DV Systems K100-C User manual

K100-C
Dec’15
- 1 -
If you require assistance, please contact your local DV Systems Distributor or Authorized Service
center. You may contact the manufacturer directly as follows:
Phone: [phone] (Canada) Web: www.dvcompressors.com
[phone] (USA)
Fax: [phone] (Canada) Email: [email protected] (Canada)
[phone] (USA) [email protected] (USA)
Quick Start ……………............................................. 2
Safety Precautions …………………………………… 5
Shipping Cleats ……………………………………… 6
Unpacking and Inspection …………………………... 7
Installation – Mechanical ……………………………. 8
Lubrication ……………………………………………. 11
Installation – Electrical ………………………………. 12
Start-up Procedures …………………………………. 15
Preventative Maintenance Schedule ………………. 16
Compressor Storage ………………………………… 18
Common Compressor Faults ………………..………… 19
Variable Speed Drive ………………………………... 20
Air Filtration & Refrigerated Air Dryer ……...………. 23
Trouble-Shooting Guide ……………………………… 26
Warranty ……………………………………………….. 29
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.
K100
Rotary Screw
Air Compressor
Unit
- - -
Installation
And
Start-up Data

K100-C
Dec’15
- 2 -
60
”
[1524mm]
Quick Start
Mechanical Installation.
(Refer to Page 8)
The Unit should be located in a dry, clean, cool, dust free,
and well ventilated area.
Allow a minimum of:
•48” (1220mm) in front of and behind the Unit. The
Access Doors swing in a 36” (915mm) arc.
•48” (1220mm) on either side of the Unit, and
•60” (1524mm) above Unit.
The ambient temperature should be between 10°C and 40°C
(50°F and 104°F).
Ensure that the floor under the Unit is smooth, level and
capable of bearing the weight of the Compressor.
If installed in a compressor room, ensure that the room is
adequately ventilated.
48
”
[1220mm]
48
”
[1220mm]
48
”
[1220mm]
48
”
[1220mm]

K100-C
Dec’15
- 3 -
Quick Start (cont’d)
Shipping Cleats.
(Refer to Page 6)
Lubrication. Rotation.
(Refer to Page 11) (Refer to Page 13)
Cover Plate
Correct
Oil Level
Before starting the Unit for
the first time, ensure the oil
level in the Reservoir is as
shown below at the Oil
Sight Glass.
Check the oil after the Unit
has been at rest for a
minimum of 10 minutes.
The Unit is not equipped with an ‘Anti
Rotation’ Switch. Operating the Unit in the
reverse direction will cause irreparable
damage.
Remove the Cover Plate from the Coupling
area and pay close attention to the arrow
indicating correct rotation. Turn Unit on and
immediately turn off using the Emergency
Stop Button.
If the rotation is not correct, simply change
two of the motor leads at the Inverter.
Reservoir
Couplings
The ‘K Series’ Screw Units are shipped
with (3) Shipping Cleats under the Feet
of the Oil Receiver, (1) under Air End
Bracket, and (1) under the Motor.
These Cleats are installed simply to
stop any lateral movement of the
components during transportation.
The Cleats must be removed before
starting the Unit.
Cleat
(1of 3) Cleats at
Oil Receiver
Locate the Orange
Cleats located under
each Foot of the Oil
Receive.
Locate the Orange Cleat
located under the Air
End Bracket.
Remove the Bolts and
Washers from each
Cleat, and slide the
Cleats out.
Motor Cleat from Front of Unit.
Motor Cleat from Rear of Unit.
Cleat
Remove the Fasteners
from the Cleat.
Slide the Cleat from
under the Motor.
Cleat at Air End

K100-C
Dec’15
- 4 -
Quick Start (cont’d)
Unit Operation.
Shown below is the ‘CSC300’ 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 using the ‘Emergency Stop’ Button unless there is a danger to the product or of
personnel injury.
2. Do not stop the Unit by use of a disconnect or breaker.
Using the Emergency Stop Button, 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.
Enter, Up, Down
& Escape
.
Used in the programming and changing
of operating parameters of the Unit.
Emergency Stop
.
Will quickly shut the
Unit off. Is only to be
used in an
emergency.
Digital Readout
.
Indicates Unit pressure,
temperature, etc.
St
op
.
Causes the Unit to
enter ‘Idle’ mode
and then shut off.
St
art
.
Starts the Unit.

K100-C
Dec’15
- 5 -
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.
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
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
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.
What to look for. How to avoid the hazard.
2 0 F T
6 1 m
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 how
to avoid a situation that may
cause minor injury.
Information that you should
pay special attention to.

K100-C
Dec’15
- 6 -
Shipping Cleats
Your DV Systems ‘K Series’ Rotary Screw Compressor is shipped with several Shipping Cleats that must be
removed prior to the initial start-up. The Shipping Cleats are installed during assembly of the Unit simply to stop
any lateral movement of the Air End, Motor, etc during shipping.
The Cleats are located a) under the (3) Feet of the Oil Receiver, b) (1) under the Air End Bracket, and c) (1) under
the Motor of the Unit. Please remove these after locating the Unit but prior to running.
Oil Receiver / Air End Cleat Removal.
1.Locate the Oil Receiver in the
front right corner of the Unit and
locate the Air End Bracket at the
back of the Unit
2.Locate the orange Shipping Cleat
under each Foot of the Oil
Receiver and one Shipping Cleat
under the Air End Bracket.
3.Remove the Bolt and Washers
from each Cleat, and slide the
Cleat out.
Note: To remove the Cleats, you
may need to apply some
sideways force on the top of
the Receiver.
Motor Cleat Removal.
The Motor is fastened to the Unit framework by means of (1) Shipping Cleat as indicated below. Access to the
Cleat is by means of both the front and rear of the Unit.
Remove the Fasteners and slide the Cleat out of the assembly.
Motor Cleat from Front of Unit.
Motor Cleat from Rear of Unit.
Shipping Cleat Fasteners Fasteners Shipping Cleat

K100-C
Dec’15
- 7 -
Unpacking and Inspection
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
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.

K100-C
Dec’15
- 8 -
Installation – Mechanical
The Importance of a Proper Installation
As with all Air Compressors, a proper installation is key to both a) long Compressor life and b) quality compressed
air. A Compressor Unit not installed correctly, and coupled with a poor maintenance program, can be plagued
with costly issues not covered by the manufacturer’s warranty.
The drawing below indicates the components required for a good installation.
As the ‘K100’ Screw Unit does not include an Air Receiver, one must be located as shown. And though additional
filtration and a Refrigerated Dryer is shown, they may not be required in all instances, this dependent on the
quality of compressed air required.
No.: Part Number: Description: Notes:
1 K100 100 HP Compressor Unit
2 SAF-C-583 & SAF-Y-583 Canister & Cyclone Element Included with Compressor
3 H-9037 2” Dia x 12” (305mm L) Long Flex
ose
4 Advanced Air Pipe Systems 2” Diameter Pipe Contact Distributor for sizing
5 TA-400165 or TA-400200 Air Receiver, 165 psi or 200 psi Safety Valves sized to application
6 SAF-C-583 & SAF-S-583 Canister & 3 Micron Element
7 ASD500 Refrigerated Air Dryer
8 SAF-C-583 & SAF-E-583 Canister & 0.01 Micron Element
9 ECOTRON180 Oil Water Separator
10 KK-9860 Zero-Loss Autodrain
Plant piping from the system as shown above should be sized based on the Unit CFM and the length of the piping
as follows. Using smaller piping will greatly restrict air flow and cause issues downstream of the Unit.
CFM @ psi: 50 Feet 75 Feet 100 Feet 150 Feet 200 Feet 250 Feet 300 Feet
355 @ 175 2” 2” 2” 2-1/2” 2-1/2” 2-1/2” 2-1/2”
388 @ 150
463 @ 100 2-1/2” 2-1/2” 2-1/2” 3” 3”







Additional dry Air Receiver down-stream
could assist for demand surges.
Piping between Unit and Tank not
to exceed 10 ft (3 m)


K100-C
Dec’15
- 9 -
The Compressor must not be operated in
a confined area where the heat from the
Unit cannot readily escape.
Installation – Mechanical (cont’d)
Moving of the Unit.
Location of the Unit.
When moving the Air Compressor,
the forklift or hand lift forks go under
the Unit from the directions as
indicated.
Please be advised that care must be
taken when moving and positioning
the Unit as it may be top heavy.
Items to consider when installing the Unit are as
follows:
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.
Allow a minimum of 48” (1220mm) at the front
and back, 48” (1220mm) at the sides, and 5
feet (1524mm) above the Unit for easy access
to the various sides, this being for both the
proper ventilation of the Unit and ease of
servicing.
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.) See Page 10.
The ambient temperature should be between
10°C to 40°C (50°F and 104°F).

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.
Ensure the Unit is in a suitable location, and
installed correctly.

K100-C
Dec’15
- 10
-
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.

K100-C
Dec’15
- 11
-
Lubrication
Oil Reservoir
Oil Drain
Valve and
Plug
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. Also,
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 Cooler, Tubing,
etc.)
Opening the Oil Fill Port, fill the Reservoir to the mid-
point on the Oil Sight Glass. (This should be approx. 33
litres of Oil.) 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’.
Do not attempt to operate the Unit without
first checking whether there is oil in the Oil
Reservoir. Add oil as required. Serious
damage may result from use, however
limited, without oil.
Use of improper oil may negatively affect
Compressor performance or shorten Unit life.
Resulting problems are not covered by the
DV Systems Air Compressor Warranty.
Condensation (water) may form in the Oil
Reservoir with the oil. If this occurs, as the
water will tend to settle on the bottom of the
Reservoir, drain the water from the Reservoir
until you notice oil draining. Top up the
Reservoir with new oil using only the DV
Systems ‘DEV-3000’ oil.
Correct
Oil Level
Oil Fill Plug
Check Oil level after Unit has been shut off for a
minimum of 10 minutes.

K100-C
Dec’15
- 12
-
Installation - Electrical
General Information.
Wiring Practices.
When making power and control wiring connections, please observe the following precautions:
Power supply to the unit must be symmetrical, three-phase power with a ‘Wye’ and grounded neutral
configuration. If the supply is open Delta, a Delta to Wye isolation transformer is strongly recommended.
Ensure that all wiring, fusing, etc is done in a manner that meets with the appropriate codes and
regulations.
See the sales drawings and electrical schematic contained in this manual for information about Motor
nameplate amps, this used to determine the appropriate Disconnect / Breaker and Wiring sizes.
Please be advised that the Unit must be a) electrically connected to power and b) protected by way of
appropriate fusing as indicated on the ‘K100’ Sales Drawing. Any deviation from the information as
indicated and resulting in a failure of the equipment will void the warranty.
Notes: a) Wiring must be sized to suit the ‘system amps’ as indicated on the Sales Drawing.
b) Fuses must be semi-conductor J type, fast acting.
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 suitable Fused Disconnect or Breaker
(by others than DV Systems) is installed in the
electrical supply before the Compressor Unit.
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
125°C (257°F) or higher.
Failure to observe any of the above precautions could result in severe personal injury or death,
and/or damage to the Unit.

Failure to correctly connect the
Compressor to your building's electrical
services may result in serious personal
injury or damage to the equipment.
Install all covers and panels before
applying power to the Unit.

Before servicing the Unit, ensure the
power source has been shut down and
locked off.
Read and understand the information
contained in this manual before installing
or operating the Unit.

K100-C
Dec’15
- 13
-
Use of an incorrect Motor for your
particular building service will result in
premature Motor failure, and is not
covered by the DV Systems or Motor
Manufacturers Warranty.
Installation – Electrical (cont’d)
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.
It is critical that the Motor and Air End in the Rotary Screw Unit be turning in the correct manner as the Unit is
not equipped with an ‘Anti Rotation Switch’. Irreparable damage will be done if the Unit rotates in the
reverse direction. The correct rotation is as indicated at the Coupling area of the Unit.
Remove the Cover Plate from the Coupling area and pay close attention to the arrow indicating the
correct rotation.
To verify the correct rotation, start the Unit and turn off immediately using the Emergency Stop Button.
If the rotation is not correct, simply change two of the Motor Leads (‘T1’ and ‘T2’) at the Inverter.
Verify correct rotation again if required.
Do not attempt to operate the Unit without first checking whether there
is oil in the Oil Reservoir. Add oil as required. Serious damage may
result from use, however limited, without oil.
Cover Plate Coupling

K100-C
Dec’15
- 14
-
Installation – Electrical (cont’d)
Cooling Fan Rotation.
To ensure that the Unit operates at optimum
temperatures, a Cooling Fan is located on the top of
the Unit to draw warm air from the Cabinet
Enclosure. It is imperative that the Fan rotate in the
correct direction.
A label inside the Unit (as
shown at right) indicates the
proper Fan rotation.
‘E:0090 Phase Sequence’ Error will appear on the
Controller Screen if the phase sequence is incorrect.
If this occurs, switch the incoming leads ‘L1’ and ‘L3’
to the Unit.
Motor Maintenance Instructions.
Cleaning.
To ensure that the Motor operates at optimum temperatures and provides years of trouble-free service,
periodically clean the outside of the Motor Housing of any build-up of dust, etc. Though it is not anticipated that, if
installed correctly and in a suitable environment, there should be much build-up on the Motor, keeping the
Housing clean will allow the Motor to operate more efficiently.
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.
Noted below is a chart outlining the interval at which the Motor should be lubricated, this based on the Motor
horsepower. This must be part of a regular maintenance schedule.
Motor HP Interval Weight of Grease Volume of Grease
in Hours Ounces Grams Cubic Inch Teaspoon
100 2,000 2.12 60.0 4.1 13.4
The above chart is based on a standard environment in which the Motor is operating of (104°F). For
other conditions, please multiply the Hour Interval from the chart above by the factor as indicated
below.
Severity of Duty Factor Environmental Conditions
Standard 1.0 40°C (104°F) , clean, little corrosion
Severe 0.5 50°C (122°F), moderate dirt, corrosion
Extreme 0.1 > 50°C (122°F), severe dirt, abrasive dust
Low Temperature 1.0 < 30°C (86°F)
Lubricant.
Baldor motors are pre-greased, normally with Chevron SR #1-2. Equivalent and compatible greases are Texaco
Polystar, Shell Dolium R and Amoco Rykon Premium #2.
Power Wires to
Starter
Wiring from
Cooling Fan

K100-C
Dec’15
- 15
-
Do not attempt to operate the Unit without first checking
whether there is oil in the Oil Reservoir. Add oil as required.
Serious damage may result from use, however limited, without
oil.
Initial Start
-
up
1) Open the RH Front Access Panel, and ensure
that there is sufficient Oil in the Oil Reservoir.
Refer to the ‘Lubrication’ section (Page 11) in this
manual for proper type and level of Oil.
2) Ensure the Shipping Cleats are removed as
indicated on Page 6.
3) Do a brief visual inspection of the Unit.
Start-up Procedures
Do not place any materials in close proximity
to the Compressor. Placing materials against
or close to the Unit will limit the cooling
required, and could lead to premature failure.
Shut off all power to the Compressor Unit
before attempting any repair or maintenance.
Adjusting the settings of the Controller could adversely affect
the performance of the Unit. Only those individuals with
knowledge of the Unit should make any adjustments.
4) Place the Fused Disconnect / Breaker in the ‘On’
Position. Check that there is power to the
Controller.
5) Turn the Unit on momentarily by pressing the
‘Start’ Button on the ‘CSC300’ Controller.
Immediately press the ‘Emergency Stop’ Button
to stop the Unit. Ensure the Motor/Air End are
rotating in the correct direction. See ‘Motor/Air
End Rotation on Page 13.
Also ensure the Cooling Fan is rotating correctly.
See Page 14.
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 ‘CSC300’ Control Pad. Check
for any air or oil leaks.
If the rotation of the Air End is incorrect,
switch the phases ‘T1’ and ‘T3’ between the
Inverter and Motor. Refer to the
accompanying wiring schem
atic.
Stop Button
Use this to
shut the Unit
off. Allows the
Unit to idle
and then stop
after several
seconds.
Unit Controls
Start Button
Allows the Unit to
start.
Emergency Stop Button
Do not use to normally stop the Unit. To be used to
stop the Unit in emergencies only. Normal use will
damage electrical controls and Shaft Seal.

K100-C
Dec’15
- 16
-
Preventative Maintenance Schedule
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.
The typical operating temperature of the Unit, this dependent on ambient temperatures, is between 70°C and
85°C (158°F and 185°F).
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 damage to the internal components
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.
When servicing the Air Compressor, shut off all
power to the Unit, and drain it of air pressure.
It is the responsibility of the Compressor owner
to ensure that a regular Maintenance Schedule
is followed.
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 ‘Maintenance Schedule’ on the
following page) must be changed more frequently.
Regular Maintenance Items.
The Maintenance Kits for your Unit are as follows:
‘MK-K100-4000’ 4000 Hour Maintenance Kit
(2) DSC-624 Oil Filter
(1) DSC-001849 Inlet Safety Filter
(1) DSC-001880 Inlet Filter Element
‘MK-K100-8000’ 8000 Hour Maintenance Kit
(2) DEV-3000 5 Gal. Pail of Synthetic Oil
(2) DSC-624 Oil Filter
(1) DSC-001849 Inlet Safety Filter
(1) DSC-001810 Air Oil Separator Kit
(1) DSC-001880 Inlet Filter Element
(1) DSC-612 Scavenge Line Filter
(1) DSC-482 Scavenge Line Tube
(1) DSC-001811 Thermo Valve Repair Kit
(1) DSC-001813 MPV Repair Kit
Internal Access for Maintenance.
The internal components of the Unit are accessible
for servicing by way of opening the Front (‘A’) and
Rear (‘B’) Panels as shown.
B
A

K100-C
Dec’15
- 17
-
Preventative Maintenance Schedule (cont’d)
Maintenance Item: Daily
Maintenance Interval (in 000’s of Hours)
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
Replace Coupling Spider (5) X X X X X
Replace Tank Relief Valve X X X
Replace Solenoid (6) X X X
Rebuild Intake Valve (7) X X X
Rebuild Thermo Valve (8) X X X
Rebuild Minimum Pressure Valve (9) X X X X X
Replace Scavenge Line Filter (10) X X X X X
Motor Bearing Lubrication Refer to Motor Manufacturer’s Recommendations on Page 14
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 29 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
(2) Oil Filter DSC-624
(3) Air / Oil Separator: DSC-001810
(4) Inlet Filter Element DSC-001880
(4) Inlet Safety Filter DSC-001849
(5) Coupling Spider DSC-001762
(6) Intake Valve Solenoid DSC-002052
(7) Intake Valve Repair Kit DSC-001812
(8) Thermo Valve Repair Kit: DSC-001811
(9) Minimum Pressure Valve Kit: DSC-001813
(10) Scavenge Line ‘In Line’ Filter DSC-612
Ambient Filter DSC-001769

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Compressor Storage
At times, it may become necessary to store a Compressor Unit for an extended period of time, this because a) the
site may not be ready, b) the Unit may be shipped overseas, or c) the Unit may not be required for a period of
time (seasonal applications, etc). When storing a Compressor, the following areas must be addressed:
Location of the Unit.
The Unit must be stored in a cool, dry place away from the elements.
The Unit cannot be exposed to frost. Frost will damage the Seals, Tubing, etc.
The Unit cannot be exposed to moisture and condensation. Moisture will lead to component corrosion,
and will affect electrical components.
Temporary De-commissioning of the Unit.
If the Unit is not required for a short period of time, and is installed in its permanent location during that time:
Run the Unit for 30 minutes under load every week. This should prevent any corrosion.
Check the oil level before running.
Long Term De-commissioning of the Unit.
If the Unit is not required for a longer period of time, and is installed in its permanent location during that time:
Run the Unit for a minimum of 30 minutes under load before shutting down.
Switch the Unit off and allow for adequate ventilation in the room.
Turn off and lock the main power supply to the Unit.
Allow the Unit to cool down fully.
Disconnect the air and electrical connections to the Unit.
Remove drive motor fuses in order to prevent accidental start-up
If possible, the placement of desiccant inside the Unit Cabinet will assist in limiting moisture in the Unit.
Regularly turn the compressor’s drive shaft manually in order to prevent damage due to lack of use
Re-commissioning of the Unit.
If the Unit has been stored for a short period of time and has been run on a weekly basis, as suggested in
‘Temporary De-Commissioning of the Unit’ above, check to ensure that the oil level is correct. Once completed,
the Unit should be ready for normal use.
If stored for a longer period of time as noted in ‘Long Term De-Commissioning of the Unit’ above:
Reconnect the air and electrical connections to the Unit.
Remove any desiccant that was previously placed inside the Unit Cabinet.
Complete the ‘Start-up Procedures’ as noted on Page 15 of this manual.
If you have any questions concerning any of the above items or require
assistance, please contact your local DV Systems Distributor or Service
Center.

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Common Compressor Faults
Common Faults.
Noted below are the most common Faults experienced.
‘CSC300’ Alarms.
There is an issue with the Unit, but it will still operate.
Code: Description: Most Common Items to Check:
A:0083 Motor phase imbalance Check supply voltage, fuses and cable
A:0119 Delivery Pressure High Solenoid not working, Intake Valve Orifice clogged, Transducer dirty or faulty, pressure changed
incorrectly, alternate external pressure source
A:0129 Delivery Temperature High 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:4819 Routine Service Due Service Unit and reset Service Timer (Page ‘P16’ on Controller)
A:4809 Grease Service Due Service motor and reset Grease Service Timer (Page ‘P16’ on Controller)
‘CSC300’ 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:0010 Emergency Emergency stop switch is pressed
E:0070 Fan Motor Alarm Check electrical connections
E:0082 Motor Overload Motor drawing high amps, low voltage, high pressure settings, low oil level
E:0083 Motor phase Imbalance Check motor connections in the control panel and motor connection box
E:0090 Phase Sequence Rotation of Motor wrong, sequence order of supply cable incorrect
E:0091-
0093 Phase L1/L2/L3 Fault Check supply voltage, fuses and cable
E:0115 Delivery Pressure Sensor Fault Transducer not making good electrical contact, or defective
E:0119 Delivery Pressure High Solenoid Not working, Intake Valve Orifice clogged, Transducer dirty or faulty, pressure
changed incorrectly, alternate external pressure source
E:0125 Delivery Temp Sensor Fault Temperature Sensor not making good electrical contact, or defective
E:0129 Delivery Temperature High Ambient temp high, Unit dirty, low oil level, no air flow through Unit, Temp Sensor defective
E:1902 Inverter Fault Variable frequency drive tripped. Check VFD screen for more info.

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Variable Speed Drive
Your DV Systems ‘K Series’ Rotary Screw Compressor Unit may be equipped with a Vacon ‘Variable Speed
Drive’, or ‘VSD’. A Compressor with an integral VSD can handle the constant loads for an extended period of time
(running at close to 100% duty cycle), but it can also run at slower speeds to accommodate lower air demands at
other times of the day.
Variable Speed Drives can reduce the overall energy costs associated with operating the Compressor Unit by
simply controlling the speed of the Motor and Air End to match consumption. As Rotary Screw Compressors
using the variable speed technology match the varying air demands and therefore have the ability to impact your
energy consumption, some energy providers have offered rebates when these Units are purchased. Consult your
local energy provider to determine if this applies.
Shown below-right is the Variable Speed Drive.
VSD Interface
The VSD Controller Interface is shown at right. It
provides a means of operating, monitoring, and adjusting
the parameters of the Variable Speed Drive.
Please note that adjustments to the parameters of the
Variable Speed Drive should be made only by qualified
Technicians, or with the guidance of factory trained
personnel. Incorrect adjustments will affect the
performance of the Unit, and could result in damage to
the Drive.
Variable Speed Drive
‘CSC300’ Controller
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