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Installation, Operating and
Maintenance Manual
®
PYRAMID 8000 SERIES
COMPRESSED BREATHING AIR
PURIFIERS
WARNING
Improper use of this equipment
may cause illness, injury or death.
This instruction manual must be read by everyone
who installs or works with this equipment.
Bulletin 289 Rev. F (10/99)
Copyright ©1999 Flair-New Castle, Inc.
Printed in USA
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Table of Contents SAFETY INSTRUCTIONS ............................1 SAFETY.......................................2 INSTALLATION..................................2 Receiving and Inspection............................2 Clearance ....................................3 Ambient Air Temperature............................3 Location.....................................3 Air Compressor Equipment...........................3 Air Piping and Connections...........................3 Drain Piping...............
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Tables Table I Maximum Allowable Carbon Monoxide Concentration.............1 Table II Purifier Dimensions*................................3 Table III Purifier Specifications ...............................3 Table IV System Operation Monitor Indicating Lights ..................6 Table V Air and Refrigerant Temperatures ........................7 Table VI Intermediate Air Temperature ..........................8 Table VII Purifier Sizing Correction Factors ........................9 Table VIII Purifi
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Labels and Figures 8DM Series Instruction Plate Part No. 44DE127B.................................1 Danger Label: Grossly Contaminated Air Part No. 56DE152A.................................2 Purifier Data Plate Part No. 44DE23A .................................2 Figure 1. Air and Refrigerant Flow Diagram...................4 Figure 2. System Operation Monitor .......................5 Warning Label: Switch Must Be On Part No. 44DE112A................................10 Danger Label: Purifier Will N
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INTRODUCTION ® Pyramid 8000 (8DM) Series compressed breathing air purifiers are designed to reduce the concentration of oil, moisture, particulates and carbon monoxide in the airstream. When applied at rated capacity and specified operating conditions as shown in Table III and properly main- tained, 8DM Series purifiers supply air that meets OSHA, Canadian Standards Association (CSA) and Compressed Gas Association (CGA) standards for compressed breathing air quality, as well as National Fire Pro
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The instruction plate is firmly attached to the purifier for quick reference to important instructions. The plate does not replace the complete manuals supplied with the purifer. Do not remove or deface the plate. SAFETY 8DM Series purifiers are designed and constructed with safety as a prime consideration. Each purifier is pressure tested to 1½ times its maximum operating pressure. DANGER The following safety rules are crucial to en- sure safe purifier operation. Failure to follow these 9 impor
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Clearance Location Allow adequate clearance on all four sides of the puri- Locate the purifier under cover in a clean, dry, well- fier for cooling air flow and for service and mainte- ventilated area. Install the purifier on a level base. Pro- nance access. Above the purifier, allow at least tect the purifier from heavy vehicles or other moving one-half the height of Model 8DM25, 8DM50 or equipment likely to cause damage. Bolt the purifier to 8DM75 to replace cartridges. Above Model 8DM100 the f
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and outlet piping must be as large as the connections ends to prevent the lines from whipping when the or larger. Piping that is smaller than the purifier con- drains discharge. nections will increase pressure drop and reduce breath- 5 ing air flow. If longer drain lines are required, O.D. flexible 16 plastic tubing up to ten feet long may be used. For dis- Install a pressure gauge at the purifier inlet to indicate 3 charge lines longer than ten feet use pipe or larger 4 purifier operating p
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The coalescing filter removes oil mists, separates SYSTEM OPERATION MONITOR liquid oil and condensate, and automatically dis- charges these contaminants from the purifier. The System Operation Monitor measures and displays critical air and refrigerant temperatures, signals operat- The activated carbon filter removes hydrocarbon ing conditions which may affect dryer performance, vapors to eliminate objectionable tastes and odors. and enables panel adjustment of the automatic drain valve. Ther
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NORMAL OPERATION — The green NORMAL SERVICE DUE — The yellow SERVICE DUE indi- OPERATION indicator will light when the tempera- cator will light under three conditions: as a reminder to ture inside the evaporator (chiller ) is normal. perform routine maintenance after 4,500 hours of dryer service (approximately six months), when a CHECK OPERATING CONDITIONS — The red thermocouple, or when a filter element must be CHECK OPERATING CONDITIONS indicator will changed. light when the temperature insid
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SYSTEM ALARM — The red SYSTEM ALARM The display will read the same temperature until the indicator signals air system or dryer operating condi- button is pressed again. While in this mode, the alarm tions that may affect dew point performance or cause set points and service due light are bypassed. damage to the dryer. Critical Air and Refrigerant Temperatures Table V provides the normal range for each displayed Temperature SCAN/SEEK Push Button The SCAN/SEEK push button on the System Opera- temp
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Refrigerant Discharge Temperature — This tem- sent every second. The baud rate is 4800, 8 bits, no perature is used by service personnel to analyze the parity. performance of the refrigeration system. Message format: Ambient Air Temperature — If the ambient air tem- perature falls outside the acceptable range, the dryer VERSION PROGRAM may fail to achieve the required dew point or dryer shutdown may result due to high refrigerant discharge 8S All Models pressure. 8S version: Intermediate Air Tem
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AUTOMATIC DRAIN VALVES (ADVs) WARNING High airflow, high inlet air temperature or low 8DM Series purifiers are equipped with two electronic inlet air pressure may cause poor purifier automatic drain valves (ADVs) that automatically dis- performance,illness, injury or death. If the charge condensate from the coalescing filter. Drain purifier is operated at conditions different valve controls for one drain are on the front panel. from the rating conditions, adjust the inlet air Controls for the se
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bient air temperatures. It is also normal if some of the red indicating lights flash. 5. After the power switch has been on for one hour, check the control panel. The red indicating lights should signal in sequence. If any red indicating light flashes call the Deltech Product Service De- partment for instructions. 6. Supply compressed air up to the inlet valve. Danger Label: Parts of Circuit May Be Energized Part No. 58DE27A 7. Slowly open the inlet valve and allow the purifier to reach operatin
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Preventive Maintenance Schedule MAINTENANCE How to Use the Maintenance Section Make the preventive maintenance procedures de- scribed beginning on page 11 a regular part of your maintenance schedule to ensure continuing safe opera- tion of the purifier. If any problems occur that are not remedied by routine maintenance, see the FIELD SERVICE GUIDE. Danger Label: Explosion Hazard For assistance with problems not covered in this in- Part No. 56DE194A struction manual, call the Deltech Product Serv
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manual) for drain valve maintenance instruc- tions. Before restarting the purifier, open the manual drain on the particulate filter. If no liquid discharges, close drain. WARNING If any liquid discharges from the particulate filter, immediately stop using the purifier out- let air for breathing. Replace all elements and the catalyst vessel. Contact Deltech before restarting the purifier. Weekly Open the manual drain on the particulate filter. If any liquid discharges, immediately stop using th
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6. Lift the vessel out from the top. Use the boom and 5. Disconnect the unions on the top and bottom of hoist for models 8DM100 and 8DM150; vessels the vessel. for smaller models can be lifted out by hand. 6. Using the hoist, lift the vessel out of the purifier 7. All vessels may be discarded, except BA17 and cabinet. AC17. These vessels can be returned to the factory for credit. See page 11 for return procedure. 7. Swing the boom to the side and use the hoist to lower the vessel to the floor. 8
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WARNING To restart the purifier, follow the procedure described in the Start-Up section of this man- ual. Afterfilter Element Replacement E1 To replace the element: 1. Shut down the purifier according to the Shutdown procedure. 2. Open the manual drain valve at the bottom of the filter. 3. Remove the threaded bowl from the top casting. 4. Remove the wing nut and element support plate from the tie rod; the element with support core will drop. 5. Slide the used element off the support core. 6. Cle
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FIELD SERVICE GUIDE DANGER Refrigeration systems can be dangerous. The problem most frequently encountered in refrigera- Work on the refrigeration system should be tion systems is liquid water downstream. Most causes done only by a competent refrigeration me- of water carry-over can be identified and remedied by chanic. using the FIELD SERVICE GUIDE. For further help, contact Deltech. Do not release fluorocarbon refrigerants in- doors or drain liquid refrigerants into floor drains. Refrigerant v
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SYMPTOM POSSIBLE CAUSE REMEDY 1. Purifier turned on less than 1. If light is still on after one hour, do not use puri- one hour. fier. Contact Deltech. Refrigerant compressor running. (REFRIG DISCHARGE tempera- 2. Have refrigeration mechanic locate and repair ture light flashes, temperature is 2. Loss of refrigerant charge. leak. Recharge. outside normal range or alarm set point is reached.) 3. Ambient temperature below 3. Relocate purifier, or heat area. 50°F. 1. Clean condenser coils (see Main
