Interface Devices AA-160 Instruction manual

AA-160 Air Amplifier
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
INTERFACE DEVICES, INC. 230 Depot Road, Milford, CT 06460
Ph: [phone], Fx: [phone], E-mail: [email protected]
www.interfacedevices.com
IMPORTANT! FILE THIS MANUAL IN A SAFE PLACE FOR FUTURE SERVICE & PARTS NEEDS
ALWAYS REFERENCE THE SERIAL NUMBER FOR SERVICE & PARTS REQUESTS
Pump Serial Number:
Pump Model Code:
Sold to:
Purchase Order:
Contact
End User:
Order Date:
STATEMENT OF WARRANTY
INTERFACE DEVICES, INC. (hereafter, the factory) warrants it’s products to be free from defects in material
and workmanship under normal use and service for a period of one (1) year from date of shipment from the
factory. Any defect discovered after the warranty period has expired will be deemed to be outside the above
coverage. No goods claimed to be under warranty shall be accepted for return unless authorized by the
factory beforehand.
Upon discovery of a defect (other than freight damage) or a shortage of an item received in the original factory container,
the purchaser shall, within (10) calendar days, deliver notice of the defect or shortage. Damaged freight claims must be
placed with the freight carrier and will not be honored by the factory. If after due investigation of a claim of defect or
shortage is found valid, the factory, at it’s sole discretion, may discharge it’s entire obligations to the purchaser by either
repair or replacement of the defective product or component and for shortages by furnishing a replacement of the missing
quantity (FOB, factory).
This express warrantee supersedes and is in lieu of all other remedies and warranties,
including the implied warranties of merchantability and fitness for a particular purpose, and
liability for negligence. IN NO EVENT SHALL THE FACTORY BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL LOSSES, EXPENSES OR DAMAGES INCLUDING
DAMAGES FOR PERSONAL INJURY OR COMMERCIAL LOSS.

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AA-160 2:1 AIR AMPLIFIER
TABLE OF CONTENTS
1.0 INSTALLATION & OPERATION PAGE
1.1 Mounting...........................................................................3
1.2 Connections......................................................................3
1.3 Start-up.............................................................................3
2.0 MAINTAINENCE
2.1 Routine Maintenance........................................................3
2.2 Recommended Spare Parts..............................................3
2.3 Troubleshooting................................................................4
3.0 DRAWINGS ENCLOSED
3.1 General Arrangement Drawing……………........................5
3.2 Exploded View & Bill of Materials ………...........................6
3.3 Exploded view: 4-way Cycling Valve………………………..7
3.4 Pneumatic Schematic........................................................8

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1.0 INSTALLATION
1.1 MOUNTING:
The amplifier comes standard with a foot mounting bracket (four 1/4 inch fasteners required).
The unit may be mounted vertically (wall mount) or horizontally (floor mount).
1.2 CONNECTIONS:
Connect a regulated and filtered air supply to the 1/2 NPT "AIR IN" port on the pump (1/2 NPT, or
larger size filter/regulator and plumbing. NO Lubricator Is required).
Connect your high pressure circuit to the 1/2 NPT "AIR OUT" port on the pump.
1.3 STARTUP:
Starting with the external air regulator backed-out all the way, slowly increase the pressure by turning
the regulator knob clockwise. The pump will start to cycle while regulated pressure flows directly
through the pump to the circuit.
The pump will stall when circuit pressure reaches 2 times the regulated pressure. The pump will
maintain this pressure even if there is some circuit leakage. At this time check for and fix any
circuit leaks since this only causes unnecessary air consumption and wear and tear on the pump.
2.0 MAINTAINENCE:
2.1 ROUTINE MAINTAINENCE:
The only routine maintenance required is to re-grease the main air spool (item 9), the pilot piston
O-ring (item 10) and the T-seals (items 7) every 6 months. Refer to the enclosed 4-way cycling valve
assembly drawing.
2.2 RECOMMENDED SPARE PARTS*
QTY PART NUMBER DESCRIPTION
1 11461 Air Reciprocation Valve
1 DSK-AA160 Dynamic Seal Kit
1 SSK-AA160 Static Seal Kit
3 10017 2-Way Air Valve Assembly
*Consult your local distributor or IDI for current price and delivery.

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2.3 TROUBLESHOOTING GUIDE:
AA-160, 2:1 AIR AMPLIFIER TROUBLESHOOTING GUIDE
(Refer to enclosed Exploded View Drawings)
SYMPTOM PROBABLE CAUSE(S) REMEDY
Pump will not cycle.
No pressure at output.
No air supply to pump.
Pump air regulator supply set
too low.
Look for and fix.
Increase setting.
Pump will not cycle with
regulated pressure at
output.
Four-way Air reciprocating
valve spool stuck at mid-
position.
After trying remedy above,
spool still sticks:
Disconnect/Reconnect air
supply
(Re-sets air spool to end
position.)
Disassemble air valve
assembly
Inspect for contamination
or mechanical bind. Repair
or replace, lubricate seals
with water-proof grease.
Pump makes one cycle,
then stops.
Faulty item 24 "2-way air
valve"
(Broken, leaks or
contaminated).
Repair or replace.
Pump cycles constantly
when "dead-headed".
External leak at pump or
downstream
high pressure circuit.
Stuck open or contaminated
item 6
"Check Valve" cartridge (4
places).
Internal leak in pump.
Look for and correct.
Clean or replace. Note
valve orientation at
assembly.
Check all dynamic and
static seals
and gaskets. Replace if
necessary.

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For further assistance call INTERFACE DEVICES, INC. at 203/878-4648.

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