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Powerex AS-XXX manual

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Table of contents for the manual

  • Page 1

    Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or prop- erty damage! Retain instructions for future reference. Powerex ?[...]

  • Page 2

    Base Actual Hp Motor Rating Compressor Compressor Capacity ACFM* Model 1Ø 3Ø Hp RPM RPM 100% Runtime 50% Runtime 33% Runtime TABLE 1: AS-XXX SERIES POWEREX SIMPLEX AIR COMPRESSORS PERFORMANCE SPECIFICA TIONS 1725 1720 1725 1725 1750 1750 1745 1745 1745 1750 — .54 — .73 — 1.07 1.54 2.0 3.1 5.6 8.2 10.3 .54 — .73 — 1.07 — — — — ?[...]

  • Page 3

    2 0.5 ON 4 6 sec. 10 40 8 10 5 0.5 45 20 30 TEST OFF min. 3 Climate Control Simplex Example 1: To order a Simplex air compressor with a 3/4 Hp single-phase motor, 60 gallon tank, single- phase 115 volt starter, automatic tank drain and an air dryer, use product code AS-107-254. Example 2: To order a Simplex air compressor with a 10 Hp three-phase m[...]

  • Page 4

    4 Climate Control Simplex Figure 6 - AS-XXX Three-Phase Wiring With Pressure Switch Used for Pilot Duty NOTE: “M” = Magnetic Contactor N.C. Pressure Switch *Comp. Motor * With Integral Overload Secondary Thermal Overloads Starter Manual Disconnect Switch 1Ø 230 VAC Manual Disconnect Switch 1Ø Line Voltage 3Ø Line Voltage N.C. Pressure Switch[...]

  • Page 5

    5 Climate Control Simplex *Inches x 2.54 = Centimeters, Pounds x 0.454 = Kilograms **Add 60.0 lbs. for units equipped with a factory mounted air dryer A D Optional Dryer Discharge Optional Starter Figure 7 - Dimensions (See Table 3) Plug B C TABLE 3: DIMENSIONS (Inches*) AND SHIPPING WEIGHTS (Pounds*) A B Shipping Weight** Base w/Starter w/o Starte[...]

  • Page 6

    Climate Control Simplex 6 D B C A PUMP AND FLYWHEEL: Motor Hp 1/2, 3/4 1 19.5 A-005-6001 1, 1 1 ⁄ 2 1 35 A-010-6001NP 2 1 59 A-020-6001NP 3 1 66 A-030-6001NP 5 1 115 A-050-6001NP 7 1 ⁄ 2 1 121 A-075-6001NP 10 1 180 A-100-6001NP B VALVE KIT: Includes valve plate, spacer and head gasket Motor Hp 1/2 1 0.4 A-005-6002 3/4 1 0.4 A-005-6002 1, 1 1 ?[...]

  • Page 7

    7 Climate Control Simplex REPLACEMENT PARTS LIST (Continued) F MOTOR PULLEY: Motor Hp Type 1/2 1A-4.4” P.D., 5/8” Bore 1 3.8 A-005-6007 3/4 1A-5.8” P.D., 5/8” Bore 1 3.9 A-007-6037 1 (1 Ø) 1A-4.0” P.D., 5/8” Bore 1 3.2 A-110-6007 1 (3 Ø) 1A-4.0” P.D., 7/8” Bore 1 3.2 A-010-6007 1 1 ⁄ 2 1A-6.0” P.D., 7/8” Bore 1 5.6 A-020-600[...]

  • Page 8

    8 Climate Control Simplex Powerex Limited Warranty Powerex 3 Year / 10,000 Hour Extended Parts Limited Warranty - Powerex warrants each Compressor Pump or Scroll Air-End against defects in material or workmanship from the date of purchase for a period of Three years or 10,000 hours , whichever may occur first. This warranty applies to the exchange [...]

  • Page 9

    Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference. Powerex • [...]

  • Page 10

    Base Actual Hp Motor Rating Compressor Compressor Capacity SCFM Model 1Ø 3Ø Hp RPM RPM 100% Runtime 50% Runtime 33% Runtime TABLE 1: AD-XXX SERIES POWEREX DUPLEX AIR COMPRESSORS PERFORMANCE SPECIFICA TIONS 1725 1720 1725 1725 1750 1750 1745 1745 1745 1750 — .54 — .73 — 1.07 1.54 2.0 3.1 5.6 8.2 10.3 .54 — .73 — 1.07 — — — — — [...]

  • Page 11

    3 Climate Control Duplex Example 1: To order a Duplex air compressor with a 3/4 Hp single-phase motor, 80 gallon tank, deluxe 230 volt alternator package, automatic tank drain and an air dryer, use product code AD-107-3G4. Example 2: To order a Duplex air compressor with a 10 Hp three-phase motor, 200 gallon tank and an auto drain, use product code[...]

  • Page 12

    Climate Control Duplex 4 Figure 4 Deluxe Alternator Package Wiring Diagram for Three-Phase Units Figure 5 Basic Alternator Package Wiring Diagram For Three-Phase Units IT 1 A2 L 3 A1 IT 2 L 2 L 1 IT 3 Motor 1 1M FU FU Alt Selector Switch X1 X2 FU 2M Motor 2 L 1 L 2 L 3 A1 A2 2T 1 2T 2 2T 3 Lag Switch Cut In: 60 psig (420 kPa) Cut-Out: 80 psig (560 [...]

  • Page 13

    5 Climate Control Duplex B B Shipping Weight** Base A with without C D E F G with without Model Alternator Alternator Alternator Alternator *Inches x 2.54 = Centimeters, Pounds x 0.454 = Kilograms **Add 60.0 lbs. for units equipped with a factory mounted air dryer TABLE 3: DIMENSIONS (INCHES) AND SHIPPING WEIGHTS (POUNDS*) Figure 6 - Dimensions (in[...]

  • Page 14

    6 D C A PUMP AND FLYWHEEL: Motor Hp 1/2, 3/4 2 19.5 A-005-6001 1, 1 1 ⁄ 2 2 35 A-010-6001NP 2 2 59 A-020-6001NP 3 2 66 A-030-6001NP 5 2 115 A-050-6001NP 7 1 ⁄ 2 2 121 A-075-6001NP 10 2 180 A-100-6001NP B VALVE KIT: Includes valve plate, spacer and head gasket Motor Hp 1/2 2 0.4 A-005-6002 3/4 2 0.4 A-005-6002 1, 1 1 ⁄ 2 2 0.5 A-010-6002NP 2 4[...]

  • Page 15

    Climate Control Duplex REPLACEMENT PARTS LIST E BELTS: 7 1 ⁄ 2 (200 gal tank) A-75 4 2.0 A-075-6056NP (Continued) 10 A-84 4 2.4 A-100-6006NP F MOTOR Motor Hp Type PULLEY: 1/2 1A-4.4” P.D., 5/8” Bore 2 3.8 A-005-6007 3/4 1A-5.8” P.D., 5/8” Bore 2 3.9 A-007-6037 1 (1 Ø) 1A-4.0” P.D., 5/8” Bore 2 3.2 A-110-6007 1 (3 Ø) 1A-4.0” P.D., [...]

  • Page 16

    Climate Control Duplex 8 Maintenance Schedule Operating Hours Item Action needed 500 2500 5000 10,000 15,000 20,000 Remarks Tank Drain moisture Daily Inlet air filter Replace  (Every 2,500 hrs or less) Blower fan Clean  Fan duct Clean  Compressor fins Clean  (Every 2,500 hrs or less) Oil change Replace (Every 1,500 [...]

  • Page 17

    Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or prop- erty damage! Retain instructions for future reference. Powerex ?[...]

  • Page 18

    2 Reciprocating Air Compr essor Pumps VENTILATION 1. If the compressor is located in a total- ly enclosed room, an exhaust fan with access to outside air must be installed. 2. Never restrict the cooling fan exhaust air. 3. Never locate the compressor where hot exhaust air from other heat generating units may be pulled into the unit. WIRING Refer to[...]

  • Page 19

    3 Reciprocating Air Compr essor Pumps LPS 010 LPS 020 LPS 030 LPS 075 LPS 100 7.5” 3.2” 6.7” 8.3” 11.5” 22.8” 4.4” 26.0” 11.4” 5.3” 29.7” 12.2” 6.3” 18.9” 17.8” 16.2” 20.2” 21.8” 21.7” Figure 2 - Dimensional Drawings CS100P 13.9 10.8 7.9 3.7 9.4 11.9” 11.9” 15.0” 18.0” 20.1” 4.4” 26.0” 11.4” 5.3[...]

  • Page 20

    Reciprocating Air Compr essor Pumps Maintenance Schedule Operating Hours Item Action needed 500 2,500 5,000 10,000 15,000 20,000 Remarks Tank Drain moisture Daily Inlet air filter Replace ●▲ (Every 2,500 hrs or less) Blower fan Clean ●●●● Fan shroud Clean ●●●● Compressor fins Clean ● (Every 2,500 hrs or less) Oil change Replac[...]

  • Page 21

    5 Reciprocating Air Compr essor Pumps Air Filter Replacement 1. Remove wing nut. 2. Remove canister and wipe after removing old cartridge. 3. Remove and discard filter cartridge. 4. Install new filter cartridge. Do not attempt to clean and reuse filter cartridge. Wipe clean with dry cloth once new filter is in place. Ring Replacement Every 15,000 H[...]

  • Page 22

    6 Reciprocating Air Compr essor Pumps CS100P Figure 5 - Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 24 16 30[...]

  • Page 23

    7 Reciprocating Air Compr essor Pumps CS100P 1 Cylinder IP036000AV 1 2 Cylinder gasket IP035901AV 1 3 Cylinder head IP035800AV 1 4 Crank case ▲ 1 5 Bearing case ▲ 1 6 Bearing case gasket IP035301AV 1 7 Oil gauge set 91117120 1 8 Oil drain pipe IP031701AV 1 9 Oil drain cap with gasket IP001900AV 1 10 Breather assembly with gasket IP002100AV 1 11[...]

  • Page 24

    8 Reciprocating Air Compr essor Pumps LPS010 Figure 6 - Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 22 23 24 25 26 27 C C 19 15 28 28 NOTE: Apply a thin layer of liquid gasket to entire surface of Item 28. 29[...]

  • Page 25

    9 Reciprocating Air Compr essor Pumps LPS010 1 Cylinder 91000560 1 2 Cylinder head 91003550 1 3 Unloader cap 01052041 1 4 Crank case ▲ 1 5 Bearing cap ▲ 1 6 Oil gauge 01909600 1 7 Oil drain pipe 01119400 1 8 Oil drain cap set 01120023 1 9 Breather assembly and gasket 01919470 1 10 Bearing cap rubber seal 01146550 1 11 Crankshaft 91223551 1 12 P[...]

  • Page 26

    10 Reciprocating Air Compr essor Pumps LPS020 Figure 7 - Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 43 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 B B C 34 18 25 38 37 39 40 36 C 41 42 NOTE: Apply a thin layer of liquid gasket to entire surface of Item 42. 42 10 31[...]

  • Page 27

    11 Reciprocating Air Compr essor Pumps LPS020 1 Cylinder 91000560 2 2 Cylinder head 91003560 2 3 Intake return pipe elbow 06800261 1 4 Unloader cap 01052041 2 5 Intake joint (1) 91345561 1 6 Intake joint (2) 91346571 1 7 Breather flange 91176580 1 8 Crankcase ▲ 1 9 Bearing cap ▲ 1 10 Oil gauge 01909600 1 11 Oil drain pipe 01119400 1 12 Oil drai[...]

  • Page 28

    12 Reciprocating Air Compr essor Pumps LPS030 Figure 8 - Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 B C D D 35 36 38 39 40 41 18 28 25 34 37 C 42 NOTE: Apply a thin layer of liquid gasket to entire surface of Item 43. 43 43 44 31[...]

  • Page 29

    13 Reciprocating Air Compr essor Pumps LPS030 1 Cylinder 91033570 2 2 Cylinder head 91004600 2 3 Intake return pipe elbow 06800281 1 4 Unloader cap 01052451 2 5 Intake joint (1) 91345570 1 6 Intake joint (2) 91346571 1 7 Breather flange 91176580 1 8 Crankcase ▲ 1 9 Bearing cap ▲ 1 10 Oil gauge 01909600 1 11 Oil drain pipe 01119430 1 12 Oil drai[...]

  • Page 30

    1 2 3 5 6 7 9 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 C C D D 30 31 42 43 44 33 39 5 26 41 40 4 11 15 34 8 Reciprocating Air Compr essor Pumps LPS050 14 Figure 9 - Replacement Parts Illustration 10 38 45 45 Note: Apply a thin layer of liquid gasket to entire surface of item #45. 42[...]

  • Page 31

    15 Reciprocating Air Compr essor Pumps LPS050 1 Cylinder 91000590 2 2 Cylinder head 91005580 2 3 Intake return pipe fitting 06801281 1 4 Unloader cap 01052451 2 5 Intake joint 91345660 2 6 Breather flange 91176580 1 7 Crank case ▲ 1 8 Bearing case ▲ 1 9 Oil gauge 91909600 1 10 Packing-oil gauge 01120600 1 11 Oil drain pipe 91119430 1 12 Oil dra[...]

  • Page 32

    16 Reciprocating Air Compr essor Pumps LPS075 Figure 10 - Replacement Parts Illustration 1 2 3 5 6 7 8 9 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 C C D D 29 30 40 41 42 32 37 40 5 25 39 38 4 10 14 43 44 44 NOTE: Apply a thin layer of liquid gasket to entire surface of Item 44. 35 45[...]

  • Page 33

    17 Reciprocating Air Compr essor Pumps LPS075 Ref. No. Description Part Number Qty 1 Cylinder 91000600 2 2 Cylinder head 91005600 2 3 Intake return pipe fitting 06801281 1 4 Unloader cap 01052451 2 5 Intake joint 91345660 2 6 Breather flange 91176580 1 7 Crankcase ▲ 1 8 Bearing cap ▲ 1 9 Oil gauge 01909600 1 10 Oil drain pipe 01119430 1 11 Oil [...]

  • Page 34

    18 Reciprocating Air Compr essor Pumps LPS100 Figure 11 - Replacement Parts Illustration 6 14 20 23 24 25 29 30 32 33 35 44 45 1 2 3 4 5 7 8 9 10 11 12 13 15 16 17 18 19 21 22 24 25 26 27 28 29 45 46 47 42 43 39 40 41 37 38 36 34 31 32 4 5 5 48 48 32 45 25 36 49 49 NOTE: Apply a thin layer of liquid gasket to entire surface of Item 49.[...]

  • Page 35

    19 Ref. No. Description Part Number Qty Reciprocating Air Compr essor Pumps LPS100 1 Cylinder 91000600 3 2 Cylinder head 91005600 3 3 Intake return pipe elbow 06801281 1 4 Unloader cap 01052451 3 5 Intake joint 91345660 3 6 Oil cap joint 01122600 1 7 Crank case ▲ 1 8 Bearing cap ▲ 1 9 Oil gauge 01909600 1 10 Gasket 01120600 1 11 Oil drain pipe [...]

  • Page 36

    Powerex Limited W arranty Powerex 3 Year / 10,000 Hour Extended Parts Limited Warranty - Powerex warrants each Compressor Pump or Scroll Air-End against defects in material or workmanship from the date of purchase for a period of Three years or 10,000 hours , whichever may occur first. This warranty applies to the exchange of part(s) of the compres[...]