GUSMER OP155 User manual
"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
2OP155, Issue 2
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
Operating Manual with Parts Identification Contents
6/15/98 3
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
Air Dryer
4OP155, Issue 2
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
Operating Manual with Parts Identification General Safety Information
6/15/98 5
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.
Air Dryer
6OP155, Issue 2
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.
Operating Manual with Parts Identification Specifications
6/15/98 7
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
Operating Manual with Parts Identification Normal Operating Procedure
6/15/98 9
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 color-
coded 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.
The Air Dryer is now ready for operation
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.
Air Dryer
10 OP155, Issue 2
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.
Operating Manual with Parts Identification Maintenance
6/15/98 11
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.
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.
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.
Operating Manual with Parts Identification Parts Identification
6/15/98 13
TABLE 3. AIR DRYER ASSEMBLY (PART NO. OP155) PARTS
Reference
Letter Part No. Description Qty.
A0375-2 Street Elbow 1
B0561 Hex Nipple 3
C0562-11-3 Flat Washer 2
D0576 Pipe Plug 2
E1253 Air Hose Assembly 2
F3145-2 Coupler 2
G4402-2 External Tee 1
H4701-5 Button head Cap Screw 2
JOP154B-21-1 Pressure Relief Valve 2
KOP155-1 Bracket 1
LOP155-2 Dryer with 1 Qt. Desiccant 1
MOP155-3 Prefilter 1
NOP155-4 Manifold 2
POP155-5 Pressure Regulator 1
QOP155-6 Pressure Gauge 1
ROP155-7 Tube Fitting 1
SOP155-8 Tube Elbow 1
TOP155-9 Tubing 1’
UOP155-10 Pipe Tee 2
VOP155-11 Check Valve 2
WOP163 Drum Adapter 2
XOP219-4 Socket Head Cap Screw 1
Air Dryer
14 OP155, Issue 2
Figure 4. Drum Adapter (Part No. OP163) Exploded View
TABLE 4. DRUM ADAPTER (PART NO. OP163) PARTS
Reference
Letter Part No. Description Qty.
A0561 Hex Nipple 1
B3145-1 Coupler Plug 1
COP154-12 Reducing Coupling 1
DOP154-15 Nipple 1
EOP154-16 Shut off Valve 1
Operating Manual with Parts Identification Instruction Manual Discrepancy Report
6/15/98 15
INSTRUCTION MANUAL DISCREPANCY REPORT
Field
Number Field Title Description
1Date
2Name
3IM Number
4Issue Number
5Date of Issue
6Page Number
7Discrepancy
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
Air Dryer
16 OP155, Issue 2
Field
Number Field Title Description
1Date Enter date report is submitted.
2Name Enter name of person making report.
3IM Number Enter the Part Number of the Instruction Manual from the title page.
4Issue Number Enter the Issue number of the Instruction Manual from the title page. If there is no
issue number, enter NONE.
5Date of Issue Enter the date of Issue of the Instruction Manual from the title page. If there is no
issue date, enter NONE.
6Page Number Enter the page number containing the discrepancy
7Discrepancy Provide a brief description of discrepancy
NOTE: You may send a marked copy of the page as an attachment to your
submittal.
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