air powered generator operation and maintenance manual€¦ · qd-205 july/09 rev(1) helping...

QD-205 July/09 Rev(1)

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Air Powered Generator

Operation and Maintenance Manual

AIR POWERED GENERATOR O&M MANUAL 2 QD-205 July/09 Rev(1)


Table of Contents Safety.................................................................................................... 3

General ...................................................................................................................................................................3 Safety Notices.........................................................................................................................................................5 Cautions, Warnings and Dangers ...........................................................................................................................6

Cautions .............................................................................................................................................................7 Warnings ..........................................................................................................................................................10 Dangers............................................................................................................................................................12

Labels ...................................................................................................................................................................13 Important Contacts ........................................................................... 15 Product Overview.............................................................................. 17

Cart Assembly ......................................................................................................................................................18 Mechanical Coupling ............................................................................................................................................19 AC Generator........................................................................................................................................................19 AC Receptacle......................................................................................................................................................20 Pneumatic Quick Connect Coupling .....................................................................................................................20 Air Valve ...............................................................................................................................................................21 Pneumatic Muffler .................................................................................................................................................21 Pneumatic Water Separator..................................................................................................................................21 Pneumatic Lubricator ............................................................................................................................................22 Light Assembly .....................................................................................................................................................22

Installation and Setup....................................................................... 23 Operating Procedure ........................................................................ 24 Maintenance....................................................................................... 25 Troubleshooting................................................................................ 26 Appendix A – Replacement Parts List Appendix B – Warranty



Safety General Congratulations on your purchase of a B&D Manufacturing Air Powered Generator. This Operation Manual provides the operator with an overview of the components incorporated in the design, the procedures and instructions on how to operate and perform routine maintenance and troubleshooting of your Air Powered Generator. The objective of this manual is to provide simple, clear, and complete details, procedures and instructions. These objectives are backed by B&D Manufacturing’s commitment to offer superior custom designed equipment and technical support. Every effort has been undertaken to ensure the accuracy and completeness of information in this manual. Constant efforts are made to improve the quality and performance of B&D Manufacturing products, so some details included in this Operation Manual may differ slightly from your Air Powered Generator. If you have any questions about these differences, please contact B&D Manufacturing. If you do not understand any of the information, instructions or procedure explanations in this manual, contact B&D Manufacturing. The operator must understand all outlined potential hazards described in the Safety section located at the front of this manual prior to operating, performing maintenance on, or troubleshooting of the Air Powered Generator. It shall be the responsibility of the employer or owner to ensure that all operators have received proper training prior to operating, performing maintenance on, or troubleshooting of the Air Powered Generator. The operator must follow all specific site procedures and guidelines when operating, performing maintenance on, or troubleshooting of the Air Powered Generator. In no circumstance shall the instructions and procedures outlined in this manual take precedence over your established specific site procedures and guidelines. Do not undertake the maintenance, troubleshooting, repairs or servicing of your Air Powered Generator unless you are familiar with the operation and servicing of technical equipment and have received proper training. If your level of training, skill or comprehension of the Manual’s instructions or procedures could possibly result in injury to personnel or damage to your Air Powered Generator, have the work done by a qualified B&D Manufacturing Representative. Your common sense and good



judgment are crucial to the safe and successful operation and maintenance of your Air Powered Generator. At any time, if the operate suspects that a safety issue may be present with the B&D Manufacturing Air Powered Generator perform an immediate shutdown on the Air Powered Generator, disconnect your site’s air supply to the Air Powered Generator and immediately notify your supervisor. NEVER permit anyone to perform maintenance on, or perform troubleshooting of your Air Powered Generator without first receiving proper training. Failure to do so could result in serious injury to personnel.

• Read and understand this Manual before you operate or perform maintenance on or troubleshooting of your Air Powered Generator.

CAUTION

Refer to this Operation Manual before operating, maintaining or troubleshooting your Air Powered Generator.

• Read the Cautions, Warnings, and Dangers in this section before you operate or

perform maintenance on, or perform troubleshooting on your Air Powered Generator. • Read instructions and procedures thoroughly before you start to operate or perform

maintenance on, or perform troubleshooting on your Air Powered Generator. • Review all warnings, cautions and dangers that accompany any instruction or

procedure. • Review the Safety section and all relevant cautions, warnings and dangers each time

you prepare to perform maintenance on or troubleshoot of your Air Powered Generator. • Improper usage can cause injury to personnel or damage to equipment. Read and

understand your site specific safety instructions thoroughly before using your Air Powered Generator.

• Contact B&D Manufacturing for additional training opportunities.



Safety Notices There are three types of Safety notices used in this manual.

• Caution Notices

CAUTION

Caution notice indicates a potential hazardous situation that if not avoided, may result in personnel injury or damage to equipment.

• Warning Notices

WARNING

Warning notice indicates a potential hazardous situation that if not avoided, may result in serious injury or death to personnel.

• Danger Notices

DANGER

Danger notice indicates an imminently hazardous situation that if not avoided, will result in serious injury or death to personnel.



Cautions, Warnings and Dangers Please read cautions, warnings and dangers before you operate or perform maintenance on, or perform troubleshooting on your Air Powered Generator. It shall be the responsibility of the employer or owner to furnish all the tools and personnel protective equipment that are required to safely operate, perform maintenance on or troubleshooting of the Air Powered Generator. Always follow established specific site procedures and guidelines and ensure tools and personnel protective equipment (PPE) are in good condition prior to performing maintenance on your Air Powered Generator. Although not all of the personnel protective safety equipment is necessary to perform all instructions, procedures and tasks on the Air Powered Generator, most sites and facilities require them as a standard and it is good practice to use them at all times. It is critical that the appropriate protective safety equipment be worn at all times when you operate or perform maintenance on, or perform troubleshooting on your Air Powered Generator. The following list all of the perceived Cautions, Warnings and Dangers that potential exist when operating, performing maintenance on or troubleshooting the Air Powered Generator. Every effort has been made to outline all of the potential Caution, Warning and Danger notices that may arise when operating, performing maintenance on or troubleshooting the Air Powered Generator. Even though every effort has been made the operator must use common sense and good judgment when operating, performing maintenance on or troubleshooting the Air Powered Generator, as unforeseen hazards may develop.



Cautions

CAUTION

Training Caution. Refer to this Operation Manual before operating, maintaining or troubleshooting your Air Powered Generator.

CAUTION

Eye Protection Caution. Wear Eye Protection, safety glasses with side shields or goggles, at all times when operating, maintaining or troubleshooting your Air Powered Generator.

CAUTION

Foot Protection Caution. Wear Foot Protection at all time when operating, maintaining or troubleshooting your Air Powered Generator.



CAUTION

Head Protection Caution. Wear a Hard Hat at all time when operating, maintaining or troubleshooting your Air Powered Generator.

CAUTION

Hand Protection Caution. Wear Protective Gloves at all time when operating, maintaining or troubleshooting your Air Powered Generator.

CAUTION

Clothing Protection Caution. Never wear loose Clothing in and around the Air Powered Generator. Ensure that any loose items of clothing, such as sleeve cuffs and pant legs, are buttoned up or tucked in at all time when operating, maintaining or troubleshooting your Air Powered Generator.



CAUTION

Long Hair Caution. Never wear long hair in and around the Air Powered Generator. Operators with long hair must ensure that their long hair is tied, pinned or capped up prior to operating, maintaining or troubleshooting your Air Powered Generator.

CAUTION

Ear Protection Caution. Although the Air Powered Generator does not typically produce harmful levels of noise, operators are cautioned to wear Ear Protection as appropriate to protect against other harmful levels of noise that may be present in the immediate area near the Air Powered Generator.



Warnings

WARNING

Improper usage can cause injury to personnel, or damage to equipment and property. Read and understand your site specific safety instructions thoroughly before operating, maintaining or troubleshooting your Air Powered Generator. This Air Powered Generator is designed exclusively for use with the Air Powered Generator’s Light Assembly. Using this Air Powered Generator as a power source for any other applications will may damage the unit, possibly result in serious injury or death to personnel and void the warranty.

WARNING

Rotating Parts Warning. Always ensure that the Safety Guard is in place before operating your Air Powered Generator. Never place any parts of your body, including hair or jewelry, in close proximity to any of the moving parts of the Air Powered Generator. Failure to do so could result in serious injury or death to personnel.



WARNING

Burn Warning. Keep your hands and other body parts away from potential hot Air Powered Generator’s Light Assembly surfaces during operation and shortly after you turn off the air supply to the Air Powered Generator. These surfaces may become extremely hot while the Air Powered Generator is operating and may seriously burn you. Wait until the Air Powered Generator’s Light Assembly cools before performing maintenance on or troubleshooting of your Air Powered Generator. Failure to do so could result in serious injury to personnel.



Dangers

DANGER

Rotating Parts Warning. Always ensure that the Safety Guard is in place before operating your Air Powered Generator. Never place any parts of your body, including hair or jewelry, in close proximity to any of the moving parts of the Air Powered Generator. Failure to do so could result in serious injury or death to personnel.



Labels Safety labels on the Air Powered Generator serve as additional reminders for safe operating practices around the Air Powered Generator. The following lists the Safety labels installed on your Air Powered Generator.

• Warning Avoid Injury. Do Not Operate With Guard Removed.

• Attention Check Oil Daily. Empty Water Separator Daily.

• Attention Pre-Inspect Equipment For Signs Of Damage Before Use.



• Warning Surface Hot. Avoid Burns. Allow Bulbs To Cool Before Replacing. Replace with GU10 120V 50 Watt Bulbs Only.



Important Contacts

B&D Manufacturing

4703 Regional Road 15 P.O. Box 519

Chelmsford, Ontario Canada, P0M 1L0

Telephone: 705-855-2363

Fax: 705-855-4134

Toll Free Number: 1-800-668-0324

Internet Website: http://www.bdmfg.com E-mail: mailto:[email protected]



General Description The Air Powered Generator has been designed to provide a 115 volt 60 hertz 1200 watts AC electrical power supply output. The AC electrical output is used to supply power to the Air Powered Generator’s Light Assembly.



Product Overview This section of the Manual provides an overview of the major components and assemblies of the Air Powered Generator supplied by B&D Manufacturing. The Air Powered Generator consists of the following major components.

• Cart Assembly • Pneumatic Air Motor • Mechanical Coupling • AC Generator • AC Receptacle • Quick Connect Coupling • Pneumatic Muffler • Air Valve • Pneumatic Water Separator • Pneumatic Lubricator • Light Assembly

Refer to Appendix A for the Replacements Parts List of the components incorporated in the Air Powered Generator’s design.



Cart Assembly The Air Powered Generator components are housed within a Cart Assembly. The Cart Assembly consists of the following components.

• Handle with Hose Caddie • Front Support Legs • Rear Wheels • Top Storage Tray • Hinged Door • Bottom Tray • Safety Guard

Front Support Legs

Hinged Door

Safety Guard

Handle

Hose Caddie

Rear Wheels

Top Storage Tray



Pneumatic Air Motor A Pneumatic Air Motor has been included in the design of the Air Powered Generator. The Pneumatic Air Motor’s function is to transform the input energy supplied from the site’s compressed air supply into mechanical output energy to be used to drive the Air Powered Generator’s AC Generator. The Pneumatic Air Motor is located inside the lower bottom right corner of the Air Powered Generator’s Cart Assembly.

Mechanical Coupling Mechanical Coupling has been included in the design of the Air Powered Generator. The purpose of the Mechanical Coupling is to physically link the output shaft of the Pneumatic Air Motor to the input shaft of the AC Generator. AC Generator An AC Generator has been incorporated into the design of the Air Powered Generator. The AC Generator’s purpose is to convert the mechanical energy supplied by the output shaft of the Pneumatic Air Motor into an electrical energy output in the form of an AC (alternating current) power supply. The AC Generator provides 115Vac 60 hertz 1200 watt electrical output that is used to power the Air Powered Generator’s Light Assembly. The electrical output of the AC Generator is hardwired to an 115Vac 15amp duplex style receptacle. The AC Generator is located inside the lower bottom left corner of the Air Powered Generator’s Cart Assembly.

AC Generator

Mechanical Coupling

Pneumatic Air Motor



AC Receptacle An AC Receptacle has also been included in the design of the Air Powered Generator. The AC Receptacle provides the operator with a mean to connect the Light Assembly’s power cord to the output of the AC Generator.

Pneumatic Quick Connect Coupling A Pneumatic Quick Connect Coupling has been installed on the Air Powered Generator’s inlet air supply line. The Pneumatic Quick Connect Coupling provides the operator with a means quick and easy means to connect the site’s air supply line to the Air Powered Generator.

The Pneumatic Quick Connect Coupling is located on the rear left side of the Air Powered Generator’s Cart Assembly. In order to ensure optimal performance of your Air Powered Generator, B&D Manufacturing recommends that you use an air supply line with a minimum overall diameter of 1 inch.

AC Duplex Receptacle

Light Assembly’s Power Cord

Pneumatic Quick Connect Coupling



Air Valve An Air Valve has been installed on the Air Powered Generator’s inlet air supply line. The Air Valve provides the operator with a means to turn on and turn off the site’s air supply to the Air Powered Generator.

Pneumatic Muffler A Pneumatic Muffler has been incorporated into the design of the Air Powered Generator. The purpose of the Pneumatic Muffler is to attenuate the noise produced by the Pneumatic Air Motor. Pneumatic Water Separator A Pneumatic Water Separator has also been included in the design of the of the Air Powered Generator’s inlet air supply line. The Pneumatic Water Separator’s function is to remove water from the compressed air line supply to ensure that the air being supplied to the Pneumatic Air Motor is clean and dry. The removal of water from the air supply ultimately improves the efficiency of operation of the motor and also to prevents motor damage.

Pneumatic Muffler

Air Valve Pneumatic Water Separator

Pneumatic Lubricator



Pneumatic Lubricator A Pneumatic Lubricator has been integrated into the design of the Air Powered Generator’s inlet air supply line. The function of Pneumatic Lubricator is to atomize the oil entering the Pneumatic Air Motor to improve upon the overall efficiency of the motor and to inhibit internal corrosion of the Pneumatic Air Motor’s components. Light Assembly The Air Powered Generator includes a portable Light Assembly. The Light Assembly consists of two (2) separate Light Housings that are connected together via a piano style hinge. Each of the Light Housings includes an array of five (5) 120Vac 50 watt light bulbs. The light bulbs are hardwired internally in a parallel circuit connection so that in the event one light bulb fails the remaining light bulbs continue to operate.

Light Housing

Light Bulb



Installation and Setup This section of the Manual describes the procedure for the installation and setup of the Air Powered Generator. Minimal setup is required to get your Air Powered Generator interconnected with your site’s compressed air supply. The following list the steps to be completed to setup the Air Powered Generator and connect it to your site’s compressed air supply.

• Roll the Air Powered Generator to a suitable location. • Perform a Pre-Inspection of the Air Powered Generator’s components for signs of

damage before use. • Check the Pneumatic Lubricator’s oil level. Add more oil if required. Use Air Tool type

oil. • Check the Pneumatic Water Separator and empty water from the Pneumatic Water

Separator. • Ensure that the Air Powered Generator’s Air Valve is closed. • Connect your site’s compressed air supply to the Air Powered Generator’s Pneumatic

Quick Connect Coupling. • Remove Air Powered Generator’s Light Assembly from the Cart Assembly’s Top

Storage Tray, mount and secure it at a location that is suitable for your usage. • Plug the Air Powered Generator’s Light Assembly power cord into the AC Receptacle.



Operating Procedure Use the following procedure to start and operate your Air Powered Generator.

• Ensure that your site’s compressed air supply is operating. • Turn on the Air Powered Generator’s Air Valve to start the Pneumatic Air Motor and

power the Light Assembly. Use the following procedure to stop your Air Powered Generator from operating.

• Turn off the Air Powered Generator’s Air Valve to stop the Pneumatic Air Motor and power down the Light Assembly.

• Disconnect your site’s compressed air supply from the Air Powered Generator’s Pneumatic Quick Connect Coupling.

• Allow the Air Powered Generator’s Light Assembly to properly cool down before returning it to the Cart Assembly’s Top Storage Tray.

WARNING

Burn Warning. Keep your hands and other body parts away from potential hot Air Powered Generator’s Light Assembly surfaces during operation and shortly after you turn off the air supply to the Air Powered Generator. These surfaces may become extremely hot while the Air Powered Generator is operating and may seriously burn you. Wait until the Air Powered Generator’s Light Assembly cools before performing maintenance on or troubleshooting of your Air Powered Generator. Failure to do so could result in serious injury to personnel.



Maintenance Performing routine maintenance is important in keeping your Air Powered Generator in good operating condition. This section of the Manual outlines the maintenance requirements for your Air Powered Generator. B&D Manufacturing recommends that all maintenance be performed indoors, whenever possible, to prevent environmental conditions, such as rain, wind, or snow from damaging any of the Air Powered Generator’s components. The following is a summary of the maintenance requirements and suggested check intervals to be performed on your Air Powered Generator.

Item Daily Check Pneumatic Lubricator’s oil level • Empty water from the Pneumatic Water Separator

•



Troubleshooting This section of the Manual provides the operator with suggestions to help troubleshoot, diagnose and resolve issues that may arise with your Air Powered Generator. Refer to the Appendix A attached at the end of this document for further assistance in troubleshooting.

• Appendix A – Replacement Parts List NEVER permit anyone to perform maintenance on, or perform troubleshooting of your Air Powered Generator without first receiving proper training. Failure to do so could result in serious injury to personnel.

• Read and understand this Manual before you operate or perform maintenance on or troubleshooting of your Air Powered Generator.

CAUTION

Refer to this Operation Manual before operating, maintaining or troubleshooting your EV-2051-M Electric Motor.

• Read the Cautions, Warnings, and Dangers in this section before you operate or

perform maintenance on, or perform troubleshooting on your Air Powered Generator. • Read instructions and procedures thoroughly before you start to operate or perform

maintenance on, or perform troubleshooting on your Air Powered Generator. • Review all warnings, cautions and dangers that accompany any instruction or

procedure. • Review the Safety section and all relevant cautions, warnings and dangers each time

you prepare to perform maintenance on or troubleshoot of your Air Powered Generator. • Improper usage can cause injury to personnel or damage to equipment. Read and

understand your site specific safety instructions thoroughly before using your Air Powered Generator.

• Contact B&D Manufacturing for additional training opportunities.



Disconnect your site’s compressed air supply from the Air Powered Generator’s Pneumatic Quick Connect Coupling and turn off the Air Powered Generator’s Air Valve when performing troubleshooting on the Air Powered Generator. Failure to do so could result in serious injury or death to personnel.

Condition or Symptom Possible Cause Corrective Action Site’s Compressed Air Supply is not connected or operating.

Connect your site’s compressed air supply into the Pneumatic Quick Connect Coupling or verify that your site’s compressed air supply is functioning

Air Valve is not turned on. Turn on the Air Valve

Pneumatic Air Motor will not start

Insufficient quantity of lubricating oil. Check the oil level of the Pneumatic Lubricator and add more oil if necessary.

Site’s Compressed Air Supply is not connected or operating.

Connect your site’s compressed air supply into the Pneumatic Quick Connect Coupling or verify that your site’s compressed air supply is functioning

Air Valve is not turned on. Turn on the Air Valve Light Assembly’s Power Cord is not plugged in

Plug in the Light Assembly’s power cord into the AC Receptacle

Light Assembly will not power on

AC Receptacle has tripped Press the reset button for the AC Receptacle



Appendix A – Replacement Parts List



Replacement Parts This section of the Manual includes a listing of the replacement parts for your Air Powered Generator. To order replacement parts, call B&D Manufacturing. Refer to the Important Contacts section of this Manual for contact information. If the replacement part does not appear on the list below, call B&D Manufacturing. Part Description Part Number Pneumatic Air Motor c/w Muffler BD-M-0029 AC Generator BD-M-0030 Pneumatic Water Separator c/w Bowl Guard BD-M-0031 Pneumatic Lubricator BD-M-0032 Light Bulb BD-E-0065 Light Assembly 26186-L



Appendix B – Warranty



Warranty All manufactured goods supplied by this Company are guaranteed against defective workmanship and material for a period of 1,000 hours or six (6) months from the date of installation or twelve (12) months from the date of shipment, whichever period expires first. If within that period, the Company receives from the customer, written notice of any alleged defect in, or non-conformances of any such product and if in the Company’s sole judgment the product does not conform or is found to be defective in material or workmanship, then the Distributor or Customer shall at the Company’s request, return the part or product transportation prepaid and the Company, at its option and expense shall repair or replace the defective part or product, or repay to Distributor or Customer, the full price paid for such part or product by Distributor or Customer. Any repayment of purchase price shall be without interest. Warranty on third party items shall be limited to the warranty passed on to the company by the original manufacturer of such items. Limitations The warranties of B&D do not cover, and the Company makes no warranty with respect to:

• Failures not reported to the Company within the warranty period specified above. • Failures or damage due to misapplication, abuse, improper installation or abnormal

condition of temperature, dirt or corrosion matter. • Failures due to operation, either intentional or otherwise, above rate capacities or in an

otherwise improper manner. • Products which have been in any way tampered with or altered by anyone other than an

authorized representative of the Company. • Expenses incurred by Distributor or Customer in an attempt to repair or rework any

alleged defective products. • The Company shall not be responsible for any special, indirect or consequential

damage of any nature arising out of or relating to the manufacture, sale or use of the Company’s products. Such excluded damages include, but are not limited to, loss of business profits, revenues, opportunities, loss of goodwill, down time of equipment and facilities, and all other type of damages, direct or indirect, foreseeable or unforeseeable.

• Any damage to the equipment caused by the Customer’s personnel, freight forwarder, installation contractor or other personnel handling the equipment, during shipment, installation or prior to completion of commissioning is to be repaired at the Customer’s expense.

Unless stated otherwise by the Client, via written exceptions, these terms and conditions are considered accepted by the Client upon receipt of a purchase order.

air powered generator operation and maintenance manual€¦ · qd-205 july/09 rev(1) helping...

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