Orion AD-5 User manual

Instruction Manual
Orion Auto Drain Trap
AD-5
CAUTION
●This product is designed specifically for "industrial
purposes; great care must be taken when handling it.
●Please read this manual carefully to ensure correct use
of this product.
●Be sure to keep this manual at hand.

1
Thank you for purchasing one of our products.
We would greatly appreciate your purchasing Orion's product.
To ensure correct use of the product in good condition, please read this manual
carefully and operate it correctly.
Information (mechanisms, specifications, etc.) in this manual is subject to change
without notice; please note that the product may be partly inconsistent with the
manual if this is the case.
To ensure correct use of this product, please read the "Safety Precautions" section
carefully beforehand. The precautions described here are intended to prevent you
and other people around you from incurring danger or damage. Each precaution is
provided with. WARNING or CAUTION.
WARNING Improper handling may cause death or serious injury.
CAUTION Improper handling may cause losses or property damage.
However, if you fail to observe even a precaution provided with CAUTION, you
could encounter a dangerous situation depending on circumstances. Please be
sure to observe both type of the precautions as they contain important information
regarding safety.
●Be sure to keep this manual at hand.
●If you resell or lend this product, please put this instruction manual in plain view
on the product so that the new user will become familiar with safe operation and
correct use.
■Symbols used in this manual
△indicates a warning or a caution. A particular event or action ("blow-off" caution in
the example to the left) may be described in the symbol。
indicates what must not be done. A particular action may be described in or near
the symbol.。
●indicates what must (or should) be done. A particular action may be described in
the symbol.
◎indicates an important item other than WARNING and CAUTION.
Instructions for safe use of this
p
roduct

1
Contents
Safety Precautions...……………………………………………………………………………………2
Locations of warning labels on this product………………………………………………………….3
Precautions that should be observed to obtain best results from this product………………….
.. 4
Part names………………………………………………………………………………………………4
Principle of operation..……….………………………………………………………………………
… 5
How to use this product………………………………………………………………………………
... 6
Installation……………………………………………………………………………………………….7
Inspection and maintenance……………..……………………………………………………………8
How to identify the cause of a problem and Troubleshooting…………………………………….11
Replacement parts and consumable parts…………………………………………………………
. 13
How to install an optional part………………………………………………………………………..14
Storage (if you are not using this product for a long period of time)…………………………
… ..14
Disposal………………………………………………………………………………………………...14
Specifications…………………………………………………………………………………………..15
External dimensions…………………………………………………………………………………..16

2
Safety Precautions
Cautions on using (Warning/ Cautions)
WARNING
Improper handling may cause death or serious injury.
Remove any compressed air from inside the pressure vessel Before
cleaning / maintenance / inspection.
The compressed air, if remained in it, gushes out of it to cause injuries.
Perform correct installation work in accordance with this manual.
Incorrect installation may result in water/air leakage.
Firmly tighten the threaded parts after cleaning / maintenance /
inspection.
If any threaded parts are loose, they may fly out when compressed air Is
supplied, resulting in injury.
Prevent screw thread wear.
If you repeatedly attach and remove the cap with foreign matter on it or its
mating Part of themain body, the thread on the cap may wear very quickly
and it could not work well as aresult. If this happens, the cap may fly out
when compressed air is supplied, resulting in adangerous situation. To avoid
such accidents, be sure to remove any foreign matter from thethreaded parts.
Apply grease to the thread on the cap.
If the thread on the cap rusts out, it cannot be loosened with your hands; it
may Become necessary to disassemble and clean the cap assembly to
remove it. Ifthis is the case, apply grease to the thread and then put the cap
back in place.
Prevent screw thread damage.
Do NOT use any tools to turn the cap; turn it only by hands. If you turn it with
a tool, the thread on the cap may become damaged due to its deformation
depending on the location of the tool on the cap; it could not work well as a
result. If this happens, the cap may fly out when compressed air is supplied,
resulting in a dangerous situation. Do NOT loosen the cap with such a met.
CAUTION
Improper handling may cause losses or property damage.
Do NOT use any fluid other than specified.
Only compressed air can be used. If any other fluid is used, the product may
Become damaged, resulting in an accident such as injury or water leakage.
Perform correct drain piping work.
Incorrect piping may result in water/air leakage.
If you resell or lend this product, be sure to attach this instruction
manual.
If you resell or lend this product, put this manual in plain view on the product
so that the new user will become familiar with safe operation and correct use.
Do not use when there is no water.
Close the valve at inlet of drain trap. Disk and washer may wear abnormally.

3
Safety Precautions
Locations of warning labels on this product
Locations of warning labels on this product
The warning labels illustrated below are regarded as extremely important in consideration of
the major issues that have been reported so far. Be sure to read these labels before use. If the
information on any of the labels cannot be read due to dirt or damage, please contact the
dealer that you purchased this product from and replace them with new ones.
■Caution label (trap)
■Caution label (cleaning)
■Caution label (cap)

4
Disc
Needle valve
Screen
Disc cap
Pipe
Bowl
Bowl guard
Inlet
O-ring
Outlet (water)
Silencer
Cap
Filter packing
Ring
Filter
Disc retainer cap
Washer
Packing
Drain plug
Nipple
Valve hole
Main body
O-ring
Precautions that should be observed to obtain best
CAUTION
●Precautions that should be observed to obtain best results from this product
1.
Be sure to use this product within its allowable ranges; if you fail to do so, it may break down.
Model AD-5
Fluid used Compressed air drainage
Operating pressure MPa 0.29～0.98
Operating temperature ℃ 2～60
2. Do NOT use this product at an ambient temperature of 2℃or lower. If it is used at 2℃or
lower, the water trapped in this product may freeze. If you have no other choice but to do so,
wrap an antifreeze band around its front and rear pipes as well as the entire Auto Drain
Trap.
Part names

5
Disc
Needle valve
Disc cap
Bowl
Inside the bowl: A
Outlet (water)
Inside the cap: B
Auxiliary pipe
Disc
To exit To exit
Disc cap
From bowl
Pressure
equalizing
hole
③
From bowl
Into cap
Principle of operation
1. A small amount of air leaks from inside the cap through the auxiliary pipe, flowing to the
drainage side; the pressure inside the bowl (A) gradually becomes higher than that inside
the cap (B).
2. Disc moves up due to the pressure difference.
3. Air (drainage) flows towards the drain outlet while the disc moves up inside the disc cap.
When the disc has reached its highest position, air leaks into the cap through the pressure
equalizing hole, making the pressure inside the bowl (A) equal to that inside the cap (B).
4. The pressure in the area under the disc temporarily lowers at the moment the drainage flows
out towards the outlet; the disc moves down when subjected to the downward pressure
generated by the pressure difference.
5. Steps 1 to 4 repeatedly occur.
6. Intervals of operation vary according to conditions (load, pressure, etc.). As the valve is
turned inthe plus (＋) direction indicated on the main body (counterclockwise), shorter
intervals of operation are obtained. Conversely, as it is turned in the minus (−) direction
(clockwise), longer intervals are obtained. Make adjustments if necessary.

6
Needle
valve
Drain
plug
How to use this product
CAUTION
●If drainage amount from compressed air is a little, the following phenomena may be induced.
1. Unusual wear of Disc
2. Shortening of Interval of drainage
3. Acceleration of wear of Disc
4. Continuous blow-off from this drain trap
In cases like the above, do not keep using this drain trap. Or continuous blow-off will happen
extremely earlier.
To dissolve it, replace this drain trap with an Electrical Auto Drain Trap or with a Float type
Auto Drain Trap. Or close Ball Valve, equipped between Air Dryer and this drain trap, during
there is no compressed air flow.
●If the product is installed at the place where too much oil mist exist, the following phenomena
may be induced.
1.Drainage will deerease.
2.Intervals of drainage become longer.
In case of installation where too much oil mist exist, adjust the needle regarding to
“important” below.
1. Adjusting the quantity of drainage water
With this drain trap, intervals of operation vary according to conditions (load, pressure, etc).
To prevent the bowl from being filled with water, adjust the needle valve.
●Adjusting intervals of drainage
The quantity of drainage water varies according to use conditions
(operating pressure, etc.); adjust the intervals of drainage with
the Auto Drain Trap's needle valve. Adjustments should be made
so that the level of water in the bowl is visible from outside (i.e.,
the bowl is not filled with water). Too short intervals of drainage will
consume much extra air.
Conversely, too long intervals will accumulate much drainage. As
the needle valve is turned in the plus (＋) (open) or minus (−)
(close) direction, shorter or longer intervals are obtained,
respectively.
●Regarding the needle valve
Do NOT forcibly turn the needle valve in the minus (−) direction; this may Cause damage to
its internal parts and drainage could be continuously discharged as a result.
●Sounds generated during drainage
If you prefer a quieter system for environmental reasons, it is recommended to install an
optionally available muffler (for AD-5); or use a float type Auto Drain Trap (FD-10-A) in
place of this product. For details, see the optional parts, consumables, and replacement parts
on page 12 and contact the dealer that you purchased the product from.
●Regarding intervals of drainage
Intervals of operation were set to 25 to 37 per 30 seconds (0.59 MPa) prior to shipment
(only compressed air can be used for operation). The continuous blow-off time setting is 3
seconds or less. Intervals may vary in the course of operation and continuous blow-off could
occur; however, this is not a failure.

7
Installation
Installation location
Installation location
1. Make sure that the incoming air and ambient temperatures are 60℃or lower.
2. Do NOT use this product at an ambient temperature of 2℃or lower. If it is used at 2℃or
lower, the water trapped in this product may freeze. If you have no other choice but to do so,
wrap an antifreeze band around pipes upstream and downstream of tje trap as well as
around the entire Auto Drain Trap.
●Some plastic parts are used in this product. Make sure the product is free from drainage/air
containing any of the substances listed below. In addition, the installation location must be
free (or protected) from direct sunlight.
Kind of
chemicals
Classification of
chemical agents
Main products of
chemical agents
Examples of general
applications
Inorganic
chemicals Acids
Hydrochloric acid, sulfuric acid,
hydrofluoic acid, phosphoric
acid chromic acid, etc.
Metal pickling solution,
acidic degreasing liquid,
coating process liquid,
etc.
Organic
chemicals
Aromatic
hydrocarbon
Benzene, toluene, xylene,
ethylbenzene, styrene, etc.
Included in thinner for
paints
Alcohols
Metyl alcohol, ethyl alcohol,
cyclohexanol, and benzyl
alcohol
Used as antifreezing
agent Leak detection
liquid
Phenols Carbolic acid, creosol,
naphthol, etc.
Antiseptic solution and
phenol resin raw
material
Ketones
Acetone, methyl ethyl ketone,
cyclohexanone, acetophenone,
etc.
Carboxylic acid
Formic acid, acetic acid, butyric
acid, acrylic acid, oxalic acid,
phthalic acid, etc.
Dye, base agent of
aluminum processing
agent coating, and leak
detection liquid
Oxyacids Glicolic acid, lactic acid, malic
acid, and citric acid Additives to foods etc.
Amines
Methylamine, dimethylamine,
ethylamine, aniline,
acetoanilide, etc.
Additive agent to brake
oil, antistatic agent, and
plastic dyes

8
Piping must be
Performed after
pressure is
released into the
air.
In case of piping
Installation
Installation method
CAUTION
●Perform correct drain piping work.
Incorrect piping may result in water/air leakage.
Installation method
■Diameters of connected pipes
■Installation and drain piping
1. Direct the drain outlet downward and install the entire body
in a vertical position.
2. Be sure to attach a stop valve to the drain inlet. This makes
it possible to remove the Auto Drain Trap for maintenance
even with the pipes under pressure. If the Auto Drain Trap's
drain pipe has a rising portion or it is too long, it may not
drain well due to back pressure.
Daily inspection and maintenance
WARNING
●Remove any compressed air from inside the Auto Drain Trap before cleaning / maintenance /
inspection.
Criteria for daily inspection and maintenance
Inspection of Auto Drain Trap Once a day
Disassembly and cleaning
of Auto Drain Trap Inside of the cap and bowl Once a month
●Timing for disassembly & cleaning differs according to installation conditions. Determine
when to perform maintenance operations in consideration of daily inspections.
Diameter of pipe connected to drain inlet Rc 1/2
Diameter of pipe connected to drain outlet Rc 1/2

9
Ball
valve
Auto drain trap
Drain
plug
Disc
Disc cap
Cap
Filter
Disc retainer cap
Washer
Threaded
parts of
the cap
Valve hole
Main body
Packing
O-ring
Disc
Disc cap
Threaded part Grooved side
Main body
Washer
Packing
Daily inspection and maintenance
Daily inspections / Monthly maintenance
Daily inspections
■Inspection of Auto Drain Trap
Visually inspect the Auto Drain Trap every day.
・Check air is not leaking (except outlet).
・Check that the Auto Drain Trap operates correctly (drains water at regular intervals).
・Check that no foreign matter is accumulated in the bowl.
Monthly maintenance
■Disassembly and cleaning of Auto Drain Trap
Each of its parts becomes dirty after long hours of use; it will not
operate correctly.To avoid this problem, remove and disassemble
the Auto Drain Trap and clean it once a month.
1. Required cleaning tools:
・Washing brush ・Small parts container ・Air gun
2. Remove any compressed air from inside the Auto
Drain Trap.
(1) Close the ball valve.
(2) Turn the drain plug clockwise to loosen it.
Water in the bowl and compressed air will be
removed from the Auto Drain Trap.
3. Disassembly and cleaning of cap
(1) Turn the cap counterclockwise to remove it.
(2) Remove any foreign matter rom the filter with
air blow.
(3) Wash the disc and disc cap.
(4) Remove any foreign matter from the valve
hole with air blow.
(5) Clean the threaded parts of the cap and main
body.
(6) Check for damaged parts .
※Worn disc, deformed packing/washer,
worn thread on cap, worn disc cap
retainer, etc.
(7) Assembling procedure
・Perform the disassembling procedure in reverse order.
・When attaching the disc, make sure that its grooved side
is directed downward.
・Attach the packing first and then the washer to the disc cap
(i.e., washer is located on top of the packing) (see the figure
to the right).
・Wipe the threaded parts of the cap and main body carefully
with a rag, and apply grease to them, and then screw them
with hands.

10
Screen
BowlO-ring
Ring
Threaded part
Daily inspection and maintenance
Monthly maintenance
4. Cleaning of inside of bowl
(1) Turn the ring counterclockwise to remove it.
(2) Remove any foreign matter from the screen with air blow.
(3) Flush the bowl with water and wipe it dry with aclean cloth.
Do NOT use any detergent to clean the bowl.
This may result in a broken bowl.
(4) Check for damaged parts.
In particular, the O-ring must be checked; use of a
Damaged O-ring may result in air leakage.
(5) Assembling procedure
・Perform the disassembling procedure in
Reverse order.
・If it is hard to screw in the ring, apply grease, etc.
to its threaded part and then screw it in with hands.
5. If air leaks after the cap and ring have been screwed in
by hand, the following parts may Be worn; replace them.
(1) Washer (2) Packing (3) Cap (disc retainer) (4) O-ring
●Some plastic parts are used in this product. Make sure the product is freefrom drainage/air
containing any of the substances listed below. In addition, the installation location must be
free (or protected) from direct sunlight.
Kind of
chemicals
Classification of
chemical agents
Main products of
chemical agents
Examples of general
applications
Inorganic
chemicals Acids
Hydrochloric acid, sulfuric
acid, hydrofluoic acid,
phosphoric acid chromic acid,
etc.
Metal pickling solution,
acidic degreasing liquid,
coating process liquid,
etc.
Organic
chemicals
Aromatic
hydrocarbon
Benzene, toluene, xylene,
ethylbenzene, styrene, etc.
Included in thinner for
paints
Alcohols
Metyl alcohol, ethyl alcohol,
cyclohexanol, and benzyl
alcohol
Used as antifreezing
agent
Leak detection liquid
Phenols Carbolic acid, creosol,
naphthol, etc.
Antiseptic solution and
phenol resin raw material
Ketones
Acetone, methyl ethyl ketone,
cyclohexanone,
acetophenone,
etc.
Carboxylic acid
Formic acid, acetic acid,
butyric acid, acrylic acid,
oxalic acid, phthalic acid, etc.
Dye, base agent of
aluminum processing
agent coating, and leak
detection liquid
Oxyacids Glicolic acid, lactic acid, malic
acid, and citric acid Additives to foods etc.
Amines
Methylamine, dimethylamine,
ethylamine, aniline,
acetoanilide, etc.
Additive agent to brake
oil, antistatic agent, and
plastic dyes

11
Bad example Good example
Use of a tool
Clearance No clearance
Screen
Pipe
Main body
Daily inspection and maintenance
Monthly maintenance
●If you loosen the cap by a tool applying force to its dodecagonal portion the thread on the cap
may become damaged due to its deformation; it could not work well as a result.
Do NOT loosen the cap with such a method.
●If the cap fails to be completely screwed in, the disc cap may move up and down and the disc,
washer, packing, cap, etc. could become damaged as a result.
Completely screw in the cap with your hands to hold the disc cap in place.
●When removing the screen, pull it straight downward to remove it. if you move it from side to
side, the pipe may become damaged.
Troubleshooting
WARNING
●Remove any compressed air from inside the Auto Drain Trap before cleaning/maintenance.
If there is any residual compressed air in it, its parts may fly out, resulting in injury.
●If the problem cannot be solved by disassembly & cleaning and/or part replacement, please
contact either the dealer that you purchased this product from or a qualified service company.

12
Troubleshooting
How to identify the cause of a problem
How to identify the cause of a problem
■If the bowl is not drained of water:
■If the Auto Drain Trap keeps discharging without a break:
■If air is leaking:
Is the disc
operating ?
Disc is clogged.
YES
No
Screen is clogged. Wash the inside of the
Bowl and ca
p
.
Wash the inside of the
Bowl and cap.
Valve hole is clogged. Wash the valve hole and
give air blow.
Filter is clogged. Wash the filter and
give air blow.
Washer and packing
Are worn or dama
g
ed.
YES
No
Replace the main body.
Replace the washe
r
And packing.
Disc is worn or damaged. Replace the disc.
Needle valve is worn or
damaged. Replace the needle valve.
Disc is not operating
correctly. Wash the inside of the bowl
and cap.
Washer, packing, cap, and/or
O-ring are worn or degraded.
Replace the washer,
packing,
Main body is worn
or dama
g
ed.
Is the disc
operating ?

13
Replacement parts
■Parts that need inspection and replacement
Replace the parts listed below if they are judged to need replacement during disassembly and
cleaning.
(Disc, packing, washer, O-ring, filter, cap, and main body.)
■When to replace them:
Part name To be replaced at intervals of:
Filter 1.5 years
Packing 6 months to 1 year
Washer 6 months to 1 year
Disc 1 to 1.5 years
Cap, main body 4 or 5 years
O-ring 1.5 years
No. Part name Part number
*Muffler assembly option
1 Main body assembly 04032157010
2 Cap 04009368010
3 Disc 04080758010
4 Disc cap 04009370010
5 Filter 04009371010
6 Filter packing 04009372010
7 Ring 04009373010
8 Bowl 04009374010
9 Bowl guard 04009375010
10 Locking nut 04009376010
11 Needle valve 04009377010
12 Drain plug 04009378010
13 Nipple 04009381010
14 Screen assembly 04009383010
15 Street elbow 50000904110
16 O-ring 35155641000
17 O-ring 35155004000
18 O-ring 35154500000
19 Silencer 04009380010
20 Packing 04090331010
21 Washer 04090332010
22 Muffler assembly* 03006716010
23 Caution label 04040963010
*Timing for replacement differs according to installation and operational conditions. If there is
less oil in drainage, the parts may need to be replaced at shorter intervals. This also applies in
case of less drainage in compressed air.
*When ordering parts, please inform us of the part names, part numbers and the quantities of
them.
*Please note that to make improvements, its mechanisms and specifications are subject to
change without notice.
2
6
5
21
20
4
3
16
1
14
16
8
9
23
7
12
17
10
18
11
15
19
13

14
Street elbow
Ball valve
Close
Silencer
Nipple
Drain plug
Muffler
Silencer
Nipple
How to install an optional part
Installing a muffler assembly (part No. 03006716010)
1. Remove any water from the Auto Drain Trap.
(1) Close the ball valve.
(2) Loosen the drain plug.
2. Remove the street elbow.
(1) Remove the silencer and nipple from the street
elbow.
3. Attach the muffler.
(1) Connect the muffler's IN port to the outlet of the
main body.
(2) Connect the silencer and nipple to the muffler's
OUTport.
*Completely installed muffler assembly is shown to
the right.
Storage (if you are not using this product for a long)
1. Drain the Auto Drain Trap.
Remove any water from the Auto Drain Trap.
Turn the drain plug--which is located at the bottom of the Auto Drain Trap--in a clockwise
direction to remove the water accumulated in the bowl.
●If you fail to remove the water, the internal parts of the Auto Drain Trap may become
damaged due to corrosion and it could fail as a result.
2. Disassemble and clean the Auto Drain Trap.
Follow the procedures described in the "Daily inspection and maintenance" section, page 7,
to clean the Auto Drain Trap.
3. Store the Auto Drain Trap in an appropriate place.
Make sure that it is not exposed to foreign matter, dust, rainwater, moisture, etc.
Disposal
■Please collect a refrigerant before disposing of this plane. The basis comes in a law / the
regulations of the country (an area) to use, and please handle the disposal of refrigerant
which I collected adequately.

15
After-sale Services
■Before you request inspection or repair
・Check and take actions according to the instructions under "Troubleshooting".
・If such actions are to no avail, or if you have questions concerning the product handling,
contact your dealer rather than attempting to fix it yourself.
■About functionality service components:
・Functionality service components are parts required for maintaining the product's
functionality.
・Orion will maintain the functionality service components for this product for at least 7 years
after its production termination.
■How to request after-sale services
・To request inspection or repair, contact your dealer and provide the following information.
(1) Product name
(2) Model name (as stated on the identification plate)
(3) Nature of concern (in as much detail as possible)
(4) Directions to your site location
・To place order for replacement parts, provide the following information:
(1) Product name
(2) Model name (as stated on the identification plate)
(3) Part names, part numbers and the quantity required
Specifications
Model AD-5
Operating principle Disk type
Operating
range
Allowable pressure range
(gauge) MPa 0.29 to 0.98
Allowable ambient temperature deg. 2 to 60
(Freezing to be avoided)
Applicable medium Compressed air
Performance Maximum discharge (drain) L／Hr 450 (at 0.69 MPa)
Discharge (air) L／min 18 (at 0.69 MPa)
Connection
diameter
Drain inlet Rc1／2
Drain outlet Rc1／2
Dimensions
Dimension (W×H) mm 86×198
Weight kg 1.2
Flow path minimal diameter mm φ3.5

16
External dimensions
Unit : mm

K No.0544 ’13.7.12 C TG TY