Powerex OPS, OPS030, OPS010, OPT Series, OPT050 Series Manual

Oilless Reciprocating Air Compressor Pumps

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

GENERAL

Powerex utilizes cutting-edge compressor technology
to provide the most advanced oilless reciprocating air
compressor in the industry. The Powerex reciprocating
compressor is available in single and two stage models.
Continuously lubricated, sealed bearings provide oil-free
compressed air and long compressor life. The onboard fan,
finned flywheel and temperature reducing composite piston
create lower operating temperatures.

DRY TYPE INLET FILTER

The inlet filter on the oilless compressor assures 99% of
particulate free air, down to 10 micron, is admitted to the
unit. Change every 2500 hours or more often in dirty locations
(See Figure 5).

PISTON AND PISTON RINGS

The Powerex oilless reciprocating compressor pistons are
made of a high-strength, self-lubricating composite using the
most advanced technology available. These heat reducing
pistons eliminate the effect of excessive grease leakage at
the wrist pin bearing. PTFE rings reduce wear and provide
self lubrication. Piston rings should be replaced every 10,000
hours of operation (See Figure 12).

BEARING REGREASE

The wrist pin bearings of the OPS and OPT oilless compressors
are needle bearings protected by two outer lip seals. This
needle bearing becomes impacted and requires regreasing at
5,000 hours (See Figure 15).

BEARING SEALS

The wrist pin bearing lip seals prevent the lubricating grease
from leaking from the bearing area. The two lip seals on each
connecting rod require replacement every 10,000 hours (See
Figure 16-22 or page 9).

Specifications (Series)

Product OPS / OPT Series Powerex Air Compressor

Performance
Specifications

Lubrication Grease-filled Bearing

Pressure Settings Cut-In: 90 psig Cut-Out: 120 psig

Pumps

See Page 2

Cut-In: 125 psig Cut-Out: 145 psig
(High Pressure Unit)

Powerex • 150 Production Drive • Harrison, OH 45030 • USA
1-888-769-7979 • www.powerexinc.com

IN258607AV 1/12

Oilless Reciprocating Air Compressor Pumps

Specifications (Performance)

Model HP

OPS010 1

1.5

OPS030 2

3

OPT050 5 145 16.5 800 2 (1) 4.13 x

OPT100 7.5

10

OPT150 15 145 47.0 1140 3 (2) 4.13 x

Max.

PSIG

145 3.6

145 7.6

145 27.5

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

SCFM @

100 PSIG RPM

5.3

10.1

35.0

625
885

845
1115

855
1090

No. of

Cyl. Bore Stroke

1 2.56 2.56 11.2 1 GR-A 24

2 2.56 2.36 13.8 1 GR-B 46

(1) 2.95

3 (2) 3.54 x

(1) 2.95

(1) 2.95

Installation

INSTALLATION SITE

1. The oilless compressor must be located in a clean, well lit

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

hazardous situation which, if

not avoided, COULD result in death or serious injury.

Caution indicates a potentially

minor or moderate injury.

Notice indicates important

information, that if not

followed, may cause damage to equipment.

2. The area should be free of excessive dust, toxic or

3. Never install the compressor where the ambient

4. Clearance must allow for safe, effective inspection and

5. If necessary, use metal shims or leveling pads to level the

Flywheel

O.D. Drive

3.35 16.9 2 GR-B 97

3.35 18.3 2 GR-B 138

3.35 19.6 2 GR-B 141

Weight

(lbs.)

and well ventilated area.

flammable gases and moisture.

temperature is higher than 105° F or where humidity is
high.

maintenance.

compressor. Never use wood to shim the compressor.

Minimum Clearances

Breathable Air Warning

This compressor / pump is NOT equipped and should NOT
be used “as is” to supply breathing quality air. For any
application of air for human consumption, you must fit
the compressor/pump with suitable in-line safety and
alarm equipment. This additional equipment is necessary
to properly filter and purify the air to meet minimal
specifications for Grade D breathing as described in
Compressed Gas Association Commodity Specification
G 7.1 - 1966, OSHA 29 CFR 1910. 134, and/or Canadian
Standards Associations (CSA).

DISCLAIMER OF WARRANTIES
In the event the compressor / pump is used for the purpose
of breathing air application and proper in-line safety and
alarm equipment is not simultaneously used, existing
warranties are void, and Powerex disclaims any liability
whatsoever for any loss, personal injury or damage.

Above 24 inches

Drive belt side 12 inches

Other side 20 inches

VENTILATION

1. If the oilless compressor is located in a totally 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 the general safety guidelines manual. All electrical
hook-ups must be performed by a qualified electrician.
Installations must be in accordance with local and national
electrical codes.

Use solderless terminals to connect the electric power source.

2

Oilless Reciprocating Air Compressor Pumps

Installation (Continued)

PIPING

Refer to the general safety guidelines manual.

1. Make sure the piping is lined up without being
strained or twisted when assembling the piping for the
compressor.

2. Appropriate expansion loops or bends should be installed
at the compressor to avoid stresses caused by changes in
hot and cold conditions.

3. Piping supports should be anchored separately from the
compressor to reduce noise and vibration.

4. Never use any piping smaller than the compressor
connection.

5. Use flexible hose to connect the outlet of the compressor
to the piping so that the vibration of the compressor
does not transfer to the piping. Make sure the flexible

hose is rated for proper pressure and temperature before

installing.

SAFETY VALVES

A safety valve must be installed in the manifold or tank
where the compressor pump is installed. The flow capacity of
the safety valve must be equal to or greater than the capacity
of the compressor.

1. The pressure setting of the safety valve must be no
higher than the maximum working pressure of the tank.

2. Safety valves should be placed ahead of any possible
blockage point in the system, i.e. shutoff valve.

3. Avoid connecting the safety valve with any tubing or
piping.

4. Manually operate the safety valve every six months to
avoid sticking or freezing.

5. The safety valve must be ASME approved.

HOURMETER

The hourmeter on the oilless compressor indicates the
actual number of hours the unit has been in operation. The
hourmeter is also used to determine maintenance and service
timing. An hourmeter must be installed with every

oilless compressor.

Operation

Powerex oilless compressors operate at a standard pressure
of 120 PSIG. Two stage compressors operate at a maximum
of 145 PSIG and are equipped for continuous run operation.
Compressor RPM’s are established by Powerex based on
horsepower and operating pressure.

BEFORE START UP

1. Make sure all safety warnings, labels and instructions
have been read and understood before continuing.

2. Be sure all pressure connections are tight.

3. Check to be certain all safety relief valves, etc., are
correctly installed.

4. Make sure the inlet filter is properly installed.

5. Visually check the rotation of the compressor pump.
If the rotation is incorrect, have a qualified electrician
correct the motor wiring.

START-UP AND OPERATION

1. Follow all the procedures under “Before start-up” before
attempting operation of the compressor.

2. Switch the electric source breaker on.

3. Open the tank discharge valve completely.

4. Check that the compressor operates without excessive
vibration, unusual noises or leaks.

5. Close the discharge valve completely.

6. Check the discharge pressure. Also make sure the air
pressure rises to the designated pressure setting by
checking the discharge pressure gauge.

7. Check the operation of the pressure switch or the pilot
valve for continuous run units by opening the stop
valve and confirming the compressor starts or reloads as
pressure drops.

Switch the breaker off if the compressor is not to be used for
a long period of time.

CONDENSATE DRAIN VALVE

A condensate drain valve must be installed on any tank
to allow removal of the liquid which will collect during
compressor operation.

Drain liquid from

tank daily.

3

Oilless Reciprocating Air Compressor Pumps

Maintenance Schedule

Operating Hours

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

Tank Drain moisture Daily Drain tank daily

Inlet Air Filter Replace

Blower Fan Clean

Fan Duct Clean

Compressor Fins Clean

Bearings Replace

Compression Rings Replace

Wrist Pin Bearings Regrease Note 4

Piston Set Replace

Cylinder Inspect

Unloader Set Replace

Gasket Set Replace

Bearing Seal Wrist Pin Replace

V-belt Inspect, Replace Note 3

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 the initial stage (500H) and inspected every 2,500 hours afterwards.
Proper belt tension for 1 to 3 HP units is 2-3 lbs./.5 inch deflection; for 5 to 15 HP units, 4-6 lbs./.5 inch deflection.

4. See page 8.

l s

l l l l

l l l l

l

l l s

l s l s

s s s s

s s

l l l l

l s l s

s s

s

l s s s s

Every 2500 hours or less

Every 2500 hours or less

2500 Hours - Air Filter Element Replacement

1. Remove wing nut.

2. Remove canister and wipe inside clean with dry cloth.

3. Remove and discard filter cartridge.

4. Install new filter cartridge. Do not attempt to clean and reuse filter cartridge.

5. Wipe inside clean with dry cloth.

Figure 5 - Air Filter Replacement

4

5000 Hours - Valve Inspection /
Replacement

Per OSHA regulations, ALL

power must be locked out

before performing any maintenance.

INSPECT VALVE SET

1. Remove head bolts from cylinder head.

2. Remove cylinder head and valve set. If it is difficult to
remove by hand, insert screwdriver between cylinder and
valve set and remove (See Figure 6 and 7).

INSPECTION AND MAINTENANCE

1. Check if exhaust valve (A) sticks to seat or is damaged
(See Figure 8).

2. Check if there is breakage, gouge or damage to
appearance of intake valve (B).

3. Lift intake valve 10 mm (3/8 inch) and check if there is
peeling and/or wear on coating surface of valve set (C).

Lifting intake valve too much

can cause damage to intake

valve.

4. Replace intake valve set if valve plate or valves are worn
or wear is over 0.5 mm (0.020 inches) in depth.
If exhaust valve rises upwards, clean seat surface of
foreign matter.

5. Clean the whole valve set taking care not to damage seat
surface and remove dust.

6. If viton seals (upper and lower) reach inspection time,
replace them. Even if its not time to inspect, be sure to
replace if they do not protrude from groove or seal has
hardened or been damaged.

7. Be sure to replace plastic seat in cylinder (See Figure 10).

8. Install valve set while paying attention to black plastic
seat of intake valve installed in cylinder (so that you do
not drop seat or insert tip of valve under seat).

9. Install cylinder head and tighten head bolts with
designated torque.

NOTES:

• Whenusingvalvesetagain,replaceupperandlower

viton seals.

• Whenreplacingvalveset,replacewithupperandlower

viton seals (valve set with packing set). You cannot reuse
disassembled valve set.

We are not responsible for any problems caused by reuse of
disassembled valve set.

Oilless Reciprocating Air Compressor Pumps

Figure 6

Figure 7

(B)

Check for
peeling or
wear (C)

REASSEMBLY

Assemble in reverse order of disassembling. Tighten each
section with designated tightening torque (See Chart on
page 6).

5

Figure 8

(A)

(A)

Oilless Reciprocating Air Compressor Pumps

Cylinder Inspection / Replacement

Per OSHA regulations, ALL

power must be locked out

before performing any maintenance.

INSPECTION / REPLACEMENT

1. Remove cylinder head and valve set. Pay attention not
to lose semicircular (black plastic) seat inserted at top
surface of cylinder (see Figure 9).

2. Remove cylinder bolts and pull off cylinder slowly. Make
sure piston does not drop down and get damaged. Note
cylinder orientation.

3. Inspect cylinder surface. If treated area is worn and metal
is exposed, replace. If there are several vertical scratches
at a narrow distance, replace (see Figure 10).

NOTE: Blackish streaks you can feel with your nail or finger
are not damage but sliding marks of piston and piston ring.
You do not need to replace the piston set or cylinder even
if there are several marks on the whole diameter of the
cylinder.

REASSEMBLY

1. Assemble in reverse order of disassembling cylinder.

2. Direction of cylinder is set so that semicircular spot
facing, to which seat (black plastic) is inserted, faces
toward flywheel side.

3. Tighten cylinder bolts with designated torque (refer to
chart below).

Figure 9

Replace if it
is scratched

Seat

Model

OPS010 / OPS030 156 in. lb. 156 in. lb.

OPT050 / OPT100 / OPT150 295 in. lb. 156 in. lb.

Cylinder Bolt

Torque

Head Bolt

Torque

Cylinder

Figure 10

6