OPERATING MANUAL MODEL AIR 500TM AIR DRYER Puregas, LLC 226-A Commerce St. Tel: 800-52-535 Broomfield, Colorado Fax: 303-657-2205 P/N P0255 REV A, 02/9/4
TABLE OF CONTENTS.0 GENERAL... 3 2.0 SPECIFICATIONS... 3 3.0 INSTALLATION AND START-UP PROCEDURES... 4 4.0 PRINCIPLES OF OPERATION... 4 Figure Air Flow Diagram... 5 5.0 COMPONENT DESCRIPTION... 5 5. AIR COMPRESSOR... 5 5.2 HEATLESS DRYER... 6 Figure 2 Heatless Dryer Operation... 7 5.3 HEATLESS AIR DRYER, CAPACITY CONTROL VALVE, & PRESSURESWITCH 7 Figure 3 Pressure Switch Adjustment Screws... 8 5.4 OUTLET PRESSURE REGULATOR & GAUGE... 8 6.0 MAINTENANCE... 8 6. SIX MONTH MAINTENANCE AND INSPECTION... 8 6.2 ANNUAL MAINTENANCE AND INSPECTION... 8 6.3 TWO YEAR MAINTENANCE AND INSPECTION... 8 6.4 AIR COMPRESSOR MAINTENANCE KIT P/N 9537... 9 6.5 HEATLESS DRYER MAINTENANCE KIT INSTALLATION P/N P200499S... 9 7.0 PARTS IDENTIFICATION... 0 Figure 4 Front View... 0 Figure 5 Wiring Diagram... Figure 6 Heatless Dryer Exploded View and Parts List... 2 2 P/N P0255 REV A, 02/9/4
.0 GENERAL. This manual covers the specifications, installation, start-up, operation, component description, parts list, air flow schematic, wiring diagram and maintenance procedures for the Model AIR 500TM portable air dryers. This unit was designed as a portable dryer to provide a continuous dry air flow at adjustable pressures of 0 5 PSIG for continuous feed pressure cables, pipe systems and other systems requiring dry air..2 The air dryer carries a One Year Warranty against defective workmanship and materials starting from the date of shipment. Only parts are covered, labor to replace defective parts is not covered by this warranty. All units are tested and inspected before shipment. Any damages incurred in transit should be reported to the carrier immediately upon receipt. The manufacturer is not responsible for damage caused during shipment. 2.0 SPECIFICATIONS PART NUMBER AIR 500TM NORMAL OUTPUT CAPACITY EMERGENCY OUTPUT CAPACITY COMPRESSOR MOTOR DELIVERED AIR HUMIDITY DEWPOINT DELIVERED AIR PRESSURE POWER REQUIREMENTS OPERATING TEMPERATURES WEIGHT DIMENSIONS AIR DRYER, 5V/60Hz 000 SCFD (28.3 Cubic Meters per Day) 500 SCFD (42.6 Cubic Meters per Day) 5 Volts, 60 Hz. -/2 HP, Rocking Piston Type. 230 Volts, 50 Hz. -/2 HP, Rocking Piston Type Under % at 70 F (2 C) -40 F (-40 C) Adjustable, 0-5 PSIG Standard: 5 Volts, Single Phase, 60 Hz., 6 Amps Optional: 230 Volts, Single Phase, 50/60 Hz., 3 Amps Minimum: 33 F (0.5 C) Maximum: 20 F (49 C) 86 Pounds (39 KG) 20"wide (50.8 cm), 7"deep (38. cm), 26"high (63.5 cm) 3 P/N P0255 REV A, 02/9/4
3.0 INSTALLATION AND START-UP PROCEDURES 3. Rubber feet are installed for floor mounting. The unit should be located in a well-ventilated area that will allow for suitable air circulation. 3.2 The air dryer is designed to operate from a 5 volts, single phase, 60 Hertz power supply (Optional 230 volts, single phase 50/60 Hertz is also available). Connect the power cord supplied with the unit to a suitable power supply with a 5 Amp fuse or circuit breaker. 3.3 Check that the capacity control valve gauge reads 50 PSIG (+/- 2 PSIG) as soon as the air compressor starts. 3.4 The system pressure should quickly rise to 50 PSIG (+/-2 PSIG) and the air compressor/heatless air dryer system should shut off. Loosen the locknut on the stem of the outlet pressure regulator knob and turn the knob clockwise to relieve air through the air outlet and check that the compressor/dryer system starts when the system pressure drops to 25 PSIG (+/- 2 PSIG). 3.5 Allow the air dryer to run for 30 minutes then turn off the dryer and connect the cable/pipe system to the air outlet of the air dryer using 3/8 plastic tubing. 3.6 Adjust the outlet pressure regulator to the desired cable pressure and allow the pressure in the cable/pipe system to stabilize. 3.7 Once installation is complete and the start-up procedure has been performed, test for leaks at all external air connections. Operate the unit for 24 hours and repeat the start-up procedure 4.0 PRINCIPLES OF OPERATION 4. An air flow diagram of the air dryer is shown in Figure. The system supplying the dry outlet air includes an air compressor, a pre-cooler, an air filter, a heatless air dryer with a capacity control valve and gauge, an air storage tank, and an outlet regulator. 4.2 Ambient air is drawn in through the intake filters into the air compressor where it is compressed to 50 PSIG. The hot, moist air then flows through the pre-cooler where the air is cooled and then into the air filter where any liquid water and particulates are taken out, the air is then directed to the inlet of the heatless air dryer. 4.3 Moisture is removed from the air as it passes through the heatless air dryer. The dry air leaving the heatless air dryer is routed through the capacity control valve, which functions as a check valve and also maintains a constant 50 PSIG in the heatless dryer. An indication of the dryness of the air is shown on the moisture indicator by a blue color. 4.4 From the capacity control valve, the dry air flows into the air storage tank. The air pressure in the air tank is monitored by the pressure switch, which turns on and off the air compressor and air dryer to maintain pressure between 25 and 50 PSIG in the tank. Air moves from the tank through the outlet pressure regulator and to the air outlet. 4 P/N P0255 REV A, 02/9/4
Figure Air Flow Diagram HEATLESS AIR DRYER SAFETY RELIEF VALVE Humid Air PRE-COOLER Dry Air UNLOADER VALVE PRE-FILTER CAPACITY CONTROL GAUGE CAPACITY CONTROL VALVE AIR COMPRESSOR OUTLET PRESSURE REGULATOR SYSTEM PRESSURE GAUGE PURGE EXHAUST DRY AIR OUTLET AIR STORAGE TANK OUTLET PRESSURE GAUGE PRESSURE SWITCH 5.0 COMPONENT DESCRIPTION 5. AIR COMPRESSOR AIR COMPRESSOR P/N 7932 (5 Volts) P/N 7934 (230 Volts) AIR INTAKE FILTER P/N 764 FILTER ELEMENT P/N 765 SAFETY RELIEF VALVE P/N 9632 AIR PRE-COOLER P/N 832 FLEX LINE P/N B-43 UNLOADER VALVE P/N 7503 (5 Volts) P/N 75 (230 Volts) 5.. The air compressor is a rocking piston type, which is driven by a /2 HP motor. It requires no lubrication. The motor is equipped with built-in thermal overload protection. If the overload shuts down the compressor due to a thermal overload, the motor will automatically reset after cooling down. 5..2 An air intake filter is mounted in the inlet port of the cylinder head. The filter assembly has a replaceable filter element that should be replaced every six months. To replace the element, remove the filter housing from the compressor by holding the filter base and turning the housing counter-clockwise. Then take the housing and turn each end in opposite directions to separate the two housing halves. Remove the filter element out of the housing. Clean the housing with a cloth and install a new filter element, then screw the two halves back together. 5 P/N P0255 REV A, 02/9/4
5..3 A safety relief valve is installed in the air compressor head to prevent the pressure in the compressor from building to more than 25 PSIG. 5..4 The pre-cooler is used to cool the hot compressed air to aid the drying process. It is mounted between the air compressor/flex line and the pre-filter. 5.2 HEATLESS DRYER HEATLESS AIR DRYER P/N 2030-32 (5V) P/N 2030-432 (230V) CAPACITY CONTROL VALVE P/N P4634 CAPACITY CONTROL GAUGE P/N P397 PRE-FILTER P/N F8-02-SH00 PRE-FILTER ELEMENT P/N FRP-96-639 PURGE MUFFLER P/N 0040 5.2. The pre-filter with the auto drain removes liquid moisture and any particulate matter from the air-cooled in pre-cooler. The heatless air dryer removes virtually all moisture from the supply air using desiccant and pressurization. The capacity control valve is used to maintain a constant back-pressure in the heatless air dryer. It also prevents more than the maximum emergency flow rate from flowing through the outlets and serves as a check valve to prevent dry air from the air storage tank from flowing back through the heatless dryer when the compressor shuts down. 5.2.2 Moist air entering the inlet of the heatless dryer manifold is routed into one of the two desiccant chambers as determined by which one of the solenoid valves is energized. The two solenoid valves are alternately energized and de-energized by the cycle timer at 30- second intervals. As the air passes across the desiccant in the chamber, water vapor is adsorbed and held on the desiccant. The dry air at the top of the desiccant chamber exits down through a center tube to the purge orifice gland. The check valve ball just below the gland is pushed downward which allows the dry air to enter the outlet passage in the manifold. Most of the dry air is then delivered to the air storage tank through the capacity control valve (See Heatless Dryer Operation - Figure 4). 5.2.3 While one of the desiccant chambers is drying the supply air, water vapor is being removed from the desiccant in the other chamber. The solenoid valve associated with this chamber is de-energized, which opens the chamber to atmosphere. A small portion of the dry air in the outlet passage is routed through the orifice in the side of the purge orifice gland and is expanded to just above atmospheric pressure. Because there is virtually no pressure in the desiccant chamber, the spring below the check valve ball holds the ball against its seat on the bottom of the purge orifice gland. This forces the dry air to pass up through the center tube and then over the desiccant. As the expanded dry air passes across the desiccant, it removes the water vapor and carries it out of the dryer through the solenoid valve. 5.2.4 The above process reverses every 30 seconds. 5.2.5 The pressure in the heatless air dryer is critical to the drying process. It must be maintained at 50 PSIG (+/- 2 PSIG) as read on the capacity control valve gauge whenever the air compressor is operating. To adjust the capacity control valve, allow the system pressure to drop to 25 PSIG and the air compressor to start. Pull the adjustment knob out away from the valve body and turn the adjustment knob either clockwise to raise the pressure or counterclockwise to lower the pressure. Once the adjustment has been made, push the knob back towards the valve body to lock it. 6 P/N P0255 REV A, 02/9/4
50 PSIG 0 PSIG 50 PSIG Figure 2 Heatless Dryer Operation 5.3 HEATLESS AIR DRYER, CAPACITY CONTROL VALVE, & PRESSURESWITCH SYSTEM PRESSURE GAUGE P/N 792 SYSTEM PRESSURE SWITCH P/N P4564 5.3. The air storage tank is an ASME coded steel pressure vessel rated for 200 PSIG MAWP. The system pressure gauge reads the pressure inside the air storage tank. 5.3.2 The system pressure switch senses the pressure in the air storage tank and energizes the air compressor and heatless air dryer (via the control board) when the system pressure drops to 25 PSIG and de-energizes the power when the pressure reaches 50 PSIG. 5.3.3 The system pressure switch is adjustable. Remove the cover and use the adjustment screws as required. The pressure adjustment screw is used to raise or lower both the energize pressure and the de-energize pressure together. The differential pressure adjustment screw will change the differential between the two pressures. 7 P/N P0255 REV A, 02/9/4
Figure 3 Pressure Switch Adjustment Screws 5.4 OUTLET PRESSURE REGULATOR & GAUGE OUTLET PRESSURE REGULATOR P/N 5000-6-7C OUTLET PRESSURE GAUGE P/N 7386 5.4. The outlet pressure regulator and outlet pressure gauge are mounted on the outlet pressure regulator. The regulator reduces the pressure of the air to the desired outlet pressure. The maximum adjustment of the regulator is 30 PSIG, however, since the tank pressure varies between 25 and 50 PSIG, the regulator should be adjusted in the 0-5 PSI range. 5.4.2 Loosen the locknut on the stem of the outlet pressure regulator knob and turn the knob clockwise to raise or counterclockwise to lower the pressure at the air outlet. 6.0 MAINTENANCE To extend the life of the air dryer and assure continued satisfactory operation, it is recommended that the following inspection and maintenance procedures be performed at the scheduled intervals. Six air compressor intake filter elements are supplied with this dryer. These are the only routine maintenance parts required during the first year of operation. The Allen wrench supplied should be kept with unit for use in performing the annual compressor maintenance. 6. SIX MONTH MAINTENANCE AND INSPECTION 6.. Perform the following every three months or at 00 hour intervals: Replace the air compressor intake filter elements. (section 5..2) Check that the capacity control valve is adjusted properly. (section 5.2.5) Check the operation of the humidity alarm system. Check the system pressure switch setting. (section 5.3.3) 6.2 ANNUAL MAINTENANCE AND INSPECTION 6.2. Perform the following once every year or at 4400 hour intervals: Perform the six-month maintenance and inspection procedures. (section 6.) Replace the pre filter element. Install an air compressor maintenance kit. (section 0) 6.3 TWO YEAR MAINTENANCE AND INSPECTION 6.3. Perform the following once every two years or at 8800 hour intervals: Perform the annual maintenance and inspection procedures. (section 6.2) Install a heatless dryer maintenance kit. (section 6.5) 8 P/N P0255 REV A, 02/9/4
6.4 AIR COMPRESSOR MAINTENANCE KIT P/N 9537 Before performing any repairs or maintenance on the air dryer, disconnect the external power supply to the unit. Refer to the maintenance kit instructions provided in the maintenance kit. 6.5 HEATLESS DRYER MAINTENANCE KIT INSTALLATION P/N P200499S Before performing any repairs or maintenance on the air dryer, make sure to disconnect the external power supply to the unit. 6.5. Disconnect the pre-cooler line from left side of the pre-filter, disconnect the outlet hose to the tank, and disconnect the power leads. 6.5.2 Loosen and remove the four mounting bolts that mount the dryer on the frame and remove the dryer from the frame. Remove the bottom cover from the dryer by loosening the screw on either side of the cover. Remove the purge mufflers from the solenoid bases. 6.5.3 Remove the solenoid coils and frames from the solenoid base assembly by removing the retaining clip at the bottom of each base assembly. Remove the solenoid base assembly from the manifold and discard. Remove the o-rings from the manifold and install new o- rings. 6.5.4 Install the new solenoid base assembly containing the new core into the manifold. DO NOT OVER-TORQUE; tighten only until snug. Reinstall the old coil in the new frame using spacers. Reinstall the retaining clip. Reinstall the cover and purge mufflers. 6.5.5 Remove the two desiccant towers, o-rings and purge orifices. Remove and discard check valve balls and springs. Install new check valve balls and springs. 6.5.6 Reinstall purge orifices with new o-rings (lubricate threads with o-ring lube or petroleum jelly). 6.5.7 Reinstall desiccant chambers with new o-rings (lubricate threads with anti-seize lubricant or petroleum jelly). Reinstall dryer into unit and hook up outlet hose and pre-cooler. 9 P/N P0255 REV A, 02/9/4
7.0 PARTS IDENTIFICATION Figure 4 Front View 0 2 7 3 6 2 5 4 4 3 5 7 8 9 INDEX NO. PART NO. DESCRIPTION QTY. 7386 OUTLET PRESSURE GAUGE (0-30 PSI) 2 7932 7934 AIR COMPRESSOR (5 VOLTS) AIR COMPRESSOR (230 VOLTS) 3 P397 CAPACITY CONTROL GAUGE (0-00 PSI) 4 P4634 CAPACITY CONTROL VALVE 5 2030-32 2030-432 HEATLESS AIR DRYER (5VOLTS) HEATLESS AIR DRYER (230 VOLTS) 6 F8-02-SH00 PRE FILTER 7 P4564 SYSTEM PRESSURE SWITCH 8 792 SYSTEM PRESSURE GAUGE (0-60 PSI) 9 2056 FLOOR VIBRATION MOUNTS 4 0 B-43 FLEX LINE 832 PRE-COOLER COIL 2 764 AIR INTAKE FILTER 3 5000-6-7C OUTLET PRESSURE REGULATOR (0-30 PSI) 4 7503 75 UNLOADER VALVE (5 VOLTS) UNLOADER VALVE (230 VOLTS) 5 0040 MUFFLER 0 P/N P0255 REV A, 02/9/4
Figure 5 Wiring Diagram INCOMING POWER Gn W Bk LINE LOAD 2 SYSTEM PRESSURE SWITCH 5 6 Gn 3 4 SOLENOID VALVE # TIMER SOLENOID VALVE #2 AIR COMPRESSOR HEATLESS AIR DRYER P/N P0255 REV A, 02/9/4
Figure 6 Heatless Dryer Exploded View and Parts List 6A 2* 6 7 3* 4 5* 8* 9* 0 3A* 3B* 3C* 2 3D 4 3E 3F 3G 5 6 2 P/N P0255 REV A, 02/9/4
Ref Description DESICCANT TOWER, 9", WITH O RING Part Number Qty / 5 VAC 230 VAC Unit 2006 2 2* O RING, TOWER 2 3* O RING, PURGE ORIFICE, INNER 2 4 PURGE ORIFICE, WITH O RINGS (SPECIFY ORIFICE NUMBER) P20040432 2 5* O RING, PURGE ORIFICE, OUTER 2 6 6A OPTIONAL PLUG, INDICATOR PORT, WITH O RING MOISTURE INDICATOR, WITH O RING P00994F2 P200405 Recommend Spare 7 O RING 8* BALL, CHECK VALVE P400375 2 9* SPRING, CHECK VALVE P300507 2 0 BRACKET P00437 2 MANIFOLD P300495P PLUG, MANIFOLD P07559 2 3 SOLENOID VALVE ASSY P400589DC P400589DC2 2 (2) 3A* CORE, SOLENOID VALVE 2 3B* O RING, SOLENOID VALVE 2 3C* BASE, SOLENOID VALVE 2 3D COIL, SOLENOID VALVE 2 3E SPRING WASHER, SOLENOID VALVE 2 3F FRAME, SOLENOID VALVE 2 3G RETAINING RING, SOLENOID VALVE 2 4 TIMER, CYCLE P00530F P00530F2 () 5 COVER, MANIFOLD P3005052 6 MUFFLER 0040 2 (2) 7 MAINTENANCE KIT (INCLUDES *STARRED ITEMS) P200499S () 3 P/N P0255 REV A, 02/9/4