Part III: Maintenance Condensate in the Receiver Tank PureFlow Air Compressors Equipped with a Manual Tank Drain Condensate in the receiver tank of Johnson Controls PureFlow air compressors is harmful in three ways: it reduces the effective tank volume which, in turn, increases the number of motor starts, resulting in unnecessary motor pump wear it decreases the time that the pressurized volume of air spends in the receiver tank, thus reducing the inherent oil moisture removal effect of the tank itself it has a corrosive effect on the receiver tank, which could eventually lead to a potentially hazardous situation if rust is allowed to build up The receiver tank on PureFlow air compressors equipped with a manual tank drain must have accumulations of condensate purged daily. To do so, proceed as follows: 1. With the receiver tank pressurized, slowly turn the hle of the manual tank drain counterclockwise to its open ON position. 2. Allow the receiver tank to drain completely, while properly disposing of the purged condensate. If a drain line is used, be sure to secure the line in place. Note: Since the receiver tank condensate may contain entrained oil, be certain to dispose of this waste properly, in accordance with local, state, federal regulations. In the open ON position, if condensate air can be freely released, proceed directly to Step 3. If no condensate or air can be purged, there may be a blockage in the drain pipe /or receiver tank drain opening. To clear the blockage, proceed as follows: a. Turn the hle of the manual tank drain clockwise to its closed OFF position. b. Disconnect the electrical power to the air compressor following Occupational Safety Health Administration (OSHA) stard lockout procedures. Then, as an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. Installation Service Manual for PureFlow Air Compressors 35
c. While wearing proper eye protection, pull on the ring of the safety relief valve to release all of the pressure from the receiver tank. d. Using a pipe wrench (or adjustable joint pliers), remove the manual tank drain drain pipe assembly from the receiver tank. e. Using a sharp probe, clear the blockage from the drain pipe /or receiver tank drain opening. f. Apply thread sealant to the threaded end of the drain pipe reinstall the manual tank drain drain pipe assembly on the receiver tank. Using a pipe wrench (or adjustable joint pliers), tighten the assembly 1/4 of a turn past h tight to secure it in place. g. Restore the electrical power to the air compressor observe the unit through two complete cycles to ensure proper operation. It is recommended that a leak detector solution be used to check the threaded fittings on the manual tank drain for air leakage. h. Once the receiver tank has become fully pressurized, turn the hle of the manual tank drain counterclockwise to its open ON position. If no air can be purged, the manual tank drain is defective must be replaced (purchase locally). 3. After all of the condensate in the receiver tank has been purged, turn the hle of the manual tank drain clockwise to its closed OFF position. PureFlow Air Compressors Equipped with an Automatic Tank Drain The function of the automatic tank drain must be checked weekly for proper operation. To do so, proceed as follows: 1. With the receiver tank pressurized, depress the manual pushbutton of the automatic tank drain. 2. Continue depressing the manual pushbutton to allow the receiver tank to drain completely, while properly disposing of the purged condensate. Note: Since the receiver tank condensate may contain entrained oil, be certain to dispose of this waste properly, in accordance with local, state, federal regulations. If the volume of condensate purged from the receiver tank is greater than 5% of the overall tank size, the automatic tank drain is defective must be replaced; order replacement automatic tank drain A-100-6021. 36 Installation Service Manual for PureFlow Air Compressors
With the manual pushbutton depressed, if condensate air can be freely released, the volume of condensate purged does not exceed 5% of the overall tank size, continue with Step 3. If no condensate or air can be purged, there may be blockage in the drain pipe /or receiver tank drain opening. To clear the blockage, proceed as follows: a. Release the manual pushbutton. b. Disconnect the electrical power to the air compressor following Occupational Safety Health Administration (OSHA) stard lockout procedures. Then, as an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. c. While wearing proper eye protection, pull on the ring of the safety relief valve to release all of the pressure from the receiver tank. d. Using a pipe wrench (or adjustable joint pliers), remove the automatic tank drain drain pipe assembly from the receiver tank. e. Using a sharp probe, clear the blockage from the drain pipe /or receiver tank drain opening. f. Apply thread sealant to the threaded end of the drain pipe reinstall the automatic tank drain drain pipe assembly on the receiver tank. Using a pipe wrench (or adjustable joint pliers), tighten the assembly 1/4 of a turn past h tight to secure it in place. Note: For proper operation, the automatic tank drain must be secured in an upright position such that the drain bowl drain bowl fitting are directed upward. g. Restore the electrical power to the air compressor observe the unit through two complete cycles to ensure proper operation. It is recommended that a leak detector solution be used to check the threaded fittings on the automatic tank drain for air leakage. h. Once the receiver tank has become fully pressurized, depress the manual pushbutton of the automatic tank drain. If no air can be purged, the drain is defective must be replaced; order replacement automatic tank drain A-100-6021. 3. After all of the condensate in the receiver tank has been purged, release the manual pushbutton. Installation Service Manual for PureFlow Air Compressors 37
Oil Level Oil Filling The oil level of each compressor pump on PureFlow air compressors should be checked weekly for proper oil fill. With the air compressor off (or during one of the off cycles), the oil level must be somewhere within the top bottom of the red ring on the oil level sight glass. Referring to Figure 3.1, the top of the red ring indicates the maximum oil level the bottom of the red ring indicates the minimum oil level. Figure 3.1: Oil Level Sight Glass When adding oil during routine maintenance, use oil of proper viscosity as outlined in the Oil Lubrication section of Part II. Johnson Controls F-1000-383 Compressor Oil (ordered separately) is a premium-grade, 30W, non-detergent oil suitable for PureFlow air compressors operating within an ambient temperature range of 32 to 115 F (0 to 46 C).! WARNING: When replenishing the level of oil in a compressor pump, never use synthetic oil. There is no advantage in lubrication, life, or carryover. Furthermore, any synthetic oil carried into the pneumatic climate control system may result in damage to certain plastic components. 38 Installation Service Manual for PureFlow Air Compressors
Table 3.1: Nominal Crankcase Capacities of PureFlow Air Compressors (Per Pump) Motor Horsepower Full Capacity (ounces) Volume Required to Fill From Minimum to Maximum Level (ounces) 1/2 12 5 3/4 (Air Compressors Shipped Prior to 16 7 8/1/90) 3/4 (Air Compressors Shipped After 8/1/90) 12 5 1 16 7 1-1/2 16 7 2 36 17 3 36 17 5 51 22 7-1/2 51 22 10 58 30 Table 3.1 lists approximate full crankcase capacities, as well as the volume of oil required to fill the crankcase from the minimum to maximum level on the oil level sight glass. To replenish the level of oil in a compressor pump, proceed as follows: 1. In order to maximize the volume of air available in the receiver tank to power the pneumatic climate control system while the oil level in the compressor pump is being replenished, wait for the air compressor to automatically cycle off. Then disconnect the electrical power to the unit following Occupational Safety Health Administration (OSHA) stard lockout procedures. As an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. On duplex air compressors with an alternator, one pump can be serviced while the other pump remains in operation. On duplex air compressors with a basic alternator package, first disconnect the power to the unit, then disconnect or separate the spade connector of the starter for the pump that is to be serviced. Close the electrical box restore the power to the unit. On duplex air compressors with the deluxe alternator package, simply turn the selector switch to disable the pump that needs to be serviced. Observe the duplex air compressor through two complete cycles of operation to ensure that the pump that needs to be serviced does not run while the stby pump continues to operate. Installation Service Manual for PureFlow Air Compressors 39
40 Installation Service Manual for PureFlow Air Compressors Figure 3.2: Breather Cap Oil Drain Location 2. Referring to Figure 3.2, locate the breather opening on the compressor pump that has the low oil level. 3. Loosen remove the black plastic breather cap by h. Note: Do not use a wrench or pliers to loosen the breather cap. 4. Using a funnel, pour oil through the breather opening into the crankcase. If a funnel is not readily available, pierce two small holes through opposite edges of the foil seal on the oil bottle. Doing so will create a vent, allowing more control over the flow of oil when pouring. Continue adding oil until the level reaches the top of the red ring on the oil level sight glass. Note: Never overfill the crankcase. Doing so will increase the probability of oil being carried over into the pneumatic climate control system. This is especially true for air compressors featuring a splash lubrication system, which is the case with PureFlow simplex duplex air compressors. With an overfilled crankcase, oil pumping can increase dramatically to a level two or more times than if the oil were at the full mark on the oil level sight glass. Overfilling the crankcase can also cause liquid oil to push out of the crankcase vent. This oil, vaporizing on the hot compressor block, will raise the oil content of the air drawn into the air compressor intake, be pumped into the air lines. In addition, oil puddling on the air compressor body could be misinterpreted as an oil leak.
5. Reinstall the black plastic breather cap. Note: Do not use a wrench or pliers to tighten the breather cap in place. 6. Restore the electrical power to the air compressor observe the unit through two complete cycles to ensure proper operation. To quickly easily determine if the PureFlow air compressor may be consuming an excessive amount of oil, proceed as follows: 1. Dedicate a bottle of Johnson Controls F-1000-383 Compressor Oil (ordered separately) to each compressor pump, using a permanent marker, label each dedicated bottle accordingly. 2. Every time that oil is added to the pump crankcase, mark the scale on the side of the oil bottle, indicating the volume of oil used along with the date that the oil level was replenished. 3. Using the data compiled on the oil bottle as a reference, determine the total volume of oil consumed over a specific period of air compressor operation. 4. Using the total volume of oil calculated in Step 3 either the graph illustrated in Figure 3.3 (for PureFlow AS Series Simplex Air Compressors) or the graph illustrated in Figure 3.4 (for PureFlow AD Series Duplex Air Compressors), determine if the air compressor may be consuming an excessive amount of oil. Some oil entrainment is inherent to all lubricated air compressors; however, an oil carryover level exceeding 4 parts per million (ppm) is cause for concern. The bold lines on the graphs in Figures 3.3 3.4 illustrate the typical volume of oil that would be consumed by a PureFlow air compressor producing an oil carryover level of 4 ppm. Identify the point of graph where the VOLUME OF OIL CONSUMED WEEKS OF AIR COMPRESSOR OPERATION values meet. If this point is above the bold line for the horsepower model of PureFlow air compressor being monitored, the air compressor may be consuming an excessive amount of oil. It is recommended that the results found here be confirmed using a more accurate oil indication test, as outlined in the Oil Carryover Test section of Part III. Installation Service Manual for PureFlow Air Compressors 41
Figure 3.3: PureFlow AS Series Simplex Air Compressors Average Volume of Oil Consumed 42 Installation Service Manual for PureFlow Air Compressors
Figure 3.4: PureFlow AD Series Duplex Air Compressors Average Volume of Oil Consumed Installation Service Manual for PureFlow Air Compressors 43
Intake Filter Dirty intake filter elements cause excessive oil carryover into the pneumatic climate control system. The intake filter assembly is located next to the head on each cylinder of PureFlow simplex duplex air compressors. For optimal air compressor performance, all intake filter elements should be inspected monthly for discoloration/dirt replaced at least annually; refer to Table 5.1 for a complete list of replacement intake filter elements available. Note: It is important to maintain the intake filter according to the above schedule or a pressure drop across the filter element could result. This pressure drop will increase oil pumping by increasing the vacuum in the cylinders on the intake stroke by decreasing the air compressor output, resulting in a higher percent of compressor pump on-time. If the air compressor is installed at a new construction site, it is recommended that the intake filter element be monitored more frequently due to high dust levels at the site. Always replace intake filter elements after construction is completed. Dirty filter elements should not be cleaned in the field; unit replacement is required. Referring to Figures 3.5 3.6, there are two styles of intake filters used in conjunction with PureFlow air compressors. One style of intake filter features a housing assembly with wing nuts (allowing access to the filter element), the other style features a housing assembly with clamps. To replace the intake filter element in either style of intake filter, refer to the procedures outlined in the Intake Filter Element Replacement section of Part VI. 44 Installation Service Manual for PureFlow Air Compressors
Figure 3.5: Wing Nut Style Intake Filter Element Housing Assembly Figure 3.6: Housing Clamp Style Intake Filter Element Housing Assembly Installation Service Manual for PureFlow Air Compressors 45
Air Compressor Oil Change The crankcase oil in PureFlow air compressors should be changed after 2000 running hours or twice a year (whichever occurs first), or whenever the oil becomes dirty due to atmospheric conditions. In addition, it is strongly recommended that the oil in the crankcase be changed whenever any component of the compressor pump is serviced (repaired or changed out), since the crankcase oil could become contaminated by dirt or other debris during the repair or changeout procedure. Note: Changing the oil more frequently than the above maintenance schedule may increase the probability of oil vapor carryover into the pneumatic climate control system. Tests have proven that fresh oil is more likely to cause oil vapor carryover than aged oil (oil used for more than 100 hours of air compressor on-time). When changing the oil during routine maintenance, use oil of proper viscosity as outlined in the Oil Lubrication section of Part II. Johnson Controls F-1000-383 Compressor Oil (ordered separately) is a premium grade, 30W, non-detergent oil suitable for PureFlow air compressors operating within an ambient temperature range of 32 to 115 F (0 to 46 C).! WARNING: When replacing the oil in a compressor pump, never use synthetic oil. There is no advantage in lubrication, life, or carryover. Furthermore, any synthetic oil carried into the pneumatic climate control system may result in damage to certain plastic components. To change the oil in a PureFlow air compressor, refer to the Air Compressor Oil Change section of Part VI. Table 3.1 lists approximate full crankcase oil capacities for all PureFlow horsepower models. Oil Carryover Test As described in detail in Part I of this manual, a properly configured air supply system must include, among other components, an A-4000-120 Oil Indicator Needle Valve Assembly (as illustrated in Figure 3.7), installed at the PureFlow air compressor receiver tank outlet. Every six months, an oil carryover test should be performed at this location to ensure proper air compressor operation. Performing this test at regular intervals, recording the results, will provide early detection of excessive oil carryover (if present), in an effort to avoid the adverse effects that oil carryover can have on control system performance. 46 Installation Service Manual for PureFlow Air Compressors
Figure 3.7: A-4000-120 Oil Indicator Needle Valve Assembly 1.6 1.4 6 ppm 5 ppm 4 ppm 3 ppm UNITS OF COLOR TRAVEL (AS READ ON A-4000-120 INDICATOR) 1.2 1.0 0.8 0.6 0.4 2 ppm 1 ppm 0.2 0.0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 EXPOSURE TIME (HOURS) Figure 3.8: Oil Carryover Rate at Average 80 PSIG (560 kpa) Line Pressure (70 to 90 PSIG Range) Installation Service Manual for PureFlow Air Compressors 47
Sensitivity of the A-4000-120 Oil Indicator Needle Valve Assembly is limited only by the total number of hours the instrument is allowed to remain in the flow path of the receiver tank output. Once the needle valve of the oil indicator has been opened, one continuous uninterrupted exposure is required to ensure greatest accuracy. With the needle valve open, less than 160 SCIM (43.7 ml/s) of 80 PSIG (560 kpa) air will flow through the calibrated indicator cartridge. Any aerosol-mist oil present in the air will then carry an oil-soluble dye up the indicator cartridge, coloring a white material in the cartridge red. The rate of color travel is directly proportional to the amount of oil present in the air. The parts per million (ppm) value of oil entrained in the air is determined using the graph illustrated in Figure 3.8 (also included with the oil indicator). Some oil entrainment is inherent to all lubricated air compressors. For testing purposes, an oil carryover level exceeding 4 ppm is cause for concern. To determine the actual level of oil carryover at the air compressor receiver tank outlet, proceed as follows: 1. Allow between one four hours of exposure time to conduct the oil carryover test. 2. Before taking an oil carryover reading, fill out the record tag furnished with the A-4000-120 Oil Indicator Needle Valve Assembly. 3. Manually rotate the needle valve hle of the oil indicator counterclockwise to its fully open position. One continuous uninterrupted exposure is required to ensure greatest accuracy. 4. Record the time that the needle valve was opened on the record tag, slide the tag over the oil indicator to avoid misplacing it. 5. After one hour of continuous air exposure through the indicator cartridge, take a reading from the calibrated scale record this value on the record tag. Note: If the humidity level of the ambient air surrounding the A-4000-120 Oil Indicator Needle Valve Assembly is relatively high, water vapor may wash traces of dye up the calibrated scale of the indicator cartridge, creating a light pink area above the darker red area. When taking a reading, measure only to the top of the dark red column. 6. Judging from the rate of color travel established at the time of the first reading, schedule a final reading incrementally for approximately 1 unit (marked 1.0) on the calibrated scale of the indicator cartridge, preferably not more than 1-1/2 units (marked 1.5 on the calibrated scale). 7. At the appropriate time (as determined in Step 6), manually rotate the needle valve hle of the oil indicator clockwise to its fully closed position. 48 Installation Service Manual for PureFlow Air Compressors
8. Record the total units of color travel (as read on the calibrated scale of the indicator cartridge) the total time elapsed in hours on the record tag. 9. Referring to the graph in Figure 3.8, determine the parts per million of oil concentration in the air at the receiver tank outlet. 10. After the oil carryover test is complete, leave the needle valve of the A-4000-120 Oil Indicator Needle Valve Assembly in line, remove discard the used indicator cartridge. At the time of the next oil carryover test (a six month interval between tests is recommended), an A-4000-121 Replacement Indicator Cartridge (ordered separately) will need to be installed on the existing needle valve, following the instructions included with the kit. Refer to the air compressor troubleshooting checklist in Part IV of this manual for the probable cause of, suggested remedy for, the excessive oil condition. Safety Relief Valve All PureFlow air compressors are equipped with a safety relief valve installed near the tank pressure gage on the front of the air compressor receiver tank; refer to Figure 3.9 for location purposes. The safety relief valve should be manually operated every six months to ensure that it is operating properly. Figure 3.9: Location of Safety Relief Valve Installation Service Manual for PureFlow Air Compressors 49
With the receiver tank pressurized while wearing proper eye protection, pull on the ring of the safety relief valve to check for sticking or freezing. If air pressure can be released from the receiver tank, the safety relief valve is functioning properly the valve will reset automatically at the appropriate pressure. If no air pressure can be released from the receiver tank, the safety relief valve is defective must be replaced; field repairs cannot be made. Refer to Table 5.1 for a complete list of replacement safety relief valves available. Belt Tension Wear Motor Pulley Pump Flywheel Alignment Drive belts on PureFlow air compressors should be checked every six months for proper belt tension using a belt tension gage, adjusted if necessary using a belt tensioning tool. Both the belt tension gage the belt tensioning tool are readily available from many industrial supply houses. At the same time that the belt tension is checked, each drive belt should also be inspected for signs of wear. Indicators of drive belt wear include cracks or nicks, fraying, glazing, or separation. If it is determined that belt changeout is necessary, a full line of replacement drive belts are available; refer to Table 5.1 for ordering details. Many models of PureFlow air compressors include more than one drive belt per air compressor. At regular six month intervals, the tension condition of all drive belts should be checked at the same time. If two drive belts are installed on a single motor pulley pump flywheel combination, only one of these belts shows signs of wear, both should be replaced at the same time using matched-length, Johnson Controls replacement drive belts. To check the belt tension or replace a worn drive belt on a PureFlow air compressor, refer to the Drive Belt Replacement section of Part VI. All PureFlow air compressors should be inspected every six months for proper alignment of the motor pulley with the pump flywheel. Excessive vibration /or drive belt wear (as a result of pulley flywheel misalignment) could affect the overall performance of the air compressor, may eventually lead to its failure. To safeguard against such a situation occurring, check for proper alignment as follows: 1. Disconnect the electrical power to the air compressor following Occupational Safety Health Administration (OSHA) stard lockout procedures. Then, as an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. On duplex air compressors with an alternator, one pump can be serviced while the other pump remains in operation. 50 Installation Service Manual for PureFlow Air Compressors
On duplex air compressors with a basic alternator package, first disconnect the power to the unit, then disconnect or separate the spade connector of the starter for the pump that is to be serviced. Close the electrical box restore the power to the unit. On duplex air compressors with the deluxe alternator package, simply turn the selector switch to disable the pump that needs to be serviced. Observe the air compressor through two complete cycles of operation to ensure that the pump that needs to be serviced does not run while the stby pump continues to operate. 2. In order to provide adequate clearance for belt guard removal, it may be necessary to first remove the intake filter element housing assembly. To do so, follow the procedures outlined in the Intake Filter Element Replacement section of Part VI. 3. Remove the belt guard following the procedures outlined in the Belt Guard Replacement section of Part VI. 4. After the belt guard has been removed exposing the pulley flywheel areas, make sure that the motor, motor pulley, pump, pump flywheel are all securely fastened. 5. Using a straightedge as illustrated in Figure 3.10, check for proper alignment between the pulley flywheel as follows: Referring to Figure 3.11, measure the distance from the straightedge the outermost edge of the drive belt groove the outermost edge of the motor pulley groove at points A, B, C. The distance measured should be approximately the same at all three points. If the three measurements are aligned within 1/16 in. of each other, the pulley flywheel are sufficiently aligned do not need to be readjusted. If any of the three measurements vary more than 1/16 in., there is a misalignment that will need to be corrected before putting the air compressor back into operation. 6. If any adjustments are made to the motor, motor pulley, pump, /or pump flywheel to correct for pulley flywheel misalignment, it will be necessary to check for proper drive belt tension. To do so, follow the procedures outlined in the Drive Belt Replacement section of Part VI. 7. Reinstall the belt guard following the procedures outlined in the Belt Guard Replacement section of Part VI. 8. Restore the electrical power to the air compressor observe the unit through two complete cycles to ensure proper operation. Installation Service Manual for PureFlow Air Compressors 51
Figure 3.10: Aligning the Pump Flywheel Motor Pulley COMPRESSOR PUMP MOTOR MOTOR PULLEY A B C FLYWHEEL STRAIGHTEDGE Figure 3.11: Alignment Check 52 Installation Service Manual for PureFlow Air Compressors
Pressure Electric (PE) Switch Settings Stby Function PureFlow air compressors that come equipped with a factory mounted starter or alternator have PE switches mounted directly to the starter enclosure or alternator cabinet respectively. PureFlow air compressors that do not feature a factory mounted starter or alternator have PE switches mounted directly to the receiver tank or to the motor. AS Series Simplex Air Compressors come equipped with a lead PE switch while AD Series Duplex Air Compressors featuring a factory mounted alternator come equipped with both a lead a lag PE switch. The function of these PE switches should be checked every six months to ensure proper operation. Figure 3.12: Close-Up of PE Switch Motor Starter Areas Lead PE Switch To check the function of the lead PE switch make any necessary adjustments, refer to Figure 3.12 proceed as follows: 1. Observe the air compressor through two complete cycles of operation to check the cut-in cut-out settings of the lead PE switch. 2. The lead switch is factory set to cut-in at approximately 70 PSIG (490 kpa) cut-out at approximately 90 PSIG (630 kpa). Installation Service Manual for PureFlow Air Compressors 53
If it is observed in Step 1 that the air compressor cuts-in out at the designated factory settings, the lead PE switch is functioning properly; proceed directly to the lag PE switch function-check (if a lag switch is present). If it is observed that the air compressor cuts-in out at values other than the designated factory settings, adjust the lead PE switch as follows: a. Disconnect the electrical power to the air compressor following Occupational Safety Health Administration (OSHA) stard lockout procedures. Then, as an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. b. Using an adjustable wrench, loosen the PE switch cover holding nut remove the cover. Figure 3.13: PE Switch with Cover Removed c. Referring to Figure 3.13, locate the large cut-in/cut-out setting adjustment nut on top of the PE switch. d. Using an adjustable wrench (or a 3/8 in. nut driver), turn the large nut clockwise to increase or counterclockwise to decrease the cut-in/cut-out setting, in order to restore the original factory settings. One complete revolution in either direction represents approximately a 3 PSI (21 kpa) change in the cut-in/cut-out setting. The lead PE switch automatically maintains a 20 PSI (140 kpa) differential between cut-in cut-out settings.! WARNING: The lead PE switch is factory set for normal operating conditions. Adjusting the cut-in cut-out settings of the lead PE switch to a higher value than the original factory settings may cause the starter overloads to trip resulting in air compressor pump /or motor damage, may void the warranty. 54 Installation Service Manual for PureFlow Air Compressors
e. Reinstall the PE switch cover using an adjustable wrench, tighten the cover holding nut. f. Restore the electrical power to the air compressor observe the unit through two complete cycles to ensure proper operation. If necessary, repeat Steps 2a through 2f to fine tune the cut-in cut-out settings of the lead PE switch, in order to more closely match the original factory settings. Lag PE Switch The lag PE switch on PureFlow AD Series Duplex Air Compressors is used as the stby switch in the event of failure of one of the compressors pumps. To check the stby function of the lag PE switch, refer to Figure 3.12 proceed as follows: 1. Disconnect the electrical power to the air compressor following Occupational Safety Health Administration (OSHA) stard lockout procedures. Then, as an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. 2. Locate the spring-loaded tripper near the thermal overload(s) of either one of the two motor starters. 3. To disable one of the compressor pumps so that it cannot run, lift up on the spring-loaded tripper to open the overload contacts. Note: Do not use cardboard or any other nonconductive object to separate the contacts of the lead PE switch. Doing so will disable both compressor pumps unless the lead lag PE switches are field wired as illustrated in Figures 2.9 through 2.15. 4. Close the starter cover (on PureFlow air compressors equipped with a basic alternator package) or alternator cabinet door (on PureFlow air compressors equipped with a deluxe alternator package). 5. Restore the electrical power to the air compressor observe the unit through two complete cycles of operation to check the cut-in cut-out settings of the lag PE switch. 6. The lag switch is factory set to cut-in at approximately 60 PSIG (420 kpa) cut-out at approximately 80 PSIG (560 kpa). Installation Service Manual for PureFlow Air Compressors 55
If it is observed in Step 5 that the air compressor cuts-in out at the designated factory settings, the lag PE switch is functioning properly; proceed directly to Step 7. If it is observed that the air compressor cuts-in out at values other than the designated factory settings, adjust the lag PE switch as follows: a. Disconnect the electrical power to the air compressor following Occupational Safety Health Administration (OSHA) stard lockout procedures. Then, as an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. b. Using an adjustable wrench (or a 3/8 in. nut driver), loosen the PE switch cover holding nut remove the cover. c. Referring to Figure 3.13, locate the large cut-in/cut-out setting adjustment nut on top of the PE switch. d. Using an adjustable wrench, turn the large nut clockwise to increase or counterclockwise to decrease the cut-in/cut-out setting, in order to restore the original factory settings. One complete revolution in either direction represents approximately a 3 PSI (21 kpa) change in the cut-in/cut-out setting. The lag PE switch automatically maintains a 20 PSI (140 kpa) differential between cut-in cut-out settings.! WARNING: The lag PE switch is factory set for normal operating conditions. Adjusting the cut-in cut-out settings of the lag PE switch to a higher value than the original factory settings may cause the starter overloads to trip, resulting in air compressor pump /or motor damage, may void the warranty. e. Reinstall the PE switch cover using an adjustable wrench, tighten the cover holding nut. f. Restore the electrical power to the air compressor observe the unit through two complete cycles to ensure proper operation. If necessary, repeat Steps 6a through 6f to fine tune the cut-in cut-out settings of the lag PE switch, in order to more closely match the original factory settings. 7. Push the reset button to restore the air compressor to normal operation. 8. Observe the air compressor through two complete cycles to ensure proper operation. 56 Installation Service Manual for PureFlow Air Compressors
Percent On-Time Percent on-time is defined as the time the compressor pump is ON divided by the sum of the time the pump is ON plus the time the pump is OFF, multiplied by 100. Percent On-Tim e = Time Pump ON Time Pump ON + Time Pump OFF x 100 PureFlow air compressors are designed for best performance operating at a maximum on-time of 33% for simplex models 50% for duplex models (25% per compressor pump). On-time values exceeding the above limits could result in objectionable levels of oil being carried over into the pneumatic climate control system, eventually lead to adverse effects on control system performance. Common causes of excessive on-time include: air leaks in the pneumatic climate control system an improperly sized air compressor for the application (extra controls may have been added requiring more capacity than the system was originally designed to deliver) inefficient air compressor operation The PureFlow air compressor should be checked every six months to be certain that it is maintaining the desired system pressure without running excessively. To do so, perform a pump-up time test according to the procedures outlined in the Pump-Up Time Test section of Part IV. For comparison purposes, Table 3.2 lists acceptable pump-up times (one compressor pump running) for all PureFlow models. The times listed are the nominal (plus or minus 10%) pump-up times required to pressurize the receiver tank from 0 to 90 PSIG (0 to 630 kpa). Installation Service Manual for PureFlow Air Compressors 57
Table 3.2: PureFlow AS Series Simplex AD Series Duplex Air Compressors Nominal Pump-Up Times* (One Pump Running) Base Model Series AS/AD-005, AS/AD-105 AS/AD-007, AS/AD-107 AS/AD-010, AS/AD-110 Air Compressor Horsepower 1/2 3/4 AS/AD-015 1-1/2 1 Receiver Tank Size (Gallons) 30 60 80 120 200 12 Minutes 23 Seconds 9 Minutes 10 Seconds 6 Minutes 2 Seconds 4 Minutes 21 Seconds AS/AD-020 2 -- -- 18 Minutes 20 Seconds 12 Minutes 5 Seconds 8 Minutes 41 Seconds AS/AD-030 3 -- -- AS/AD-050 5 -- -- AS/AD-075 7-1/2 -- -- 33 Minutes 0 Seconds 24 Minutes 27 Seconds 16 Minutes 6 Seconds 11 Minutes 35 Seconds 5 Minutes 7 Minutes 30 Seconds 20 Seconds 5 Minutes 0 Seconds 2 Minutes 44 Seconds 1 Minute 55 Seconds -- -- -- -- -- -- -- -- -- -- 7 Minutes 30 Seconds 4 Minutes 6 Seconds 2 Minutes 52 Seconds -- 6 Minutes 49 Seconds 4 Minutes 46 Seconds AS/AD-100 10 -- -- -- 2 Minutes 3 Minutes 20 Seconds 53 Seconds * Pump-up time is the time required (±10%) to pressurize the receiver tank from 0 to 90 PSIG (0 to 630 kpa). If the time required for the air compressor to fully pressurize exceeds the nominal pump-up time listed in Table 3.2 for the specific model, the PureFlow unit should be inspected for air leaks, restricted intake filters, worn or broken rings, scored cylinders, blown gaskets, or faulty valves. Genuine Johnson Controls maintenance supplies repair materials are available; refer to Table 5.1 for ordering details. If the pump-up time is satisfactory excessive on-time is still observed, the pneumatic climate control system should be checked for air leaks /or greater-than-designed-for system dem. 58 Installation Service Manual for PureFlow Air Compressors
DryFlow Refrigerated Air Dryer Motor Lubrication PureFlow air compressors that come equipped with a factory mounted DryFlow refrigerated air dryer require the dryer to be inspected every six months to ensure proper operation. Those areas on the air dryer that need periodic inspection routine maintenance include the following: the automatic condensate drain trap (for proper drain valve operation) the particle filter assembly (for filter element maintenance) the service bypass valve (for proper bypass valve plunger positioning, directing the flow of air through the condenser oil removal filters) the coalescing oil removal filter (for excessive pressure drop as shown by the the red color of the integral indicator) the activated carbon oil vapor removal filter (for filter element maintenance) the evaporator pressure gage (for proper evaporator pressure) the condenser (for dust buildup between the fins, which could eventually lead to a reduction in heat transfer) Refer to the Air Dryer Installation Maintenance Manual for more detailed maintenance information, as well as a comprehensive list of DryFlow air dryer maintenance supplies repair materials available. Two styles of motors are used on PureFlow AS Series Simplex AD Series Duplex Air Compressors: motors with grease fittings motors without grease fittings. Those motors without grease fittings are factory sealed lubricated for the life of the motor; no field maintenance is necessary. Motors with grease fittings should be lubricated once every two to three years. To lubricate a motor equipped with grease fittings, proceed as follows: 1. In order to maximize the volume of air available in the receiver tank to power the pneumatic climate control system while the motor bearings are being greased, wait for the air compressor to automatically cycle off. Then disconnect the electrical power to the unit following Occupational Safety Health Administration (OSHA) stard lockout procedures. As an extra precaution, use a suitable electrical tester to verify that all power has been properly disconnected. On duplex air compressors with an alternator, one motor can be serviced while the other motor remains in operation. Installation Service Manual for PureFlow Air Compressors 59
On duplex air compressors with a basic alternator package, first disconnect the power to the unit, then disconnect or separate the spade connector of the starter for the motor that is to be serviced. Close the electrical box restore the power to the unit. Observe the duplex air compressor through two complete cycles of operation to ensure that the motor to be serviced does not run while the stby motor continues to operate. 2. Locate both grease fittings on the compressor motor. Some motors are equipped with grease outlet plugs. If outlet plugs are present, they will need to be removed before proceeding further. 3. Using a stard, h-operated grease gun filled with a medium consistency, polyurea base, ball bearing grease (Shell Dolium R or Chevron SR 1 are recommended; purchase locally), slowly add grease (approximately two teaspoons) at both fittings. Note: Do not overgrease the motor. Overgreasing the motor may cause the bearing seal to rupture, resulting in damage to the bearing /or motor. 4. Reinstall the outlet plugs if they were removed previously in Step 2. 5. Restore the electrical power to the air compressor observe the unit through two complete cycles to ensure proper operation. 60 Installation Service Manual for PureFlow Air Compressors
Maintenance Checklist Table 3.3: Maintenance Checklist for PureFlow Air Compressors Maintenance Task Frequency Drain Condensate from Receiver Tank Check Function of Automatic Tank Drain (If Present) Check Oil Level for Proper Fill Inspect Intake Filter Element Replace Intake Filter Element Change Air Compressor Oil Perform Oil Carryover Test Check Function of Safety Relief Valve Check Belt Tension Inspect for Belt Wear Check Motor Pulley Pump Flywheel Alignment Check Settings of Pressure Electric (PE) Switches Check Stby Function of Lag PE Switch (If Present) Check Percent On-time Check Operation of DryFlow Refrigerated Air Dryer (If Present) Lubricate Motor Daily Weekly Weekly Monthly At Least Annually (More Often if Necessary) After 2,000 Running Hours or Every 6 Months (Whichever Occurs First), or Whenever the Compressor Pump is Repaired or Changed Out Every 6 Months Every 6 Months Every 6 Months Every 6 Months Every 6 Months Every 6 Months Every 6 Months Every 6 Months Every 6 Months Every 2 to 3 Years (For Motors with Grease Fittings) Installation Service Manual for PureFlow Air Compressors 61
Table 3.4: Service Record for PureFlow Air Compressors 62 Installation Service Manual for PureFlow Air Compressors
Installation Service Manual for PureFlow Air Compressors 63