WALKER FILTRATION PROSFD P006SFD, Technical Manual And Instructions For Use

Page 1: ...Instruction Technical Manual ULTIMATE FILTRATION TECHNOLOGY Walker Filtration Ltd Spire Road Glover East Washington Tyne Wear NE37 3ES ENGLAND ...

Page 2: ...er to the dryer 8 5 2 Reconfiguration of the inlet and outlet ports 9 5 3 Installing the dryer in a horizontal orientation 10 6 Installation 11 7 Electrical supply 12 8 Energy management and PC interfacing 14 9 Operation 24 10 Start up 25 11 Service and fault diagnosis 26 12 Dryer troubleshooting 35 13 Dryer sizing table 37 14 Environmental conditions 38 15 EC Declaration of conformity 39 ...

Page 3: ... please have the following information available Serial number Date of commissioning The serial number can be found on the identification plate located at the upper right hand side of the unit and this information should be copied into this manual for future use The dryer is delivered in protective packaging Take care when transporting loading and unloading the unit The dryer is delivered configur...

Page 4: ...regenerating adsorption dryer is designed and manufactured exclusively for drying of compressed air within conditions as described in section 11 of this manual Any other use of the unit will be considered inappropriate and Walker Filtration shall not be liable where this is permitted under law for any damage incurred as a result of misuse The following symbols give indication of potential hazard A...

Page 5: ...isconnection 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 this manual and electrical safety rules and regulations should be allowed to carry out work on the electrical components and power supply to the unit When carrying out any work on the unit use only correctly siz...

Page 6: ...sembly 4 Bottom mounting block 5 Bottom valve fixing bolt 6 Front panel 7 Front panel fixing screw 8 Pressure housing 9 Pressure housing retaining bolt 10 Desiccant cartridge c w dust filter 11 Multiport manifold 12 Top cover 13 Top cover fixing screw 14 Rear panel 15 DIN connector 16 Banjo fixing bolt 17 Pressure seal 18 Exhaust silencer 19 Purge plug 13 12 11 16 17 2 3 6 7 5 4 18 10 8 9 1 14 19 ...

Page 7: ...contain the agent desiccant that has been developed for the drying of compressed air The desiccant is housed in a clear tube that has a holder permeable to air at both ends Located in the top of each cartridge is a 1 micron filter for removal of residual dust from the desiccant The length of the cartridge varies with the flow capacity of the dryer 4 4 Pressure housing The cartridges are contained ...

Page 8: ...32 black tubing to filter and drain valve inlet 4 Pipe away condensate with 4mm 5 32 tubing from drain outlet Ensure condensate is drained into an oil water separator 5 Fit any further filtration or ancillary equipment All tubing should be secured up to the point of drain to prevent whipping during discharge 5 1 Recommendation It is recommended that a bypass line including filter is installed C D ...

Page 9: ...old removed 4 Remove multiport manifold by means of 4 fixing bolts 8 Port configuration following procedure above 2 Remove top cover by means of 2 fixing screws 3 Dryer with top cover removed 7 Replace top cover by means of 2 fixing screws INLETS OUTLETS OUTLETS INLETS 6 Rotate multiport manifold through 180º and replace by means of 4 fixing bolts Ensure 2 0 rings in valve block are properly seate...

Page 10: ...d 3 Inlet filter must be fitted vertically and coupled as closely as possible to inlet port on multiport manifold 4 Dryer in horizontal plane Consideration must be given to supporting and to clearance for removal of inlet filter bowl 2 For horizontal orientation dryer must be suitably supported in flat plane only as shown A nippled adaptor not supplied is required for connection of the pre filter ...

Page 11: ...Instruction Technical Manual 11 Correct Wrong 35 C 35 C 16 barg 4 barg 12 V 12 V Correct Wrong 6 Installation requirements ...

Page 12: ...st be fitted to the power connection not in use 2 The power supply is to the DIN plug 3 The dryer is double insulated therefore no earth is required 4 Suitable external fuse connection must be provided 5 The cable selection must suit local installation regulations and be appropriate to power consumption Supply Amp 12 VDC 0 8 24 VDC 0 4 100 VAC 0 16 115 VAC 0 14 230 VAC 0 07 240 VAC 0 067 No connec...

Page 13: ...Instruction Technical Manual 13 7 2 DIN plug drawings Voltages 100 to 240 VAC Voltages 12 to 24 VDC cover cover ...

Page 14: ...dows 95 Windows 98 Windows 2000 Windows ME Windows XP 8 1 3 Installing the application software Simply load the CD into the PC and the software will automatically load up and complete installation The Walker Filtration icon will be visible on the desktop 8 1 4 Connecting the PC to the controller Ensure that power to controller is isolated Access to the controller is by removing the screw on the fr...

Page 15: ...position for reasons of clarity 1 Condensate solenoid valve 2 Tower 1 solenoid pilot valve 3 Tower 2 solenoid pilot valve 4 AC DC supply DIN connections 5 Energy management DIN connection 6 Controller clear LED cover 7 RS232 Software connection 8 Alarm DIN connection ...

Page 16: ... the next time the application software starts the language will be in the requested language 1 Establish communication Click the Establish Communication switch on the screen this will look for the link between the PC and the dryer controller The serial number on the software must match the serial number on the controller to allow communications to be established If communication cannot be made a ...

Page 17: ...so a real time view which illustrates the operation of the dryer valves as it happens It also counts down the remaining time to run on the valve operation This is useful in confirming faults which are displayed with the LED s on the front display panel To view the status of the controller in real time click the real time view switch A new window will appear animating the dryer controller status in...

Page 18: ...ve method of resetting service hours than using the re set disc after a service has been carried out 11 Address Indicates the network address for networked dryers 12 Faults The first column indicates the number of faults up to 50 every 30 minutes The second column indicates the type of fault and the hour it occurred from new 13 Serial number Indicates software dryer serial number to ensure they co...

Page 19: ...agement connection 1 Remove DIN plug from EM connection on controller 2 Remove blanking plug from cable entry nut on DIN plug 3 Remove fixing screw and gasket from DIN plug body 4 Separate DIN plug body internal from cover 5 Remove jumper wire from pins 1 2 on DIN plug body internal 6 Connect external switching device cable to pins 1 2 on DIN plug body internal ensuring that cable entry nut washer...

Page 20: ...This links the operation of the energy management to the outlet dew point from the dryer The flow diagram below illustrates the correct selection Energy management required Point of use dryer application remote from compressor Dewpoint dependant energy management switching Dewpoint monitoring Continuous running compressor Dewpoint dependant energy management switching Dryer directly connected to l...

Page 21: ... input the high and low pressure set points for the compressor switch the internal volume of the receiver and the flow rate of the dryer The purpose of the delay is to prevent dryer saturation when using a large receiver with large range of set pressures Once the application conditions have been input click OK this will return the screen to main application software click Program CD will set and f...

Page 22: ...witching pole of an externally powered alarm device to terminals 1 and 2 of alarm DIN connector 2 With the power removed from the dryer and the alarm lead wired as described in 1 above remove the cover from the DIN connection marked Alarm and connect the wired DIN connector ensuring the seal and screw are fitted Alarm relay rating 3 Amp Max 28 VDC Alarm connection type Hirschmann GDS 207 industria...

Page 23: ...Instruction Technical Manual 23 8 4 Schematic wiring and fault diagrams 8 4 1 General wiring diagram 8 4 2 Remote alarm wiring diagram ...

Page 24: ...t cartridge and to atmosphere by means of an exhaust silencer thereby effecting regeneration of the desiccant After 120 seconds of operation the cartridge under regeneration is sealed by closing of the exhaust valve and the pressure housing is brought up to full system pressure by the purge air After 170 seconds the pressure in the first housing is released to atmosphere by means of the correspond...

Page 25: ...ribed is factory setting i Power LED illuminates green and tower LED X illuminates green ii After 120 seconds tower LED X switches off and drain LED Z illuminates green iii After a further 50 seconds drain LED Z switches off and tower LED Y illuminates green iv After a further 120 seconds tower LED Y switches off v After a further 50 seconds tower LED X illuminates green this is i in the cycle des...

Page 26: ...FT HAND TOWER PURGE CYCLE REPRESSURISATION CYCLE RIGHT HAND TOWER PURGE CYCLE REPRESSURISATION INCLUDING SECOND DRAIN SERVICE WARNING EVERY 11 500 HOURS SERVICE DUE EVERY 12 000 HOURS RIGHT LEFT HAND SOLENOID FAULT DRAIN VALVE FAULT CONTROLLER FAULT LOW POWER FAULT ...

Page 27: ...ll not be possible 11 2 Servicing and maintenance 1 Service intervals are every 12 000 operational hours See chart below 2 The shutdown procedure above must be carried out before a service is carried out 3 The following kits are available C D A B Kit A 12 000 hour service kit Desiccant cartridges Pre filter element Hex wrench O rings and seals Re set disc Instruction leaflet Kit B 24 000 hour serv...

Page 28: ...vals and the kits required are detailed below 2 years or 12 000 hours Kit A 4 years or 24 000 hours Kit B 6 years or 36 000 hours Kit A 8 years or 48 000 hours Kit A 10 years or 60 000 hours Recommended service overhaul Contact Walker Filtration ...

Page 29: ... diagram on both towers Important do not fully tighten retaining bolts until all towers have been serviced When complete tighten up all bolts to torque 5nm 4 Dispose of desiccant cartridges in accordance with local waste regulations 5 Follow the start up procedure as detailed in 10 A B C D E F G H I J Service Date 12 000 hours 24 000 hours 36 000 hours 48 000 hours 60 000 hours Works overhaul ...

Page 30: ...ont facia panel fitted 4 Dryer with front facia panel removed 2 Remove single retaining screw 3 Remove front facia panel by tilting outwards and downwards 6 Replace single retaining screw 5 Re fit front facia panel by insertion of tongue into groove and pushing upwards and inwards ...

Page 31: ...be cleaned with warm soapy water Do not use sharp implements or tools 2 Remove purge plug fixing screw from upper valve block 5 After thoroughly drying purge plug push back into port in valve block Ensure that o rings are in place and in good condition 3 Remove purge plug from port in upper valve block downwards 6 Replace and tighten purge plug fixing screw in upper valve block ...

Page 32: ...acement See 11 8 4 Clean threads on silencer 2 Disconnect silencer from valve block 5 Silencer can be thoroughly cleaned in warm soapy water Do not use sharp instruments or tools 3 Remove silencer from dryer 6 Ensure silencer is thoroughly clean and dry then replace by following the above procedure in reverse ...

Page 33: ...ect tubing from fitting on bonnet 4 Separate bonnet from valve block 9 Replace diaphragm and bonnet by following above procedure in reverse Repeat above procedure for all diaphragms on dryer 8 Diaphragm and bonnet components 2 Lower bonnets 6 Locate diaphragm assembly to be changed 3 Remove bonnets by means of four fixing screws 7 Remove diaphragm assembly ...

Page 34: ...sing the re set disc supplied with 12 000 hour service kit then 2 Hold the disc against the blue pad on the front display of the dryer panel for 5 seconds 3 During the five second period the power indicator D will flash green When the reset has been successful indicator B will flash red once to confirm that it has been completed successfully Y POWER ...

Page 35: ...t time of ordering and used for product selection The table below gives possible causes and corrective actions to faults that may occur on the dryer Problem Possible cause Action Poor dewpoint Liquid water at dryer inlet Check pre filtration and drains Excessive flow Check actual flow against maximum specified Low inlet pressure Check against specification High inlet temperature Check against spec...

Page 36: ... Replace solenoid operation or short circuit valve Right solenoid open Flashing red P1 Y LED Replace solenoid or short circuit valve Controller fault Flashing red P2 Power LED Replace controller Lower power fault Continuous red P1 Power LED Check supply Drain not Energy management None Check installation operating active Drain solenoid open Flashing red P1 Z LED Replace solenoid or short circuit v...

Page 37: ...mperature and pressure correction factors below should be applied to the above flow rates to suit the application and ensure dryer performance All flow rates are based on 7 0 barg 100 psig and 35 C 95 F at the dryer inlet Always use the pressure correction factor PCF closest to the actual inlet pressure condition Operating pressure barg psig 4 58 5 72 6 87 7 100 8 116 9 130 10 145 11 160 12 174 13...

Page 38: ...IEC664 Class II Pollution degree 2 IEC 664 For operation extended from the above conditions please contact Walker Filtration 15 Warranties and liability Claims for warranty and liability concerning personal injury or material damage are excluded if they resulted due to one or more of the following factors Inappropriate use or application of the dryer Technically incorrect installation startup oper...

Page 39: ...FD 033SFD Pro SFD 044SFD Pro SFD 066SFD Standards Used BS EN 292 1 BS EN 292 2 BS EN 61010 1 BS EN 50081 1 BS EN 50082 1 ASME VIII Div 1 CRN CAN CSA 22 2 FCC Part 15 UL61010C 1 2002 Notified Body 97 23 EC only Lloyds Register of Shipping 71 Fenchurch Street London EC3M 4BS Conformity Assessment Module 97 23 EC only A1 D1 Name of authorized representative Brian Walker Position of authorized represe...

Page 40: ...1 417 7816 Fax 44 0 191 415 3748 email sales walkerfiltration co uk www walkerfiltration com Walker Filtration Inc 2220 West 50th Street Erie PA 16506 USA Tel 1 814 836 2900 Fax 1 814 836 7921 email info walkerfiltration com www walkerfiltration com www walkerfiltration com telephone 44 0 191 417 7816 fax 44 0 191 415 3748 04 409 001 01 Walker Filtration Ltd reserves the right to make changes and ...