Instrument Air System
Instrument Air System
Instrument Air System
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. Please refer to safety manual IN258200AV for additional important safety
information..
SPECIFICATIONS
Product
DESCRIPTION
The Powerex instrument air package is designed to
provide instrument air for hospitals and medical
institutes. This system meets NFPA99 requirements for
Instrument Air.
PRESSURE LUBRICATED COMPRESSOR
The reciprocating compressor is provided in duplex,
triplex or quadplex configurations. Pressure lubricated
technology provides reliability for years to come.
RECEIVER TANK
The ASME, National Board registered air receiver is
provided in sizes from 120 to 240 gallons. Each
receiver is rated at 250 PSIG working pressure.
Receivers are provided with sight glass and moisture
drain (manual and electric).
CONTROL PANEL
The NEMA 12 control panel complies with NFPA 99
requirements for Instrument Air. The controls operate
the duplex, triplex, or quadplex 250 psi capable air compressor modules as needed in response to a pressure signal from pressure switches or a pressure transducer
depending on the model. The individual unit wiring
diagrams show which pressure sensing device is used.
Table of Contents
Specifications
Pg 1, 9
Electrical
Pg 8
Installation
Pg 3-4
Parts Lists
Pg 11
Operation
Pg 4-7
Warranty
Pg 15-16
Maintenance
Pg 10
Performance Specifications
See page 9
Compression Cycle
Reciprocating
Control Enclosure
NEMA 12
Control Panel
Drive
V-Belt
Est. Weight
Lubrication
Pressure Lubricated
Minimum Recommended
Tank Sizes
Motor
ODP Enclosure
Operating Pressure
200-220
Operating Temperature
34-104o F
Operating Voltages
208/230/460
Overpressure Protection
Power
Power Requirements
60 Hz
Pressure Setting
Working Pressure
Pump
Tank
Tank Isolation
Yes
Tank Sizes
Unit Isolation
Yes
Yes
60Hz
IN563102AV 01/14
1
ALONG WITH THIS MANUAL. READ AND UNDERMotor circuit breakers with lockable disconnects, on/off/ STAND THE SAFETY BOOKLET. This manual contains
information that is very important to know and understand.
auto switches, run lights, power on lights, hour meters
This information is provided for SAFETY and to PREVENT
and high temperature indicator lights and remote alarm EQUIPMENT PROBLEMS. To help recognize this informacontacts are provided for each compressor module.
tion, observe the following symbols. MAKE SURE EVRYONE OPERATING OR SERVICING THE COMPRESSOR
DEW POINT MONITOR
READS AND UNDERSTANDS ALL THE INFORMATION
The Powerex dewpoint monitor provides indication of
PROVIDED.
dew point and temperature. Its microprocessor controlled with user programmable output range, alarm and
calibration. The NEMA enclosure includes a polymer
viewing cover.
INSTALLATION
UNPACKING
RECEIVING THE UNIT
Immediately upon receipt of this compressor system, inspect
for any damage which may have occurred during shipment.
The compressor nameplate should be checked to verify the
correct model and voltage as ordered.
DO NOT OPERATE UNIT IF
DAMAGED DURING
SHIPPING, HANDLING, OR USE. DAMAGE MAY
RESULT IN BURSTING AND CAUSE INJURY OR
PROPERTY DAMAGE.
INSTALLATION SITE
1. The compressor must be located in a clean, well lit
and well ventilated area.
2. The area should be free of excessive dust, toxic or
flammable gases and moisture.
3. Never install the compressor where the surrounding
temperature is higher than 104oF or where humidity is
high.
4. Clearance must allow for safe, effective inspection
and maintenance.
SAFETY VALVES
Compressors are shipped from the factory with the
safety valves installed in the tank. The flow capacity of
the safety valve is 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.
Minimum Clearances
Above
24
Other Sides
36
INSTALLATION (Contd)
CONNECTING PIPING
1. Locate connection for piping at rear of unit for compressors module to receiver tank module.
2. Remove plastic caps that protect piping against contamination.
3. Connect flex joint to frame securely making sure
flex line is not pinched or kinked.
NOTE: All piping is provided and sealed for this
portion of installation.
4. Connect outlet source from filter package located on
dryer module to outlet source piping.
size.
9. Make sure the inlet filter is properly installed.
OPERATION
Powerex Instrument Air Package Systems operate at a
maximum pressure of 250 PSIG. Compressor RPMs
are established by Powerex based on horsepower and
operating pressure.
OPERATION (Contd)
systems and the facility piping. The compressor will
start and stop each pump as needed to maintain the
pressure between the high and low set points.
14. After a few hours and again after a few days, check
the display screen to see if the ALARM screen has
appeared. If a HIGH TEMPERATURE or MOTOR
OVERLOAD condition occurs, the alarm screen will
appear and the affected pump-motor will be taken out
of service.
STOPPING THE COMPRESSOR DURING
NORMAL OPERATION
1. Close the discharge or isolation valve.
2. Allow the air pressure to build and the compressor to
stop.
STOPPING THE COMPRESSOR DURING
EMERGENCY OPERATION
Stop the compressor by turning the power off at the
main disconnect panel.
CONTROL PANEL - DISPLAY AND INPUT
OPERATION (Contd)
OPERATING PANEL & SETTINGS
The Instrument Air Compressor System is controlled
by a PLC programmed at the Powerex factory. The
operating status is displayed on the HMITouch
Screen panel on the front of the compressor unit. The
touch screen allows the user to view system functions
and set points set at the factory. The touch screen also
allows the user to navigate through the screens to get
more information about the operation of the individual
compressor modules and to take action based on alarms
and warnings. The Instrument Air Compressor System
utilizes a PLC for alternation and will change the pump
sequence (Lead, Lag1, Lag2, etc.) after every start or
after 10 minutes, whichever happens first. The HMI
displays individual pump set points. These are not
field adjustable.
ALARM SIGNALS
OTHER ALARMS
Reserve Pump in Use: Should the last pump in the
system be brought on, this alarm will be activated.
This alarm must be acknowledged by pushing the
ACKN button and be reset.
Reserve Transformer in Use: Should the main control
circuit transformer fail, the backup transformer will
immediately provide control voltage to the system.
This will result in a visual alarm indication. This alarm
must be acknowledged by pushing the ACKN button,
but will automatically reset when the main transformer
is returned to operation.
Specifications
Instrument Air Package Duplex-IPD
MODEL
HP
PHASE
SCFM
@ 250
PSI
RPM
VOLTAGE
SHIPPING
WT. (LBS)
IPD0504
5(2)
13.6
640
208/230/460
33/31/16
120
66X63X79
1794
IPD0754 7.5(2)
18.2
870
208/230/460
45/42/22
120
66X63X79
1888
IPD1004 10(2)
27.5
640
208/230/460
60/56/29
120
66X63X79
2470
HP
PHASE
SCFM
@ 250
PSI
RPM
VOLTAGE
IPT0504
5(3)
27.2
640
208/230/460
49/45/24
120
66X95X79
2539
IPT0754 7.5(3)
36.4
870
208/230/460
67/62/32
120
66X95X79
2828
IPT1005
55.0
640
208/230/460
89/82/42
200
66X95X79
3772
10(3)
SHIPPING
WT. (LBS)
HP
PHASE
SCFM
@ 250
PSI
RPM
VOLTAGE
SYSTEM
FLA
IPQ0504
5(4)
40.8
640
208/230/460
64/59/31
120
66X126X79
3205
IPQ0755 7.5(4)
54.6
870
208/230/460
89/82/42
200
66X126X84
3608
IPQ1006 10(4)
82.5
640
208/230/460
118/109/56
240
66X126X95
4774
TANK DIMENSIONS
(GAL.)
LXWXH ()
SHIPPING
WT. (LBS)
Tank
Inlet air filter
Compressor Fins
V-belt
Safety belt
Action Needed
Drain moisture
Operating Hours
500
2500
Daily
2500
5000
10000
15000
20000
Replace
Clean
Inspect, Replace
Remarks
Confirm
Operation
Pressure gauge
Inspect
Air leaks
Inspect
Dryer filters
Replace
(View delta
pressure
indication)
Inspect
Heat exchanger
Dryers
Alternate
Monthly
Inspect
Replace
NOTES:
1. Inspect and perform maintenance periodically according to the 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 perform maintenance accordingly.
3. The tension of the V-belt should be adjusted during the initial stage and inspected every 1,500 hours afterwards. Check
10
Ref.
No.
1
Description
Compressor Pump:
5HP
7-1/2 HP
10 HP
Corrosion Resistant
Vertical Tank
120 Gal.
200 Gal.
240 Gal.
Control Panel
Pressure Gauge
Part Number
Qty.
PL15A
PL15A
PL30A
1
1
1
1
1
1
PDPM1001AJL
AC0300100
Spring Mounts
Isolation Mounts
10
Desiccant Dryer
11
Temperature Switch
(one per pump)
AM003018AV
1 (per
pump)
11
Notes
12
Notes
13
Notes
14
15