WALKER FILTRATION PD004, Installation, Operating And Maintenance Manual

Page 1: ...Installation Operating and Maintenance Manual All models PD004 PD365 EN Heatless Desiccant Dryers In Canada Contact CAG Purification Inc www cagpurification com...

Page 2: ...complete the following information at the time of installation found on the rating label on the upper right hand side of dryer Model Number Serial Number Regulated Inlet Pressure Filtration present w...

Page 3: ...ation 10 4 Electrical Installation 16 5 Operation 19 Start Up 19 Shut Down 20 6 Maintenance 23 Servicing 23 Purge Plug 28 Exhaust 30 Replacing Shuttle Valves 36 7 Energy Management 38 8 Troubleshootin...

Page 4: ...ectrical disconnection plus isolation from the compressed air supply and full depressurisation Only trained and competent persons familiar with the electrical requirements of the unit as laid out in t...

Page 5: ...he responsibility for their own Health and Safety and the Health and Safety of others around them If you feel there is a significant risk you must take steps to either remove the risk altogether or re...

Page 6: ...While one chamber is on stream removing water vapour the other is being carefully depressurised in preparation for regeneration The desiccant bed is regenerated by expanding a small amount of dry proc...

Page 7: ...is delivered in protective packaging Take care when transporting loading and unloading the unit The package contains the following items refer to figure 2 1 Figure 2 1 Package contents 1 Dryer unit 6...

Page 8: ...valve fixing bolt 6 Front panel 7 Front panel fixing screw 8 Pressure housing 9 Pressure housing retaining bolt 10 Desiccant cartridge comes with dust filter 11 Multiport manifold 12 Top cover 13 Top...

Page 9: ...rol valve unit 5 Quadra port manifold 6 Pressure housing 7 Desiccant cartridge c w dust filter 8 Pressure housing retaining bolt 9 Quadra port manifold retaining bolt 10 Quadra port manifold top cover...

Page 10: ...from drain outlet Ensure condensate is drained into an oil water separator Fit any further filtration or ancillary equipment Drain kits supplied with dryer and comprise of the following Swivel elbow a...

Page 11: ...Pro Dry range of dryers is designed to operate in both vertical and horizontal orientation 11 Pro Dry Instruction Manual Walker Filtration 11 Pro Dry Instruction Manual Walker Filtration Figure 3 3 H...

Page 12: ...ded pressure plugs Dryer can be reconfigured to interchange position of inlet and outlet ports Figure 3 6 A B C D E F A C D E F B Section 3 Mechanical Installation Tools required 4mm hex key 6mm hex k...

Page 13: ...n Manual Walker Filtration www walkerfiltration com Section 3 Mechanical Installation Figure 3 7 Level ground Figure 3 8 Drainage all tubing should be secured up to the point of drain to prevent whipp...

Page 14: ...C 122O F Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Figure 3 10 Hard piped installation Max 50O C 122O F Max 50O C 122O F Figure 3 11 Exposure to heat Max 50O C 122O F Max 50O...

Page 15: ...ure 3 12 Direction of flow Section 3 Mechanical Installation A C Figure 3 13 Typical installation To prevent back flow into the dryer a non return valve should be placed in line downstream of the drye...

Page 16: ...to the correct socket as shown in figure 4 3 and 4 4 The dryer controller is double insulated therefore no earth is required on the power connector External fuse to be connected to plug The cable sel...

Page 17: ...struction Manual Walker Filtration www walkerfiltration com Section 4 Electrical Installation Different voltage setting Figure 4 3 100 to 240 VAC RIGHT Pin 1 Pin 2 Figure 4 2 Wiring diagram Figure 4 4...

Page 18: ...IP65 Transient over voltage IEC 60664 Class II Pollution degree 2 IEC 60664 A circuit breaker or switch must be installed near the dryer This should be easy to reach and shall be certified according t...

Page 19: ...ash simultaneously green four times then simultaneously red four times to acknowledge application of power and readiness to function Observe display panel for one complete cycle Note cycle described i...

Page 20: ...wer Power connected to controller Shut down Procedure Close valve B Close valve A Leave dryer running for 15 minutes to fully de pressurise Switch off all electrical power to the dryer Under no circum...

Page 21: ...alve 2 2 NC solenoid valve 9 Exhaust silencer 10 Purge valve 11 RH desiccant bed 12 RH built in dust filter 13 LH exhaust valve 2 2 NC solenoid valve 14 Left diaphragm control valve 15 Right diaphragm...

Page 22: ...365 Note Diagram shown in one of six possible positions Left Tower Drying Right Tower Purge Certain feature are intentionally shown out of position for reasons of clarity Stage Time Seconds SV Valve S...

Page 23: ...ERING OR FOR ANY OTHER PURPOSE WITHOUT THEIR WRITTEN PERMISSION C 2000 aei2 aei3 aei4 aei5 aet2 aet3 aet4 aet5 aed3 aed4 aed5 aed2 aeu4 aeu2 aeu3 aeu5 Figure 6 1 Models PD004 PD035 Maintenance Front P...

Page 24: ...HEET 1 2 3 sheet version ident Figure 6 3 Models PD045 PD365 Tools required 5mm hex key Front Panel Removal Models PD045 PD365 only See figure 6 3 Using a hex key remove screw from the front panel Ope...

Page 25: ...kit 9 Ensure O ring seals are in place when installing cartridge and assembly in pressure housing 10 Follow above steps in reverse to finish installing new cartridge into the dryer 11 Repeat steps 1 1...

Page 26: ...place installed desiccant cartridges with new cartridges supplied as part of the cartridge service kit 7 Ensure o ring seals are in place when installing desiccant cartridges 8 Follow steps 1 to 4 in...

Page 27: ...sc against the blue pad on the front display of the dryer panel for 5 seconds During the five second period the power indicator will flash green When the reset has been successful indicator X will fla...

Page 28: ...O ring to ensure ease of fit Appropriate purge plug selection is very important for function of the dryer Failure to comply with this may affect your warranty 1 Securing screw 2 Purge plug Tools requ...

Page 29: ...lding the purge orifice Remove purge plug from remaining bonnet Tools required 6mm hex key Figure 6 14 PD045 PD365 Purge plug change out stage 2 Important information Ensure shutdown and start up proc...

Page 30: ...screw silencer from bottom valve block and remove Replace with new silencer Tools required Not required Important information Ensure shutdown and start up procedures are followed prior to carrying out...

Page 31: ...D085 Silencer changout stage 1 Exhaust Silencer Changeout Models PD045 PD085 only Remove dryer front panel Unscrew silencer from bottom valve block and remove Replace with new silencer Important infor...

Page 32: ...lock and remove Replace with new silencer Important information Ensure shutdown and start up procedures are followed prior to carrying out any maintenance work on the dryer Walker Filtration will not...

Page 33: ...r from bottom valve block and remove Replace with new silencer Tools required Spanner Important information Ensure shutdown and start up procedures are followed prior to carrying out any maintenance w...

Page 34: ...gs ensuring Diaphragm holes are clear Tools required 4mm hex key Section 6 Maintenance Figure 6 21 PD004 PD035 Diaphragm changeout stage 2 Important information Ensure shutdown and start up procedures...

Page 35: ...enance Replacing Shuttle Valves Models PD004 PD035 Remove tower Pull out shuttle seat Remove shuttle Replace shuttle Reinsert shuttle seat Re secure tower Tools required 5mm hex key Figure 6 22 PD004...

Page 36: ...tower Tools required 8mm hex key Section 6 Maintenance Figure 6 25 PD045 PD365 Shuttle seat and shuttle removal Bottom block Important information Ensure shutdown and start up procedures are followed...

Page 37: ...Purge Control The simplest of arrangements a manual switch may be employed to shut the purge off when the air downstream of the dryer is not being used Commonly used on point of use systems For examp...

Page 38: ...ated at 100 psig in the example the purge shuts off until the pressure switch deactuates at 95 psig in example The point at which the switch deactuates may be adjusted to suit the system If it is dete...

Page 39: ...an overview of the devices mentioned as they might be connected for use in controlling a dryer s purge function Please note that specific details differ between device manufacturers so in all cases th...

Page 40: ...ollowing schematic offers an overview of the devices mentioned as they might be connected for use in controlling a dryer s purge function Please note that specific details differ between device manufa...

Page 41: ...plug 1 and 2 and discard Slip cable end through DIN connector s cable gland and out through the front of the DIN connector Strip the outer insulation of the cable back approx 20mm 3 4 Strip the conduc...

Page 42: ...e cable is brought into the controller via the rear panel with a grommet An external power source is required 1 Connect the switching pole of an externally powered alarm device to terminals 1 and 2 of...

Page 43: ...inlet pressure Check against specification High inlet temperature Check against specification Silencer blocked or damaged Replace silencer Air leaks Tighten joints or fit new seals Desiccant life exce...

Page 44: ...r short circuit Flashing red P1 Z LED Replace solenoid valve Controller fault Flashing red P2 POWER LED Replace controller Tube connections from filter into dryer and from filter to drain reversed Non...

Page 45: ...filtration com LED Controller Display Status LED Signal Description Power off Left hand tower purge cycle Repressurisation cycle Right hand tower purge cycle Repressurisation including second drain Se...

Page 46: ...ation www walkerfiltration com LED Controller Display Status LED Signal Description Service due every 12 000 hours Right hand solenoid fault Left hand solenoid fault Drain valve fault Controller fault...

Page 47: ...s please contact Walker Filtration Reference Conditions Measurement Performance Effective inlet pressure 7 barg 101 5 psig Effective inlet temperature 35 C 95 F Relative humidity of air at inlet 95 Pr...

Page 48: ...simplex 968 530 272 64 141 1 38 20 9 10 7 PD065 A078 PD085 1 144 85 simplex 1170 530 272 75 165 4 46 20 9 10 7 PD085 A108 PD105 1 178 105 simplex 1480 530 272 91 200 7 58 20 9 10 7 PD105 A108 PD135 1...

Page 49: ...B C C OUTLET PORT SIZE Rp TO Rp1 A B OUTLET PORT SIZE Rp TO Rp1 INLET PORT SIZE Rp TO Rp1 INLET PORT SIZE Rp1 A B C C OUTLET PORT SIZE Rp TO Rp1 A B Figure 9 2 Models PD045 PD175 55 OUTLET PORT SIZE R...

Page 50: ...m 1 9 2 5 10 7 6 8 4 3 11 Fig 10 1 PD004 PD035 PD004 PD035 1 Cover plate 2 Cruciform 3 Tower assembly 4 Front panel 5 Top block assembly 6 Controller 7 Bottom block assembly 8 Base skid 9 Back panel 1...

Page 51: ...ion 10 Component Parts 4 8 3 2 1 5 6 7 9 Fig 10 3 Bottom block assembly 1 Top Block 2 Shuttle seat 3 Shuttle 4 Purge Plug 5 Diaphragm with disc 6 Compression spring 7 Top bonnet 1 Bottom block 2 Shutt...

Page 52: ...ig 10 4 Tower assembly Fig 10 5 Top tower plug assembly 1 2 3 4 5 6 7 8 9 Fig 10 6 Bottom tower plug assembly 10 11 1 Top tower plug assembly 2 Cartridge 3 Extrusion bolt 4 Extrusion 5 Extrusion corne...

Page 53: ...10 8 7 1 XA pre filter 2 Back panel 3 Tower assembly 4 Downpipe 5 Top valve block assembly 6 Exhaust manifold assembly 7 Bottom valve block assembly 8 Base skid 9 Controller 10 Front panel 11 Silencer...

Page 54: ...0 10 Exhaust manifold assembly Fig 10 11 Bottom valve block assembly 17 18 19 20 1 QPM cover 2 QPM 3 Extrusion gasket 4 Cartridge 5 Extrusion 6 Extrusion bolt 7 QPM bush 8 Top valve manifold 9 Shuttle...

Page 55: ...5 PPK006 5 PPK006 5 PD008 PPK012 PPK011 PPK010 PPK010 PPK009 PPK008 PPK008 PPK007 5 PPK007 5 PPK007 5 PPK007 PPK007 PPK007 PD010 PPK013 PPK012 PPK011 PPK011 PPK010 PPK009 PPK009 PPK009 PPK008 5 PPK00...

Page 56: ...s shuttles exhaust block shuttles O rings and seals PD044SFD PD066SFD PD1SKD01 PD045 PD175 PD2SKS01 PD215 PD365 PD2SKD01 PD004 PD035 top diaphragm kit PD1TDKS01 Diaphragm kit includes valve diaphragms...

Page 57: ...ar Improper completion of repairs Use of non original or non approved parts for service or maintenance Important Note Industrial Compressed Air Desiccant Dryers The Walker Filtration Ltd desiccant dry...

Page 58: ...2011 PED 97 23 EC Generally in accordance with ASME VIII Division1 Rules for construction of pressure vessels Notified Body 97 23 EC only Not applicable to SEP or Cat I Products Lloyd s Register EMEA...

Page 59: ...59 Pro Dry Instruction Manual Walker Filtration www walkerfiltration com Notes...

Page 60: ...60 Pro Dry Instruction Manual Walker Filtration www walkerfiltration com Notes...

Page 61: ...04 1078 001 01 Rb 3770B Laird Road Unit 2 Mississauga ON toll 1 800 951 0777 fax 1 905 829 8331 In Canada Contact CAG Purification Inc...