PSB G5C-50, G5C-18, G5C-30, G5C-75, G5C-100 Operation And Maintenance Manual

PSB INDUSTRIES INC.

Phone : 814-45—3651 Fax : [phone] • www.PSBINDUSTRIES.com • [e-mail]

•

General Air Division • 1202 West 12th Street, Erie, PA. 16501 G5C Dryers

GLACIER

Cycling Refrigerated Compressed Air Dryers with “Zero-Loss” Drain Trap

Operation & Maintenance Manual

MODELS G5C 0018 thru G5C 0250

- TABLE OF CONTENTS -

1.0 GENERAL 2

1.1 How to use this manual

1.2 Symbols

1.3 Warranty

1.4 Standard Equipment

1.5 Description of Operat ion

1.6 Use

1.7 General Safety Instructions

2.0 M ACHINE UNPACKING AND HANDLING 3

2.1 Unpacking and handling

2.2 Package disposal

2.3 Returned Equipment

3.0 SET-UP

3.1 Positioning 4

3.2 Installation

3.3 Filling the thermal mass reservoir

3.4 Start-Up

3.5 Dryer Transpor tation or Long-T erm Storage

4.0 MAINTENANCE 5

4.1 Weekly

4.2 Monthly

4.3 Semi-annually

5.0 EQUIPMENT DATA 5

6.0 CONT ROL PANEL OPERAT ION 6

6.1 Status LEDs

6.2 Button Functions

6.3 Set Point Modification

6.4 Digital Display

6.5 Error Codes

7.0 TROUBLESHOOTING 7

8.0 INTELLIDRAIN 8

8.1 Operation

8.2 Controls

8.3 Maintenance

9.0 DIM ENSIONAL DATA 9

10.0 REFRIGERATION CIRCUIT DIAGRAMS 10

11.0 ELECT RICAL WIRING DIAGRAM S 10

12.0 SYSTEM INSTALLATION & LAYOUT 13

1/16 Cod. 710.062.01.00 – Rev.08 – 02.05.02

PSB INDUSTRIES INC.

Phone : 814-45—3651 Fax : [phone] • www.PSBINDUSTRIES.com • [e-mail]

1.0 GENERAL

1.1 How to use this manual

All features of this machine, including information on safety, installation, operation, and maintenance are described in this manual.
This manual is an integral part of the machine and must be read and understood by any person involved with its operation or
maintenance. In the event of re-sale of this unit, this manual should be forwarded to the new owner. Replacement manuals may be
obtained from your authorized dealer.

1.2 Symbols

The symbols below are used throughout this manual, and on the unit itself, to indicate specific unit components or potential safety
hazards that will be encountered during machine operation and maintenance.

•

General Air Division • 1202 West 12th Street, Erie, PA. 16501 G5C Dryers

Air inlet

Air outlet

Electric shock danger!

1.3 Warranty

This product has been factory tested before shipment. It is guaranteed to be free from defects in material and/or workmanship for a
period of 12 months from the date of shipment. This warranty applies provided the machine has been installed and used in
accordance with the instructions detailed in this manual. The manufacturer agrees, at its discretion, to repair or replace all defective
parts free of charge. Further, the manufacturer agrees to cover charges associated with field labor required to make authorized
warranty repairs, provided the PSB-General Air warranty policy is followed and an S.I.R. authorization is issued by PSB-General Air.
Labor coverage shall be limited to maximum rates as published in the latest price list. Field repairs may only be performed by a
factory authorized service technician. This warranty is limited to defects associated with operation and manufacture only. All parts
subject to wear due to their normal operation are not covered by this warranty. All transportation costs associated with factory repair
of equipment are the sole responsibility of the owner.

1.4 Standard Equipment

• Refrigerated air drying circuit with economizing heat exchanger & condensate separator.

• Automatic condensate drain system.

• Microprocessor-based control panel with LED display and pushbutton user interface.

• Instruction and maintenance manual with wiring diagram.

1.5 Description Of Operation

These dryers have been specially designed to provide dry compressed air, while consuming electrical power in direct proportion to the
actual load, thereby saving energy. The dryers utilize mechanical refrigeration, in conjunction with thermal storage, to condense
moisture by lowering the compressed air temperature to about 37°F. The dryer “stores” its refrigeration ability during periods of low
load by making ice. This allows simple and efficient “on/off” control of the refrigerant compressor to be used for capacity control. An
air-to-air economizer is employed to minimize the size of the refrigeration plant and to save electrical energy. Condensed moisture is
accumulated in the built-in moisture separator and is discharged through the zero air-loss drain. When the dryer is started it is
automatically in the direct expansion mode and cools the compressed air by direct heat exchange with refrigerant. When the sensor
temperature drops below setpoint (indicating that the dryer capacity is in excess of the load), the refrigerant solenoid valve is closed,
forcing refrigerant through the ice-making circuit only. The dryer continues to run, making ice, for a predetermined time interval after
which the refrigerant compressor is switched off. At this time, the LED displays the code “ICE” indicating that the dryer is cooling the
compressed air by melting the ice-mass. When the sensor temperature rises sufficiently, indicating that the ice-mass has been
depleted, the refrigeration system is re-started and the control cycle is repeated.

ATTENTION: although this dryer is equipped with an on/off switch & internal individual component protection, complete unit

over-current & short circuit protection MUST be provided by the installer, in the user’s power supply, before the dryer.

2/16 Cod. 710.062.01.00 – Rev.08 – 02.05.02

Condensate drain outlet

Direction of rotation of fan motor

PSB INDUSTRIES INC.

Phone : 814-45—3651 Fax : [phone] • www.PSBINDUSTRIES.com • [e-mail]

1.6 Use

The use of a dryer is recommended for nearly all compressed air applications, but especially when high purity and low moisture
content is required, such as in the pharmaceutical & food industry, medical applications and for coating & painting applications.

1.7 General Safety Instructions

Read this manual carefully before performing any operation. This machine has been designed and manufactured to be used only as
described below. The supplier is not responsable for difficulties associated with operation other than the intended use or operation
that is not in compliance with the instructions mentioned in this manual. All maintenance or cleaning operations involving interior
parts must be performed by trained technicians only.

ALWAYS:

• Always be familiar with all controls.

• Always be sure that the dryer is isolated from the compressed air network (inlet and outlet valves closed) and that internal

• Always disconnect electrical power and allow 15 minutes for the inner parts to cool down before removing the protection panels.

• Always be sure to disconnect electrical power before removing the cooling fan protection grill.

• Always be sure that all protection panels are properly attached during operation and after any maintenance operation.

pressure has been released before performing any maintenance.

•

General Air Division • 1202 West 12th Street, Erie, PA. 16501 G5C Dryers

NEVER:

• Never place flammable objects near the dryer.

• Never use the dryer if the power cable is faulty or the connection is not safe.

• Never allow anyone to operate the dryer without giving him/her proper instructions.

• Never make any alterations to safety parts.

• Never strike or use excessive force on internal parts.

• Never touch any part of the cooling circuit when the machine is running. They are very hot!

• Never drain the condensate directly into the sewage system... request PSB-General Air oil/water separator information

All installation, use and maintenance operations must be perfomed according to the instructions detailed in this manual. All

dryer maintenance should only be performed by qualified personnel taking the proper safety precautions.

2.0 MACHINE UNPACKING AND HANDLING

2.1 Unpacking and Handling

The dryer is shipped on a wooden skid and packaged in a protective cardboard carton with banding straps. The package must
always be lifted from the bottom and must be kept in an upright position at all times. Unpack the dryer by cutting straps (always
wear safety gloves and eye protection and cut either with scissors or cutting nippers), removing the carton from the top and moving
the dryer from the wooden pallet to the chosen position.

2.2 Package Disposal

It is recommended that the packaging materials be retained at least thoughout the warranty period. Should the dryer need to be
transported for service, the original packaging will allow for easier and safer shipping.

2.3 Returned Equipment

• Repack the dryer in its original carton or with one of the same dimensions.

• The dryer must be kept vertical and packed as supplied from the manufacturer.

• Do not transport the dryer without proper packing, shipment damage remains the responsibility of the sender.

Materials returned without proper packing and authorization documents will not be accepted.

3/16 Cod. 710.062.01.00 – Rev.08 – 02.05.02

PSB INDUSTRIES INC.

Phone : 814-45—3651 Fax : [phone] • www.PSBINDUSTRIES.com • [e-mail]

3.0 SET-UP

•

General Air Division • 1202 West 12th Street, Erie, PA. 16501 G5C Dryers

3.1 Positioning

The dryer should be located in an area with a flat floor and protection against weather conditions and, if possible, direct sun light.
The area must also be properly ventilated (& heated, if necessary) so that the temperature is kept between 40 °F and 110 °F when the
dryer is running (remember that the operating dryer will add heat to the room). It must also be large enough to allow at least three
feet of free space adjacent to both the condenser air inlet and outlet grills to allow for proper unit cooling.

3.2 Installation

• Air by-pass piping is recommended to allow uninterrupted air service during instances of maintenance of repair.

• Prior to installation check to insure that the compressed air piping is free of debris or other contaminants.

• Connect the dryer to the compressed air line in accordance with one of the diagrams shown in section 11 and per unit labeling.

• Always use a back-up wrench to prevent damage to the connections during piping of the air inlet and outlet.

• Make sure that line power agrees with the unit data plate and the service complies with local electrical codes.

• Always include a fused safety switch in the line power supply (refer to data plate amperage for proper selection).

• A particulate filter is recommended at the air inlet to avoid any deposit of solid particles into the dryer.

• Position the dryer so that all controls can be easily read and so that all maintenance operations are easily performed.

• Connect the condensate drain tube in compliance with local regulations. The condensate is a pollutant and cannot be drained

directly into the sewage system. A Motivair oil/water separator of suitable capacity is recommended.

3.3 Filling The Thermal Mass Reservoir

• Remove the threaded plug (A) from the fill port located on the top panel of the dryer.

• Slowly fill the reservoir with clean, tap water until it can be seen coming from the flexible overflow tube (B) at the rear of the dryer.

• Replace the fill port plug.

3.4 Start-Up

• Close inlet and outlet valves, switch on S1 and ON/OFF (hold for 3 seconds), and check for the pilot light on the control panel.

• Allow the dryer to run until the word “ICE” appears in the digital display (usually about 15 minutes).

• Open the outlet air valve completely and then gradually pressurize the dryer by slowly opening the inlet air valve.

• Compressed air flow rates in excess of rating will reduce performance but will not compromise safety.

4/16 Cod. 710.062.01.00 – Rev.08 – 02.05.02

PSB INDUSTRIES INC.

Phone : 814-45—3651 Fax : [phone] • www.PSBINDUSTRIES.com • [e-mail]

•

General Air Division • 1202 West 12th Street, Erie, PA. 16501 G5C Dryers

3.5 Dryer Transportation or Long-Term Storage

• Close inlet and outlet valves, switch off the devices (S1) and (ON/OFF), and disconnect power.

• Depressurize the air circuit using the condensate trap TEST button & remove the fill port plug to vent the reservoir.

• Drain the reservoir tank into a suitably sized container by removing right side panel (B) & turning drain valve (A) counter-

clockwise.

• Replace the fill port plug & close the drain valve (A) by turning clockwise.

4.0 MAINTENANCE

4.1 Weekly

• Visually inspect for proper condensate drain operation.

4.2 Monthly

• Isolate the dryer from the compressed air system by closing inlet & outlet valves and release pressure.

• Clean or replace condesate drain trap filter to remove any accumulated debris.

4.3 Semi-annually

• Check compressor electrical current draw against amperage listed on the data plate.

• Remove power from the dryer and clean condenser finned surfaces with compressed air jet.

5.0 EQUIPMENT DATA

Model

Capacity (scfm)* 18 30 60 75 100 120 150 200 250 250

Compressor Power (HP) 1/6 1/4 1/3 1/2 ¾ 1 1-1/2 1-1/2 2 2

Power Supply (V/Ph/Hz) 115/1/60 115/1/60 115/1/60 115/1/60 115/1/60 115/1/60 230/1/60 230/1/60 230/1/60 460/3/60

Rated Current (A) 1.1 3.7 5.2 6.8 8.1 9.2 7.5 7.5 8.5 3

Full Load Current (A) 2 4.6 6.8 8 9.8 11 8.7 10.5 12.5 5.2

Refri gerant Type R-134a R-134a R-134a R-134a R-134a R-134a R-134a R-134a R-134a R-134a

Refri gerant Charge (LBS) 0.66 0.79 1.21 1.21 1.21 1.32 1.75 2.16 2.0 2.0

Connection Size F (NPT) 1/2 1/2 3/4 3/4 ¾ 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2

Weight (lbs) 66 77 119 132 141 203 232 232 247 247

Max. Air Inlet (°F) 113 113 113 113 113 113 113 113 113 113

Max. Ambient (°F) 104 104 104 104 104 104 104 104 104 104

Max. Pressure (psig) 230 230 230 230 230 230 230 230 230 230

G5C-18 G5C-30 G5C-50 G5C-75 G5C-100 G5C-120 G5C-150 G5C-200 G5C-250 G5C-250

*Rated capacity @ air inlet of 100°F & 100 psig, 100°F ambient & 33 – 39° F leaving dewpoint

5/16 Cod. 710.062.01.00 – Rev.08 – 02.05.02

PSB INDUSTRIES INC.

Phone : 814-45—3651 Fax : [phone] • www.PSBINDUSTRIES.com • [e-mail]

•

General Air Division • 1202 West 12th Street, Erie, PA. 16501 G5C Dryers

6/16 Cod. 710.062.01.00 – Rev.08 – 02.05.02