B57

Sept ‘09

Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca

Contents: Page:
...
B5 (T) Basic Unit Operation ............................................. 2
B7.5 (T) Safety Precautions ................................................ 3
Rotary Screw Unpacking & Inspection ......................................... 4
Installation - Mechanical ....................................... 5
Air Compressor
Lubrication ............................................................ 6
Units Installation - Electrical ........................................... 7-8
... Start-Up Procedures .............................................. 9
Installation Preventative Maintenance Schedule ................... 10
Maintenance Procedures ...................................... 11-13
Maintenance
DV Systems ’CSC50’ Controller ........................... 14-16
and Service Trouble-Shooting Guide ........................................ 17-19
Data Warranty ................................................................ 20
...

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.
Keep this booklet 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, contact your local DV Systems Distributor or Authorized Service
Centre. If you wish to contact DV Systems directly or need to locate your closest Distributor,
please reach us at :
Phone: (705) 728-5657 Website: www.dvsystems.ca
Fax: (705) 728-4974 Email: sales@dvsystems.ca
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Basic Unit Operation

Congratulations on your purchase of a DV Systems ‘B Series’ Rotary Screw Compressor.

In following the guidelines in this manual with respect to installation, maintenance, and service, you should have years
of trouble-free use of your Unit.

The Rotary Screw Compressor Units contain several items which, when working together in concert, provide
uninterrupted compressed air for your application. A brief and simple description of the operation of the Unit is as
follows.

Ø An internal Pressure Transducer senses the pressure in the compressed air system, and decides whether the
Unit should operate or not. The Transducer has two limits, namely a ‘cut-in’ pressure and a ‘cut-out’ pressure. The
‘cut in’ pressure (or below) is the pressure at which the Unit will start. The ‘cut-out’ pressure is the maximum
pressure at which the Unit will build pressure to.
Ø Once the Pressure Transducer senses that there is a need for air, the Electric Motor begins. The Electric Motor is
coupled to the Air End by means of Belts.
Ø The Air End (similar to as noted on the sketch below) contains two large Rotors which, when turned, compress air.
The Rotors turn at velocities dependent on the Unit horsepower and pressure.
Ø The Rotors inside the Air End do not touch, but are separated by a very thin film of oil. It is critical that the Unit have
a) the correct type, b) a sufficient level, and c) clean oil. Oil is a crucial part of the Unit, and can cause irreparable
damage if not maintained.
Ø The initial turning of the Air End and the building of slight pressure causes the Air Inlet Valve to open, allowing the
Unit to ingest air to compress.
Ø Once the Unit reaches maximum pressure, the Air End continues to turn in ‘idle’ mode, but does not compress air.
Ø After a preset interval, and if the pressure in the system does not drop down to the ‘cut-in’ pressure, the Unit will
shut down.
Ø If the pressure in the system drops down to the ‘cut-in’ pressure, the Unit will start automatically.

Internal Rotors

Driver Rotor

Driven Rotor

Internal Workings of a Typical Air End

The proper installation and maintenance are very important in keeping the Compressor running at its optimum.
Though Rotary Screw Compressors can provide a very steady supply of compressed air, they are relatively
unforgiving with regards to the manner in which they are installed and maintained.

Please take the time to read this manual, and to familiarize yourself with the Unit requirements.

-2-
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
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 safety information. A
hazard that may cause serious
injury or loss of life.
NOTE
Important information that indicates
how to prevent damage to Information that you should pay
equipment, or to avoid a situation special attention to.
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 How to avoid the hazard
observed.

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

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

As the Unit starts and stops automatically, do not come Shut off all power to the Unit before attempting to
into contact with moving parts. repair or maintain the Compressor.

Air compressed by the Unit is not suitable for inhaling. It Never breath untreated compressed air produced
may contain poisonous vapours harmful to your health. by the Compressor.

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

As the electrical components on the Compressor are
General Purpose, there is a potential for explosion,
20FT
6.1m should vapours be present in the area. Do not install in
hazardous locations.
The Compressor must be a minimum of 20 Feet (6.1
Metres) from any source of potentially explosive
vapours.

-3-
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Unpacking and Inspection

NOTE
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

-4-
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Installation - Mechanical

Moving of the Unit:

When moving the Air Compressor Unit, care must

be taken as the Unit is very top-heavy.

Location of the Unit:

Items to consider when installing the Unit are:
Ø The Unit should be located in a dry, clean, cool,
dust free, and well ventilated area. If possible, the
Compressor should be located in a separate room
or area, away from the general operations of the
shop.
Ø Allow approximately 3 feet around and 5 feet
above the Unit for easy access to the various
sides, this being for both the proper ventilation of
the Unit and ease of servicing.
Ø If installing the Unit on a mezzanine, ensure that
the structure can safely support the weight of the
Unit. As well, the sound level of the Unit may
increase due to the harmonics created by the
structure; use Vibration Pads to lessen this.
Many common Compressor problems can be
attributed to the location or installation of the Unit.
Make sure the Unit is in a suitable location, and
installed correctly.

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

-5-
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
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
basis. This must be done when the Unit is off. Top up
the Oil level on a monthly basis.

Use only DV Systems ‘DEV-3000’ Synthetic Oil. As

well, do not mix the ‘DEV-3000’ with any other Do not attempt to operate the Unit without first
lubricant.
checking whether there is Oil in the Oil
Reservoir. Add Oil as required. Serious
Subsequent Oil Changes.
Drain the existing oil from the Unit. (Please be advised damage may result from use, however limited,
that the Unit cannot be drained fully of oil, as some oil without Oil.
may remain in various components ie Cooler, Tubing,
etc.)

Fill the Oil Reservoir to the top of the Oil Fill Port as
shown below. Do not under or overfill. See drawing
below.
Use of improper Oil may negatively affect
Use only DV Systems ‘DEV-3000’ Synthetic Oil, Compressor performance or shorten the Unit
available in both 1 US gallon jugs or 5 US gallon pails. life. Resulting problems are not covered by the
Any remaining oil may be used for ‘top-ups’.‘
DV Systems Inc. Air Compressor Warranty.
The ‘MK-B57’ Maintenance Kit includes:
(1) Gallon Oil (‘DEV-3000’)
(1) Oil Filter (’DSC-603’)
(1) Air/Oil Separator Filter (’DSC-302’)
(2) Air Filters (’DSC-001569’)
And should be used in the regular servicing of your
Unit.

Air End

Oil Fill Port

Proper Oil Level

Bottom Drain
Valve

-6-
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
Installation - Electrical
It is your responsibility to ensure that the Compressor
Unit is electrically connected in a safe and correct
manner. Any electrical work should be carried out by a
competent Electrician, and be done in such a way that
it meets all applicable Codes and Regulations.
Ensure that a Fused Disconnect (by others than DV
Systems) is installed in the electrical supply before the
Compressor Unit.
The sales drawing found at the back of this booklet
indicates the various Motor nameplate amp ratings for
the two horsepowers available and at various voltages.
This information is required in sizing a Disconnect,
Fuses, and/or a suitable Breaker.
Failure to correctly connect the Compressor to
your building's electrical services may result in
serious personal injury, or damage to the
equipment.
Motors
Wiring must be done in a manner that the full Motor
nameplate voltage +/- 10% is available at the Motor
terminals during startup. Contact your local Distributor
or Service Centre if additional information is needed.
As well, the service required for the Compressor to
operate the Unit effectively is approximately 6x the
Motor nameplate amp rating.
NOTE
Use of an incorrect Electric Motor for your
particular building service will result in
premature Motor failure, and is not covered by
the DV Systems or Motor manufacturer's
Warranty.
-7-
B57
Sept ‘09
Electrical wiring and conduit from the building supply,
through the Compressor Cabinet, and to the Switch in
the Compressor Control Panel, must be rated for
110°C or higher.
Please note that, under normal conditions, the
Compressor Unit will operate continuously. It may
also start and stop without warning.
Should it be necessary to service the Unit, ensure
the power source has been shut down and locked
off. This must be done to prevent personal injury,
or damage to the unit.
Do not attempt to operate the Air Compressor Unit
without first checking the Oil level in the Oil
Reservoir. Add Oil as required. Serious damage
may result from use without Oil.
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 Rotation
Correct Air End rotation is critical to the correct and
safe operation of the Unit. The correct rotation is as
indicated inside the Cabinet Enclosure by the
directional arrows. (The Unit is equipped with an Anti-
Rotation Switch, and will only operate in one direction.)
If the rotation is reversed, simply change #1 and #3
leads in the Control Panel.
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Installation - Electrical (cont'd)

AC Motor Installation - Maintenance Instructions

Handling.
The weight of the motor and shipping container will vary. Use correct
material handling equipment to avoid injury.
Receiving.
Inspect the motor for damage before accepting it. The motor shaft should
rotate freely with no rubs. Report any damage immediately to the
commercial carrier that delivered you motor.
Safety Notice.
Only qualified personnel trained in the safe installation and operation of
this equipment should install this motor. When improperly installed or
used, rotating equipment can cause serious or fatal injury. Equipment
must be installed in accordance with the National Electrical Code (NEC),
local codes, and NEMA Mg2 Safety Standards for Construction and
Guide for Selection, Installation and Use of Electric Motors and
Generators. Observe the following guidelines:
1. When eyebolts are provided, they must be fully tightened and are
intended to lift the motor and its included accessories only.
2. Ground the motor according to NEC and local codes.
3. Provide a permanent guard to prevent accidental contact of body
parts or clothing with rotating or moving parts or burns if motor is
hot.
4. Shaft key must be secured before starting motor.
5. Do not apply power to the motor until the motor is securely mounted
by its mounting holes.
6. This motor must only be connected to the proper line voltage, line
frequency and load size.
7. If a motor mounted brake is installed, provide proper safeguards for
personnel in case of brake failure.
8. Disconnect all power services and stop the motor before servicing.
9. For single phase motors, discharge the start and/or run capacitors
before servicing.
10. Do not bypass or render inoperative any safety devices.
11. When using AC motors with frequency inverters, be certain that the
Maximum Speed rating (on nameplate) is not exceeded.
12. Mounting bolts should be high tensile steel. Be sure to use a
suitable locking device on each bolt (spring washer or thread lock
compound.)
Motor Enclosure.
ODP, Open drip proof motors are intended for use in clean, dry locations
with adequate supply of cooling air. These motors should not be used in
the presence of flammable or combustible materials. Open motors can
emit flame and/or molten metal in the event of insulation failure.
Wiring.
Connect the motor as shown in the connection diagram. The wiring,
fusing and grounding must comply with the National Electrical Code and
local codes. When the motor is connected to the load for proper direction
of rotation and started, it should start quickly and run smoothly. If not,
stop the motor immediately and determine the cause. Possible causes
are: low voltage at the motor, motor connections are not correct, or the
load is too heavy. Check the motor current after a few minutes of
operation and compare the measured current with the nameplate rating.
Lubrication.
This is a ball bearing motor. The bearings have been lubricated at the
factory. Motors that do not have regrease capability are factory lubricated
for the normal life of the bearings.
Relubrication Intervals. (For motors with regrease capability.)
New motors that have been stored for a year or more should be
relubricated. Lubrication is also recommended at these intervals:
NEMA (IEC) Rated Speed (RPM)
Frame Size 3600 1800 1200 900
Up to 210 incl. (132) 5500 hrs 12000 hrs 18000 hrs 22000 hrs
Over 210 to 280 incl. (180) 3600 hrs 9500 hrs 15000 hrs 18000 hrs
Over 280 to 360 incl. (225) *2200 hrs 7400 hrs 12000 hrs 15000 hrs
Over 360 to 5000 incl. (300) *2200 hrs 3500 hrs 7400 hrs 10500 hrs
*Lubrication interval for 6313 or 6314 bearings that are used in 360
through 5000 frame , 2 pole motors. If roller bearings are used,
bearings must be lubricated more frequently; divide the interval by 2.
Lubricant.
Baldor motors are pregreased, normally with Chevron SR #2. Equivalent
and compatible greases are Texaco Polystar, Shell Dolium R and Amoco
Rykon Premium #2.
Procedure.
Clean the grease fitting (or area around the grease hole, if equipped with
slotted grease screws.) If motor has a purge plug, remove it. Motors can
be regreased while stopped (at less that 80°C) or running.

TEFC, totally enclosed motors are intended for use where moisture, dirt
and/or corrosive materials are present in indoor and outdoor locations.
Explosion proof motors, as indicated by the Underwriters Laboratories
Inc. Label are intended for use in hazardous areas as specified by the
NEC.
Apply grease gun to fitting (or grease hole). Too much grease or injecting
grease too quickly can cause premature bearing failure. Slowly apply the
recommended amount of grease, taking 1 minute or so to apply. Operate
motor for 20 minutes, then reinstall purge plug if previously removed.
Caution: Keep grease clean. Mixing dissimilar grease is not
recommended.

NEMA (IEC) Weight of Volume of grease to

Mounting. grease to add
Foot mounted machines should be mounted to a rigid foundation to Frame Size 3
Ounce (gram) Inches Teaspo
prevent excessive vibration. Shims may be used if location is uneven.
Up to 210 incl. (132) 0.30 (8.4) 0.6 2.0
Flange mounted machines should be properly seated and aligned. Note:
If improper rotation direction is detrimental to the load, check rotation Over 210 to 280 incl. (180) 0.61 (17.4) 1.2 3.9
direction prior to coupling the load to the motor shaft.
Over 280 to 360 incl. (225) 0.81 (23.1) 1.5 5.2
For V-belt drive, mount the sheave pulley close to the motor housing.
Allow clearance for end movement of the motor shaft. Do not overtighten Over 360 to 5000 incl. (300) 2.12 (60.0) 4.1 13.4
belts as this may cause premature bearing failure or shaft breakage.
P.O. Box 2400
Direct coupled machines should be carefully aligned and the shaft should Fort Smith, AR Tele: (501) 646-4711
rotate freely without binding. 72902-2400
USA

-8-
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Start-Up Procedures

Do not attempt to operate the Unit without first checking

whether there is Oil in the Oil Reservoir. Add Oil as required.
NOTE Serious damage may result from use, however limited, without
Oil.

Initial Start-Up

1) Open the Cabinet Side Access Panel, and

ensure that there is Oil in the Air End. Refer to
the "Lubrication" section (page 6) in this manual
for proper type and level of Oil.
2) Do a visual inspection of the Unit, and ensure
that all fasteners are sufficiently tightened. This
must be done, as some fasteners may become
loose in transit.
Do not place any materials in close
proximity to the Compressor Unit. Placing
materials there will limit the cooling of the
Compressor, and could lead to premature
failure.

4) Place the Fused Disconnect in the ‘On’ Position.
Turn the Compressor 'On' momentarily by
pressing the ‘Start’ Button on the Units Exterior
Control Pad. Ensure that the Air End and Motor
are turning in the correct direction. See "Motor
Rotation” (Page 7).
6) Allow the Unit to operate for approximately 15
minutes. During this time, measure the amp draw
and voltage of the Unit at full load, and ensure that
these do not exceed the figures as noted on the
Unit.
7) Stop the Compressor by pressing the ‘Stop’ Button
on the Units Exterior Control Pad.

NOTE

If the rotation of the Unit is incorrect, adjust Shut off all power to the Air Compressor Unit
the wiring at the supply side in the Electrical before attempting any repair or
Control Panel. maintenance.

5) When operating the Unit, keep the Access
Panels closed at all times. As well, do not place
any obstructions in the way of the Intake Cooling
Fan and the Top Exhaust Port.
8) With the Unit off, check for any oil leaks on the Unit,
or air leaks in the Unit or shop air system. Correct as
required.
9) Do not adjust the Unit pressure settings. Consult
your DV Systems Distributor if required.

NOTE
During the first few days of operation, check the Unit periodically to ensure it is running smoothly and the
controls are operating properly. Should you notice any areas of concern, contact your DV Systems
Distributor or Authorized Service Centre.

-9-
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Preventative Maintenance Schedule

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

Noted below 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), 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), 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.

Order (1) ‘MK-B57’ Maintenance Kit containing (1) Gallon ‘DEV-3000’ Oil, (2) ‘DSC-603’ Oil Filters, (1) ‘DSC-302’ Air/Oil Separator
Filter, and (2) ‘DSC-001569’ Air Filters.

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

Maintenance Interval (thousands of hours)

Maintenance Item: Daily
Compressor Room 1 2 4 6 8 10 12 14 16 18 20 22 24 26
Temperature Inspect Ambient temperature should be between 10°C and 40 °C (50°F and 104°F)

Cleanliness Inspect Clean as required

Air Compressor Unit

Oil Level Inspect

Oil Change Change Change Change Change Change Change

Oil Filter Change Change Change Change Change Change Change

Air / Oil Separator Change Change Change Change Change Change Change

Air Intake Filter Change Change Change Change Change Change Change Change Change Change Change Change Change Change

Belt Tension / Replacement Check Replace Check Replace Check Replace Check

Solenoid Change Change

Intake Valve Rebuild Rebuild

Thermo Valve Service Kit Rebuild Rebuild Rebuild

Scavenge Line Sight Glass Change Change Change Change Change Change Change

Motor Bearing Lubrication Refer to Motor Manufacturers Recommendation. See Page 10.

Note: If a component, during a regular inspection, has proven to be defective or unfit for regular operation, it must be repaired or replaced.
Repair Kits are as follows: Intake Valve Repair Kit: DSC-001712
Thermo Valve Repair Kit: DSC-001711

Note: The items as noted above must be completed as part of your regular Compressor maintenance
to comply with the manufacturers Compressor Warranty.

- 10 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Maintenance Procedures

Regular Maintenance Items Internal Access for Maintenance

DV Systems offers Maintenance Kit for your Unit, The internal components of the Unit are accessible by
namely: means of removing the Back and Side Panels.
MK-B57 5 and 7-1/2 HP ‘B Series’ Units

Each Kit consists of the following items, these suitable

for approximately 2000 hours of operation.

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

(1) DSC-603 Oil Filter
(1) DSC-302 Air/Oil Separator Filter
(2) DSC-001569 Air Filter

Element Top c/w

Changing the Air Intake Filter. (2) Wing Nuts

1. Remove the (2) Wing Nuts holding the Element Top in place, and
then remove the Top.
2. Remove the Air Filter Element from the Unit.
3. Ea of any dust or build-up.
4. Install a new Air Filter (DV Systems Part Number ‘DSC-001569’),
place the Element Top on the Filter, and fasten down with the
Wing Nuts.

Note:
Depending on the quality of the air in the compressor room, it may
be necessary to check and/or change the Air Filter more often
than indicated on the 'Maintenance Schedule'.
Air Filter Element
Cleaning the Heat Exchanger.
The circulation of air through the Heat Exchanger is critical
to the correct operation of the Unit. Clean the Heat
Exchanger on a regular basis.

1. Remove the Back and Side Panels.

2. Blow compressed air through the Heat Exhanger in
the direction as shown by the arrow. Heat
Exchanger
Note:
When cleaning the Heat Exchanger, do not use
sharp objects or a wire brush. These items could
damage the cooling coils.
- 11 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Maintenance Procedures (cont’d)

Changing the Oil.

1. Allow the Compressor Oil to cool down before draining
the Oil.
2. To remove the Oil, open the Bottom Drain Valve on the
Air End, and drain the existing Oil into an appropriate
container.
3. Once all the existing Oil has been drained, close the Oil Fill
Bottom Drain Valve. Plug
4. Open the Oil Fill Plug, and fill to the appropriate level
as shown with new DV Systems Synthetic Lubricant,
part number 'DEV-3000'. Correct
Oil Level
Notes:
You may be required to add Oil on a regular basis, this
depending on the usage of the Unit.

Bottom Drain
Valve
Changing the Oil Filter.
Oil
The Oil Filter should be changed only after all the oil has been drained Filter
from the Unit.
1. Ensure that you have a bucket and strap wrench available.
2. Holding the bucket under the Oil Filter to capture any spillage, use the
strap wrench to turn the Oil Filter counter-clockwise. The Filter maystill
contain oil, so care must be taken.
3. On the replacement Oil Filter, lubricate the Filter Gasket with
Compressor Oil before installing. This will prevent the Gasket from
sticking to the Housing.
4. Hand tighten the Oil Filter snug.

Notes:
As noted in '2' above, as the Oil Filter may contain Oil, care must be
taken when loosening and removing it.

Changing the Oil Separator.

1. Use the strap wrench to turn the Oil Separator counter-
clockwise. Separator
Filter
2. On the replacement Oil Separator, lubricate the
Separator Gasket with Compressor Oil before installing.
3. Hand tighten the Oil Separator snug.

- 12 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Maintenance Procedures (cont’d)

Adjusting the Drive Belts.

The tightening and loosening of the Belts is done by way of moving the Air End horizontally either towards
or away from the Motor.

To adjust the Belt tension, simply:

A) loosen the (4) Air End HoldDown Bolts, (2) on each side of the Air End
B) loosen the (2) Adjusting Nuts (turning counter-clockwise) on the Slider Bolts
C) adjust the Slider Bolts to the desired position
Note: The Belts (new) should be tensioned as follows:
5 HP Unit: 47 lb force and 0.32” deflection
7-1/2 HP Unit: 48 lb force and 0.33” defelction
D) tighten the Adjusting Nut so it is tight against the Tension Bracket
E) re-torque the (4) Air End Bolts to lock the Air End in position.

Adjusting Nut

Air End

Tension
Bracket

Slider Bolts
(1 of 2)
Air End HoldDown
Bolt (1 of 4)

Compressor Storage

At times, it may become necessary to store a Compressor Unit for an extended period of time, this because the
site may not be ready, it may be shipped overseas, etc. When storing a Compressor, the following areas must be
addressed:
- the Drive Belts must be loosened off or taken off the assembly, this to prevent any deterioration of the Belts.
- the Air End must have oil added to prevent deterioration of the Rotors, Bearings, etc.

- 13 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
‘CSC50’ Controller

Description of Controller:
The ‘CSC50’ Controller is the ‘brains’ of the ‘B’ Series of Rotary Screw Compressor Units. It monitors, enables,
and indicates the various functions of the Units.

The Controller is comprised of two levels of access, segregated into:

- an Operational Menu and
- a Configuration Menu

Codes are required to access these levels of the Controller, this to ensure that the Unit variables are not altered in
error.

Controller Operator Interface:

The Operator Interface as mounted on the Compressor Unit is shown below.

Start

Stop

Reset

Up or Increase
Value

Down or Decrease
Value

Emergency Stop
Enter

Description of Interface: 1 2 5
1. Main Display Value (0.1 to 999)

2. Main Display Value Units (°C, °F, BAR, PSI)

3. User Menu Item Display Value (0.1 To 99999)

4. User Menu Item Display Value (°C, °F, BAR, PSI, Hr, Lhr)

5. Status Symbols Started Running Loaded

6
6. Service / Fault Symbols Service Fault: Alarm
Warning/Trip 3 4

- 14 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
‘CSC50’ Controller (cont’d)

Display:
The Controller Display is programmed to indicate a variety of items as shown below. To view the items, simply
press the ‘Up/+’ or ‘Down/-’ Buttons.

Unit Pressure

Press to scroll through items

Unit Temperature

Total Run Hours

Total Run Hours Loaded

Total Hours Left Until Service is Due

Unit Status:
Standby. The Compressor is in a ‘start’ state but not running.
The Unit will automatically start and load once the pressure
falls to the lower limit set point.

Running. The Compressor is running offloaded (ie not

compressing air).

Loading. The Compressor is running and loading (ie

compressing air).

Fault Conditions:
If a fault condition occurs, the ‘Fault Triangle’ will either:

A) switch on steady (Alarm / Warning) or

B) flash (Trip / Shutdown)

The User Menu Display will indicate the appropriate fault.

The more common faults are as follows:

Alarm Warning (Unit will continue to operate) Shutdown/Trip (Unit will stop)
A:2118 High Pressure E:0010 Emergency Stop
A:2128 High Temperature E:0020 Motor Overload
A:2816 Power Failure Detected E:0040 Anti-Rotation
A3123 Run Inhibited - Temperature too low E:0115 Pressure Sensor Fault
A3423 Load Inhibited - temperature too low E:0119 Excessive Pressure
A:4804 Service due E:0125 Temperature Sensor Fault
E:0129 Excessive Temperature
- 15 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
‘CSC50’ Controller (cont’d)

Operational Menu:
The following values are as programmed into the ‘CSC50’ Controller.

Symbol: Description Default Value

1.Sh Service Interval Hours (The maximum time between 2000 hours
service/maintenance of the Unit.)
1.Pu Upper Pressure set Point (Unit maximum pressure) 145 psi
1.PL Lower Pressure Set Point (Pressure at which Unit will 120 psi
Begin to Load)
1.rt Run-On-Time (Time that the Unit idles (does not compress 300 seconds (5 minutes)
Air) before shutting down)
1.bt Blowdown Time 30 seconds
1.St Stop Time 10 seconds
1.P- Pressure Display Units PSI
1.t- Temperature Display Units °C
1.At Auto Restart Time 10 seconds

Service Due Countdown Timer:

As noted above, the Unit has a Service Interval Timer as part of the Controller. When new, the counter is set for
2000 hours. As the Unit operates, the Timer counts down from 2000 until it reaches 0. Once it reaches 0, the
‘A:4804 Service Due’ fault code will appear on the Controller. (The Timer will continue to count down, going into
the negative (’-’) values.

Service Interval Timer Access Code: ‘0009’

The Timer must be reset as follows:

1. Turn the Compressor off, but ensure there is still power to the Unit.
2. Press the ‘Up’ and ‘Down’ arrows at the same time.
3. After 1 or 2 seconds, four ‘0’s will appear, with the left one flashing.
4. Press the ‘Up’ or ‘Down’ arrows to adjust the first character to match the access code.
5. Press ‘Enter’ to move to the next character, change the character as noted in ‘4’ above, and press ‘Enter’.
6. Once the correct access code has been entered, access will be given to the ‘Operational Menu’.
7. If not already listed on the screen, use the ‘Up’ or ‘Down’ arrows to hi-light ‘1.Sh Service Interval Hours’.
8. Using the ‘Up’ arrow, adjust the value to ‘2000’.
9. Press ‘Enter’ to store the value into memory, and press ‘Reset’ to return to the normal operating display
screen.
At this stage, the fault code will disappear from the screen, and the Unit can be run.

- 16 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Trouble Shooting Guide

When servicing the Compressor, shut off all power to the Compressor, and ensure that the air
pressure in the Unit is relieved.

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. 1. No power to the Unit. Fuses blown. 1. Check the Fuses, both primary and secondary.

2. Loose and/or missing wires in electrical circuit. 2. Check that all screws are tight. With the wiring
schematic, ensure all wiring is correct.

3. ‘Emergency Stop’ Button depressed. 3. Release the ‘Emergency Stop’ Button by pulling out.

4. Motor Overload tripped. 4. Reset the Overload

5. Compressor overheated and stopped, Alarm Light ‘on’. 5. Insufficient air flow.
Ambient temperature too high.
Heat Exchanger is dirty.
Faulty Temperature Switch.
Oil level too low.

6. Compressor stopped by over-pressure. 6. Solenoid Valve to Intake Valve faulty.

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

7. Automatic Idle Time stopped the Compressor. 7. Drop the pressure.

8. Power Interruption. 8. Reset the Controller.

B. No or Insufficient Air 1. Air Filter is dirty. 1. Replace the Air Filter.

Output. 2. Oil Separator is blocked. 2. Replace the Oil Separator.

3. Intake Valve is faulty. 3. Repair or replace the Intake Valve.

4. Air leaks in the system. 4. Check for air leaks.

5. Belts are broken. 5. Replace all Belts, as they must be matched set.

6. Belts are slipping. 6. Adjust the Belt tension.

7. Pressure limits are incorrectly set. 7. Adjust the pressure settings at the Controller.

8. Ambient temperature is too high. 8. Ensure sufficient air flow.

9. Blowdown Solenoid Valve is open. 9. Check wiring and replace as necessary.

- 17 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Trouble Shooting Guide (cont’d)

Condition Cause Suggested Correction

C. Unit is Overheating. 1. Ambient temperature too high. 1. Check cooling air circulation.

2. Blocked air circulation at or to Unit. 2. Check the air circulation in and around the Unit.

3. Heat Exchanger dirty. 3. Clean the Heat Exchanger.

4. Oil level is low. 4. Add Oil.

5. Using wrong type of Compressor Oil. 5. Change to the factory recommended Oil and Filter.

6. Thermo Valve faulty. 6. Check and.repair as necessary.

7. Oil Filter blocked. 7. Replace the Oil Filter.

8. Thermostat faulty. 8. Replace the thermostat.

9. Pressure too high. 9. Lower the pressure.

10. Cabinet Door / Panel left open / off. 10. Secure the Door / Panel onto the Unit

D. Oil Consumption too 1. Oil level is too high. 1. Reduce the Oil level to the proper level.
High. 2. Oil Return Line (Scavenge Line) or Orifice on Air End is 2. Clean Return Line, Clean Orifice, Filter, and One Way
blocked. Check Valve.
3. Oil Separator is saturated with oil. 3. Replace the Oil Separator.
4. Wrong type of Oil used. 4. Change to factory recommended Oil.
5. Unit is operating at too high a temperature. 5. See ‘Section C’.
6 Oil leak. 6. Repair oil leak.
7. Unit load is light or excessive load/idle cycles. 7. Ensure Unit is set to correct pressures, and there is a 20
psi differential. As well, the Unit could be oversized for
the Tank capacity.

E. Intake Valve Leaks Oil 1. Intake Valve Seal leaks. 1 Replace using a Valve Repair Kit.
When Unit Stops. 2. Intake Valve stuck in open position. 2. Repair or replace the Intake Valve.

3. Blowdown Check Valve not functioning. 3. Replace.

F. Compressor Starts 1. Intake Valve leaking or open. 1. Seal leak or Magnetic Valve not functioning properly.
Slowly. 2. Using wrong type of Oil. 2. Change to factory recommended Oil.

3. Ambient temperature is too low. 3. Stop and re-start.

4. Pressure in the Air Receiver is too high. 4. Reduce Air Receiver pressure.

5. Minimum Pressure Valve leaking back to Oil Receiver. 5. Repair or replace the Minimum Pressure Valve.

6. Minimum Pressure Valve setting is not correct. 6. Adjust to 65 psi maximum to open.

- 18 -
 Distributed by: CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
B57
Sept ‘09
Trouble Shooting Guide (cont’d)

Condition Cause Suggested Correction

G. Compressor Surges. 1. Restriction in Heat Exchanger. 1. Flush out or replace.

2. Transducer setting is incorrect. 2. Set Pressure as per instructions.

3. Blockage at outlet of Tube. 3. Check and replace.

H. High Power 1. Improper air pressure setting on the Unit. 1. Reset the pressure.
Consumption 2. Blowdown Solenoid is not functioning. 2. Inspect and/or replace as necessary.

3. The voltage in the building is too low. 3. Contact an Electrician or your DV Systems Distributor.

4. There is an electrical phase imbalance. 4. Contact an Electrician.

5. The Motor is failing. 5. Replace the Motor.

H. Fault Alarms 1. Anti Rotation. Check the rotation.

2. High Temperature. Check the Anti-Rotation Switch.

3. High Pressure. Check the Oil Level.

Check the wiring to the Transducer.

Check the Transducer.

Check the pressure settings.

- 19 -
 - DV Systems Limited Warranty - B57
‘B Series’ Rotary Screw Air Compressors Sept ‘09
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 2000 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 2000 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 1000 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 2000 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 kilometer (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
Distributed by: CENTRAIR AirTele:
490 Welham Road
Systems & Supplies
(705) 728-5657
Barrie, Ontario 68 Hooper Rd., Unit
Fax: 5, Barrie,
(705) ON L4N 8Z9
728-4974
Canada Phone: 705-722-5747 Fax: 705-722-5458
L4N 8Z4 sales@centrair.ca www.centrair.ca