Installation and Service Manual for PureFlow Air Compressors

Pneumatic Air Supply Manual Air Compressors Section Technical Bulletin Issue Date

718

AS/AD Series 0994

Installation and Service Manual for PureFlowTM Air Compressors

Part I: Introduction

3

? General Information

3

? Properly Configured Air Supply System

5

? Safety Information

6

? General Warranty Information

8

? Air Compressor Identification

8

Part II: Installation

9

? Pre-Installation Checkout

9

? Installation Site Location

9

? Oil Lubrication

12

? Securing the Air Compressor in Place

13

? Intake Filter

16

? Receiver Tank Drain Installation

16

? Wiring and Current Draw

18

? Air Compressor Power Requirements

30

? Piping the Air Compressor

31

? Starting the Air Compressor for Operation

33

Part III: Maintenance

35

? Condensate in the Receiver Tank

35

? Oil Level and Oil Filling

38

? Intake Filter

44

? Air Compressor Oil Change

46

? Oil Carryover Test

46

? Safety Relief Valve

49

? Belt Tension and Wear

50

? Motor Pulley and Pump Flywheel Alignment

50

? Pressure Electric (PE) Switch Settings and Standby Function

53

? Percent On-Time

57

? DryFlow? Refrigerated Air Dryer

59

? Motor Lubrication

59

? Maintenance Checklist

61

? Service Record

62

? 1994 Johnson Controls, Inc.

1

IN 188100AV

Part IV: Troubleshooting

63

? Excessive Oil Carryover

63

? Pump-Up Time Test

63

? System Consumption Test

65

? Air Compressor Troubleshooting Checklist

68

? Alternator Troubleshooting Checklist

72

Part V: Repair Part Offerings

75

Part VI: Repair Procedures

95

? Intake Filter Element Replacement

95

? Air Compressor Oil Change

101

? Belt Guard Replacement

105

? Drive Belt Replacement

107

? Automatic Tank Drain Replacement

111

? Safety Relief Valve Replacement

113

? Check Valve Replacement

115

? Tank Pressure Gage Replacement

117

? Shuttle Valve Replacement

119

? Cooling Fan Shroud Replacement

121

? Cylinder and Ring Replacement

123

? Valve Plate Replacement

129

? Pump and Flywheel Replacement

133

? Motor Pulley Replacement

136

? Motor Replacement

139

? Pressure Electric (PE) Switch Replacement

143

? Thermal Overload (Heater) Replacement

146

? Starter Assembly Replacement

150

? Contactor and Coil Replacement

155

? Alternator Relay Replacement

160

? Control Transformer Replacement

166

Part VII: PureFlow Warranty Policy and

Repair/Service Procedure

169

? Warranty Policy

169

? Warranty Repair/Service Procedure

169

? Date Code Identification

170

2 Installation and Service Manual for PureFlow Air Compressors

Part I: Introduction

General Information

Figure 1.1: PureFlowTM AS Series Simplex Air Compressor

Figure 1.2: PureFlow AD Series Duplex Air Compressor Johnson Controls PureFlow air compressors have been carefully engineered and manufactured to provide many years of reliable, trouble-free operation. However, correct installation, regular maintenance, and proper repair procedures are key to extending air compressor life, while at the same time maintaining the highest level of performance possible.

Installation and Service Manual for PureFlow Air Compressors 3

Figure 1.3: Genuine Johnson Controls Maintenance Supplies and Repair Materials The purpose of this manual is threefold: ? to familiarize you with the simple, straightforward engineering of your PureFlow air compressor ? to acquaint you with the vast selection of genuine Johnson Controls maintenance supplies and repair equipment available from your local branch office ? to furnish you with a comprehensive, step-by-step guide that allows you to quickly and easily install, maintain, and repair your PureFlow air compressor Models covered in this manual include 1/2 through 10 horsepower PureFlow AS Series Simplex and AD Series Duplex Air Compressors. As a result of Johnson Controls commitment to continuous quality improvement, slight variations in PureFlow air compressor design will be noted from one manufacturing year to another. The procedures which follow acknowledge these variations, and have been modified to accommodate the significant improvements that have occurred since PureFlow was introduced in 1989. Except where noted, the instructions which follow apply to both simplex and duplex air compressors, with or without a factory mounted alternator/motor starter package. Since the majority of the instructions in this manual are provided for one pump and motor, routine checks and maintenance procedures must be performed twice on duplex air compressors (once on each pump and motor).

4 Installation and Service Manual for PureFlow Air Compressors

Properly Configured Air Supply System

Designed as a supplement to the repair procedures included in this manual, Training Video No. 317 entitled Service Procedures for PureFlowTM Air Compressors is available from your local Johnson Controls branch office; refer to Table 5.1 for ordering details and additional information. This 45 minute color video is a visual, step-by-step guide to performing a number of maintenance and repair procedures on your PureFlow air compressor.

PUREFLOW TM AS SERIES SIMPLEX OR

AD SERIES DUPLEX AIR COMPRESSOR

INTAKE FILTER

MANUAL OR AUTOMATIC TANK DRAIN

A-4000-120 OIL INDICATOR

SERVICE BYPASS VALVE (INTEGRAL TO A-4300 SERIES

AIR DRYER)

DRYFLOW R A-4300 SERIES REFRIGERATED

AIR DRYER

AUTO-DRAIN AND PARTICLE FILTER

(INTEGRAL TO A-4300 SERIES

AIR DRYER)

COALESCING OIL REMOVAL FILTER 10 SCFM: A-4000-148 20 SCFM: A-4000-149

ACTIVATED CARBON OIL VAPOR

REMOVAL FILTER 10 SCFM: A-4000-147 20 SCFM: A-4000-146

A-4000-120 OIL INDICATOR

A-4000-138 PRESSURE REDUCING STATION

WITH INTEGRAL GAGE AND SAFETY RELIEF VALVE

OPTIONAL A-4000-138 FOR DUAL PRESSURE SYSTEMS

TO SYSTEM TO SYSTEM

Figure 1.4: Properly Configured Air Supply System

Pressure regulated, clean, dry, oil-free supply air, from a properly configured air supply system, is the key to efficient and continuous operation of the individual components comprising a pneumatic climate control system. This high quality source of supply air is only possible when the air supply system from which it originates is properly configured to include all of the following equipment: ? a properly sized PureFlow AS Series Simplex or AD Series Duplex Air Compressor

with integral intake filter and manual or automatic tank drain, configured for a maximum on-time of not more than 33% for simplex models and 50% for duplex models (25% per compressor pump) ? an A-4000-120 Oil Indicator and Needle Valve Assembly, installed at the PureFlow air compressor receiver tank outlet

Installation and Service Manual for PureFlow Air Compressors 5

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