Powerex OTD Series User manual

Oilless Tankmount Duplex
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 property damage! Retain instructions for future reference.
Powerex • 150 Production Drive • Harrison, OH 45030 • USA
1-888-769-7979 • www.powerexinc.com
IN256905AV 1/14
Description
The OTD Series Powerex Duplex Air Compressors have
been designed and tested to meet the most demanding
specifications for reliability in the pneumatic oil-free industry.
All Powerex air compressors have reliable operation and
feature high quality construction and components. An
unloading feature is included on all compressors to provide
loadless starting. Powerex oilless pumps use composite piston
technology, low compressor speeds and PTFE compression
ring(s) at low maintenance costs.
All 2 through 15 HP models are also equipped with an
auxiliary cooling fan and air control shroud to achieve low
head temperatures, further minimizing ring wear.
Powerex compressor motors are NEMA Class B or better
design. Single-phase motors have built-in overload protection
and a DPST disconnect switch. Three-phase motors require
a manual or magnetic starter and three overload heater
coils which may be ordered as a factory mounted-and-wired
option.
Features
• Oilless reciprocating compressor pump
• High efficiency ODP motors
• Three year warranty on compressor pump
• Optional Isolation pads
• Optional R134 dryer
• ASME tank
• UL listed controls (with optional panel)
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these
specifications, consult the local Powerex office. Powerex shall not be liable for damages resulting from misapplication or misuse of its products.
Specifications
Product OTD Series Powerex Duplex Air Compressors
Performance
Specifications See Page 2
Lubrication Grease Filled Bearings
Operating
Voltages
1Ø 1 HP - 1-1/2 HP 115 - 280 / 230 Volts, 60 Hz
2 HP - 5 HP 280 / 230 Volts, 60 Hz
3Ø 280 - 230 / 460 Volts, 60 Hz
Compression
Cycle
Single-Stage (1 HP - 3 HP Models)
Two-Stage (5 HP - 15 HP Models)
Motor
Overload
Protection
1Ø Built-in Thermal Overload (Standard)
3Ø IEC Magnetic Starter with Adjustable
Overload (Optional)
Pressure
Settings
Lead Cut-In: Factory Set at Approx. 90 psig (621 kPa)
Cut-Out: Factory Set at Approx. 120 psig (827 kPa)
Lag Cut-In: Factory Set at Approx. 80 psig (552 kPa)
Cut-Out: Factory Set at Approx. 110 psig (758 kPa)
Overpressure
Protection
ASME Safety Valve Factory Set and Sealed
Outlet Air
Connections
1/2 inch NPT (30, 60, and 80 Gallon Tanks)
1 inch NPT (120, 200 and 240 Gallon Tanks)
Tank Sizes See Page 2
California
Ordinance
462 (L) (2)
Meets Requirements of this Ordinance
Tank Isolation Standard All Units
Drive V Belt
Control Panel Optional Panel UL508A Listed

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Oilless Tankmount Duplex
Installation
MOUNTED AND CONNECTED OPTIONS
Magnetic Motor Starter
An optional magnetic motor starter which has been selected
and wired for the intended input voltage is available for all
units. All starters are furnished with properly sized overload
relay.
Refrigerated Air Dryer
A factory mounted refrigerated air dryer with automatic
condensate drain trap assembly and bypass valve is available
as an option on all 1/2 through 3 HP Powerex Duplex Air
Compressors. The air dryer is piped to the compressor at the
factory; power wiring to the dryer is done in the field using
the integral cord and plug which fits into a standard 120 volt
receptacle.
Automatic Tank Drain
Powerex air compressors are ordered with either a manual
or electric type automatic tank drain. This unit is furnished
with a manual drain as standard. An electric drain must be
mounted to the compressor in the field.
Vibration Dampening Pads
Waffle type design vibration pads are provided as optional
equipment.
Safety Guidelines
This manual contains information that is very important
to know and understand. This information is provided for
SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help
recognize this information, observe the following symbols.
Danger indicates an imminently
hazardous situation which, if
not avoided, WILL result in death or serious injury.
Warning indicates a potentially
hazardous situation which, if
not avoided, COULD result in death or serious injury.
Caution indicates a potentially
minor or moderate injury.
Notice indicates important
information, that if not
followed, may cause damage to equipment.
NOTE: Information that requires special attention.
CALIFORNIA PROPOSITION 65
This product or its power cord
may contain chemicals known
to the State of California to cause cancer and birth defects or
other reproductive harm. Wash hands after handling.
Performance Specifications
Model HP Phase SCFM @ 100 psig RPM Voltage
Gallon
Tank
OTD110 1 (2) 1 7.2 625 115 /208 /230 30
80
OTD010 1 (2) 3 7.2 625 208 /230 /460 30
80
OTD115 1-1/2 (2) 1 10.6 885 115 /208 /230 80
OTD015 1-1/2 (2) 3 10.6 885 208 /230 /460 80
OTD120 2 (2) 1 13.2 845 115 /208 /230 80
OTD020 2 (2) 3 13.2 845 208 /230 /460 80
OTD130 3 (2) 1 20.2 1115 208 /230 80
120
OTD030 3 (2) 3 20.2 1115 208 /230 /460 80
120
OTD151 5 (2) 1 35.8 800 208 /230 120
200
OTD050 5 (2) 3 35.8 800 208 /230 /460 120
200
OTD075 7.5 (2) 3 52.2 855 208 /230 /460 240
OTD100 10 (2) 3 70 1090 208 /230 /460 240
OTD150 15 (2) 3 108.4 1140 208 /230 /460 240
NOTE: See Electrical Diagram shipped with the unit for Motor Full Load Amp Ratings

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Oilless Tankmount Duplex
Discharge
Alternator Panel
(Optional)
Plug
Electric
Auto Drain
(Optional)
Aftercooler
(Optional)
Figure 1 - 1.5 HP through 5 HP
Figure 2 - 1.5 HP through 3 HP with Refrigerated Air Dryer Option
Plug
Electric
Auto Drain
(Optional)
Aftercooler
Alternator Panel
(Optional)
Discharge
Refrigerated
Air Dryer
Regulator
with Gauge
.01 Micron
Coelescing
Afterfilter

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Oilless Tankmount Duplex
Discharge
Figure 3 - 7.5 HP through 5 HP
Alternator Panel
(Optional)
Aftercooler
(Optional)
Plug
Electric
Auto Drain
(Optional)

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Oilless Tankmount Duplex
Maintenance Schedule
Item
Action
needed
Operating Hours
RemarksDaily 500 1500 2500 5000 10,000 15,000 20,000
Tank Drain moisture ●Drain tank daily
Inlet air filter Inspect,
Replace ●▲ Every 2500 hours or less
Blower fan Clean ●●●●
Fan duct Clean ●●●●
Compressor
fins Clean ●Every 2500 hours or less
Compression
rings
Inspect,
Replace ●▲●▲
Every 2500 hours
or less
Wrist pin
bearing Regrease ▲▲▲▲
Replace high
pressure wrist pin
Piston set Inspect ●●
V-belt Inspect,
Replace ●▲▲▲▲
See Note 3
Pressure
switch
Confirm
operation ●●
Magnetic
starter Inspect ●●
Replace if contact
points deteriorated
Safety valve Confirm
operation ●Every 2500 hours or 6 months
Pressure
gauge Inspect ●Every 2500 hours 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 initial start up and inspected every 1,500 hours afterwards.
Proper belt tension for 1 to 3 HP units is 2-3 lbs. / 0.5 inch deflection; for 5 to 15 HP units, 4-6 lbs. / 0.5 inch deflection.

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Oilless Tankmount Duplex
Figure 4 - Single Phase
Wiring Diagram

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Oilless Tankmount Duplex
Figure 5 - Three Phase
Wiring Diagram

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Oilless Tankmount Duplex
Quantity Code
Item Description Required Number
A PUMP AND FLYWHEEL:
Motor HP 1, 1-1/2 2 OPS010
2, 3 2 OPS030
5 2 OPT050
7-1/2, 10 2 OPT100
15 2 OPT150
B †BELT:
Motor HP Size
1 (1Ø) AX-43 2 BT009400AV
1(3Ø) AX-41 2 BT023300AV
1-1/2 A-45 2 BT009500AV
2 B-62 2 BT011300AV
3 BX-66 2 BT008500AV
5 (120 gallon tank) B-68 4 BT022100AV
5 (200 gallon tank) B-80 4 BT010400AV
7-1/2 B-84 4 BT011200AV
10 B-87 4 BT009200AV
15 B-92 4 BT010200AV
C MOTOR PULLEY:
Motor HP Type
1 (1Ø) 1A-4.0 inch P.D., 5/8 inch Bore 2 PU009723AV
1 (3Ø) 1A-2.0 inch P.D., 5/8 inch Bore 2 PU202617AV
1-1/2 1A-5.5 inch P.D., 7/8 inch Bore 2 PU009725AV
2 (1Ø) 1A-6.4 inch P.D., 1-1/8 inch Bore 2 PU009787AV
2 (3Ø) 1A-6.4 inch P.D., 7/8 inch Bore 2 PU009778AV
3 1B-8.4 inch P.D., 1-1/8 inch Bore 2 PU009777AV
5 2B-7.4 inch P.D., 1-1/8 inch Bore 2 PU202634AV
7-1/2 2B-8.6 inch P.D., 1-3/8 inch Bore 2 PU009775AV
10 2B-11.0 inch P.D., 1-5/8 inch Bore 2 PU009772AV
15 2B-12.4 inch P.D., 1-5/8 inch Bore 2 PU009756AV
D ** INTAKE FILTER ELEMENT
Motor HP
1, 1-1/2 2 ST073923AV
2, 3 2 ST073905AV
5 2 ST073905AV
7-1/2, 10 2 ST073907AV
15 2 ST073907AV
E IN-TANK CHECK VALVE:
Motor HP Size
1 Through 3 1/2 inch MPT x 1/2 inch FPT 2 CV003204AV
5 Through 15 3/4 inch MPT x 3/4 inch FPT 2 CV003205AV
Replacement Parts List
A
B (Inside belt guard)
E
C (Inside belt guard)
F
G
H
J
K
D

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Oilless Tankmount Duplex
Quantity Code
Item Description Required Number
F SAFETY RELIEF VALVE: Set at approximately 140 psig (965 kPa)
1 Through 5 HP Models 1 V-215100AV
7.5 Through 15 HP Models 1 V-215400AV
G PRESSURE ELECTRIC SWITCHES: (For all models)
Lead Switch: Set at approximately
90 psig (630 kPa) cut-in and
120 psig (827 kPa) cut-out 1 CW207558AV
Lag Switch: Set at approximately
80 psig (560 kPa) cut-in and
110 psig (758kPa) cut-out 1 CW207559AV
H TANK:
Motor HP Tank Size
1 Through 1-1/2 30 gallon 1 AR022600ST
2 & 3 80 gallon 1 AR022900ST
3 120 gallon 1 AR023600ST
5 120 gallon 1 AR022800ST
5 200 gallon 1 JQ000200AJ
7-1/2 Through 15 240 gallon 1 JQ000100AJ
J BELT GUARD:
Motor HP
1 Through 1-1/2 (Whole Assembly: ZZ000605AJ) 2 BG012400AV
2, 3, 5 2 BG012802AV
7-1/2, 10 (Whole Assembly: ZZ000605AJ) 2 BG218500AV
15 (Whole Assembly: ZZ000620AJ) 2 BG218500AV
K MOTOR:
Motor HP
1 (1 Ø) 2 MC022371AV
1 (3 Ø) 2 MC301561AV
1-1/2 (1 Ø) 2 MC022320AV
1-1/2 (3 Ø) 2 MC303317AV
2 (1 Ø) 2 MC022317AV
2 (3 Ø) 2 MC303300AV
3 (1 Ø) 2 MC022309AV
3 (3 Ø) 2 MC303301AV
5 2 MC303303AV
7-1/2 2 MC303308AV
10 2 MC303310AV
15 2 MC303312AV
L Optional Refrigerated Dryer and Parts (not shown)
1HP-1.5HP
10 CFM Dryer 1 ACO016010
Regulator 1 ST178408AJ
.01 µ Filter 1 ST178184AV
.01 µ Filter Element 1 ST178185AV
Electric Auto Tank Drain 1 SL300701AV
Beltguard Mounted Aftercooler * 2 SL300100AV
2HP
15 CFM Dryer 1 ACO016015
Regulator 1 ST178408AJ
.01 µ Filter 1 ST178184AV
.01 µ Filter Element 1 ST178185AV
Electric Auto Tank Drain 1 SL300701AV
Beltguard Mounted Aftercooler * 2 SL300100AV
3HP
25 CFM Dryer 1 ACO016025
Regulator 1 ST178409AJ
.01 µ Filter 1 ST178108AV
.01 µ Filter Element 1 ST178109AV
Electric Auto Tank Drain 1 SL300701AV
Beltguard Mounted Aftercooler * 2 SL300100AV
* = Part number includes only the Aftercooler. For complete Aftercooler Assembly, including mounting hardware and flex hoses, order part
number ACO700015.
** = Replace every 2,500 hours
† = Replace every 5,000 hours
Replacement Parts List (Continued)

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Oilless Tankmount Duplex
Maintenance Log
Date Maintenance Required Maintenance Performed

11
Oilless Tankmount Duplex
Powerex Limited Warranty – Applicable to Non-OEM Customers in the U.S. & Canada Only
Warranty and Remedies.
(a) General. Powerex warrants each Compressor System, Vacuum System, Vacuum Pump, Compressor Air-End, or Powerex branded Accessory
(collectively “Products”, individually each a “Product”) to be free from defects in material and workmanship (“Defects”) at the date of
shipment. This warranty shall apply only to Products that are purchased and used in the United States of America and in Canada. EXCEPT AS
SET FORTH BELOW, NO OTHER WARRANTY, WHETHER EXPRESS OR IMPLIED, INCLUDING ANYWARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, SHALL EXIST IN CONNECTION WITH THE SALE OR USE OF SUCH PRODUCTS. TO THE EXTENT PERMITTED BY LAW,
ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. All warranty claims must be made in writing and delivered to Powerex in accordance
with the procedures set forth on its website (www.powerexinc.com), or such claim shall be barred. Upon timely receipt of a warranty claim,
Powerex shall inspect the Product claimed to have a Defect, and Powerex shall repair, or, at its option, replace, free of charge, any Product
which it determines to have had a Defect; provided, however, that if circumstances are such as to preclude the remedying of Defect by repair
or replacement, Powerex shall, upon return of the Product, refund to buyer any part of the purchase price of such Products paid to Powerex.
Freight for returning Products to Powerex for inspection shall be paid by buyer. The warranties and remedies herein are the sole and exclusive
remedy for any breach of warranty or for any other claim based on any Defect, or non-performance of the Products, whether based upon
contract, warranty or negligence.
(b) (i) Standard Period of Warranty – Parts and Labor - The purchase of any system includes our standard warranty. Powerex warrants
and represents all Products shall be free from Defects for the first eighteen (18) months from the date of shipment by Powerex, or twelve
(12) months from the documented date of startup, or five thousand (5,000) hours of use, whichever occurs first. During such warranty period,
Powerex shall be fully liable for all Defects in the Products (the “Product Defects”), i.e., all costs of repair or replacement, which may include
“in and out” charges, so long as the Products are located in the United States or Canada, and the Products are reasonably located and
accessible by service personnel for removal. “In and out” charges include the costs of removing a Product from buyer’s equipment for repair or
replacement.
(ii) Premium Period of Warranty – Parts and Labor - In order to be eligible for premium warranty coverage, a premium warranty for
each system must be purchased when order is placed. Powerex warrants and represents all Products shall be free from Defects for the first thirty
(30) months from the date of shipment by Powerex, or twenty-four (24) months from the documented date of startup, or seven thousand five
hundred (7,500) hours of use, whichever occurs first. During such warranty period, Powerex shall be fully liable for all Defects in the Products
(the “Product Defects”), i.e., all costs of repair or replacement, which may include “in and out” charges, so long as the Products are located in
the United States or Canada, and the Products are reasonably located and accessible by service personnel for removal. “In and out” charges
include the costs of removing a Product from buyer’s equipment for repair or replacement.
(c) Additional Period of Warranty – Parts Only (No Labor). In addition to the above, Powerex warrants each Powerex branded Compressor
Air- End and Vacuum Pump shall be free of Defects for a period of forty-two (42) months from the date of shipment by Powerex, or thirty-six
(36) months from the documented date of startup, or ten thousand (10,000) hours of use, whichever occurs first. Supplier’s repair or replacement
of any Product shall not extend the period of any warranty of any Product. This warranty applies to the exchange of part(s) found to be
defective by an Authorized Powerex Service Representative only.
(d) Replacement Pumps – Parts Only (No Labor). For any replacement Air-End or Vacuum Pumps installed on a Powerex manufactured
system or unit after any initial warranty period has expired or where another warranty does not apply for any reason, Powerex warrants
that the Air-End or Vacuum Pumps shall be free of Defects for a period of thirty-six (36) months from the date of shipment by Powerex or
ten thousand (10,000)hours of use, whichever comes first. For any replacement Air-End or Vacuum Pumps installed on a system that was not
manufactured by Powerex after any initial warranty period has expired or where another warranty does not apply for any reason, Powerex
warrants that the Air-End or Vacuum Pumps shall be free of Defects for the first twelve (12) months from the date of shipment by Powerex.
Supplier’s repair or replacement of any Product shall not extend the period of any warranty of any Product. This warranty applies to the
exchange of part(s) found to be defective by an Authorized Powerex Service Representative only.
(e) Replacement Motors – Parts Only (No Labor). For any replacement motor installed on a Powerex manufactured system or unit after any
initial warranty period has expired or where another warranty does not apply for any reason, Powerex warrants that the replacement motor
shall be free of Defects for the first twelve (12) months from the date of shipment by Powerex. For any replacement motor installed on a system
or unit that was not manufactured by Powerex after any initial warranty period has expired or where another warranty does not apply for
any reason, Powerex warrants that the replacement motor shall be free of Defects for the first ninety (90) days from the date of shipment by
Powerex. Supplier’s repair or replacement of any Product shall not extend the period of any warranty of any Product. This warranty applies to
the exchange of part(s) found to be defective by an Authorized Powerex Service Representative only.
(f) Replacement Parts – Parts Only (No Labor). For other replacement parts besides motors, Air-End or Vacuum Pumps installed on a Powerex
manufactured system or unit after any initial warranty period has expired or where another warranty does not apply for any reason, Powerex
warrants that such replacement parts will be free from Defects for the first twelve (12) months from the date of shipment by Powerex. For other
replacement parts besides motors, Air-End or Vacuum Pumps installed on a system or unit that was not manufactured by Powerex after any
initial warranty period has expired or where another warranty does not apply for any reason, Powerex makes no warranties. Supplier’s repair or
replacement of any Product shall not extend the period of any warranty of any Product. This warranty applies to the exchange of part(s) found
to be defective by an Authorized Powerex Service Representative only.
(g) Coverage. The warranty provided herein applies to Powerex manufactured units or systems only.
(h) Exceptions. Notwithstanding anything to the contrary herein, Powerex shall have no warranty obligations with respect to Products:
(i) that have not been installed in accordance with Powerex’s written specifications and instructions;
(ii) that have not been maintained in accordance with Powerex’s written instructions;
(iii) that have been materially modified without the prior written approval of Powerex; or
(iv) that experience failures resulting from operation, either intentional or otherwise, in excess of rated capacities or in an otherwise
improper manner.

Powerex • 150 Production Drive • Harrison, OH 45030 • USA
1-888-769-7979 • www.powerexinc.com 12
Oilless Tankmount Duplex
(i) The warranty provided herein shall not apply to:
(i) any defects arising from corrosion, abrasion, use of insoluble lubricants, or negligent attendance to or faulty operation of the
Products;
(ii) ordinary wear and tear of the Products;
(iii) defects arising from abnormal conditions of temperature, dirt or corrosive matter; or
(iv) any OEM component which is shipped by Powerex with the original manufacturer’s warranty, which shall be the sole applicable
warranty for such component.
Limitation of Liability. NOTWITHSTANDING ANYTHING TO THE CONTRARY HEREIN, TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW,
UNDER NO CIRCUMSTANCES SHALL POWEREX BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTAL, PUNITIVE, SPECULATIVE OR INDIRECT LOSSES
OR DAMAGES WHATSOEVER ARISING OUT OF OR IN ANY WAY RELATED TO ANY OF THE PRODUCTS OR GOODS SOLD OR AGREED TO BE SOLD
BY POWEREX TO BUYER. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, 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 its literature, including its Price
Book,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, installation, 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. Any non-warranty claims pertaining to the Products 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. Powerex shall
not be liable for any delay or failure arising out of acts of the public enemy, fire, flood, or any disaster, labor trouble, riot or disorder, delay in
the supply of materials or any other cause, whether similar or dissimilar, beyond the control of Company. All shipments are carefully inspected
and counted before leaving the factory. Please inspect carefully any receipt of Products noting any discrepancy or damage on the carrier’s
freight bill at the time of delivery. Discrepancies or damage which obviously occurred in transit are the carrier’s responsibility and related claims
should be made promptly directly to the carrier. Returned Products will not be accepted without prior written authorization by Powerex and
deductions from invoices for shortage or damage claims will not be allowed. UNLESS OTHERWISE AGREED TO IN WRITING, THE TERMS
AND CONDITIONS CONTAINED IN THIS LIMITED WARRANTY 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 will not control. All orders are subject to acceptance by
Powerex.