Powerex AS-XXX User Manual

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 • 150 Production Drive • Harrison, OH 45030 • USA

• 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, bro­ken-in and tested to meet the most
demanding specifications in the pneu­matic climate control industry for low
oil carryover and long life.

All Powerex air compressors have reli­able operation and feature high quality
construction and components. An
unloading feature is included on all
compressors to provide loadless start­ing. Oil entrainment is minimized by
the use of lap joint piston rings, low
compressor speeds and a special lubri­cating 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 mini­mize 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.

Climate Control Simplex

IN259601AV 10/04

Specifications

Product
Performance
Specifications
Models & Options
Lubrication
Operating
Voltages
Compression
Cycle
Motor Overload
Protection

Pressure Settings

Overpressure
Protection
Outlet Air
Connections
Tank Sizes
California
Ordinance 462
(L) (2)
Tank Isolation
Manuals

1/2 Through 10
1Ø
3Ø
1/2 Through
10 Hp Models
1Ø
3Ø

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

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.

Figure 1 - AS-XXX 1 Hp Simplex Air Compressor

Features

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 SPECIFICATIONS

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

—

—

—

—

—

—

—

AS-105

AS-005

AS-107

AS-007

AS-110

AS-010

AS-015

AS-020

AS-030

AS-050

AS-075

AS-100

—

.54

—

.73

—

1.07

1.54

2.0

3.1

5.6

8.2

10.3

800

1040

625

955

800

775

690

795

685

1.8

2.5

3.8

6.4

8.6

12.0

22.0

28.5

43.0

0.9

1.25

1.9

3.2

4.3

6.0

11.0

14.3

21.5

0.6

0.83

1.25

2.11

2.84

4.0

7.33

9.44

14.2

2

Climate Control Simplex

MAGNETIC MOTOR STARTER

An optional magnetic motor starter
which has been selected and wired for
the intended input voltage is available
for all units. All starters are furnished
with properly sized overload heaters.

REFRIGERATED AIR DRYER

A factory mounted Model Hankinson
HPR 5-10 Series refrigerated air dryer
with automatic condensate drain trap
assembly, bypass valve is available as an
option on all 1/2 through 3 Hp Powerex
Simplex air compressors. Piping for air
dryer is done at the factory. Wiring to
power source must be done in the field
using integral cord and plug which fits
into a standard 120 volt receptacle.
Refer to Table 2 for ordering details.

AUTOMATIC TANK DRAIN

Powerex air compressors are ordered
with either a manual or electric type
automatic tank drain. This unit is fur­nished with a manual drain attach­ment.

VIBRATION DAMPENING PADS

Waffle type design vibration pads are
provided as standard equipment.

Factory calibrated snap-acting DPST
pressure electric switches provide auto­matic cut-in and cut-out. Overpressure
protection is provided by an ASME safe­ty relief valve. Receiver tanks have a
condensate drain valve with an exten­sion for easy access. All mounting bases
are slotted for V-belt tension adjust­ment to aid in maintaining proper com­pressor and motor alignment.

All units are run through the factory
break-in and are tested for air delivery,
leakage and power consumption.

Units are shipped with a proper fill of
compressor oil in the crankcase and are
furnished with an intake filter/silencer
with a replaceable cartridge. This fil­ter/silencer combination is designed to
remove contaminates in the inlet air
and provide quieter operation. The 5
through 10 Hp models are compliment­ed by this design utilizing dual element
filtration which consists of a pleated
element and a foam element for filtra­tion against larger particles from the
atmosphere.

LUBRICATION

Check lubricating oil level at gauge.
Refill if necessary.

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.

Oil gauge

Oil drain

cap

Full

Low

Round (red)

Operation

Mounted and
Connected Options

OIL GAUGE

Figure 2 - Lubrication

!

WARNING

3

Climate Control Simplex

Example 1: To order a Simplex air compressor with a
3/4 Hp single-phase motor, 60 gallon tank, single­phase 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 motor, 200 gallon tank and an
auto drain, use product code AS-100-502.

}

Horsepower &

Voltage Phase

TABLE 2: MODEL NUMBER

Tank Size

Starter

Tank

Drain/Dryer

AS

Tank Size
(Gallons) Available on:

NA = Not Available

Tank Drain/Dryer Options

Starter Options

Motor Horsepower, Voltage Phase

1Ø Horsepower 3Ø

105 = 1/2 = 005
107 = 3/4 = 007
110 =1 = 010

NA = 1

1

⁄2 = 015
NA = 2 = 020
NA = 3 = 030
NA = 5 = 050
NA = 7

1

⁄2 = 075
NA = 10 = 100

30 = 1 1/2 Through 1

1

⁄2 Hp
60 = 2 3/4 Through 2 Hp
80 = 3 2 Through 7

1

⁄2 Hp

120 = 4 5 Through 10 Hp
200 = 5 7

1

⁄2 and 10 Hp

None = 0

3Ø, 208V Starter* = 2

3Ø, 208/230V Starter** = 3

3Ø, 460V Starter = 4
1Ø, 115V Starter = 5

1 Ø, 208/230 V Starter = 6

1Ø vs 3 Ø selection must agree with

base model selection.

**This starter selection is dual

rated. Choosing digit “3”
means 230 V.

}

Manual Drain,

No Dryer = 1

E-Drain,

No Dryer = 2

Manual Drain,

with Dryer = 3

E-Drain,

with Dryer = 4

Available on

1/2 through 3 Hp

models only.

}

OR

Figure 3 - Auto E-Drain

Manifold
Assembly

AUTO E-DRAIN ASSEMBLY (See
Figure 3)

NOTE: The automatic E-drain is assem­bled to tank.

1. Plug E-drain into 115V power outlet
supply.

2. Adjust times accordingly.

TEST

OFF

ON

6

4

20

30

10

2

40

8

5

0.5
10

0.5
45

sec.

min.

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

N.C.

Pressure

Switch

Thermal

Overloads

M

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

*Comp.

Motor

* With

Integral

Overload

*Comp.

Motor

Manual
Disconnect
Switch

m

M

m

m

M

M

O.L.

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 Starter w/Starter w/o Starter w/Starter w/o Starter w/Starter w/o Starter C D E F with without

Model w/oDryer or Dryer and Dryer w/Dryer w/o Dryer or Dryer and Dryer w/Dryer Starter Starter

AS-105-1XX

42

1

⁄2 40 43

19

⁄32 42 21

1

⁄4 17

3

⁄4 21

13

⁄16 18

3

⁄4 35

1

⁄2 18 15

3

⁄4 12

1

⁄4 209 200

AS-005-1XX

AS-107-1XX

42

1

⁄2 40 43

19

⁄32 42 21

1

⁄4 17

3

⁄4 21

13

⁄16 18

3

⁄4 36 18 15

3

⁄4 12

1

⁄4 209 200

AS-007-1XX

AS-107-2XX

50

3

⁄4 50

3

⁄4 51

27

⁄32 52

3

⁄4 22

1

⁄4 20 22

5

⁄16 21 40 29 18 14 339 330

AS-007-2XX

AS-110-1XX

42

1

⁄2 40 43

19

⁄32 42 21

1

⁄4 17

3

⁄4 21

13

⁄16 18

3

⁄4 36 18 15

3

⁄4 12

1

⁄4 219 210

AS-010-1XX

AS-110-2XX

50

3

⁄4 50

3

⁄4 51

27

⁄32 52

3

⁄4 22

1

⁄4 20 22

5

⁄16 21 40 29 18 14 349 340

AS-010-2XX

AS-015-1XX 42

1

⁄2 40 43

1

⁄32 42 21

1

⁄4 17

3

⁄4 21

13

⁄16 18

3

⁄4 36 18 15

3

⁄4 12

1

⁄4 219 210

AS-015-2XX 50

3

⁄4 50

3

⁄4 51

27

⁄32 52

3

⁄4 22

1

⁄4 20 22

5

⁄16 21 40 29 18 14 349 340

AS-020-2XX 51

1

⁄2 50

3

⁄4 52

19

⁄32 52

3

⁄4 23

1

⁄4 20 23

5

⁄16 21 42 29 18 14 349 340

AS-020-3XX 65 64 66

23

⁄32 66 23

1

⁄4 20 23

5

⁄16 21 41 40 18

1

⁄2 13 384 375

AS-030-3XX 65

1

⁄2 64 66

23

⁄32 66 23

1

⁄4 20 23

5

⁄16 21 41 40 18

1

⁄2 13 509 500

AS-050-3XX 64 64 — — 23

1

⁄4 20 — — 46 43

3

⁄4 18

1

⁄2 13 609 600

AS-050-4XX 70

3

⁄4 70

3

⁄4 — — 26

1

⁄4 24 — — 49

1

⁄4 42 22 15

3

⁄4 714 705

AS-075-3XX 64 64 — — 23

1

⁄4 20 — — 46 43

3

⁄4 18

1

⁄2 13 621 610

AS-075-4XX 70

3

⁄4 70

3

⁄4 — — 26

1

⁄4 24 — — 49

1

⁄4 42 22 15

3

⁄4 725 714

AS-075-5XX 81

3

⁄4 81

1

⁄2 — — 30 30 — — 55

1

⁄2 42 22 18

3

⁄4 951 940

AS-100-4XX 79 76

1

⁄2 — — 27

1

⁄4 24 — — 51 42 22 15

3

⁄4 915 904

AS-100-5XX 81

3

⁄4 79

1

⁄4 — — 30 30 — — 58 42 22 18

3

⁄4 1141 1130

E

F

Climate Control Simplex

6

D

B

C

A PUMP AND FLYWHEEL:

Motor Hp 1/2, 3/4 1 19.5 A-005-6001

1, 11⁄2 1 35 A-010-6001NP
2 1 59 A-020-6001NP
3 1 66 A-030-6001NP
5 1 115 A-050-6001NP
71⁄2 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, 11⁄2 1 0.5 A-010-6002NP
2 2 0.5 A-010-6002NP
3 2 0.7 A-030-6002NP
5 2 1.2 A-050-6002NP
71⁄2 2 1.2 A-075-6002NP
10 3 1.2 A-075-6002NP

C RING/CYLINDER KIT: Includes all compression rings, oil control rings, cylinder, gasket and sealant

Motor Hp 1/2 1 3.6 A-005-6004

3/4 1 3.6 A-005-6004
1, 11⁄2 1 4.8 A-010-6004NP
2 2 4.8 A-010-6004NP
3 2 5.5 A-030-6004NP
5 2 10 A-050-6004NP
71⁄2 2 10 A-075-6004NP
10 3 10 A-075-6004NP

D INTAKE FILTER ELEMENT:

Motor Hp 1/2 1 0.1 A-005-6023

3/4 1 0.1 A-005-6023
1, 11⁄2 1 0.2 A-010-6023NP
2 1 0.2 A-030-6023NP
3 1 0.2 A-030-6023NP
5 2 0.2 A-030-6023NP
71⁄2 2 0.2 A-030-6023NP
10 3 0.2 A-030-6023NP

E BELT: Motor Hp Size

1/2 AX-42 1 0.3 A-005-6006
3/4 AX-42 1 0.3 A-005-6006
1 A-43 1 0.3 A-010-6006
11⁄2 A-46 1 0.3 A-015-6006NP
2 A-65 1 0.4 A-020-6006NP
3 A-62 1 0.4 A-030-6006NP
5 A-65 2 1.6 A-050-6006NP
71⁄2 (120 gal tank) A-67 2 2.0 A-075-6046NP
71⁄2 (200 gal tank) A-75 2 2.0 A-075-6056NP
10 A-84 2 2.4 A-100-6006NP

REPLACEMENT PARTS LIST

E

(Inside Belt Guard)

F

(Inside Belt Guard)

A

G

H

J

M

Shipping

Quantity Weight Code

Item Description Required (lbs.) Number

L

N

K

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
11⁄2 1A-6.0” P.D., 7/8” Bore 1 5.6 A-020-6007
2 1A-6.0” P.D., 7/8” Bore 1 5.2 A-020-6007
3 1A-6.0” P.D., 11⁄8” Bore 1 6.3 A-030-6007NP
5 2A-5.6” P.D., 11⁄8” Bore 1 7.6 A-050-6007NP
71⁄2 2A-7.6” P.D., 13⁄8” Bore 1 12.5 A-075-6007NP
10 2A-7.6” P.D., 15⁄8” Bore 1 13.5 A-100-6007NP

G IN-TANK CHECK VALVE:

Motor Hp Size

1/2 Through 3 1/2” MPT x 1/2” FPT 1 0.3 A-010-6008
5 Through 10 3/4” MPT x 3/4” FPT 1 0.4 A-075-6008

H SAFETY RELIEF VALVE: Set at approximately 115 psig (805 kPa)

1/2 Through 5 Hp Models 1 0.1 A-050-6009
71⁄2 Through 10 Hp Models 1 0.2 A-200-6009

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

1/2 Through 11⁄2 30 gallon 1 134.0 A-010-6030NP**
1/2 Through 11⁄2 60 gallon 1 175.0 A-010-6060NP
2 & 3 60 gallon 1 184.0 A-020-6060NP
1/2 Through 11⁄2 80 gallon 1 235.0 A-010-6080NP**
2 & 3 80 gallon 1 243.0 A-020-6080NP**
2 & 3 120 gallon 1 398.0 A-020-6120NP**
5 & 71⁄2 120 gallon 1 415.0 A-050-6120NP**
5 Through 10 200 gallon 1 677.0 A-100-6200NP**

L COOLING SHROUD:

Motor Hp

1/2 1 1.0 A-005-6013
3/4 1 1.0 A-005-6013
2 1 1.7 A-020-6013NP
3 1 1.7 A-030-6013NP
5 1 1.9 A-050-6013NP
71⁄2 1 1.9 A-075-6013NP
10 1 4.5 A-100-6013NP

M BELT GUARD:

Motor Hp

1/2 Through 11⁄2 1 2.4 A-010-6012
2 & 3 1 12.5 A-020-6012
5 & 71⁄2 1 12.5 A-050-6012
10 1 18.5 A-100-6012

N LIQUID GASKET:

Motor Hp

1/2 Through 10 1 0.1 A-999-6000

**This replacement tank is also the replacement tank used on duplex air compressors and will include mounting hardware for a second pump.

Shipping

Quantity Weight Code

Item Description Required (lbs.) Number

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 of part(s) of the compressor pump or air-end found to be defective by an Authorized
Powerex Service Center.

Powerex 1 Year / 5,000 Hour Inlet to Outlet Limited Warranty - Powerex warrants each Compressor Unit, System, Pump, or Air­End against defects in material or workmanship from the date of purchase for a period of One Year or 5,000 Hours, whichever may
occur first. This warranty applies to the exchange of defective component part(s) and labor performed by an Authorized Powerex
Service Center.

The above mentioned warranty applies to POWEREX manufactured units or systems only.

Items listed in the operator’s manual under routine maintenance are not covered by

this or any other warranty.

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PAR­TICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF PURCHASE: AND TO THE EXTENT PERMITTED BY LAW, ANY AND
ALL IMPLIED WARRANTIES ARE EXCLUDED. THIS IS THE EXCLUSIVE REMEDY AND LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER
ANY AND ALL WARRANTIES IS EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW.

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. All ship­ments are carefully inspected and counted before leaving the factory. Please inspect carefully any receipt of merchandise 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 merchandise 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.

Maintenance Schedule

Operating Hours

Item Action needed 500 2500 5000 10,000 15,000 20,000 Remarks

Tank Drain moisture Daily 2500
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 hrs)

Compression rings Replace 
Check oil Inspect Daily
Piston set Replace 

V-belt Inspect, replace *Note 3 
Pressure switch Confirm operation 

Magnetic starter Inspect Replace if contact

points deteriorated
Safety valve Confirm operation  (Every 2,500 hrs or less)
Pressure gauge Inspect  (Every 2,500 hrs or less)

() Inspect

() 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
1/2 to 3 HP units is 2-3 lbs./.5” deflection; for 5 to 10 Hp units, 4-6 lbs./.5” deflection.

150 Production Drive
Harrison, OH 45030
Phone: [phone]
Fax: [phone]

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 • 150 Production Drive • Harrison, OH 45030 • USA

• Guaranteed low oil carryover rate of
less than 2 PPM

• Three year warranty on compressor
pump

• High efficiency motors

• UL listed controls

• R134A Air Dryer (Optional)

The AD-XXX 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-XXX 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 on­time provides a lower average head
temperature with reduced oil
entrainment potential and improves
the motor life by holding down the
average heat rise.

Climate Control Duplex

IN259702AV 3/05

Specifications

Product
Performance
Specifications
Models & Options
Lubrication

Operating
Voltages
Compression
Cycle
Motor Overload
Protection

Pressure Switch
Settings

Overpressure
Protection
Outlet Air
Connections
Tank Sizes
California
Ordinance 462 (L)(2)
Isolation Mounts

1/2 Through
10 Hp Models
1Ø
3Ø
1/2 Through
10 Hp Models
1Ø and 3Ø

Lead

Lag

AD-XXX Series Powerex Duplex Air Compressors

See Table 1
See Table 2

Splash Lubrication System
115/230 Volts, 60 Hz
208-230/460 Volts, 60 Hz

Single-Stage
Overloads (Supplied with all Factory Mounted
Alternators; Otherwise Field Supplied)
Cut-In: Factory Set at Approximately 70 psig (490kPa)
Cut-Out: Factory Set at Approximately 90 psig (630 kPa)
Cut-In: Factory Set at Approximately 60 psig (420kPa)
Cut-Out: Factory Set at Approximately 80 psig (560 kPa)
ASME Safety Valve Factory Set and Sealed at
Approximately 115 psig (805 kPa)
1/2" NPT on 30 and 80 Gallon Tanks;
1" NPT on 120, and 200 Gallon Tanks
See Table 2

Meets requirements of this Ordinance
Vibration pads are included with each unit

Figure 1 - AD-XXX Series 2 Hp Duplex Air Compressor

with Optional Deluxe Alternator Package

Features

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 SPECIFICATIONS

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

—

—

—

—

—

—

—

AD-105

AD-005

AD-107

AD-007

AD-110

AD-010

AD-015

AD-020

AD-030

AD-050

AD-075

AD-100

—

.50

—

.75

—

1.0

1.5

2.0

3.0

5.0

7.5

10.0

800

1040

625

955

800

775

690

795

685

1.8

2.5

3.8

6.4

8.6

12.0

22.0

28.5

43.0

0.9

1.25

1.9

3.2

4.3

6.0

11.0

14.3

21.5

0.6

0.83

1.25

2.11

2.84

4.0

7.33

9.44

14.2

2

Climate Control Duplex

All units are run through a factory
break-in and are tested for air delivery,
leakage and power consumption. Units
are shipped with a proper fill of
compressor oil in the crankcase and are
furnished with an intake filter/silencer
with a replaceable cartridge. This
filter/silencer combination is designed to
remove contaminates in the inlet air, as
well as provide quieter 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.

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 three­position selector switch. The three­position 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. Refer
to Table 2 for ordering details and
figure 4 for wiring diagram.

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. Refer to Table 2 for ordering
details and figure 5 for wiring diagram.

REFRIGERATED AIR DRYER

A factory mounted, Hankinson HPR 5-10
series refrigerated air dryer with
automatic condensate drain trap
assembly, bypass valve is on all 1/2
through 3 Hp Powerex duplex air
compressors. Piping for air dryer is done
at the factory. Wiring to power source
must be done in the field using integral
cord and plug which fits into a standard
120 volt receptacle. Refer to Table 2 for
ordering details.

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. Refer to
Table 2 for ordering details. (Order
electric drains separately.)

VIBRATION DAMPENING PADS

Waffle type design vibration pads are
provided as standard equipment.

Refer to Installation Data AS/AD-XXX
for detailed installation instructions.

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 have built-in
overload protection with automatic
reset. Three-phase motors require a
manual or magnetic starter and three
overload heaters. Heaters are included
with three-phase compressors that have
a factory mounted alternator.

LUBRICATION

Check lubricating oil level at gauge.
Refill if necessary.

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.

Dispose of oil in
accordance with

state or local codes.

Operation

Mounted and
Connected Options

!

WARNING

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 AD-100-502.

}

Horsepower &

Voltage Phase

TABLE 2: MODEL NUMBER

Tank Size

Alternator

Tank

Drain/Dryer

AD

Tank Size

(Gallons) Available on:

Tank Drain/Dryer Options

Starter Options

Motor Horsepower, Voltage Phase

1Ø Horsepower 3Ø

105 = 1/2 = 005
107 = 3/4 = 007
110 =1 = 010

NA = 1

1

⁄2 = 015
NA = 2 = 020
NA = 3 = 030
NA = 5 = 050
NA = 7

1

⁄2 = 075
NA = 10 = 100

30 = 1 1/2 Through 1-1/2 Hp

80 = 3 1/2 Through 3 Hp
120 = 4 3 Through 7-1/2 Hp
200 = 5 5 Through 10 Hp

Basic Deluxe

0= None = 0
2= 3Ø, 208V = A
3= 3Ø, 230V = B
4= 3Ø, 460V = C
5= 1Ø, 115V = E
6= 1 Ø, 208V = N/A
7= 1 Ø, 230V = G

1Ø vs 3 Ø selection must agree with

base model selection

}

Manual Drain,

No Dryer = 1

E-Drain,

No Dryer = 2

Manual Drain,

with Dryer = 3

E-Drain,

with Dryer = 4

Available on

1/2 through 3 Hp

models only.

}

OR

1. Plug E-drain into 115V power outlet
supply.

2. Adjust timer accordingly.

LUBRICATION (Continued)

AUTO E-DRAIN ASSEMBLY (See

Figure 3)

NOTE: The automatic E-drain is
assembled to tank.

Remove cap and
add oil

Oil
gauge

Oil drain cap

Full

Low

Round (red)

Oil Gauge

Figure 2

Figure 3 - E-Drain

Manifold
Assembly

TEST

ON

OFF

6

4

20

30

2

10

8

40

5

0.5
10

0.5
45

min.

sec.