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Powerex AS-XXX, Product Manual

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Powerex AS-XXX Product Manual Download Page 23

7

Reciprocating Air Compressor Pumps

CS100P

1

Cylinder

IP036000AV

1

2

Cylinder gasket

IP035901AV

1

3

Cylinder head

IP035800AV

1

4

Crank case

▲

1

5

Bearing case

▲

1

6

Bearing case gasket

IP035301AV

1

7

Oil gauge set

91117120

1

8

Oil drain pipe

IP031701AV

1

9

Oil drain cap with gasket

IP001900AV

1

10

Breather assembly with gasket

IP002100AV

1

11

Fan side rubber seal

IP035200AV

1

12

Crank shaft

IP035100AV

1

13

Flywheel

IP035000AV

1

14

Woodruff key

IP002700AV

1

15

Oil seal

IP003000AV

2

16

Ball bearing

IP031300AV

2

17

Fan

IP034900AV

1

18

Fan shroud

IP034800AV

1

19

Connecting rod

IP033800AV

1

20

Piston Assembly (Includes items 22 - 24)

IP033700AV

1

21

Piston ring set

IP033600AV

1

22

Piston

IP033500AV

1

23

Piston pin

IP033300AV

1

24

Stop ring

IP033200AV

2

25

Valve assembly (Includes items 27 - 28)

IP305000AV

1

26

Valve plate

IP032800AV

1

27

Cylinder head gasket

IP032701AV

1

28

Valve spacer gasket

IP032601AV

1

29

Air intake filter cover

IP032500AV

1

30

Air intake filter element

IP630100AV

1

▲

Replace Pump

Ref.
No.

Description

Part Number

Qty

Summary of Contents for AS-XXX

Page 1: ...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 ...

Page 2: ... drain This unit is fur nished with a manual drain attach ment VIBRATION DAMPENING PADS Waffle type design vibration pads are provided as standard equipment Factory calibrated snap acting DPST pressure electric switches provide auto matic cut in and cut out Overpressure protection is provided by an ASME safe ty relief valve Receiver tanks have a condensate drain valve with an exten sion for easy a...

Page 3: ...Voltage Phase 1Ø Horsepower 3Ø 105 1 2 005 107 3 4 007 110 1 010 NA 11 2 015 NA 2 020 NA 3 030 NA 5 050 NA 71 2 075 NA 10 100 30 1 1 2 Through 11 2 Hp 60 2 3 4 Through 2 Hp 80 3 2 Through 71 2 Hp 120 4 5 Through 10 Hp 200 5 71 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 selecti...

Page 4: ...rloads 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 ...

Page 5: ... 110 1XX 42 1 2 40 43 19 3 2 42 21 1 4 17 3 4 21 13 1 6 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 3 2 52 3 4 22 1 4 20 22 5 1 6 21 40 29 18 14 349 340 AS 010 2XX AS 015 1XX 42 1 2 40 43 1 3 2 42 21 1 4 17 3 4 21 13 1 6 18 3 4 36 18 15 3 4 12 1 4 219 210 AS 015 2XX 50 3 4 50 3 4 51 27 3 2 52 3 4 22 1 4 20 22 5 1 6 21 40 29 18 14 349 340 AS 020 2XX 51 1 2 50 3 4 52...

Page 6: ...04 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 ...

Page 7: ...0 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...

Page 8: ...auses 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 carrie...

Page 9: ...pressor for repair while the other compressor is running An alternating type operation is desirable for many reasons When a duplex air compressor is alternated the temperature of both units is kept above the ambient dew point to minimize moisture deterioration and corrosion Also the reduction in on time provides a lower average head temperature with reduced oil entrainment potential and improves t...

Page 10: ...tor 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 assembl...

Page 11: ...A 11 2 015 NA 2 020 NA 3 030 NA 5 050 NA 71 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 ...

Page 12: ...A1 A2 2T1 2T2 2T3 Lag Switch Cut In 60 psig 420 kPa Cut Out 80 psig 560 kPa Lead Switch Cut In 70 psig 490 kPA Cut Out 90 psig 630 kPa L3 L2 L1 Motor 2 1M 2M Motor 1 A151 L1 PSI L2 Starter IT1 L3 Lag Switch Cut In 60 psig 420 kPa Cut Out 80 psig 560 kPa 2T1 2T2 2T3 IT2 IT3 A252 PS 2 PS 2 C2 Lead Switch Cut In 70 psig 490 kPA Cut Out 90 psig 630 kPa Red Red Black Blue Alt R Alt L Alt C Red Red Red ...

Page 13: ... 260 240 AD 007 1XX AD 107 3XX 64 1 4 22 1 4 20 39 40 18 1 2 13 77 3 4 425 405 AD 007 3XX AD 110 1XX 41 1 2 21 1 4 17 3 4 36 18 15 3 4 12 1 4 68 1 2 270 250 AD 010 1XX AD 110 3XX 64 1 4 22 1 4 20 39 40 18 1 2 13 77 3 4 435 415 AD 010 3XX AD 015 1XX 41 1 2 21 1 4 17 3 4 36 18 15 3 4 12 1 4 68 1 2 270 250 AD 015 3XX 64 1 4 22 1 4 20 39 40 18 1 2 13 77 3 4 435 415 AD 020 3XX 65 1 4 23 1 4 20 41 40 18...

Page 14: ...1 2 2 4 8 A 010 6004NP 2 4 4 8 A 010 6004NP 3 Kit includes piston 4 5 5 A 030 6004NP 5 4 10 A 050 6004NP 71 2 4 10 A 075 6004NP 10 6 10 A 075 6004NP D INTAKE FILTER ELEMENT Motor Hp 1 2 2 0 1 A 005 6023 3 4 2 0 1 A 005 6023 1 11 2 2 0 2 A 010 6023NP 2 4 0 2 A 030 6023NP 3 4 0 2 A 030 6023NP 5 4 0 2 A 030 6023NP 71 2 4 0 2 A 030 6023NP 10 6 0 2 A 030 6023NP E BELT Motor Hp Size 1 2 AX 42 2 0 3 A 00...

Page 15: ... 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 80 gallon ...

Page 16: ... 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...

Page 17: ...r 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 Association Commodity Specification G 7 1 1966 OSHA 29 CFR 1910 134 and or Canadian Standards Associations CSA DISCLAIMER OF WARRANTIES...

Page 18: ...blished 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 Remove any shipping materials brackets etc 3 Confirm that the electric power source and ground have been firmly connected 4 Be sure all pressure connections are tight 5 Check to be certain all safety relief valves et...

Page 19: ...010 LPS 020 LPS 030 LPS 075 LPS 100 7 5 3 2 6 7 8 3 11 5 22 8 4 4 26 0 11 4 5 3 29 7 12 2 6 3 18 9 17 8 16 2 20 2 21 8 21 7 Figure 2 Dimensional Drawings CS100P 13 9 10 8 7 9 3 7 9 4 11 9 11 9 15 0 18 0 20 1 4 4 26 0 11 4 5 3 21 8 18 0 LPS050 ...

Page 20: ...ance 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 4 Oil Level To ...

Page 21: ...inder bolts and cylinder Note the cylinder orientation Inspect for abnormal wear NOTE Liquid gasket required between cylinder crankcase and bearing cap on all LPS Models P N JP013400AV 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 v...

Page 22: ...6 Reciprocating Air Compressor Pumps CS100P Figure 5 Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 24 16 yy yyy yyy 30 ...

Page 23: ...IP035000AV 1 14 Woodruff key IP002700AV 1 15 Oil seal IP003000AV 2 16 Ball bearing IP031300AV 2 17 Fan IP034900AV 1 18 Fan shroud IP034800AV 1 19 Connecting rod IP033800AV 1 20 Piston Assembly Includes items 22 24 IP033700AV 1 21 Piston ring set IP033600AV 1 22 Piston IP033500AV 1 23 Piston pin IP033300AV 1 24 Stop ring IP033200AV 2 25 Valve assembly Includes items 27 28 IP305000AV 1 26 Valve plat...

Page 24: ...ompressor Pumps LPS010 Figure 6 Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 22 23 24 25 26 27 C C 19 15 28 28 NOTE Apply a thin layer of liquid gasket to entire surface of Item 28 29 ...

Page 25: ...551 1 13 Key woodruff 06600008 1 14 Bearing cap oil seal 07192201 1 15 Bearing cap ball bearing 07112200 2 16 Piston 91902560 1 17 Piston ring set 91924120 1 18 Wrist pin 01232120 1 19 Retainer 06613160 2 20 Intake filter set 91906550 1 21 Intake filter 91348550 1 22 Intake valve seat 01301560 1 23 Tube 01909400 1 24 Return tube nipple 01161470 1 25 Connecting rod 91251550 1 26 Valve gasket set 91...

Page 26: ...ure 7 Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 43 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 B B C 34 18 25 38 37 39 40 36 C 41 42 NOTE Apply a thin layer of liquid gasket to entire surface of Item 42 42 10 31 ...

Page 27: ...nk case ball bearing 07112300 1 21 Fan 91220560 1 22 Fan cover 91134560 1 23 Right connecting rod Facing flywheel 91251560 1 24 Left connecting rod Facing flywheel 91224560 1 25 Piston set with rings 91902560 2 26 Piston ring set 91924120 2 27 Wrist pin 01232120 2 28 Retainer 06613160 4 29 Intake filter set 91907570 1 30 Intake filter 91353660 1 31 Intake pipe o ring 06630032 2 32 Intake pipe 9140...

Page 28: ...8 Replacement Parts Illustration 1 2 3 4 5 6 7 8 9 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 B C D D 35 36 38 39 40 41 18 28 25 34 37 C 42 NOTE Apply a thin layer of liquid gasket to entire surface of Item 43 43 43 44 31 ...

Page 29: ...3300 1 21 Fan 91220570 1 22 Fan cover 91134570 1 23 Right connecting rod Facing flywheel 91224570 1 24 Left connecting rod Facing flywheel 91936570 1 25 Piston set with rings 91903571 2 26 Piston ring set 91946571 2 27 Wrist pin 01232041 2 28 Retainer 01240581 4 29 Intake filter set 91907570 1 30 Intake filter 91353660 1 31 Intake pipe o ring 06630032 2 32 Intake pipe 91407570 1 33 Intake valve se...

Page 30: ...26 27 28 29 30 31 32 33 35 36 37 C C D D 30 31 42 43 44 33 39 5 26 41 40 4 11 15 34 8 Reciprocating Air Compressor Pumps LPS050 14 Figure 9 Replacement Parts Illustration 10 38 45 45 Note Apply a thin layer of liquid gasket to entire surface of item 45 42 ...

Page 31: ...Crack case ball bearing 07113400 1 22 Fan 91220690 1 23 Fan cover 91134660 1 24 Right connecting rod facing flywheel 91207600 1 25 Left connecting rod facing flywheel 91901600 1 26 Piston set 91902590 2 27 Piston ring set 91924590 2 28 Piston pin 01232060 2 29 Retainer 01240040 4 30 Intake filter set 91907660 2 31 Filter set 91353660 2 32 Seat 01301691 2 33 Intake joint o ring 06639906 2 34 Unload...

Page 32: ... Replacement Parts Illustration 1 2 3 5 6 7 8 9 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 C C D D 29 30 40 41 42 32 37 40 5 25 39 38 4 10 14 43 44 44 NOTE Apply a thin layer of liquid gasket to entire surface of Item 44 35 45 ...

Page 33: ...nkcase ball bearing 07113400 1 21 Fan 91220690 1 22 Fan cover 91134660 1 23 Right connecting rod Facing flywheel 91207600 1 24 Left connecting rod Facing flywheel 91901600 1 25 Piston set 91902600 2 26 Piston ring set 91946600 2 27 Wrist pin 01232060 2 28 Retainer 01240040 4 29 Intake filter set 91907660 2 30 Intake filter 91353660 2 31 Intake valve seat 01301692 2 32 Intake joint o ring 06639906 ...

Page 34: ...t Parts Illustration 6 14 20 23 24 25 29 30 32 33 35 44 45 1 2 3 4 5 7 8 9 10 11 12 13 15 16 17 18 19 21 22 24 25 26 27 28 29 45 46 47 42 43 39 40 41 37 38 36 34 31 32 4 5 5 48 48 32 45 25 36 49 49 NOTE Apply a thin layer of liquid gasket to entire surface of Item 49 ...

Page 35: ...g 07112500 1 22 Fan 91220690 1 23 Fan cover 91134690 1 24 Left and right connecting rods 91901600 2 25 Piston set 91902600 3 26 Piston ring set 91946600 3 27 Wrist pin 01232060 3 28 Retainer 01240040 6 29 Intake filter set 91907660 3 30 Intake filter 91353660 3 31 Intake valve seat 01301692 3 32 Intake joint o ring 06639906 3 33 Oil cap 01918600 1 34 Cover bracket 01413690 2 35 Return pipe 9116258...

Page 36: ... 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 specif...

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