Powerex OTD110 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
IN256903AV 1/12
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efciencyODPmotors
• Threeyearwarrantyoncompressorpump
• OptionalIsolationpads
• OptionalR134dryer
• ASMEtank
• ULlistedcontrols(withoptionalpanel)
NORGREN
N
OUTLET
INLET
INOUT
1/2X1/4
2"X 1 1/2"
RESET RESET
0 0 0 0 0 0 0
PUMP
NO.2
ALT.
PUMP
NO.1
000 00
80
PRESSUREGAGE
40
20
60
PSI
100
0
ON
min.
TEST OFF
45
sec.
0.5
2
4
10
5
0.5
20
8
630
40
PSI
160
200
60
0
20
100
180
PRESSUREGAGE
80
140
120
40
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

2
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
Dimensions
L x W x H
Ship Weight
(Lbs.)
OTD110 1 (2) 1 7.2 625 115 /208 /230 30 42x21x35 272
80 64x22x39 432
OTD010 1 (2) 37.2 625 208 /230 /460 30 42x21x35 270
80 64x22x39 435
OTD115 1-1/2 (2) 1 10.6 885 115 /208 /230 80 65x23x41 439
OTD015 1-1/2 (2) 3 10.6 885 208 /230 /460 80 65x23x41 435
OTD120 2 (2) 1 13.2 845 115 /208 /230 80 65x23x41 504
OTD020 2 (2) 3 13.2 845 208 /230 /460 80 65x23x41 500
OTD130 3(2) 1 20.2 1115 208 /230 80 65x23x41 658
120 71x26x44 788
OTD030 3(2) 3 20.2 1115 208 /230 /460 80 65x23x41 650
120 71x26x44 780
OTD151 5 (2) 1 35.8 800 208 /230 120 79x26x49 941
200 82x30x56 1167
OTD050 5 (2) 3 35.8 800 208 /230 /460 120 79x26x49 930
200 82x30x56 1155
OTD075 7.5 (2) 352.2 855 208 /230 /460 240 86x51x69 1430
OTD100 10 (2) 370 1090 208 /230 /460 240 86x51x69 1510
OTD150 15 (2) 3 108.4 1140 208 /230 /460 240 86x51x69 1620
NOTE: SeeElectricalDiagramshippedwiththeunitforMotorFullLoadAmpRatings

3
Oilless Tankmount Duplex
Unit Dimensions (inches*) and Shipping Weights (pounds*)
Base
Model A
B
with
Alternator
B
without
Alternator C D E F G
Unit Weight**
with
Alternator
without
Alternator
OTD-110-1XX 433/8233/817 3/4383/818 15 3/412 1/458 7/8270 250
OTD-010-1XX 433/8233/817 3/4383/818 15 3/412 1/458 7/8270 250
OTD-110-3XX 64 241/220 431/240 18 1/2145/871 1/4435 415
OTD-010-3XX 64 241/220 431/240 18 1/2145/871 1/4435 415
OTD-015-1XX 433/8233/817 3/4383/818 15 3/412 1/458 7/8270 250
OTD-150-1XX 433/8233/817 3/4383/818 15 3/412 1/458 7/8270 250
OTD-015-3XX 64 241/220 431/240 18 1/2145/871 1/4435 415
OTD-150-3XX 64 241/220 431/240 18 1/2145/871 1/4435 415
OTD-020-3XX 651/4263/420 453/440 18 145/880 5/8500 480
OTD-120-3XX 651/4263/420 453/440 18 145/880 5/8500 480
OTD-030-3XX 653/8263/420 453/440 18 145/880 5/8500 480
OTD-130-3XX 653/8263/420 453/440 18 145/880 5/8500 480
OTD-030-4XX 70 3/427 3/424 50 1/442 18 167/882 3/4780 760
OTD-130-4XX 70 3/427 3/424 50 1/442 18 167/882 3/4780 760
OTD-050-4XX 70 3/4291/424 58 1/442 18 167/8-- 930 910
OTD-151-4XX 70 3/4291/424 58 1/442 18 167/8-- 930 910
OTD-050-5XX 791/4323/430 591/442 22 18 3/4-- 1155 1135
OTD-151-5XX 791/4323/430 591/442 22 18 3/4-- 1155 1135
OTD-075-6XX 845/851 5/8461/2647/854 391/219 -- 950 925
OTD-100-6XX 845/851 5/8461/2647/854 391/219 -- 1440 1415
OTD-150-6XX 845/851 5/8461/2647/854 391/219 -- 2828 2800
 * inchesx2.54=centimeters;poundsx0.454=kilograms
 ** Add60.0poundsforunitsequippedwithafactorymountedairdryer
A
A
B
B
G
E E
DD
C
C
FF
3/4HP
through
5 HP
Models
7-1/2 HP
through
15 HP
Models
Plug
Optional
Dryer
Optional Alternator
2 inch NPT Plug
1 inch NPT Discharge
Discharge

4
Oilless Tankmount Duplex
 3. Removeanddiscardltercartridge.
 4. Wipeinside base clean with dry cloth.
 5. Installnewltercartridge.Do not attempt to clean and
reuse filter cartridge.
RING AND PISTON SET REPLACEMENT [10,000 HOURS]
(See Figure 2)
 1. Removeunloaderline(Two-stagepumpsonly).
 2. Removecylinderheadboltsoneachcylinder.
 3. Inspectandreplaceformsealifneeded.
 4. Removevalveplateandcleanwithdrycloth.
 5. Inspectandreplacespacergasketifneeded.
 6. Inspectandreplacecylindersealifneeded.
 7. Inspectandreplacevalvewearpadifneeded.
 8. Removecylinderboltsandcylinder.Notethecylinder
orientation. Wipe cylinder with dry cloth.
 9. Removepistonringorrings.
10. Removewristpinandpiston.Replacewithnewpiston
and wrist pin set.
11. Replaceringorrings.
12. Installcylinder.Becarefuloforientation.Torquecylinder
boltsto300in-lb.
13. Installvalvesetwithnewseals.
14. Installheadandcylinderheadbolts.Torqueheadboltsto
156in-lb.
15. Reconnectunloadertubing.
16. Unitisreadyforfulloperation.Nobreak-inisrequired.
Operation
Factory calibrated snap-acting DPST pressure electric switches
provide automatic cut-in and cut-out. Overpressure protection
isprovidedbyanASMEsafetyreliefvalve.Receivertankshave
a condensate drain valve with an extension for easy access. All
mountingbasesareslottedforV-belttensionadjustmentto
aid in maintaining proper compressor and motor alignment.
Allunitsarerunandtestedforairdelivery,leakageandpower
consumption.
Unitsarearefurnishedwithan5micronintakelter/silencer(s)
with a replaceable cartridge. This filter/ silencer combination is
designed to remove contaminates in the inlet air and provide
quieter operation.
Maintenance
AIR FILTER REPLACEMENT (See Figure 1)
 1. Remove wing nut.
 2. Removecanisterandwipeinsidecleanwithdrycloth.
Figure 1
Wing Nut
Canister
Filter Cartridge
Filter Base
Cylinder Bolt Torque
OPS010
OPS030
OPT050, OPT100
OPT150, OPS200
156in-lb. 300in-lb.
Head Bolt Torque
OPS010, OPS030, OPT050,
OPT100, OPT150, OPS200
156in-lb.
Figure 2
Unloader
Line
Cylinder
Head Bolt
Form Seal
Valve Plate
Spacer
Gasket
Cylinder
Seal Valve
Wear Pad
Cylinder
Bolt
Cylinder
Piston
Ring(s)
Piston
Head
Wrist
Pin Set

5
Oilless Tankmount Duplex
Maintenance Schedule
Item
Action
needed
Operating Hours
RemarksDaily 500 1500 2500 5000 10,000 15,000 20,000
Tank Drain moisture lDraintankdaily
Inletairlter Replace l s Every 2500 hours
or less
Blower fan Clean llll
Fan duct Clean llll
Compressor
fins Clean lEvery 2500 hours or less
Compression
rings Replace l s l s Every 2500 hours or less
Wrist pin
bearing Regrease ssssReplacehigh pressure wrist pin
Piston set Inspect l l
V-belt Inspect,
Replace lssssSeeNote3
Pressure
switch
Confirm
operation l l
Magnetic
starter Inspect l l Replaceifcontact points deteriorated
Safety valve Confirm
operation lEvery 2500 hours or6months
Pressure
gauge Inspect lEvery 2500 hours or less
l Inspect
s 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deection;for5to15HPunits,4-6lbs./0.5inchdeection.

6
Oilless Tankmount Duplex
Figure 3 - Single Phase
Wiring Diagram

7
Oilless Tankmount Duplex
Figure 4 - Three Phase
Wiring Diagram

8
Oilless Tankmount Duplex
Quantity Shipping Code
Item Description Required Weight (lbs.) Number
A PUMP AND FLYWHEEL:
Motor HP 1,1-1/2 2 34.0 OPS010
   2,3 2 65.0 OPS030
   5 2 95.0 OPT050
   7-1/2,10 2 134.0 OPT100
15 2 137.0 OPT150
B VALVE KIT:Includesvalveplateandseals
Motor HP 1,1-1⁄2 2 0.5 91933640
   2,3 4 0.7 91933640
   5(Highpressure) 2 1.0 91934683
   5(Lowpressure) 2 1.2 91933681
   7-1/2,10(Highpressure) 2 1.2 91934683
   7-1/2,10(Lowpressure) 4 1.2 91934691
   15(HighPressure) 2 1.0 91934683
   15(LowPressure) 4 1.2 91933681
C RING/CYLINDER KIT:Includesallcompressionrings,oilcontrolring(s)
Motor HP 1,1-1/2 2 0.1 91237640
   2,3 4 0.1 91237640
   5(Highpressure) 2 0.1 91930680
   5(Lowpressure) 2 0.1 91236681
   7-1⁄2,10(Highpressure) 2 0.1 91930680
   7-1⁄2,10(Lowpressure) 4 0.1 91236671
   15(Highpressure) 2 0.1 91930680
   15(Lowpressure) 4 0.1 91236681
D INTAKE FILTER ELEMENT:
Motor HP 1,1-1/2 2 0.2 ST073923AV
   2,3 2 0.2 ST073905AV
   5 2 0.3 ST073905AV
   7-1/2,10 2 0.3 ST073907AV
   15 2 0.3 ST073907AV
E BELT:
Motor HP Size
1 (1Ø) AX-43 2 0.3 BT009400AV
1(3Ø) AX-41 2 0.3 BT023300AV
1-1/2 A-45 2 0.3 BT009500AV
2 B-62 2 0.4 BT011300AV
3 BX-66 2 0.4 BT008500AV
5(120gallontank) B-68 4 1.6 BT022100AV
5(200gallontank) B-80 4 2.0 BT010400AV
7-1/2 B-84 4 2.0 BT011200AV
10 B-87 4 2.4 BT009200AV
  15 B-92 4 4.0 BT010200AV
Replacement Parts List
D
B
C
N
E (inside belt guard)
K
H
F (inside belt guard)
A
G
G
J
LM
P

9
Oilless Tankmount Duplex
Quantity Shipping Code
Item Description Required Weight Number
F MOTOR PULLEY:
Motor HP Type
  1(1Ø) 1A-4.0inchP.D.,5/8inchBore 2 3.2 PU009723AV
1(3Ø) 1A-2.0inchP.D.,5/8inchBore 2 3.2 PU202617AV
1-1/2 1A-5.5inchP.D.,7/8inchBore 2 5.6 PU009725AV
2(1Ø) 1A-6.4inchP.D.,1-1/8inchBore 2 5.2 PU009787AV
2(3Ø) 1A-6.4inchP.D.,7/8inchBore 2 5.2 PU009778AV
3 1B-8.4inchP.D.,1-1/8inchBore 2 6.3 PU009777AV
5 2B-7.4inchP.D.,1-1/8inchBore 2 7.6 PU202634AV
7-1/2 2B-8.6inchP.D.,1-3/8inchBore 2 12.5 PU009775AV
10 2B-11.0inchP.D.,1-5/8inchBore 2 13.5 PU009772AV
  15 2B-12.4inchP.D.,1-5/8inchBore 2 13.5 PU009756AV
G IN-TANK CHECK VALVE:
Motor HP Size
  1Through3 1/2inchMPTx1/2inchFPT 2 0.3 CV003204AV
  5Through15 3/4inchMPTx3/4inchFPT 2 0.4 CV003205AV
H SAFETY RELIEF VALVE:Setatapproximately140psig(965kPa)
1 Through 5 HP Models 1 0.1 V-215100AV
  7.5Through15HPModels  1 0.1 V-215400AV
J 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 0.9 CW207558AV
Lag Switch: Set at approximately
  80psig(560kPa)cut-inand
  110psig(758kPa)cut-out  1 0.9 CW207559AV
K TANK:
Motor HP Tank Size
  1Through1-1/2 30gallon 1 134.0 AR022600ST
2&3 80gallon 1 243.0 AR022900ST
3 120gallon 1 415.0 AR023600ST
5 120gallon 1 415.0 AR022800ST
5 200gallon 1 677.0 JQ000200AJ
  7-1/2Through15 240gallon 1 810.0 JQ000100AJ
L COOLING SHROUD:
Motor HP
  2,3  2 1.7 91134560
5  2 1.7 91134660
  7-1/2,10,15  2 1.9 91134690
M BELT GUARD:
Motor HP
  1Through1-1/2(WholeAssembly:ZZ000605AJ) 2 2.4 BG012400AV
2,3,5  2 12.5 BG012802AV
7-1/2,10(WholeAssembly:ZZ000605AJ) 2 18.5 BG218500AV
  15(WholeAssembly:ZZ000620AJ) 2 26.5 BG218500AV
N GASKET SET:
Motor HP
  3/4,1,1-1/2  2 0.1 91936640
  2,3  4 0.1 91936640
  5(Highpressure)  2 0.1 91937681
  5(Lowpressure)  2 0.1 91936680
  7-1/2,10(Highpressure)  2 0.1 91937681
  7-1/2,10(Lowpressure)  4 0.1 91936670
  15(Highpressure)  2 0.1 91937681
  15(Lowpressure)  4 0.1 91936680
P MOTOR:
Motor HP
1(1Ø) 2 36 MC022371AV
  1(3Ø) 2 23 MC301561AV
  1-1/2(1Ø) 2 39 MC022320AV
  1-1/2(3Ø) 2 40 MC303317AV
  2(1Ø) 2 65 MC022317AV
  2(3Ø) 2 44 MC303300AV
  3(1Ø) 2 73 MC022309AV
  3(3Ø) 2 59 MC303301AV
  5 2 69 MC303303AV
  7-1/2 2 103 MC303308AV
  10 2 109 MC303310AV
  15 2 187 MC303312AV
Replacement Parts List (Continued)

Notes
10
Oilless Tankmount Duplex