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General Pneumatics Optima Series Installation, Operation & Maintenance Manual

Regenerative desiccant dryer system
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Optima Series
Regenerative Desiccant Dryer System
Models: OP15 through OP500
Installation
Operation
Maintenance
Manual

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Summary of Contents for General Pneumatics Optima Series

  • Page 1 Optima Series Regenerative Desiccant Dryer System Models: OP15 through OP500 Installation Operation Maintenance Manual...
  • Page 2 Warranty Policy The following clearly defines the General Pneumatics Warranty Policy. General Pneumatics management is solely responsible for establishing service rates and determining the dispo- sition of warranty claims. Approval for deviation from this policy must have prior approval of General Pneumatic management.

  • Page 3: Table Of Contents

    Contents Section 1 General Information Foreword ................1 - 1 General System Information ..........1 - 1 1.2.1 Dryer ..................1 - 1 1.2.2 Prefilter Assembly ..............1 - 1 1.2.3 Automatic Drain Valves ............1 - 2 1.2.4 Afterfilter Assembly ..............1 - 2 Section 2 Installation...
  • Page 4 Section 4 Maintenance and Repair Preventative Maintenance Schedule ........4 - 1 Weekly................... 4 - 1 Quarterly ................4 - 1 Semi-Annually ................ 4 - 1 Annually ................. 4 - 2 Desiccant Charging Procedures ..........4 - 2 Filter Element Replacement ..........4 - 3 Dryer Models OP15 through OP250 ........

  • Page 5: General Information

    General Information CAUTION: Each component of a General Pneumatics Foreword Regenerative Desiccant Dryer System has been selected to compliment the performance of the other components of This manual is designed to serve as the installation, opera- the system. Therefore, use of unauthorized parts or sup- tion, and maintenance guide for your dryer system.

  • Page 6: 1.2.3 Automatic Drain Valves

    As previously stated, the accumulated water and oil mix- ture collected by a prefilter must be periodically drained from the prefilter housing sump. A General Pneumatics Automatic Drain Valve is a recommended and reliable means of removing collected moisture, oil and sludge from coalescing prefilter housings and other components requir- ing periodic draining.

  • Page 7: Installation

    Installation Dryer models OP15 through OP300 are designed to be Receiving and Inspection moved by means of forklift slotting at the base of the dryer’s protective shipping framework and lifting straps in- Immediately upon receipt of the dryer, thoroughly inspect stalled on the dryer.

  • Page 8: General Piping Information

    Table 2.1 General Piping Information CONNECTIONS Connections NOTE 1: Use the proper pressure rated piping, fittings Model (Inches) and valves as approved by ASME, ANSI, ASA, etc. Separate or special requirements by local Inlet Outlet and/or municipal codes may also apply. OP15 1"...

  • Page 9: Purge Exhaust Restrictor

    Purge Exhaust Restrictor con- alarm. Adequate surge, spike, brownout, and black- nection. Consult with your local General Pneumatics Sales out protection must be provided to protect your equip- Representative for requirements when the equivalent feet ment and allow safe shutdown time (an uninterrupted of pipe exceeds 100 feet.
  • Page 10 CAUTION STATIC SENSITIVE DEVICES STATIC SENSITIVE DEVICES CAN BE DAMAGED BY ELECTROSTATIC DISCHARGE. YOU CAN MINIMIZE THE CHANCES OF DESTROYING SUCH DEVICES BY: 1. KNOWING THAT THERE IS A POTENTIAL STATIC SENSITIVE PROBLEM. 2. ADHERING TO THE GUIDELINES LISTED BELOW FOR HANDLING THEM. 3.

  • Page 11: Remote Alarm Connection

    Maintenance and Repair section of this Any adjustments of DIP switches should only be made manual, if charging is necessary. by a qualified General Pneumatics Field Service Engi- neer. CAUTION: Dryer models covered within the scope of this manual are designed to use a specific desiccant.

  • Page 12: 2.10 Instrumentation

    2.10 Instrumentation Optitek 2 EMS Energy Management System (optional) The optional Optitek 2 EMS energy management system The following instrumentation helps in monitoring dryer automatically adjusts dryer operation to compensate for operation and performance. Instruments which are avail- changes in operating conditions. Air samples are periodi- able as options are so noted.

  • Page 13: Operation

    General Pneumatics Sales Representative CAUTION: Each component of a General Pneumatics for assistance. Regenerative Desiccant Dryer System has been selected to compliment the performance of the other components of Close the customer-supplied System Inlet Isolation the system.

  • Page 14: Dryer Models Op250 And Op300

    For dryers with the OPTITEK 2 EMS Energy Manage- due to special installation or other problems, contact ment System: During operation in the Energy Man- your local General Pneumatics Sales Representative agement Mode, the off-stream chamber may remain for assistance.
  • Page 15 Close the customer-supplied System Inlet Isolation 16. Energize the dryer’s electrical power supply. Valve. 17. PURGE SETTING AND ADJUSTMENT Open customer-supplied System Bypass Valve, if in- a) Locate the Critical Orifice Calibration Curve in stalled. Appendix A of this manual. Close customer-supplied System Outlet Isolation b) To calculate purge flow consumption on the criti- Valve.

  • Page 16: Dryer Models Op400 And Op500

    Dryer's Outlet Pressure Gauge to exceed a 5% due to special installation or other problems, contact drop in pressure while pressurizing downstream pip- your local General Pneumatics Sales Representative ing. for assistance. 15. Close the System Bypass Valve (if gas system has Close the customer-supplied System Inlet Isolation been so-equipped).

  • Page 17: Normal Operational Checks

    19. SLOWLY rotate dryer’s Purge Adjusting Valve until 5a. The dryer's microprocessor control should automati- the Purge Pressure Indicator indicates the calculated cally switch the system from left to right and right to purge pressure setting. (See following Note). left chamber drying on a fixed time cycle. If the sys- tem fails to switch drying chambers twice within its Note: The purge pressure can only be read and ad- designated NEMA Cycle, refer to the TROUBLE-...
  • Page 18 Close the System Inlet Isolation Valve (customer sup- plied). IMPORTANT: Inlet and Outlet Isolation Valves MUST be closed to prevent moisture overloading of desiccant beds, due to continuous flow without regen- eration. Close the Moisture Indicator Supply Valve (if dryer has been so-equipped).

  • Page 19: Maintenance And Repair

    Guide and conduct checks listed for the Moisture In- damage. dicator. CAUTION: Each component of a General Pneumatics Check the dryer’s Indicator Panel for the presence of Regenerative Desiccant Dryer System has been selected any illuminated alarm indicators. If an alarm indicator to compliment the performance of the other components of is illuminated, refer to the Troubleshooting Guide.

  • Page 20: Annually

    Annually CAUTION: Prior to installing desiccant, review all appli- cable Material Safety Data Sheets and container warnings. Safety Data Sheets may be obtained from the manufactur- WARNING! ers Safety Coordinator. Exercise all necessary precau- Ensure that the Dryer and any associated Prefilters tions for your health and welfare.

  • Page 21: Filter Element Replacement

    —— OP25 —— Coalescing prefilters and particulate afterfilters are in- OP30 —— cluded with all Optima Series Dryers. The filter elements OP40 —— should be replaced when the differential pressure gauge OP50 —— on top of the filter reads 7 to 10 psid, or once a year, whichever comes first.

  • Page 22: Dryer Models Op300 Through Op500

    LIGHTLY lubricate the new O-ring with a petroleum- Remove the used element cartridges. Discard the based lubricant that is compatible with your applica- cartridges in accordance with applicable regulations. tion before installing the new element. Used elements typically hold contaminants, such as compressor lubricants and particulate matter.

  • Page 23: Automatic Drain Valve Disassembly And Servicing

    CAUTION: Filter bowls may be heavy. Caution should be 14. Once the filter has been pressurized, slowly open the taken when removing the bowl. outlet isolation valve. Remove the bottom bowl by unscrewing it from the 15. After both isolation valves have been opened, close head.
  • Page 24 WARNING! Ensure that the Dryer is de-energized, valve isolated, and fully depressurized before attempting to remove or disassemble any Dryer component or subassembly. Failure to do so may result in serious personal injury and/or equipment damage. Remove hose that connects the drain valve to the fil- ter.

  • Page 25: Moisture Indicator Recharging Procedure

    Moisture Indicator Recharging Remove porous disc [4] and clean sight dome. (see following CAUTION.) Procedure CAUTION: Sight Dome [2] is an acrylic plastic. Do Not clean with any type of solvent. Note: Dryer shutdown is not necessary to perform the fol- lowing procedure and can be accomplished without remov- Replace O-ring [9], and re-install screw [6] in sight ing the entire assembly.

  • Page 26: (Models Op15 Through Op200)

    Inlet and Purge Exhaust Switching Valve Components Switching Valve Maintenance Item Description Total (Models OP15 through OP200) Valve Body Valve Cover (Left Side) WARNING! Valve Cover (Right Side) Ensure that the Dryer is de-energized, valve isolated, Valve Piston (Inlet) and fully depressurized before attempting to remove Valve Piston (Purge Exhaust) or disassemble any Dryer component or subassembly.
  • Page 27 NOTE: 1. When the unit is located in a corrosive environment, coat sockethead cap screws with a corrosion resistant compound. Figure 4.4 INLET AND PURGE EXHAUST SWITCHING VALVE (OP15, OP25, OP30, OP40, OP50, OP60, OP75, OP100, OP125, OP150, OP200) Maintenance and Repair 4 - 9...

  • Page 28: 3" Inlet Switching Valve Maintenance (Models Op250 And Op300)

    3" Inlet Switching Valve 3" Switching Valve Components Maintenance Item Description Total (Models OP250 and OP300) Sockethead Cap Screw Valve Cover WARNING! O-Ring Ensure that the dryer is de-energized, valve isolated, Bonnet Cylinder and fully depressurized before attempting to remove Locknut or disassemble any dryer component or subassembly.
  • Page 29 NOTE: 1. When the unit is located in a corrosive environment, coat sockethead cap screws with a corrosion resistant compound. Figure 4.5 3" INLET SWITCHING VALVE (OP250, OP300) Maintenance and Repair 4 - 11...

  • Page 30: 2" Purge Exhaust Switching Valve Maintenance (Model Op250 Only)

    2" Purge Exhaust 2" Switching Valve Components Switching Valve Maintenance Item Description Total (Model OP250 only) Sockethead Cap Screw Valve Cover WARNING! O-Ring Ensure that the Dryer is de-energized, valve isolated, Valve Piston and fully depressurized before attempting to remove Piston Seal or disassemble any Dryer component or subassembly.
  • Page 31 NOTE: 1. When the unit is located in a corrosive environment, coat sockethead cap screws with a corrosion resistant compound. Figure 4.6 2" PURGE EXHAUST (OP250) Maintenance and Repair 4 - 13...

  • Page 32: 3" Purge Exhaust Switching Valve Maintenance (Model Op300 Only)

    4.10 3" Purge Exhaust 3" Switching Valve Components Switching Valve Maintenance Item Description Total (Model OP300 only) Sockethead Cap Screw Valve Cover WARNING! O-Ring Ensure that the dryer is de-energized, valve isolated, Bonnet Cylinder and fully depressurized before attempting to remove Locknut or disassemble any dryer component or subassembly.
  • Page 33 NOTE: 1. When the unit is located in a corrosive environment, coat sockethead cap screws with a corrosion resistant compound. Figure 4.7 3" PURGE EXHAUST SWITCHING VALVE (OP300) Maintenance and Repair 4 - 15...

  • Page 34: 1" Purge And Outlet Check Valve Maintenance (Models Op15 Through Op40)

    Note: The purge orifice [5] is specifically sized and drilled Purge Block for your dryer. If the purge orifice is lost or damaged, con- O-Ring tact your local General Pneumatics Sales Representative O-Ring for the correct replacement. Purge Adjusting Valve...
  • Page 35 NOTE: 1. When the unit is located in a corrosive environment, coat items (2) and (3) with a corrosion resistant com- pound. 2. Torque 1/4 - 20 screws to 40 in-lbs. Torque 5/16 - 18 screws to 135 in-lbs. Figure 4.8 1"...

  • Page 36: 1-1/2" Purge And Outlet Check Valve Maintenance (Models Op50 Through Op75)

    Note: The purge orifice [5] is specifically sized and drilled Purge Block for your dryer. If the purge orifice is lost or damaged, con- O-Ring tact your local General Pneumatics Sales Representative O-Ring for the correct replacement. Purge Adjusting Valve...
  • Page 37 NOTE: 1. When the unit is located in a corrosive environment, coat items (2) and (3) with a corrosion resistant com- pound. 2. Torque 1/4 - 20 screws to 40 in-lbs. Torque 5/16 - 18 screws to 135 in-lbs. Figure 4.9 1-1/2"...

  • Page 38: 2" Purge And Outlet Check Valve Maintenance (Models Op100 Through Op150)

    Note: The purge orifice [4] is specifically sized and drilled Valve Spring for your dryer. If the purge orifice [4] is lost or damaged, Square O-Ring contact your local General Pneumatics Sales Representa- O-Ring tive for the correct replacement. O-Ring...
  • Page 39 NOTE: 1. When the unit is located in a corrosive environment, coat items (13) and (14) with a corrosion resistant compound. 2. Torque 5/16 - 18 screws to 135 in-lbs. Torque 3/8 - 16 screws to 245 in-lbs. Figure 4.10 2"...

  • Page 40: 3" Purge And Outlet Check Valve Maintenance (Models Op200 Through Op300)

    Note: The purge orifice [4] is specifically sized and drilled Valve Spring for your dryer. If the purge orifice [4] is lost or damaged, Square O-Ring contact your local General Pneumatics Sales Representa- O-Ring tive for the correct replacement. O-Ring...
  • Page 41 NOTE: 1. When the unit is located in a corrosive environment, coat items (13) and (14) with a corrosion resistant compound. 2. Torque 5/16 - 18 screws to 135 in-lbs. Torque 3/8 - 16 screws to 245 in-lbs. Figure 4.11 3"...

  • Page 42: Remote Flow Restrictor Maintenance (Model Op250 Only)

    4.15 Remote Flow Restrictor Maintenance (Model OP250 only) WARNING! Ensure that the dryer is de-energized, valve isolated, and fully depressurized before attempting to remove or disassemble any dryer component or subassembly. Failure to do so may result in serious personal injury and/or equipment damage.

  • Page 43: (Models Op300 Through Op500)

    4.16 Flow Restrictor Maintenance FLOW RESTRICTOR ASSEMBLY (Models OP300 through OP500) Item Description Total Valve Body WARNING! Actuator Subassembly Ensure that the dryer and any associated prefilters Valve Flange and afterfilters are valve isolated and fully depressur- O-Ring ized before attempting to remove or disassemble any Hex Nut components or subassemblies.
  • Page 44 DISASSEMBLY/ASSEMBLY INSTRUCTIONS ACTUATOR SUBASSEMBLY Item Description Total ACTUATOR SUBASSEMBLY Valve Flange Shaft Subassembly 1. Disassemble/Build the actuator subassembly in the Spacer order shown by the Actuator Subassembly Diagram Mounting Plate (Figure 4.15). Vibration Pad Retaining Plate A) Secure the retaining plate in the jaws of a vise. Sockethead Cap Screw B) Apply Loctite™...
  • Page 45 2. Adjust orifice stroke. DETAIL 'C' A) Invert the actuator subassembly and place in a vice as shown in Detail C. B) Gently press the flange to the orifice. C) Tighten the nut until the spring retainer slightly contacts the shaft guide. D) Continue tightening nut for an additional 1/2 turn.

  • Page 46: Purge Adjusting Valve (Models Op400 And Op500)

    4.17 Purge Adjusting Valve (Models OP400 and OP500) WARNING! Ensure that the dryer is de-energized, valve isolated and fully depressurized before attempting to remove or disassemble any dryer component or subassembly. Failure to do so may result in serious personal injury and/or equipment damage.

  • Page 47: Pilot Gas Filter Maintenance (Models Op400 And Op500)

    4.18 Pilot Gas Filter Maintenance (Models OP400 and OP500) WARNING! Ensure that the dryer is de-energized, valve isolated, and fully depressurized before attempting to remove or disassemble any dryer component or subassembly. Failure to do so may result in serious personal injury and/or equipment damage.

  • Page 49: Troubleshooting Guide

    Dryer’s Electrical Power Supply is energized. THEREFORE, A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS. These checks should be conducted by a qualified electrical technician or a General Pneumatics authorized field service engineer ONLY. The Dryer’s Electrical Power Supply must be de-energized before any electrical mainte- nance or repair work is conducted.
  • Page 50 5. Isolate and depressurize Prefilter Assembly. Inspect prefilter cartridges and end seals for loosening and/or damage. Tighten or replace as necessary. CAUTION: Each component of an General Pneumatics Air Purification System has been selected to compliment the per- formance of the other components of the system. Therefore, use of unauthorized parts or supplies or improper operation will degrade system performance.
  • Page 51 3. De-energize Dryer Power Supply. Replace fuse if blown, in- vestigate and remedy cause. 4. Damaged components. 4. For damaged solid state components and/or circuit boards of microprocessor units, contact your local General Pneumatics Sales Representative for assistance. Troubleshooting Guide 5 - 3...
  • Page 52 PROBLEM/POSSIBLE CAUSE CHECKS AND REMEDY Excessive pressure drop across dryer. 1. Badly broken, dusted or fouled desiccant. 1. Shutdown and Depressurize Dryer. Inspect desiccant through fill ports and replace if badly broken, dusted or fouled. Note: If the “normally white” desiccant is fouled or discolored, inspect prefilter cartridges and drain valve or trap.
  • Page 53 PROBLEM/POSSIBLE CAUSE CHECKS AND REMEDY b) For Models OP300 through OP500 WARNING! Removal of the Flow restrictor should not be done un- less the piping to the Purge Exhaust Muffler is ad- equately supported. Failure to do so may result in se- rious personal injury and/or equipment damage.
  • Page 54 PROBLEM/POSSIBLE CAUSE CHECKS AND REMEDY 4. During Repressurization Cycle. 4. Check for pilot gas pressure at on-stream chamber exhaust Purge Exhaust Switching Valve has failed to valve’s pilot tubing connection. close due to fouled or worn valve internals. If pilot pressure is present, Shutdown and Depressurize Dryer.
  • Page 55 PROBLEM/POSSIBLE CAUSE CHECKS AND REMEDY High Humidity Warning Note: A High Humidity Warning will ALWAYS cause the control system to automatically shift to fixed cycle operation. 1. Optitek Sensor has sensed a moisture over- load condition within a desiccant bed due to the presence of one (or both) of the follow- ing conditions: 1a.
  • Page 56 PROBLEM/POSSIBLE CAUSE CHECKS AND REMEDY Automatic drain valve continually discharging or venting. 1. Clogged diaphragm. 1. Clean diaphragm. 2. Short in electrical component. 2. Check and replace connector or timer assembly. Automatic drain valve not discharging. 1. No electrical power. 1.

  • Page 57: Appendix A Purge Curves

    Appendix A Purge Curves To Calculate Purge Flow: Inlet Flow (SCFM) × 14.7 PSIG × 1.15 = Purge (SCFM) Inlet Pressure (PSIG) + 14.7 PSIG Cross the Purge Flow requirement calculated above to the same number on the Critical Orifice Calibration Curve. Follow this line ver- tically and then horizontally once intersection is made with the curve line to find the actual purge pressure setting.
  • Page 58 Orifice Dia. .156 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP15) A - 2 Appendix A / Purge Curves...
  • Page 59 Orifice Dia. .219 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP25) Appendix A / Purge Curves A - 3...
  • Page 60 Orifice Dia. .250 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP30, OP40) A - 4 Appendix A / Purge Curves...
  • Page 61 Orifice Dia. .281 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP50) Appendix A / Purge Curves A - 5...
  • Page 62 Orifice Dia. .375 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP60, OP75) A - 6 Appendix A / Purge Curves...
  • Page 63 Orifice Dia. .406 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP100) Appendix A / Purge Curves A - 7...
  • Page 64 Orifice Dia. .500 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP125, OP150) A - 8 Appendix A / Purge Curves...
  • Page 65 Orifice Dia. .563 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP200) Appendix A / Purge Curves A - 9...
  • Page 66 Orifice Dia. .688 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP250, OP300) A - 10 Appendix A / Purge Curves...
  • Page 67 Orifice Dia. .750 Gas: Temp: 100°F CRITICAL ORIFICE CALIBRATION CURVE (OP400, OP500) Appendix A / Purge Curves A - 11...

  • Page 69: Appendix B Spare Parts

    Appendix B Spare Parts Instrumentation and Pilot Air Spare Parts (Choose the appropriate components pertaining to your dryer) Local Mounted Moisture Indicator Cat# Description 1207278 Ind, Moisture; Repair Kit Local Mounted Pressure Gauges Cat# Description 1125546 2-1/2 in, Brass, 0-200 PSIG, LOMTD Pilot Filter Cartridges Cat# Description...
  • Page 70 Valve Option Spare Parts (Choose the appropriate Valve Option size pertaining to your dryer) Model Description Cat# Qty. Per Dryer OP15/OP25 Inlet/Exhaust Valve Pkg Kit 1272490 Outlet & Purge Chk Valve Pkg Kit 1256393 Inlet/Exhaust Valve Repair Kit 1272482 Outlet Valve Repair Kit 1256408 Purge Valve Repair Kit 1256414...
  • Page 71 OP300 Inlet Valve Pkg Kit 1256169 Exhaust Valve Pkg Kit 1256168 Outlet & Purge Chk Valve Pkg Kit 1256401 Inlet Valve Repair Kit 1256174 Exhaust Valve Repair Kit 1256173 Outlet Valve Repair Kit 1256413 Purge Valve Repair Kit 1256415 Flow Restrictor Repair Kit 1205911 Flow Restrictor Rebuild Kit 1205937...
  • Page 72 Desiccant Spare Parts: (Choose the appropriate Model and size for Desiccant replacement) Model Catalog No. Desiccant Part No. Container Size Qty. Per Dryer OP15 1269703 OPD-4-17-S 17 lbs. 1269704 OPD-4-34-S 34 lbs. OP25 1269703 OPD-4-17-S 17 lbs. 1269704 OPD-4-34-S 34 lbs. OP30 1269705 OPD-4-150#...
  • Page 73 Spare Orifices Purge Flow Details Purge Orifice Model Inlet Purge Orifice Gauge Catalog Quantity Number Flow Flow Diameter Setting Number (scfm) (scfm) (inches) (psig) OP15 0.156 1180925 OP25 0.219 1180928 OP30 0.250 1180929 OP40 0.250 1180929 OP50 0.281 1183534 OP60 0.375 1198374 OP75...
  • Page 74 Spare Electrical Items Cat# Description Qty. Per Dryer 1274947 PCB Assy 1270702 Programmed IC 1256386 Fuse 1276724 Solenoid Valve Coil 1261094 Power Supply 1274958 PCB Assy (Hazardous Location) 1177244 Fuse (Hazardous Location) 1222747 Relay (Hazardous Location) Optional Electrical Components Cat# Description Qty.

This manual is also suitable for:

Optima op15Optima op25Optima op30Optima op40Optima op50Optima op60 ... Show all

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