P U R E A I R T E C H N O L O G Y

Scroll Air Compressor Service and Maintenance

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.

Description Dry Type Inlet Filter

! DANGER
GENERAL 2500 HOURS - MAINTENANCE

The Powerex Oilless Rotary Scroll Air The inlet filter on the scroll compressor Breathable Air Warning
Compressor has advanced scroll com- assures 99% particulate free air is
This compressor/pump is not equipped
pressor technology through the devel- admitted to the unit. Order P/N
and should not be used “as is” to supply
IP032901AV for both the 3 HP and 5HP
opment of a completely oilless unit. breathing quality air. For any application
units. Change every 2,500 hours or
The Powerex Scroll Compressor offers a more often in dirty locations. of air for human consumption, the air
dynamically balanced air end which compressor/pump will need to be fitted
1. Remove filter cover by releasing
insures vibration-free operation. The spring clamps (See Figure 1). with suitable in-line safety and alarm
rotary design permits a continuous equipment. This additional equipment is
2. Remove wing screw.
100% duty cycle. No oil separation, oil necessary to properly filter and purify
Do not attempt to
filtration, or inlet valves are required ! CAUTION clean filter . This the air to meet minimal specifications for
on the Powerex Scroll air compressor . filter requires replacement and is to be Grade D breathing as described in
replaced when contaminated. Compressed Gas Association Commodity
The Powerex oilless rotary scroll air
3. Clean inlet plate, filter cover and six Specification for air, OSHA, ANSI and/or
compressor is based on the theory of
(6) silencer tubes using an air gun or Canadian Standards Associations (CSA).
scroll compression. A scroll is a free
by wiping dry with a cloth.
standing, intricate spiral bounded on DISCLAIMER OF WARRANTIES
4. Install new inlet filter (Part Number
one side by a solid, flat plane or base. In the event the compressor is used for
IP032901AV) and reassemble cover.
A scroll set, the basic compression ele- the purpose of breathing air application
ment of a scroll compressor, is made up See Service and Maintenance Video
and proper in-line safety and alarm
for Visual and Audio Instructions
of two identical spirals which form equipment is not simultaneously used,
(Part Number IP633900AV).
right and left hand parts. One of these existing warranties shall be voided, and
scroll components is indexed or phased Powerex disclaims any liability whatso-
180o with respect to the other so the ever for any loss, personal injury or dam-
scrolls can mesh. age.
Crescent-shaped gas pockets are
formed and bounded by the spirals and
the base plate of both scrolls. As the
moving scroll is orbited around the
fixed scroll, the pockets formed by the
meshed scrolls follow the spiral toward
the center and diminish in size. The
moving scroll is prevented from rotat-
ing during this process so the 180o Silencer Tubes
phase relationship of the scrolls is
maintained. The compressor’s inlet is at
the outer boundary of the scrolls. The Inlet Plate
compressed gas is discharged through Filter Cover
the outlet at the center of the fixed
scroll so no valves are needed.
Figure 1 Inlet Filter and Cover Assembly

Powerex • 150 Production Drive • Harrison, OH 45030 • USA IN259801AV 1/02

Scroll Air Compressors

Grease Compressor Plastic

Dust Cap
Grease Gun

Bearings Grease
Fitting
10,000 HOURS - MAINTENANCE

This service should

! CAUTION be performed by
an authorized Powerex Service Center
to avoid failure. Extension
Adaptor
MAIN BEARINGS
1. Remove the plastic dust cap. Use
only one of two locations found on Counter
the air end (See Figure 2). Weight
Key
2. Rotate the compressor pulley until Way 45°
the grease fitting is visible through Figure 2
the dust cap hole (See Figure 2).
This will allow regreasing of the 5. Grease all three pin crank bearings 6. Replace grease caps, fan shroud,
main bearings. (See Figures 3, 4 & 5 and Grease pulley, etc.
3. Use a grease gun extension adaptor Delivery Chart below). (See Scroll Service and
to engage the grease fitting and The grease fitting, Maintenance Video for Audio and
supply the proper volume of grease !CAUTION located in the cen- Visual Instructions.)
as indicated on the grease delivery ter of the pin crank bearing, feeds only
the orbit scroll side bearing. Use a
chart (See Grease Delivery chart needle adapter to supply grease to the
below & Figure 2). housing side bearing. PUMP GREASE
GUN BEFORE FEEDING TO ELIMINATE
Use only Powerex
! CAUTION genuine grease.
AIR FROM GREASE PASSAGE OF THE
NEEDLE ADAPTER. Hold grease gun for
Pump grease gun before feeding (this
5 - 10 seconds after feeding to prevent
eliminates air from the grease passage
grease blowback from the grease fit-
of the extension adapter. (Complete
ting.
Grease Kit Part Number IP616200AJ and
Grease Tube Part Number IP600000AV).

Orbit Scroll Housing

GREASING PIN CRANK BEARINGS Bearings Side Bearings

4. Replace plastic dust cap.

3 Grease Caps
The bearings on the scroll compressor Grease Fitting
are regreaseable to allow extended Extension
compressor life. Service should be per- Adaptor
formed every 10,000 hours of operation.
1. Remove the V-Belts and the fan
cover.
2. Remove the air end pulley and cool-
ing fan with a gear puller (See Grease
Figure 3). Gun
3. Remove the fan duct shroud.
4. Remove the three grease caps. Do
not attempt to loosen or tight- Fan Duct Shroud
Air End Pulley & Cooling
en the bolt. Figure 3 (Not Shown)
Fan (Not Shown)

GREASE DELIVERY
SLAE03 SLAE05
Bearing 1st Time 2nd Time 1st Time 2nd Time
Orbit Scroll Bearing 5 Times 3 Times 6 Times 4 Times
Pin Crank Bearing Orbit Scroll Side 5 Times 3 Times 6 Times 4 Times
Pin Crank Bearing Housing Side 5 Times 3 Times 6 Times 4 Times
NOTE: Each pump of the grease gun equals 0.65 grams of grease.

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 Scroll Air Compressors

Orbit Scroll Bearings

Housing
Side Bearings

Grease Fitting

Extension Needle
Adaptor Adaptor

Figure 4 Figure 5

Maintenance Schedule
Operating Hours
Item Action needed 500 2500 5000 10,000 15,000 20,000 Remarks

Tank Drain moisture Daily

Inlet air filter Replace ● ▲ (Every 2,500 hrs or less) Part #IP032901AV
Blower fan Clean ● ● ● ●
Fan Duct Clean ● ● ● ●
Compressor Fins Clean ● (Every 2,500 hrs or less)
Bearings Grease ▲ ▲ Service Center Only
Tip seal Replace ▲ ▲
Dust seal Replace ▲ ▲
V-belt Inspect, replace *Note 3 ● ▲ ▲ ▲ ▲
Pressure Switch Confirm operation ● ●
Magnetic starter Inspect ● ● Replace if contact
points deteriorated
Safety valve Confirm operation ● (Every 2,500 hrs or less)
Pressure gauge Inspect ● (Every 2,500 hrs or less)
● Inspect
▲ Replace
NOTES:
1. Inspect and perform maintenance periodically according to maintenance schedule.
2. The maintenance schedule relates to the normal operating conditions. If the circumstances and load condition are adverse,
shorten the cycle time and do maintenance accordingly.
3. * The tension of the V-belt should be adjusted during the initial stage and inspected every 2,500 hours afterwards. Proper
belt tension for 3 HP units is 7 lbs./.16” deflection; for 5 HP units, 7 lbs./.19” deflection.
4. See Compressor Pump Manuals for replacement or service procedures.

3
Scroll Air Compressors

Tip Seal Set 4

1
2 5
6
3
Replacement
10,000 HOURS - MAINTENANCE

The “Tip Seal Set” is a replacement

part for SLAE03 and SLAE05 air ends.
Please read these instructions thor-
oughly and carefully to ensure correct
replacement. Figure 6
(See Scroll Service and
REPLACEMENT Insert tip seal so that the lip of tip seal
Maintenance Video for Audio and
is on the bottom of seal groove and
Visual Instructions.)
1. Remove six nuts with T-type wrench inner side of involute and the direction
Tip Seal and then FS set from air end (See of lip faces the center of involute (curv-
Set SLAE03 SLAE05 Figure 7). ing spiral). See Figure 9. This is to be
2. Remove LP and HP tip seals from done for both FS and OS sets.
Air End Model 3 Hp 5 Hp
Fixed Scroll set and Orbit set. Using Use caution not to tear or distort lip.
Part No. IP604500AV IP604600AV
the tip of a ball-point pen at the 1. Insert new HP tip seal from the cen-
start will make it much easier (See ter section for OS or Orbit Scroll so
The tip seal on the scroll compressor is
Figure 7). that there will be no clearance at the
self-lubricated and allows the unit to
operate efficiently without oil and 3. Remove dust from Scroll with clean tip (start) section (See Figure 8
expensive filtration. The tip seal should cloth or air. and 9).
be replaced every 10,000 hours of oper-
INSERTING TIP SEALS
ation.
NOTE: Tips seals for Fixed Scroll and
CONFIRMATION OF THE PARTS Orbit Scroll have opposing seal cut
angels (See NOTE and explanatory dia-
1. Confirm if the tip seal you pur- gram below).
chased is correct for the air end you
Figure 8
are repairing (See Parts Listing
below).
Item
No. Description Qty.
1 HP tip seal for FS 1
2 LP tip seal for FS 1
3 HP tip seal for OS 1
4 LP tip seal for OS 1
5 Dust Seal 1
6 Backup Tube 1
HP = High Pressure LP = Low Pressure
FS = Fixed Scroll OS = Orbital Scroll
OS or Orbit
Scroll
2. Confirm if the following parts are FS or Fixed
included (See Figure 6). Scroll Tip Seal Removal
Figure 7

NOTE: In order to distinguish between the tip seal for Fixed Scroll and the tip seal for Orbit Scroll place the tip seal as
shown below then view from the arrow direction and refer to the figure on the right.

Fixed Scroll Orbit Scroll

Lip
(Inside)

Lip
(Bottom Side) Facing Facing
Left Right

4
 Scroll Air Compressors
5. Insert new dust seal on the backup
Tip Seal Set tube. Face seamed section of the
Replacement (Continued) dust seal in the 3 o’clock position
(See Figure 10).
2. Insert so that new LP tip seal will
8. After replacing tip seal set, reassem-
contact closely with HP tip seal
ble Fixed Scroll set to the Orbit
inside Scroll Groove (See Figure 7
Scroll. Tighten 6 nuts temporarily
on page 4).
and confirm if crankshaft rotates
Insert approxi- smoothly by hand and tighten them
! CAUTION mately half of the firmly. Tightening torques are:
LP tip seal and remove the tip seal to
confirm that a notch in the tip seal has Bolt
been achieved. This will prevent move- Torque First Second
ment during installation (See Figure
11).
SLAE03 15 in lb. 175 in lb.
3. Repeat the same procedure for FS SLAE05 15 in lb. 175 in lb.
or Fixed Scroll tip seal set, remove
both the dust seal and backup tube NOTE: Assemble so that dust seal and
located on outermost side FS set. tip seal will not drop between Orbit
4. Insert new backup tube in the FS Scroll set and Fixed Scroll set.
Scroll in the 6 o’ clock position (See
Figure 10).

Lip Direction
Enter
Side

Lip Side
(Grooved Bottom)
Lip Surface
(Inside)

3 o’clock
Position

Figure 9
Dust
Seal

Back-up
Tube

6 o’clock
Machined Position
To Avoid Movement
During Installation
Figure 11 Figure 10

5
Scroll Air Compressors

4
A

18

18

3 8
A

B
15
6

20

B
16

9
17

12 13 1

16

10
11
19
14

Figure 12 - Compressor Parts

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 Scroll Air Compressors

Service Parts List

Ref. Part No. For Models Quantity Per Unit
No. Description SLAE03 SLAE05 SLAE03 SLAE05

1 Stational Scroll Set IP600100AV IP600200AV 1 1

2 Airend Pulley IP600300AV IP600400AV 1 1

3 Key IP600600AV IP600600AV 1 1

4 Centrifugal Fan IP601300AV IP601300AV 1 1

5 Fan Duct (1) IP601400AV IP601400AV 1 1

6 Fan Duct (2) IP601500AV IP601600AV 1 1

7 Fan Cover IP601700AV IP601700AV 1 1

8 Fan Dust Gasket (1) IP601800AV IP601900AV 1 1

9 Heat Insulation Pipe IP602000AV IP602000AV 1 1

10 Filter Plate IP602100AV IP602100AV 1 1

11 Cartridge Filter IP032901AV IP032901AV 1 1

12 Intake Pipe IP602200AV IP602200AV 1 1

13 Intake Filter Cover IP016101AV IP016101AV 1 1

14 Filter Cover Pipe IP602300AV IP602300AV 6 6

15 Fan Duct Gasket (2) IP602400AV IP602400AV 1 1

16 O-Ring IP603200AV IP603200AV 2 2

17 Long Nipple IP603300AV IP603300AV 1 1

18 Dust Cap IP603500AV IP603500AV 2 2

19 Wing Bolt IP604200AV IP604200AV 1 1

20 Tip Seal Set IP604500AV IP604600AV 1 1

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Scroll Air Compressors

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.

Coverage. 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.
Failure to complete maintenance as stated in the maintenance schedule will void this warranty.
THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MER-
CHANTABILITY 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 WAR-
RANTIES ARE EXCLUDED. THIS IS THE EXCLUSIVE REMEDY AND LIABILITY FOR CONSEQUENTIAL
DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED TO THE EXTENT EXCLUSION IS PER-
MITTED BY LAW.

Limitation of Liability. To the extent allowable under applicable law, Powerex’s liability for consequential
and incidental damages is expressly disclaimed. Powerex’s liability in all events is limited to, and shall not
exceed, the purchase price paid.

Warranty Disclaimer. Powerex has made a diligent effort to illustrate and describe the products in this lit-
erature accurately; however, such illustrations and descriptions are for the sole purpose of identification,
and do not express or imply a warranty that the products are merchantable, or fit for a particular purpose,
or that the products will necessarily conform to the illustrations or descriptions.

Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installa-
tion, and/or use of products for certain purposes, which may vary from those in neighboring areas. While
Powerex attempts to assure that its products comply with such codes, it cannot guarantee compliance, and
cannot be responsible for how the product is installed or used. Before purchase and use of a product,
please review the product applications,and national and local codes and regulations, and be sure that the
product, installation, and use will comply with them.

Claims. 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 agree-
ments are contingent upon strikes, accidents, or other causes beyond our control. All shipments are care-
fully 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 dam-
age 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 autho-
rization 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.

Powerex • 150 Production Drive • Harrison, OH 45030 • USA