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AIRPREP

AIR DRYER SYSTEM

OPERATION AND MAINTENANCE MANUAL

NOVEMBER 2007

SAVE THIS MANUAL AND MAKE AVAILABLE

TO ALL USERS OF THIS EQUIPMENT!

Manual Part Number 7200-230

IOM Manufacturing, Inc.

11927 S. Highway 6, Fresno, Texas 77545

800.231.2085 * 281.431.0581 * fax 281.431.1717

Содержание 7031-033

Страница 1: ...AND MAINTENANCE MANUAL NOVEMBER 2007 SAVE THIS MANUAL AND MAKE AVAILABLE TO ALL USERS OF THIS EQUIPMENT Manual Part Number 7200 230 AXXIOM Manufacturing Inc 11927 S Highway 6 Fresno Texas 77545 800 231 2085 281 431 0581 fax 281 431 1717 ...

Страница 2: ...efore loading abrasive or performing any maintenance 6 Do Not use abrasives containing free silica Silica can cause silicosis or other related respiratory damage You must wear personal protective equipment for all abrasive blasting operations Observe all applicable local state and federal safety regulations in conjunction with airline filters and respiratory protection Reference OSHA 29 CFR 1910 1...

Страница 3: ...TION Indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices that may cause property damage This manual contains terms that may be specific to the abrasive blast industry Understanding these terms will help you understand the procedures and instructions given in this manual Please familiarize yours...

Страница 4: ...600 ADS 2000 ADS 2500 Not Applicable 3 1 7031 001 Medium h id Not Applicable 4 2 7031 007A Danger Pressurized Vessel Propelled objects will cause serious injury or death Depressurize vessel prior to performing any maintenance See Section 6 2 5 1 7031 017 Inlet Not Applicable 6 1 7031 018 Outlet Not Applicable 7 1 7031 057 Warning Read manual before using this machine Read and understand operator s...

Страница 5: ...iii 5 7031 017 6 7031 018 7 7031 057 Figure 0 1 b Warning decal summary continued Figure 0 2 a Warning decal location for ADS 250 Dryer ...

Страница 6: ...iv Figure 0 2 b Warning decal location for ADS 400 2500 Dryer Figure 0 2 b Warning decal location for ADS 3500 Dryer ...

Страница 7: ...tem General Operation 14 5 0 AirPrep System General Operation 15 6 0 Pre operation Procedures 20 7 0 Operating Instructions 27 8 0 Maintenance and Inspection Instructions 30 9 0 Drawings and Parts Lists 34 10 0 Recommended Spare Parts List 45 11 0 AirPrep System Technical Data and Troubleshooting 46 12 0 Warranty and Reference Information 47 13 0 Blasting Data Tables 51 Table of Contents ...

Страница 8: ...S IF ALL SAFETY PRECAUTIONS ARE NOT FOLLOWED FAILURE TO OPERATE THE AIRPREP SYSTEM WITHOUT FOLLOWING ALL THE RULES FOR SAFER OPERATION MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATING PERSONNEL OR PERSONS IN THE OPERATING VICINITY 1 2 KNOW YOUR EQUIPMENT Do Not operate this equipment in a manner other than its intended application see Section 4 0 Do Not operate this equipment or any other Schmid...

Страница 9: ...R 1910 134 Abrasive blasting produces dust which may contain Silica and other toxic substances that can cause severe and permanent lung damage cancer and other serious diseases if inhaled Wear OSHA approved respiratory protection See Section 3 9 and OSHA 29 CFR 1910 134 1 7 BREATHING AIR QUALITY Do Not use breathing air that does not meet OSHA Class D standards Extreme caution must be taken when s...

Страница 10: ...performing maintenance on this equipment 1 12 DO NOT USE DRUGS ALCOHOL or MEDICATION Do Not operate this equipment while under the influence of drugs alcohol or any medication 1 13 PROTECT BYSTANDERS Do Not allow blast equipment and related equipment operators and other personnel to enter the vicinity of the blast operation without providing respiratory protective equipment that meets OSHA regulat...

Страница 11: ...cause failure of the pressure vessel See sections 1 22 through 1 31 below An Airprep System is a Pressurized Vessel Alterations damage or misuse of the pressure vessel can result in rupturing Damaged or incorrect components used on the Airprep System pressure vessel can result in rupturing The compressed air inside a pressurized vessel contains a dangerously high level of energy which can propel o...

Страница 12: ...r technical support See Section 8 0 1 30 CHECK FOR LEAKS IN VESSEL Do Not operate this equipment if there is a leak in the pressure vessel If leaking take out of service immediately and have it inspected and or repaired by a qualified facility Contact Axxiom Manufacturing Inc for technical support 1 31 NEVER MODIFY BLOWDOWN Do Not connect the blowdown on this equipment onto a common header with an...

Страница 13: ...to prevent accidental disconnections Accidental hose disconnection can cause serious injury or death See Section 5 14 and 8 8 1 37 ALWAYS USE CORRECT REPLACEMENT PARTS AND ACCESSORIES Do Not use replacement parts or accessories that are not rated for pressures equal to or higher than your abrasive blaster s operating pressure Improper hoses and or fittings used on or connected to your abrasive bla...

Страница 14: ...IVE ENVIRONMENTS Do Not locate this equipment in corrosive atmospheres as rapid deterioration of fan shroud cooling coil fan and motor may take place resulting in reduced life 1 46 AVOID EXTREME TEMPERATURES Do Not expose AirPrep Systems fan motors to extreme temperatures The motors furnished are built for fan duty only Consideration should be given to the installation location so motors are not s...

Страница 15: ...tion and maintenance manual as needed as well as any additional information included from other manufacturers Never permit anyone to operate this equipment without having him her first read this manual and receive proper training Make this manual readily available to all operating and maintenance personnel If the manual becomes lost or illegible replace it immediately This operation and maintenanc...

Страница 16: ...hway 6 Fresno Texas 77545 Phone 1 800 231 2085 Fax 1 281 431 1717 Website www axxiommfg com 2 2 Air Dryer System ADS Operating Specifications Maximum Working Pressure 150 psi 250 F Minimum Operating Temperature 35 F 150 psi Air Flow Capacity See section 6 0 table 1 Tank Volume See table below MODEL NO ADS 250 ADS 400 ADS 750 ADS 950 ADS 1200 ADS 1600 ADS 2000 ADS 2500 ADS 3500 VOLUME cu ft Liters ...

Страница 17: ...oad and unload this equipment using fork trucks with a sufficient load rating 2 7 Air Dryer System ADS Dimensional Specifications MODEL NO PART NO HEIGHT in mm WIDTH in mm LENGTH in mm INLET NPT OUTLETS NPT WEIGHT lbs kg AIR MOTOR ELECTRIC MOTOR ADS 250 1310 021 1310 022 59 1499 29 737 34 864 1 1 4 1 1 1 4 420 191 ADS 400 1310 041 1310 042 62 1575 30 762 42 1066 2 1 2 2 1 980 445 ADS 750 1310 071 ...

Страница 18: ...duced in size by installing pipe bushings to match the connecting equipment Again the air requirement of the connecting equipment must be considered so that the proper size piping hose is selected See Section 5 14 3 4 AirPrep System Air Pressure The standard maximum operating pressure for AirPrep Systems is 150 psig however custom systems may have varying operating pressure The maximum operating p...

Страница 19: ...lations set the specifications for pressure relief valves therefore it is the responsibility of the owner of the abrasive blaster to install a pressure relief valve that meets all applicable regulations The pressure relief device must be set at the maximum allowable working pressure of the AirPrep System pressure vessel See the ASME vessel nameplate attached to the pressure vessel All AirPrep Syst...

Страница 20: ...ment required for each abrasive blast operator Also identified are the OSHA references for each and the ANSI standard each PPE item must meet All PPE clothing and equipment should be selected for safe design and quality of construction Select each for proper fit and for comfort which will encourage operator use Figure 3 9 Personal Protective Equipment The function of the Schmidt AirPrep System is ...

Страница 21: ... occurrences of cooling are inside the blaster when the air expands and on the surface of the object that is being blasted An Airprep System greatly reduces the moisture content in the blast air and air supplied to other equipment such as breathing air filters used in the blast operation The abrasive blast stream and the dust it creates are harmful therefore all blast operators and other personnel...

Страница 22: ...w causes the condensed moisture to fall to the bottom of the vessel The moisture collected is drained from the bottom of the separator tank through the drain valve 19 The AirPrep fan air motor is turned on and off by the ball valve 21 Closing the ball valve will disable the fan air motor 9 The AirPrep System separator vessel 20 is depressurized by closing the air compressor outlet ball valve and t...

Страница 23: ...n oiled and should not exceed the specified pressure therefore a filter air regulator and an automatic lubricator are installed in the air line upstream of the motor refer to Section 11 0 Table 2 for air motor specifications Ball valve 21 turns off the air motor Note The air motor air supply must be clean dry and lubricated to prevent motor failure 5 5 Air Filter fan air motor The compressed air s...

Страница 24: ...tom of the tank As the air flow rises through the tank it passes through a bed of marbles 15 then into the deliquescent desiccant tablets 14 The absorbed adsorbed moisture then drops to the bottom of the separator tank The moisture collected in the separator tank can be drained through the drain ball valve 19 This ball valve should be left slightly open anytime the system is in operation This allo...

Страница 25: ...d anytime the unit in not in use If the drain ball valve is left open the deliquescent desiccant tablets will remove moisture from air entering from the outside the tank Airborne particles and loud noise hazards from blowdown exhaust air can cause serious injury and loss of hearing Wear approved eye and ear protection Stay clear of blowdown air path DO NOT place hands or other body parts in the bl...

Страница 26: ...ose Connection Hose connections 2 and smaller can be made with 4 lug type crowfoot couplings All air hose couplings have pin holes that align when connected To prevent accidental hose disconnections safety pins must be installed through these holes As a secondary safety measure each hose connection should also include a hose whip check that will hold the hose if there is an accidental disconnectio...

Страница 27: ...ow the depressurizing procedure given in Section 6 2 Airborne particles and loud noise hazards from blowdown exhaust air can cause serious injury and loss of hearing Wear approved eye and ear protection Stay clear of blowdown air path DO NOT place hands or other body parts in the blowdown air path Make sure no personnel are in the blowdown air path 6 1 3 Do Not operate this equipment without a pre...

Страница 28: ...21 Figure 6 1 Typical AirPrep Dryer System 6 1 5 Units having electric aftercooler fan motors must be installed by qualified personnel Follow manufacturer s recommendations ...

Страница 29: ...or 24 with detergent SAE 10 automotive engine oil 6 1 11 Tighten the bowls on air filter 22 and air lubricator 24 6 1 12 Check the level of the deliquescent desiccant tablets 14 Fill if necessary through the upper handway opening 10 6 1 13 Properly install the handways 10 on the separator tank 20 See Section 6 3 6 1 14 Turn the aftercooler fan 8 by hand to be sure that no damage has occurred to fa...

Страница 30: ...pressurize the separator tank 20 Airborne particles and loud noise hazards from blowdown exhaust air can cause serious injury and loss of hearing Wear approved eye and ear protection Stay clear of blowdown air path DO NOT place hands or other body parts in the blowdown air path Make sure no personnel are in the blowdown air path The AirPrep System separator tank 20 is completely depressurized when...

Страница 31: ...INTENTIONALLY BLANK 6 3 Handway Cover Installation Procedures See Figure 6 3 a 6 3 1 Check that the handway cover crab bolt and gasket are dimensionally correct for the size handway weld ring of the pressure vessel ...

Страница 32: ...handway weld ring sealing surface inside the vessel Inspect the handway cover sealing surface Both surfaces must be smooth 6 3 4 Place the gasket on the handway cover then fit both through the opening 6 3 5 Place the cover and gasket in position against the inside edge of the handway weld ring Apply a pulling force to hold in position then proceed 6 3 6 Center the gasket on the handway weld ring 6...

Страница 33: ... 6 3 b Handway Components 6 x 8 Handway Dimensions Component A B Weld Ring 6 5 8 8 1 2 Handway Cover 7 11 16 9 7 8 Handway Gasket 7 3 4 9 3 4 Handway Crab 2 3 8 8 3 4 Square Head Bolt 3 4 10 UNC 4 1 2 Table 6 3 c Handway Component Dimensions ...

Страница 34: ...tes that the AirPrep System is depressurized See Figure 7 1 7 1 3 Remove the handway cover 10 at the top of the separator tank 20 7 1 4 Check inside the separator tank for looseness of the deliquescent desiccant tablets 14 Extended exposure to moisture will fuse the tablets together and can possibly block or restrict air flow Break apart fused tablets with a long rod or similar device Fill with ta...

Страница 35: ...e aftercooler has an air motor open the air motor on off ball valve 21 7 2 6 Adjust air pressure regulator 23 to the required pressure See Section 11 0 for correct air motor inlet pressure setting Turn clockwise to increase pressure motor speed and counter clockwise to decrease pressure motor speed Do not exceed maximum air motor pressure Exceeding the air motor operating pressure can cause system...

Страница 36: ...e filter 4 and after filter 5 and petcock valve 22 units with air motor to drain moisture and clean out dirt particles 7 3 5 Completely depressurize the AirPrep System separator tank 20 by slowly opening the drain blowdown ball valve 19 See Section 6 2 for blowdown procedure Airborne particles and loud noise hazard from the blowdown exhaust air can cause serious injury and loss of hearing Wear app...

Страница 37: ...l reduce the wall thickness of the vessel If excessive corrosion is found have the AirPrep System pressure vessel inspected by a qualified facility Contact Axxiom Manufacturing Inc for technical support Check the pressure vessel internal piping for corrosion cracks and holes 8 4 MOISTURE ACCUMULATION Once a day with the AirPrep System pressurized completely open the drain valves 7 on the pre filte...

Страница 38: ...5 5 Electric Motor Keep outside surface free of dirt and grease so motor will cool properly Make sure cooling air over motor is not obstructed The motors are normally furnished with ball bearings and require lubrication every six months If the motor is equipped with an Alemite fitting clean the tip and apply grease gun Use 1 to 2 full strokes on motors in NEMA 215 frame and smaller 2 to 3 strokes ...

Страница 39: ...d whip checks Failure to install safety pins on all hose couplings could result in serious injury or death Figure 8 1 Hose Connection Disconnect Protection 8 9 Check daily to verify that all personal protective equipment is available for each blast operator Check daily to verify that all personal protective equipment is in good operating condition Consult the operating and maintenance instructions...

Страница 40: ... Section 8 4 X Aftercooler Clean inspect radiator fan shroud guard motor See Section 8 5 X Deliquescent Desiccant Check level of deliquescent desiccant inside separator tank See Section 8 6 X Control Hoses Wires Check control hoses wiring for bare spots fraying or cracks See Section 8 7 X Air Hose Couplings Check for safety pins and whip checks See Section 8 8 X Hose Coupling Gaskets Check for lea...

Страница 41: ...ystem is equipped with pneumatic or electric controls then reference the appropriate drawing and parts list to determine the required parts To insure the proper operation of the AirPrep System only use Schmidt original factory replacement parts furnished by an authorized Schmidt distributor See Section 1 38 and Section 12 2 12 9 0 Drawings and Parts Lists ...

Страница 42: ...35 ...

Страница 43: ...36 ...

Страница 44: ...assembly 7000 001 06 Handway gasket 6 x 8 11 3014 011 Plug 3 12 7064 009 Sight glass 2 13 3014 007 Plug 1 1 4 14 Furnished by user Deliquescent desiccant tablets 15 1310 000 01 Air dryer bed marbles 16 3026 111 04 Bushing 3 x 1 2 17 3006 104 90 Street elbow 1 2 galv 18 3029 104 11 Nipple 1 2 x 3 galv 19 2401 504 Ball valve 1 2 full port 20 1310 020 01 250 Dryer vessel 21 2401 504 Ball valve 1 2 fu...

Страница 45: ...d marbles 16 3026 111 06 Bushing 3 x 1 galv 17 3006 106 90 Street elbow 1 galv 18 3029 106 15 Nipple 1 x 6 galv 19 2401 506 Ball valve 1 full port 20 1310 040 01 400 Dryer vessel 21 2401 504 Ball valve 1 2 full port 22 2302 204 50 Air filter 1 2 40 micron 2302 204 99 Repair kit 1 2 air filter 23 2003 004 Air regulator 1 2 relieving 2003 004 99 Repair kit 1 2 air regulator 24 2304 004 Air lubricato...

Страница 46: ...galv 19 2401 506 Ball valve 1 full port 20 1310 070 01 750 Dryer vessel 21 2401 504 Ball valve 1 2 full port 22 2302 204 50 Air filter 1 2 40 micron 2302 204 99 Repair kit 1 2 air filter 23 2003 004 Air regulator 1 2 relieving 2003 004 99 Repair kit 1 2 air regulator 24 2304 004 Air lubricator 1 2 2304 004 99 Repair kit 1 2 air lubricator 25 2010 009 01 Pressure gauge 0 160 psi 26 2011 002 01 Muff...

Страница 47: ... 40 micron 2302 204 99 Repair kit 1 2 air filter 23 2003 004 Air regulator 1 2 relieving 2003 004 99 Repair kit 1 2 air regulator 24 2304 004 Air lubricator 1 2 2304 004 99 Repair kit 1 2 air lubricator 25 2010 009 01 Pressure gauge 0 160 psi 26 2011 004 01 Muffler 1 2 27 4101 004 01 Hose push on 1 2 28 3008 004 45 Street elbow 1 2 29 4201 504 04 Straight swival 1 2 male x 1 2 female 3031 304 04 H...

Страница 48: ...304 004 Air lubricator 1 2 2304 004 99 Repair kit 1 2 air lubricator 25 2010 009 01 Pressure gauge 0 160 psi 26 2011 004 01 Muffler 1 2 27 4101 004 01 Hose push on 1 2 28 3008 004 45 Street elbow 1 2 29 4201 504 04 Straight swival 1 2 male x 1 2 female 3031 304 04 Hex nipple 1 2 x 1 2 30 4200 304 04 Push on hose insert 1 2 x 1 2 31 4203 504 04 90 Swivel 1 2 male x 1 2 female 32 4203 504 04 90 Swiv...

Страница 49: ...7 Air hose 1 1 4 28 3006 107 90 Street elbow 1 1 4 galv 29 3029 007 99 Nipple 1 1 4 x close 30 4205 107 Hose insert swivel 1 1 4 4205 107 99 Hose swivel gasket 1 4228 509 Hose clamp 1 1 4 3029 007 99 Nipple 1 1 4 x close 31 3006 107 90 Street elbow 1 1 4 galv 3000 107 90 Elbow 1 1 4 galv 3029 007 99 Nipple 1 1 4 x close 32 3006 106 90 Street elbow 1 galv 33 3029 006 99 Nipple 1 x close 34 7025 503...

Страница 50: ...0 7000 001 11 Handway crab assembly 7000 001 06 Handway gasket 6 x 8 11 3014 011 Plug 3 12 7064 009 Sight glass 2 13 3014 007 Plug 1 1 4 14 Furnished by user Deliquescent desiccant tablets 15 1310 000 01 Air dryer bed marbles 16 3026 111 06 Bushing 3 x 1 galv 17 3006 106 90 Street elbow 1 galv 18 3029 106 21 Nipple 1 x 12 galv 19 2401 506 Ball valve 1 full port 20 1310 350 01E 3500 Dryer vessel 35...

Страница 51: ...44 ...

Страница 52: ...ter Replacement Parts Kit 23 1 2003 XXX 99 Air Regulator Replacement Parts Kit 24 1 2304 XXX 99 Air Lubricator Replacement Parts Kit 25 1 2010 009 01 Pressure Gauge 0 160 psi 26 1 2011 XXX 01 Air Motor Muffler 27 10ft 410X XXX XX Air Hose 27 4 4235 007 Hose Clamp Double Bolt only required for systems larger than ADS 750 C Items for Electric Fan Motors Systems Only see note below ITEM QTY PART DESC...

Страница 53: ...5 200 87 117 151 191 81 104 129 159 ADS 400 210 384 520 605 175 375 430 500 160 300 400 464 135 250 340 396 125 235 305 355 ADS 750 355 650 890 1025 308 560 760 880 290 545 725 840 245 450 605 701 225 410 540 625 ADS 950 480 871 1178 1360 415 754 1020 1180 390 712 950 1100 320 588 785 910 280 520 690 780 ADS 1200 600 1090 1475 1710 520 950 1290 1460 490 900 1200 1380 405 735 980 1130 355 650 865 9...

Страница 54: ...rosion erosion normal wear and tear alterations or modifications made to the machine without express written consent of Axxiom Manufacturing Inc 4 Warranty requests must be submitted in writing within thirty 30 days after failure 5 Written authorization to return merchandise under warranty must first be obtained from Axxiom Manufacturing Inc In no case is merchandise to be returned to Axxiom for c...

Страница 55: ... RESULTING FROM THE USE OF THE PRODUCT OR ARISING OUT OF ANY BREACH OF ANY WARRANTY OR FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY CHARACTER INCLUDING WITHOUT LIMITATIONS DAMAGES FOR ANY LOSS OF GOODWILL WORK STOPPAGE OR ANY AND ALL OTHER COMMERCIAL DAMAGES OR LOSSES 15 AXXIOM MANUFACTURING INC MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES O...

Страница 56: ...d questions can be found at the OSHA website shown below Phone 1 800 321 6742 Website www osha gov U S Department of Labor Occupational Safety and Health Administration 200 Constitution Avenue Washington D C 20210 National Institute of Occupational Safety and Health NIOSH is a federal agency responsible for conducting research and recommendations for the prevention of work related injuries and sic...

Страница 57: ...ical Use Corn Cobs 2 angular 35 45 tan none 4 5 low stripping paint from delicate substrates Sodium Bicarbonate 2 8 crystal 60 white none 4 5 medium cleaning and stripping paint from delicate substrates Walnut Shell 3 angular 45 lt brown none 4 5 low stripping paint from delicate substrates Plastic 3 2 angular 45 60 white none 8 10 medium Paint stripping deburring and cleaning Glass Beads 4 5 sphe...

Страница 58: ... Guide blasting 100 Psi NOZZLE SIZE No 4 1 4 No 5 5 16 No 6 3 8 No 7 7 16 No 8 1 2 CFM 100psi 90 140 200 270 350 AIR HOSE 1 1 4 1 1 4 1 1 2 1 1 2 2 BLAST HOSE 1 1 1 4 1 1 4 1 1 2 1 1 2 ABRASIVE lbs per hr 560 900 1260 1750 2250 13 4 Additional Information on Blasting Productivity Air volume and pressure are very important The blasting production rate will increase with higher blasting pressures an...

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