"Teamwork & Communication" Model OP155 Air Dryer Operating Manual with Parts Identification OP155-INST June 15, 1998 Issue 2 GUSMER CORPORATION A Subsidiary of Gusmer Machinery Group, Inc. One Gusmer Drive Lakewood, New Jersey, USA 08701-8055 Toll Free 1-800-367-4767 (USA & Canada) Phone: (732) 370-9000 Fax: (732) 905-8968 Copyright 1998, GUSMER CORPORATION http://www.gusmer.com NOTICE: This manual contains important information for your GUSMER equipment. Read and retain for future reference.
Air Dryer CONTENTS WARRANTY... 4 GENERAL SAFETY INFORMATION... 5 GENERAL SAFETY PROCEDURES... 5 SPECIFICATIONS... 7 GENERAL DESCRIPTION... 8 NORMAL OPERATING PROCEDURE... 9 INITIAL SETUP... 9 OPERATION... 9 SHUT DOWN PROCEDURES... 10 MAINTENANCE... 11 PARTS IDENTIFICATION... 12 INSTRUCTION MANUAL DISCREPANCY REPORT... 15 2 OP155, Issue 2
Operating Manual with Parts Identification Contents LIST OF FIGURES FIGURE 1. SPECIFICATIONS... 7 FIGURE 2. DESCRIPTION OF PARTS... 8 FIGURE 3. AIR DRYER ASSEMBLY (PART NO. OP155) EXPLODED VIEW... 12 FIGURE 4. DRUM ADAPTER (PART NO. OP163) EXPLODED VIEW... 14 LIST OF TABLES TABLE 1. SPECIFICATIONS... 7 TABLE 2. DESCRIPTION OF PARTS... 8 TABLE 3. AIR DRYER ASSEMBLY (PART NO. OP155) PARTS... 13 TABLE 4. DRUM ADAPTER (PART NO. OP163) PARTS... 14 6/15/98 3
Air Dryer WARRANTY Gusmer Corporation (Gusmer) provides a limited warranty to the original purchaser (Customer) of Gusmer manufactured parts and equipment (Product) against any defects in material or workmanship for a period of one year from the date of shipment from Gusmer facilities. In the event Product is suspected to be defective in material or workmanship, it must be returned to Gusmer, freight prepaid. If Product is found to be defective in material or workmanship, as determined solely by Gusmer, Gusmer will issue full credit to Customer for the freight charges incurred in returning the defective Product, and either credit will be issued for the replacement cost of the Product or a replacement part will be forwarded no-charge, freight prepaid to Customer. This warranty shall not apply to Product Gusmer finds to be defective resulting from: installation, use, maintenance, or procedures not accomplished in accordance with our instructions; normal wear; accident; negligence; alterations not authorized in writing by Gusmer; use of look alike parts not manufactured or supplied by Gusmer; or Product used in conjunction with any other manufacturer's pumping or proportioning equipment. Further, the terms and conditions of this warranty shall not apply to services or repairs made to Product by any third party not authorized in writing by Gusmer. For such Product, a written estimate will be submitted to Customer at a nominal service charge, itemizing the cost for repair. Disposition of Product will be done in accordance with the terms stated on the written estimate. The warranty provisions applied to product that are not manufactured by Gusmer will be solely in accordance with the warranty provided by the original manufacturer of the product. GUSMER MAKES NO WARRANTY WHATSOEVER AS TO THE MERCHANTABILITY OF, OR SUITABILITY FOR, ITS PRODUCT TO PERFORM ANY PARTICULAR PURPOSE. CREDIT FOR, OR REPLACEMENT OF, PRODUCT DEFECTIVE IN MATERIAL OR WORKMANSHIP SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUSMER OBLIGATIONS TO CUSTOMER. NO OTHER WARRANTY, EXPRESSED OR IMPLIED ON ANY PRODUCT IT MANUFACTURES AND/OR SELLS, WILL BE RECOGNIZED BY GUSMER UNLESS SAID WARRANTY IS IN WRITING AND APPROVED BY AN OFFICER OF GUSMER. Under no circumstances shall Gusmer be liable for loss of prospective or speculative profits, or special indirect, incidental or consequential damages. Further, Gusmer shall have no liability for any expenses including, but not limited to personal injury or property damage resulting from failure of performance of the product, use of the product, or application of the material dispensed through the product. Any information provided by Gusmer that is based on data received from a third source, or that pertains to product not manufactured by Gusmer, while believed to be accurate and reliable, is presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Gusmer through the sale, lease, or rental of Product in no way expresses or implies a license for the use of, nor encourages the infringement of any patents or licenses. To insure proper validation of your warranty, please complete the warranty card and return it to Gusmer within two weeks of receipt of equipment. Revised 11/12/98 4 OP155, Issue 2
Operating Manual with Parts Identification General Safety Information GENERAL SAFETY INFORMATION The instructions in this manual must be understood and followed to insure proper and safe operation of the equipment. As with most mechanical equipment, certain safety precautions must be taken when the equipment discussed in this manual is operated or serviced. If the instructions and precautions listed throughout this manual are not followed, severe bodily injury or damage to equipment and property may result. Needless to say, sufficient guidelines cannot be developed to eliminate the need for good common sense in the use and servicing of this equipment, and in the use and application of the products this equipment has been designed to process. Users of this equipment must therefore, make their own determination as to the suitability of the information contained in this manual to their specific operation and requirements. There should be no assumption made that the safety measures and instructions contained herein are all-inclusive, and that other safety measures may not be required for specific use or application. The following safety guidelines are generally applicable to the safe and efficient use of the equipment. General Safety Procedures WARNING: DO NOT REMOVE THE METAL BOWL GUARD. THE UNIT MUST NOT BE PUT INTO SERVICE WITHOUT THE METAL BOWL GUARD INSTALLED TO MINIMIZE THE DANGER OF FLYING FRAGMENTS IN THE EVENT OF PLASTIC BOWL FAILURE. CAUTION: Certain compressor oils, chemicals, household cleaners, solvents, paints and fumes will attack the plastic bowl and cause bowl failure. Do not use the Air Dryer near these materials. When the bowl becomes dirty, replace it or wipe it with a clean, dry cloth. Immediately replace any crazed or cracked, damaged or deteriorated plastic bowl. CAUTION: This product is specifically designed for compressed air service. Use with any other fluid (liquid or gas) is a misapplication. 6/15/98 5
Air Dryer WARNING: TO PREVENT CONTAINER RUPTURE AND BODILY INJURY NEVER PRESSURIZE A DRUM OR CONTAINER THAT WILL NOT WITHSTAND 7 PSI WORKING PRESSURE. THE MAXIMUM OUTLET PRESSURE ALLOWABLE IS 3 PSI. OPERATION ABOVE THIS PRESSURE MAY CAUSE CONTAINER RUPTURE AND SERIOUS BODILY INJURY. WARNING: SAFETY GLASSES MUST HE WORN WHEN OPERATING OR SERVICING THIS EQUIPMENT. 6 OP155, Issue 2
Operating Manual with Parts Identification Specifications SPECIFICATIONS Figure 1. Specifications TABLE 1. SPECIFICATIONS Maximum Inlet pressure 150 psi Maximum Outlet pressure 3 psi Maximum air temperature 125 F Desiccant capacity 1.64 lbs Maximum air flow 10 cfm @ 100 psi Dew point -45 F Drying Capacity @ 70 F saturated air approximately 300 drum sets @ 100 F saturated air approximately 120 drum sets 6/15/98 7
Air Dryer GENERAL DESCRIPTION Figure 2. Description of Parts TABLE 2. DESCRIPTION OF PARTS 1. Coalescing Filter 6. Metal Bowl Guard 2. Water drain 7. Pressure Relief Valve 3. Pressure Regulator 8. Air Hose 4. Pressure Gauge 9. Drum Adapter 5. Desiccant Bowl 10. Needle Valve 8 OP155, Issue 2
Operating Manual with Parts Identification Normal Operating Procedure NORMAL OPERATING PROCEDURE Initial Setup It is recommended that a main air shutoff valve and a main air line filter be installed ahead of the Air Dryer System. The main air shut off valve will provide shutoff of the main system air for servicing of the Air Dryer. The Air Line Filter will remove excess oil and moisture to extend the service life of the desiccant used in the dryer 1. Mount the Air Dryer in any suitable location. The mounting hole requirements and hose lengths are shown in the specification section. 2. Fill the Desiccant Bowl with the Desiccant provided. WARNING: FOR THE PROTECTION OF THE OPERATOR THE METAL BOWL GUARD MUST BE REINSTALLED AFTER SERVICING. 3. Install the Drum Adapters. CAUTION: Because of the blowing agent contained in the resin material, there will be a noticeable escape of gas pressure when removing the vent cap of the resin drum at temperatures above approximately 60 F. NOTE: Each air line hose has been colorcoded red for isocyanate and blue for resin. To prevent contamination from the fumes of the respective chemicals do not to interchange these hoses. 4. Determine that both needle valves are closed, and then connect the air lines to their respective drum adapters. Operation The Air Dryer is now ready for operation 1. Set the Regulator to the zero Pressure position (full counter clockwise). Determine that the Needle Valves on the Drum Adapters are closed (full clockwise). 2. Open the Main Air Valve. WARNING: ALWAYS DETERMINE THAT THE PRESSURE REGULATOR IS OFF (FULL COUNTER CLOCKWISE) BEFORE TURNING ON MAIN SYSTEM AIR TO THE AIR DRYER. FAILURE TO DO SO COULD CAUSE A PRESSURE SURGE, WHICH COULD DAMAGE THE SUPPLY DRUM AND CAUSE INJURY TO THE OPERATOR. 6/15/98 9
Air Dryer 3. Adjust the regulator clockwise until the needle on the Pressure Gauge begins to move. Stop the adjustment and allow the needle to stabilize. Continue with the adjustment until a stable pressure of 1 to 2 psi is reached. 4. Open the needle valves. The pressure will drop to zero and then gradually build up to 1 to 2 psi. IMPORTANT: Pressure Relief valves are installed on the Air Dryer system to prevent the supply drum pressure from exceeding allowable limits. Each valve is set to open at 4 ± 1 psi. When the Pressure within the Supply Drum reaches 4 psi, a plunger in the Relief valve is tripped which opens the Valve Chamber to the pressure in the Drum. At this point, the Cap pops off the Relief Valve, venting the Drum to atmosphere and exposing a red warning band. This will reduce the drum pressure to zero. To reset the Relief Valve, proceed as follows: a) Reduce the regulator setting. b) Replace the cap. c) Adjust the regulator setting to 1 to 2 psi. WARNING: IF THE PRESSURE TO THE DRUM EXCEEDS THE MAXIMUM ALLOWABLE (3 PSI), IMMEDIATE ACTION MUST BE TAKEN TO RELIEVE THE EXCESS PRESSURE. To relieve the excess pressure in the drum, proceed as follows: a) Turn off the Air Regulator (Full Counter Clockwise). b) Manually activate the Pressure Relief Valve to bleed off the excess pressure. As a general rule, we have found that maintaining pressures of 1 to 2 psi permits further build-up of pressure from external sources such as heat or blowing agent boiling off without endangering safety. However, it is imperative that the Pressure Gauge be constantly monitored to insure that pressure build-up within the drums never exceeds the maximum allowable. Shut Down Procedures To shut down the Air Dryer, proceed as follows: 1. Turn off the Needle Valve on each supply drum. 2. Close the Air Regulator (full counter clockwise). 3. Close the main Air Valve. 10 OP155, Issue 2
Operating Manual with Parts Identification Maintenance NOTE: The replacement Desiccant Container holds 2 1/4 lbs of desiccant. The dryer has a 1.6 lb. capacity; take care to protect the desiccant which is not used from moisture contamination. MAINTENANCE Before servicing the Air Dryer, execute the shut down procedures listed previously:. Coalescent Filter: The Coalescent filter has an automatic water drain and will not need daily servicing. It is recommended that the porous bronze filter be removed and cleaned prior to long term shut downs or general maintenance. Dry the filter thoroughly before replacement. Desiccant Dryer: The desiccant should be monitored on a daily basis and changed before it turns completely pink. To recharge the used desiccant, spread it in a shallow pan and bake for 1 1/2 hours at 450 F or 4 hours at 250 F. Each time the desiccant is recharged some it its effectiveness is lost. Remove the bowl and fill with fresh or recharged desiccant. Reinstall the bowl and metal bowl guard. CAUTION: Certain compressor oils and fumes will attack the plastic bowl and cause bowl failure. Do not use the Air Dryer near these materials. When the bowl becomes dirty, replace it or wipe it with a clean, dry cloth. Re-install the metal bowl guard. Immediately replace any crazed or cracked, damaged or deteriorated plastic bowl. For further information on substances which are harmful to Polycarbonate Plastic check with a Bayer Chemical or General Electric representative. 6/15/98 11
Air Dryer PARTS IDENTIFICATION Figure 3. Air Dryer Assembly (Part No. OP155) Exploded View 12 OP155, Issue 2
Operating Manual with Parts Identification Parts Identification TABLE 3. AIR DRYER ASSEMBLY (PART NO. OP155) PARTS Reference Letter Part No. Description Qty. A 0375-2 Street Elbow 1 B 0561 Hex Nipple 3 C 0562-11-3 Flat Washer 2 D 0576 Pipe Plug 2 E 1253 Air Hose Assembly 2 F 3145-2 Coupler 2 G 4402-2 External Tee 1 H 4701-5 Button head Cap Screw 2 J OP154B-21-1 Pressure Relief Valve 2 K OP155-1 Bracket 1 L OP155-2 Dryer with 1 Qt. Desiccant 1 M OP155-3 Prefilter 1 N OP155-4 Manifold 2 P OP155-5 Pressure Regulator 1 Q OP155-6 Pressure Gauge 1 R OP155-7 Tube Fitting 1 S OP155-8 Tube Elbow 1 T OP155-9 Tubing 1 U OP155-10 Pipe Tee 2 V OP155-11 Check Valve 2 W OP163 Drum Adapter 2 X OP219-4 Socket Head Cap Screw 1 6/15/98 13
Air Dryer Figure 4. Drum Adapter (Part No. OP163) Exploded View TABLE 4. DRUM ADAPTER (PART NO. OP163) PARTS Reference Letter Part No. Description Qty. A 0561 Hex Nipple 1 B 3145-1 Coupler Plug 1 C OP154-12 Reducing Coupling 1 D OP154-15 Nipple 1 E OP154-16 Shut off Valve 1 14 OP155, Issue 2
Operating Manual with Parts Identification Instruction Manual Discrepancy Report Field Number INSTRUCTION MANUAL DISCREPANCY REPORT 1 Date 2 Name Field Title 3 IM Number 4 Issue Number 5 Date of Issue 6 Page Number 7 Discrepancy Description Instructions: Complete the above fields of the form by following the instructions listed on the reverse side of this sheet and mail to: Gusmer Corporation One Gusmer Drive PO Box 2055 Lakewood, NJ 08701 6/15/98 15
Air Dryer Field Number Field Title 1 Date Enter date report is submitted. Description 2 Name Enter name of person making report. 3 IM Number Enter the Part Number of the Instruction Manual from the title page. 4 Issue Number Enter the Issue number of the Instruction Manual from the title page. If there is no issue number, enter NONE. 5 Date of Issue Enter the date of Issue of the Instruction Manual from the title page. If there is no issue date, enter NONE. 6 Page Number Enter the page number containing the discrepancy 7 Discrepancy Provide a brief description of discrepancy NOTE: You may send a marked copy of the page as an attachment to your submittal. 16 OP155, Issue 2