Instrument Air Package System

Product catalog summary

Overview
The Powerex Instrument Air Package System is engineered to supply instrument air for hospitals and medical facilities, adhering to NFPA99 standards. It features a pressure-lubricated compressor available in multiple configurations, an ASME-rated receiver tank, and a NEMA 12 control panel.

Specifications
The system functions at pressures of 200-220 PSIG and temperatures between 34-104°F. It supports voltages of 208/230/460 at 60Hz and offers a dew point capability of -40°F at 200 PSIG. Key components include a pressure-lubricated compressor, V-belt drive, and ASME safety valves.

Control Panel
The control panel manages compressor modules based on pressure signals, featuring motor circuit breakers, run lights, and high-temperature indicators. It alternates compressor modules every ten minutes to balance run time.

Dew Point Monitor and Air Dryer
The microprocessor-controlled dew point monitor provides temperature and dew point readings. The desiccant air dryer system ensures a -40°F dew point air at 200 PSI, with dual towers for redundancy.

Medical Filter System
The system includes filters to eliminate solids, liquids, submicronic particles, aerosols, and odors, with a maximum operating temperature of 125°F and pressure of 232 PSIG.

Installation Guidelines
Install the compressor in a clean, well-ventilated area, avoiding excessive dust and high temperatures. Ensure proper electrical connections by a qualified electrician and maintain minimum clearances for safety and maintenance.

Safety Guidelines
Adhere to all safety instructions to prevent injury or equipment damage. Regularly operate safety valves and ensure all safety devices are correctly installed.

Start-Up and Operation
Before starting, ensure all connections are secure, and safety devices are in place. Follow the start-up procedure to verify system operation, including checking for leaks and ensuring proper compressor rotation.

Maintenance
Regular maintenance involves checking belts, pressure connections, and safety valves. Ensure the system is leak-free and operates within specified parameters.

Control Panel - Display and Input
The system features a touch screen HMI panel for operation and monitoring, allowing navigation to the System Status screen from the MAIN screen.

Operation Procedures
Stopping the Compressor:
- Normal Operation: Close the discharge or isolation valve and allow pressure to build until the compressor stops.
- Emergency Operation: Turn off the power at the main disconnect panel.
Initial Start-Up and Control Setup:
The control system is pre-programmed with default settings. Access requires a seven-digit authorization code, typically the last seven digits of the unit's serial number. The system manages pump operations to maintain pressure between set points.

Alarm Signals and Operating Panel
The system is controlled by a PLC and monitored via the HMI touch screen, displaying system functions and alarms. Alarms must be acknowledged and reset manually. Key alarms include high temperature and motor overload.

Maintenance Schedule
Regular maintenance is essential, with specific actions required at various operating hours, such as daily tank moisture drainage and air filter replacement every 2,500 hours. Adjust maintenance frequency based on operating conditions.

Specifications
Details for various models include horsepower, phase, SCFM at 250 PSI, RPM, voltage, system FLA, tank capacity, dimensions, and shipping weight.

Warranty Information
Powerex offers a warranty covering defects in materials and workmanship, with different coverage periods based on standard, premium, and additional parts-only warranties. Warranty claims must be submitted in writing, and Powerex will repair or replace defective products within the warranty terms.

Warranty Overview
Powerex provides a warranty for replacement parts, including Air-End or Vacuum Pumps, motors, and other components, installed on Powerex manufactured systems or units after the initial warranty period has expired. The warranty covers defects for a specified period depending on the part and system origin.

Air-End or Vacuum Pumps
- For Powerex systems: 36 months or 10,000 hours, whichever comes first.
- For non-Powerex systems: 12 months.

Replacement Motors
- For Powerex systems: 12 months.
- For non-Powerex systems: 90 days.

Other Replacement Parts
- For both Powerex and non-Powerex systems: 12 months.

Warranty Conditions
The warranty applies only to parts found defective by an Authorized Powerex Service Representative. Repair or replacement does not extend the warranty period.

Coverage and Exceptions
The warranty is applicable only to Powerex manufactured units. Exceptions include improper installation, maintenance, unauthorized modifications, and operation beyond rated capacities. It does not cover defects from corrosion, abrasion, or normal wear and tear.

Limitation of Liability
Powerex limits its liability to the purchase price paid and is not responsible for incidental or consequential damages.

Product Suitability and Claims
Powerex advises reviewing product applications and local codes before purchase. Non-warranty claims must be filed within 6 months of the invoice date. Claims for transit damage should be directed to the carrier.

Terms and Conditions
All transactions are subject to Powerex's terms and conditions, which override any conflicting terms from the buyer.

Catalog excerpts

Instrument Air Package System 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. Please refer to safety manual IN258200AV for additional important safety information.. SPECIFICATIONS Product Instrument Air Package Units (IPD, IPT, IPQ) Performance Specifications Parts Lists Motor Protector with Adjustable Overload Operating Pressure Operating Temperature Operating Voltages Overpressure Protection Factory Set ASME safety valves Power Requirements Pressure Setting Working Pressure Duplex: Lead 200-220, Reserve 195-215 Triplex: Lead 203-220, Lag 1 200-217, Reserve 195-214 Quad: Lead 206-220, Lag 1 203-217 Lag 2 200-214, Reserve 195-211 5, 7.5 HP, PLI5A; 10 HP, PL30A Internally Lined ASME Rated 250 PSI Tank Isolation Tank Sizes Unit Isolation Base Unit Isolation Powerex - 150 Production Drive - Harrison, Ohio 45030 - USA 1-888-769-7979 - www.powerexinc.com Motor Overload Protection Pressure Lubricated Minimum Recommended Tank Sizes -40o F Pressure Dew Point at 200 psig Control Panel Control Enclosure The Powerex instrument air package is designed to provide instrument air for hospitals and medical institutes. This system meets NFPA99 requirements for Instrument Air. PRESSURE LUBRICATED COMPRESSOR The reciprocating compressor is provided in duplex, triplex or quadplex configurations. Pressure lubricated technology provides reliability for years to come. RECEIVER TANK The ASME, National Board registered air receiver is provided in sizes from 120 to 240 gallons. Each receiver is rated at 250 PSIG working pressure. Receivers are provided with sight glass and moisture drain (manual and electric). CONTROL PANEL The NEMA 12 control panel complies with NFPA 99 requirements for Instrument Air. The controls operate the duplex, triplex, or quadplex 250 psi capable air compressor modules as needed in response to a pressure signal from pressure switches or a pressure transducer depending on the model. The individual unit wiring diagrams show which pressure sensing device is used. Meets Requirements of this Ordinance Compression Cycle

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Instrument Air Package System CONTROL PANEL (Cont.) The pressure signals from the main air line are inputs to the programmable logic controller (PLC) or time alternating circuit and it is designed to operate one, two, or three compressor modules as needed to maintain the system minimum pressure of 200 psig. A reserve pump in use alarm circuit provides local indicator light and audible alarm along with remote indication if the air demand increases beyond the system rated capacity or the pressure drops for any other reason and the reserve compressor module is ever called for. An acknowledge button...

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Instrument Air Package System PIPING Refer to the general product 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...

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Instrument Air Package System BEFORE START UP 1. Make sure all safety warnings, labels and instructions have INSTALLATION (Cont’d) CONNECTING PIPING 1. Locate connection for piping at rear of unit for compressors module to receiver tank module. 2. Remove plastic caps that protect piping against contamination. 3. Connect flex joint to frame securely making sure flex line is not pinched or kinked. NOTE: All piping is provided and sealed for this portion of installation. 4. Connect outlet source from filter package located on dryer module to outlet source piping. been read and understood before...

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Instrument Air Package System If the System Status screen is not visible, go back to the MAIN screen and select System Status. (see below) Instrument Air Package System INITIAL START UP AND SET UP OF THE CONTROL The control system is programmed at the factory and default settings are installed. To access all the control functions you may need to enter a seven digit authorization code. You may select your own code, but we recommend using the last seven digits of the unit serial number. The following screens display a quadplex system. For a duplex system, the buttons for pumps 3 and 4 are grayed...

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Instrument Air Package System being disabled. The alarm must be acknowledged by pushing the ACKN button and manually reset after the condition causing the alarm has been resolved. The pump will not return to the operating sequence until it has been reset. If a high temperature condition occurs the reason should be determined and corrected before attempting to reset the alarm as un-repairable damage could result from the operation of the system with repeated high temperature alarms. OPERATION (Cont’d) OPERATING PANEL & SETTINGS The Instrument Air Compressor System is controlled by a PLC programmed...

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Instrument Air Package System OPERATION (Cont’d) SCREENS FOR RESETTING MAINTENANCE INDICATOR OTHER INFORMATION DISPLAYS ALARM LOG A record of all alarm or warning events is kept in the alarm log. Reset status is tracked as well. The alarm log is maintained as long as the unit is powered and for up to three days after power is removed from the control. See below for an example of the alarm log display screen. The following additional information is available by selecting the SYSTEM TRENDS from the MAIN screen: The control tracks the amount of time the pumps are in use and compares that to the...

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