Thermal Wraps. GT Exhaust Accessories Installation and Operation Manual. Rev. A. Copyright 2012 GT Exhaust, Inc. All Rights Reserved

Transcription

1 Thermal Wraps GT Exhaust Accessories Installation and Operation Manual Rev. A Copyright 2012 GT Exhaust, Inc. All Rights Reserved Published: December 20, 2012

2 NOTICE The instructions herein must be expressly carried out in order to preserve WARRANTY COVERAGE. Ensure that all periodic checks and maintenance schedules are adhered to as directed. IMPORTANT SAFETY WARNINGS IF THERE IS ANY CONCERN ABOUT THE SAFETY OF THIS OR ANY SYSTEM, CLEAR THE AREA IMMEDIATELY OF ALL PERSONNEL AND CONTACT THE APPROPRIATE PERSON FOR FURTHER INSTRUCTIONS. WARNING: ANYONE WORKING AROUND OR NEAR THE INSTALLATION SHOULD BE TRAINED IN THE PROPER SAFETY PRECAUTIONS AND PROCEDURES INCLUDING EMERGENCY SHUTDOWN. THESE PRECAUTIONS AND PROCEDURES MUST BE FOLLOWED. WARNING: WORK ON THE INSTALLATION IS TO BE DONE ONLY BY TRAINED, QUALIFIED INDIVIDUALS. THIS INCLUDES ALL ELECTRICAL AND MECHANICAL WORK. ALL WORKERS MUST BE TRAINED IN THE PROPER SAFETY PRECAUTIONS AND PROPER ATTIRE MUST BE WORN AT ALL TIMES INCLUDING HARD HATS, SAFETY GLASSES, PROTECTIVE OUTERWEAR, EAR PROTECTION, AND STEEL-TOED BOOTS.

3 Introduction Congratulations on your decision to promote optimal safety in your work environment through the recent purchase of your GT Exhaust Thermal Wrap. GT Exhaust s flexible, removable, and easy-to-install thermal wraps are made of state-of-the-art layered material. The GT Exhaust thermal wraps are customizable and can be installed on engine exhaust manifolds, turbochargers, flex, piping, silencers, valves, heat exchanges, and other industrial applications, where health and well-being need to be protected from the extreme operating temperatures that exhaust systems operate at. When properly installed, the durable and protective thermal wraps significantly reduce heat and excess noise while providing a safe environment for individuals working with and around such applications. This guide will walk you through the steps to successfully install a GT Exhaust Thermal Wrap and provide all other relevant information to ensure your exhaust system is optimally effective. READ THROUGH THE ENTIRE MANUAL BEFORE PROCEEDING WITH ACTUAL INSTALLATION. Copyright 2012 GT Exhaust, Inc. ERRORS and OMISSIONS EXCEPTED

4 Selection and Description A full list of specification and application sheets for the complete line of GT Exhaust Silencers, Emissions Products, and Accessories can be found at Thermal Silencer / Accessory Wrap Overview Thermal Wraps are asbestos-free, thermal insulation blankets that are used to reduce the danger associated with high surface temperatures of exhaust system components. Wraps also minimize the heat transferred to the surrounding environment ensuring that exhaust temperature remains elevated for efficient catalytic activity as well as to air temperature management for interior installations. Thermal wraps can be installed before or after exhaust system installation depending on the site and installers preference. IMAGE 1: Picture of typical GT Exhaust Wrap Applications

5 Receiving Inspection Upon receipt of the system, check the nameplate against the packing list to verify the correct part numbers are received. Verify all items on the packing list are present. Keep the shipping container to protect the unit until installation has been completed. Prior to unpacking, check all components for shipping damage. Advise of shipping damage within three days of receipt of the product. Storage Leave any cardboard boxing, plywood covering, crating, shipping bars, and/or plastic covering intact until ready to install. Store the product on blocks, a minimum of 4 high, so that air can freely circulate around the unit. Do not store the product in contact with the ground or in a wet, humid or flooded area. Inspect the product s exterior and interior surfaces prior to installation. If there are any areas of significant damage, i.e. tears, deep scratches, contact the factory before proceeding with installation.

6 Thermal Wrap Specifications For more information, please visit,

7 General Installation Considerations Installation of GT Exhaust Accessories requires that the user ensure the entire exhaust system is properly designed before installing parts. Exhaust components such as expansion joints, rain caps, elbows, supports, etc. are critical installation pieces which, if they fail, may compromise the integrity of the system as well as damage other components and, possibly the engine and surrounding components. The installation of GT Exhaust Thermal Wraps must be performed by qualified personnel. Inspect the surface to which you will be installing the wrap. The surface should be clean, dry, and free of any flammable or corrosive substances. Also, ensure there are no sharp or foreign objects that could tear or potentially cause other damage to the wrap. Verify that the thermal wraps are of proper size for the silencer or accessory. Note: Verify no part of the exhaust system is in the vicinity of flammable materials. Observe all OSHA mandated regulations for the safe rigging of exhaust equipment. Maximum operating temperature for GT Exhaust Thermal Wraps is 1100 F (590 C). Note: If the thermal wrap component only has 1 seam, ensure the seam is positioned on the bottom of the exhaust product to prevent moisture from becoming entrapped and causing corrosion. See Image 2 and 3. IMAGE 2: Illustration of Thermal Wrap Installation 1. Remove all thermal wraps components from the shipping box ensuring that all items are present. 2. Lay all pieces on a flat surface while putting them in position as shown in the example above. 3. Thermal wraps need to be flattened and stretched on the clean flat surface, after removing from the shopping box to maintain their proper shape. Handle the thermal wraps with care during this procedure to avoid any damage to the fabric.

8 4. Begin the installation of the thermal wraps while referring to the example above thermal wrap components will be numbered according to how many pieces are included in the thermal wrap kit. 5. Connect the middle sections (3 of 7 and 2 of 7, from the above example) together ensuring that the seams are centered on both the top and bottom. 6. Do not tightly secure thermal wrap components until all pieces are in place. 7. Tighten all components of the thermal wraps starting with 1. IMAGE 3: Pictures of Exhaust Accessories (Ensure to position seam on bottom for installation)

9 Velcro Thermal Wrap Installation Procedure Before beginning installation, review your order to make certain all items have been received as specified by the packing slip. Inspect the surface to which you will be installing the wrap. The surface should be clean, dry, and free of any flammable or corrosive substances. Also, ensure there are no sharp or foreign objects that could tear or potentially cause other damage to the wrap. Carefully examine the thermal wrap to ensure all edges are tightly hemmed, straps are securely in place and there are no tears, cuts, or defects to the outer liner of the thermal wrap. IMAGE 4: Illustration of Velcro Thermal Wrap Components Installation/Replacement 1. Place the appropriate thermal wrap section around the corresponding fitting. 2. Position the wrap so the side with the Velcro straps overlaps the other side. 3. Align the Velcro strips that run parallel with the edges of the wrap. Firmly push down along the entire length of the strip to ensure it is securely fastened. 4. Starting at one end of the thermal wrap section, pull the Velcro strap through both D-rings. 5. Loop the end of the strap back through the first D-ring. Pull the strap firmly until snuggly fastened. 6. Pull the end of the strap to its base. Press down firmly to secure the Velcro. 7. Repeat steps 3-5 on the opposite end of the thermal wrap section, then on all remaining straps. 8. To remove the thermal wrap, complete the above steps in reverse order. Note: If the thermal wrap component only has 1 seam, ensure the seam is positioned on the bottom of the exhaust product to prevent moisture from becoming entrapped and causing corrosion.

10 Spring Fastened Thermal Wrap Installation Procedure Before beginning installation, review your order to make certain all items have been received as specified by the packing slip. Be sure to check for: All sections of thermal wrap Tension springs Tension spring applicator Inspect the surface to which you will be installing the wrap. The surface should be clean, dry, and free of any flammable or corrosive substances. Also, ensure there are no sharp or foreign objects that could tear or potentially cause other damage to the wrap. Carefully examine the thermal wrap to ensure all edges are tightly hemmed, straps are securely in place and there are no tears, cuts, or defects to the outer liner of the thermal wrap. Installation/Replacement 1. Place the appropriate thermal wrap section around the corresponding fitting. 2. Starting at one of the end hooks on the wrap, loop one end of the tension spring around the support hook. Refer to IMAGE Holding the attached end of the spring in place, insert the other end into the tension spring applicator. 4. Using the tension spring applicator, pull the spring across the seam and loop it around the adjacent hook. Refer to IMAGE If so desired, use a soft mallet to flatten the hooks, locking the springs into place. 6. Install another spring on the other end of the wrap, as well as one in the middle to secure the wrap into place and allow for easier installation of the rest of the springs. Repeat the installation process with all hooks on each section of thermal wrap. Note: As additional tension springs are applied, gaps between the seams will begin to close with the seams nicely meeting to cover all originally exposed sections. Do not be alarmed by a gap in the seam at the beginning of the installation process, as it will close. Note: If the thermal wrap component only has 1 seam, ensure the seam is positioned on the bottom of the exhaust product to prevent moisture from becoming entrapped and causing corrosion. IMAGE 5: Picture of Tension Spring and Applicator

11 IMAGE 6: Illustration of thermal wrap spring installation IMAGE 7: Illustration of thermal warp spring installation

12 Installation Examples IMAGE 8: Picture of a 501 Silencer with Drop-In Option and Wrap within an Enclosure IMAGE 9: Picture of a typical exhaust installation with Silencer and Accessory Wraps

13 IMAGE 10: Picture of a typical exhaust installation with thermal wrap. Post Installation Checklist Subsequent to following the above procedure, review the following check list to ensure that all components of your exhaust system are properly installed and ready for operation: For areas with thermal wrap installed over any fittings or connections, pull the thermal wrap back, and check the tightness of the bolted connections and torque to the specifications provided in the Silencer Installation Manual. Ensure there is no debris in the joint that would prevent a secure and tight fit. Re-install the thermal wrap. Verify that the type and amount of movement generated by the system are identical with movements the exhaust system is designed for. After the initial engine run and cool down, re-check all bolts for tightness and torque as required in the Silencer Installation Manual.

14 Maintenance Note: Ensure exhaust components are cool prior to inspection and maintenance activities. While thermal wraps from GT Exhaust are very durable, proper maintenance will ensure the longevity of your thermal wrap and exhaust system. Maintenance tips: Keep any flammable or corrosive substances off of the outer liner. Prevent rips and tears by keeping sharp objects away from the outer liner. Eliminate any obstructive objects that could prevent monitoring or cause damage to your thermal wrap. If you feel your thermal wrap is not performing at an optimal level, review this guide to ensure it has been installed properly. Also, inspect the wrap for any damage that could have happened over time. To ensure proper operation and maintenance of your exhaust system, it is recommended that you inspect your system on the following schedule: 1. Weekly: Physically examine exhaust system for any sign of gas leakage, cracks, or significant areas of damage. 2. Quarterly: Examine the exhaust system for corrosion. Clean and remove any minor corrosion and refinish per GT Exhaust recommendations. If major corrosion has occurred such that the integrity of the exhaust system is in question, contact GT Exhaust for recommendation and resolution. Examine connecting flanges and support bolting retighten any loose bolts as required.

15 Product Registration / Warranty To register your GT Exhaust product and claim your warranty, please visit or Customer Care, at care@gtexhaust.com. Sourcing of Spare or Replacement Parts For spare or replacement parts, a full-line of accessories, warranty details, and other questions about the GT Exhaust Products, contact: 4121 NW 37th Lincoln, NE Tel: Toll Free: Fax: Customer Care Tel: care@gtexhaust.com Technical Support Tel: help@gtexhaust.com