

For Parts and Service, always give Model and Serial Number.

VAV-5062-69

Devair Air Compressors

Model

Caution:

Serial Number Max. Press.

Model No.

500 Min RPM Lubrication

Serial No.

Max RPM @

PSI

447

54321

900 175

600 300

Devair

- 6 -

Compressor Identification

HDI-01

Mar ‘07

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

all-guides.com

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.

Air Compressor: is the heart of the compressed air system. Ensure it is sized for the

application, is installed in a safe and correct manner, and is

maintained according to the manufacturers guidelines.

Flex Hose: protects the building air lines from any undue vibration caused by

the Compressor, and allows for any mis-alignment between the

Unit outlet and the building piping.

Refrigerated Air Dryer: removes the moisture from the compressed air by lowering its

temperature.

Oil-Water Separator: separates the oil from the moisture drained by the Refrigerated Air

Dryer and Filters. The oil is trapped by internal Filters, while the

water is allowed to be dispensed to the building drain.

Separator Filter: acts as a pre-filter to the Refrigerated Air Dryer.

Coalescing Filter: removes oil from the compressed air

Vibration Isolators: absorb any vibration caused by the Compressor, allow for any

irregularities in the floor, and make the Unit marginally quieter.

Automatic Drain: drains the Compressor Tank on a regular basis.

Component: Description:

- 7 -

HDI-01

Mar ‘07

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

Please refer to the drawing below, as it identifies the major components of a typical Air Compressor Unit

and their function. (Some Units may vary slightly from this design, eg. gas powered or base-mounted

Compressors.

Please refer to the Compressor Pump Service Bulletin provided with your Unit to identify the

part numbers, location, and quantities for your particular Compressor Pump model.

Check Valve

One way Valve that allows air

to enter the Tank, but prevents

the air from flowing back into

the Compressor Pump

Compressor Pump

Compresses the air

Aftercooler Tube

This Tube leads the compressed

air to the Air Receiver while

allowing the air to cool

Intercooler Tube

This Tube cools the compressed air while

leading it from the low pressure Cylinder to

the high pressure Cylinder

Electric Motor

Belt Guard

Ball Valve

Discharge/outlet

Drain Valve

Allows the operator to drain

the moisture from the Tank

Air Receiver (Tank)

Pressure Switch

A pneumatically operated electric

Switch for starting and stopping the

Unit at predetermined minimum

and maximum pressures

Pressure Gauge

Gauge reflects current Tank

pressure

Magnetic Starter

An electrically operated device which

receives a signal from the Pressure

Switch and allows power to flow to the

Motor.

Compressor Terminology

- 8 -

Pump Components

HDI-01

Mar ‘07

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

The Compressor Unit must be located in a dry,

clean, cool, 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 room for easy access to the Unit for

maintenance purposes, as well as to ensure a

maximum cooling effect caused by the

Flywheel. To ensure that the Unit is cooling

properly, allow a minimum of 18” (0.5 m)

between the Beltguard and any adjacent wall,

etc. as shown below.

Ensure that the floor under the Unit is smooth

and level. The Compressor must sit squarely on

all four Feet.

Devair has available Installation Kits which

include a) (4) Isolator Pads for use under each

Foot, and b) stainless steel Flex Hose for

installation between the Unit Tank and the shop

piping.,

If anchoring a Unit to the floor, ensure that there

is roughly a 1/4” (0.75 cm) gap between the nut

and the Compressor Foot. Do not bolt down

tightly.

A Compressor Unit releases a great deal of heat

that, when not taken from the Unit area, could

cause severe problems. It is very important that

the Unit be located in a relatively large area or,

when in an enclosed area, cool air is introduced

and the heat is taken out, this by means of

intake and exhaust fans.

The amount of heat generated by an Air

Compressor is calculated by simply multiplying

the Unit Horsepower by 2500.

Example: 15 HP Unit x 2500 = 37500 BTU/hour

The Compressor must not be

operated in a confined area where

the heat from the Unit cannot readily

escape.

NOTE

Never clamp or bolt air receiver Feet

tightly to the floor or support

structure. Doing so may greatly

increase stress on the Tank, causing

it to weaken and/or fracture.

Installation - Mechanical

Location of the Unit.

18” (0.5 m)

minimum

Building

Wall, etc.

Floor

Isolator

Pad

Compressor

Foot

1/4” (0.75 cm)

Gap

Compressor

BeltGuard

Devair Installation

Kit Number

IK515

IK2530

5 To 15 HP

25 and 30 HP

‘HDI’ Compressor

Horsepower

- 9 -

HDI-01

Mar ‘07

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

Fill the Crankcase to the lowest thread at the Oil

Fill Port Opening. Do not under or overfill.

See drawing below.

Always replace the O-Ring when filling, and

tightly screw in Oil Fill Plug using a crescent

w r e n c h . U s e o n l y D e v a i r P r e m i u m

Compressor Oil for the Air Compressor, as it

has been specially formulated for your Unit, and

contains only two additives, a rust inhibitor and

an anti foaming agent.

The following Maintenance Kits are available

through your Devair Distributor, the Kits

including Devair Premium Oil and Air Filter (s).

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.

Use of improper Oil may negatively a f fect

Compressor Pump performance or

shorten Pump life. Resulting problems are

not covered by the Devair Inc. Air

Compressor Warranty.

Pump Lubrication

- 10 -

Devair Premium

Mineral Oils

Devair Pump Model

Devair Premium Synthetic Oil (used in

high heat or high duty applications or

when Beltguard Aftercoolers are used)

DV Lube20 (20 Wgt)

Part No. ‘PR20’

DV Lube30 (30 Wgt)

Part No. ‘PR30’

123

247

44642

OJ-2000 (20 Weight)

223

447

247

447

Up to 90°F (32°C)

MK-223

MKS-247

MK-247

90°F + (32°C +)

MK-223

MKS-447

MK-247

MK-447

Room (Ambient)

Temperature

Kit Part Number

'O' Ring

Proper Oil Level

(to bottom thread of Oil Port)

Oil Filler

Plug

Section Through CrankCase

at Oil Fill Port

Kits c/w Mineral Oil (20 Weight only)

Kits c/w Synthetic Oil

HDI-01

Mar ‘07

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9

Phone: 705-722-5747 Fax: 705-722-5458 [email protected] www.centrair.ca

All manuals and user guides at all-guides.com

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