Devair HDI-01 Manual

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: [phone] Fax: [phone] Email: [e-mail] 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
2
3-4
5
6
7
8
9
10
11-12
13
14
15-16
17
18
19
20-23
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: [phone] Fax: [phone]
[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: [phone] Fax: [phone] [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.
X
X
X
X
X
X
X
X
X
X
X
X
X
- 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: [phone] Fax: [phone] [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 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.
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: [phone] Fax: [phone] [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: [phone] Fax: [phone] [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 @
Max RPM @
PSI
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: [phone] Fax: [phone] [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: [phone] Fax: [phone] [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: [phone] Fax: [phone] [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: [phone] Fax: [phone] [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 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
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: [phone] Fax: [phone] [email protected] www.centrair.ca
All manuals and user guides at all-guides.com