Powerex OPS Series User manual

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
IN258607AV 1/12
Description
GENERAL
Powerex utilizes cutting-edge compressor technology
to provide the most advanced oilless reciprocating air
compressor in the industry. The Powerex reciprocating
compressor is available in single and two stage models.
Continuously lubricated, sealed bearings provide oil-free
compressed air and long compressor life. The onboard fan,
finned flywheel and temperature reducing composite piston
create lower operating temperatures.
DRY TYPE INLET FILTER
The inlet filter on the oilless compressor assures 99% of
particulate free air, down to 10 micron, is admitted to the
unit. Change every 2500 hours or more often in dirty locations
(See Figure 5).
PISTON AND PISTON RINGS
The Powerex oilless reciprocating compressor pistons are
made of a high-strength, self-lubricating composite using the
most advanced technology available. These heat reducing
pistons eliminate the effect of excessive grease leakage at
the wrist pin bearing. PTFE rings reduce wear and provide
self lubrication. Piston rings should be replaced every 10,000
hours of operation (See Figure 12).
BEARING REGREASE
The wrist pin bearings of the OPS and OPT oilless compressors
are needle bearings protected by two outer lip seals. This
needle bearing becomes impacted and requires regreasing at
5,000 hours (See Figure 15).
BEARING SEALS
The wrist pin bearing lip seals prevent the lubricating grease
from leaking from the bearing area. The two lip seals on each
connecting rod require replacement every 10,000 hours (See
Figure 16-22 or page 9).
Specifications (Series)
Product OPS / OPT Series Powerex Air Compressor
Pumps
Performance
Specifications
See Page 2
Lubrication Grease-filled Bearing
Pressure Settings Cut-In: 90 psig Cut-Out: 120 psig
Cut-In: 125 psig Cut-Out: 145 psig
(High Pressure Unit)
Oilless Reciprocating Air Compressor Pumps

2
Oilless Reciprocating Air Compressor Pumps
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.
Installation
INSTALLATION SITE
1. The oilless compressor must be located in a clean, well lit
and well ventilated area.
2. The area should be free of excessive dust, toxic or
flammable gases and moisture.
3. Never install the compressor where the ambient
temperature is higher than 105°F or where humidity is
high.
4. Clearance must allow for safe, effective inspection and
maintenance.
5. If necessary, use metal shims or leveling pads to level the
compressor. Never use wood to shim the compressor.
VENTILATION
1. If the oilless compressor is located in a totally enclosed
room, an exhaust fan with access to outside air must be
installed.
2. Never restrict the cooling fan exhaust air.
3. Never locate the compressor where hot exhaust air from
other heat generating units may be pulled into the unit.
WIRING
Refer to the general safety guidelines manual. All electrical
hook-ups must be performed by a qualified electrician.
Installations must be in accordance with local and national
electrical codes.
Use solderless terminals to connect the electric power source.
Minimum Clearances
Above 24 inches
Drive belt side 12 inches
Other side 20 inches
Specifications (Performance)
Model HP
Max.
PSIG
SCFM @
100 PSIG RPM
No. of
Cyl. Bore Stroke
Flywheel
O.D. Drive
Weight
(lbs.)
OPS010 1
1.5
145 3.6
5.3
625
885
1 2.56 2.56 11.2 1 GR-A 24
OPS030 2
3
145 7.6
10.1
845
1115
2 2.56 2.36 13.8 1 GR-B 46
OPT050 5 145 16.5 800 2 (1) 4.13 x
(1) 2.95
3.35 16.9 2 GR-B 97
OPT100 7.5
10
145 27.5
35.0
855
1090
3 (2) 3.54 x
(1) 2.95
3.35 18.3 2 GR-B 138
OPT150 15 145 47.0 1140 3 (2) 4.13 x
(1) 2.95
3.35 19.6 2 GR-B 141
Breathable Air Warning
This compressor/pump is NOT equipped and should NOT
be used “as is” to supply breathing quality air. For any
application of air for human consumption, you must fit
the compressor/pump with suitable in-line safety and
alarm equipment. This additional equipment is necessary
to properly filter and purify the air to meet minimal
specifications for Grade D breathing as described in
Compressed Gas Association Commodity Specification
G 7.1 - 1966, OSHA 29 CFR 1910. 134, and/or Canadian
Standards Associations (CSA).
DISCLAIMER OF WARRANTIES
In the event the compressor/pump is used for the purpose
of breathing air application and proper in-line safety and
alarm equipment is not simultaneously used, existing
warranties are void, and Powerex disclaims any liability
whatsoever for any loss, personal injury or damage.

3
Oilless Reciprocating Air Compressor Pumps
Installation (Continued)
PIPING
Refer to the general safety guidelines manual.
1. Make sure the piping is lined up without being
strained or twisted when assembling the piping for the
compressor.
2. Appropriate expansion loops or bends should be installed
at the compressor to avoid stresses caused by changes in
hot and cold conditions.
3. Piping supports should be anchored separately from the
compressor to reduce noise and vibration.
4. Never use any piping smaller than the compressor
connection.
5. Use flexible hose to connect the outlet of the compressor
to the piping so that the vibration of the compressor
does not transfer to the piping. Make sure the flexible
hose is rated for proper pressure and temperature before
installing.
SAFETY VALVES
A safety valve must be installed in the manifold or tank
where the compressor pump is installed. The flow capacity of
the safety valve must be equal to or greater than the capacity
of the compressor.
1. The pressure setting of the safety valve must be no
higher than the maximum working pressure of the tank.
2. Safety valves should be placed ahead of any possible
blockage point in the system, i.e. shutoff valve.
3. Avoid connecting the safety valve with any tubing or
piping.
4. Manually operate the safety valve every six months to
avoid sticking or freezing.
5. The safety valve must be ASME approved.
HOURMETER
The hourmeter on the oilless compressor indicates the
actual number of hours the unit has been in operation. The
hourmeter is also used to determine maintenance and service
timing. An hourmeter must be installed with every
oilless compressor.
CONDENSATE DRAIN VALVE
A condensate drain valve must be installed on any tank
to allow removal of the liquid which will collect during
compressor operation.
Drain liquid from
tank daily.
Operation
Powerex oilless compressors operate at a standard pressure
of 120 PSIG. Two stage compressors operate at a maximum
of 145 PSIG and are equipped for continuous run operation.
Compressor RPM’s are established by Powerex based on
horsepower and operating pressure.
BEFORE START UP
1. Make sure all safety warnings, labels and instructions
have been read and understood before continuing.
2. Be sure all pressure connections are tight.
3. Check to be certain all safety relief valves, etc., are
correctly installed.
4. Make sure the inlet filter is properly installed.
5. Visually check the rotation of the compressor pump.
If the rotation is incorrect, have a qualified electrician
correct the motor wiring.
START-UP AND OPERATION
1. Follow all the procedures under “Before start-up” before
attempting operation of the compressor.
2. Switch the electric source breaker on.
3. Open the tank discharge valve completely.
4. Check that the compressor operates without excessive
vibration, unusual noises or leaks.
5. Close the discharge valve completely.
6. Check the discharge pressure. Also make sure the air
pressure rises to the designated pressure setting by
checking the discharge pressure gauge.
7. Check the operation of the pressure switch or the pilot
valve for continuous run units by opening the stop
valve and confirming the compressor starts or reloads as
pressure drops.
Switch the breaker off if the compressor is not to be used for
a long period of time.

4
Oilless Reciprocating Air Compressor Pumps
Maintenance Schedule
Item Action needed 500 2500 5000 10,000 15,000 20,000 Remarks
Tank Drain moisture Daily Drain tank daily
Inlet Air Filter Replace l s Every 2500 hours or less
Blower Fan Clean llll
Fan Duct Clean llll
Compressor Fins Clean lEvery 2500 hours or less
Bearings Replace l l s
Compression Rings Replace l s l s
Wrist Pin Bearings Regrease Note 4 ssss
Piston Set Replace s s
Cylinder Inspect llll
Unloader Set Replace l s l s
Gasket Set Replace s s
Bearing Seal Wrist Pin Replace s
V-belt Inspect, Replace Note 3 lssss
Operating Hours
lInspect
sReplace
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 (500H) and inspected every 2,500 hours afterwards.
Proper belt tension for 1 to 3 HP units is 2-3 lbs./.5 inch deflection; for 5 to 15 HP units, 4-6 lbs./.5 inch deflection.
4. See page 8.
1. Remove wing nut.
2. Remove canister and wipe inside clean with dry cloth.
3. Remove and discard filter cartridge.
4. Install new filter cartridge. Do not attempt to clean and reuse filter cartridge.
5. Wipe inside clean with dry cloth.
Figure 5 - Air Filter Replacement
2500 Hours - Air Filter Element Replacement

5
5000 Hours - Valve Inspection/
Replacement
Per OSHA regulations, ALL
power must be locked out
before performing any maintenance.
INSPECT VALVE SET
1. Remove head bolts from cylinder head.
2. Remove cylinder head and valve set. If it is difficult to
remove by hand, insert screwdriver between cylinder and
valve set and remove (See Figure 6 and 7).
INSPECTION AND MAINTENANCE
1. Check if exhaust valve (A) sticks to seat or is damaged
(See Figure 8).
2. Check if there is breakage, gouge or damage to
appearance of intake valve (B).
3. Lift intake valve 10 mm (3/8 inch) and check if there is
peeling and/or wear on coating surface of valve set (C).
Lifting intake valve too much
can cause damage to intake
valve.
4. Replace intake valve set if valve plate or valves are worn
or wear is over 0.5 mm (0.020 inches) in depth.
If exhaust valve rises upwards, clean seat surface of
foreign matter.
5. Clean the whole valve set taking care not to damage seat
surface and remove dust.
6. If viton seals (upper and lower) reach inspection time,
replace them. Even if its not time to inspect, be sure to
replace if they do not protrude from groove or seal has
hardened or been damaged.
7. Be sure to replace plastic seat in cylinder (See Figure 10).
8. Install valve set while paying attention to black plastic
seat of intake valve installed in cylinder (so that you do
not drop seat or insert tip of valve under seat).
9. Install cylinder head and tighten head bolts with
designated torque.
NOTES:
• Whenusingvalvesetagain,replaceupperandlower
viton seals.
• Whenreplacingvalveset,replacewithupperandlower
viton seals (valve set with packing set). You cannot reuse
disassembled valve set.
We are not responsible for any problems caused by reuse of
disassembled valve set.
REASSEMBLY
Assemble in reverse order of disassembling. Tighten each
section with designated tightening torque (See Chart on
page 6).
Oilless Reciprocating Air Compressor Pumps
Figure 6
Figure 7
Figure 8
Check for
peeling or
wear (C)
(A)
(A)
(B)

6
Cylinder Inspection / Replacement
Per OSHA regulations, ALL
power must be locked out
before performing any maintenance.
INSPECTION / REPLACEMENT
1. Remove cylinder head and valve set. Pay attention not
to lose semicircular (black plastic) seat inserted at top
surface of cylinder (see Figure 9).
2. Remove cylinder bolts and pull off cylinder slowly. Make
sure piston does not drop down and get damaged. Note
cylinder orientation.
3. Inspect cylinder surface. If treated area is worn and metal
is exposed, replace. If there are several vertical scratches
at a narrow distance, replace (see Figure 10).
NOTE: Blackish streaks you can feel with your nail or finger
are not damage but sliding marks of piston and piston ring.
You do not need to replace the piston set or cylinder even
if there are several marks on the whole diameter of the
cylinder.
REASSEMBLY
1. Assemble in reverse order of disassembling cylinder.
2. Direction of cylinder is set so that semicircular spot
facing, to which seat (black plastic) is inserted, faces
toward flywheel side.
3. Tighten cylinder bolts with designated torque (refer to
chart below).
Model
Cylinder Bolt
Torque
Head Bolt
Torque
OPS010 / OPS030 156 in. lb. 156 in. lb.
OPT050 / OPT100 / OPT150 295 in. lb. 156 in. lb.
Oilless Reciprocating Air Compressor Pumps
Figure 9
Figure 10
Seat
Replace if it
is scratched
Cylinder

7
Oilless Reciprocating Air Compressor Pumps
10,000 Hours - Piston Ring
Replacement
Per OSHA regulations, ALL
power must be locked out
before performing any maintenance.
INSPECTION / REPLACEMENT
1. Remove cylinder head tubing and cylinder bolts.
2. Pull cylinder and head assembly off slowly. Do not allow
piston to drop out of cylinder and get damaged.
3. Remove piston rings. Do not use ring tool to remove
ring. Expand by hand only wide enough to remove from
piston. Note orientation of each for proper replacement.
NOTE: Expanding ring too much and deforming can cause
wear and leakage. (See Figure 12). Mark upper surface (not
lower surface) of removed ring for easy distinction.
4. Inspect lower surface (A) and outer side surface (B) of
ring (See Figure 13). Measure thickness (C) of ring with
calipers. Replace if foreign matter enters (A, B) or deep
damage is found or (C) dimension is less than 2.5 mm
(0.10 inches) at any point around the rings circumference.
NOTE: Clean the whole ring and ring groove with soft clean
cloth.
Ring and piston dust build up
in the ring groove can cause
knocking. This is sometimes mistaken for bad valve or bearing.
REASSEMBLE: Pay attention to the fit of the piston and wrist
pin fit. There should be no axial play or looseness in the wrist
pin area.
NOTE: Do not separate piston from connecting rod when
inspecting piston or ring. If you remove piston from
connecting rod, you may damage oil seal of connecting rod
and needle bearing.
PISTON INSPECTION/REPLACEMENT
1. Inspect for appearance; if there is deep damage or crack
on top of piston or at pin boss, replace piston.
2. Remove piston ring and inspect for breakage or droop of
ring land; if damage is found, replace piston.
3. Remove o-rings on both sides of wrist pin. Push wrist pin
to one side
NOTE: Install bearing retention sleeve in grease kit/piston set.
The retention sleeve is to prevent the needle bearing from
falling out of the bearing area. On the HP cylinder only.
4. Remove wrist pin; remove piston.
5. Install o-ring in flywheel side of new piston (see Page 8).
6. Install piston onto con rod. Slide wrist pin into place.
Install second o-ring. Make sure piston is in proper
direction (see Page 8).
7. Install rings in proper grooves (for inspection) and proper
gap orientation.
Figure 11
Figure 12
Figure 13
(A)(C)
(B)
Figure 14
Piston rings
O-ring
Piston
Wrist pin

8
Oilless Reciprocating Air Compressor Pumps
10,000 Hours - Piston Ring
Replacement (Continued)
WRIST PIN BEARING REGREASE
1. Remove cylinder/head assembly and piston.
2. For low pressure wrist pin bearings, fill needle area with
IP634500AJ Powerex approved grease.
Piston Orientation Chart for Oilless OPS / OPT Series
Pump Compressor Model Bore No. Cylinders
No. of Piston Rings
per Piston Mark on Top of Piston
OPS010 65 mm 1 1
Flywheel side
Fan Side
OPS030 65 mm 1 1
Flywheel side
Fan Side
OPT050
LP 105 mm 1 1 Flywheel side
Fan Side
HP 75 mm 1 2
OPT100
LP 90 mm 2 1 Flywheel side
Fan Side
HP 75 mm 1 2
OPT150
LP 105 mm 2 1 Flywheel side
Fan Side
HP 75 mm 1 2
3. For high pressure wrist pin bearings, replace wrist pin
(#91924680). (OPT Pumps Only)
4. Replace cylinder/head assembly and piston as in
procedures above.
5. Tighten all fittings and bolts to designated torques.
NOTE: When removing HP piston on two-stage pumps,
remove piston and then insert retention sleeve having
the same diameter of wrist pin or piston to small end of
connecting rod. If not, you may drop or lose needles from the
bearing, as HP needle bearing does not have support.
Fit piston by referring the
marking on the top of the
piston surface and list on above chart.
NOTE: Gradually insert wrist pin while turning it. Inserting
with force can damage oil seal of needle bearing.
* FOR LOW PRESSURE
WRIST PIN BEARINGS
ONLY
Figure 15
Small end of connecting rod
Small end of connecting rod
Wrist pin
NOTE: The orientation in which the pistons are reinstalled
is very important. Improper placement will cause premature
wear of the ring and piston.
Oilless Reciprocating
Grease
6 Grams
#IP634500AV
Powerex
Oilless
Reciprocating
Grease
6 Grams
#IP634500AJ

9
Oilless Reciprocating Air Compressor Pumps
Figure 16
1. Insert the plastic retention sleeve which protects the
needle bearing from dropping out.
Wrist Pin Bearing Seal Replacement (Replace Every 10,000 Hours)
REPLACING OIL SEAL
Figure 17
2. Remove the two oil seals by using a screwdriver.
Figure 18
3. Clean both surfaces where oil seals are removed.
Figure 19
4. Push the oil seal into the small bearing end horizontally.
Figure 21
7. Apply a small volume of adhesive at several points.
Figure 22
8. Remove the retention sleeve inserted at the first step.
NOTE: You may use a “C” clamp or two large washers and
bolt with nut through the bearing. Then apply pressure
to install the seals. This makes it easy to replace the seals
without removing the crankshaft.
Figure 20
5. Press the oil seal with a C-clamp into the small bearing
end.
6. Repeat on opposite side.
Pushing Board

10
Oilless Reciprocating Air Compressor Pumps
20,000 Hours - Connecting Rod,
Wrist Pin and Crankshaft
Per OSHA regulations, ALL
power must be locked out
before performing any maintenance.
REPLACE CONNECTING ROD SET AND CRANKSHAFT
AS A SET
Pressing bearing into connecting rod and connecting rod
set into crankshaft requires special fixtures. Without such
fixtures, the squareness and parallelism of each part will be
affected.
REMOVE CYLINDER/HEAD ASSEMBLY AND PISTONS IN
THIS ORDER
1. Bearing at large end of connecting rod: Replace if it does
not move or feels stuck holding and moving small end of
connecting rod.
2. Bearing of crankshaft: Replace if you feel some resistance
when slowly turning shaft.
3. Bearing at wrist pin: Check for breakage of needle
bearing and damage of cage.
DISASSEMBLING: CRANKSHAFT SET
1. Remove cylinder/head, assemblies and pistons.
2. Remove bolts from bearing cap and remove bearing cap.
3. Lightly tap shaft fan side with non-shock hammer (avoid
metal hammer) and remove crankshaft. After bearing
leaves the crankcase bore, pull connecting rod out as
illustrated and remove it from crankcase (See Figure 23).
REASSEMBLY
1. Heat bearing housing of crankcase with industrial dryer
or simple burner just the same as disassembling.
2. Insert crankshaft set into crankcase in reverse order of
disassembling and insert bearing into housing.
3. Tap shaft from pulley side with non-shock hammer and
insert it inwards.
4. Fit bearing case. Grease bearing housing of bearing case.
5. Replace pistons and cylinder/head assemblies per the
inspection procedure listed previously.
Figure 23