Sullair SD Series Manuel utilisateur
USER MANUAL
SD2000 – SD3400
DDS OPTION
LDP OPTION
3V OPTION
SD Heatless Desiccant
Compressed Air Dryers
SERIES SD
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-2000 / SD-3400
REV 1 – October 29th,.2001
Page 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.................................................................................................................... 11
1.4.6 Storage....................................................................................................................... 11
1.4.7 Use of a pre and after filter.......................................................................................... 11
SECTION 2 INSTALLATION................................................................................................... 12
2.1 SET-UP AND INSTALLATION....................................................................................... 12
SECTION 3 START UP AND OPERATION.......................................................................... 13
3.1 START UP/ SHUT DOWN ............................................................................................... 13
3.2 DESCRIPTION OF THE OPERATION ........................................................................... 13
3.2.1 Description of the operation......................................................................................... 14
3.2.2 Dryer operating sequence (No control or alarm option)................................................ 15
3.2.3 Operating sequence (DDS Option).............................................................................. 17
3.2.4 Alarms........................................................................................................................ 19
3.2.5 Electrical control......................................................................................................... 20
3.3 SPECIAL EQUIPMENT................................................................................................... 20
3.3.1 DDS Controls............................................................................................................. 20
3.3.2 DDS Controls – Start up and operation....................................................................... 21
SECTION 4 MAINTENANCE.................................................................................................. 22
4.1 REPLACEMENT OF THE DESICCANT......................................................................... 24
4.2 DISPOSAL OF THE DESICCANT.................................................................................. 24
4.3 CHANGING OF THE REGENERATION ORIFICE........................................................ 24
4.4 FILTERS............................................................................................................................ 25
4.4.1 General comments and use.......................................................................................... 25
4.4.2 Function...................................................................................................................... 25
4.4.3 Assembly and installation............................................................................................. 25
4.4.4 Maintenance ............................................................................................................... 25
4.4.5 Changing of filter elements........................................................................................... 26
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-2000 / SD-3400
REV 1 – October 29th,.2001
Page 3
4.4.6 Accessories ................................................................................................................ 26
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
5.4 PRESSURE SWITCH ADJUSTMENT............................................................................. 29
SECTION 6 SPARE PARTS LIST.......................................................................................... 30
6.1 SPARE PARTS LIST FOR SD2000 – SD3400................................................................. 30
6.2 SERVICE BULLETIN ....................................................................................................... 35
SECTION 7 TROUBLE SHOOTING & FAULTS................................................................... 52
7.1 THE DEW POINT IS TOO HIGH..................................................................................... 52
7.2 THE ADSORPTION DRYER DOES NOT SWITCH OVER............................................ 52
7.3 BACK PRESSURE IS TOO HIGH DURING REGENERATION PHASE....................... 53
7.4 SHORT-TERM SHUT-DOWN......................................................................................... 53
7.5 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE.............................. 54
7.6 RE-STARTING................................................................................................................. 54
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-2000 / SD-3400
REV 1 – October 29th,.2001
Page 4
FOREWORD
This technical manual of Sullair 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-2000 / SD-3400
REV 1 – October 29th,.2001
Page 5
SECTION 1 INTRODUCTION
1.1 GENERAL INFORMATION
The adsorption dryer of the SD2000 – SD3400 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. Sullair 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 Sullairand
confirmed in writing.
In the interest of further development, Sullair 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-2000 / SD-3400
REV 1 – October 29th,.2001
Page 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!
410
Danger! / Attention!
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-2000 / SD-3400
REV 1 – October 29th,.2001
Page 7
SECTION 1
Attention!
−
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-2000 / SD-3400
REV 1 – October 29th,.2001
Page 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 SD2000 – SD3400
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
Attention!
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.
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-2000 / SD-3400
REV 1 – October 29th,.2001
Page 9
SECTION 1
1.4.4 Technical data sheet
Type SD2000 SD2350 SD2750 SD3400
Medium Air, free of aggressive elements
Connection FLG – 150# 4” 4” 6” 6”
Flow capacity (1) (STD)
SCFM 2000 2350 2750 3400
Flow capacity (1) (LDP)
SCFM 1400 1645 1925 2380
Desiccant
Standard Input temp.: from 100°F and dew point (2) -40°F (-40°C)
Filled with: activated alumina
LDP Dryers Input temp.: from 100°F and dew point (2) -100°F (-73°C)
Filled with: activated alumina
Quantity of desiccant
Per vessel [Lbs.] 1100 1350 1500 2000
Filter size PH/PR 2100 PH/PR 2750 PH/PR 2750 PH/PR 4100
Control PLC Controller
Operating voltage
Standard 120 V / 60 Hz (AC)
Special voltage Consult factory
Drying time
Standard 5 min
LDP Dryers 2 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 -43°F(-41°C) High humidity –33°F (-36°C)
LDP Dryers DDS Control -100°F(-74°C) High humidity –92°F(-69°C)
INSTALLATION, START-UP & MAINTENANCE MANUAL
MODEL NO.: SD-2000 / SD-3400
REV 1 – October 29th,.2001
Page 10
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