OMEGA AIR A-DRY Series Page 63 Installation And Operating Manual Download

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16 Maintenance record

TYPE OF MAINTENANCE

DATE

SIGNATURE

NOTES

Commissioned

Summary of Contents for A-DRY Series

Page 1: ...the following instructions carefully before installing the product Trouble free and safe operating of the product can only be guaranteed if recommendations and conditions stated in this manual are res...

Page 2: ...2...

Page 3: ...24 5 6 SET SWITCH POINT 24 5 7 DEW POINT ALARM 25 5 8 SET ALARM 25 5 9 TIMER DRAIN 26 5 10 TIMER DRAIN SETTING 27 5 11 INPUT OUTPUT 28 5 12 SET STANDBY 28 5 13 STATISTICS 29 6 EFFICIENCY CONSIDERATION...

Page 4: ...2 The downstream system is oversized 57 14 4 3 Oil in the adsorption dryer 58 14 4 4 Dryer connected to the system in the opposite way 58 14 4 5 Solenoid control valves malfunction 58 14 4 6 Clogged p...

Page 5: ...n enables proper and efficient maintenance of the device selection of spare parts and technical support 1 2 Supplier information Adsorption dryer model Serial number Year of production Commissioning d...

Page 6: ...ations for the adsorption dryers are outdoor installations where the risk of freezing occurs and applications with high quality requirements in terms of air dryness PDP 3 C such as the process air in...

Page 7: ...r GROUP 2 fluids PED 2014 68 EU Desiccant dryer can not be used for explosive toxic flammable corrosive and GROUP 1 fluids PED 2014 68 EU Warning internal corrosion can seriously reduce the safety of...

Page 8: ...ng the adsorption dryer The adsorption dryer has been designed in accordance with the generally recognized rules of engineering It complies with the requirements of directive 2014 68 EU concerning pre...

Page 9: ...o not use the adsorption dryer in hazardous areas with potentially explosive atmospheres All installation and maintenance work on the adsorption dryer may only be carried out by trained and experience...

Page 10: ...dryer which can cause serious injury or even death For transportation please check and follow local regulations for lifting and transporting heavy objects Do not climb on the dryer Do not use water to...

Page 11: ...Note The adsorption dryer displayed on the pictures of this manual is A DRY 6 from A DRY series adsorption dryer Part 1 Control valves 2 Consoles 3 Tower 1 4 Tower 2 5 Controller 6 Pressure indicator...

Page 12: ...14 2 DRY 24 24 14 9 1105 395 130 19 3 DRY 36 36 22 4 1500 395 130 24 4 DRY 60 60 37 3 1105 475 160 45 0 DRY 75 75 46 7 1300 475 160 53 0 DRY 105 105 65 3 1700 475 160 70 0 DRY 150 1 150 93 3 1440 570...

Page 13: ...orrect flow capacity of a given device based on actual operating conditions multiply the nominal flow capacity by the appropriate correction factor s Example Corrected flow capacity for nominal flow c...

Page 14: ...or DRY 6 to DRY 105 70 W for DRY 150 to DRY 200 Stand by contact 24 VDC Protection class housing IP 65 Digital output Type of contact Voltage free NO or NC Maximum switching voltage 250 Vac or 30 Vdc...

Page 15: ...rption in the first tower is stopped and the control valves are run through a sequence that pressurises both towers and starts the adsorption in second tower and regeneration in the first tower Time o...

Page 16: ...16...

Page 17: ...d right purge valve Y6 drain valve d p dew point sensor depend of the model dp 2 L 1 Y1 Inlet Y2 Y4 Y3 Y6 Outlet drain 4 3 6 5 8 7 10 9 12 11 N 14 13 16 15 18 17 20 19 N L dig in dew point L N L N L N...

Page 18: ...ng to standby according to settings 3 Red Alarm is triggered It may be dew point alarm or some other internal alarms 4 Cancel 5 Decrement 6 Increment 7 Enter The chart on Figure shows how to navigate...

Page 19: ...Dew Point Set Dew Point at 4mA 40 C 20mA 20 C 2 sec Dew Point Set Switch Point 40 C Mode Variable Cycle 2 sec Dew Point Set Alarm 30 C Output Dryer Active 2 sec Timer Drain Set Period OFF 00 30 Period...

Page 20: ...he purge valve closes and pressure in the right column builds up slowly After the adsorption period in the left column is over dryer passes sequence of three states to switch columns The sequence is n...

Page 21: ...ed in statistics This way number of cycles corresponds to number of pressurization depressurizations of each vessel The bottom line of the operation menu is clear unless a dew point sensor is connecte...

Page 22: ...d This mode is entered in the Test Cycle menu by pressing increment key During the test cycle periods of adsorption and regeneration are short Because of that condition of columns does not change much...

Page 23: ...t helps us to test proper operation of the sensor 5 4 Dew Point Sensor Setting On the market there are many dew point sensors with different ranges Because of that the range of sensor is set in the dr...

Page 24: ...ected In this case adsorption phase is lengthened The duration of regeneration is the same but it takes place less often This way amount of compressed air which is lost during regeneration is reduced...

Page 25: ...t signal is taken away That is the regeneration should be completed before standby Until the regeneration is active compressor should be powered Only after the regeneration is over and the output is c...

Page 26: ...e done by manual drain which is quite an obligation for operator Instead an automatic or electronic drain can be used Besides the dryer can control one electromagnetic valve to discharge condensate by...

Page 27: ...er Drain Setting Operation of the timer drain is set by on and off periods in the Timer Drain Setting menu The off period can be selected in range from 30 seconds to 45 minutes The on period can be se...

Page 28: ...ch valve is energized at the moment Information provided by this menu is valuable during troubleshooting 5 12 Set standby The dryer enters standby when the input is opened If stand by is not needed th...

Page 29: ...signal is set again the dryer continues adsorption and regeneration If a column is already regenerated and it is idling then the dryer completes the cycle before it enters stand by 5 13 Statistics Thi...

Page 30: ...ation or the operating conditions have changed it is recommended that you contact your supplier for the technical counselling Replacement nozzles for different operating conditions are readily availab...

Page 31: ...can cause serious injury or even death In case where the dryer is firmly attached to the standard pallet it can be lifted by a forklift Don not under any circumstance use dryer piping installation fo...

Page 32: ...the outlet to the dryer are closed with a plug In case you intend to store the dryer which has been in operation follow the procedure specified below Close the outlet valve Leave the dryer to operate...

Page 33: ...ndard version DOES NOT COMPLY WITH ATEX Vibration free installation refers to floor and piping Compressed air which is supplied to DRY needs to meet the following requirements Compressed air quality 2...

Page 34: ...fied bellow are not obligatory but only provided as an example Different arrangement of certain components is always possible 1 Compressor 2 Aftercooler 3 Cyclone separator 4 Pre filter e g 3 m 5 Pres...

Page 35: ...e compressor is treated by the dryer LAYOUT 2 Dryer is installed upstream from pressure vessel When total flow rate of the compressor is treated by the dryer When consumption of compressed air varies...

Page 36: ...he dryer sufficient air treatment is provided e g aftercooler cyclone separator filter condensate drains Remove caps plugs from the inlet and the outlet of the dryer Connect the air supply to the inle...

Page 37: ...37 5 9 1...

Page 38: ...38 Console layout for DRY 6 DRY 12 DRY 24 and DRY 36 Console layout for DRY 60 DRY 75 and DRY 105 9 3 9 2...

Page 39: ...be turned off LED interface lights are off Open the inlet valve slightly until you hear first flow noise Wait until you no longer hear flow noise Fully open the inlet valve and wait until the tower ma...

Page 40: ...s opened Listen for any leaking sound Turn on the electrical power source if there is a switch or simply plug in DRY 11 Decommissioning To decommission DRY adsorption dryer follow the decommissioning...

Page 41: ...ing Below is the information on the recommended condensate separators pre filters after filters and condensate drains that can be ordered as additional equipment for the adsorption dryers EQUIPMENT MO...

Page 42: ...es REPLACE x Adsorbent REPLACE x Dew point sensor optional CALIBRATION x Refers to moving parts and sealings For stable operation replacement of adsorbent is required after every 4 years of operation...

Page 43: ...dsorption dryer Pictures 13 1 and 13 2 The tower sealing O rings should be changed at the same time the molecular sieve is changed The damaged components are to be replaced by the new ones If a marked...

Page 44: ...RY 12 48 48 months replacement kit 1 x 2 year replacement kit 6 36 2 x tower tubes including molecular sieve for DRY 12 KIT SERVIS DRY 24 48 48 months replacement kit 1 x 2 year replacement kit 6 36 2...

Page 45: ...and lower screws at the sides of the blocks beside the tower you are servicing Picture 13 5 7 Slightly lift the upper block and take the tower out 8 Replace the O ring seals on the blocks with the O r...

Page 46: ...46 13 6 13 7...

Page 47: ...ised You can check this by inspecting the pressure indicators at the top of the adsorption dryer Picture 13 8 3 Carefully place the adsorption dryer on the side Picture 13 9 4 Disconnect the connector...

Page 48: ...48 Normally open valve Normally closed valve 13 10 13 11...

Page 49: ...k 6 Place the block on a horizontal surface bottom up and clean the bottom surface 7 Unscrew and remove the non return valve components You can screw the valves with pliers 8 Replace the non return va...

Page 50: ...50 13 15...

Page 51: ...nd the electrical power 2 Make certain that the adsorption dryer is depressurised You can check this by inspecting the pressure indicators at the top of the adsorption dryer Picture 13 16 3 Unscrew th...

Page 52: ...p of the adsorption dryer Picture 13 19 3 Unscrew and pull out the back panel Picture 13 20 4 Unscrew the nuts at the top of the adsorption dryer Picture 13 21 5 Pull the block connection hose out and...

Page 53: ...olding a steel object screw driver etc under the coil of the valve See the bottom picture 14 2 Please mind that the point of view on the picture is due to better presentation the adsorption dryer shou...

Page 54: ...and the electrical power 1 Make certain that the adsorption dryer is depressurised You can check this by inspecting the pressure indicators at the top of the adsorption dryer Picture 14 3 2 Unscrew th...

Page 55: ...orption dryer Picture 14 3 3 Carefully place the adsorption dryer on the side Picture 14 6 4 Disconnect the connector on the coil of the leaking electromagnetic control valve 5 Unscrew the screws that...

Page 56: ...56 14 6 14 7...

Page 57: ...ps but it will be between 0 2 1 0 bar When the compressor is too small the ammount of inlet volumetric flow of compressed air that is used by purge release during regeneration will exceed 21 and may e...

Page 58: ...improve pre filtration Compressed air at the dryer inlet should be free of solid particles oil particles and liquid water For more information on proper air preparation see the chapter Installation La...

Page 59: ...Replacement of non return valves 14 5 High outlet dew point In normal operating conditions the heatless adsorption dryer DRY operates in fixed adsorption regeneration cycles and maintains a pressure d...

Page 60: ...bed the molecular sieve will be destroyed and it will not adsorb the water vapor anymore The result is a higher pressure dew point Replace the adsorbent and service and or improve pre filtration For...

Page 61: ...ming up considerably compared to other coils then the coil is malfunctioning and could be causing the failure to open the purge release valve during the regeneration purge interval Order the control v...

Page 62: ...e The unit was not operated properly and appropriately The unit was operated when it was clearly defective Non original spare parts or replacement parts were used The unit was not operated within the...

Page 63: ...63 16 Maintenance record TYPE OF MAINTENANCE DATE SIGNATURE NOTES Commissioned...

Page 64: ...64...

Page 65: ...65 OMEGA AIR d o o Ljubljana Cesta Dolomitskega odreda 10 SI 1000 Ljubljana Slovenia T 386 0 1 200 68 00 F 386 0 1 200 68 50 info omega air si...

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