Powerex AS-XXX Product Manual

Powerex AS-XXX Product Manual

1hp simplex air compressor

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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.
Features
• Guaranteed low oil carryover rate of
less than 2 PPM
• Three year warranty on compressor
pump
• Isolation pads
• Optional R134 dryer
• ASME tank
• UL listed controls
The AS-XXX Series Powerex Simplex Air
Compressors have been designed, bro-
ken-in and tested to meet the most
demanding specifications in the pneu-
matic climate control industry for low
oil carryover and long life.
All Powerex air compressors have reli-
able operation and feature high quality
construction and components. An
unloading feature is included on all
compressors to provide loadless start-
ing. Oil entrainment is minimized by
the use of lap joint piston rings, low
compressor speeds and a special lubri-
cating oil with a high flash point and
low carbon content.
All 1/2 through 10 hp models are also
equipped with an auxiliary cooling fan
and air control shroud to achieve low
head temperatures and further mini-
mize oil carryover.
Powerex compressor motors are NEMA
Class B design. Single-phase motors
have built-in overload protection and a
DPST disconnect switch. Three-phase
motors require a manual or magnetic
starter and three overload heater coils
which may be ordered as a factory
mounted and wired option.
Powerex • 150 Production Drive • Harrison, OH 45030 • USA
Figure 1 - AS-XXX 1 Hp Simplex Air Compressor
Product
Performance
Specifications
Models & Options
Lubrication
1/2 Through 10
Operating
Voltages
Compression
1/2 Through
Cycle
10 Hp Models
Motor Overload
Protection
Pressure Settings
Overpressure
Protection
Outlet Air
Connections
Tank Sizes
California
Ordinance 462
(L) (2)
Tank Isolation
Manuals
The performance specifications are nominal and conform to acceptable industry standards. For applica-
tion at conditions beyond these specifications, consult the local Powerex office. Powerex shall not be
liable for damages resulting from misapplication or misuse of its products.
Climate Control Simplex
Specifications
AS-XXX Series Powerex Simplex Air Compressors
See Table 1
See Table 2
Splash Lubrication System
115 - 208/230 Volts, 60 Hz
208-230/460 Volts, 60 Hz
Single-Stage
Built-In Thermal Overload (Standard)
Magnetic Starter and Three Thermal Overload
Switches (Optional)
Cut-In: Factory Set at Approximately 70 psig (490kPa)
Cut-out: Factory Set at Approximately 90 psig (630 kPa)
ASME Safety Valve Factory Set and Sealed at
Approximately 115 psig (805 kPa)
1/2" NPT on 30, 60 and 80 Gallon Tanks;
1" NPT on 120 and 200 Gallon Tanks
See Table 2
Meets Requirements of this Ordinance
Standard All Units
200 Page Service Manual Available
IN259601AV 10/04

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Summary of Contents for Powerex AS-XXX

  • Page 1 200 Page Service Manual Available The performance specifications are nominal and conform to acceptable industry standards. For applica- tion at conditions beyond these specifications, consult the local Powerex office. Powerex shall not be liable for damages resulting from misapplication or misuse of its products.
  • Page 2: Performance Specifications

    Climate Control Simplex TABLE 1: AS-XXX SERIES POWEREX SIMPLEX AIR COMPRESSORS Base Actual Hp Model 1Ø 3Ø AS-105 — — AS-005 AS-107 — — AS-007 1.07 AS-110 — — AS-010 1.07 — AS-015 1.54 — AS-020 — AS-030 — AS-050 —...
  • Page 3 NA = = 100 NA = Not Available 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.
  • Page 4 Climate Control Simplex N.C. Pressure Switch Figure 4 - AS-XXX Single-Phase Wiring With Pressure Switch Used for Pilot Duty Figure 5 - AS-XXX Single-Phase Wiring With Pressure Switch Used as Contactor 3Ø Line Voltage Figure 6 - AS-XXX Three-Phase Wiring With Pressure Switch Used for Pilot Duty 1Ø...
  • Page 5 Climate Control Simplex...
  • Page 6: Replacement Parts List

    Climate Control Simplex REPLACEMENT PARTS LIST Item Description PUMP AND FLYWHEEL: Motor Hp VALVE KIT: Includes valve plate, spacer and head gasket Motor Hp RING/CYLINDER KIT: Includes all compression rings, oil control rings, cylinder, gasket and sealant Motor Hp INTAKE FILTER ELEMENT: Motor Hp BELT: Motor Hp...
  • Page 7: Motor Pulley

    REPLACEMENT PARTS LIST (Continued) Item Description MOTOR PULLEY: Motor Hp 1 (1 Ø) 1 (3 Ø) ⁄ ⁄ IN-TANK CHECK VALVE: Motor Hp 1/2 Through 3 5 Through 10 SAFETY RELIEF VALVE: Set at approximately 115 psig (805 kPa) 1/2 Through 5 Hp Models ⁄...
  • Page 8: Maintenance Schedule

    UNLESS OTHERWISE AGREED TO IN WRITING, THESE TERMS AND CONDITIONS WILL CONTROL IN ANY TRANSACTION WITH POWEREX any different or conflicting terms as may appear on any order form now or later submitted by the buyer. All orders are subject to acceptance by POWEREX.
  • Page 9 Powerex • 150 Production Drive • Harrison, OH 45030 • USA Figure 1 - AD-XXX Series 2 Hp Duplex Air Compressor with Optional Deluxe Alternator Package...
  • Page 10 Climate Control Duplex TABLE 1: AD-XXX SERIES POWEREX DUPLEX AIR COMPRESSORS Base Actual Hp Model 1Ø 3Ø AD-105 — — AD-005 AD-107 — — AD-007 1.07 AD-110 — — AD-010 1.07 — AD-015 1.54 — AD-020 — AD-030 — AD-050 —...
  • Page 11 ⁄ = 075 NA = = 100 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.
  • Page 12 Climate Control Duplex Figure 4 Deluxe Alternator Package Wiring Diagram for Three-Phase Units Figure 5 Basic Alternator Package Wiring Diagram For Three-Phase Units Single Disconnect Field Supplied IT 3 IT 2 IT 1 Motor Selector Switch Black Blue Alt R Alt L Alt C IT 2...
  • Page 13 Optional Dryer Figure 6 - Dimensions (in./cm) TABLE 3: DIMENSIONS (INCHES) AND SHIPPING WEIGHTS (POUNDS*) Base with Model Alternator Alternator AD-105-1XX ⁄ ⁄ AD-005-1XX AD-105-3XX ⁄ ⁄ AD-005-3XX AD-107-1XX ⁄ ⁄ AD-007-1XX AD-107-3XX ⁄ ⁄ AD-007-3XX AD-110-1XX ⁄ ⁄ AD-010-1XX AD-110-3XX ⁄...
  • Page 14 Climate Control Duplex E (Behind beltguards) REPLACEMENT PARTS LIST Item Description PUMP AND FLYWHEEL: Motor Hp 1/2, 3/4 1, 1 ⁄ ⁄ VALVE KIT: Includes valve plate, spacer and head gasket Motor Hp 1/2 1, 1 ⁄ ⁄ RING/CYLINDER KIT: Includes all compression rings, oil control rings, cylinder, gaskets and sealant Motor Hp 1/2 1, 1 ⁄...
  • Page 15 REPLACEMENT PARTS LIST Item Description BELTS: ⁄ (200 gal tank) (Continued) MOTOR Motor Hp PULLEY: 1 (1 Ø) 1 (3 Ø) ⁄ ⁄ IN-TANK CHECK VALVE: Motor Hp 1/2 Through 3 5 Through 10 SAFETY RELIEF VALVE: Set at approximately 115 psig (805 kPa) 1/2 Through 5 Hp Models ⁄...
  • Page 16 UNLESS OTHERWISE AGREED TO IN WRITING, THESE TERMS AND CONDITIONS WILL CONTROL IN ANY TRANSACTION WITH POWEREX any different or conflicting terms as may appear on any order form now or later submitted by the buyer. All orders are subject to acceptance by POWEREX.
  • Page 17: Breathable Air Warning

    These heat reducing cylinders eliminate the Figure 1 - Models CS100P, LPS010, LPS020, LPS030, LPS075, LPS100 Powerex • 150 Production Drive • Harrison, OH 45030 • USA Lubricated Compressor Pumps effect of excessive ring and cylinder wear. Piston rings should be replaced every 15,000 hours of operation.
  • Page 18 4. Manually operate the safety valve every six months to avoid sticking or freezing. Operation Powerex single stage compressors oper- ate at a maximum pressure of 140 PSIG. Compressor RPM’s are established by Powerex based on horsepower and operating pressure.
  • Page 19 Reciprocating Air Compressor Pumps 7.5” 11.9” 10.8 16.2” 13.9 3.2” 6.7” CS100P LPS 010 18.9” 11.9” 22.8” 15.0” 17.8” 20.2” 8.3” 4.4” 4.4” 11.5” LPS 020 LPS 030 26.0” 18.0” 26.0” 18.0” 21.8” 21.8” 5.3” 5.3” 11.4” 11.4” LPS 075 LPS050 29.7”...
  • Page 20: Oil Level

    Reciprocating Air Compressor Pumps Maintenance Schedule Item Action needed Tank Drain moisture Inlet air filter Replace Blower fan Clean Fan shroud Clean Compressor fins Clean Oil change Replace Compression rings Replace Check oil Inspect V-belt Inspect, replace Pressure switch Confirm operation...
  • Page 21 Reciprocating Air Compressor 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.
  • Page 22 Reciprocating Air Compressor Pumps CS100P Figure 5 - Replacement Parts Illustration...
  • Page 23 Reciprocating Air Compressor Pumps Ref. Description Cylinder Cylinder gasket Cylinder head Crank case Bearing case Bearing case gasket Oil gauge set Oil drain pipe Oil drain cap with gasket Breather assembly with gasket Fan side rubber seal Crank shaft Flywheel...
  • Page 24 Reciprocating Air Compressor Pumps Figure 6 - Replacement Parts Illustration NOTE: Apply a thin layer of liquid gasket to entire surface of Item 28. LPS010...
  • Page 25 Reciprocating Air Compressor Pumps Ref. Description Cylinder Cylinder head Unloader cap Crank case Bearing cap Oil gauge Oil drain pipe Oil drain cap set Breather assembly and gasket Bearing cap rubber seal Crankshaft Pulley flywheel Key woodruff Bearing cap oil seal...
  • Page 26 Reciprocating Air Compressor Pumps LPS020 NOTE: Apply a thin layer of liquid gasket to entire surface of Item 42. Figure 7 - Replacement Parts Illustration...
  • Page 27 Reciprocating Air Compressor Pumps Ref. Description Cylinder Cylinder head Intake return pipe elbow Unloader cap Intake joint (1) Intake joint (2) Breather flange Crankcase Bearing cap Oil gauge Oil drain pipe Oil drain cap assembly Breather assembly and gasket Bearing cap rubber seal...
  • Page 28 Reciprocating Air Compressor Pumps Figure 8 - Replacement Parts Illustration NOTE: Apply a thin layer of liquid gasket to entire surface of Item 43. LPS030...
  • Page 29 Reciprocating Air Compressor Pumps Ref. Description Cylinder Cylinder head Intake return pipe elbow Unloader cap Intake joint (1) Intake joint (2) Breather flange Crankcase Bearing cap Oil gauge Oil drain pipe Oil drain cap set Breather assembly and gasket Bearing cap rubber seal...
  • Page 30 Reciprocating Air Compressor Pumps Figure 9 - Replacement Parts Illustration Note: Apply a thin layer of liquid gasket to entire surface of item #45. LPS050...
  • Page 31 Reciprocating Air Compressor Pumps Ref. Description Cylinder Cylinder head Intake return pipe fitting Unloader cap Intake joint Breather flange Crank case Bearing case Oil gauge Packing-oil gauge Oil drain pipe Oil drain cap set Breather set Bearing cap rubber seal...
  • Page 32 Reciprocating Air Compressor Pumps Figure 10 - Replacement Parts Illustration NOTE: Apply a thin layer of liquid gasket to entire surface of Item 44. LPS075...
  • Page 33 Reciprocating Air Compressor Pumps Ref. Description Cylinder Cylinder head Intake return pipe fitting Unloader cap Intake joint Breather flange Crankcase Bearing cap Oil gauge Oil drain pipe Oil drain cap set Breather assembly and gasket Bearing cap rubber seal Crank shaft...
  • Page 34 Reciprocating Air Compressor Pumps Figure 11 - Replacement Parts Illustration NOTE: Apply a thin layer of liquid gasket to entire surface of Item 49. LPS100...
  • Page 35 Reciprocating Air Compressor Pumps Ref. Description Cylinder Cylinder head Intake return pipe elbow Unloader cap Intake joint Oil cap joint Crank case Bearing cap Oil gauge Gasket Oil drain pipe Oil drain cap set Breather assembly and gasket Bearing cap rubber seal...
  • Page 36 All claims pertaining to the merchandise in this schedule, with the exception of warranty claims, must be filed with POWEREX within 6 months of the invoice date, or they will not be honored. Prices, discounts and terms are subject to change without notice or as stipulated in specific product quotations. All agreements are contingent upon strikes, accidents, or other causes beyond our control.

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