ZANDER HDK 50/100, Operating Instructions Manual

Page 1: ...High Pressure Dryer HDK 50 100 600 350 Operating Instructions Issue 05 2005 EN...

Page 2: ...175 1 by Lloyd s Register Quality Assurance GmbH Hamburg is available The quality assurance system is monitored by the service provider stated below Lloyd s Register Quality Assurance GmbH identificat...

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Page 5: ...time any appliance data not stated above to keep these appliance data up to date The above stated appliance data provide for a clear identification of the dryer and its components and significantly f...

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Page 7: ...tion and storage 23 Information on transportation packaging 23 What to do in the case of transport damage occurring 23 Transporting and installing the dryer 24 Installing and anchoring 25 Storing the...

Page 8: ...nce 45 Regular maintenance intervals 46 Daily maintenance tasks 47 Weekly maintenance tasks 48 Maintenance work to be completed every 12 months 48 Maintenance work to be completed every 48 months 52 I...

Page 9: ...0 2054 934 0 Telefax 49 0 2054 934 164 Internet www zander de E mail info zander de Service and orders Service and spare part order Telephone 49 0 2054 934 180 Telefax 49 0 2054 934 117 You can also...

Page 10: ...ed without prior approval and confirmation in writing by the manufacturer for purposes other than those specified in these operating instructions or contractually agreed If preset parameters e g on th...

Page 11: ...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 threatening situations for yourself a...

Page 12: ...fied personnel not used within its intended design specifications is repaired or maintained incorrectly Note For your own safety and to prevent machine damage please note the information and safety no...

Page 13: ...orized specialist personnel only Warning against overpressure The entire dryer is under pressure Before commencing any work the plant must be depressurised Warning against sudden air ejection When the...

Page 14: ...tear off or become damaged in another way General safety notes For your own safety when carrying out any work on the dryer comply with all applicable national safety regulations Personnel qualificati...

Page 15: ...escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Carry out all prescribed tests and checks The factory settings on the control boar...

Page 16: ...ction Depressurising and shutting down the dryer on page 43 The unit may only be restarted after all defects have been eliminated Maintenance of the dryer and fault removal Hazard due to a sudden rele...

Page 17: ...move any parts of the dryer or manipulate the same in any way for as long as the plant is still pressurised A sudden escape of pressure may cause serious injuries Before carrying out any work on the d...

Page 18: ...ummary drawing Front view Vessel pressure gauge Manometer On Off Switch Pressure reducer with manometer Control cabinet Power supply connector Differential pressure gauge Compressed air outlet Compres...

Page 19: ...ration are described below Adsorption Via a compressor humid compressed air is supplied to the upstream filter From here the compressed air flows upwards through the absorption vessel which is pressur...

Page 20: ...owing options are available for the dryer Start up device Outside installation Auxiliary heater Signalling contacts of control system Regeneration gas return line for compressor synchronisation Dewpoi...

Page 21: ...It is used for the transmission of operating signals and for the output of dewpoint alarms Regeneration gas return for compressor synchronisation Compressor synchronisation helps reduce energy costs...

Page 22: ...an reduce the quality of the paint finish Even minute quantities of oil and grease containing foreign materials or solvents above all silicones are sufficient to cause pits discolorations swellings an...

Page 23: ...on transportation packaging Depending on the type of transportation the dryer is delivered in different types of packaging All transportation types the apertures of the dryer are closed off by means...

Page 24: ...tion site it should be taken into account that the noise emission of the dryer can exceed 95 dB A temporarily for further information on the noise emission see also page 16 The installation area must...

Page 25: ...move the packaging of the dryer Attach suitable lifting gear to the stand profiles and cross beams Risk of tilting The dryer should only be transported in an upright position However this means that t...

Page 26: ...dryer must be covered by a protective sheet The storage room must have an ambient temperature of at least 1 C 33 8 F In order to store the dryer proceed as follows Take dryer out of operation as desc...

Page 27: ...te If you wish to take the dryer back into service after an extended period of storage please proceed as described for its first commissioning and start up see page 37 Store drying agents Do not store...

Page 28: ...All pipes couplings and connections must have the correct diameter and match the operating pressure Hazard caused by exceeding the limit values A safety device must be provided in order to protect aga...

Page 29: ...valve owner end 7 Outlet dry air Example of an installation The connection lines for the upstream filter 3 are to be installed at a slight incline in the direction of the upstream filter One shutdown...

Page 30: ...o the connector and use bolt to remount the connector with seal on the switchbox In all phases the dryer must be protected against short circuits by means of fuses In order to relief cable strain re t...

Page 31: ...n for example be transmitted to a remote control room Dryer on contact made Power supply disconnected no contact Dewpoint alarm only with dewpoint sensing control option no contact To install the exte...

Page 32: ...ed up Requirements for initial start up For the first start up the following preconditions must have been met The pipe system is free from scales thread abrasions welding beads and other contamination...

Page 33: ...aximum Overview of operating and control elements ON OFF switch The ON OFF switch 2 is located to the side of the control cabinet and above the mains plug 1 see figure If it is set to 0 the power supp...

Page 34: ...atus of the dryer 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 Vessel B1 Ves...

Page 35: ...ta 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 option...

Page 36: ...attached to the pressure reducer allows operators to check the pressure settings Emergency shutdown In the event of an emergency shut down the dryer as described in chapter Depressurising and shuttin...

Page 37: ...ryer is pressurised If necessary pressurise switch on compressor Slowly open compressed air inlet valve Avoid sudden pressure build up in any circumstance If pressure builds up too fast this may cause...

Page 38: ...he dryer Smaller compressed air systems can be pressurised also by means of compressed air fed through the dryer Slowly open compressed air outlet valve Avoid a sudden drop in pressure in any circumst...

Page 39: ...oint sensing control option these two optional devices can only started together The compressor synchronisation has thereby precedence over the dewpoint sensing control With regeneration gas return fo...

Page 40: ...How do I change cycle mode Wait until the dryer has reached the pressure build up phase phase prior to switchover One LED for Adsorption B1 B2 is on in the flow diagram Set the ON OFF switch to posit...

Page 41: ...ox 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 vessels The dewpoi...

Page 42: ...closed all expansion valves are closed As a result the pressure at the inlet side of the dryer is increased while the compressor is on until the compressor is automatically switched off by the contro...

Page 43: ...essure in the dryer at both vessel pressure gauges The pressure gauges should show value 0 Disconnect voltage supply Switch off the dryer by setting the ON OFF switch to position 0 ON OFF switch If wo...

Page 44: ...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 quite sl...

Page 45: ...ntenance work only when the plant has been shut down and depressurised Bolt connections must be undone with care Note ram pressure values Otherwise emerging media may cause personal injury Do not modi...

Page 46: ...ponent Maintenance task to be carried out daily weekly 12 months 24 months 48 months see page Complete dryer Carry out visual and function checks 47 Vessel pressure gauge Check dam pressure For a dam...

Page 47: ...be completed Contact the service department of the manufacturer Clean dryer Remove any loose dust by means of a dry cloth and if required also by means of a moist and well wrung cloth Clean the surfa...

Page 48: ...ducer The pressure should be set to 8 bar If the pressure is set to a value above or below 8 bar turn the thumbscrew 2 to adjust the pressure reducer settings Pressure reducer with manometer Maintenan...

Page 49: ...roperty Therefore the mufflers must be replaced every 12 months and after each change of desiccant Warning against sudden air ejection During expansion the pressure is released suddenly through the mu...

Page 50: ...if subjected to forceful vibrations or shocks Therefore please handle the dew point sensor with great care at all times For calibration the pressure dewpoint sensor must be dismantled In order to limi...

Page 51: ...caps and placed in a solid box Place the protective caps 4 5 onto the old dewpoint sensor and pack it properly in the box Send the old dewpoint sensor to the manufacturer Clean or replace check valves...

Page 52: ...Renew drying agent The service life of the drying agent is usually approx 3 to 5 years However in favourable installation conditions the change of drying agent may be carried out at a substantially la...

Page 53: ...e taken up immediately Remove used drying agent Depressurise dryer and take out of service see page 43 Place a suitable collecting vessel underneath the unit Disconnect the control block from the upst...

Page 54: ...he dryer must not be misused as a climbing aid The components have not been designed for such loads and could fracture Only use approved climbing aids when filling the vessels Loosen connection at the...

Page 55: ...r hammer to tap regularly against the vessel wall during filling or use a rod to distribute and compact the drying agent through the vessel opening Repeat the process on the second vessel Insert clean...

Page 56: ...pansion valve Summary of faults There are different fault types In the case of most electrical faults e g short circuit defective fuse etc the main valves close In the case of some process faults the...

Page 57: ...lement of muffler if necessary z z Pressure in vessel too low Excessive differential pressure at upstream filter Check differential pressure at the upstream filter replace filter element if necessary...

Page 58: ...to open or close properly Check voltage at cables contacts and coils replace if necessary z With dewpoint sensing control optional Fault code Description of fault Possible cause Remedy Specialised pe...

Page 59: ...D Danger notes Danger 11 Danger warning maintenance 47 Date of manufacture 5 Dehumidification explanation 19 Design paint compatible 22 Dew point sensor maintenance interval 46 Dewpoint sensing contr...

Page 60: ...8 Operating signalling contact installation 31 Operation signalling contact 21 Original replacement parts 17 45 Outside installation 20 overpressure hazard 13 P Packaging 23 Parameters preset 10 Perso...

Page 61: ...symbols explanation 13 T Target group 11 Temperature ambient minimum maximum 64 Transport damage 23 Type plate 12 U Use intended 14 Use safe 11 V Variable cycle 21 Vessel pressure gauge maintenance in...

Page 62: ...5 05 10 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...

Page 63: ...0 1710 450 275 250 bar HDK 50 250 80 635 1155 400 110 HDK 80 250 140 635 1205 400 115 HDK 140 250 205 685 1220 400 132 HDK 250 250 420 740 1350 450 195 HDK 400 250 655 810 1410 450 245 HDK 600 250 102...

Page 64: ...0 bar min operating overpressure 10 bar min ambient temperature 1 C 33 8 F max ambient temperature 50 C 122 F Rel humidity 60 Noise level 3 dB A relative to free field measurement 1 m surr field 65 95...

Page 65: ...ent 1140 XP 211010011411 2 3 Filterelement 2010 XP 211010020110 Manual drain EV05 631120008001 Condensate trap optional Trap 2 250 Trap 2 400 104100000016 104100000018 Differential pressure gauge HZD8...

Page 66: ...250 Valves 9 Pressure build up valve Expansion valves DN 6 641400023001 10 Main valve DN 12 641400023001 13 Check valve 16 620300001629 14 Check valve 8 620300000825 15 Check valve 8 620300000840 Man...

Page 67: ...HZD80 420 bar 104000008000 3 Downstream filter G7V G11V 3 3 Filter element 1140 V 211040011410 3 3 Filter element 2020 V 211040020200 Manual drain EV05 631120008001 Differential pressure gauge HZD80 4...

Page 68: ...Logic control diagram 68 HDK350_EN_01_2005 05 10 Logic control diagram Adsorption in B1 and regeneration in B2...

Page 69: ...Annex with technical documentation HDK350_EN_01_2005 05 10 69 Regeneration in B1 and adsorption in B2...

Page 70: ...Flow diagram Item Designation Item Designation 1 Vessel 12 Control cabinet 2 Upstream filter 13 14 15 Check valves 3 Downstream filter 17 Pressure reducer 7 Dust sieve 18 Vessel manometer 9 Pressure...

Page 71: ...K350_EN_01_2005 05 10 71 Dimensional drawing Type HDK 100 250 350 bar Dimensions mm 50 80 140 250 400 600 A 640 640 640 775 845 905 B 1155 1205 1220 1350 1410 1710 C 400 400 400 450 450 450 Connection...

Page 72: ...Dimensional drawing 72 HDK350_EN_01_2005 05 10 Items Option...