Climate Control Simplex
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
Figure 1 - AS-XXX 1 Hp Simplex Air Compressor
The AS-XXX Series Powerex Simplex Air
Compressors have been designed, bro-
ken-in and tested to meet the most
Specifications
Product
AS-XXX Series Powerex Simplex Air Compressors
demanding specifications in the pneu-
matic climate control industry for low
oil carryover and long life.
Performance
Specifications
Models & Options
Lubrication
Operating
See Table 1
See Table 2
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.
1/2 Through 10 Splash Lubrication System
1Ø
115 - 208/230 Volts, 60 Hz
208-230/460 Volts, 60 Hz
Voltages
3Ø
Compression
Cycle
1/2 Through
10 Hp Models
1Ø
Single-Stage
Motor Overload
Protection
Built-In Thermal Overload (Standard)
Magnetic Starter and Three Thermal Overload
Switches (Optional)
3Ø
Pressure Settings
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
Overpressure
Protection
Outlet Air
Connections
Tank Sizes
California
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.
Ordinance 462
(L) (2)
Meets Requirements of this Ordinance
Tank Isolation
Manuals
Standard All Units
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.
Powerex • 150 Production Drive • Harrison, OH 45030 • USA
IN259601AV 10/04
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Simplex
AUTO E-DRAIN ASSEMBLY (See
Figure 3)
NOTE: The automatic E-drain is assem-
bled to tank.
1. Plug E-drain into 115V power outlet
supply.
2. Adjust times accordingly.
Manifold
Assembly
ON
4
TEST
OFF
30
6
20
2
8
10
5
40
0.5
10
0.5
45
sec.
min.
Figure 3 - Auto E-Drain
TABLE 2: MODEL NUMBER
AS
OR
Tank Drain/Dryer Options
Motor Horsepower, Voltage Phase
Tank Size
1Ø
Horsepower
3Ø
(Gallons)
Available on:
Manual Drain,
No Dryer = 1
E-Drain,
105 =
107 =
110 =
NA =
NA =
NA =
NA =
NA =
NA =
1/2
3/4
1
= 005
= 007
= 010
= 015
= 020
= 030
= 050
= 075
= 100
30 = 1
60 = 2
80 = 3
120 = 4
200 = 5
1/2 Through 11⁄2 Hp
3/4 Through 2 Hp
2 Through 71⁄2 Hp
5 Through 10 Hp
71⁄2 and 10 Hp
No Dryer = 2
Manual Drain,
}
with Dryer = 3
E-Drain,
with Dryer = 4
11⁄
2
2
3
5
Available on
1/2 through 3 Hp
models only.
71⁄
2
Starter Options
None = 0
10
3Ø, 208V Starter* = 2
3Ø, 208/230V Starter** = 3
3Ø, 460V Starter = 4
NA = Not Available
1Ø, 115V Starter = 5
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.
1 Ø, 208/230 V Starter = 6
1Ø vs 3 Ø selection must agree with
base model selection.
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.
**This starter selection is dual
rated. Choosing digit “3”
means 230 V.
3
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Simplex
* With
Integral
Overload
*Comp.
Motor
m
Secondary
Thermal
Overloads
N.C.
Pressure
Switch
Starter
m
m
Manual
Disconnect
Switch
Figure 4 - AS-XXX Single-Phase Wiring
With Pressure Switch Used for Pilot Duty
1Ø 230 VAC
Manual
N.C.
Disconnect
Switch
Pressure
Switch
1Ø
Line
Voltage
* With
Integral
Overload
*Comp.
Motor
Figure 5 - AS-XXX Single-Phase Wiring
With Pressure Switch Used as Contactor
Manual
Disconnect
Switch
Thermal
Overloads
M
M
O.L.
3Ø
Line
Voltage
*Comp.
Motor
M
M
N.C.
Pressure
Switch
Figure 6 - AS-XXX Three-Phase Wiring
With Pressure Switch Used for Pilot Duty
NOTE: “M” = Magnetic Contactor
4
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Simplex
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Simplex
M
A
E
L
(Inside Belt Guard)
F
(Inside Belt Guard)
D
J
B
C
G
K
N
H
REPLACEMENT PARTS LIST
Shipping
Weight
(lbs.)
Quantity
Required
Code
Number
Item
Description
A
PUMP AND FLYWHEEL:
Motor Hp
1/2, 3/4
1
1
1
1
1
1
1
19.5
35
A-005-6001
1, 11⁄
2
A-010-6001NP
A-020-6001NP
A-030-6001NP
A-050-6001NP
A-075-6001NP
A-100-6001NP
2
3
5
59
66
115
121
180
71⁄
2
10
B
C
D
E
VALVE KIT: Includes valve plate, spacer and head gasket
Motor Hp
1/2
3/4
1
1
1
2
2
2
2
3
0.4
0.4
0.5
0.5
0.7
1.2
1.2
1.2
A-005-6002
A-005-6002
1, 11⁄
2
A-010-6002NP
A-010-6002NP
A-030-6002NP
A-050-6002NP
A-075-6002NP
A-075-6002NP
2
3
5
71⁄
2
10
RING/CYLINDER KIT: Includes all compression rings, oil control rings, cylinder, gasket and sealant
Motor Hp
1/2
3/4
1
1
1
2
2
2
2
3
3.6
3.6
4.8
4.8
5.5
10
A-005-6004
A-005-6004
1, 11⁄
2
A-010-6004NP
A-010-6004NP
A-030-6004NP
A-050-6004NP
A-075-6004NP
A-075-6004NP
2
3
5
71⁄
2
10
10
10
INTAKE FILTER ELEMENT:
Motor Hp
1/2
3/4
1
1
1
1
1
2
2
3
0.1
0.1
0.2
0.2
0.2
0.2
0.2
0.2
A-005-6023
A-005-6023
1, 11⁄
2
A-010-6023NP
A-030-6023NP
A-030-6023NP
A-030-6023NP
A-030-6023NP
A-030-6023NP
2
3
5
71⁄
2
10
BELT:
Motor Hp
Size
1/2
3/4
1
AX-42
1
1
1
1
1
1
2
2
2
2
0.3
0.3
0.3
0.3
0.4
0.4
1.6
2.0
2.0
2.4
A-005-6006
AX-42
A-005-6006
A-43
A-010-6006
11⁄
2
A-46
A-015-6006NP
A-020-6006NP
A-030-6006NP
A-050-6006NP
A-075-6046NP
A-075-6056NP
A-100-6006NP
2
3
5
A-65
A-62
A-65
71⁄
2
(120 gal tank) A-67
(200 gal tank) A-75
A-84
71⁄
10
2
6
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Simplex
REPLACEMENT PARTS LIST (Continued)
Shipping
Weight
(lbs.)
Quantity
Required
Code
Number
Item
Description
F
MOTOR PULLEY:
Motor Hp
1/2
Type
1A-4.4” P.D., 5/8” Bore
1A-5.8” P.D., 5/8” Bore
1A-4.0” P.D., 5/8” Bore
1A-4.0” P.D., 7/8” Bore
1A-6.0” P.D., 7/8” Bore
1A-6.0” P.D., 7/8” Bore
1A-6.0” P.D., 11⁄8” Bore
2A-5.6” P.D., 11⁄8” Bore
2A-7.6” P.D., 13⁄8” Bore
2A-7.6” P.D., 15⁄8” Bore
1
1
1
1
1
1
1
1
1
1
3.8
3.9
A-005-6007
A-007-6037
A-110-6007
A-010-6007
A-020-6007
A-020-6007
A-030-6007NP
A-050-6007NP
A-075-6007NP
A-100-6007NP
3/4
1 (1 Ø)
3.2
1 (3 Ø)
3.2
11⁄
2
5.6
2
3
5
5.2
6.3
7.6
71⁄
2
12.5
13.5
10
G
IN-TANK CHECK VALVE:
Motor Hp
Size
1/2 Through 3
1/2” MPT x 1/2” FPT
3/4” MPT x 3/4” FPT
1
1
0.3
0.4
A-010-6008
A-075-6008
5 Through 10
H
J
SAFETY RELIEF VALVE: Set at approximately 115 psig (805 kPa)
1/2 Through 5 Hp Models
1
1
0.1
0.2
A-050-6009
A-200-6009
71⁄
Through 10 Hp Models
2
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
1
0.9
0.9
A-100-6010
A-100-6011
Lag Switch: Set at approximately
60 psig (420 kPa) cut-in and
80 psig (560kPa) cut-out
K
TANK:
Motor Hp
Tank Size
30 gallon
60 gallon
60 gallon
80 gallon
80 gallon
120 gallon
120 gallon
200 gallon
1/2 Through 11⁄
2
1
1
1
1
1
1
1
1
134.0
175.0
184.0
235.0
243.0
398.0
415.0
677.0
A-010-6030NP**
A-010-6060NP
1/2 Through 11⁄
2 & 3
2
A-020-6060NP
1/2 Through 11⁄
2 & 3
2
A-010-6080NP**
A-020-6080NP**
A-020-6120NP**
A-050-6120NP**
A-100-6200NP**
2 & 3
5 & 71⁄
2
5 Through 10
L
COOLING SHROUD:
Motor Hp
1/2
3/4
2
1
1
1
1
1
1
1
1.0
1.0
1.7
1.7
1.9
1.9
4.5
A-005-6013
A-005-6013
A-020-6013NP
A-030-6013NP
A-050-6013NP
A-075-6013NP
A-100-6013NP
3
5
71⁄
2
10
M
N
BELT GUARD:
Motor Hp
1/2 Through 11⁄
2
1
1
1
1
2.4
12.5
12.5
18.5
A-010-6012
A-020-6012
A-050-6012
A-100-6012
2 & 3
5 & 71⁄
10
2
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.
7
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Simplex
Maintenance Schedule
Operating Hours
Item
Action needed
500
2500
5000
10,000
15,000
20,000
Remarks
Tank
Inlet air filter
Blower fan
Drain moisture
Replace
Clean
Daily
G
2500
L
(Every 2,500 hrs or less)
G
G
G
G
G
G
Fan duct
Clean
G
G
Compressor fins
Oil change
Clean
Replace
G
(Every 2,500 hrs or less)
(Every 1,500 hrs)
Compression rings
Check oil
Piston set
Replace
Inspect
Replace
L
Daily
G
V-belt
Pressure switch
Inspect, replace
Confirm operation
*Note 3
G
L
L
G
L
L
G
Magnetic starter
Inspect
G
G
Replace if contact
points deteriorated
Safety valve
Pressure gauge
Confirm operation
Inspect
G
G
(Every 2,500 hrs or less)
(Every 2,500 hrs or less)
(G) Inspect
(L) 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.
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 Air-
End 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 PAR-
TICULAR 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 stipulat-
ed in specific product quotations. All agreements are contingent upon strikes, accidents, or other causes beyond our control. All ship-
ments 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.
150 Production Drive
Harrison, OH 45030
Phone: 1-888-769-7979
Fax: 513-367-3125
8
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Features
• 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.
Figure 1 - AD-XXX Series 2 Hp Duplex Air Compressor
with Optional Deluxe Alternator Package
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.
Specifications
Product
AD-XXX Series Powerex Duplex Air Compressors
Performance
Specifications
Models & Options
Lubrication
See Table 1
See Table 2
1/2 Through
10 Hp Models
1Ø
Splash Lubrication System
115/230 Volts, 60 Hz
Operating
Voltages
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
3Ø
208-230/460 Volts, 60 Hz
Compression
Cycle
1/2 Through
10 Hp Models
1Ø and 3Ø
Single-Stage
Motor Overload
Protection
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)
Lead
Lag
Pressure Switch
Settings
compressor for repair while the other
compressor is running.
Overpressure
Protection
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
Outlet Air
1/2" NPT on 30 and 80 Gallon Tanks;
1" NPT on 120, and 200 Gallon Tanks
See Table 2
Connections
Tank Sizes
California
Ordinance 462 (L)(2)
Isolation Mounts
Meets requirements of this Ordinance
Vibration pads are included with each unit
entrainment potential and improves
the motor life by holding down the
average heat rise.
Powerex • 150 Production Drive • Harrison, OH 45030 • USA
IN259702AV 3/05
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Duplex
TABLE 1: AD-XXX SERIES POWEREX DUPLEX AIR COMPRESSORS
PERFORMANCE SPECIFICATIONS
Base
Actual Hp
1Ø 3Ø
Motor Rating
Compressor
RPM
Compressor Capacity SCFM
Model
Hp
RPM
1725
1720
100% Runtime 50% Runtime 33% Runtime
.54
—
AD-105
AD-005
AD-107
AD-007
AD-110
AD-010
AD-015
AD-020
AD-030
AD-050
AD-075
AD-100
—
—
—
800
1040
625
1.8
2.5
3.8
0.9
0.6
—
.50
.54
.73
.73
—
1725
1725
1.25
1.9
0.83
1.25
—
.75
1.07
—
—
1.0
1.5
2.0
3.0
5.0
7.5
10.0
1.07
1.54
2.0
—
—
—
—
—
—
1750
1750
1745
1745
1745
1750
955
800
775
690
795
685
6.4
8.6
3.2
4.3
6.0
2.11
2.84
4.0
12.0
22.0
28.5
43.0
3.1
11.0
7.33
9.44
5.6
14.3
21.5
8.2
14.2
10.3
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.
BASIC ALTERNATOR PACKAGE
Operation
Refer to Installation Data AS/AD-XXX
for detailed installation instructions.
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.
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.
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
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.
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.
alignment while adjusting tension.
Mounted and
Connected Options
AUTOMATIC TANK DRAIN
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. Refer
to Table 2 for ordering details and
figure 4 for wiring diagram.
LUBRICATION
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.)
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.
VIBRATION DAMPENING PADS
Waffle type design vibration pads are
provided as standard equipment.
Dispose of oil in
!
WARNING
accordance with
state or local codes.
2
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Duplex
LUBRICATION (Continued)
1. Plug E-drain into 115V power outlet
supply.
AUTO E-DRAIN ASSEMBLY (See
Figure 3)
2. Adjust timer accordingly.
NOTE: The automatic E-drain is
assembled to tank.
Manifold
Assembly
Remove cap and
add oil
Oil
gauge
Oil drain cap
Round (red)
ON
4
TEST
OFF
30
6
20
2
8
10
5
40
0.5
10
0.5
45
sec.
min.
Full
Low
Oil Gauge
Figure 3 - E-Drain
Figure 2
TABLE 2: MODEL NUMBER
AD
OR
Tank Drain/Dryer Options
Manual Drain,
Motor Horsepower, Voltage Phase
Tank Size
1Ø
Horsepower
3Ø
(Gallons)
Available on:
No Dryer = 1
E-Drain,
No Dryer = 2
105 =
107 =
110 =
NA =
NA =
NA =
NA =
NA =
NA =
1/2
3/4
1
= 005
= 007
= 010
= 015
= 020
= 030
= 050
= 075
= 100
30 = 1
1/2 Through 1-1/2 Hp
1/2 Through 3 Hp
3 Through 7-1/2 Hp
5 Through 10 Hp
80 = 3
120 = 4
200 = 5
Manual Drain,
}
with Dryer = 3
E-Drain,
with Dryer = 4
11⁄2
2
3
Available on
1/2 through 3 Hp
models only.
5
71⁄2
Starter Options
10
Basic
0=
Deluxe
= 0
None
2=
3Ø, 208V
3Ø, 230V
3Ø, 460V
1Ø, 115V
1 Ø, 208V
1 Ø, 230V
= A
3=
= B
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.
4=
= C
5=
= E
6=
= N/A
= G
7=
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.
1Ø vs 3 Ø selection must agree with
base model selection
3
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Duplex
Figure 4
Deluxe Alternator
Package Wiring
Diagram for
L
L
3
L
2
1
Three-Phase Units
L
L
L
1
2
3
A2
A1
A1
A2
Lag Switch
Cut In: 60 psig (420 kPa)
Cut-Out: 80 psig (560 kPa)
Alt
Lead Switch
Cut In: 70 psig (490 kPA)
Cut Out: 90 psig (630 kPa)
FU
X1
FU
2T 2T 2T
3
1
2
IT
IT
3
IT
2
1
Motor
2
Motor
1
X2
FU
2M
1M
Selector
Switch
Figure 5
Basic Alternator
Package Wiring
Diagram For
Lag Switch
Cut In: 60 psig (420 kPa)
Cut-Out: 80 psig (560 kPa)
Three-Phase Units
L
L
L
3
2
1
Red
PSI
Single
Disconnect
Field Supplied
Red
L
1
Black
Blue
L
2
L
3
Starter
Alt R
Alt L
Overloads
Alt C
IT
IT
IT
1
2
2T
2T
3
3
2T
2
1
Alt
A251
1M
2M
Motor
1
Motor
2
C2
A151
A252
Lead Switch
Cut In: 70 psig (490 kPA)
Cut Out: 90 psig (630 kPa)
PS 2
PS 2
4
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Duplex
Plug
Optional
Dryer
A
D
B
C
Discharge
F
G
E
1/2 Through 10 HP Models
Figure 6 - Dimensions (in./cm)
TABLE 3: DIMENSIONS (INCHES) AND SHIPPING WEIGHTS (POUNDS*)
B
with
B
Shipping Weight**
with without
Alternator Alternator
Base
Model
A
without
C
D
E
F
G
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
AD-010-3XX
AD-015-1XX
AD-015-3XX
AD-020-3XX
AD-030-3XX
AD-030-4XX
AD-050-4XX
AD-050-5XX
AD-075-4XX
AD-075-5XX
AD-100-5XX
41 1⁄2
64 1⁄4
41 1⁄2
64 1⁄4
41 1⁄2
64 1⁄4
21 1⁄4
22 1⁄4
21 1⁄4
22 1⁄4
21 1⁄4
22 1⁄4
17 3⁄4
20
35 1⁄4
39
18
40
18
40
18
40
15 3⁄4
18 1⁄2
15 3⁄4
18 1⁄2
15 3⁄4
18 1⁄2
12 1⁄4
13
68 1⁄2
77 3⁄4
68 1⁄2
77 3⁄4
68 1⁄2
77 3⁄4
260
420
260
425
270
435
240
400
240
405
250
415
17 3⁄4
20
36
12 1⁄4
13
39
17 3⁄4
36
12 1⁄4
20
39
13
41 1⁄2
64 1⁄4
65 1⁄4
65 1⁄4
70 3⁄4
71 1⁄4
81 1⁄2
71 1⁄4
81 1⁄2
84
21 1⁄4
22 1⁄4
23 1⁄4
23 1⁄4
25 3⁄4
26 1⁄4
30
26 1⁄4
30
30
17 3⁄4
20
20
20
24
24
30
24
30
30
36
39
41
41
18
40
40
40
42
42
42
42
42
42
15 3⁄4
18 1⁄2
18 1⁄2
18 1⁄2
22
22
22
22
22
12 1⁄4
13
13
68 1⁄2
77 3⁄4
90 3⁄4
90 3⁄4
96 1⁄4
—
—
—
—
—
270
435
500
650
780
930
1155
950
1175
1440
250
415
480
630
760
910
1135
925
1150
1415
13
44
15 3⁄4
15 3⁄4
18 3⁄4
15 3⁄4
18 3⁄4
18 3⁄4
49 1⁄4
55 1⁄2
49 1⁄4
55 1⁄2
58
22
*Inches x 2.54 = Centimeters, Pounds x 0.454 = Kilograms
**Add 60.0 lbs. for units equipped with a factory mounted air dryer
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Duplex
E (Behind beltguards)
L
J
M
D
F
(Behind
Motor)
B
C
H
G
A
N
G
K
REPLACEMENT PARTS LIST
Shipping
Weight
(lbs.*)
Quantity
Required
Code
Number
Item
A
Description
PUMP AND FLYWHEEL:
Motor Hp 1/2, 3/4
2
2
2
2
2
2
2
19.5
35
59
A-005-6001
1, 11⁄
2
A-010-6001NP
A-020-6001NP
A-030-6001NP
A-050-6001NP
A-075-6001NP
A-100-6001NP
2
3
5
66
115
121
180
71⁄
2
10
B
C
D
E
VALVE KIT: Includes valve plate, spacer and head gasket
Motor Hp 1/2
2
2
2
4
4
4
4
6
0.4
0.4
0.5
0.5
0.7
1.2
1.2
1.2
A-005-6002
A-005-6002
3/4
1, 11⁄
2
A-010-6002NP
A-010-6002NP
A-030-6002NP
A-050-6002NP
A-075-6002NP
A-075-6002NP
2
3
5
71⁄
2
10
RING/CYLINDER KIT: Includes all compression rings, oil control rings, cylinder, gaskets and sealant
Motor Hp 1/2
2
2
2
4
4
4
4
6
3.6
3.6
4.8
4.8
5.5
10
10
10
A-005-6004
A-005-6004
3/4
1, 11⁄
2
A-010-6004NP
A-010-6004NP
A-030-6004NP
A-050-6004NP
A-075-6004NP
A-075-6004NP
2
3 (Kit includes piston)
5
71⁄
2
10
INTAKE FILTER ELEMENT:
Motor Hp
1/2
3/4
2
2
2
4
4
4
4
6
0.1
A-005-6023
A-005-6023
0.1
0.2
0.2
0.2
0.2
0.2
0.2
1, 11⁄
2
A-010-6023NP
A-030-6023NP
A-030-6023NP
A-030-6023NP
A-030-6023NP
A-030-6023NP
2
3
5
71⁄
2
10
BELT:
Motor Hp
Size
1/2
3/4
1
AX-42
AX-42
A-43
A-46
A-65
A-62
A-65
A-67
2
2
2
2
2
2
4
4
0.3
0.3
0.3
0.3
0.4
0.4
1.6
2.0
A-005-6006
A-005-6006
A-010-6006
A-015-6006NP
A-020-6006NP
A-030-6006NP
A-050-6006NP
A-075-6046NP
11⁄
2
2
3
5
71⁄
2
(120 gal tank)
*lb. x 0.454 = kg
6
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Duplex
REPLACEMENT PARTS LIST
Shipping
Weight
(lbs.*)
Quantity
Required
Code
Number
Item
E
Description
BELTS:
(Continued)
71⁄
10
2
(200 gal tank)
A-75
A-84
4
4
2.0
2.4
A-075-6056NP
A-100-6006NP
F
MOTOR
PULLEY:
Motor Hp
1/2
3/4
Type
1A-4.4” P.D., 5/8” Bore
1A-5.8” P.D., 5/8” Bore
1A-4.0” P.D., 5/8” Bore
1A-4.0” P.D., 7/8” Bore
1A-6.0” P.D., 7/8” Bore
1A-6.0” P.D., 7/8” Bore
1A-6.0” P.D., 11⁄8” Bore
2A-5.6” P.D., 11⁄8” Bore
2A-7.6” P.D., 13⁄8” Bore
2A-7.6” P.D., 15⁄8” Bore
2
2
2
2
2
2
2
2
2
2
3.8
3.9
3.2
3.2
5.6
5.2
6.3
7.6
12.5
13.5
A-005-6007
A-007-6037
A-110-6007
A-010-6007
A-020-6007
A-020-6007
A-030-6007NP
A-050-6007NP
A-075-6007NP
A-100-6007NP
1 (1 Ø)
1 (3 Ø)
11⁄
2
2
3
5
71⁄
2
10
G
IN-TANK CHECK VALVE:
Motor Hp
Size
1/2 Through 3
5 Through 10
1/2” MPT x 1/2” FPT
3/4” MPT x 3/4” FPT
2
2
0.3
0.4
A-010-6008
A-075-6008
H
J
SAFETY RELIEF VALVE: Set at approximately 115 psig (805 kPa)
1/2 Through 5 Hp Models
1
1
0.1
0.2
A-050-6009
A-200-6009
71⁄
Through 10 Hp Models
2
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
1
0.9
0.9
A-100-6010
A-100-6011
Lag Switch: Set at approximately
60 psig (420 kPa) cut-in and
80 psig (560kPa) cut-out
K
L
TANK:
Motor Hp
Tank Size
30 gallon
80 gallon
80 gallon
120 gallon
120 gallon
200 gallon
1/2 Through 11⁄
2
1
1
1
1
1
1
134.0
235.0
243.0
398.0
415.0
677.0
A-010-6030NP
A-010-6060NP
A-020-6060NP
A-020-6080NP
A-050-6120NP
A-100-6200NP
1/2 Through 11⁄
2 & 3
2
2 & 3
5 & 71⁄
2
5 Through 10
COOLING
SHROUD:
Motor Hp
1/2
3/4
2
2
2
2
2
2
2
2
1.0
1.0
1.7
1.7
1.7
1.9
4.5
A-005-6013
A-005-6013
A-020-6013NP
A-030-6013NP
A-050-6013NP
A-075-6013NP
A-100-6013NP
3
5
71⁄
2
10
BELT GUARD: Motor Hp
1/2 Through 11⁄
M
N
2
2
2
2
2
2.4
12.5
12.5
18.5
A-010-6012
A-020-6012
A-050-6012
A-100-6012
2 & 3
5 & 71⁄
10
2
LIQUID GASKET:1 through 10 Hp
1
0.4
A-999-6000
*lb. x 0.454 = kg
7
Download from Www.Somanuals.com. All Manuals Search And Download.
Climate Control Duplex
Maintenance Schedule
Operating Hours
Item
Action needed
500
2500
5000
10,000
15,000
20,000
Remarks
Tank
Inlet air filter
Blower fan
Drain moisture
Replace
Clean
Daily
G
L
(Every 2,500 hrs or less)
G
G
G
G
G
G
Fan duct
Clean
G
G
Compressor fins
Oil change
Clean
Replace
G
(Every 2,500 hrs or less)
(Every 1,500 hrs)
Compression rings
Check oil
V-belt
Replace
Inspect
Inspect, replace
Confirm operation
L
L
Daily
*Note 3
G
L
L
G
L
G
Pressure switch
Magnetic starter
Inspect
G
G
Replace if contact
points deteriorated
Safety valve
Pressure gauge
Confirm operation
Inspect
G
G
(Every 2,500 hrs or less)
(Every 2,500 hrs or less)
G
Inspect
L
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./5” deflection; for 5 to 10 Hp units, 4-6 lbs./.5” deflection.
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 Air-
End 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.
150 Production Drive
Harrison, OH 45030
Phone: 1-888-769-7979
Fax: 513-367-3125
8
Download from Www.Somanuals.com. All Manuals Search And Download.
P
U
R
E
A
I
R
T
E
C
H
N
O
L
O
G
Y
General Product Manual
Lubricated 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 prop-
erty damage! Retain instructions for future reference.
effect of excessive ring and cylinder
wear. Piston rings should be replaced
every 15,000 hours of operation.
Descriptions
!
DANGER
GENERAL
Breathable Air Warning
The Powerex reciprocating air compres-
sor has advanced compressor technolo-
gy. The Powerex reciprocating com-
pressor is available in single stage
model. Individually precision machined
cylinders and lap joint rings provide the
lowest oil carryover in the industry. The
onboard cooling fan and finned fly-
wheel create lower operating tempera-
tures.
VALVING
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 neces-
sary to properly filter and purify
the air to meet minimal specifica-
tions for Grade D breathing as
described in Compressed Gas
Low lift Swedish stainless steel valves
resist carbon build-up and offer out-
standing durability. The reduced num-
ber of valves lessens the risk of failure.
Installation
INSTALLATION SITE
1. The compressor must be located in a
clean, well lit and well ventilated
area.
DRY TYPE INLET FILTER
2. The area should be free of excessive
dust, toxic or flammable gases and
moisture.
The inlet filter on the Powerex com-
pressor assures 99% of particulate free
air is admitted to the unit. Change
every 500 hours or more often in dirty
locations.
Association Commodity
Specification G 7.1 - 1966, OSHA 29
CFR 1910. 134, and/or Canadian
Standards Associations (CSA).
3. Never install the compressor where
the ambient temperature is higher
than 104 F or where humidity is high.
o
DISCLAIMER OF WARRANTIES
PISTON RINGS AND CYLINDERS
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 war-
ranties are void, and Powerex dis-
claims any liability whatsoever for
any loss, personal injury or damage.
4. Clearance must allow for safe, effec-
tive inspection and maintenance.
The Powerex reciprocating compressor
cylinder is made of a 390R cast alloy
construction machined with the most
advanced technology available. These
heat reducing cylinders eliminate the
5. If necessary, use metal shims or level-
ing pads to level the compressor.
Never use wood to shim the com-
pressor.
Figure 1 - Models CS100P, LPS010, LPS020, LPS030, LPS075, LPS100
Powerex • 150 Production Drive • Harrison, OH 45030 • USA
IN259102AV 3/01
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
VENTILATION
SAFETY VALVES
7. Make sure the inlet filter is properly
installed.
1. If the compressor is located in a total-
ly enclosed room, an exhaust fan
with access to outside air must be
installed.
Tank mounted compressors are shipped
from the factory with safety valves
installed in the tank manifold. The flow
capacity of the safety valve is equal to
or greater than the capacity of the
compressor.
8. Confirm that the drain valve is closed.
9. Visually check the rotation of the
compressor pump. If the rotation is
incorrect, have a qualified electrician
correct the motor wiring.
2. Never restrict the cooling fan exhaust
air.
1. The pressure setting of the safety
valve must be no higher than the
maximum working pressure of the
tank.
3. Never locate the compressor where hot
exhaust air from other heat generating
units may be pulled into the unit.
START-UP AND OPERATION
1. Follow all the procedures under
“Before start-up” before attempting
operation of the compressor.
Minimum Clearances
2. Safety valves should be placed ahead
of any possible blockage point in the
system, i.e. shutoff valve.
2. Switch the electric source breaker on.
Above
24”
12”
20”
3. Open the tank discharge valve com-
pletely.
Drive belt side
Other sides
3. Avoid connecting the safety valve
with any tubing or piping.
4. Check that the compressor operates
without excessive vibration, unusual
noises or leaks.
WIRING
4. Manually operate the safety valve
every six months to avoid sticking or
freezing.
Refer to the general product manual.
All electrical hook-ups must be per-
formed by a qualified electrician.
Installations must be in accordance
with local and national electrical codes.
5. Close the discharge valve completely.
6. Check the discharge pressure. Also
make sure the air pressure rises to the
designated pressure setting by check-
ing the discharge pressure gauge.
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.
Use solderless terminals to connect the
electric power source.
7. Check the operation of the pressure
switch or the pilot valve for continu-
ous run units by opening the stop
valve and confirming the compressor
starts or reloads as pressure drops.
PIPING
Refer to the general product manual.
1. Make sure the piping is lined up
without being strained or twisted
when assembling the piping for the
scroll compressor.
BEFORE START UP
1. Make sure all safety warnings, labels
and instructions have been read and
understood before continuing.
Switch the breaker OFF if the compres-
sor is not to be used for a long period
of time.
2. Appropriate expansion loops or
bends should be installed at the com-
pressor to avoid stresses caused by
changes in hot and cold conditions.
2. Remove any shipping materials,
brackets, etc.
Two stage units are
equipped with head
unloaders for continuous operation.
NOTICE
3. Confirm that the electric power
source and ground have been firmly
connected.
3. Piping supports should be anchored
separately from the compressor to
reduce noise and vibration.
4. Be sure all pressure connections are
tight.
4. Never use any piping smaller than
the compressor connection.
5. Check to be certain all safety relief
valves, etc., are correctly installed.
5. Use flexible hose to connect the out-
let of the compressor to the piping so
that the vibration of the compressor
does not transfer to the piping.
6. Check that all fuses, circuit breakers,
etc., are the proper size.
Dimensions (Refer to Figure 2)
Max
psig
SCFM @
100 psig
RPM @
100 PSIG
Number/
Cylinders Bore
Flywheel
Stroke Outer Diam.
Weight
(lbs.)
Model
HP
Drive
CS100P .75/.5
140
140
140
140
140
140
2.3/1.7
5.1/3.4
7.7
990/805
900/665
720
1
1
2
2
2
3
1.9
2.6
2.6
3.0
4.1
4.1
2.2
11.2
10.5
13.7
14.6
18.3
19.7
1GR-A
1GR-A
1GR-B
1GR-B
2GR-B
2GR-B
28
LPS010
LPS020
LPS030
LPS075
LPS100
1.5/1
2
2.6
34
2.4
65
5/3
15.4/11.5
29.2
1050/765
790
2.9
76
7.5
3.35
3.35
116
137
15/10
62.1/41.3
1080/695
2
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
7.5”
11.9”
10.8
9.4
16.2”
13.9
3.7
7.9
3.2”
6.7”
LPS 010
CS100P
18.9”
11.9”
22.8”
15.0”
17.8”
20.2”
8.3”
4.4”
4.4”
11.5”
26.0”
LPS 020
LPS 030
18.0”
26.0”
18.0”
21.8”
21.8”
5.3”
5.3”
11.4”
11.4”
LPS 075
LPS050
29.7”
20.1”
21.7”
6.3”
LPS 100
Figure 2 - Dimensional Drawings
12.2”
3
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
Maintenance Schedule
Operating Hours
5,000 10,000
Item
Action needed
500
2,500
15,000
20,000
Remarks
Tank
Inlet air filter
Blower fan
Drain moisture
Replace
Clean
Daily
G
G
(Every 2,500 hrs or less)
G
G
G
G
G
Fan shroud
Clean
G
G
G
Compressor fins
Oil change
Clean
Replace
G
(Every 2,500 hrs or less)
(Every 1,500 hrs)
Compression rings Replace
G
Check oil
Inspect
Daily
V-belt
Pressure switch
Inspect, replace
Confirm operation
*Note 3
G
G
G
G
G
G
G
Magnetic starter Inspect
G
G
Replace if contact
points deteriorated
Safety valve
Pressure gauge
Confirm operation
Inspect
G
G
(Every 2,500 hrs or less)
(Every 2,500 hrs or less)
G
G
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 3/4 to 3 HP units is 2-3 lbs./.5” deflection; for 5 to 10 HP units, 4-6 lbs./.5” deflection.
Oil Level
To check lubricating oil, see oil gauge. Refill if necessary.
Remove cap
and add oil
using funnel
How to Read Oil Gauge
Full
Low
Round (red)
Oil gauge
Oil Change
Replace lubricating oil fully within designated time. Before
draining oil, remove oil supply cap and then oil drain cap in
order to release air.
RECOMMENDED OIL
Mobil Rarus 427, Shell Turbo T68, Exxon Esstic T68 and Texaco
Rando T68.
CLIMATE CONTROL APPLICATIONS
Mobil DTE Heavy and Mobil Rarus 427
Dispose of oil in accordance with
state or local codes.
!
WARNING
Oil drain cap
4
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
Air Filter Replacement
Ring Replacement Every 15,000 Hours
1. Remove wing nut.
1. Remove cylinder head
bolts on each cylinder.
2. Remove canister and wipe
after removing old cartridge.
2. Remove and discard form seal
or gasket.
3. Remove and discard filter
cartridge.
4. Install new filter cartridge.
Do not attempt to clean
and reuse filter cartridge.
3. Replace form seal or gasket.
4. Remove valve plate and clean
with dry cloth.
Wipe clean with dry cloth
once new filter is in place.
5. Remove and discard cylinder
seal or gasket.
6. Replace with the new seal or
gasket.
Figure 3 - Air Filter Replacement
7. Remove and discard valve
wear pad.
8. Replace with new pad.
Cylinder Bolt Torque
9. Remove cylinder bolts and
cylinder. Note the cylinder
orientation. Inspect for
abnormal wear.
Torque
(in. lb.)
Model
CS100P
LPS010
LPS020
LPS030
LPS050
LPS075
LPS100
156
156
156
156
295
295
295
NOTE: Liquid gasket required
between cylinder & crankcase
and bearing cap on all LPS
Models (P. N. #JP013400AV).
10. Remove piston rings.
11. Replace rings. Orientate ends
180˚ opposite from each other.
12. Apply thin continuous layer of
liquid gasket to cylinder flange.
Install cylinder. Be careful of
orientation. Torque cylinder
bolts (See chart).
13. Install valve set with new seals.
14. Install head and cylinder head
bolts. Torque head bolts (See
chart).
Head Bolt Torque
Torque
(in. lb.)
Model
CS100P
LPS010
LPS020
LPS030
LPS050
LPS075
LPS100
156
156
156
156
295
156
156
Figure 4 - Ring Replacement
15. Unit is ready for full operation.
No break-in is required.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
CS100P
27
26
28
25
29
23
24
24
21
20
22
19
30
3
14
1
12
10
2
7
17
11
18
16
4
8
9
13
15
16
5
6
Figure 5 - Replacement Parts Illustration
6
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
CS100P
Ref.
No.
Description
Part Number
Qty
1
2
Cylinder
IP036000AV
IP035901AV
IP035800AV
G
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
Cylinder gasket
Cylinder head
3
4
Crank case
5
Bearing case
G
6
Bearing case gasket
Oil gauge set
IP035301AV
91117120
7
8
Oil drain pipe
IP031701AV
IP001900AV
IP002100AV
IP035200AV
IP035100AV
IP035000AV
IP002700AV
IP003000AV
IP031300AV
IP034900AV
IP034800AV
IP033800AV
IP033700AV
IP033600AV
IP033500AV
IP033300AV
IP033200AV
IP305000AV
IP032800AV
IP032701AV
IP032601AV
IP032500AV
IP630100AV
9
Oil drain cap with gasket
Breather assembly with gasket
Fan side rubber seal
Crank shaft
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
G
Flywheel
Woodruff key
Oil seal
Ball bearing
Fan
Fan shroud
Connecting rod
Piston Assembly (Includes items 22 - 24)
Piston ring set
Piston
Piston pin
Stop ring
Valve assembly (Includes items 27 - 28)
Valve plate
Cylinder head gasket
Valve spacer gasket
Air intake filter cover
Air intake filter element
Replace Pump
7
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS010
3
2
20
24
27
23
26
1
21
C
22
17
16
25
13
14
C
19
18
19
12
28
9
5
15
28
11
29
15
6
10
NOTE: Apply a thin layer of liquid gasket
to entire surface of Item 28.
8
4
7
Figure 6 - Replacement Parts Illustration
8
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS010
Ref.
No.
Description
Part Number
Qty
1
2
Cylinder
91000560
91003550
01052041
G
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
Cylinder head
Unloader cap
Crank case
3
4
5
Bearing cap
G
6
Oil gauge
01909600
01119400
01120023
01919470
01146550
91223551
91201551
06600008
07192201
07112200
91902560
91924120
01232120
06613160
91906550
91348550
01301560
01909400
01161470
91251550
91935560
91933560
JP013400AV
01120600
7
Oil drain pipe
Oil drain cap set
Breather assembly and gasket
Bearing cap rubber seal
Crankshaft
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Pulley flywheel
Key woodruff
Bearing cap oil seal
Bearing cap ball bearing
Piston
Piston ring set
Wrist pin
Retainer
Intake filter set
Intake filter
Intake valve seat
Tube
Return tube nipple
Connecting rod
Valve gasket set
Valve set with gasket
Liquid gasket
Oil gauge gasket
∆
∆
Not shown
G
Replace Pump
9
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS020
29
30
34
5
31
B
37
31
32
C
38
34
35
6
13
7
3
17
25
21
23
B
20
42
16
8
9
18
18
22
14
19
15
42
43
4
11
2
12
C
10
40
41
33
36
1
26
39
24
28
27
25
NOTE: Apply a thin layer of liquid gasket
to entire surface of Item 42.
Figure 7 - Replacement Parts Illustration
10
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS020
Ref.
No.
Description
Part Number
Qty
1
2
Cylinder
91000560
91003560
06800261
01052041
91345561
91346571
91176580
G
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2
2
4
1
1
2
1
2
2
1
2
1
1
2
2
2
1
1
Cylinder head
3
Intake return pipe elbow
Unloader cap
4
5
Intake joint (1)
6
Intake joint (2)
7
Breather flange
Crankcase
8
9
Bearing cap
G
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Oil gauge
01909600
01119400
91908600
01919470
01146560
91214560
91202560
0660013
Oil drain pipe
Oil drain cap assembly
Breather assembly and gasket
Bearing cap rubber seal
Crank shaft
Flywheel pulley
Key woodruff
Bearing cap oil seal
Bearing cap ball bearing
Crank case ball bearing
Fan
07192252
07112250
07112300
91220560
91134560
91251560
91224560
91902560
91924120
01232120
06613160
91907570
91353660
06630032
91407560
01301560
06639906
01909400
91135560
01095570
01095560
91935560
91933560
01471452
JP013400AV
01120600
Fan cover
Right connecting rod (Facing flywheel)
Left connecting rod (Facing flywheel)
Piston set with rings
Piston ring set
Wrist pin
Retainer
Intake filter set
Intake filter
Intake pipe o-ring
Intake pipe
Intake valve seat
Intake joint o-ring
Tube
Fan guard
Intake joint bolt
Intake joint bolt
Valve gasket set
Valve set with gasket
Rubber seal (Unloader piston)
∆ Liquid gasket
Oil gauge gasket
Not shown.
∆
G
Replace Pump
11
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS030
29
30
34
5
39
31
35
38
B
31
32
6
C
9
34
13
3
14
25
17
7
23
20
8
43
18
16
19
21
15
18
22
36
43
D
4
11
12
2
44
10
C
33
42
37
41
1
40
26
24
28
27
D
NOTE: Apply a thin layer of liquid gasket
to entire surface of Item 43.
28
25
Figure 8 - Replacement Parts Illustration
12
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS030
Ref.
No.
Description
Part Number
Qty
1
2
Cylinder
91033570
91004600
06800281
01052451
91345570
91346571
91176580
G
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2
2
4
1
1
2
1
2
2
1
1
2
1
1
2
2
2
1
1
Cylinder head
3
Intake return pipe elbow
Unloader cap
4
5
Intake joint (1)
6
Intake joint (2)
7
Breather flange
Crankcase
8
9
Bearing cap
G
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Oil gauge
01909600
01119430
91908600
01919600
06634062
91214570
91201570
06600013
07192302
07112300
07113300
91220570
91134570
91224570
91936570
91903571
91946571
01232041
01240581
91907570
91353660
06630032
91407570
01301692
06639906
91162570
91240570
91144570
01095570
01344690
91936601
91934603
01471452
JP013400AV
01120600
Oil drain pipe
Oil drain cap set
Breather assembly and gasket
Bearing cap rubber seal
Crankshaft
Pulley flywheel
Key woodruff
Bearing cap oil seal
Bearing cap ball bearing
Crankcase ball bearing
Fan
Fan cover
Right connecting rod (Facing flywheel)
Left connecting rod (Facing flywheel)
Piston set with rings
Piston ring set
Wrist pin
Retainer
Intake filter set
Intake filter
Intake pipe o-ring
Intake pipe
Intake valve seat
Intake joint o-ring
Return pipe
Fan retainer oil seal
Fan shield
Intake joint bolt
Intake joint bolt
Valve set with gasket
Valve gasket set
Rubber seal (Unloader piston)
Liquid gasket
∆
Oil gauge gasket
Not shown.
∆
G
Replace Pump
13
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS050
31
30
31
30
33
42
16
5
3
42
35
27
C
5
33
17
28
29
13
24
26
21
6
45
7
45
15 20
22
18
14
19
23
40
8
37
38
4
39
36
11
12
2
D
10
9
43
C
34
41
32
1
26
25
D
44
Note: Apply a thin layer of liquid gasket to
entire surface of item #45.
Figure 9 - Replacement Parts Illustration
14
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS050
Ref.
No.
Description
Part Number
Qty
1
2
Cylinder
91000590
91005580
06801281
01052451
91345660
91176580
G
2
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
4
2
2
2
2
2
1
1
1
1
1
1
2
2
2
2
1
Cylinder head
Intake return pipe fitting
Unloader cap
Intake joint
3
4
5
6
Breather flange
Crank case
7
8
Bearing case
G
9
Oil gauge
91909600
01120600
91119430
91908600
91919600
01146430
91200580
91201580
06600016
07192355
07192405
07112350
07113400
91220690
91134660
91207600
91901600
91902590
91924590
01232060
01240040
91907660
91353660
01301691
06639906
01471452
01909400
01117600
01118600
01121600
01123601
01148600
91144660
01344690
91933591
91936590
JP013400AV
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Packing-oil gauge
Oil drain pipe
Oil drain cap set
Breather set
Bearing cap rubber seal
Crank shaft
Flywheel pulley
Woodruff key
Oil seal
Oil seal
Bearing cap ball bearing
Crack case ball bearing
Fan
Fan cover
Right connecting rod (facing flywheel)
Left connecting rod (facing flywheel)
Piston set
Piston ring set
Piston pin
Retainer
Intake filter set
Filter set
Seat
Intake joint o-ring
Unloader cap seal
Return pipe
Oil gauge adapter
Oil gauge adapter lid
Gasket
Adapter packing
Retainer
Fan guard
Intake joint bolt
Valve set with gasket
Valve gasket set
Liquid gasket
Not shown.
∆
∆
G
Replace Pump
15
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS075
30
29
30
29
32
40
15
5
3
40
33
26
C
5
32
16
27
28
12
23
25
20
6
44
7
14 19
21
17
13
18
22
38
8
35
36
44
4
37
34
10
11
2
D
45
9
41
C
43
39
31
1
25
24
D
42
NOTE: Apply a thin layer of liquid gasket
to entire surface of Item 44.
Figure 10 - Replacement Parts Illustration
16
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS075
Ref.
No.
Description
Part Number
Qty
1
2
Cylinder
91000600
91005600
06801281
01052451
91345660
91176580
G
2
2
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
4
2
2
2
2
1
1
1
1
1
1
2
2
2
2
3
1
1
Cylinder head
3
Intake return pipe fitting
Unloader cap
4
5
Intake joint
6
Breather flange
Crankcase
7
8
Bearing cap
G
9
Oil gauge
01909600
01119430
91908600
01919600
01146430
91200580
91201580
06600016
07192355
07192405
07112350
07113400
91220690
91134660
91207600
91901600
91902600
91946600
01232060
01240040
91907660
91353660
01301692
06639906
91162580
01117600
01118600
01121600
01123601
01148600
91144660
01344690
91937600
91933601
01471452
JP013400AV
01120600
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
∆
Oil drain pipe
Oil drain cap set
Breather assembly and gasket
Bearing cap rubber seal
Crank shaft
Pulley flywheel
Key woodruff
Bearing cap oil seal
Crank case oil seal
Bearing cap ball bearing
Crankcase ball bearing
Fan
Fan cover
Right connecting rod (Facing flywheel)
Left connecting rod (Facing flywheel)
Piston set
Piston ring set
Wrist pin
Retainer
Intake filter set
Intake filter
Intake valve seat
Intake joint o-ring
Return pipe
Oil gauge case
Oil gauge cap
Oil gauge case gasket
Oil gauge crank case gasket
Retainer fan oil seal
Fan guard
Intake joint bolt
Valve set with gasket
Valve gasket set
Rubber seal (Unloader cap)
∆ Liquid gasket
Oil gauge gasket
Not shown.
G
Replace Pump
17
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS100
29
45
4
48
5
29
32
30
2
46
47
5
45
31
3
NOTE: Apply a thin layer of liquid
gasket to entire surface of Item 49.
32
35
1
26
25
25
27
36
18
17
28
24
42
15
33
13
49
21
16
8
14
34
19
43
20
38
49
6
36
23
40
39
37
10
7
11
45
41
12
5
22
48
32
9
4
24
25
44
Figure 11 - Replacement Parts Illustration
18
Download from Www.Somanuals.com. All Manuals Search And Download.
Reciprocating Air Compressor Pumps
LPS100
Ref.
No.
Description
Part Number
Qty
1
2
3
4
5
6
7
8
9
Cylinder
Cylinder head
Intake return pipe elbow
Unloader cap
Intake joint
Oil cap joint
Crank case
Bearing cap
Oil gauge
91000600
91005600
06801281
01052451
91345660
01122600
G
3
3
1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
3
3
6
3
3
3
3
1
2
1
1
1
1
1
1
1
2
1
2
3
3
3
3
1
G
01909600
01120600
01119430
91908600
01919600
01146690
91200600
01201600
06600016
07192452
07192405
07113450
07112500
91220690
91134690
91901600
91902600
91946600
01232060
01240040
91907660
91353660
01301692
06639906
01918600
01413690
91162580
91207600
01117600
01118600
01121600
01123601
01148600
01138600
01139600
01135690
01344690
91937600
91933601
01471452
JP013400AV
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
∆
Gasket
Oil drain pipe
Oil drain cap set
Breather assembly and gasket
Bearing cap rubber seal
Crank shaft
Pulley flywheel
Key woodruff
Bearing cap oil seal
Crank case oil seal
Bearing cap ball bearing
Crank case ball bearing
Fan
Fan cover
Left and right connecting rods
Piston set
Piston ring set
Wrist pin
Retainer
Intake filter set
Intake filter
Intake valve seat
Intake joint o-ring
Oil cap
Cover bracket
Return pipe
Center connecting rod
Oil gauge case
Oil gauge cap
Oil gauge case gasket
Oil gauge crank case gasket
Oil seal fan retainer
Bypass joint
Bypass pipe
Fan guard
Intake joint bolt
Valve gasket set
Valve set with gasket
Rubber seal (Unloader piston)
Liquid gasket
∆
Not shown.
G
Replace Pump
19
Download from Www.Somanuals.com. All Manuals Search And Download.
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 Air-End 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 com-
ponent 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 EXCLU-
SIVE REMEDY AND LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUD-
ED 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 dam-
age 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 WRIT-
ING, THESE TERMS AND CONDITIONS WILL CONTROL IN ANY TRANSACTION WITH POWEREX any differ-
ent 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.
Limited warranty applies in the U.S. and Canada only and gives you specific legal rights. You may also have
other rights which vary from state to state or country to country.
Download from Www.Somanuals.com. All Manuals Search And Download.
|