Powerex ad series User Manual

Page 1
Climate Control Duplex
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.
Description
The units consist of two equally rated motor-compressor assemblies mounted on a single ASME tank. The compressor motors are NEMA Class B design. The AD Series Compressors are ideal for instrumentation systems requiring an alternate compressor for standby or overload capacity. See Table 1 for motor sizes and air delivery capacities available.
Compressor assemblies are available with or without a factory mounted basic or deluxe alternator/motor starter package. An unloading feature is included on all compressors to provide loadless starting. Models with an alternator are prewired and ready for operation. Internal wiring allows for shutdown of either compressor for repair while the other compressor is running.
An alternating type operation is desirable for many reasons. When a duplex air compressor is alternated, the temperature of both units is kept above the ambient dew point to minimize moisture deterioration and corrosion. Also, the reduction in on-time provides a lower average head temperature with reduced oil entrainment potential and improves the motor life by holding down the average heat rise.
All units are run through a factory break-in and are tested for air delivery, leakage and power consumption. Tank­mounted units are shipped with a proper fill of compressor oil in the crankcase and are furnished with an intake filter with a replaceable cartridge. This filter is designed to remove contaminates in the inlet air, as well as provide a quiet operation.
All models have conveniently located oil drain and filler ports to facilitate routine maintenance. Tanks have a condensate drain valve with an extension for easy access. Mounting bases are slotted to allow tension adjustments to aid in maintaining proper compressor and motor alignment while adjusting tension.
INLET
OUT IN
OUTLET
NORGRENN
40
60
PRESSURE GAGE
80
20
100
0
PSI
Specifications
Product AD Series Powerex Duplex Air Compressors
Performance Specifications
Lubrication Splash Lubrication System (3/4 HP - 10 HP Models)
Operating Voltages
Compression Cycle
Motor Overload Protection
Pressure Settings
Overpressure Protection
Outlet Air Connections
Tank Sizes 30 Gallon to 200 Gallon
California Ordinance 462 (L) (2)
Tank Isolation Standard All Units
See Page 2
115 - 280 / 230 Volts, 60 Hz 3Ø 280 - 230 / 460 Volts, 60 Hz
Single-Stage (3/4 HP - 10 HP Models)
Built-in Thermal Overload (Standard) 3Ø Magnetic Starter and Three Thermal Overload Heaters (Optional)
Lead
Cut-In: Factory Set at Approximately 70 psig (490 kPa) Cut-Out: Factory Set at Approximately 90 psig (630 kPa)
Lag
Cut-In: Factory Set at Approximately 60 psig (420 kPa) Cut-Out: Factory Set at Approximately 80 psig (560 kPa)
ASME Safety Valve Factory Set and Sealed at Approximately 115 psig (805 kPa)
3/4 inch NPT (30, 60, and 80 Gallon Tanks) 1 inch NPT (120 and 200 Gallon Tanks)
Meets Requirements of this Ordinance
TEST
ON
OFF
6 4
20
30
10
2
8
40
5
0.5 10
0.5 45
min.
sec.
The performance specifications are nominal and conform to acceptable industry standards. For application 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.
Powerex • 150 Production Drive • Harrison, OH 45030 • USA
IN558203AV 9/11
1-888-769-7979 • www.powerexinc.com
Page 2
Climate Control Duplex
Performance Specifications
Motor Rating
Base Model
AD-107 0.75 1725 980 2.1 1.07 0.71
AD-007 0.75 1725 980 2.1 1.07 0.71
AD-110 1.0 1725 1120 3.5 1.74 1.15
AD-010 1.0 1750 1120 3.5 1.74 1.15
AD-015 1.5 1760 860 4.6 2.3 1.5
AD-020 2.0 1755 1250 6.9 3.4 2.3
AD-030 3.0 1725 1050 10.3 5.2 3.4
AD-050 5.0 1750 1150 19.0 9.5 6.3
AD-075 7.5 1750 950 28.6 14.3 9.5
AD-100 10.0 1765 880 37.8 18.9 12.5
NOTE: 0.75 HP pumps must be used under altitudes of 5000 feet.
Above 5000 feet, 1 HP pumps must be used.
HP RPM 100% Runtime 50% Runtime 33% Runtime
Compressor RPM
Safety Guidelines
This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.
Danger indicates an imminently
hazardous situation which, if
not avoided, WILL result in death or serious injury.
Warning indicates a potentially
not avoided, COULD result in death or serious injury.
Caution indicates a potentially
Notice indicates important
followed, may cause damage to equipment.
hazardous situation which, if
minor or moderate injury.
information, that if not
NOTE: Information that requires special attention.
CALIFORNIA PROPOSITION 65
This product or its power cord
may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
Installation
MOUNTED AND CONNECTED OPTIONS
Deluxe Alternator Package
All Powerex Duplex air compressors may be ordered with an optional deluxe alternator package consisting of two magnetic motor starts with thermal overloads, an alternating coil, a 120 VAC control transformer and a three-position selector switch. The three-position switch allows for automatic alternation or only running one unit at a time. This will allow for service on one unit while other unit is running.
Compressor Capacity ACFM @ 80 psig
Basic Alternator Package
All Powerex duplex air compressors may be ordered with a simplified line voltage basic alternator package. The basic alternator package consists of an alternating coil and two magnetic motor starters. Motor starters are selected and wired for intended input voltage and are furnished with properly sized overload heaters.
Automatic Tank Drain
Powerex air compressors may be ordered with a manual or electric type automatic tank drain. A manual drain attachment is furnished with each unit.
Vibration Dampening Pads
Waffle type design vibration pads are provided as standard equipment.
Operation
Factory calibrated DPST pressure switches provide lead and lag settings. When using an alternator-starter package, the lead switch energizes the alternator and the alternator activates the compressor that was on standby during the previous cycle. If the demand exceeds the capacity of one compressor, the lag switch will cause both compressors to run simultaneously. Upon failure of either compressor, the lag switch will continue to activate the workable compressor.
Single-phase motors (3/4 HP & 1 HP) have built-in overload protection with manual reset. Three-phase motors require a magnetic starter and three overload heaters. Heaters are included with three-phase compressors that have a factory mounted alternator.
NOTE: All pump models operate turning clockwise opposite the motor shaft / pump flywheel / belt guard side of the unit. Improper rotation will cause oil to spray out of the breather
vent opening.
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Climate Control Duplex
Operation (Continued)
LUBRICATION
Check lubricating oil level at gauge. Refill if necessary. See Figure 1.
Change oil according to maintenance schedule. Before draining oil, remove oil supply cap and loosen oil drain cap to release trapped air. Use Mobil Rarus 427® or Mobil DTE heavy oils.
Dispose of oil in accordance
with state or local codes.
Remove cap and use funnel to add oil
Round (Red)
Full
Low
Oil drain
cap
Oil gauge
AUTO E-DRAIN ASSEMBLY (See Figure 2)
NOTE: The automatic E-drain is assembled to tank.
1. Plug E-drain into 115V power outlet supply.
2. Adjust times accordingly.
Manifold Assembly
TEST
ON
OFF
6
4
20
30
2
10
8
40
5
0.5 10
0.5 45
sec.
min.
Auto E-Drain
Figure 1
Single Disconnect Field Supplied
Red
Red
L
L 2L
1
Red
IT1IT2IT
Motor
1
3
Black
Blue
3
1M
Red
Red
Black
Blue
Alt L Alt R
Alt C
Alt
A251
A251
2M
PS 1
2M
A252
PS 2
Oil gauge close-up
Lag Switch Cut In: 60 psig (420 kPa) Cut Out: 80 psig (560 kPa)
L
1
L
2
L
3
2T12T22T
Motor
2
3
PS 2
Starter
Overload
Lead Switch
Cut In: 70 psig
(490 kPa)
Cut Out: 90 psig
(630 kPa)
Figure 2
A1 A2
1M
L 1L 2L
1
2
IT
IT
Motor
1
Lag Switch
Cut In: 60 psig
3
(420 kPa)
Cut Out: 80 psig
(560 kPa)
L
1L 2L 3
A1
A2
Alt
FU
FU
3
IT
X2
X1
2M
2T12T22T
Motor
2
3
FU
Selector
Switch
Lead Switch
Cut In: 70 psig
(490 kPa)
Cut Out: 90 psig
(630 kPa)
Figure 3 - Basic Alternator package wiring diagram for
three-phase units
Figure 4 - Deluxe Alternator package wiring diagram for
three-phase units
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Climate Control Duplex
Unit Dimensions (inches *) and Shipping Weights (pounds *)
Optional Dryer
(3 HP and under)
Discharge
A
Plug
B
F
D
G
Base
Model A
AD-107-1XX 41.50 24.00 17.75 36.50 18.00 15.75 12.25 57.25 298 278
AD-007-1XX 41.50 24.00 17.75 36.50 18.00 15.75 12.25 57.25 298 278
AD-107-3XX 63.60 27.00 20.00 42.50 40.00 18.00 14.60 70.00 463 443
AD-007-3XX 63.60 27.00 20.00 42.50 40.00 18.00 14.60 70.00 463 443
AD-110-1XX 41.50 24.00 17.75 36.50 18.00 15.75 12.25 57.25 297 277
AD-010-1XX 41.50 24.00 17.75 36.50 18.00 15.75 12.25 57.25 297 277
AD-110-3XX 63.60 25.00 20.00 43.30 40.00 18.00 14.60 69.80 462 442
AD-010-3XX 63.60 25.00 20.00 43.30 40.00 18.00 14.60 69.80 462 442
AD-015-1XX 41.50 25.80 17.75 38.75 18.00 15.75 12.25 57.10 322 302
AD-015-3XX 63.75 25.00 20.00 43.30 40.00 18.00 14.60 69.80 487 467
AD-020-3XX 63.75 26.00 20.00 43.60 40.00 18.00 14.60 80.60 512 492
AD-030-3XX 64.10 25.4 20.00 43.70 40.00 18.00 14.60 80.25 715 695
AD-030-4XX 70.75 28.10 24.00 48.20 42.00 18.00 16.80 81.75 845 825
AD-050-4XX 71.60 29.00 24.00 50.50 42.00 18.00 16.80 -- 988 968
AD-050-5XX 82.60 33.25 30.50 56.60 42.00 22.00 18.75 -- 1213 1193
AD-075-4XX 71.58 29.57 24.80 54.25 42.00 18.00 16.80 -- 1113 1088
AD-075-5XX 82.62 33.25 30.00 59.40 42.00 22.00 18.75 -- 1338 1313
AD-100-5XX 82.62 33.25 30.00 59.40 42.00 22.00 18.75 -- 1553 1528
* inches x 2.54 = centimeters; pounds x 0.454 = kilograms
** Add 60.0 pounds for units equipped with a factory mounted air dryer
B
with
Alternator
B
without
Alternator C D E F G
E
Unit Weight **
with
Alternator
without
Alternator
C
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Page 5
Maintenance Schedule
Climate Control Duplex
Action
Item
Tank Drain moisture
Inlet air filter
Pump flywheel
Compressor fins
Oil change Replace
Compression rings
Check oil Inspect
V-belt
Pressure switch
Magnetic starter
Safety valve
Pressure gauge
needed
Inspect, Replace
Clean
Clean
Replace
Inspect, Replace
Confirm operation
Inspect
Confirm operation
Inspect
Operating Hours
RemarksDaily 500 1500 2500 5000 10,000 15,000 20,000
l
l s
l l l l
l
s
s
l
l s s s s
l l
l l
l
l
Drain tank daily
Every 2500 hours or less
Every 2500 hours or less
Every 1500 hours
See Note 3
Replace if contact points deteriorated
Every 2500 hours or 6 months
Every 2500 hours or less
 l Inspect
s Replace
NOTES:
1. Inspect and perform maintenance periodically according to maintenance schedule.
2. The maintenance schedule relates to the normal operating conditions. If the circumstances and load condition are adverse, shorten the cycle time and do maintenance accordingly.
3. The tension of the V-belt should be adjusted during initial start up and inspected every 1,500 hours afterwards. Proper belt tension for 3/4 to 3 HP units is 2-3 lbs. / 0.5 inch deflection; for 5 to 10 Hp units, 4-6 lbs. / 0.5 inch deflection.
Oil Capacity Chart
Model HP
LPS007 0.75 0.44 0.12
LPS010A 1.0 0.44 0.12
LPS020A 1.5 / 2 0.44 0.12
LPS030A 3 0.70 0.20
LPS050A 5 1.03 0.35
LPS075A 7.5 1.70 0.45
LPS100A 10 1.70 0.45
Oil Capacity
0 to High (liters)
Oil Range
Low to High (liters)
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Climate Control Duplex
L
G (inside belt guard)
J
H (inside belt guard)
D
M
B
C
A
E
K
E
F
Replacement Parts List
Quantity Shipping Code Item Description Required Weight (lbs.) Number
A PUMP AND FLYWHEEL:
Motor HP 3/4 2 38 A-007-6001AP
1 2 38 A-010-6001AP 1-1/2, 2 2 51 A-020-6001AP 3 2 93 A-030-6001AP 5 2 120 A-050-6001AP 7-1/2 2 175 A-075-6001AP 10 2 198 A-100-6001AP
B VALVE KIT: Includes valve plate, spacer and head gasket
Motor HP 3/4, 1 2 0.5 A-010-6002AP
1-1/2, 2 2 0.5 A-010-6002AP 3 4 0.7 A-030-6002AP 5 4 1.2 A-050-6002AP 7-1/2 4 1.2 A-075-6002AP
10 6 1.2 A-075-6002AP C RING/CYLINDER KIT: Includes all compression rings, oil control rings, cylinder, gasket and sealant
Motor HP 3/4, 1 2 4.8 A-010-6004AP
1-1/2, 2 2 4.8 A-010-6004AP 3 4 5.5 A-030-6004AP 5 4 10 A-050-6004AP 7-1/2 4 10 A-075-6004AP
10 6 10 A-075-6004AP
D INTAKE FILTER ELEMENT:
Motor HP 3/4, 1 2 0.1 A-010-6023AP 1-1/2, 2 2 0.2 A-010-6023NP 3 4 0.2 A-010-6023NP 5 4 0.2 A-010-6023NP 7-1/2 4 0.2 A-010-6023NP 10 4 0.2 A-010-6023NP
E IN-TANK CHECK VALVE:
Motor HP Size 3/4 Through 3 1/2 inch MPT x 1/2 inch FPT 2 0.3 A-010-6008 5 Through 10 3/4 inch MPT x 3/4 inch FPT 2 0.4 A-075-6008
F SAFETY RELIEF VALVE: Set at approximately 115 psig (805 kPa) 3/4 Through 5 HP Models 1 0.1 A-050-6009 7-1/2 Through 10 HP Models 1 0.2 A-200-6009
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Climate Control Duplex
Replacement Parts List (Continued)
Quantity Shipping Code Item Description Required Weight Number
G BELT:
Motor HP Size 3/4 A-42 2 0.3 A-010-6006AP
1 A-43 2 0.3 A-010-6006AP 1-1/2 AX-46 2 0.3 A-015-6006AP 2 A-59 2 0.4 A-020-6006AP 3 B-62 2 0.4 A-030-6006AP 5 B-67 2 1.6 A-050-6006AP 7-1/2 B-69 4 2.0 A-075-6036AP 7-1/2 B-75 4 2.0 A-075-6056AP
10 A-80 4 2.4 A-100-6006AP
H MOTOR PULLEY:
Motor HP Type 3/4 1A-5.7 inch P.D., 5/8 inch Bore 2 3.9 A-007-6007AP
1 (1Ø) 1A-5.7 inch P.D., 5/8 inch Bore 2 3.2 A-110-6007AP 1 (3Ø) 1A-6.0 inch P.D., 7/8 inch Bore 2 3.2 A-010-6007AP 1-1/2 1A-5.5 inch P.D., 7/8 inch Bore 2 5.6 A-015-6007AP 2 1BK-8.0 inch P.D., 7/8 inch Bore 2 5.2 A-020-6007AP 3 1B-8.0 inch P.D., 1-1/8 inch Bore 2 6.3 A-030-6007AP 5 1B-9.4 inch P.D., 1-1/8 inch Bore 2 7.6 A-050-6007AP 7-1/2 2B-8.6 inch P.D., 1-3/8 inch Bore 2 12.5 A-100-6007AP
10 2B-8.6 inch P.D., 1-3/8 inch Bore 2 13.5 A-100-6007AP J PRESSURE ELECTRIC SWITCHES: (For all models) Lead Switch: Set at approximately
70 psig (490 kPa) cut-in and 90 psig (630 kPa) cut-out 1 0.9 A-100-6010
Lag Switch: Set at approximately 60 psig (420 kPa) cut-in and 80 psig (560kPa) cut-out 1 0.9 A-100-6011
K TANK:
Motor HP Tank Size 3/4 Through 1-1/2 30 gallon 1 134.0 A-015-6030AP
3/4 Through 1-1/2 80 gallon 1 235.0 A-015-6080AP 2 & 3 80 gallon 1 243.0 A-030-6080AP 2 & 3 120 gallon 1 398.0 A-030-6120AP 5 & 7-1/2 120 gallon 1 415.0 A-075-6120AP
5 Through 10 200 gallon 1 677.0 A-100-6200AP
L BELT GUARD:
Motor HP 3/4 Through 1-1/2 2 2.4 A-015-6012AP
2 2 12.5 A-020-6012AP 3 2 12.5 A-030-6012AP 5 2 12.5 A-075-6012AP 7-1/2 7-1/2
10 2 12.5 A-100-6012AP
M MOTOR:
Motor HP 3/4 (1Ø) 2 32.0 MC301510AV 3/4 (3Ø) 2 25.0 MC301511AV
1 (1Ø) 2 36.0 MC022371AV 1 (3Ø) 2 36.0 MC301512AV 1-1/2 (1Ø) 2 42.0 MC022320AV 1-1/2 (3Ø) 2 44.0 MC301513AV 2 (1Ø) 2 65.0 MC022317AV 2 (3Ø) 2 44.0 MC303300AV 3 2 58.0 MC303301AV 5 2 70.0 MC303303AV 7-1/2 2 73.0 MC303308AV
10 2 124.01 MC303310AV
(120 Gal) 2 12.5 A-075-6012AP (200 Gal) 2 12.5 A-075-6022AP
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Climate Control Duplex
Powerex Limited Warranty
Warranty and Remedies.
(a) General. Powerex warrants each Compressor System, Vacuum System, Vacuum Pump, Compressor Air-End, or Powerex branded
Accessory (collectively “Products”, individually each a “Product”) to be free from defects in material and workmanship (“Defects”) at the date of shipment. EXCEPT AS SET FORTH BELOW, NO OTHER WARRANTY, WHETHER EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL EXIST IN CONNECTION WITH THE SALE OR USE OF SUCH PRODUCTS. TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. All claims under this warranty must be made in writing and delivered to Powerex, or such claim shall be barred. Upon timely receipt of a claim, Powerex shall inspect the Product claimed to have a Defect, and Powerex shall repair, or, at its option, replace, free of charge, any Product which it determines to have had a Defect at the time of shipment from Powerex; provided, however, that if circumstances are such as to preclude the remedying of Defect by repair or replacement, Powerex shall, upon return of the Product, refund to buyer any part of the purchase price of such Products paid to Powerex. Freight for returning Products to Powerex for inspection shall be paid by buyer. The warranties and remedies herein are the sole and exclusive remedy for any breach of warranty or for any other claim based on any Defect, or non­performance of the Products, whether based upon contract, warranty or negligence.
b) Initial Period of Warranty – Parts and Labor. Powerex warrants and represents all Products shall be free from Defects for the first twelve (12) months from the date of shipment by Powerex, or five thousand (5,000) hours of use, whichever occurs first. During such warranty period, Powerex shall be fully liable for all Defects in the Products (the “Product Defects”), i.e., all costs of repair or replacement, which may include “in and out” charges, so long as the Products are located in the continental United States, and the Products are reasonably located and accessible by service personnel for removal. “In and out” charges include the costs of removing a Product from buyer’s equipment for repair or replacement.
(c) Additional Period of Warranty – Parts Only (No Labor). In addition to the above, Powerex warrants each Powerex branded Compressor Air-End, and Vacuum Pump shall be free of Defects for a period of thirty-six months from the date of shipment of Product, or 10,000 hours of use, whichever occurs first. Supplier’s repair or replacement of any Product shall not extend the period of any warranty of any Product. This warranty applies to the exchange of part(s) found to be defective by an Authorized Powerex Service Center only.
(d) Coverage. The above mentioned warranty applies to Powerex manufactured units or systems only.
(e) Exceptions. Notwithstanding anything to the contrary herein, Powerex shall have no warranty obligations with respect to Products:
(i) that have not been installed in accordance with Powerex’s written specifications and instructions;
(ii) that have not been maintained in accordance with Powerex’s written instructions;
(iii) that have been materially modified without the prior written approval of Powerex; or
(iv) that experience failures resulting from operation, either intentional or otherwise, in excess of rated capacities or in an otherwise
improper manner.
(f) The warranty provided herein shall not apply to: (i) any defects arising from corrosion, abrasion, use of insoluble lubricants, or negligent attendance to or faulty operation of the Products; (ii) ordinary wear and tear of the Products; or (iii) defects arising from abnormal conditions of temperature, dirt or corrosive matter; (iv) any OEM component which is shipped by Powerex with the original manufacturer’s warranty, which shall be the sole applicable warranty for such component.
Limitation of Liability. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, NOTWITHSTANDING ANYTHING TO THE CONTRARY HEREIN, UNDER NO CIRCUMSTANCES SHALL POWEREX BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTAL, PUNITIVE, SPECULATIVE OR INDIRECT LOSSES OR DAMAGES WHATSOEVER ARISING OUT OF OR IN ANY WAY RELATED TO ANY OF THE PRODUCTS OR GOODS SOLD OR AGREED TO BE SOLD BY POWEREX TO BUYER. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, POWEREX’S LIABILITY IN ALL EVENTS IS LIMITED TO, AND SHALL NOT EXCEED, THE PURCHASE PRICE PAID.
Warranty Disclaimer. Powerex has made a diligent effort to illustrate and describe the Products in this literature accurately; however, such illustrations and descriptions are for the sole purpose of identification, and do not express or imply a warranty that the Products are merchantable, or fit for a particular purpose, or that the Products will necessarily conform to the illustrations or descriptions.
Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of Products for certain purposes, which may vary from those in neighboring areas. While Powerex attempts to assure that its Products comply with such codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a Product, please review the Product applications, and national and local codes and regulations, and be sure that the Product, installation, and use will comply with them.
Claims. Claims pertaining to the Products, 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. All shipments are carefully inspected and counted before leaving the factory. Please inspect carefully any receipt of Products noting any discrepancy or damage on the carrier’s freight bill at the time of delivery. Discrepancies or damage which obviously occurred in transit are the carrier’s responsibility and related claims should be made promptly directly to the carrier. Returned Products will not be accepted without prior written authorization by Powerex and deductions from invoices for shortage or damage claims will not be allowed. 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.
Powerex • 150 Production Drive • Harrison, OH 45030 • USA 1-888-769-7979 • www.powerexinc.com
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