Powerex SLAE03E Installation and user guide

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Powerex • 150 Production Drive • Harrison, OH 45030 • USA
Scroll Air Compressor Service and Maintenance
IN557302AV 10/07
Description
The Powerex Oilless Rotary Scroll Air Compressor has ad-
vanced scroll compressor technology through the develop-
ment of a completely oilless unit.
The Powerex Scroll Compressor offers a dynamically balanced
air end which insures vibration-free operation. The rotary
design permits a continuous 100% duty cycle. No oil separa-
tion, oil filtration, or inlet valves are required on the Powerex
Scroll air compressor.
The Powerex oilless rotary scroll air compressor is based on
the theory of scroll compression. A scroll is a free standing,
intricate spiral bounded on one side by a solid, flat plane or
base. A scroll set, the basic compression element of a scroll
compressor, is made up of two identical spirals which form
right and left hand parts. One of these scroll components
is indexed or phased 180° with respect to the other so the
scrolls can mesh.
Crescent-shaped gas pockets are formed and bounded by the
spirals and the base plate of both scrolls. As the moving scroll
is orbited around the fixed scroll, the pockets formed by the
meshed scrolls follow the spiral toward the center and diminish
in size. The moving scroll is prevented from rotating during this
process so the 180° phase relationship of the scrolls is main-
tained. The compressor’s inlet is at the outer boundary of the
scrolls. The compressed gas is discharged through the outlet at
the center of the fixed scroll so no valves are needed.
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 rec-
ognize 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.
NOTE: This provides information that requires special attention.
Breathable Air Warning
This compressor/pump is not equipped and should not be
used “as is” to supply breathing quality air. For any applica-
tion of air for human consumption, the air compressor/pump
will need to be fitted with suitable in-line safety and alarm
equipment. This additional equipment is necessary to prop-
erly filter and purify the air to meet minimal specifications for
Grade D breathing as described in Compressed Gas Associa-
tion Commodity Specification for air, OSHA, ANSI and/or
Canadian Standards Associations (CSA).
DISCLAIMER OF WARRANTIES
In the event the compressor is used for the purpose of breath-
ing air application and proper in-line safety and alarm equip-
ment is not simultaneously used, existing warranties shall be
voided, and Powerex disclaims any liability whatsoever for
any loss, personal injury or damage.
Specifications
Product SLAE03E, SLAE05E, SLAE05HP
Disharge Pressure 95-115 (125-145 optional)
Compression Cycle Scroll
Motor Overload Protection IEC Magnetic Starter
Maximum Operating
Ambient Temperature 104° F

2
Scroll Air Compressor Service and Maintenance
Item Action needed Operating Hours Remarks
500 2500 5000 10,000 15,000 20,000
Tank Drain moisture Daily
Inlet Air Filter Replace ●▲ (Every 2,500 hrs or less)
Blower Fan Clean ●●● ●
Fan Duct Clean ●●● ●
Compressor Fins Clean ●(Every 2,500 hrs or less)
Bearings Regrease ●▲
Service Center Only
(Every 5,000 hours for
145 psig scroll)
Tip Seal Set Replace ▲▲
(Every 5,000 hours for
145 psig scroll)
V-bet Inspect, replace ●▲▲▲ ▲
*Note 3
Pressure Switch Confirm operation ●●
Magnetic Starter Inspect ●●
Replace if contact points
deteriorate
Safety Valve Confirm Operation ●(Every 2,500 hrs or less)
Pressure Gauge Inspect ●(Every 2,500 hrs 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 the initial stage and inspected every 2,500 hours afterwards.
Proper belt tension for 3 HP units is 7 lbs./.16” deflection; for 5 HP units, 7 lbs./.19” deflection.
4. See Compressor Pump Manuals for replacement or service procedures.
MAINTENANCE SCHEDULE
GREASE DELIVERY
SLAE03E SLAE05E SLAE05EHP
Bearing 1st Time 2nd Time 1st Time 2nd Time 1st Time 2nd Time
Orbit Scroll Bearing 5 Times 4 Times 7 Times 6 Times 7 Times 6 Times
Pin Crank Bearing Orbit Scroll Side 4 Times 4 Times 5 Times 5 Times 7 Times 7 Times
Pin Crank Bearing Housing Side Do Not Have to Grease Do Not Have to Grease Do Not Have to Grease
NOTE: Each pump of the grease gun equals 0.65 grams of grease.

3
Scroll Air Compressor Service and Maintenance
Maintenance
DRY TYPE INLET FILTER
2500 Hours - Maintenance
The inlet filter on the scroll compressor assures 99% particu-
late free air is admitted to the unit. Change every 2,500 hours
or more often in dirty locations.
1. Remove filter cover.
Do not attempt to clean filter.
This filter requires replacement
and is to be replaced when contaminated.
2. Install new filter element and reassemble cover.
CLEAN COMPRESSOR FINS
2500 Hours - Maintenance
1. Remove the FS cover (see page 6).
2. Clean compressor fins using compressed air.
3. Put the FS cover back.
GREASE COMPRESSOR BEARINGS
10,000 Hours - Maintenance
Per OSHA regulations, ALL
power must be locked out
before performing any maintenance.
This service should be
performed by an authorized
Powerex Service Center to avoid failure.
OS Bearing
1. Remove the plastic dust cap (See Figure 1).
2. Rotate the compressor pulley until the grease fitting is
visible through the dust cap hole (See Figure 1). This will
allow regreasing of the OS bearing.
3. Use a grease gun extension adaptor to engage the grease
fitting and supply the proper volume of grease as indi-
cated on the grease delivery chart (See Grease Delivery
chart below and Figure 1).
Use only Powerex genuine
grease. Pump grease gun before
feeding. This eliminates air from the grease passage of the
extension adapter.
4. Replace plastic dust cap.
Greasing Pin Crank Bearings
The bearings on the scroll compressor are regreaseable to
allow extended compressor life. Service should be performed
every 10,000 hours of operation.
1. Remove the fan duct (2).
2. Remove the nuts and bolts and then the fixed scroll (FS)
from the air end.
3. Grease all three pin crank bearings (See Figure 2 below
and Grease Delivery Chart on page 2).
4. Replace the fixed scroll and fan duct (2). See the Bolt
Torques chart on page 5.
TIP SEAL SET REPLACEMENT
10,000 hours - Maintenance
Per OSHA regulations, ALL
power must be locked out
before performing any maintenance.
The “Tip Seal Set” is a replacement part for SLAE03E and
SLAE05E air ends. Please read these instructions thoroughly
and carefully to ensure correct replacement.
Grease Gun
Grease
Fitting
Extension
Adapter
Counter
Weight
Key Way
Plastic Dust
Cap
Figure 1
Grease Fittings
for pin crank
bearings
Figure 2

4
Replacement
1. Remove nuts and bolts and then FS set from air end.
2. Remove LP and HP tip seals from Fixed Scroll set and
Orbit set. Using the tip of a ball-point pen at the start will
make it much easier (See Figure 4).
3. Remove dust from Scroll with clean cloth or air before
inserting tip seals.
Maintenance (continued)
NOTE: Replace tip seal on SLAE03E and SLAE05EHP at 5,000
hours when operated at 145 psig.
The tip seal on the scroll compressor is self-lubricated and al-
lows the unit to operate efficiently without oil and expensive
filtration. The tip seal should be replaced every 10,000 hours
of operation.
Confirmation of the Parts
1. Confirm if the tip seal you purchased is correct for the air
end you are repairing (See Parts Listing below).
2. Confirm if the following parts are included (See Figure 3).
12 5 643
Figure 3
Tip Seal Removal
Figure 4
Item
No. Description Qty.
1 HP tip seal for FS 1
2 LP tip seal for FS 1
3 HP tip seal for OS 1
4 LP tip seal for OS 1
5 Dust Seal 1
6 Backup Tube 1
HP= High Pressure LP= Low Pressure
FS= Fixed Scroll OS- Orbital Scroll
NOTE: In order to distinguish between the tip seal for Fixed
Scroll and the tip seal for Orbit Scroll place the tip seal as
shown below then view from the arrow direction and refer
to the figure below.
Lip
(Inside)
Lip
(Bottom Side)
Facing
Left
Facing
Right
Fixed Scroll
Orbit Scroll
Scroll Air Compressor Service and Maintenance

5
Maintenance (continued)
Inserting tip seals
NOTE: Tips seals for Fixed Scroll and Orbit Scroll have opposing
seal cut angels (See NOTE and explanatory diagram below).
Insert tip seal so that the lip of tip seal is on the bottom of
seal groove and inner side of involute and the direction of lip
faces the center of involute (curving spiral). See Figure 5. This
is to be done for both FS and OS sets.
Use caution not to tear or distort lip.
1. Insert new HP tip seal
from the center sec-
tion for OS or Orbit
Scroll so that there
will be no clearance at
the tip (start) section
(See Figure 5 and 6).
2. Insert so that new LP
tip seal will contact
closely with HP tip
seal inside Scroll
Groove (See Figure 4
on page 4).
Insert approximately half of
the LP tip seal and remove the
tip seal to confirm that a notch in the tip seal has been created.
This will prevent movement during installation (See Figure 7).
3. Repeat the same procedure for FS or Fixed Scroll tip seal
set, remove both the dust seal and backup tube located
on outermost side FS set.
4. Insert new backup tube in the FS Scroll in the 6 o’ clock
position (See Figure 8).
5. Insert new dust seal on the backup tube.
6. After replacing tip seal set, reassemble Fixed Scroll set
to the Orbit Scroll. Tighten nuts and bolts temporarily
and confirm if crankshaft rotates smoothly by hand and
tighten them firmly. Tightening torques are:
NOTE: Assemble so that dust seal and tip seal will not drop
between Orbit Scroll set and Fixed Scroll set.
Figure 6
Figure 7
Machined
To Avoid Movement
During Installation
Figure 5
Enter
side
Lip Direction
Lip Side
(Grooved bottom)
Lip Surface
(Inside)
Bolt
Torque First Second
SLAE03E 17 in lb. 175 in lb.
SLAE05E/ SLAE05EHP 17 in lb. 265 in lb.
Scroll Air Compressor Service and Maintenance
Figure 8 Back-up Tube
Dust Seal

6
Scroll Air Compressor Service and Maintenance
Figure 9 - Compressor Parts
6
1
3
4
2
12
5
7
11
8
10
FS cover
15
16
14
13
13a
9

7
Ref. Part Number for Model
No. Description SLAE03E SLAE05E SLAE05EHP Quantity
1 Air End Pulley 02843051 02549110 02549110 1
2 Key IP600600AV IP600600AV IP600600AV 1
3 Centrifugal Fan IP601300AV IP601300AV IP601300AV 1
4 Fan Duct (1) IP601400AV IP601400AV IP601400AV 1
5 Fan Duct (2) IP601500AV 02519042 02519042 1
6 Fan Cover IP601700AV IP601700AV IP601700AV 1
7 Fan dust Gasket (1) IP601800AV IP601900AV IP601900AV 1
8 Heat Insulation Pipe IP602000AV IP602000AV IP602000AV 1
9 Fan Duct Gasket (2) IP602400AV IP602400AV IP602400AV 1
10 Long Nipple 96647011 96647011 96647011 1
11 Dust Cap IP603500AV IP603500AV IP603500AV 1
12 Tip Seal Set 92834090 92832070 92832080 1
13 Filter Assembly ST073922AV ST073922AV ST073922AV 1
13a Filter Element 91348550 91348550 91348550 1
14 Street Elbow RB90SF34 RB90SF34 RB90SF34 1
15 Adaptor Plate IP086100AV IP086100AV IP086100AV 1
16 Intake Gasket IP088200AV IP088200AV IP088200AV 1
* Grease Gun Kit IP616201AJ IP616201AJ IP616201AJ
* Grease Gun IP616100AJ IP616100AJ IP616100AJ
* Grease (80g.) IP600000AV IP600000AV IP600000AV
* Not Shown
Scroll Air Compressor Service and Maintenance

Powerex • 150 Production Drive • Harrison, OH 45030 • USA
Powerex Limited Warranty
Powerex 3 Year / 10,000 Hour Extended Parts Limited Warranty - Powerex warrants each Compressor
Pump or Scroll Air-End against defects in material or workmanship from the date of purchase for a period of
Three years or 10,000 hours, whichever may occur first. This warranty applies to the exchange of part(s) of
the compressor pump or air-end found to be defective by an Authorized Powerex Service Center.
Powerex 1 Year / 5,000 Hour Inlet to Outlet Limited Warranty - Powerex warrants each Compressor Unit,
System, Pump, or Air-End against defects in material or workmanship from the date of purchase for a period
of One Year or 5,000 Hours, whichever may occur first. This warranty applies to the exchange of defective
component part(s) and labor performed by an Authorized Powerex Service Center.
Coverage. The above mentioned warranty applies to Powerex manufactured units or systems only.
Items listed in the operator’s manual under routine maintenance are not covered by this or any
other warranty. Failure to complete maintenance as stated in the maintenance schedule will void this
warranty.
THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR
FROM THE DATE OF PURCHASE: AND TO THE EXTENT PERMITTED BY LAW, ANY AND ALL
IMPLIED WARRANTIES ARE EXCLUDED. THIS IS THE EXCLUSIVE REMEDY AND LIABILITY
FOR CONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED TO THE
EXTENT EXCLUSION IS PERMITTED BY LAW.
Limitation of Liability. To the extent allowable under applicable law, Powerex’s liability for
consequential and incidental damages is expressly disclaimed. 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 this literature 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. Claims pertaining to the merchandise in this schedule, with the exception of warranty claims,
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. All agreements are contingent upon strikes, accidents, or other causes beyond our control.
All shipments are carefully inspected and counted before leaving the factory. Please inspect carefully
any receipt of merchandise 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 merchandise 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, THESE TERMS
AND CONDITIONS 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. All orders are
subject to acceptance by POWEREX.
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Scroll Air Compressor Service and Maintenance