B57-II-C

Jan ’16

B5 (T) (TD) & Contents: Page:

B7.5 (T) (TD) Quick Start ……………............................................. 2
Safety Precautions …………………………………… 4
Rotary Screw Unpacking and Inspection …………………………... 5
Air Compressor Installation – Mechanical ……………………………. 6
Lubrication ……………………………………………. 8
Units Installation – Electrical ………………………………. 9
--- Start-up Procedures …………………………………. 11
Preventative Maintenance Schedule ………………. 12
Installation Common Compressor Faults ……………..…………. 14
Separator Filter and Refrigerated Air Dryer ………... 15
And Trouble-Shooting Guide ……………………………… 18
Service Data Warranty ……………………………………………….. 21

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.

If you require assistance, please contact your local DV Systems Distributor or Authorized Service
center. You may contact the manufacturer directly as follows:

Phone: (705) 728-5657 (Canada) Web: www.dvcompressors.com

(704) 799-0046 (USA)
Fax: (705) 728-4974 (Canada) Email: [email protected] (Canada)
(704) 799-0355 (USA) [email protected] (USA)

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 B57-II-C
Jan ’16
Quick Start

Mechanical Installation.
(Refer to Page 6) 36”
[915 mm]

18”
[458mm]
18”
[458mm]
18”
[458mm]

The Unit should be located in a dry, clean, cool,

Note: Dimensions indicated are typical for all
dust free, and well ventilated area. variations of ‘B Series’ Units, ie base
mounted, vertical, or horizontal.
Allow a minimum 18” (458mm) around and 36”
(915mm) above Unit.

The ambient temperature should be between

10°C and 40°C (50°F and 104°F).
Drain condensate (water) from oil tank.
Ensure that the floor under the Unit is smooth, If compressor work cycle experiences long
level and capable of bearing the weight of the pauses, condensate will gather in oil tank.
Compressor. Drain condensate EVERY 50HRS OR WEEKLY.
(Refer to Page 8 for details)
If installed in a compressor room, ensure that the
room is adequately ventilated

Lubrication. Rotation.
(Refer to Page 8) (Refer to Page 10)

Ensure the oil level in the Air End is between the The correct rotation is as shown.
top (maximum) or bottom (minimum) thread as
shown. The Unit is equipped with an Anti-Rotation
Switch. Check that the rotation is correct.
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 B57-II-C
Jan ’16
Quick Start (cont’d)

Unit Operation.
Shown below is the ‘CSC50’ Controller which regulates the operation of the Unit. It is used to start and stop the
Unit, and it provides information as to system pressure, temperature, etc.

Starting the Unit: Press the ‘Start’ Button.

Stopping the Unit: Press the ‘Stop’ Button

Note:
1. Do not stop the Unit by use of a disconnect or breaker.

Using the disconnect, or breaker to stop the Unit will not allow the Unit to go
through an unloading sequence, and could result in damage to the Motor, Starter,
or other electrical components. Damage caused in this manner is not covered by
the manufacturers Warranty.

Digital Readout.
Provides system
pressure, temperature,
Start.
Allows the Unit to begin
etc.
compressing air.

Stop.
Causes the Unit to enter
‘Idle’ mode and then
shut off.

Up, Down, Enter & Reset

Used in the programming and changing
of operating parameters of the Unit.

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 B57-II-C
Jan ’16
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 may occur if precautions are not

What to look for. How to avoid the hazard.
observed.

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

As the Unit starts and stops Shut off all power to the Unit before
automatically, serious injury may attempting to repair or maintain
result from working on the Compressor the Compressor.
with the power still in the 'on' position.
As the Unit starts and stops Shut off all power to the Unit before
automatically, do not come into attempting to repair or maintain
contact with moving parts. the Compressor.

Air compressed by the Unit is not Never breath untreated compressed

suitable for inhaling. It may contain air produced by the Compressor.
vapours harmful to your health.

Compressor Air End, Motor, and Never touch the Air End, Motor, or
Tubing become hot when running. Tubing during or immediately after
Touching these areas may cause operation.
serious burns.
As the electrical components on the Do not install in hazardous locations.
Compressor are General Purpose, The Compressor must be a minimum
20FT
6.1m
there is a potential for explosion, should of 20 feet (6.1 meters) from any source
vapours be present in the area. of potentially explosive vapours.

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 B57-II-C
Jan ’16
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 the exterior of the Cabinet for damage, either cosmetic or mechanical.
c) If there is mechanical damage, open the Cabinet to determine whether there is any internal
damage to the Unit.

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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 B57-II-C
Jan ’16
Installation – Mechanical
Moving of the Unit.

When moving the Air Compressor, the forklift or

hand lift forks go under the Unit from the directions
as indicated.

When lifting from position ‘A’, use extended forks.

Please be advised that, though care must be taken

when moving all Units, extra care must be taken
when positioning a vertical Compressor as they are
top heavy.

‘A’

Location of the Unit.

Items to consider when installing the Unit are as If installing the Unit on a mezzanine, ensure that
follows: 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 structure; use Vibration Pads to lessen this.
the Compressor should be located in a
separate room or area, away from the general
operations of the shop. Many common Compressor problems can be
attributed to the location or installation of the Unit.
Allow approximately a minimum of 18” (458mm) Make sure the Unit is in a suitable location, and
around and 3 feet (915mm) above the Unit for installed correctly. The Unit should be located in a
easy access to the various sides, this being for dry, clean, cool, dust free, and well ventilated area.
both the proper ventilation of the Unit and ease If possible, the Compressor should be located in a
of servicing. separate room or area, away from the general
operations of the shop.
Ensure that the floor under the Unit is smooth,
level and capable of bearing the weight of the
Compressor. The Compressor must sit
squarely on the floor.

If installed in a compressor room, ensure that the

room is adequately ventilated. (One
Horsepower produces approximately 2500
BTU/HR.)
The Compressor must not be operated in
The ambient temperature should be between a confined area where the heat from the
10°C and 40°C (50°F to 104°F). Unit cannot readily escape.

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 B57-II-C
Jan ’16
Installation – Mechanical (cont’d)
Shown below are items which assist in making a good installation. These are both intake and exhaust ductwork,
helping the Unit to a) draw in clean outside air and b) exhaust the warmer air away from the Unit. The warmer air
may be used, with the inclusion of a damper in the exhaust ducting, to warm the interior of the building during the
colder months of the year.

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 B57-II-C
Jan ’16
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 Air
the Oil level on a monthly basis. End Reservoir. Add oil as required. Serious
damage may result from use, however
Use only DV Systems ‘DEV-3000’ Synthetic Oil. As limited, without oil.
well, do not mix the ‘DEV-3000’ with any other
lubricant.

Subsequent Oil Changes.

Drain the existing oil from the Unit. (Please be
advised that the Unit cannot be drained fully of oil, as
some oil may remain in various components ie Use of improper oil may negatively affect
Cooler, Tubing, etc.) Compressor performance or shorten Unit life.
Resulting problems are not covered by the
Fill the Oil Reservoir to the top of the Oil Fill Port as DV Systems Inc. Air Compressor Warranty.
shown below. Do not under or overfill. See drawing
below.

Use only DV Systems ‘DEV-3000’ Synthetic Oil,

available in both 1 US gallon (3.8 litre) jugs or 5 US
gallon (5 x 3.8 litre) pails. Any remaining oil may be
used for ‘top-ups’.‘
Condensation (water) may form in the Air End
The ‘MK-B57’ Maintenance Kit includes: if the compressor work cycle experiences
(1) US Gallon (3.8 litre) Oil (‘DEV-3000’) long pauses. If this occurs, the condensate
(1) Oil Filter (’DSC-603’) MUST be drained EVERY 50HRS OR
(1) Air/Oil Separator Filter (’DSC-002476’) WEEKLY:
(2) Air Filters (’DSC-001569’) - Wait for compressor to cool for approx.
2HRS.
This Kit should be used in the regular servicing of - Remove service panel
your Unit. - Slowly remove/open the oil drain cap/valve
on the air end & drain condensate
- When the first traces of oil appear, close
the cap/valve
- Top up the Air End with new oil using only
DV Systems ‘DEV-3000’ oil.

Air End

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 B57-II-C
Jan ’16
Installation - Electrical

General Information.

It is your responsibility to ensure that the Compressor The sales drawing found at the back of this booklet
Unit is electrically connected in a safe and correct indicates the amp rating for the Unit. This information
manner. Any electrical work should be carried out is required in sizing a Disconnect, Fuses, and/or a
by a competent Electrician, and be done in such suitable Breaker. As well, the enclosed electrical
a way that it meets all applicable Codes and schematic indicates the correct wiring and fuse types
Regulations. and sizes.

Ensure that a Fused Disconnect (by others than DV Electrical wiring and conduit from the building supply,
Systems) is installed in the electrical supply before through the Compressor Cabinet, and to the Switch
the Compressor Unit. in the Compressor Control Panel, must be rated for
110°C (230°F) or higher.

Failure to correctly connect the Before servicing the Unit, ensure the
Compressor to your building's electrical power source has been shut down and
services may result in serious personal locked off.
injury or damage to the equipment.
Read and understand the information
Disconnect all power before servicing the contained in this manual before installing
drive. or operating the Unit.

Install all covers and panels before

applying power to the Unit.

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

Wiring Practices.

When making power and control wiring connections, please observe the following precautions:

Ensure that all wiring, fusing, etc is done in a manner that meets with the appropriate codes and
regulations.
See the sales drawing and electrical schematic contained in this booklet for Unit amp draw, as well as
Unit fuse sizes and overload settings.
A licensed Electrician is to determine the appropriate Disconnect/Breaker and wiring sizes based on the
Unit amp draw and the appropriate Electrical Code.

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 B57-II-C
Jan ’16
Installation – Electrical (cont’d)

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

Electrical Connection.
The Electrician is to bring
power to the Unit at the
Electrical Panel accessible
by means of removing the
Unit LH Panel.

A licensed Electrician is to
determine the appropriate
Disconnect/Breaker and
wire size based on the
Unit amp draw as
indicated on the sales
drawing at the back of this
booklet.

Motors.

Wiring must be done in a manner that the full Motor nameplate voltage +/- 10% is available at the Motor terminals
during start-up. Contact your local Distributor or Service Centre if additional information is needed.

The Warranty that exists on the Electric Motor is that of the original 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.

Motor/Air End Rotation.

The correct rotation is as indicated by the

arrow on the Air End, or as shown at right.

The Unit is equipped with an Anti-Rotation

Switch. If the Unit will not start and an ‘Anti
Rotation’ error is noted on the Controller,
simply change #1 and #3 leads to the Control
Panel.

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 B57-II-C
Jan ’16
Start-up Procedures

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

Initial Start-up
1) Remove the LH Side Access Panel, and 6) Once the Unit reaches 145 psi (10bar), it will
ensure that there is sufficient Oil in the Air idle for 5 minutes and shut off.
End. Refer to the ‘Lubrication’ section (page
8) in this manual for proper type and level of 7) Open the Ball Valve slightly and allow the air
Oil. to bleed from the Tank. Once the pressure
reaches approx 120 psi (8.3bar), the Unit will
2) Do a visual inspection of the Unit, and ensure start and begin to compress air after a short
that all fasteners are sufficiently tightened. delay.
This must be done, as some fasteners may
become loose in transit. 8) Measure the amp draw when the Unit
reaches the maximum pressure of 145 psi
3) Place the Fused Disconnect or Breaker in the (10bar).
‘On’ Position. Check that there is power to
the Controller. 9) Close the Ball Valve, allow the Unit to reach
maximum pressure, idle, and shut off. Once
4) During normal operation of the Unit, keep the off, check the various fittings etc inside the
Access Panels closed at all times. As well, Cabinet to ensure there are no internal leaks.
do not place any obstructions against or on
top of the Unit, thereby limiting the flow of
cooling air.

Shut off all power to the Air

Do not place any materials in close Compressor Unit before attempting any
proximity to the Compressor. Placing
repair or maintenance.
materials against or close to the Unit
will limit the cooling required, and
could lead to premature failure.

5) Ensure the Ball Valve on the Unit is closed,

press the ‘Start’ Button, and run the Unit up
to maximum pressure. The Unit will run up to
approx. 145 psi (10bar), at which point the
Motor will continue to run but not compress Adjusting the settings of the Controller
air. could adversely affect the performance
of the Unit. Only those individuals with
knowledge of the Unit should make any
adjustments.

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 B57-II-C
Jan ’16
Preventative Maintenance Schedule

When servicing the Air Compressor, shut off all It is the responsibility of the compressor owner
power to the Unit, and drain it of air pressure. to ensure that a regular Maintenance Schedule
is followed.

Noted on the following pages are general Maintenance guidelines based on average working conditions. Should
the Unit be worked under extreme conditions, please contact your DV Systems Distributor for further input. As
well, all maintenance/service work must be carried out by a qualified Technician.

If the operating temperature of the Unit is too low (less than 70°C (158°F)):
condensation will build up in the system and mix with the oil, causing internal component problems in the
Unit
Change the ambient conditions to increase the operating temperature.

If the operating temperature of the Unit is too high (above 85°C (185°F)):
the oil will oxidize and lose it’s properties, this causing internal damage to components as well
to combat this, the oil must be changed more often than noted below.

Note: For Compressor Units used in an environment where the ambient temperature is above
32°C (90°F), the components marked with a ‘ # ’ (on the chart on the following page) must
be changed more frequently, and not as noted below.

Regular Maintenance Items. Internal Access for Maintenance.

DV Systems offers a Maintenance Kit for your Unit, The internal components of the Unit are accessible
namely: for servicing by way of removing the LH Side Panel.

MK-B57 5, 7½ and 10 HP ‘B Series’ Units The Back Panel is also removable to access the
Belts if required.
Each Kit consists of the following items, these
suitable for approximately 2000 hours of operation.

(1) DEV-3000-K1 1 Gal. of Synthetic Oil

(1) DSC-603 Oil Filter
(1) DSC-002476 Air/Oil Separator Filter
(2) DSC-001569 Air Filter

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 B57-II-C
Jan ’16
Preventative Maintenance Schedule (cont’d)

Maintenance Interval (in 000’s of Hours)

Maintenance Item: Daily
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40

Compressor Room
Temperature Inspect Ambient Temperature should be between 10°C and 40°C (50°F and 104°F)
Cleanliness Inspect

Air Compressor Unit

Check Oil Level Inspect

Replace Oil # (See Note b) (1) X X X X X
Replace Oil Filter # (2) X X X X X X X X X X
Replace Air / Oil Separator # (3) X X X X X

Replace Air Intake Filter # (4) X X X X X X X X X X X X X X X X X X X X

Check Belt Tension X X X X X X X X X X X X X X X

Replace Belts (5) X X X X X
Replace Tank Relief Valve X X X
Replace Solenoid X X X X X
Rebuild Intake Valve (6) X X X X X
Rebuild Thermo Valve (7) X X X
Rebuild Minimum Pressure Valve (8) X X X X X
Motor Bearing Lubrication Refer to Motor Manufacturer’s Recommendations

Notes: a) For Compressor Units used in an environment where the ambient temperature is above 32°C (90°F),
or b) where the Unit temperature runs regularly above 80°C (175°F), the components marked with a
‘#’ must be changed twice as often (example: in 4000 hours instead of 8000), and not as noted
above.
b) The DV Systems Oil used in the Rotary Screw Units is rated as an 8000 hour Oil. A complete Oil
change must be done every 8000 hours of Unit operation, or every 12 months, whichever occurs first.
Please refer to the Warranty on Page 20 for further information.
c) If a component, during a regular inspection, has proven to be defective or unfit for regular operation, it
must be repaired or replaced.

Parts and Repair Kits based on the above chart are as follows:
(1) Oil: DEV-3000-K1
(2) Oil Filter DSC-603
(3) Air / Oil Separator: DSC-002476
(4) Air Intake Filter DSC-001569
(5) Belts (5 HP Unit) DSC-002256 (Qty of 2 Req’d)
(5) Belts (7.5 HP Unit) DSC-002257 (Qty of 2 Req’d)
(6) Intake Valve Repair Kit DSC-001712
(7) Thermo Valve Repair Kit: DSC-002057 (for Units of s/n ‘37214’ and greater)
(7) Thermo Valve Repair Kit: DSC-001711 (for Units of s/n ‘37213’ and lower)
(8) Minimum Pressure Valve Kit: DSC-001713
Shaft Seal Kit DSC-002055

As noted previously, the ‘MK-B57’ Maintenance Kit includes the following items:

(1) DEV-3000-K1 1 Gal. of Synthetic Oil

(1) DSC-603 Oil Filter
(1) DSC-002476 Air/Oil Separator Filter
(2) DSC-001569 Air Filter

Use only ‘Genuine DV Systems’ parts and kits for your DV Systems Screw Compressor, this to ensure that
a) it works at it’s optimum performance level and
b) you maintain your DV Systems Compressor Warranty.

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 B57-II-C
Jan ’16
Common Compressor Faults

Common Faults.
Noted below are the most common Faults experienced.

‘CSC50’ Alarms.
There is an issue with the Unit, but it will still operate.

Code: Description: Most Common Items to Check:

Solenoid not working, Intake Valve Orifice clogged, Transducer dirty or faulty, pressure changed
A:2118 High Pressure
incorrectly, alternate external pressure source

A:2128 High Temperature Ambient temp high, Unit dirty, low oil level, no air flow through Unit, Temp Sensor defective

A:2816 Power Failure Occurred Press ‘Reset’ Button and restart Unit

A:3123 Run Inhibited – Temp too low Ambient temp low, Temp Sensor defective

A:3423 Load Inhibited – Temp too low Ambient temp low, Temp Sensor defective

A:4804 Service Due Service unit (please refer to Preventative Maintenance Schedule on pg. 13)

‘CSC50’ Shutdown Errors.

There is an issue with the Unit, and the Unit will not operate until the Fault has been addressed.

Code: Description: Most Common Items to Check:

E:0020 Motor Overload Motor drawing high amps, low voltage, higher pressure settings, low oil level, loose wires

E:0040 Anti-Rotation Rotation of Motor wrong, Solenoid Valve not relieving pressure, Intake Valve Orifice clogged

E:0115 Pressure Sensor Fault Transducer cable loose, Pressure Transducer defective

Solenoid Not working, Intake Valve Orifice clogged, Transducer dirty or faulty, pressure
E:0119 Excessive Pressure
changed incorrectly, alternate external pressure source

E:0125 Temperature Sensor Fault Temperature Sensor not making good electrical contact, or defective

E:0129 Excessive Temperature Ambient temp high, Unit dirty, low oil level, no air flow through Unit, Temp Sensor defective

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 B57-II-C
Jan ’16
Separator Filter and Refrigerated Air Dryer

Your Unit may be equipped with a Separator Filter and an ‘ASD15’ (on ‘B5TD’ Units) or ‘ASD30’ (on B7.5TD
Units) Refrigerated Air Dryer Unit as indicated below. These items are located in the compressed air lines after
the air is compressed but before it enters the Air Receiver. This allows for what is termed a ‘dry’ Tank.

Dryer Model and

Serial Numbers
Refrigerated
Air Dryer
From Air
End

Separator
Filter

To Air
Receiver

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

Readout
On/Off
Button

Test/Programming
Buttons

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 B57-II-C
Jan ’16
Separator Filter and Refrigerated Air Dryer (cont’d)

Typical Dryer Operation.

Motors.

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. 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 horizontal bar.
• Once at approx. 1°C, the Fan will stop, only to be called to run again once the temperature increases to
approx. 5°C
• 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.)

• 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.

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

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 B57-II-C
Jan ’16
Separator Filter and Refrigerated Air Dryer (cont’d)

Typical Separator Filter.

As previously noted, the Separator Filter is located between the Air End and the Refrigerated Dryer. It contains a
1 micron Separator Element which protects the Dryer Unit by removing liquids and solid particles 1 micron and
larger.
Dual Indicating Gauge (DF001)
Arrow pointing to Green = Filter Element is Clean
Arrow pointing to Red = Filter Element is Dirty
Arrow Indicates
Direction of Air Flow

Alignment
Indicators:
triangles on
canister and The label shown above is included with a
head will align & replacement Filter Element, and should be
prevent further affixed to the outside of the Bowl for future
tightening when reference. (part number changes based on hp)
canister is
secured to the
head
Bowl which Contains Filter Element
DF18A (5hp) or DF24A (7.5hp)

Float Drain (DF003)

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.
• Pull the Filter Element out of the Canister Head
• Clean any debris from the inside of the Bowl
• Remove the O-ring from the inside of the Canister Head
• Install the new O-ring making sure it is properly seated
• Place the new 1 micron Separator Filter Element into the Bowl (the filter is self-centring).
• Screw the Canister with the Element inside it to the Canister Head until the indicators line up.
• Gauge will return to green when Filter is once again under pressure.

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 B57-II-C
Jan ’16
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/Service Center.

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 primary and secondary fuses.

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.

Emergency Stop Button pressed in. Release by twisting and pulling out.

Motor Overload is tripped. Reset the overload inside the Control Panel.

Compressor over-heated and stopped. Insufficient air flow to cool Unit.

Ambient temperature too high.
Heat Exchanger is dirty.
Faulty Temperature Switch.
Oil level is low.

Compressor stopped by over-pressure. Solenoid Valve faulty.

Seals on Intake Valve leaking.
Intake Valve Spring broken.
Pressure Transducer stopped Unit. Lower
maximum pressure setting.

Unit shut off because pressure is not below Drop pressure below 120 psi.
120 psi.

Automatic Idle Time stopped the Unit. Drop the pressure below 120 psi.

Power interruption. Reset the Unit.

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 B57-II-C
Jan ’16
Trouble Shooting Guide (cont’d)

Condition: Cause: Suggested Correction:

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

Oil Separator is blocked. Replace the Oil Separator.

Intake Valve is faulty. Repair or replace the Intake Valve.

Air leaks in the system. Check the Unit and system for air leaks.

Pressure limits are incorrectly set. Adjust the pressure settings.

Blowdown Solenoid Valve is open. Check the wiring to the Solenoid and replace as
necessary.

Belt are broken or slipping Check Belt tension and that Belts are in good
condition.

C. Unit is overheating. Ambient temperature is too high. Check cooling air circulation.

Blocked air circulation at the Unit. Check the air circulation in and around the Unit.

Heat Exchanger is dirty. Clean the Heat Exchanger

Oil level is too low. Add oil as required.

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

Thermo Valve is faulty. Check and repair as necessary.

Oil Filter is blocked. Replace the Oil Filter.

Temperature Sensor is faulty. Check the wiring to the Temperature sensor.

Replace the Sensor if necessary.

Thermostat is faulty. Replace the Thermostat.

Pressure is too high. Lower the pressure setting.

Cabinet door/panel is open/off. Secure the door/panel to the Unit.

D. Compressor Starts Slowly. Intake Valve Seal is closed. Intake Valve is seized. Repair or replace.

Ambient temperature is too low. Stop and restart once ambient increases.

Minimum Pressure Valve leaking back to Air Repair or replace the Minimum Pressure Valve.
End.

Minimum Pressure Valve setting is too high. Adjust Minimum Pressure Valve setting to 65 psi.

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

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 B57-II-C
Jan ’16

Trouble Shooting Guide (cont’d)

Condition: Cause: Suggested Correction:

E. Intake Valve Leaks Oil Intake Valve Seal leaks. Repair using an Intake Valve Repair Kit.
When Unit Stops.
Intake Valve stuck in open position. Repair or replace the Intake Valve.

Blowdown Solenoid not functioning. Replace the Solenoid.

F. Oil Consumption is Too Oil level is too high. Reduce the oil level to the proper level.
High.
Oil Return Line (Scavenge Line) is blocked. Clean and/or replace the Scavenge Line Sight
Glass.

Oil Separator is saturated with oil. Replace the Oil Separator.

Wrong type of oil used. Change to factory recommended oil.

Unit is operating at too high a temperature. See ‘Section C’.

Oil leak. Repair oil leak.

Unit load is light or excessive load/idle cycles. Ensure Unit is set to operate at correct pressures,
and there is a minimum of 10 psi differential. Also
the Unit could be oversized for the tank capacity.

G. Compressor Surges. Restriction in Heat Exchanger or Hoses. Flush out or replace.

Pressure Transducer setting is incorrect or Set pressure as per instructions or replace.

malfunctioning.

Blockage at Unit outlet. Check for obstructions in outlet piping.

Dryer is freezing up, not allowing air to pass Check that the Dryer parameters are correct.
through. Increase dew point to 2.0 if required.

H. High Power Consumption. Improper air pressure settings. Reset the pressure as per factory defaults.

Blowdown Solenoid is not functioning. Inspect or replace as necessary.

The voltage in the building is too low or there is Contact an Electrician to verify.
a phase imbalance.

The Motor is failing. Have Motor inspected.

I Fault Alarms. Emergency Stop. Ensure Emergency Stop Button is not pressed in.

High Temperature. See ‘Section C’.

Low Temperature. Ambient temperature is too low. Increase to 10°C.

High pressure. Check the pressure settings, the Pressure

Transducer and the wiring to the Transducer.

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 B57-II-C
Jan ’16
Limited Warranty : B5 & B7 Series Screw Compressors
The manufacturer warrants the product manufactured by it and sold to the original purchaser, when properly installed, operated, applied, and
maintained in accordance with procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free of defects in material
and workmanship for a period of one (1) year from the date of installation, not to exceed eighteen (18) months from the date of manufacture, provided
such defect is discovered and brought to the manufacturers attention within the aforesaid warranty period, conditional upon the following:
1) Genuine ‘DEV-3000’ Lubricant and Parts are used for the full warranty period.
2) The Unit is maintained in accordance with the manufacturer’s instruction manual for the Unit, with the following minimum maintenance
requirements:
A) Complete Oil change every 8000 hours (not to exceed 12 months) from the date of initial start-up using ‘DEV-3000’ Lubricant. When
operating in adverse conditions, Oil changes must be done more frequently.
B) Oil Filter must be changed every 4000 hours (not to exceed 12 months) from the date of initial start-up using the appropriate DV Systems
part. When operating in adverse conditions, Oil Filter changes must be done more frequently.
C) Air Intake Filter must be changed every 2000 hours (not to exceed 6 months) from the initial date of start-up using the appropriate DV
Systems part. When operating in adverse conditions, Air Intake Filter changes must be done more frequently.
D) Air/Oil Separator Filter must be changed every 8000 hours (not to exceed 12 months) from the date of initial start-up using the appropriate
DV Systems part. When operating in adverse conditions, Air/Oil Separator changes must be done more frequently.
E) Appropriate and complete maintenance records must be kept by the End User. As well, the End User must retain copies of invoices
indicating the timely purchase of the DV Systems Compressor Oil and maintenance/service parts. All records and invoices must be kept for
the duration of the manufacturer’s warranty period.
3) Disclaimer:
A) The following items are considered normal wear items, and are warranted for a period of one (1) year from the date of installation, not to
exceed eighteen (18) months from the date of manufacture; the Shaft Seal on the Air End Drive Shaft, the Intake Valve Assembly (and its
components), and the Minimum Pressure Valve.
B) All electrical components are warranted for a period of one (1) year from the date of installation, not to exceed eighteen (18) months from the
date of manufacture.

An additional four (4) year extended Air End Warranty and a four (4) year extended Three Phase Baldor Motor Warranty are available on those
Units that:
A) have been registered with the manufacturer within thirty (30) days from the date of purchase, this done by returning the ‘DV Systems Rotary
Screw Compressor Start-Up Sheet’ and
B) have been maintained in accordance with the manufacturer’s instruction manual as noted in ‘2’ above.

The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within the warranty period, provided such
defect occurred in normal service and is not the result of misapplication, misuse, abuse, neglect, incorrect maintenance, accident, or normal wear.
Normal maintenance items requiring routine replacement are not warranted. Please refer to the appropriate service bulletin to determine normal
maintenance requirements.

The warranty covers parts and labour for the warranty period (excluding the Three Phase Baldor Motors. Labour is not covered in the (4) year extended
Baldor Motor Warranty.) Either repair or replacement shall be at the sole option of the manufacturer. Any service performed on the product by anyone
other than the manufacturer must first be authorized by the manufacturer. Unauthorized service voids the warranty and any resulting charge or
subsequent claim will not be paid.

Products repaired or replaced under warranty shall be warranted for the unexpired portion of the warranty applying to the original product, based on the
original date of invoice as outlined above.

There is no other expressed warranty. Implied warranties including those of merchantability and fitness for a particular purpose are limited to one (1)
year from the date of invoice to the extent permitted by law and any and all implied warranties are excluded. This is the exclusive remedy. Liability for
consequential damages under any and all warranties are excluded to the extent exclusion is permitted by law.

This warranty gives you specific rights, and you may also have other rights within your jurisdiction.

This warranty does not cover:

1) Merchandise that has become inoperative because of ordinary wear, misuse, neglect, accident, or improper and unauthorized repair or alteration.
2) Electric Motors manufactured and identified as the product of another company.
3) Compressor Units that have not been properly maintained in accordance with the recommended maintenance and lubrication change procedures
and/or that have been subject to inordinate use through being inadequately sized or poorly installed.
4) Compressor Units using other than the recommended lubricant.
5) Costs occasioned by the removal, replacement, or repair of merchandise (other than by DV Systems) without previous authorization from DV
Systems.
6) Expenses incurred in travel or lodging beyond a 100 kilometre (60 mile) distance from the nearest DV Systems Authorized Service Centre.
7) Expenses incurred in the return of equipment for inspection purposes to the manufacturers facility. All returns must be pre-authorized, returned
‘Freight Prepaid’, and accompanied by a ‘Return Material Authorization (RMA) Number’ (obtainable through DV Systems).
8) Products, parts, materials, components, or accessories manufactured by others or supplied in connection with the sale of the manufacturers
products.
9) Repair and transportation costs of merchandise determined not to be defective under the terms and conditions of this warranty.
10) The cost of rental or loaner equipment while the customer’s original equipment is being assessed, repaired, or replaced.
11) Consequential damages in the event of product failure.

All decisions by DV Systems Inc. with regard to this policy shall be final. DV Systems will not be responsible for any claimed defective materials
returned other than in accordance with this statement of policy or without our prior authorization.

DV Systems, Inc. (Canada) DV Systems, Ltd. (USA)

490 Welham Road Tel: (705) 728-5657 128-B Talbert Road Tel: (704) 799-0046
Barrie, Ontario, L4N 8Z4, Canada Fax: (705) 728-4974 Mooresville, NC, 28117, USA Fax: (704) 799-0355

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