Puregas P05860-GLTG Use and care manual

Made in USA P011641 Rev –C-
OPERATING INSTRUCTIONS
AND PARTS LIST FOR
P05860-GLTG
Nitrogen Bottle Replacement Units

PREFACE
Please direct all inquiries to:
PUREGAS Service Department
226A Commerce St.
Broomfield, CO 80020
1-800-521-5351 or [phone]
This instruction manual is for the benefit of our customers. It is intended to provide the
basic information that will enable our customers to install, maintain and service
PUREGAS air dryers economically, capably, and with minimum delay. Careful
observation of the instructions and maintenance procedures will ensure maximum life and
efficiency of the unit.
This manual should be read thoroughly before installing operating, or servicing the air
dryer to familiarize the technician with the unit and the proper operating procedures. This
will minimize the possibility of damage to the unit due to improper operation and handling
or disassembly.
NO PART OF THIS MANUAL MAY BE REPRODUCED WITHOUT
THE EXPRESS WRITTEN CONSENT OF PUREGAS.
KEEP THIS MANUAL FOR FUTURE REFERENCE.

LIMITED WARRANTY AGREEMENT
Puregas Air Dryers carry a one-year warranty against defective workmanship and material.
This period starts at the date of shipment. Not included are the components subject to normal
replacement during a year’s operating time. These parts include, but are not limited to;
electrical components, pressure switches, pressure regulators, and air compressors which
carry a one-year warranty.
On refrigeration type air dryers, the basic refrigeration circuit carries a five-year warranty.
This warranty covers the refrigeration compressor, refrigeration tubing and coils but NOT the
thermostat, thermometer, or fan motor.
Liquid ring compressors, heatless dryers and circuit boards carry a two-year warranty.
No claims for labor in replacing defective parts or for consequential damages will be
allowed. Replacement parts will be invoiced in the regular way, with invoices subject to
adjustment after the parts claimed defective are examined at our factory. In addition, no
material or parts will be accepted at our factory for in-warranty repairs or credit without
previous authorization from Puregas.
Responsibility for damages incurred in transit will be borne by the user and the user in turn
should file any damage claim against the carrier. All warranty items are F.O.B. our plant.
Freight charges are the responsibility of the user.
This warranty shall not apply to any air dryer which shall have been repaired or altered in any
way by anyone other than Puregas so as to affect, in our judgment, its proper functioning or
reliability, neither will it apply to a dryer which has been subject to misuse, negligence or
accident.
THE INSTALLING OF PARTS PURCHASED FROM OTHER THAN PUREGAS WILL
VOID THE WARRANTY ON OUR AIR DRYERS.

PUREGAS INSTRUCTION MANUAL
MODEL P05860-GLTG
TABLE OF CONTENTS
SECTION 1 -GENERAL .............................................................................................1
SECTION 2 - INSPECTION AND INSTALLATION..............................................2
2.1 Initial Inspection................................................................................... 2
2.2 Installation............................................................................................. 2
2.3 Electrical Requirements....................................................................... 2
SECTION 3 - PRINCIPLES OF OPERATION........................................................3
3.1 Air System ............................................................................................. 3
3.2 Air Compressor..................................................................................... 3
3.3 Pressure Switch, and Safety Relief Valve........................................... 3
3.4 Air Buffering Dryer.............................................................................. 3
3.5 Manual Drain Valve ............................................................................. 3
3.6 Water Drain Instructions..................................................................... 3
SECTION 4 - GENERAL MAINTENANCE.............................................................4
4.1 Nitrogen Bottle Replacement Module................................................. 4
4.2 Air Compressor Safety Valve.............................................................. 5
4.3 Air Compressor Pressure Switch........................................................ 5
4.4 Air Compressor Troublshooting Chart.............................................. 6
4.5 Air Compressor Maintenance ............................................................. 7
4.6 Air Compressor Disassembly............................................................... 8
4.7 Air Compressor Assembly................................................................... 8
4.7 Air Compressor Assembly (continued)............................................... 9
4.8 Air Buffering Dryer.............................................................................. 9
4.9 Recommended Spare Parts List............................................................ 9
SECTION 5 – TROUBLESHOOTING INFORMATION GUIDE.......................13
FIGURES
WIRING DIAGRAM ...........................................................................................2
FLOW DIAGRAM ...............................................................................................4
AIR COMPRESSOR PRESSURE SWITCH ....................................................5
EXPLODED VIEW OF COMPRESSOR AND MOTOR ASSEMBLY.........10
AIR DRYER..........................................................................................................11
NBRM PARTS IDENTIFICATION...................................................................12
CHARTS
MODULE SPECIFICATIONS............................................................................1
AIR COMPRESSOR TROUBLESHOOTING CHART..................................6

1
PUREGAS INSTRUCTION MANUAL
MODEL P05860-GLTG
NITROGEN BOTTLE REPLACEMENT MODULE
SECTION 1 -GENERAL
This instruction manual covers the description, installation, operation, maintenance and,
service part identification for the P05860-GLTG Nitrogen Bottle Replacement Modules
(NBRM). The P05860-GLTG are self-contained, assembled and tested units, designed to
effectively replace the nitrogen bottle for dry air buffering and pneumatic tool applications.
The P05860-GLTG models can be installed in a nitrogen bottle rack in a truck.
The ratings, characteristics and features for the Nitrogen Bottle Replacement Module are
specified below.
NITROGEN BOTTLE REPLACEMENT
CHART 1
MODULE SPECIFICATIONS
Specifications
SIZE: 12” wide x 11.5” high x 64.25” long
NET WEIGHT: 140 lbs. (63.5 kg)
ELECTRICAL: GLTG – 220 VAC, 1 PH, 60 Hz, 10.6 amps
DEWPOINT: -40
oF
DESICCANT: capable of drying 4400 standard cubic feet of
saturated air at 70 oF to an effluent output
dewpoint of below –40 oF. The color-indicating
desiccant can easily be replaced after saturation
(color changes from blue to pink when desiccant
is saturated)
AIR COMPRESSOR: Four cylinder, oilless type, 1.5 hp,
output capacity of 5.0 cfm at 100 PSIG
OPERATING PRESSURE: 80 to 110 PSIG

2
SECTION 2 - INSPECTION AND INSTALLATION
2.1 Initial Inspection
Before installing unit, carefully inspect for shipping damage.
2.2 Installation
The module must be installed inside the vehicle compartment to prevent weather damage. The
optimum operating temperature range is between 40 to 95 oF. Although the unit will operate at
higher temperatures, the operating life of the compressor decreases dramatically.
2.3 Electrical Requirements
Refer to Chart 1 for product specific electrical requirements. The recommended generator size
is 4.0 kW. Refer to Figures 1, 2, and 3 for electrical hookup.
Figure 1
WIRING DIAGRAM
NOTE:
Shipping damage must be brought to the immediate attention of the carrier.
CAUTION!!!
Condensation in the storage tank must be drained to prevent freezing.
NOTE:
Adequate power is required for ALL equipment being used when
using a portable generator.

3
SECTION 3 - PRINCIPLES OF OPERATION
3.1 Air System
The air flows from the air compressor to the storage tank and then to the air buffering dryer.
Drying steps involved are summarized as follows:
3.2 Air Compressor
Ambient air is drawn through the intake filters of the air compressor and is compressed to
approximately 80-110 PSIG in the storage tank.
3.3 Pressure Switch, and Safety Relief Valve
The air pressure in the storage tank is controlled by the unloader pressure switch. The
pressure switch starts the air compressor at 80 PSIG and stops it at 110 PSIG. This unloader
pressure switch releases the static air from the air compressor discharge line, allowing for
easy start-up. The inline check valve prevents the air from flowing out of the tank back
through the compressor after the compressor has shut off. The tank pressure safety relief
valve is factory preset to prevent pressure building above 165 PSIG.
3.4 Air Buffering Dryer
Air now flows from the air storage tank to the air buffering dryer which uses silica gel to
remove the moisture. The silica gel is dry when it is a blue color. If the silica gel turns pink,
it must be replaced. Refer to Figure 7.
3.5 Manual Drain Valve
The manual drain provides a means of draining water from the storage tank. The water
should be drained each day after the unit has been in service.
3.6 Water Drain Instructions
With at least 20 PSIG pressure in the storage tank, slowly open the water drain valve
allowing water to drain from tank; close the water drain valve when all moisture or water has
drained. Repeat Procedure as needed. Refer to Figure 7.
NOTE:
Never operate system with the safety relief valve removed from the tank.
DO NOT make adjustments to this valve. This is an A.S.M.E. requirement and
MUST NOT be tampered with.
NOTE:
Important to keep tank drained under freezing conditions.

4
Figure 4
FLOW DIAGRAM
SECTION 4 - GENERAL MAINTENANCE
4.1 Nitrogen Bottle Replacement Module
The Nitrogen Bottle Replacement Module requires minimal maintenance. The following
paragraphs provide procedures for routine maintenance of various parts. If further assistance
is required, contact, Puregas Technical Service Department at
1-800-521-5351 or [phone].
The tank pressure MUST BE RELEASED before attempting to service any components.
Use either the drain valve, or the tank relief valve on the air tank.
Check the following:
9Safety valve - Refer to Paragraph 4.2.
9Pressure Switch - Refer to Paragraph 4.3.
9Install Compressor Maintenance Kit (P07102) - Refer to Paragraph 4.5.
9Check all wire connections.
9Soap test all pressure fittings.
CAUTION!!!
Release all tank pressure using either the drain valve or the
Tank relief valve prior to servicing any components.
CAUTION!!!
DISCONNECT POWER When working around energized circuits,
extreme caution should be taken to prevent injury to
personnel and damage to equipment.
CAUTION!!!
It is very important that routine maintenance be performed on the
compressor each year, or every 4,000 hours.
check valve

5
4.2 Air Compressor Safety Valve
The air compressor safety valve, located on the head of the air compressor, is factory preset
to prevent the air compressor from delivering air over 115 PSIG(+/- 2 PSIG). Check for
proper operation. If adjustment is required, use the following procedure while the
compressor is operating.
A. Adjust pressure switch cut out to 115 PSIG. Refer to Figure 5.
B. Referring to Figure 6, loosen the safety valve lock nut and adjust the nut until the
maintained pressure is 115 PSIG and the relief valve is releasing air.
C. Allow the compressor to cycle through the cycling pressure range several times and
soap test to insure the safety valve is tight and does not leak.
D. If the safety valve is defective and requires changing, always check replacement
valve for proper adjustment.
E. Readjust air compressor pressure switch cut out to 110 PSIG.
4.3 Air Compressor Pressure Switch
The pressure switch is factory set to stop and start the air compressor and maintain the
pressure in the air storage tank. The pressure in the air storage tank will cycle between 80
PSIG(+/- 2 PSIG) and 110 PSIG(+/- 2 PSIG) as noted on the tank pressure gauge. To adjust
the ON/OFF pressure switch, refer to Figure 5 below.
Step 1: Turn clockwise to increase
both cut-out and cut-in pressure.
Step 2: Turn clockwise to increase
cut-out pressure without affecting
cut-in pressure.
Figure 5
Air Compressor Pressure Switch

6
4.4 Air Compressor Troublshooting Chart
CHART 2
Air Compressor Troubleshooting Chart
COMPLAINT
REASON Low
Pressure
Overheating
or
Excessive
Excessive
Noise Won't Start Under Load
worn piston rings X
worn rider rings X piston hitting
cylinder
dirty valves X
bent valves X
blown head
gasket Xair blowing out
intake filter
dirty filters X
low voltage X X
cylinder mis-
adjustment piston hitting intake valve piston hitting intake valve X
leaky connections X
relief valve set too
high X
relief valve set too
low X
wrong voltage
hook-up XXX
dirt or liquid in top
of piston XX XX

7
4.5 Air Compressor Maintenance
The P07102 maintenance kit contains parts necessary for scheduled routine maintenance on
the nitrogen bottle replacement module when operated under normal conditions. Refer to
Figure 6. The contents of the maintenance kit are as follows:
If the air compressor shows evidence of overheating or excessive noise, stop immediately for
repairs.
Regular inspection may prevent expensive repairs. The rider ring thickness can indicate
when the air compressor needs maintenance. If a rider ring measures .055 inches or less in
thickness, the maintenance kit, P07102 should be installed. The thickness of a new rider ring
is .060 inches.
The wear of the air compressor rings are affected by ambient conditions. At 80 oF. maximum
ambient temperature and relative humidity 40% maximum average, it is suggested the
compressor life between maintenance be approximately 4,000 hours of run time.
The air compressor is oilless and requires no lubrication. It is recommended the piston rings,
piston seals, rider rings, inlet valves, valve plates and gaskets be replaced at 4,000 hours of
run time.
Part Number Description QTY/Kit
P3861 pistonseal 8
P3862 pistonring 8
P3864 manifold sleeve 5
P3866 head gasket 4
P3867 outlet valve 4
P3868 inlet valve 4
P3869 cylinder gasket 4
P3870 valve plate 4
P3981 rider ring 4
P3986 filter felt 4
NOTE:
At higher ambient temperatures, maintenance
must be performed more frequently.

8
4.6 Air Compressor Disassembly
A. Remove or loosen the four screws which secure the fan shroud to the motor and slide
the shroud off. Remove the four cylinder head bolts and separate them from the
cylinder bolts. Remove the air manifold tube and the cylinder head with the valve
components.
B. Remove the two cylinder bolts at the motor and lift the cylinder off the piston.
C. Remove the piston rings, seals and rider rings.
D. The head gaskets may have become firmly attached to the flat surfaces of cylinder
heads or cylinders. Remove the old gasket material. Use No. 240 grit emery cloth
(or wet/dry abrasive material) to flat sand the cylinder surfaces. Follow with No. 400
grit emery cloth (or wet/dry) to dress these flat surfaces before reassembly with new
gaskets.
4.7 Air Compressor Assembly
A. Install the new piston springs, rings and rider rings on the piston. Locate the piston
ring joints approximately opposite each other.
B. Attach cylinder to motor with cylinder bolts and lock washer and finger tighten bolts.
Move the piston to the top dead center position and adjust the cylinder flush with the
top of the piston.
C. Install valve components, gaskets and valve plates by lining them up as outlined in
Figure 6. Valves are pre-lined in the maintenance kit; however, they should be
checked. The leaves of the intake and discharge valves have been pre-bent and do not
require adjusting.
D. Install the head assembly using the four heat bolts and finger tighten.
NOTE:
Clean all components with a non-flammable, non-toxic cleaning solvent.
DO NOT FLOOD THE PISTON WRIST PIN, OR CONNECTING ROD
MAIN BEARING WITH SOLVENT OR THE PERMANENT
LUBRICANT WILL BE WASHED AWAY.
NOTE:
Top dead center can be checked by using a straight edge across the
cylinder head and then moving the piston flush with the straight edge.
Move the piston up and down to insure there is no binding in the cylinder
and tighten the cylinder bolts.
NOTE:
The ends of the two fins on the cylinder head have been omitted.
They are always on the exhaust port.

9
4.7 Air Compressor Assembly (continued)
E. Install new manifold seals on the manifold and assemble to the elbow fitting on the
head assembly. DO NOT TIGHTEN.
F. Install the second head assembly and assemble the manifold. Tighten all head bolts
and manifold nuts.
G. Install maintenance kit on remaining half of air compressor.
H. Soap test all fittings with compressor running.
4.8 Air Buffering Dryer
The air buffering dryer does not require maintenance, other than changing the silica gel. The
silica gel only needs to be changed if the blue color turns to pink. The air buffering dryer
contains 1.67 lbs. of silica gel.
4.9 Recommended Spare Parts List
Quantities listed are recommended spare parts for one or more nitrogen bottle replacement
units. Refer to Figure 8.
Call Puregas Service Department at 1-800-521-5351 for ordering information.
Description Part No.
instruction manual P011641
air dryer bracket P03308
air dryer P03311
ASME air tank P05814P
front panel P010465
unloader pressure switch P011548
air dryer o-ring P06771
pressure gauge P010167
check valve P3877
compressor GLTG P08391
frame weldment P010402
maintenance kit P07102
compressor discharge line P010161F4
silica gel - 1.75 lb. can P8030A
drain valve P3757
safety relief valve P500066
air tube P010161F6
quick connect PAT10508

10
Figure 6
Exploded View of Compressor and Motor Assembly
Ref.
No. Part No. Description QTY Ref.
No. Part No. Description QTY
1 P02619 air intake filter 4 26 P3862 piston ring 8
5 P3986 felt filter 4 27 P3861 piston seal 8
9 P3998 pipe plug 4 28 P3872 piston rod assy. 4
10 ref elbow, 1/4" 1 29 P3981 rider ring 4
11 P02209 safety valve 1 30 P03069 eccentric 4
12 ref (included in #11) 1 31 ref square key 2
13 ref (included in #11) 1 32 ref retaining ring 2
14 ref (included in #11) 1 33 P02210 fan, CW 1
15 ref (included in #11) 1 34 P02211 fan, CCW 1
16 ref (included in #11) 1 35 P02212 fan shroud 2
17 ref (included in #11) 1 36 ref shaft adapter 2
18 P4024 manifold elbow 4 37 P02213 manifold sleeve 4
19 P3875 cylinder head 4 38 P02214 manifold 2
20 P3866 head gasket 4 45 P4043 manifold nut 4
21 P3867 outlet valve 4 P3979 cylinder screw 8
22 P3870 valve plate 4 P4025 head screw 16
23 P3868 inlet valve 4 P4026 lock washer 24
24 P3869 cylinder gasket 4 P4033 fan shroud screw 8
25 P3874 cylinder 4
1716 15
14
13 12
11 9
1
26
30
31
36
32
34
35
26 28
9
40 39
41
1
27
44
45
43
18 37 45
38
4529
30 29
27
26
28
30
36 32
18
9
910
1
45 37
29
30 29
27 18
1
9
18 37 45
38
45 37
20 21 22 23 24 25
26
27
33
35
31
28
19
37
28

11
*NNR : not normally replaced
FIGURE 7
AIR DRYER
Description Part No.
screen P07149
o-ring kit P07148
air dryer o-ring P06771
transparent bowl P07147
siphontube and screen P07146
bowl guard P07145
palnut PS344
screen
*NNR
*NNR
o-ring kit
siphon tube and screen
bowl guard
air dryer o-ring
transparent bowl
pal nut

12
front panel
Figure 8
NBRM PARTS IDENTIFICATION

13
SECTION 5 – TROUBLESHOOTING INFORMATION GUIDE
This troubleshooting guide is set in a columnar format to simplify the isolation of problems,
possible causes, areas to check and corrective action required to restore the air dryer to normal
operation. It is further divided into system headings for easy referral. Where possible, the most
likely causes have been listed first. Otherwise, the causes start with the simplest and progress to
more complicated possibilities. The steps should be followed in sequence to expedite service. It
is further suggested that once the problem has been isolated, the corresponding text in the
Maintenance Section be reviewed to provide additional information.
This guide will require a volt ohmmeter (VOM), and will specify DC (direct current) or AC
(alternating current) setting.
The troubleshooting information guide can by no means cover every possible cause of
malfunction, but will help solve most problems. If the problem persists after thoroughly
consulting the troubleshooting section, contact
Puregas Technical Service Department at 1-800-521-5351 extension 2156, or [phone].
WARNING !!!
This section requires access to components inside the cabinet of the air dryer. In
most cases, an energized and operating air dryer is necessary to conduct a test
and make adjustments. Extreme care should be exercised to avoid contact with
live electrical or moving parts.

14
TROUBLESHOOTING GUIDE
Problem 1. Air Compressor Will Not Operate
Problem 2. Air Compressor Will Not Build Up Pressure
Problem 3. Air Compressor Will Not Turn On
Problem 4. Silica Gel Is Pink In Color
Possible Cause: Check: Corrective Action:
power has been interrupted to the
module external power supply restore power supply
a faulty electrical connection on the
module
disconnect electrical power at the
supply source and carefully
inspect all wire connections
replace wire connections as
necessary. restore power to the
unit
Possible Cause: Check: Corrective Action:
air leak in the system inspect all tube and air
connections on the module repair or replace defective component
defective safety relief valve check for proper adjustment and
function. Refer to Section 4 replace defective component
air compressor rings and valves are
worn check for worn rings and valves. Refer to Section 4 install maintenance kit, P07102
Possible Cause: Check: Corrective Action:
defective ON/OFF pressure switch check for proper function. Refer
to Section 4 replace defective component
defective unloader operation check for proper function. Refer
to Section 4 replace defective component
defective compressor centrifugal
switch check centrifugal switch replace defective component
Possible Cause: Check: Corrective Action:
silica gel is saturated check color of gel. Refer to
Section 4 depressurize system and change gel. Refer to Section 4