Distributed by:
...
‘Heavy Duty
Industrial’
(HDI)
Air Compressor
Installation
Maintenance
and Service
Data
...
HDI-01
Mar ‘07
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
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
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.
If you require assistance, contact your Devair Distributor or Authorized Service Centre. If you wish to contact
Devair directly or need to locate your closest Distributor, please reach us at :
Phone: (705) 728-5657
Fax: (705) 728-4974
Email: sales@dvair.ca
Web: www.dvair.ca
All of the Policies and Procedures in this reference manual apply
exclusively to Devair Inc., here-in after referred to as Devair.
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
HDI-01
Mar ‘07
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.
NOTE
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.
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
observed.
How to avoid the hazard
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.
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
-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
HDI-01
Mar ‘07
Preventative Maintenance Schedule
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.
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
Daily
Weekly
Monthly
Every 3
Months
Every 6
Months
Yearly
X
Drain Air Receiver.
X
Check Oil level (and top up as required).
X
Replace Air Filter.
Replace Oil (mineral).
X
Check condition/alignment of Belts, Pulley, Flywheel
X
Check Safety Valves.
X
Check that Unit unloads when shutting down.
X
Clean and/or blow dust/dirt off Unit.
X
Replace oil (synthetic).
X
Check lubrication of Motor. Consult literature.
X
Inspect Valve Assemblies.
X
Inspect Check Valve.
X
Inspect Pressure Gauge.
X
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.
Second Year Maintenance
In the 2nd year of operation, the items as noted in the ‘First Year Maintenance’ must be done as well as the following:
Replace Belts.
Replace Valve Discs and Springs.
(Replace Valve Assemblies as required.)
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.
Third Year Maintenance
In the 3rd year of operation, complete the items as noted in the ‘First Year Maintenance’.
-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
HDI-01
Mar ‘07
Preventative Maintenance Schedule
Fourth Year Maintenance
In the 4th year of operation, the items as noted in the ‘First Year Maintenance’ must be done as well as the following:
Replace Belts.
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.
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.
Fifth Year Maintenance
In the 5th year of operation, complete the items as noted in the ‘First Year Maintenance’ on Page 3.
Sixth Year Maintenance
In the 6th year of operation, the items as noted in the ‘First Year Maintenance’ must be done as well as the following:
Replace Belts.
Replace Valve Discs and Springs.
(Replace Valve Assemblies as required.)
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.
Seventh Year Maintenance
In the 7th year of operation, complete the items as noted in the ‘First Year Maintenance’ on Page 3.
Insist on Genuine Devair Parts and Kits
when maintaining your Devair Compressor
Pump and Unit.
-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
HDI-01
Mar ‘07
Unpacking and Inspection
NOTE
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.
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
-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
HDI-01
Mar ‘07
Unit Identification
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.
Compressor Identification
Model Number of Unit:
Example:
VAV-5062-69
Serial Number of Unit:
Example:
12345 AB
Electrics of Unit:
Example:
230volt/60/3phase
Model Number of Pump:
Example:
447
Serial Number of Pump:
Example:
54321
Date Purchased:
Pump Nameplate
Model No.
Serial No.
447
54321
900
Max RPM @
175
PSI
600
Max RPM @
300
PSI
500 Min RPM Lubrication
Devair
Unit Nameplate
Devair Air Compressors
Model
Serial Number
Max. Press.
VAV-5062-69
12345 AB
175 psi
Caution:
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.
-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
HDI-01
Mar ‘07
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.
Component:
Description:
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.
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.
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.
Separator Filter:
acts as a pre-filter to the Refrigerated Air Dryer.
Refrigerated Air Dryer:
removes the moisture from the compressed air by lowering its
temperature.
Coalescing Filter:
removes oil from the compressed air
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.
-7-
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
HDI-01
Mar ‘07
Compressor Terminology
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.
Compressor Pump
Intercooler Tube
Compresses the air
This Tube cools the compressed air while
leading it from the low pressure Cylinder to
the high pressure Cylinder
Aftercooler Tube
This Tube leads the compressed
air to the Air Receiver while
allowing the air to cool
Belt Guard
Electric Motor
Pressure Switch
Check Valve
A pneumatically operated electric
Switch for starting and stopping the
Unit at predetermined minimum
and maximum pressures
One way Valve that allows air
to enter the Tank, but prevents
the air from flowing back into
the Compressor Pump
Pressure Gauge
Gauge reflects current Tank
pressure
Ball Valve
Discharge/outlet
Magnetic Starter
Air Receiver (Tank)
An electrically operated device which
receives a signal from the Pressure
Switch and allows power to flow to the
Motor.
Drain Valve
Allows the operator to drain
the moisture from the Tank
Pump Components
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.
-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
HDI-01
Mar ‘07
Installation - Mechanical
Location of the Unit.
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.
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.
Compressor
Foot
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.
Building
Wall, etc.
1/4” (0.75 cm)
Gap
Isolator
Pad
Floor
18” (0.5 m)
minimum
BeltGuard
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.
Compressor
Ensure that the floor under the Unit is smooth
and level. The Compressor must sit squarely on
all four Feet.
NOTE
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.,
Devair Installation
Kit Number
The Compressor must not be
operated in a confined area where
the heat from the Unit cannot readily
escape.
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.
‘HDI’ Compressor
Horsepower
IK515
5 To 15 HP
IK2530
25 and 30 HP
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
-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
HDI-01
Mar ‘07
Pump Lubrication
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
wrench.Use only Devair Premium
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.
Devair Premium
Mineral Oils
Room (Ambient)
Temperature
DV Lube20 (20 Wgt)
Part No. ‘PR20’
Up to 90°F (32°C)
DV Lube30 (30 Wgt)
Part No. ‘PR30’
90°F + (32°C +)
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 f e c t
Compressor Pump performance or
shorten Pump life. Resulting problems are
not covered by the Devair Inc. Air
Compressor Warranty.
Devair Premium Synthetic Oil (used in
high heat or high duty applications or
when Beltguard Aftercoolers are used)
OJ-2000 (20 Weight)
The following Maintenance Kits are available
through your Devair Distributor, the Kits
including Devair Premium Oil and Air Filter (s).
Oil Filler
Plug
Kits c/w Mineral Oil (20 Weight only)
Devair Pump Model
Kit Part Number
123
MK-223
223
MK-223
44642
MK-247
247
MK-247
447
MK-447
Proper Oil Level
(to bottom thread of Oil Port)
'O' Ring
Kits c/w Synthetic Oil
Devair Pump Model
Kit Part Number
247
MKS-247
447
MKS-447
Section Through CrankCase
at Oil Fill Port
- 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
HDI-01
Mar ‘07
Installation - Electrical
It is your responsibility to ensure that the
Compressor Unit is electrically connected in a
safe and correct manner. Any electrical work
must be carried out by a competent Electrician,
and be done is such a way that it meets all
applicable Codes and Regulations.
Please note
that, under normal
conditions, the Compressor Unit will
operate intermittently .
A Magnetic Starter, as shown below, must be an
integral part of the Compressor Unit circuit as it
provides overload protection to the Electric
Motor. A Magnetic Starter can be purchased
separate from the Unit, or factory-mounted at
time of manufacture.
The Unit starts/stops 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 Pump. Add Oil as
required. Serious damage may result
from use without Oil.
Failure to connect the Compressor
correctly to your building's electrical
services may result in serious
personal injury, or damage to
equipment.
Main Fuse Box
Fused Disconnect
or Circuit Breaker
L1
L2
L3
Magnetic Starter
C
Pressure
Switch
Motor
Typical Electrical Installation
of a Compressor Unit
Typical Magnetic Starter Wiring
(Subject to Local Codes & Authorities)
- 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
HDI-01
Mar ‘07
Installation - Electrical (cont’d)
Why hire a licensed Electrician?
Motors
Wiring must be done in a manner that the full
Motor nameplate voltage +/- 10% is available at
the Motor terminals during startup.
NOTE
Use of an incorrect Electric Motor for
your particular building service will
result in premature Motor failure, and
is not covered by the Devair or Motor
manufacturer's Warranty.
The Warranty that exists on the Electric Motor is
that of the original manufacturer. In the event of
a Motor failure, contact your Devair Distributor or
Service Centre for the location of the nearest
authorized Motor Service Centre.
To ensure that your new Devair Compressor will
work when required, you must ensure that it is
correctly wired to your building service. It is the
responsibility of the licenced Electrician to ensure
that:
A) the Unit that you have purchased is suitable for
your particular buildings electrical service.
B) protective devices such as a Magnetic Starter,
Fused Disconnect, etc. have been sized and
installed correctly.
C) any electrical accessories purchased with your
Compressor have been wired correctly
D) the wiring of the Unit meets with all applicable
codes and regulations.
E) when completed, the Unit works in both a safe
and correct manner.
Failure of the Compressor due to an incorrect
electrical installation is not covered by the
manufacturers warranty.
Pump Rotation
The Compressor is to be wired in a manner that
the rotation of the Flywheel causes the air to be
blown from the Flywheel forward over the Pump.
This, coupled with the free area of a minimum of
18” (0.5 m) behind the Beltguard, allows the
Pump to cool properly.
When facing the nameplate
side of the Unit, the
Flywheel rotation must be
clockwise.
- 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
HDI-01
Mar ‘07
Accessories - Pneumatic Autodrain
What is the purpose of the ‘AD-9400’ Autodrain?
The ‘AD-9400’ Autodrain is designed to drain moisture from the Compressor Unit each time the Unit
reaches maximum pressure and shuts off. As shown, the Unit receives its ‘pilot’ signal from the
Compressor Unloader, being tied into the Unloader Line by means of a Compression Tee.
All that is required for the automatic operation of the Autodrain is an intermittent air source like that
obtained by tapping into the Compressor Unloader Line.
A) The pilot signal (or air pressure) on the Unloader Line forces an internal Piston past the Drain Port,
sealing the internal Chamber from atmosphere.
B) As the Piston is forced forward, the internal Stainless Steel Ball Valve is opened, permitting
condensate and oil to be forced up into the Reservoir.
C) The air in the top of the Reservoir is compressed to system pressure.
D) As the pilot signal is returned to zero, the internal Piston returns, closing the system from the
atmosphere.
E) When the Piston reaches it’s original position, the Drain Port is opened, allowing the condensate to
escape.
As noted, suitable arrangements must be made to contain the condensate that is expelled from the
Autodrain. As the condensate may contain traces of oil, it must be disposed of accordingly.
Specifications:
Moisture
from Tank
Reservoir
Maximum working pressure of 200 psi (13.8 Bar).
Minimum working pressure of 30 psi (2.1 Bar).
Anodized aluminum body.
Stainless steel piston, spring, ball, screens, and
reservoir.
Buna seals and teflon ring.
Important Information:
1.
Maintenance/service work must only be done when
the Autodrain is not under pressure.
2.
Ensure the Autodrain is not subjected to
temperatures below freezing.
3.
Suitable arrangements must be made to ensure the
moisture is properly contained once evacuated from
the AutoDrain.
AutoDrain Assembly
Drain
Port
Pilot Signal
from
Unloader
Maintenance:
The Trap Mesh and Flat Mesh in the AutoDrain must be
cleaned periodically in order to ensure the Unit works
properly, and does so for a long period of time.
Devair offers a Repair Kit for the Unit, namely an ‘RK-AD9400’. The Kit includes a Flat Screen, Trap Screen, ‘O’
Ring, Piston and Seal Assembly, and an End Cap
Gasket.
- 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
HDI-01
Mar ‘07
Accessories - Electronic Autodrain
What is the purpose of the ‘KK-9840’ Autodrain?
The ‘KK-9840’ Autodrain is designed to drain moisture from the Compressor Unit based on an internal
Timer. The Timer is an electrical device, requires 120-60-1 to operate, and can therefore be plugged
into any wall outlet. A six foot (1.8 m) power cord is supplied.
The Autodrain is equipped with a Ball Valve, this allowing the air/moisture supply to the Drain to be
closed. The Ball Valve is also coupled with an internal wire mesh Filter, this to clean any impurities from
the air/moisture and prevent them from clogging the Autodrain mechanism.
By simply adjusting the two dials on the Autodrain Timer, the duration of the drains and the time
between drains can be altered to suit your particular application. The duration for the drain can be set
between 0.5 to 10 seconds, the time between drains 1 to 45 minutes.
As noted, suitable arrangements must be made to contain the condensate that is expelled from the
Autodrain. As the condensate may contain traces of oil, it must be disposed of accordingly.
Timer
Specifications:
Maximum working pressure of 230 psi (16 Bar).
Includes Manual Ball Valve and Filter
Drain duration of between .05 to 10 seconds
Moisture
from Tank
Operating cycle time of 1 to 45 minutes
UL and CSA approved
End Cap
Ball Valve
Wire Mesh
Filter
Important Information:
1.
Maintenance/service work must only be done when
the Autodrain is not under pressure.
2.
Ensure the Autodrain is not subjected to
temperatures below freezing.
3.
Suitable arrangements must be made to ensure the
moisture is properly contained once evacuated from
the AutoDrain.
Maintenance:
The Wire Mesh Filter as shown above must be cleaned
periodically in order to ensure that the Unit works
properly, and does so for a long period of time.
De-pressurize the Unit, remove the End Cap, and remove
the Wire Mesh Filter. Clean with water, and replace.
- 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
HDI-01
Mar ‘07
Accessories - Oil Monitor
What is the purpose of the ‘OM-9400’ Oil Monitor?
The ‘OM-9400’ Oil Monitor provides a means of ensuring there is sufficient oil in the Pump during
regular Compressor operation. It contains a Micro-switch which registers the level of oil in the Pump.
Should the level of oil drop below a preset limit, the Micro-switch will open, causing the Unit to shut
down.
The Oil Monitor is an electrical device, requiring 120 or 230 volts to operate. On Units where the
voltage is 460 or 575, a Step-down Transformer or alternate power source must be provided by a
licensed Electrician. The Electrician must then ensure that the wiring of the Monitor(s) meets all
applicable codes and regulations.
To ensure the Oil Monitor is functioning as designed, it is best to a) test the Monitor on a regular basis
and b) check the oil level manually on a regular basis. To test the Monitor, simply turn the Knob on the
Monitor Face in a counter-clockwise direction, thereby leading the Switch to believe the oil level is
below the preset limit.
Please be advised that, in some instances, the Level Indicator may read as ‘Low’ on the Monitor. This is
acceptable. Please test the Monitor to ensure it is functioning correctly in this case.
Electrical
Access Panel
Specifications:
Level Indicator
Die cast aluminum case painted black.
Internal brass float registers oil level.
Lens allows viewing of oil level.
Suitable for use with voltages up to 230v ac.
Maximum working pressure of 25 psi (1.72 Bar).
Test Knob
Important Information:
Maintenance:
1.
The Oil Monitor, if not electrically wired by the
manufacturer, must be connected by a licensed
Electrician. Please wire as per the following page.
Test the Oil Monitor on a regular basis to ensure it is
working as designed.
2.
Test the Oil Monitor on a regular basis to ensure it is
operating correctly.
As well, check for any oil or air leaks on the Monitor and
on the oil tubing and air piping leading to the Pump.
- 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
Accessories - Oil Monitor (Cont’d)
- 16 -
HDI-01
Mar ‘07
Distributed by:
CENTRAIR Air Systems & Supplies, 68 Hooper Rd., Unit 5, Barrie, ON L4N 8Z9
Phone: 705-722-5747 Fax: 705-722-5458 sales@centrair.ca www.centrair.ca
HDI-01
Mar ‘07
Accessories - Beltguard Aftercoolers
What is the purpose of a Beltguard Aftercooler?
A Beltguard Aftercooler is designed to decrease the temperature of the compressed air as it exits the
Compressor Pump and before it enters the Air Receiver Tank. The compressed air is cooled as it
passes through the ‘radiator style’ Aftercooler, the air flow created by the draw of the Pump Flywheel as
it turns.
When using a Beltguard Aftercooler, it is imperative that:
A) the Beltguard be at least the required minimum distance of 18” (0.5 m) from any obstruction or
wall. With this design, maximum air flow through the Aftercooler is critical to both ensure the
cooler works effectively and the Pump receives proper cooling.
B) the Oil used in the Pump be a synthetic oil, namely ‘Oj2000’.
If the above criteria are not met, the Aftercooler will not work effectively, and the Pump could fail
prematurely.
Piping from
Pump
Specifications:
Maximum working pressure of 175 psi (12.08 Bar).
Reduces the temperature of the compressed air by
approximately 100°F to 125°F between the input
and output of the Cooler
Piping to
Tank
Beltguard
Aftercooler
Important Information:
Maintenance:
1. There must be a minimum of 18” (0.5 m)
between the Aftercooler and any obstruction.
2. Devair ‘OJ2000’ Oil must be used in the
Compressor Pump.
3. The Beltguard Aftercooler must be cleaned on
a regular basis with compressed air to ensure
the unobstructed air flow through the cooler.
The Beltguard Aftercooler must be cleaned with
compressed air on a regular basis in order that
any dust, residue, etc is removed and does not
impede the air flow through the cooler. Failure to
do this will result in premature Compressor
failure.
- 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
HDI-01
Mar ‘07
Accessories - Duplex Alternator Relays
What is the purpose of an Alternator Relay ?
An Alternator Relay is used with a Duplex Compressor Unit, namely a Unit with two Pumps and two
Motors on one large Tank. Coupled with two Magnetic Starters, the Alternator Relay allows the Pumps
to alternate back and forth. This is necessary to spread the compressed air load over the two Pumps.
Naming the Pump and Motor assemblies on the Tank as being Unit #1 and Unit #2 allows the
alternating to take place. The ‘Lead Pressure Switch’ (or ‘PS1’) regulates the Units to start, and is
therefore set at the maximum pressure setting. (In smaller Compressors, this is generally the Switch
with the Unloader.) The ‘Lag Pressure Switch’ (or ‘PS2’) is set at 10 psi less than the Lead Switch, and
will bring the second Unit on only if the pressure in the Tank goes below that of the ‘cut-in’ pressure of
‘PS2’. (For example, this will occur when the Unit is started at 0 psi in the Tank.)
Shown below is a typical schematic for a Duplex Unit c/w (2) Magnetic Starters and Alternator Relay.



































































- 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
HDI-01
Mar ‘07
Initial Start-up Procedure
NOTE
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.
Initial Start-Up
1) Remove the Oil Filler Plug, and ensure
that there is Oil in the Crankcase. Refer to
the "Lubrication" section (page 8) in this
manual for proper type and level of Oil.
Do not place any materials on or against
the Belt Guard, or the Compressor Unit as
a whole. Placing materials there will limit
the cooling of the Compressor, and could
lead to premature failure.
2) Replace the Oil Filler Plug, and use a
crescent wrench to tighten snug plus 1/4
turn.
3) Do a visual inspection of the Unit, and
ensure that all Bolt heads are sufficiently
tightened. This must be done, as some
fasteners may become loose in transit.
4) Turn the Compressor 'On' momentarily by
positioning the Fused Disconnect in the 'On'
position. Ensure that the Flywheel is turning
in the correct direction. See "Pump
Rotation" (page 10).
NOTE
6) After having run the Compressor Unit for 30
minutes, close the Ball Valve, and allow the
unit to reach maximum operating pressure.
Ensure that the Compressor shuts down at
the pre-set maximum pressure, and the
head pressure is released through either
the front of the Pump (the CPR) or at the
Pressure Switch.
7) Check the Compressor and Piping Systems
for air leaks, and correct as required.
On Compressors with 3 phase power,
adjust the wiring at the Motor terminals if
the rotation is incorrect. Refer to the
wiring diagram at the Motor terminal
box.
5) Open the Compressor's Ball Valve, and
start the Unit. Ensure that the air is
escaping to atmosphere. Allow the Unit to
operate in this fashion for approximately 30
minutes. This lubricates the Pistons,
Bearings, and all internal surfaces.
NOTE
Shut off all power to the Air Compressor
Unit before attempting any repair or
maintenance.
8) Stop the Compressor, and check the Oil
level in the Crankcase. Add Oil as required.
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 Devair Distributor or Authorized Service
Centre.
- 19 -
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
HDI-01
Mar ‘07
Trouble-Shooting Guide
When servicing the 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.
Cause
Condition
A. Excessive Noise
1.
2.
Loose flywheel or motor pulley.
Loose valve.
1.
2.
3.
If noisy only during start-up, check for
loose belts.
Vibrating beltguard, piping, or loose belts.
Unit not installed level.
Improper grade or level of oil in crankcase.
3.
Carbon or other foreign material on head
of piston.
Normal sound amplified through floor or
carried through remote air intake (when
used).
If the noise is a knock, and cannot be
attributed to any of the above, the
problem could be worn bearings.
7.
9.
Worn main bearings can usually be
detected by noticeable end play on the
flywheel. Replace the main bearings.
Worn connecting rod insert bearings
or connecting rods may be detected by
removing a valve and watching the
piston while moving the flywheel by
hand. If the flywheel can be moved at
midstroke without movement of the
piston, bearing inserts or connecting
rod may need to be replaced.
1.
High ambient temperature and/or
humidity.
1.
2.
High percentage of running time. (80%
to 100%)
2.
3.
Obstructed or undersized air intake
piping, where remote air Intake is
used.
3.
4.
5.
6.
Restricted air intake filter.
Overfilling the crankcase with oil.
Wrong type of oil.
4.
5.
6.
7.
8.
9.
Carbonned exhaust valves.
Worn valves.
Worn piston rings.
7.
8.
9.
Install a moisture separator and/or oil
filter in the air line at least 8 feet
from the air receiver.
Check for air leaks. If no leaks are
found, you may require an additional
compressor unit, as your air demand
is too much for the existing unit.
Clean or replace the piping. Contact
Devair or contact your local
Distributor or Service Centre for sizing
requirements.
Replace air intake filter.
Fill to proper level.
Check 'Lubrication' in this manual or
contact your local Devair Distributor or
Service Centre.
Clean or replace as required.
Replace valve assemblies.
Replace rings and check cylinder
walls for scoring.
4.
5.
6.
7.
8.
9.
B. Oil Pumping and
Excessive Carbon
Formation
or
Appearance of Water
and Oil in the in the Air
Lines.
Suggested Correction
- 20 -
4.
5.
6.
8.
Tighten as required.
Inspect valve for damage. Replace as
required. Check to ensure valve is
seated properly in head. Reinstall,
tightening valve plug and set screw
Tighten until no slippage is apparent.
Allow some slack.
Tighten as required.
Ensure that unit is mounted level.
Use correct oil and ensure level is
correct.
Clean top of piston. Check cylinder
walls for scoring, etc.
Mount unit on vibration isolators.
Insulate intake piping from building.
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
HDI-01
Mar ‘07
Trouble-Shooting Guide (cont’d)
C. Reduced Air Delivery or
Insufficient Air
D. Compressor Overheating
Suggested Correction
Cause
Condition
1.
2.
Restricted air intake piping or filter.
Loose 'V' belt.
3.
4.
5.
Pump valves or tank check valve
leaking,sticking, or carbonned-up.
Air leaks in system.
Undersized unit for air requirements.
1.
1.
2.
3.
Clean or replace.
Tighten as required. Do not overtighten.
Clean, repair, or replace.
4.
5.
Fix leaks.
Contact local distributor or service
centre for suggestions.
Undersized unit for air requirements.
1.
2.
Compressor too close to building wall.
2.
3.
Pump rotating wrong way.
3.
4.
5.
Air leaks in air lines.
Remote air intake piping restricted or
too small.
4.
5.
6.
7.
Restricted air filter.
Improper level and/or grade of oil in
the crankcase.
6.
7.
Maximum pump operating time
should be 75% to 80%, which relates to
45 minutes per hour.
Relocate compressor. See 'Location of
the Unit' (page 7) in this bulletin.
Check rotation of the flywheel;
rotation must be clockwise when
facing the unit. Reversing the leads at
the motor will correct.
Check for source of leak and correct.
Clean or replace piping. Contact
Devair or your local distributor or
service centre.
Clean or replace air filter.
See 'Lubrication' (page 8) in this bulletin,
or contact your local Distributor or
Service Centre.
Clean or replace as required.
Replace components as required.
8.
9.
Worn or carbonned valves.
Broken valve discs or springs, loose
valve assemblies, or badly worn or
damaged valve seats.
10. Carbonned aftercooler tube or check
valve.
8.
9.
10. Clean or replace.
Should the items as noted in 'D' not provide any insight as to why the unit is overheating, the problem
may lie in the environment in which the unit is operating. A compressor unit located in a warm room
may show signs of overheating.
The unit should either be moved to a cooler environment, or the existing environment modified. Wall
louvers or stationary fans may improve conditions. Contact your local Distributor or Service Centre
for further information.
E. 'V' Belt(s) roll off the
Flywheel or Motor Pulley
1.
2.
3.
4.
F. Flywheel or motor pulley
wobbles or comes loose.
1.
2.
Flywheel and motor pulley not
aligned properly.
In the case where 2 belts are used,
belts may not be 'matched set'.
A nick or tear on the edge of the belt.
Belts do not match the flywheel
groove (such as 'A' or 'B' section).
1.
Align using a straight edge.
2.
Purchase new set of matched belts.
3.
4.
Purchase new set of matched belts.
Purchase new set of matched belts,
paying close attention to 'section'
requirements.
Clamping bolt not tight enough on
flywheel.
Set screw on motor pulley not tight
enough.
1.
Tighten as required.
2.
Take existing set screw out purchase
new one. Set screws have a lock-tite
coating, and can only be adjusted once.
- 21 -
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
HDI-01
Mar ‘07
Trouble-Shooting Guide (cont’d)
Suggested Correction
Cause
Condition
G. Water in Air Receiver.
1.
Condensation in the air receiver.
H. Crack in Air Receiver.
Though this condition is rare, damage to the
Receiver may occur in transit or be caused
by incorrect mounting on site.
1.
This is not caused by faulty
equipment, but rather the natural
result of compressing air. This
condition is corrected by draining the
Receiver daily, or purchasing an
automatic drain. Contact your local
Distributor or Service Centre.
Do not attempt to repair the receiver. Do
not continue to operate the compressor
unit. Contact your local Distributor or
Service Centre for further guidance.
1.
2.
3.
4.
5.
Started without oil.
Ran low on oil.
Worn rod bearing Inserts.
Piston & pin assembly seized.
Worn crankshaft bearings.
1.
Spillage of oil when filling.
1.
2.
3.
Overfilling of crankcase with oil.
Leak at oil filler plug.
2.
3.
4.
Oil leak at gaskets, cap screws,
head, cylinder, or crankcase.
4.
5.
6.
7.
Loose valve plugs.
Loose side or end plates.
Oil seal leak.
5.
6.
7.
8.
L. Centrifugal Pressure
Release (CPR) does
not function, or leaks
Air when unit is
operating .
1.
CPR may be dirty or faulty.
1.
Clean, repair or replace. Repair kit is
available for CPR mechanism.
M. Unloader leaks air
constantly when unit
is not operating.
1.
The Disc in the check valve is not
seating properly, as it may be wedged
open by debris, or damaged. Air is then
allowed to escape from the receiver out
through the unloader.
1.
Clean or replace check valve as
required.
J. Compressor Tie-ups.
(Can the Flywheel be
turned freely?)
K. Oil Leaks
or
Appearance of Oil on the
Compressor
- 22 -
The Pump will require a major teardown, at
which time defective parts must be repaired
or replaced.
Use care in filling, and wipe unit
clean.
Drain oil until proper level is reached.
Check filler plug for any irregularities;
file as needed. Replace 'O' ring if
required. Tighten plug with crescent
wrench.
Replace gaskets as required. Use
Pipe Dope or Gasket Compound on all
cap screw threads.
Tighten valve plugs.
Tighten plates.
Replace oil seal.
File or sand with emery cloth.
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
HDI-01
Mar ‘07
Trouble-Shooting Guide (cont’d)
N. InterCooler Safety Valve
continuously pops.
Suggested Correction
Cause
Condition
1.
2.
Dirty or defective high pressure Intake or
exhaust valves may cause the safety valve
to pop while the pump is running. Back
pressure from the high pressure cylinder
will escape back through the intercooler,
and pop the 75 psi safety valve.
Intercooler clogged with carbon.
1.
Clean, repair, or replace the valves as
required.
2.
Clean or replace.
Devair 7 Year Limited Pump Warranty
Devair has implemented a new 7 Year Limited Pump Warranty, this being unprecedented in the Piston
Compressor market. The new Warranty reflects the Devair commitment to providing quality Air Compressor Units
to our Customers, this being the cornerstone of our long history in building Heavy Duty Industrial Air
Compressors.
The ‘7 Year Limited Warranty’ applies only to those Pump Assemblies that:
• are provided on and sold as a complete ‘HDI’ Devair Heavy Duty Cast Iron Compressor Unit. Pumps sold
as ‘separate sale items’ or having the ‘IS’ or ‘SDI’ designation are governed by their own Warranty
applicable to that product.
• have been manufactured by Devair after January 1, 2007.
• have been registered with the manufacturer within thirty (30) days from the date of purchase, this done by
returning the completed ‘Warranty Registration Card’ by email, fax, or post.
• have been maintained in accordance with the Devair ‘Preventative Maintenance Schedule’ as provided
here-in.
• have been maintained and serviced using only ‘Genuine Devair’ parts and kits, this including (but not limited
to) Oil and Filters.
Devair 5 Year Limited Motor Warranty - 3 Phase Motors Only
With the above noted Warranty, Devair has also implemented a new 5 Year Limited Motor Warranty for 3-Phase
Motors. This Warranty applies only to those Motors that:
• are provided on and sold as a complete ‘HDI’ Devair Heavy Duty Cast Iron Compressor Unit. Motors sold as
‘separate sale items’ or having the ‘IS’ or ‘SDI’ designation are governed by their own Warranty applicable to
that product.
• are provided on ‘HDI’ Units manufactured by Devair after January 1, 2007.
• have been registered (along with the Compressor Unit) with Devair within thirty (30) days from the date of
purchase, this done by returning the completed ‘Warranty Registration Card’ by email, fax, or post.
• have been maintained in accordance with the manufacturers recommendations as provided with the Unit.
The ‘Five Year Limited Motor Warranty’ includes repair parts / Motor assemblies only, this at the discretion of
Devair. Any costs of labour, shipping, or travel incurred are not included in the Limited Warranty.
Please note that single phase Motors are explicitly excluded from this Warranty.
- 23 -
Copyright Devair Inc., 2007
Printed in Canada