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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