Sullair SD Series Manuel utilisateur
SD-220 / SD-600
DDS OPTION
3V OPTION
SD Heatless Desiccant
Compressed Air Dryers
REF: 02250130-734
SERIES SD
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
2
TABLE OF CONTENTS
FOREWORD................................................................................................................................. 4
SECTION 1 INTRODUCTION.................................................................................................. 5
1.1 GENERAL INFORMATION............................................................................................. 5
1.2 SAFETY INSTRUCTIONS................................................................................................ 5
1.2.1 Identification of signs and symbols in this technical manual ..................................... 6
1.2.2 Safety tips for maintenance, inspection and assembly work....................................... 6
1.3 PERSONNEL QUALIFICATION...................................................................................... 7
1.4 PRODUCT INFORMATION............................................................................................. 8
1.4.1 Pressure vessel regulations.......................................................................................... 8
1.4.2 Airtightness test .......................................................................................................... 8
1.4.3 Overloading................................................................................................................. 8
1.4.4 Technical data sheet.................................................................................................... 9
1.4.5 Transport................................................................................................................... 10
1.4.6 Storage ...................................................................................................................... 10
1.4.7 Use of a pre and after filter ....................................................................................... 10
SECTION 2 INSTALLATION.................................................................................................. 11
2.1 SET-UP AND INSTALLATION...................................................................................... 11
SECTION 3 START UP AND OPERATION........................................................................ 12
3.1 START UP/ SHUT DOWN.............................................................................................. 12
3.2 DESCRIPTION OF THE OPERATION .......................................................................... 13
3.2.1 Description of the operation...................................................................................... 13
3.2.2 Dryer operating sequence (No control or alarm option)........................................... 14
3.2.3 Operating sequence (DDS Option)........................................................................... 15
3.2.4 Alarms....................................................................................................................... 16
3.2.5 Electrical control....................................................................................................... 17
3.3 SPECIAL EQUIPMENT .................................................................................................. 18
3.3.1 DDS Controls............................................................................................................ 18
3.3.2 DDS Controls – Start up and operation .................................................................... 18
SECTION 4 MAINTENANCE................................................................................................. 20
4.1 REPLACEMENT OF THE DESICCANT ....................................................................... 21
4.2 DISPOSAL OF THE DESICCANT ................................................................................. 21
4.3 CHANGING OF THE REGENERATION ORIFICE ...................................................... 22
4.4 TECHNICAL DOCUMENTS.......................................................................................... 23
4.4 TECHNICAL DOCUMENTS.......................................................................................... 24
4.5 FILTERS........................................................................................................................... 25
4.5.1 General comments and use ....................................................................................... 25
4.5.2 Function .................................................................................................................... 25
4.5.3 Assembly and installation......................................................................................... 25
4.5.4 Maintenance.............................................................................................................. 25
4.5.5 Changing of filter elements....................................................................................... 26
4.5.6 Accessories ............................................................................................................... 26
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
3
SECTION 5 DRYER FLOW CAPACITY AND PURGE ADJUSTMENT.......................... 27
5.1 DRYER FLOW CAPACITY............................................................................................ 27
5.2 CORRECTION FACTOR FOR INLET TEMPERATURE............................................. 27
5.3 PURGE ADJUSTMENT.................................................................................................. 28
SECTION 6 SPARE PARTS LIST......................................................................................... 29
6.1 SPARE PARTS LIST FOR SD-220 TO SD-400 ............................................................. 29
6.1 SPARE PARTS LIST FOR SD-500 TO SD-600 ............................................................. 30
6.2 INLET-EXHAUST VALVE MANIFOLD....................................................................... 31
6.2 OUTLET-CHECK VALVE MANIFOLD........................................................................ 32
SECTION 7 TROUBLE SHOOTING & FAULTS................................................................. 33
7.1 THE DEW POINT IS TOO HIGH ................................................................................... 33
7.2 THE ADSORPTION DRYER DOES NOT SWITCH OVER......................................... 33
7.3 BACK PRESSURE IS TOO HIGH DURING REGENERATION PHASE.................... 34
7.4 SHORT-TERM SHUT-DOWN........................................................................................ 34
7.5 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE............................. 35
7.6 RE-STARTING ................................................................................................................ 35
SECTION 8 ANNEX................................................................................................................... 1
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
4
FOREWORD
This technical manual of S
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is an aid in getting to know the adsorption dryer
better and in utilising its possibilities for application in accordance with its intended
use. Furthermore, this manual contains important information for safe, proper and
economic operation.
All instructions must be followed as written in order to avoid danger and damages
which could cause downtime and premature wear and tear on the adsorption dryer.
In addition to the technical manual and the accident prevention regulations which
are valid and compulsory in the country and in the particular workplace where the
adsorption dryer is being used, the recognized special rules for safe and proper
working procedures are also to be heeded. The technical manual must always be
within reach wherever the adsorption dryer is being used.
Each person involved with the set-up, start-up, operation, maintenance and repair
of the adsorption dryer in the User Company must have first read and understood
the technical manual and especially the safety tips.
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
5
SECTION 1 INTRODUCTION
1.1 GENERAL INFORMATION
The adsorption dryer of the SD-220 / SD-600 series is built according to the latest
technological developments and recognized safety rules. Its use however can
endanger life and limb of the user or of third parties, and can lead to considerable
damage to the adsorption dryer and other material assets if:
•it is operated by personnel not trained or instructed in its use,
•it is improperly used,
•it is improperly maintained or serviced.
This can result in the loss of all damage claims.
This adsorption dryer is designed for neutral media free of aggressive water, oil and
solid elements. S
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accepts no liability for corrosion damage and malfunctions
caused by aggressive media.
Applications other than those mentioned in this manual must be agreed to by S
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and confirmed in writing.
In the interest of further development, S
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reserves the right to make changes at
any time, which, in keeping with the essential characteristics of the adsorption dryer
described here, may be necessary for increasing efficiency or for reasons relating
to safety or to normal business practice.
1.2 SAFETY INSTRUCTIONS
This technical manual contains basic tips, which must be followed during set-up,
operation and servicing. It is thus of utmost importance that it be read by the
assembly technician before installation and start-up as well as by the specialist /
operator in charge, and it must always be within reach at the place where the
adsorption dryer is being used.
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
6
SECTION 1
1.2.1 Identification of signs and symbols in this technical manual
The safety tips contained in this technical manual, whose disregard could endanger
people and machines, are indicated by a general danger sign and the additional
markings Danger! or Attention!
Danger! / Caution!
Safety sign in accordance with DIN 4844 - W9
Warning against electrical voltage!
Safety sign in accordance with DIN 4844 - W8
Safety tips printed directly on the adsorption dryer must be heeded at all times and
must be kept completely legible.
*Advices
This sign refers to a procedure or sequence of particular interest
or importance. All tips must be followed to ensure proper use of
this adsorption dryer.
•This dot refers to working or operational steps. The steps are to
be carried out in the order of their appearance from top to bottom.
•The sign of a hyphen marks enumerations.
1.2.2 Safety tips for maintenance, inspection and assembly work
The operator is to make sure that all maintenance, inspection and assembly work
is carried out by special personnel who are authorized and qualified, and who are
adequately informed through careful study of the technical manual. For this reason,
special attention should be paid to the following attention and danger sign:
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
7
SECTION 1
CAUTION!
•Never make structural changes to the adsorption dryer!
•Only use original spare and accessory parts!
•Never weld on a pressure vessel or change it in any way!
Carry out maintenance work only when the adsorption dryer is
switched off, is depressurized and disconnected from the electric
power supply.
*Advices
Refer to the desiccant material safety data sheet (MSDS) when
installing or disposing of desiccant.
DANGER!
Wear protective goggles when working with the desiccant!
*Advices for protection
•If desiccant comes into contact with the eyes, rinse eyes
immediately with a lot of clear water.
•If the desiccant is spilled, clean up without causing swirls of dust.
•In case of fire, there is no restriction on the use of fire extinguishing
material; the reaction with water and foam is defined as strong.
•A mask must be worn.
1.3 PERSONNEL QUALIFICATION
The personnel involved in operation, maintenance, inspection and assembly must
have the corresponding qualifications to do this work. Areas of responsibility and
supervision of the personnel must be precisely established by the operator. Should
the personnel not possess the necessary knowledge, then they must be trained and
instructed. If need be, this training may be carried out by the manufacturer / supplier
at the request of the operator of the adsorption dryer. Further, the operator is to
make sure that the personnel completely understand the contents of the technical
manual.
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
8
SECTION 1
1.4 PRODUCT INFORMATION
The adsorption dryer is used for the purpose of drying compressed air and other
gases according to its respective design. As a "standard model" the adsorption dryer
is equipped with two desiccant vessels and a pre- and after-filter, and depending on
certain conditions at the outlet, provides pure, dry and oil-free compressed air or
gases.
1.4.1 Pressure vessel regulations
The pressure vessels are designed according to the standard technical
requirements. They fulfill the test of the certifying procedure and carry the “U”,
“UM” ASME Symbol.
Range of application
Type SD-220 TO SD-600
Operating overpressure Max. 150 PSIG
Temperature Max.
Min. 500 °F
-20 °F
1.4.2 Airtightness test
All adsorption dryers are subjected to an airtightness test prior to shipment using
compressed air.
1.4.3 Overloading
CAUTION!
Protect the adsorption dryer from overloads!
The adsorption dryer can become overloaded, if:
•The flow capacity of the medium to be dried increases,
•The temperature of the air at entry, and correspondingly its
humidity increases,
•The min. operating pressure is under cut,
•The pre-filtration and separation of impurities are not sufficient, or
filter drain fails.
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
9
SECTION 1
1.4.4 Technical data sheet
TYPE SD-220 SD-300 SD-400 SD-500 SD-600
Medium Air, free of aggressive elements
Connection NPT 1-1/2" NPT 1-1/2" NPT 1-1/2" NPT 2” 2”
Flow capacity (1) (STD) SCFM 220 300 400 500 600
Desiccant
Standard Input temp.: from 100°F and dew point (2) -40°C (-40°F)
Filled with: activated alumina
Quantity of desiccant / Vessel
[Lbs.] 126 167 220 272 350
Filter size (mph/mpr) 300 300 420 470 700
Control Electronic board or PLC Controller
Operating Voltage
Standard 120 V / 60 Hz (AC)
Special voltage Consult factory
Drying time
Standard 5 min
(1) Flow capacity in SCFM at 100 PSIG according to DIN ISO 7183
(2) Pressure dew point
NOTE: Settings for DDS:
Standard dryers DDS Control (-41°C) High humidity (-36°C)
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-220 TO SD-600- DDS OPTION
REV 0 – May 24,,.2001
10
SECTION 1
1.4.5 Transport
After the adsorption dryer has been delivered, it must be checked for damage that
may have occurred during transport. If necessary, the Transport company must be
informed to register the damage.
*Advices
For transport within the company, only the skid of the adsorption
dryers SD-220 /SD- 600 may be used.
1.4.6 Storage
If the adsorption dryer is to be stored for a longer period of time, its place of storage
must be dry and free of dust. There has to be a min. ambient temp. of +1°C (33°F).
1.4.7 Use of a pre and after filter
In order to prevent droplets of condensate, oil and dirt from getting into the
desiccant, a pre-filter is installed in front of the adsorption dryer, since an oil film on
the desiccant reduces the drying capacity and the dewpoint. In order to prevent
breakdowns in downstream consumers caused by material that has been abraded
from the desiccant bed, an after-filter is mounted behind the adsorption dryer. Since
no condensate accumulates in the after-filter, this filter is always equipped with a
manual valve.
Both filters are equipped with a differential pressure gauge (standard) as this
ensures an indirect display of the degree of contamination of the filter elements.
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