Parker Zander BSP-MT 10/D3, Operating Manual

Page 1: ...BSP MT 10 95 D3 Dryer for Breathing air system Operating manual 28 01 2020 rev01 EN Cod 398H271981 Generation 3 ...

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Page 3: ...for installation 18 Connect piping 19 Installing the electrical connection 20 Start up 22 Requirements for initial start up 22 Setting times of the operating phases 23 Overview of operating and control elements 23 Start up dryer 26 Changing cycle mode optional 28 Monitoring dryer operation 29 With dewpoint sensing control optional 29 Shutdown and restart dryer 30 Emergency shutdown 30 Depressurisi...

Page 4: ...EN User Manual 2 BSP MT 10 95 D3 Technical data 45 Replacement and wear part list 47 Tightening torque values 49 Logic control diagram 50 Flow diagram 52 Dimensional drawing 53 ...

Page 5: ...p these appliance data up to date The above stated appliance data provide for a clear identification of the dryer and its compo nents and significantly facilitate any service measures Further important data on the dryer such as the details on the permissible operating pressure and the electrical connection are found on the type plate for position of the type plate see page 8 ...

Page 6: ...ng of 1 double chamber hollow section vessel fillied with drying agent 1 single chamber hollow section vessel filled with purifying agent 2 upstream filter 1 downstream filter Muffler Control system Associated documents Operating instructions present Technical documentation see annex Circuit diagrams see separate document Operating manual for installed filters separate document Notes on supplement...

Page 7: ...ch damage Danger These danger notes with a grey background warn against personal injury and or danger to life and limb danger notes help you to avoid serious or life threa tening situations for yourself and or third parties Target group of these operating instructions These operating instructions are intended for all persons working on and using the dryer We assume that all such persons are specia...

Page 8: ...d A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Risk of injury due to voltage carrying parts The electrical supply cable and external power lines are live even after the dryer is switched off and in the event of body contact may cause serious injury Before carrying out any work on the electrical system the electrical su...

Page 9: ... dries compressed air for industrial use The dryer is designed for compressed air which is free from aggressive water oil and solid matter constituents As standard the dryer is intended to be sited within a building and protected against the weather The dryer may be operated only in accordance with the data on the type plate and in accord ance with the contractual conditions Suspected misuse The d...

Page 10: ...er zones at the dryer Signs and instructions Front view Please note the above plates and instructions attached to the dryer Ensure that they are not removed and are always readable Type plate of the upstream filter Type plate of the dryer Vessel plate Type plate of the down stream filter ...

Page 11: ... depressurised Warning against sudden air ejection When the vessels are depressurised air flows suddenly out of the sound absorber This causes a sudden loud cracking noise Due to particles carried in the air flow there is a very considerable risk of eye injury When working on the dryer always wear eye and ear protection equipment Skid risk When emptying and filling the vessels with drying agent th...

Page 12: ...storage instruc tions on page 13 Information on transportation packaging Depending on the type of transportation the dryer is delivered in different types of packag ing All transportation types the apertures of the dryer are closed off by means of plugs In addition when transportation is effected by air the dryer is packaged in a wooden box In addition when transportation is effected by ship the d...

Page 13: ... dryer The weight of the dryer is specified in the technical data section of the annex The dryer should be installed with sufficient spacing at the top sides and rear in order to be able to carry out maintenance work and change the drying agent without any hindranc es see figure If in doubt the installation site must be inspect ed by specialists If you have any queries in this regard please contac...

Page 14: ...th the upper pipe bridge and thus damage it Remove the packaging of the dryer Attach suitable lifting gear to the transport lugs of the vessels see figure I Raise the dryer see figure II and remove the transportation pallet Place the dryer at its installation site I Transport lugs on pressure vessel II Installing by crane Anchoring the dryer Use suitable attachment material to anchor the dryer to ...

Page 15: ...er and the installed compressed air outlet valve installed by the owner are both closed and that the dryer is depressurised Disconnect dryer from the compressed air system Disconnect the dryer from the electrical power supply and all external lines Use film material or similar to close the compressed air inlet apertures and compressed air outlet apertures on the dryer in order to protect them agai...

Page 16: ...pressed air from drying agent abrasions be fore it is fed into the compressed air system The two vessels contain an extremely porous drying agent by means of which humidity is removed from the compressed air and stored just as in a sponge The stored humidity is then removed again from the drying agent and re introduced into the ambient environment To this end the two vessels alternate between diff...

Page 17: ...he regeneration is subdivided into three phases expansion dehumidification and pres sure build up With the dewpoint sensing control option the regeneration phase is followed by a standby phase Expansion phase During the expansion phase the pressure in the right chamber is released via the muffler down to ambient pressure within just a few seconds The outflow of the compressed air becomes noticeabl...

Page 18: ...option When in standby phase the fully regenerated vessel is ready for absorption operation The system is switched to this vessel as soon as the measured dewpoint at the compressed air outlet has reached the set dewpoint value for switchover Switchover When the drying agent in the adsorbing chamber has taken up a sufficient level of humidity then the switchover between the vessels will be effected...

Page 19: ...r is treated as the prime controller The control system can also be equipped with an optional operation signalling contact with which the dryer operation can be monitored from an external device Dryers with the optional dewpoint sensing control are equipped with such a contact as standard It is used for the transmission of operating signals and for the output of dewpoint alarms Dewpoint sensing co...

Page 20: ...an be installed and maintained in a depressurised condition see also the installation example on page 19 All pipes couplings and connections must have the correct diameter and match the oper ating pressure Hazard caused by exceeding the limit values A safety device must be provided in order to protect against the maximum permissible operating pressure from being exceeded The safety device must be ...

Page 21: ...pes subject to stress may burst due to the load placed on them during opera tion This may cause damage to property and personal injury Use steel pipes to connect the dryer to the compressed air system The following figure shows an installation example Compressed air system Item Component Example of an installation with bypass line 1 Entry humid air 2 Compressed air inlet valve owner end 3 Upstream...

Page 22: ...ector and withdraw connector with seal from the switchbox Use a suitable tool to remove the terminal block from the connection box Undo the PG union and pull the cable th rough the aperture 3 The exposed phase ends should not be longer than 35 mm max Now make the cable connection as follows Earth to terminal PE L1 to terminal 1 N to terminal 2 Terminal 3 is not used Fit terminal block into the con...

Page 23: ...ol board see circuit diagram Hinweis The compressor synchronisation controller is a higher level controller than the pressure dew point controller When both options are in place the compressor synchronisation controller is treated as the prime controller For operation monitoring system optional Operators have the option to connect the dryer to a fault signalling system connecting the respective li...

Page 24: ...rd to the dryer being started up Requirements for initial start up For the first start up the following preconditions must have been met The pipe system is free from contaminations All shutdown valves are closed The dryer is correctly sited and installed Checks before start up Ensure that all pipe cable and bolt connections on the dryer have been retightened no pipes chafe against body edges all m...

Page 25: ...ax Overview of operating and control elements ON OFF switch The ON OFF switch 2 is located to the side of the switchbox and above the mains plug 1 see figure If it is set to 0 the power supply is disconnected and the dryer is switched off The main valves are V1 V2 are open while the expansion valves V3 V4 are closed This means that the air can circulate in the main processing direction even if the...

Page 26: ...ryer Display panel at the switchbox LED Power 1 LED is on when dryer is switched on Flow diagram 2 The current operating phases of the dryer are indicated by means of 4 LEDs Depending on the operating phase the following LEDs might be on simultaneously Adsorption B1 and regeneration B2 or regeneration B1 and adsorption B2 Vessel B1 Regeneration 1 Adsorption 1 Vessel B2 Regeneration 2 Adsorption 2 ...

Page 27: ... service personnel of the manufacturer as a routine service is now due 25 With the dewpoint sensing control option the display shows the currently measured dewpoint instead of the default data The range of display is 100 C 148 F to 20 C 68 F If the measured dewpoint exceeds the preset alarm limit 5 C 41 F above the switchover value the displayed dewpoint value is flashing With the optional dewpoin...

Page 28: ...essure equipment Check the dryer regularly for externally visible damage and defects Any changes even in its operating behaviour must be reported immediately to the competent office or person In the event of an emergency or if a safety relevant disruption occurs e g escaping com pressed air defective component the dryer must be shut down immediately as described in the section on page 30 The unit ...

Page 29: ...t the compressed air system downstream of the dryer is pressurised or that a start up device option see page 17 was installed into the compressed air system directly downstream of the dryer The importance of this increases with the size of the compressed air system downstream of the dryer Smaller compressed air systems can be pressurised also by means of compressed air fed through the dryer Slowly...

Page 30: ...wpoint sensing control With compressor synchronisation If compressor synchronisation is enabled the dryer can only be operated in conjunction with the compressor As soon as the compressor is switched off the dryer is automatically set to standby mode In standby mode the control system remains on and the dryer is ready for the next switcho ver which is made as soon as the compressor is switched on ...

Page 31: ...tchbox shows the currently measured dewpoint The range of display is 100 C 148 F to 20 C 68 F If the set dewpoint is exceeded the system automatically completes a switchover between the chambers The dewpoint at which a switchover is made is preset at the factory After commissioning or extensive maintenance work check the dewpoint display at the dryer Under certain circumstances the desired dewpoin...

Page 32: ...itchover Note If the unit is equipped with a compressor synchronisation system first switch off the compressor and then wait until the dryer has reached the standby phase before switching it off with the ON OFF switch This ensures that the regeneration cycle is completed and that the pressure in both chambers is at the same level As soon as the dryer is switched on again the programme continues the...

Page 33: ...ure Ensure that the compressed air inlet valve provided by the operator is open Set ON OFF switch to I The programme continues the cycle from the point at which it was interrupted Slowly open compressed air outlet valve Avoid a sudden drop in pressure in any circumstance If pressure drops too fast this may cause damage to the dryer Therefore the compressed air outlet valve must always be opened qu...

Page 34: ...nd switch on dryer page 26 The compressed outlet valve must be closed and the downstream filter housing must be open Operate the dryer for approx thirty minutes blowing the dust particles off from the down stream filter Shut down the dryer Close the compressed air inlet valve installed by the owner Switch off the dryer by setting the ON OFF switch to position 0 Reassemble the filter and commission...

Page 35: ...o of the dryer These data are found on the type plate Carry out all maintenance work only when the plant has been shut down and depressur ised Bolt connections must be undone with care Note ram pressure values Otherwise emerging media may cause personal injury Do not modify the factory settings of the control system in any way without prior consulta tion with the manufacturer Never carry out any m...

Page 36: ...ve this work to be performed by author ised specialists Component Maintenance task to be carried out Maintenance interval daily 12 months 24 months See page Complete dryer Carry out visual checks and function checks 36 Vessel pressure gauge Check dam pressure For a dam pressure exceeding 0 3 bar Check muffler Check dust sieve Check drying agent 36 Air quality Must be check 37 muffler Replace muffl...

Page 37: ...or servicing The message appears flashing every 60 seconds once the preset number of operating hours e g 8000 oh has been reached After maintenance has been carried out you can use the dongle to reset the counter to 0 and delete the message from the display A dongle is enclosed with every service kit Each dongle can only be used once Switch off the controller Caution The electric line is still liv...

Page 38: ...oth Clean the surfaces with a moist well wrung cloth Check dam pressure If following depressurisation of a vessel e g after the expansion phase the overpressure has not decreased to 0 bar then there is a residual pressure designated as dam pressure in the vessel Check for dam pressure if the dryer functions correctly the respective pressure gauge indicates 0 bar Then there is no dam pressure If th...

Page 39: ...hange of desiccant Warning against sudden air ejection During expansion the pressure is released suddenly through the muffler A loud cracking noise occurs which can injure your hearing Particles carried in the air flow act like bullets and can injure your eyes or skin Always wear eye and ear protection therefore when you are in the vicinity of the dryer Depressurise the dryer and shut it down see pa...

Page 40: ... manufacturer well in advance and order a new dewpoint sensor After receipt of the new pressure dewpoint sensor replace the sensor as follows Hold the box of the dewpoint sensor ready Release pressure from dryer and shut down the unit see page 30 Loosen the screw at the adapter 1 and disconnect signal cable with the adapter and seal Remove dewpoint sensor from the sensor cell 3 by turning the nut ...

Page 41: ...fter approx 8 500 operating hours If the compressed air is insufficiently dried before it reaches the adsorber see technical data in the appendix the service life of the purifying agent can be considerably shortened In this case the agent must be replaced every 6 months after ap prox 4 000 operating hours Renew drying agent The service life of the drying agent is usually approx 3 to 5 years Howeve...

Page 42: ...owner s specialist personnel or the manufacturer s service engineer Table of possible faults Fault Possible cause Remedy Specialised personnel Service technician Excessive dam pres sure during regener ation Muffler or filter element of the muffler is contaminated Check mufflers or filter elements for contamination clean if nec and poss renew Expansion valve V3 V4 does not open correctly Check expa...

Page 43: ...o expansion Solenoid valve Y3 Y4 can not be opened Check supply voltage ca ble contacts and solenoid replace if necessary Solenoid valve Y3 Y4 can not be opened properly audible humming sound or valve flapping Check supply voltage Check spring and solenoid replace if necessary Check solenoid valve for contam ination clean or replace if necessary Dryer is continuously bled Solenoid valve Y3 Y4 cann...

Page 44: ...ential pressure on the upstream filter is too high Check differential pressure on the upstream filter if nec renew filter element Condensate trap on the up stream filter does not work Check function of the con densate trap if nec clean or renew Drying agent is contaminat ed or too old Check upstream filter for contamination if nec renew element Check drying agent for contamination if nec renew dry...

Page 45: ...ted Replace sensor sens o 999 Sensor not powered or cable or sensor defective Sensor sensor cable or sensor adapter defective Visual inspection check power supply 24 V to terminals 4 and 6 Replace defective com ponent s SEr Display for service interval Regular maintenance tasks must be carried out The display appears after every 8000 operating hours Inform the manufactur er s service staff and ord...

Page 46: ...umentation 44 BSP MT 10 95 D3 Annex with technical documentation This annex comprises the following information and technical documentation Technical data Replacement and wear parts list Logic control diagram Flow diagram Dimensional drawing ...

Page 47: ...I AAP025EGMI AOP025EGMI 16 50 BSP MT 15 210 1 AOP025EGFI AAP025EGMI AOP025EGMI 16 50 BSP MT 20 274 1 AOP025EGFI AAP025EGMI AOP025EGMI 16 50 BSP MT 25 371 1 1 2 AOP030GGFI AAP030GGMI AOP030GGMI 16 50 BSP MT 35 484 1 1 2 AOP030GGFI AAP030GGMI AOP030GGMI 16 50 BSP MT 45 589 1 1 2 AOP035GGFX AAP035GGMX AOP035GGMX 16 50 BSP MT 60 839 2 AOP040HGMX AAP040HGFX AOP040HGMX 16 50 BSP MT 75 1129 2 AOP040HGMX ...

Page 48: ...ean Carbon monoxide CO 15ppm 5ppm 10ppm 10ppm 2ppm 5ppm Carbon dioxidv CO2 500ppm 500ppm 1000ppm 800 ppm 150ppm 500ppm humidity H2 O 5 C 5 C 10 F 100mg m3 15 ppm 67 ppm oxygen O2 21 1 20 23 21 5 20 8 21 1 20 4 21 4 Oil quantity 0 5 mg m3 0 5 mg m3 0 5 mg m3 1 0 mg m3 0 003mg m3 0 1 mg m3 odoriferous aro matic substance Free free Free Free Free free Sufur dioxideSO2 0 1 ppm 1 ppm mitrous gases NO N...

Page 49: ...P3 12 BSP MT 35 115V 230V SKK35 BP3 12 BSP MT 45 115V 230V SKK45 BP3 12 BSP MT 60 to BSP MT 75 115V 230V SKK60 K75 BP3 12 BSP MT 95 115V 230V SKK95 BP3 12 Service kits 24 and 48 months For model Mains voltage Order ID Scope of delivery BSP MT 10 to BSP MT 20 115V SKK10 K20 BP3 24 115 Reset module muffler filter elements inlet expansion and check valves solenoid 230 V SKK10 K20 BP3 24 BSP MT 25 115...

Page 50: ... Vessel pressure gauge Dessicant and activated carbon packages Order ID BSP MT 10 BSP MT 15 BSP MT 20 BSP MT 25 BSP MT 35 BSP MT 45 BSP MT 60 BSP MT 75 BSP MT 95 12 months purifying agent DESPAC3AK 2 3 1 2 2 DESPAC10AK 1 1 1 2 2 4 5 DESPAC1KTY 1 7 4 5 5 2 2 DESPAC4KTY 2 2 3 4 6 7 10 14 18 12 months drying agent DESPAC6EF 2 1 DESPAC20EF 1 2 2 3 4 3 7 9 12 Replacement Element filter P TYPE GRADE Samp...

Page 51: ...T 10 95 D3 49 Tightening torque values After the performance of maintenance activities reconnect the aluminum elbows indicated in the images to the valves blocks and to the vessels by applying to the screws a tightening torque between 8 Nm min and 10 Nm max ...

Page 52: ...EN User Manual Annex with technical documentation 50 BSP MT 10 95 D3 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 53: ...EN User Manual Annex with technical documentation BSP MT 10 95 D3 51 Regeneration in B1 and adsorption in B2 ...

Page 54: ... Designation Pos Designation 2 Dust sieve 200 Muffler 50 Check valve block V5 V6 350 Control system 56 Regeneration gas orifice plate 65 Upstream filter Optional devices 70 Upstream filter 380 Dewpoint sensing unit 80 Downstream filter 400 Start up device 100 Solenoid valve block V1 V4 ...

Page 55: ... MT 15 G 1 1300 880 1750 490 400 60 1320 1320 197 BSP MT 20 G 1 1100 930 1530 490 400 60 1160 1160 197 BSP MT 25 G 1 1100 930 1760 530 400 60 1320 1320 239 BSP MT 35 G 1 1390 1220 1810 585 400 60 1320 1320 288 BSP MT 45 G 1 1460 1250 1820 605 400 80 1320 1320 342 BSP MT 60 G 2 1515 1290 1870 635 500 80 1320 1320 437 BSP MT 75 G 2 1670 1440 2000 640 500 80 1515 1515 564 BSP MT 95 G 2 1715 1490 2020...

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Page 60: ...ico MI Italy Sede Operativa Gas Separation and Filtration Division EMEA Strada Zona Industriale 4 35020 S Angelo di Piove PD Italy tel 39 049 971 2111 fax 39 049 9701911 Web site www parker com hzd e mail technical support hiross parker com A division of Parker Hannifin Corporation ...