DeVilbiss DAD-504 Reference manual

SB-6-176-C
Replaces SB-6-176-B
SERVICE BULLETIN
DAD-504 (130096) breAthAble AIr retro FIt KIt
IMPORTANT: Read and follow all INSTRUC-
TIONS and SAFETY PRECAUTIONS before
installing, operating or maintaining this
equipment. Keep this manual for future
reference.
DESCRIPTION
The DAD-504 is designed to attach to an
existing DeVilbiss DAD-500 Desiccant Air
Dryer. The DAD-504 offers appropriate
filtration and a connection for the attach-
ment of a DeVilbiss Breathable Air Hose
and Air VizorTM supplied air breathing
system.
SPECIFICATIONS
Charcoal Filter:
Air Inlet 1/2" NPT(F)
Air Outlet 1/2" NPT(F)
Air Flow Capacity 75 CFM
Maximum Operating
Pressure 150 PSIG (10.3 Bar)
Maximum Temperature 150° F (65.6°C)
Manual Mechanical Drain Standard
Pressure Differential
Indicator Standard
Aerosol Filter .003 ppm./wt.
Particulate Filter 3.0 micron
Flow Thru Regulator:
Flow Thru Ports 1/2" NPT(F)
Regulated Ports 1/4" NPT(F)
Air Flow Capacity (regulated)
with 100 PSI Inlet 28 CFM @ 60 PSI
Maximum Inlet Pressure 300 PSIG
Regulated Pressure 0-125 PSIG
Maximum Temperature 175° F (79.4°C)
SAFETY PRECAUTIONS
This manual contains important information that all users must know and understand
before using the equipment. This information relates to USER SAFETY and PREVENT-
ING EQUIPMENT PROBLEMS.
To help you recognize this information, we use the following terms to draw your at-
tention to certain equipment labels and portions of this manual. Please pay special
attention to any label or information that is highlighted by one of these terms:
Note
Information that you
should pay special atten-
tion to.
Important information that
tells how to prevent damage
to equipment, or how to avoid
a situation that might cause
minor injury.
Important information
to alert you to a situation
that might cause serious
injury if instructions are
not followed.
BREATHING AIR REQUIREMENTS
Supplied breathing air, as defined by
OSHA 29 CFR 1910.134i and NIOSH 42 CFR
84.141, MUST meet or exceed the following
requirements for Type 1-Grade D breath-
able air, as defined in Compressed Gas
Association (CGA-G7-1-1997):
Oxygen = 19.5-23.5% (Typical
atmospheric levels)
Oil (condensed) = 5 mg/m (mil-
ligrams per cubic meter) maximum
Carbon Monoxide (CO) = 10 ppm
(parts per million) max.
Carbon Dioxide (CO2)= 1OOO ppm
(parts per million) max. (Typical
atmospheric levels)
Odor = The presence of a pro-
nounced odor should render the
air as unsatisfactory
It is up to the employer to assure that the
air compressor is properly maintained,
that the air compressor intake is located
in a clean contaminate free location
and that the air compressor is drawing
in typical atmospheric air, meeting all of
the national and local requirements for
breathing air.
This filter unit, when added to a DAD-500,
does not remove or filter Carbon Monoxide
(CO). It is up to the employer to ensure
that the level of CO does not exceed the
maximum national or local allowed level.
The recommended method to assure that
the CO level is not exceeded is to install
a carbon monoxide monitor and alarm.
This filter unit, when added to a DAD-
500, will only remove particulate matter,
water, oil and odor. This filter unit will
meet the particulate matter, oil and odor
requirements of Type 1-Grade D Breath-
able Air and Compressed Breathing Air,
CSA-Z180.1 when:
• The lter unit is connected to a
compressed air source:
The compressor is properly
maintained
The air compressor intake is
located in a clean contaminate
free location
The air compressor is draw-
ing in typical atmospheric air,
meeting all of the national
and local requirements for
breathing air
• The lters are properly maintained
• A properly operating CO monitor
is installed
Risk of explosion or fire.
Improper use can cause
personal injury.
•  This product is designed and
intended for use in industrial com-
pressed air systems only. Do not use
for liquids or gasses other than air.
•Donotusewherepressureortem-
perature can exceed rated operating
conditions (see specifications).
•  Regulated outlet pressure must
never be set higher than the maxi-
mum operating pressure of the
downstream air tool or equipment.
An outlet pressure gauge should
always be used.
Risk of illness or death. Carbon
monoxide can cause nausea, faint-
ing or death. Stop using if carbon
monoxide is present. This unit does
not remove carbon monoxide. A
carbon monoxide monitor should be
incorporated into your air supply line
to warn of the presence of carbon
monoxide.

Page 2 SB-6-176-C
MAINTENANCE
Risk of injury. Components
under pressure. Relieve air
pressure before performing any
maintenance.
1. Check system at least once per shift
to insure proper drainage. Look for
water in the drain tubing.
2. Before performing maintenance on
system, close main shut-off valve
located upstream. Bleed off residual
air in system.
INSTALLATION – RETRO FIT KIT
1. Be sure to read all "Cautions" and
"Warnings" in this manual and on the
unit before installation or using this
equipment.
2. This unit is designed to fit a DeVilbiss
DAD-500 desiccant air dryer. Installa-
tion on non-DeVilbiss desiccant dryers
is not recommended, as we cannot
assure the performance of those
devices.
3. Shut off the air supply to the DAD-500
and bleed air from the system.
4. Separate the air filter, coalescing filter
and nipple from the desiccant tank.
(This might be a good time to change
the desiccant beads, Part No. DAD-1).
5. Attach retro fit kit (DAD-504) to desic-
cant tank. Reattach air filter, coalescing
filter and nipple to retro fit kit.
6. Position the filters in line with the des-
iccant tank, with the regulator gauge
facing straight forward.
Note
Use PTFE tape on pipe plug threads
and all threaded fittings to facilitate
removal in the future. Do not use
loctite or any material that may bond
and make removal difficult.
2
5
Existing DAD-500
Existing DAD-500
4
Existing DAD-500 DAD-504
WITH RETRO FIT KIT
OPERATION
After the system is installed and ready
to use;
1. Attach breathable air hose to Q.D. on
flow-thru regulator.
2. Attach air hose(s) to outlet valve.
3. Open main shut-off valve upstream of
system.
4. Attach breathable air hose to supplied
air respirator.
5. Adjust regulator (3) to read 60 PSIG
(flowing air to the visor). The pressure
should never be allowed to drop below
50 PSI in a flowing condition.
3
1
Risk of injury. Do not place unit in
service without metal bowl guard
installed. Filter units are sold only
with metal bowl guards. To minimize
the danger of flying fragments in the
event of plastic bowl failure, guard
must not be removed. If the unit is
in service without the metal bowl
guard installed, manufacturer’s war-
ranties are void and the manufacturer
assumes no responsibility for any
resulting loss. If unit has been in
service and does not have a metal
bowl guard, order one and install
before placing back in service.
Certain compressor oils, cleaning
agents and solvents may attack the
plastic and rubber components used
in the construction of this product.
This product should not be used in
conjunciton with or in the vicinity
of these materials. Read and follow
material labels carefully. Please
consult DeVilbiss if in doubt.
Figure 1 DAD-500 /DAD-504
Replace- I nd.
Ref. ment Parts
No. Part No. Description Req.
1 HAF-517 Charcoal Filter 1
2 — Nipple 1
3 HAR-508 Flow-Thru Regulator 1
4 GA-316 Gauge 1
5 MPV-424 Breathable Air Quick 1
Release Socket
PARTS LIST

SB-6-176-C Page 3
MAINTENANCE – FLOW-THRU
REGULATOR
Do not submerge regulator or
components in solvent or use
solvent to clean regulator parts.
Damage may occur to regulator
and components. Use a cloth
dampened in warm, soapy water
to clean exterior of regulator.
Note
This unit may be serviced with-
out removing the unit from the
compressed air line.
1. Frequency of servicing depends largely
on the condition of the compressed air
system and the degree of contamina-
tion in the system.
2. Before attempting to service this
product in-line, depressurize both
the upstream and downstream sides
of regulator.
3. Remove the bottom plug, valve spring
and valve assembly. Inspect all seals
and components for damage and re-
place as required. Clean seals and
components with mild detergent and
water. Use a clean, dry cloth to wipe
any contamination from valve seal
inside the body. Lubricate the valve
stem and lower valve "O"ring seal
with a light coat of MAGNALUBE-G
Figure 3 – HAR-508 Regulator
MAINTENANCE – HAF-517
CHARCOAL FILTER
1. Before performing maintenance on
unit, close any main shut-off valve
located upstream of filter. Bleed off
residual air in unit.
2. To open filter, press button located
on clamp ring and rotate ring either
clockwise or counterclockwise while
pulling down on ring. The metal bowl
guard and plastic bowl can then be
removed from the filter body.
3. Remove the filter element by loosen-
ing counterclockwise. Clean or replace
the filter element. Replace the char-
coal element when it no longer re-
moves oil vapor odors or when the
red indicator is visible.
4. Inspect "O"ring for damage. Replace
if necessary.
5. Inspect plastic bowl for signs of dam-
age such as cracks, crazing or deterio-
ration. Replace if necessary.
HAF-517 Parts List
Replace- Ind.
Ref. ment Parts
No. Part No. Description Req.
1 HAF-404 Filter Change Ind. 1
(Not shown)
1A --- Body 1
2 --- O-Ring 1
3 HAF-36 Filter Element and 1
O-Ring Kit
4 HAF-11 Manual Drain 1
5 HAF-8 Plastic Bowl 1
6 HAF-19 Metal Bowl Guard 1
7 HAF-409 Clamp Ring 1
Figure 2 – HAF-517
1 (not shown)
5
6
7
1A
3
2
4
or similar lubricant. Reassemble.
Bottom plug torque should not exceed
25 in./lbs.(2.8 N-m).
4. To replace main spring or diaphragm,
turn adjusting knob counterclockwise
to remove all spring force, then re-
move bonnet. Remove the adjusting
screw assembly, main spring, slip ring
and diaphragm assembly. Inspect the
diaphragm and the relief seat for dam-
age and contamination. Replace dia-
phragm assembly if necessary. Clean
the relief seat with a soft dry cloth.
Reassemble in reverse order making
sure the slip ring is properly posi-
tioned on top of the diaphragm.
Bonnet torque should not exceed
120 in./lbs. (13.6 N-m).
5. Before returning unit to service, en-
sure that all seals have been properly
reinstalled or replaced and compo-
nents requiring torque values have
been properly set.
6. If regulated pressure begins to creep
(an uncontrolled rise in regulated
pressure), it will most likely be caused
by contamination on the valve seat.
7. If the unit leaks from the vent holes in
the bonnet, it may be caused by con-
tamination, deterioration or damage
to the valve seat or diaphragm relief
seat. Replace any damaged or worn
components.
Knob
*Adjusting
Screw
Assembly
*KK-5045
Diaphragm
Repair Kit
Body
Cover
Panel
Nut
Bonnet
*Thrust
Washer
*Main
Spring
*Slip
Ring
*Diaphragm
Assembly
*Valve
Assembly
*Valve
Spring
*Bottom
Plug
O-Ring
Bottom
Plug
Body
Assembly

Page 4 SB-6-176-C
MAINTENANCE – DESICCANT DAD-1
1. Replace the desiccant when the hu-
midity indicator changes to a pink
color. Remove the pipe plug at the
bottom of the tank. Allow the material
to drain into a two (2) gallon or larger
container.
2. Once all the material has been re-
moved, replace the pipe plug (see
"Note" following) and tighten securely
(air tight).
Note
Use PTFE tape on pipe plug
threads and all threaded fittings
to facilitate removal in the future.
Do not use loctite or any material
that may bond and make removal
difficult.
3. Replace the DAD-3 humidity indicator
paper (supplied with DAD-1 Desic-
cant) by removing the DAD-400 hu-
midity indicator. Pry out the old paper
and push in the new paper (printed
side facing away from the glass).
4. Remove the pipe plug on top of the
unit.
5. Using a funnel (suppplied with des-
iccant), fill the unit using DeVilbiss
Desiccant Material Part No. DAD-1
(19-0831) until full.
6. Replace the pipe plug (see "Note"
above) and tighten until air tight.
7. The humidity indicator will return to
a blue color within five minutes.
8. The desiccant material should be
disposed of properly.
9. Refer to the appropriate service
bulletin for checking the filters and
components.
Note
A desiccant Tune-Up Kit Part No.
DAD-600, is available. Contains
the following parts to completely
recondition a desiccant air station:
Part No. Description Qty.
Supplied
DAD-1 Desiccant 1
— Humidity Indicator 1
HAF-6 #1 Filter Element 1
and O-Ring
WARRANTY
This product is covered by DeVilbiss' 1 Year Limited Warranty.
DeVilbiss Sales and Service: www.devilbiss.com
DeVilbiss
DeVilbiss has authorized distributors throughout the world. For technical
assistance or the distributor nearest you, see listing below.
U.S.A./Canada Customer Service Office:
195 Internationale Blvd., Glendale Heights, IL 60139
Toll-Free Telephone: [phone] (U.S.A. and Canada only)
Toll-Free Fax: [phone]
DeVilbiss Automotive Refinishing
DeVilbiss has authorized distributors throughout the world.
For equipment, parts and service, check the Yellow Pages
under “Automotive Body Shop Equipment and Supplies.”
For technical assistance, see listing below.
U.S.A./Canada Customer Service Office:
11360 S. Airfield Road, Swanton, OH 43558
Toll-Free Telephone: [phone] (U.S.A. and Canada only)
Toll-Free Fax: [phone]
5/12 ©2012 DeVilbiss All rights reserved. Printed in U.S.A.