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 AD Series Powerex Duplex Air Compressors have been
designed, broken-in and tested to meet the most demanding
specifications for low oil carryover and long life in the
pneumatic climate control industry.
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
1Ø 115 - 280 / 230 Volts, 60 Hz
3Ø 280 - 230 / 460 Volts, 60 Hz
Single-Stage (3/4 HP - 10 HP Models)
1Ø 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
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.
2
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
3
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